ENGINEERING EXCELLENCEMANUFACTURINGwww.industrialdirector.comJuly/August2022 Manufacturing | Machinery | Production | Automation | C & I | Electronics | Procurement Subcontractor Takes-Off With 17th Nakamura Page 12 Entry-Level Trumpf Shows Its Punching Power At Olson Electronics - Page 8
August 2022 - industrialdirector.com - 3 ...In This Issue... 09-02-2005Incorporated05359182Companywww.mslmedialtd.comEC3VEngland,London,OneLowerSuiteMSL+44(0)207Telephonewww.industrialdirector.comWebsiteadvertise@industrialdirector.comSteveMichaelAdvertisingeditorial@industrialdirector.comMichaelPublisherDominguezDominguezPheasant1931396Medialtdone,GroundFloor,georgeyard,9DFNumber Page 6 - 7 Energy Management Page 8 - 23 Manufacturing Mangement Page 24 - 25 IIOT Page 26 - 27 Boiler Management Page 28 - 38 What’s New Page 40 - 41 Smarter Technologies
· Move loads safely and efficiently up to 8,000
· Heavy-duty, high-performance interchangeable batteries for 24/7 operation
· A range of features to keep operators safe and efficient
Award-winning manufacturer of electric tugs, MasterMover, has announced the latest addition to its popular Power Steered range with the introduction of the OriginallyPS800+.created to fulfil a bespoke customer requirement, the PS800+ has been designed by in-house engineers and added to the Power Steered range to meet the growing demands of the business, where customers regularly ask for bespoke or personalised machines to drive safe and efficient movement of heavy and/or awkward Theloads.PS800+ joins the already-popular PS3000+, which has the capacity to manoeuvre up to 30,000kg, and its addition to the range offers customers a smaller solution with a capability to move loads of up to 8,000kg. The Power Steered range features remotecontrolled operation, allowing operators to take the optimal viewing point for increased visibility and improved safety.
The Power Steered range include innovative Multi-Link technology, enabling two or more machines to work together in sync. This makes the movement of particularly long or awkward loads simple to achieve. For example, the manufacturer of aeroplane wings – notoriously tricky and heavy items to move - can use two machines at each end of the load to manoeuvre them carefully and efficiently. A simple remotecontrol operation means only one operator is required, cutting down on manpower and increasing productivity. “Here at MasterMover, we are continuously working to evolve and improve on existing products and ranges,” said James Jones, Partner and Director at MasterMover. “The new PS800+ will provide a greater choice and flexibility for our customers while still delivering the same great quality and service they’ve come to expect from us. “As with a number of our machines, the PS800+ was originally created to meet the specific need of a customer in the aerospace industry. However, it is now available as an option within our product portfolio, giving customers greater choice and flexibility, especially in terms of remote-controlled movement of loads.
· Strong steel chassis, built for indoor and outdoor operation
Specifications & Further Details
· Wireless operation for better visibility
Multi-Link Technology
· Non-marking polyurethane tyres
·kg Secure coupling that connects to the load whilst maintaining traction
· Multi-Link capable, allowing multiple PS800+ machines to work together For more information visit https://www. mastermover.com/.
The PS800+ safety features include four emergency stop buttons, an audible horn, a flashing beacon with audible alarm, a wireless transmitter with a safety shut-off if the signal is lost or interrupted, a caster guard preventing entrapment and a hydraulic coupling that provides maximum load security.
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MasterMover Introduces New Remote-Control Electric Tug Machine To Extend Power Steered Range
August 2022 - industrialdirector.com - 5sales@northridgepumps.com | www.northridgepumps.com North Ridge House, 3 Chrysalis Way, Eastwood, Nottingham, NG16 3RY, UK +44 (0) 1773 302 660 with specialist support AOD, SELF PRIMING AND VANE PUMPS FROM STOCK NORTH RIDGE HAVE YOU COVERED!
Konrad Sippel, Head of Research at Solactive, the index provider for the Electric Vehicle Charging Infrastructure UCITS ETF (ELEC), expands on this issue: “I think the interesting thing to observe is how quickly past policy decisions become obsolete in the light of a real and immediate threat of an energy shortage: discussions about increasing the use of coal power, the re-opening of a discussion on nuclear energy in Germany, just to name some examples. “On the other hand, the short-term crisis is also likely to accelerate adoption and expansion of renewable and alternative energy sources and an affirmation of the Paris Agreement goals which should also in the mid-term benefit the Electric Vehicle ecosystem and provide an additional push for the expansion of the charging networks.”
Stephen Derkash, manager of the Solar Energy UCITS ETF (TANN) comments: “Global oil prices and European gas and electricity prices have spiked in the aftermath of Russia’s invasion of Ukraine. As the conflict in Ukraine continues, European leaders are pushing for a faster switch to renewables as part of a strategy to end dependence on Russian gas.
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HANetf, Europe’s first full service ‘white label’ ETP platform, recently reached out to its expert partners in the energy sector to articulate their thoughts on the ongoing energy crisis in Europe’sEurope.
Energy Crisis Creates A ‘Trilemma’, According To Experts In The Energy Sector
With Europe currently sweltering under extreme temperatures, cold weather is likely the last thing on the mind of many. However, with Russia dialling back supplies to Europe, the continent potentially faces an energy shock this winter. Gabriela Herculano, manager of the iClima Global Decarbonisation Enablers UCITS ETF (CLMA) and iClima Smart Energy UCITS ETF (DGEN) comments on the difficult decisions being faced by European countries: “Countries are facing a “trilemma” during the coming energy transition, as we must decarbonize the energy industry while guaranteeing security of supply and affordability. European countries are doing two things in parallel: passing legislation that supports a massive acceleration in the energy transition, while going back to using fossil fuel for electricity generation. Coal burning related emissions are thus likely to increase in Europe. The consequences of the reduced flow of natural gas from Russia that started in June are profound. “In the long run, Germany will decarbonize its energy sources and renewable energy will replace Russian hydrocarbons, but in the short term the alternative is to replace natural gas (that can only be either liquified as LNG and then transported or sent via long pipelines) with coal (that is transportable in bulk) for electricity needs and store the natural has still being supplied for heat purposes ahead of next winter. Germany, Italy, Austria, and the Netherlands have all announced plans to restart coal fired power plants; Germany’s Economy Minister Robert Habeck, a Green Party member, referring to the decision as “painful but a necessity. “However, the mid to longer term growth prospects of green solutions – from EV adoption to long duration energy storage – are extremely strong, again led by Germany in a material way. That means that longer term investors have a unique opportunity to invest in the companies leading the energy transition at a steep discount.”
Currently, approximately 40% of the EU’s gas and about 25% of its oil is imported from Russia. The EU’s ambitious plans now call for fast-tracking deployment of solar and tripling clean energy capacity by 2030. The effects of the conflict have implications for greenhouse gas emissions and energy “Expertspolicy.say that electricity has to take over from natural gas in sectors where just months ago gas seemed a secure long-term bet, which would significantly enhance prospects for solar power. The European Commission believes it can replace 24 billion cubic metres (bcm) of Russian gas with zero-emissions renewable energy sources this year. Furthermore, The International Energy Agency (IEA) issued a 10-point plan in March to reduce Russian gas imports by 63bcm, approximately half of what Europe imported last year, through a mixture of diversification and economy. The organisation says these measures could be enacted in the next year, without building new infrastructure.
Furthermore, Europe’s energy crisis has implications far beyond the continent. Stacey Morris, manager of the Alerian Midstream Energy Dividend UCITS ETF (MMLP), comments: “Benchmark Dutch natural gas prices have reached record highs in the wake of Russia’s invasion. Unlike oil, there are no strategic reserves for natural gas, and European inventories were already tight this winter. “Although it will take time, Europe can reduce its dependency on Russian natural gas through the ongoing shift towards renewables and by purchasing LNG. To facilitate this, additional import capacity may be needed with Germany recently committing to the construction of two LNG import terminals.
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The EU’s REPowerEU plan and the “solar rooftop initiative” is introducing a phased-in legal obligation to install solar panels on new public and commercial buildings, as well as new residential buildings by 2029. If successful, solar energy will become the largest electricity source in the EU by 2030, with more than half of the share coming from rooftops.”
www.hanetf.com
“While the near-term impact of Russia’s invasion on energy commodity prices is readily apparent, the intermediate and long-term implications for the US energy landscape are less certain. Changes in how Europe sources natural gas should have positive long-term implications for US LNG exports with direct and indirect benefits for energy infrastructure. The extent to which US producers will accelerate production growth is less clear but could result in more volumes for energy infrastructure companies to handle.”
Following the IEA’s statement, the European Commission announced an even more ambitious plan, the REPowerEU plan, to reduce reliance on Russian gas by two-thirds before Christmas and abolish all Russian fossil fuels – including coal and oil – by 2030. “The IEA plan would reduce Russian gas use by 33bcm by asking Europeans to turn down their thermostats by 1 degree Celsius (33.8 Fahrenheit) and increasing electricity generation from nuclear power and biofuels and renewable energy. Additionally, the EU is aiming to make solar panels mandatory on all new buildings by 2029 under a new proposal aimed at rapidly replacing its reliance on Russian oil and gas.
The compact entry-level TruPunch 1000 is extremely flexible, cost-effective and quick, processing sheet up to 6.4mm thick at up to 600 strokes per minute. Importantly, innovative Delta Drive dynamics eliminate the need for the sheet and support table to move in the Y axis, while full automation is possible in line with business development. Installed in April 2022, the TruPunch 1000 at Olson Electronics is predominantly processing galvanised steel or zintec from 0.9 to 1.5mm thick, sometimes up to 2mm. Batch sizes extend from 1-offs up to thousands. All enclosures are Olson Electronics, a market leader in the design and manufacture of specialised power distribution units (PDUs), has invested in a new TruPunch 1000 entry-level CNC punching machine to replace manual manufacturing methods. The move is bringing new levels of flexibility and efficiency to this ambitious and highly competitive business.
“It made sense to invest in the TruPunch 1000, as well as TRUMPF tooling and software, to provide brand familiarity across the business,” says Mr Rebeiro. “We now have everything that we need from one supplier.”
ENTRY-LEVEL
8 - industrialdirector.com - August 2022 Founded in 1961, family-run Olson Electronics today employs 27 people at the company’s ISO9001accredited facility in Stanmore, northwest London. By adopting an in-house design and manufacturing strategy, Olson Electronics assures the superiority of its components, development methodologies and quality testing procedures. Many of the PDUs manufactured at Olson Electronics are rack-mounted for use in data centres and other IT applications. Desk-mounted PDUs are also popular, typically for schools, colleges and laboratories. Another important industry is healthcare, in particular mobile trolleys for hospitals that require an electrical supply. In short, the company sells its PDUs to anyone who needs one, even household consumers can acquire them from Amazon or the company’s website, with products shipped worldwide. Alongside over 30 different standard catalogue product ranges - including intelligent PDUs with monitoring and switching capabilities – many of the products manufactured at Olson Electronics are bespoke, which provides important market differentiation and opens doors to new business. Until recently, the company relied on manual equipment such as power presses, shears and guillotines to produce the enclosures for its PDUs. However, the arrival of Mark Rebeiro as Production Manager 16 months ago confirmed a shift in thinking. “I had a CNC punching machine at my previous employer and knew the advantages it could bring,” he says. “While there was no problem with quality regarding our previous methods of manufacturing enclosures, it was all about gaining efficiencies and being more flexible. The previous process was quite rigid: if the equipment had a 50mm square tool, we got a 50mm square cut-out – that was it. In contrast, investing in a CNC punching machine would allow us to produce any size of cut-out using just one Olsontool.”Electronics shortlisted two CNC punching machines, but the company already had a TRUMPF TruBend 3066 CNC press brake that arrived a few years ago to replace manual sheetmetal bending, a factor that was set to influence the purchase decision.
TRUMPF SHOWS ITS PUNCHING POWER AT OLSON ELECTRONICS
“Business is currently good; we’re seeing steady growth year-on-year and increasing our headcount in certain areas,” concludes Mr Rebeiro. “In addition, our new TruPunch 1000 has opened up other markets that we are now looking to penetrate.”
August 2022 - industrialdirector.com - 9 programmed using TRUMPF TruTops Boost software. The company creates models in 3D modelling software and exports them into TruTops Boost for automated disassembly. By activating the ‘Boost’ button, Olsen Electronics can take advantage of a quicker process from geometry to NC program, while the software also allows more efficient material use thanks to a shared order pool and ‘Lean Nest’ nesting “It’sprocessor.earlydays in terms of cycle time and process cost reductions, however, these are things we can now measure as we get actual run times from the TruPunch 1000 for evaluation,” explains Mr Rebeiro. “For us, the investment is more about flexibility, particularly with the global supply chain issues that the whole manufacturing industry is currently witnessing. If a component we use regularly is unavailable, we can select an alternative safe in the knowledge that the TruPunch 1000 can produce different cut-out sizes in our enclosures without any need for new tooling. Previously, the components we specified were set in stone because of the tooling we had
TRUMPFavailable.”offers the largest range of punching tools on the market. Among the innovations are MultiTool, which allows users to perform punching, forming and embossing processes highly productively. Up to 10 different inserts in one tool adapter ensure shorter set-up and toolchange times. Clearly, the transition from manual equipment to affordable CNC punching technology at Olson Electronics is yielding many benefits.
VINCI Building has been appointed on an early works contract and preconstruction services agreement at Sheffield Forgemasters, worth more than £70 million.
Winspear, Regional Director at VINCI Building, said: “We are delighted to have been awarded the contract to kick off the first phase of a significant investment into the company and to the wider benefit of the Sheffield City Region.
The company will construct a new service road, undertake demolition works and services diversions at Sheffield Forgemasters’ Brightside Lane site to accommodate a new forging line.
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The appointment marks the first phase of the wider investment, valued up to £400 million over ten years, to underpin critical defence assets at the engineering company’s Brightside Lane site, with construction of the UK’s largest open-die forging operation to install a 13,000 tonne forgeChrisline.
“VINCI Building will input into the current phase of the RIBA 3 design works which should promote buildability and development of the subsequent main-works contract to install a new, circa 140,000 sq ft building, to house the new
Sheffield Forgemasters recently announced that its new 13,000 tonne Mitsubishi press has been shipped from Japan and is now in secure storage prior to installation.
Garethdecommissioned.Barker, Chief Operating Officer at Sheffield Forgemasters, said: “This contract is a key milestone in our recapitalisation project, which will see up to £400 million invested across the site to first establish a new heavy forging-line and to then install 16 new machining centres to increase our capabilities as a world-leading engineering facility.
VINCI Building UK joins Turner & Townsend (Cost Management Services/Independent Quantity Surveyor and Principal Designer), Tetra Tech (Engineering Services Provider/Lead Designer) and JLL (Planning Consultant) on Sheffield Forgemasters’ recapitalisation project.
“Furtherforge-line.to this, we are looking invest locally through our contracting partners as we launch the first phase of construction works.”
“Initially, VINCI Building will handle construction of a new access road onto Sheffield Forgemasters’ site, including all necessary service diversions and partial demolition of existing buildings. “We will also undertake intrusive survey works and provide support with scheduling and risk management, engagement of supply chain and development of costs for the main construction
Vinci Building Appointed On A £400 Million
Recapitalisation Project
Theworks.”contract, covering the forging line installation, is set to run until 2025, when the new forge is commissioned and Sheffield Forgemasters’ existing 10,000 tonne press will be
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The Bideford subcontract manufacturing company has endured challenges over the last couple of years like all businesses in the automotive, aerospace and general subcontract manufacturing supply chain, but business is certainly booming with the company taking delivery of a Nakamura-Tome NTY3-150 just over 12 months ago and a WT150II this summer. With 15 sliding head turning centres, multi-spindle autos, centreless grinding and 17 Nakamura machines, the Bideford company is no run-ofthe-mill manufacturing business.
“We are working a double shift just to keep up with demand. Of course, our customers went a little quieter a couple of years ago, but over the last 18 months, things have just gotten bigger and bigger. Our biggest customer has probably doubled in size and their demand has gone up massively - and we just have to keep up. Hence the level of investment we are putting into the business at the moment. We can’t continue with the equipment that we have got, so now is the time to invest as the opportunities are there.”
Subcontractor Takes-Off With 17th Nakamura August 2022 - industrialdirector.com - 13
The Success
As Alex Dziurzynski from West End Precision says: “We are predominantly a high volume manufacturer and we will typically set the machine and run it for an awfully long time. We do all the programming at the console, we don’t do any off-line programming and the onus is that once the machine has been set - it will keep running and running. This also helps us from an operator perspective as we can have one operator running a couple of machines - and as long as the machines are running and the spindles are turning, you are making money. The Nakamura machines give us that ability.”
Located on the North coast of Devon, West End Precision Ltd has recently taken delivery of its seventeenth Nakamura-Tome turning centre from the Engineering Technology Group (ETG) – a machine that has landed only months after its sixteenth Nakamura.
Discussing why the company has gone for the Nakamura-Tome NTY3-150 three turrect twinspindle turning centre, Alex adds: “Originally, we completely gambled on this machine. It was a step into the unknown for us and with three turrets, it was a dream of our engineers – so we
Looking at the work on the shop floor, Mark Hamley from West End Precision adds: “When I first came here to start work on a twin-spindle machine, it was great to work on a machine where you can finish a part ‘complete’ on the machine without any secondary operations. Now, we are doing more and more complex work as the years go by - and we’re doing it faster and Lookingfaster.”
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at the technology improvements built into the Nakamura NTY3-150 machine, Mark continues: “With the new Nakamura NTY3-150, we have load monitoring which is something we don’t have on the older machines. This detects any drill breakages and other issues and immediately stops the machine. It also detects when the cutting tool tips are getting worn and provide a warning. This prevents you from inadvertently creating any tool damage as it stops the machine and prompts the operator to inspect and change the inserts.”
thought we’d give it a go. We initially bought the machine to set up five very similar jobs of the same material. This meant we could tool the machine for the five jobs and run a batch of each job every week, so we could keep the machine running five different products in the family of parts. These are highly complex jobs which are against the grain of what we do, as we typically machine easier components and set the machine for high-volume parts.”
Looking at one particular job that was previously done on an older Nakamura machine and has since been transferred to the Nakamura NTY3150, Mark says: “We have one job machined from a billet on an old Nakamura machine that was too big for the spindle, we had to gantry load it into the machine. We can now put this job directly on the Nakamura NTY3-150. This has reduced cycle times from 5 minutes 40 seconds to 3 minutes 35
“It has always been the changeovers that have caused us the problem. However, in the last six months, our volumes have gone through the roof, so the machine that was bought with the older technology in it, was only ever making one component and this made it somewhat of a wasted resource. Since that time, we’ve had a very complicated job come on and that has gone onto the three turret machine. To go from a two turret to a three turret machine, we are getting the parts completed around 50% faster. This makes the production rate increase on the shop floor massive. This suddenly gives you an understanding of what the NTY3-150 machine is all “Theabout.”guys on the shop floor are already asking ‘can we have another one please?’ It is a fantastic machine that is working perfectly well.”
a look at the Nakamura-Tome brand, in particular, Alex adds: “the technology continues to move on and this is evident with the Nakamura NTY3-150 triple turret and what it can do. What this machine can do is what dreams were made of years ago – and now it is the norm with Nakamura. So, they are stepping forward, they are not standing still, we are not standing stilll and neither is ETG. We are certainly on this journey together.”
With another WT150II machine just landing at West End Precision and ETG forward ordering machines to guarantee availability for its customers, Alex says: “It’s fantastic actually. There’s lots of noise about machines not being delivered and you cannot get machines. Whilst I don’t expect to get a machine tomorrow, I ordered a machine in February that has just been delivered and ETG were very honest and told us that delivery would be in May - true to their word it arrived in May. This has given us the ability to plan and they have done everything they said
August 2022 - industrialdirector.com - 15 seconds. It has also cut out the second operation. This job now comes off the Nakamura NTY3150 machine complete and ready to go to the customer.”
“There is absolute confidence in ETG to be able to deliver what they say they are going to do. They also recognise the number of machines we have on-site, and they have taken another step forward and said - ‘do you think you will need another machine?’ without any prior commitment. We recognise we will need more machines and we have committed to another machine that is planned to be delivered before the end of the year - but we will review this in Q3 and decide whether we need to take the machine or Takingnot.”
www.engtechgroup.com
The ETG service is the difference Looking at the quality of the Nakamura machines from ETG and the service and support, Alex Dziurzynski says: “Purchasing decisions often come down to the reliability of the machines and Nakamura consistently gives us very good reliability. Even with the old machines, the maintenance and performance are so good that they have sold themselves throughout history, which has paved the path for new machines as we go forward.”
they were going to do. ETG has been fantastic.”
Howden Agrees Outage Service Provision With Millmerran
“Ourpractice.team is laser focused on delivering the most value for our customer, and doing the right thing in order to create a sustainable long term partnership with customers like Millmerran. We are looking forward to continuing this relationship over the next five years and delivering the service they have come to expect.”
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Howden provides a multi-platform aftercare service for maximising performance and longevity. Partnering with Howden is the key to continuous, efficient plant performance with minimum downtime once it’s up and running. Outage services, in particular, support ongoing performance, reduce failure risk, avoid lost revenue, and improve return on investment.
Leading global provider of mission critical air and gas handling products, technologies and services, Howden, has signed a longterm service agreement with Millmerran Power Station to provide full turnkey outage services for its boiler draft plant. Over the next five years, Howden will deliver more than 95,000 hours of outage services, monitoring 16 assets including air heaters; induced draft, primary air, and forced draft fans; ducting; and baghouses. Howden will strategically plan and execute the outage services, with more than 65 people on site providing technical expertise, supervision, trade labour, and tooling. Due to the short duration of each outage, Howden has improved its schedules, work methods and scope to maximise productivity and deliver best practice as it executes its monitoring. This optimises performance and efficiency, and supports the ongoing operation of Millmerran’s critical Camilleasset.Levy, President of Asia Pacific at Howden, said: “Howden has worked with Millmerran for 20 years, commissioning and delivering equipment and providing outage Thisservices.isa significant relationship and we have upgraded our existing field service capabilities with expanded local tooling, spare part stock and warehouse facilities to deploy this service, as well as investing in our estimating, scheduling and planning capabilities to ensure Howden continues to evolve our service delivery best
industrialdirector.com - 17 Take thetour Missed us at Engineering Expo? See what you’ve been missing! Visit our incredible new Virtual Showroom including: • 3D virtual walk-through • Unique ‘try me’ feature • Full 360 product examination Experience our: • Ergonomic inspection systems • Revolutionary digital stereo solutions • Great value metrology systems Take the tour NOW!
www.rohde-schwarz.com
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& Schwarz Announces On-Wafer Device Characterization Test Solution
Rohde & Schwarz now offers a test solution for full RF performance characterization of the DUT on-wafer which combines the powerful R&S ZNA vector network analyzer from Rohde & Schwarz with industryleading engineering probe systems from FormFactor. As a result, semiconductor manufacturers can perform reliable and repeatable on-wafer device characterization in the development phase, during product qualification and inRohdeproduction.
G RF front-end designers aim to ensure proper RF capabilities for frequency coverage and output power while optimizing energy efficiency. An important phase in this process is investigating the RF design, to get feedback on the design as early as possible and assess the performance and capabilities already on the wafer level. Characterizing a DUT in an on-wafer environment requires a measurement system which includes a vector network analyzer (VNA), a probe station, RF probes, cables or adapters, a dedicated calibration method as well as calibration substrates for the particular DUT or application. To perform these essential measurements, Rohde & Schwarz is supplying the high-end R&S ZNA vector network analyzer, which characterizes all RF qualification parameters at coaxial and waveguide levels, as well as frequency extenders for application ranges above 67 GHz. FormFactor addresses the wafer contact with manual, semiautomated and fully automated probe systems including thermal control, high-frequency probes, probe positioners, and calibration tools. The calibration of the complete test system, including the R&S ZNA, is fully supported in the FormFactor WinCal XE calibration software. In the test setup, the user has access to all test capabilities of the R&S ZNA thanks to the fully calibrated setup. Generic S-parameter tests allow characterization for filters and active devices, but distortion, gain and intermodulation tests can also be performed to qualify power amplifiers. Frequency translating measurements for mixers with phase characterization across the bandwidth of the device are another example of the supported measurement applications of the joint solution. The fully calibrated setups also allow all results to be directly taken from the VNA without postprocessing as the calibration data are applied directly to the VNA. Frequency extenders from Rohde & Schwarz open up sub-THz frequencies such as Dband, currently in the focus of 6G research. The extenders will be integrated to the probe station to ensure shortest cabling and enable optimal dynamic range while avoiding losses due to cabling to the probe tip.
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As of the 1st of July 2022, sharpening specialist VOLLMER holds a majority share in the start-up company ultraTEC Anlagentechnik Münz GmbH, which will be known as ultraTEC innovation GmbH in future. ultraTEC launched its ultrasonic deburring systems in 2019 and is keen to advance its economic and marketing development together with VOLLMER. VOLLMER was mainly impressed by the start-up’s innovative spirit, the unique ultrasonic deburring technology and the fact that ultraTEC is a family-owned company from Swabia, just like VOLLMER.
“When we founded our company three years ago, we based our foundations on our son Jonas’ successful project on ultrasonic deburring as part of the ‘Jugend forscht’ initiative, my wife’s economic expertise and my will to turn these into a start-up company,” said Dieter Münz, CEO of ultraTEC innovation. “Today, we offer four different ultrasonic deburring systems and with VOLLMER, we have an experienced partner at our side who can help us bring our technology to customers across the world with their size.”
It was not only the innovative and patented ultrasonic deburring technology with inhouse sonotrode development that convinced VOLLMER to take on a majority share in ultraTEC Anlagentechnik Münz GmbH. The start-up’s history and philosophy are a particularly good match for the Biberach-based sharpening specialist. Like VOLLMER, ultraTEC is a familyowned machine manufacturer and what’s more, it is based only around 20 kilometres away from Biberach in the Swabian town of Laupheim.
High-pressure water jet deburring systems, for example, need around twenty times more energy for deburring similar parts than ultrasonic deburring systems from ultraTEC. Ultrasonic deburring is also an alternative for components that are difficult to deburr and currently require manual deburring.
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The core expertise of ultraTEC innovation lies in the contact-free deburring of metal and plastic components with specially developed sonotrodes. Burrs or protruding fibres are created during machining processes like cutting or injection moulding. For tools, hydraulic components, micro components or medical implants - deburring edges after machining is absolutely essential. Ultrasonic deburring is the only method that can be implemented in a fully automated, contactfree and energy-efficient manner, for virtually any material and in a validatable process, unlike common methods using high-pressure water jets or ECM (electrochemical machining).
“Aside from the name change to ultraTEC innovation, we aim to allow the innovative spirit of this outstanding start-up by the Münz family to develop with only minor influence from our side,” said Stefan Brand and Jürgen Hauger, CEOs of the VOLLMER Group. “We see our task in expanding the immense technological market potential of the method and the current team of ten employees and to advance the global sales, service and marketing for current and future ultrasonic deburring systems using our years of www.vollmer-group.comexperience.”
VOLLMER And ultraTEC Enter Partnership For The Future
ultraTEC Anlagentechnik Münz GmbH from Laupheim and the VOLLMER Group from Biberach see eye to eye:
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The investment will also increase production capacity to IEC 1400 frame size electric motors and equivalent MV/HV drives. This is in addition to specialist flameproof, smoke extraction and marine motors, engineered automation solutions, as well as the range of WEG digital and automation tools such as Motion Fleet Management (MFM). Among the additions at the new factory is a substantial investment in a new testing laboratory. The space will be suitable for full-load testing to meet the new portfolio of products from WEG, and will continue to enable customers to remotely monitor tests in real time.
The new factory will also see WEG intensify its use of robotics and automation, with planned incremental investments for the years to come.
“WEG has long believed in the importance of manufacturing products local to the market where they will be sold,” explained António Duarte, managing director of WEG Portugal.
“The new investment will significantly improve the site’s manufacturing capabilities, our flexibility and time-to-market, and reinforces our continued commitment to the European market.”
WEG Portugal, registered as WEGeuroIndústria Eléctrica, S.A., has been the heart of the company’s European production of electric motors and MV/HV drives since its inception 20 years ago. Currently split across two sites in Maia and Santo Tirso in Portugal, the facilities manufacture over 10,000 motors annually, deliver to over 50 countries on five continents and employ over 750 people.
Global motor manufacturer, WEG is undergoing a substantial project to expand the size and capabilities of its production facility in Europe. Further to the facility built in 2017, a new investment will see WEG double the size of the manufacturing site in Portugal, hire 100 new employees and create Europe’s most complete testing laboratory for medium voltage (MV) and high voltage (HV) motion drives (electric motors and drives).
In fact, the facility will be the most complete testing laboratory in Europe for MV/HV motion drives, products and solutions.
~ Substantial investments for WEG’s largest European plant ~
WEG Builds New Factory In Europe
Now, WEG is constructing an additional 22,680 sqm factory at the Santo Tirso site to support the manufacture of MV/HV motors and drives, LV electrical panels and the provision of the corresponding servicing activities on shop floor as well as on site. The project will see the transfer of the Maia factory to the new plant in Santo Tirso, centralising all operations to a single site.
These technologies include automated guided vehicles (AGVs), six-axis robots, and the creation of an automated vertical warehouse for picking of smaller parts and products.
More information on WEG can be found at www.weg.net.
“Our plans are based on the WEG Manufacturing System (WMS), a programme WEG follows to continually improve the way we manufacture,” continued Duarte. “This philosophy helps us to eliminate waste and achieve the best possible efficiency. In fact, we employ the WMS model throughout our entire business, including our offices. The upcoming investments in Santo Tirso follows this way of thinking, and will make us more resilient for decades to come.”
The construction of the second factory in Santo Tirso is currently underway and is expected to be fully operational by 2024. The transfer will be initiated during 2023 and will be gradual, ensuring no impact on production or deliveries.
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Advanced IIoT Gateways with Seamless Azure IoT Edge Integration for Remote Management at Unmanned Sites
When embracing the new era of the Industrial Internet of Things (IIoT), many system integrators and engineers face the critical challenge of finding a secure and reliable IIoT-gateway solution that offers regular security patches to remedy system vulnerabilities in a timely manner. Moxa’s newly launched AIG-300 IIoTSeriesgateways come with Azure IoT Edge integration that adds significant value in the form of unique features that help build a cost- and time-efficient IIoT system. Seamless Azure IoT Edge Integration for Quick and Reliable Connectivity to the Cloud IIoT gateways need to be highly secure and reliable to facilitate seamless edge-to-cloud data acquisition and device management. The AIG-300 IIoT gateway, seamlessly integrated with Azure IoT Edge and powered by ThingsPro, is a market-leading solution for reliable, quick, and easy data acquisition and device management. Data collected from devices can be transferred to Azure IoT Edge and then on to the Azure IoT Hub with a few simple configuration steps. Conversely, devices can be effectively managed via the route of Azure IoT Hub to the Azure IoT Edge on the AIG series IIoT gateways. This seamless one-stop edge-tocloud platform can greatly help customers shrink the system development time and cost. Device Provisioning Made Easier and the Bootup Process Safer Than Ever Before Most IIoT applications are deployed in remote, unmanned, and harsh environments such as a smart grid, energy storage systems, solar fields, oil and gas refineries, and rail-wayside applications.
AIG-300upgrades.Series Highlights •
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The AIG series gateways, with their widetemperature design and low power consumption, are well-suited for use in these environments. With capabilities such are resume file transmission, over-the-air (OTA) upgrades, and Secure Boot, the AIG series gateways, located in remote sites, can be upgraded, and maintained to ensure their continuous availability and effectively protected against cyberattacks. To avoid disconnections during device crashes and sudden shutdowns, the AIG series comes with built-in recovery functions to enable rollback to the previous stable version of the firmware for uninterrupted network connectivity at remote sites. When a software upgrade fails, the gateways will automatically revert to the software version in the backup, ensuring system stability. A ThingsPro tool simplifies the provisioning process by enabling bulk provisioning of IIoT gateways and performing remote software Advanced IIoT gateways with Arm® Cortex™-A7 dual-core 1 GHz processor, 1 CAN port, 4 DIs, 4 -40DOs,to 70°C operating temperature Simplify data acquisition and device and seamless integration with Azure IoT Edge to enable easy, reliable, yet secure cloud connectivity Support easy device provisioning Provide robust OTA function to prevent system failure during software upgrades
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For
Moxa delivers lasting business value by empowering industry with reliable networks and sincere service for industrial communications infrastructures. Information about Moxa’s solutions is available at www.moxa.com.
About Moxa Moxa is a leading provider of edge connectivity, industrial computing, and network infrastructure solutions for enabling connectivity for the Industrial Internet of Things. With over 30 years of industry experience, Moxa has connected more than 71 million devices worldwide and has a distribution and service network that reaches customers in more than 80 countries.
Maintaining normal operations and monitoring statuses effectively is crucial to these systems.
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• Equipped with Secure Boot to prevent malicious code execution and software injection attacks product information and technical specifications of the AIG Series IIoT gateways, visit the product page.
•managementPoweredbyThingsPro
In a recent refurbishment of its Greenwich site, to both increase capacity and reduce its carbon footprint, Meantime Brewery appointed industrial process heating specialist Babcock Wanson to undertake the boiler replacement works. This included supplying the BWD40 Fire Tube Boiler and carrying out all the mechanical and electrical works as part of a turnkey solution. Babcock Wanson developed the plans in close consultation with chief engineers from across parent company, Asahi UK, and ensured the site meets BG01 Guidance on the Safe Operation of Boilers. BG01 advises on boiler control technology and how to achieve the safety standards laid out in the HSE’s ‘Safe management of industrial steam and hot water boilers’ document (INDG436).
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The Babcock Wanson BWD40 Fire Tube Boiler was chosen as the process heat source for this site due to its high efficiency, long life and low cost maintenance. Efficiency comes as a result of the optimised matching of the boiler shell and the burner, along with advanced burner head geometry which provides stable combustion with near constant efficiency throughout the
ABabcock Wanson BWD40 Fire Tube Boiler has been installed into Meantime Brewing’s Greenwich, London site, which is used in multiple aspects of brewery operation, from wort production through to packaging line operations. The 4 tonne BWD40 is a replacement for the existing 2.5 tonne boiler, which had come to the end of its working life.
Meantime Brewing Replaces Boiler And Expands Capacity With Babcock Wanson
Established in 1999, and based in Greenwich, London, Meantime Brewing Company is part of Asahi UK and has earnt a reputation as a modern pioneer of craft beer in the UK. It has an exciting line-up of core beers such as London Lager and Anytime IPA and innovative collaborations and seasonal beer releases throughout the year.
August 2022 - industrialdirector.com - 27 complete burner modulating range. Longevity and reduced maintenance requirements are a direct result of the three pass design and use of a coaxially located furnace tube providing optimum distribution of mechanical stress in operation. This is an important feature for boilers that operate under variable steam load, such as at Meantime Brewing, and ensures long equipment life. Further benefits of the BWD40 are lower total exhaust emissions. Using Babcock Wanson’s latest Optimo burner, the BWD40 has emission rates of less than 100mg/Nm3 NOx throughout the firing range when burning natural gas, making it one of the best performing burners on the Themarket.newboiler in place, with its low NOx emission rates, readily meets the Medium Combustion Plant Directive (MCPD), which covers emissions of sulphur dioxide, nitrogen oxides and dust pollutants to the air. Babcock Wanson assisted Meantime Brewing with the required application for a new MCPD environmental permit, working with a third party who conducted a detailed boiler house risk assessment covering all relevant aspects - including steam, electrics, operations –and produced a written report. Babcock Wanson offers a complete range of products and services for boiler houses and other process heating needs, from steam boilers, thermal fluid heaters, rapid steam generators and hot water boilers to VOC and odour treatment by thermal oxidation, water treatment or process air heating solutions. The company has extensive experience in the brewing and distilling sectors. For more information, please contact Babcock Wanson on 020 8953 7111 or info@babcockwanson.com or go coil-type-steam-boilers/www.babcock-wanson.com/product-category/to
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FourJaw co-founder and Chief Technology Officer, Robin Hartley-Willows, says: “The feedback from our customers across the country has been invaluable, enabling us to create FourJaw 2.0, an operational tool developed to meet the needs of everyone in the business from machine operatives, cell leads, factory floor managers and managing directors.”
“We’ve learned over the last year what a difficult job our manufacturing businesses have, whether they’re making brassware for kitchens or parts for the automotive sector – if every machine is making different components, with different tooling, materials and techniques at every hour of the day, you get a complex system which naturally leads to inefficiency, and creates the productivity problem we all know too well. “We have huge respect for the manufacturers we work with, who confront this complexity daily, and we’ve built FourJaw 2.0 as a software tool to support them in managing their factory floor operations to achieve their productivity
Forpotential”.existing customers, FourJaw 2.0 will be experienced as a seamless upgrade of the existing app. But what they, get, along with new customers, is an iterative tool that evolves to meet their Hartley-Willowsneeds. said “We founded FourJaw upon the belief that productive manufacturing elevates individuals, communities and our society. Whilst FourJaw 2.0 is a significant milestone in our journey, it is also the foundation for our wider company roadmap that ends with every manufacturer achieving their productivity www.fourjaw.compotential.”
Developed after more than 12 months of customer feedback and industry learning, FourJaw 2.0 launches later this week with improved functionality and additional features to empower manufacturers with the information they need to understand, manage and improve their factory floor operations.
Hartley-Willows added “The big takeaway from the feedback is that manufacturers don’t want huge quantities of data to interrogate and scrutinise – that would just mean more workload for people who are already very busy.“What they need is an easy-to-use operational tool that guides them with the right information at the right time, helps them to manage the complexities of the factory floor and enables the continuous improvement process.
FourJaw, the tech startup behind the cloudbased ‘fitness tracker’ for manufacturing will this week launch its nextgeneration machine monitoring platform designed as an operational tool to enable manufacturers to achieve big gains in factory floor productivity. The new platform features a simplified and more intuitive dashboard design, enhanced mobile experience, powerful new work list imports, and a dedicated reporting section, as well as hundreds of performance improvements.
Fourjaw 2.0 - Launching The Next Generation Of Accessible Manufacturing Analytics Technology
on this milestone achievement, Olivia Whitlam, Head of Sustainability, Siemens Plc said: “Siemens is taking a holistic approach to achieving net zero and we are pleased to be guided by the Carbon Trust who helps us monitor our progress each year.
Partnership between Siemens Digital Industries and Smart Infrastructure businessesaccelerates factory towards net zero
The 50-year-old Siemens Congleton factory began its sustainability journey in 1990 when it began manufacturing drives to meet the demands of industry. In 2018 the factory became fully digital by embracing lean manufacturing methods to achieve continuous improvement and by adopting leading-edge Industry 4.0 processes. Using advanced manufacturing methods include Virtual Reality, Digital Twin, the Industrial Internet of Things (IIoT), Advanced Robotics, Cloud Technology and Additive Manufacturing, it has mastered producing up to 50,000 variations of its products to fulfil the shifting demands of its customers and markets, increased productivity by driving down costs, and improved efficiency. In 1990, 400 workers made 50,000 variable speed drives and controls a year. Today, a similar number of workers produce 1.2 million electrical devices - including 600,000 variable speed drives (VSDs). What is more is that it has been achieved within the same physical footprint. The factory is bounded by industrial units and housing estates, with no room to expand, meaning Congleton has one of the highest productivity rates per m2 of any Siemens’ sites.
Faye Bowser, Head of Siemens’ Energy & Performance Services GB&I, said: “The climate emergency puts the demand on businesses of all sizes and sectors to really accelerate their efforts for decarbonisation. But a challenge is that often decarbonisation isn’t their core business. So, at Energy and Performance Services we make it our business to use our skills, our knowledge and our tools to help our customers transition to net zero in a way that contributes to their business priorities.
“We have 8,600 people spread across offices and 11 manufacturing sites across the UK and we are creating innovation up and down the country with sustainability at the core of our operations and services. Our Congleton factory is paving the way for sustainability whilst setting a great example on how manufacturers can join this amazing journey to net Congleton’szero.”trailblazing story will be shared at Siemens’ two-day conference and exhibition, Transform 2022 at Manchester Central on July 12 and 13.
target in 2022 - eight years ahead of goal
Commenting on the achievement, Andrew Peters, Managing Director of Siemens Digital Industries Congleton, said: “Siemens believes that sustainability is a force for good and can deliver value for all its stakeholders. We want to help customers achieve sustainable growth and to transform their industries through decarbonisation. The first step of that is for us to achieve these ambitions in our own operations. “I am delighted that by leveraging a culture of continuous improvement and sustainabilitythe vital components to Siemens’ Congleton’s long-term success - we have achieved carbon neutrality, a major milestone in our ambitions to reach net zero emissions by 2030.”
To register for Transform 2022 fairs-events/events/transform-2022.htmlhttps://new.siemens.com/uk/en/company/visit:
Sustainability milestone paves way for UK manufacturing sector
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“Despite us being from the Siemens family, we have approached working with Congleton the same we do with any organisation. It has been fantastic. In Andrew Peters you have a leader in a business which has put continuous improvement and sustainability at the heart of their long-term success. Our job was to apply those components to their energy system and their energy strategy. What we ended up with is an engineered roadmaps to net zero that considers timelines, finance, digital services, all there to safeguard business continuity, and to have a method to continuously identify more opportunities to reduce carbon on site.”
The Congleton factory is leading the way for Siemens which has committed, as a global organisation, to ensure all its operations are carbon neutral by 2030 and for all production facilities and buildings to achieve net zerocarbon footprint by 2030. In the UK Siemens’ progress has been recognised by The Carbon Trust, an expert partner for supporting organisations to achieve science-based targets. In June it awarded Siemens its Route to Net Zero Standard tier one certification for ‘Taking CommentingAction’.
The event will bring together hundreds of industry leaders, influencers and regulators from across the UK and Ireland to collaborate and solve some of the most pressing organisational challenges.
Siemens Congleton on track to hit carbon neutral
Siemens’ Congleton factory is on track to achieve carbon neutrality this year - eight years ahead of its original target. The operation, which manufactures more than 1.2m controls and drives each year, is inching its way to the major milestone after deploying a range of sustainable solutions for energy generation and demand with support from Siemens’ energy and performance services business, Smart Infrastructure. These include generating 75kw of renewable energy through a hydro-electric plant at Havannah Weir on the river Dane and using carbon neutral, certified biogas to power its on-site gas engine. These measures alone saved over £250,000 pounds a year and took the 80% power-independent factory off the Beyondgrid. these innovations, Siemens Congleton adopted a building management system which automatically adjusts to drive energy efficiency improvements, while modern windows and LED lighting have reduced the total energy bill by 13% and 30% Combinedrespectively.with reducing waste to landfill to zero and EV charging for staff and visitors, the Cheshire site is eight years ahead of Siemens’ original 2015 commitment to ensure carbon neutral operations by 2030.
30 - industrialdirector.com - August 2022 Delta announces the launch of their MPD Series inverter with motor, suitable for pump and fan applications.
MZ Hoofddorp The Phone:JudyNetherlandsWu+31(0)20
Energy-efficient and fully featured With energy costs rising, the efficiency of water pumps during operation is of growing importance. Thanks to the use of a high-efficiency motor coupled with the latest variable frequency drive technology, the MPD Series fulfills efficiency class IES2 according to IEC 618009-2. The motor-mounted Delta PLC supports 14k steps to implement a range of multi-pump operating modes, such as alternating operation to facilitate maintenance and extend equipment life, constant pressure mode for energy-efficient staging, and redundancy. A sleep mode can automatically detect falling water demand, entering a hibernation mode to avoid frequent switching on and off. The integrated clean function removes foreign objects from the blades and minimizes extended periods of no operation. Scheduling can also be defined to improve overall energy efficiency. Further protection mechanisms, such as burst pipe and high/low pressure detection, limit property damage by stopping water flow and providing an alarm output. Should the water supply be cut off, the pump slows to a stop to avoid damage. Cavitation events are also monitored: If small vapor-filled cavities form in the pump, the inverter can give an immediate warning in order to increase reliability and reduce wear. System integration through smart communication
with
The MPD Series offers an in-built RS-485 communication interface for easy integration into existing control systems. If required, optional communication cards are available for EtherNet/ IP, DeviceNet, and PROFINET DP. An optional Bluetooth communication interface is also available for more efficient commissioning and maintenance. When coupled with the Android app, smartphone users can access operational information via a dashboard, configure pump operating parameters, and are provided with handling guidance on error messages. If desired, the motor drive, MP300, is available separately for use with alternative motors. 2132 655 09 06 / 31(0) 611-581-859 energy-saving motor integrated fanless suited both installations
The new series delivers the benefits of energy efficiency, intelligent water supply and ease of operation by featuring a Delta MSI class IE5 energy efficiency synchronous reluctance motor coupled with a motormounted Delta MP300 variable frequency drive. This combination drives down the cost of daily operation, while the high level of integration supports decentralized solutions, reducing wiring and simplifying setup. Available in power classes from 0.75 to 22 kW, it features the IP55 construction that keeps out dust and jetted water from all directions. The fanless drive provides long-term reliability and low maintenance. “Whether targeting residential areas, commercial buildings, or factories, pump system manufacturers can be sure of delivering their customers’ significant energy savings. Additionally, thanks to the integrated monitoring system the drive can handle the conditions that lead to mishaps such as flooding and production delays in the pump system. With support for IEC standard motor flanges, the MPD Series is ideal for both new installations and retrofitting,” said Martien Heesterbeek, Product Manager of Industrial Automation Business Group, Delta Electronics EMEA region.
DELTA ELECTRONICS NETHERLANDS BV Zandsteen 15
jwu@deltaww.com High efficiency,
and retrofitting Delta Supports Intelligent Water Supplies with New Energy Efficient MPD Series Motor-Drive Solution
inverter
new
to
The Spill Recovery Machine: Saving Money, Materials, and the Environment
PROMOTIONAL FEATURE
The SRM-22 Spill Recovery Machine could make an excellent investment for your facility
For further information email Warren Eburn at: sales@industrysuperstore.co.uk or visit www.industrysuperstore.co.uk
There are certain absorbents can you wring and re-use. After exhaustive tests, we have found that the absorbent mats manufactured by Darcy Spillcare work the best with the SRM-22. Socks and pillows are not recommended. Once you finish a spill clean-up, be it from an IBC or drum leak, pass your wet absorbents through the SRM-22. You’ll easily recover and recycle the otherwise oil spill wastage fluids. Note that any liquid materials you wish to recover must be non-flammable. Which typically excludes many solvents, paints, or combustible fuels. Coming soon and in development is our SRM-22E which will have an electric motor.
How do you get more out of your absorbents? And how do you increase efficiency for your bottom line, including reducing waste? If these questions sound familiar to your business, the SRM-22 is for you! Too often, companies lose materials because of an inability to recover valuable resources after absorption. For example, following an accidental oil spill or during day-to-day overflow leakage while handling IBC’s or other containers. This prevents those companies from meeting environmental standards, by forcing them to waste fluids when they could be recycling them. Likewise, the expense of using universal absorbent pads only once before disposal quickly adds up. As do the monthly bills of paying for waste removal services. However, using an SRM-22 can easily solve these problems. Not only will absorbent materials last longer, you can also keep and re-use the liquids you recover. There are multiple benefits of using the SRM-22 for absorbents. Here are just a few of the great reasons to consider investing in an absorbent wringer today:
By employing the SRM-22, the EPA reports that you can achieve annual savings of 51-75%
• Help your business go green! The SRM-22 allows you to recycle fluids, improving your environmental compliance. Not only that, you’ll meet waste minimisation goals by sending less materials to landfill. Which can also help minimise risks of them potentially leeching toxic hazmat chemicals. By employing the SRM-22 at your facility, the EPA reports that you can achieve annual savings of 51-75%. That is to say, you’ll spend less on purchasing brand new absorbent pads. Not to mention reducing outlays on chemicals and other liquids you use at your facility. That’s because you can easily recover fluids, so they last longer and you don’t need to buy them as often. As well, you’ll be reducing your monthly bill for waste disposal management services.
• Those cost savings quickly add up through spending less on supplies along with reducing your waste disposal costs. Enjoy buying your absorbents by the box instead of high volume pallets!
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• On average, the Environmental Protection Agency (EPA) reports that a hand wringer pays for itself in just three to five short weeks!
• It pays itself off quickly
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NORD-LogiDrive.jpg: LogiDrive is an energyefficient, service-friendly and standardised modular system for many different requirements and purposes Image: NORD DRIVESYSTEMS LogiDrive is an energy-efficient, service-friendly and standardised modular system. Depending on the industry and objective, different NORD products are combined into one drive solution, which is 100% tailored to the respective industry standards and application requirements.
The new extended LogiDrive solution space is intended for conveyor applications in the fields of post & parcel, airport and warehouse, and comprises one advanced version with IE5+ synchronous motor technology and a basic version with IE3 asynchronous motors.
additional applications access to the benefits of standardised, industry-optimised geared motor versions. With the new LogiDrive product family, the North German company offers a wide portfolio of perfectly matched drive solutions, which meet many different requirements and purposes – be it energy efficiency, version reduction, cost-effectiveness or flexibility.
While the LogiDrive advanced drives address issues such as energy efficiency, version reduction and Total Cost of Ownership (TCO), the basic LogiDrive’s main focus is on cost efficiency.
Extended solution space of standardised geared motor versions
User-friendly plug-and-play technology All LogiDrive systems are efficient and extremely easy to maintain and install thanks to plug-andDevelopment of the NORD LogiDrive system solution into a product family
NORD andwithLogiDriveexpandsDRIVESYSTEMSitssuccessfulconceptnewmarketsproductstogive
Give
With Brady Corporation’s complete RFID solution, assets in any industrial environment can be given unique digital identities just by applying a label. Users will be able to identify and locate labelled assets all at once, from a distance, in real time, without needing line of sight. Your needs. Your solution. To make RFID driven efficiency possible in any unique workplace, Brady leverages its global manufacturing capabilities and services to customise each of the components in its complete RFID solution. Label read range can be adapted, as well as all other label properties that enable labels to stay attached to any user’s asset selection in a wide range of industrial environments. Sensors can be embedded to capture environmental data including temperature or moisture levels. Scanners can be equipped with custom programmed apps that processes data to unlock the benefits a specific business needs, and Brady can integrate the entire solution with existing ICT infrastructure. A major leap in workplace efficiency Well implemented, quality RFID solutions enable a major leap in operational efficiency for many industries. With a handheld RFID scanner, multiple assets can be located, identified, tracked and traced from a 15m distance without needing line of sight. Fixed RFID scanners can even cover the entire workplace to considerably accelerate asset tracking. As a result, employees can quickly find any labelled asset they need, inventories can be automated, and outgoing cargo can be checked for completeness in seconds. Business at your fingertips Automatically collected data on all labelled assets can help inform strategic decision making on capital asset numbers, their locations, preventive maintenance and environmental elements. Decisions on stock levels can be supported by the latest data, all generated and collected automatically, to further drive business efficiency and profitability, all by giving assets a unique digital identity.
• Basic: IE3 asynchronous motor, two-stage helical bevel gear unit and NORDAC FLEX frequency inverter LogiDrive for warehouse • Advanced: IE5+ synchronous motor (ventilated or unventilated), two-stage helical bevel gear unit and NORDAC ON+ frequency inverter with integrated multi-protocol Ethernet interface
The whole concept is designed for optimum performance, highest efficiency and best possible userfriendliness. Utilising the high overload capacity of the motors and the system’s wide adjustment range, all solutions are individually tailored to each customer and specifically designed for the system’s individual load range.
August 2022 - industrialdirector.com - 33 play technology. The entire system has a modular design, so that all components of the drive technology can be individually serviced. This minimises maintenance and repair costs. All connections are made using simple plug connections while integrated maintenance switches and manual control switches ensure a high level of user-friendliness. NORD also supplies the cables. Potential sources of error are thus eliminated, and commissioning is facilitated. The compact design saves space and is light in weight thanks to the aluminium housing. Thanks to the design of the motors used and the operation on the frequency inverter, the same motor variant can be universally used Theworldwide.optimum solution for every application The new LogiDrive solution space comprises the following geared motor versions: LogiDrive for post & parcel and airport • Advanced: IE5+ synchronous motor and twostage helical bevel gear unit or DuoDrive plus NORDAC LINK frequency inverter installed close to the motor.
Brady www.bradyeurope.com/rfidCorporation Every Asset A Unique Digital Identity
• Basic: Fixed motor-inverter combinations consisting of IE3 asynchronous motor (87 Hz) and NORDAC ON frequency inverter with integrated multi-protocol Ethernet interface plus worm gear unit
Meta title: NORD: Development of the LogiDrive system solution Meta description: NORD DRIVESYSTEMS expands its successful LogiDrive concept by new markets and products. Learn more! www.nord.com
For more information about the functionality of C2 Lever Latches, please visit www.southco.com or email the 24/7 customer service department at info@southco.com.
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Southco’sfeature
New C2 Lever Latch Offers Auto-Relock Funtionality And Modern Appearance
With alockingfeatures,customizableversatilestylesandstreamlined industrial appearance, the push to lock C2 Lever Latch provides upgraded functionality that can be used to demonstrate compliance with industry regulations. The push to lock C2 Lever Latch from Southco offers a new autorelock feature to comply with industry regulations requiring a key to access equipment panels, such as ISO-TS 28923. With adjustable grip that overcomes manufacturing tolerances and prevents gasket setting, and multiple locking styles, the C2 series can be customized to fit a variety of applications. An integrated bumper helps to absorb vibration and noise, while preventing scratches to the panel frame. Additionally, the push to lock C2 Lever Latch has been redesigned with a more modern industrial appearance, providing a fresh option for manufacturers and design engineers. According to Global Product Manager Jonathan Coulter, “The push to lock C2 Lever Latch is an exciting new addition to one of our most successful product classes. The latch offers an auto-relock function to comply with regulations,new and the product’s versatile functionality makes it an ideal choice for a wide variety of applications.”
Southco has introduced the newest product in its successful C2 series of lever latches, with a new push to lock option that incorporates an autorelock
Theindustry.contract, recently completed successfully, is phase one of two for the refit of a 1989 vintage 3000 Ton ‘Chester Hydraulics’ SPF press, at BAE Systems Samlesbury in the North West.
Rhodes Interform, part of Group Rhodes, continues to lead the way in mechanical and hydraulic press manufacture and refurbishment with another major project win in the aerospace
The press is a critical piece of equipment that manufactures major parts for the Typhoon (Eurofighter) Aircraft.
Rhodes Interform’s machine refurbishments offer customers a cost-effective solution to dramatically improve equipment life and increase productivity. The company provides a complete one-stop refurbishment service, from arranging where necessary for the machine to be transported to the company’s maintenance facility in Wakefield, through to retrofitting new components and re-commissioning on site.
Rhodes Interform’s parent company Group Rhodes, based in West Yorkshire, boasts a 200 year metalforming history and has also been manufacturing presses to form composite materials from as early as the 1930s. The company has won Queen’s Awards for both Innovation and International Trade in recent years, particularly for its work in the aerospace sector.
Rhodes Interform’s Technical Director Peter Anderton said: “This is a specialist repair to the ‘hotbox’ ensuring the stringent temperature accuracies required during the manufacturing process are maintained. We won the contract based on our vast expertise in the manufacture, design and repair of SPF presses in the aerospace sector. The lockdown was obviously a difficult time for the industry, but over the past few months we have won a number of contracts for both new machinery and equipment refurbishment. We are very optimistic for the continued recovery of the UK aerospace sector.”
New InterformContractAerospaceForRhodes
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For more information please visit the website www.grouprhodes.co.uk or contact the Technical Sales department on + (44) 01924 37 11 61.
NSK High-Load Ball Screws Now Offer Even Longer Life 36 - industrialdirector.com - August 2022
Thedependent).newtechnology came about through a combination of NSK’s proprietary highprecision machining capabilities (including the development of dedicated machinery), the company’s digital-twin simulation technology, and its precision measurement systems (improved measurement accuracy by linking with machining data). As a further benefit for builders of machines serving high-load applications, adopting NSK’s new super longlife ball screw technology permits the use of a smaller shaft diameter, delivering a cost saving. The importance of new developments in ballscrew technology are vital for many machine builders. For instance, with sustainable development goals and carbon neutrality initiatives advancing in many countries, there is of course a need to enhance the environmental friendliness and functionality of industrial machinery. Here, manufacturers of injection moulding machines and servo presses, for example, are switching from hydraulic to electric drive systems using servo motors and ball screws to save energy.
August 2022 - industrialdirector.com - 37
Demand is increasing for high-productivity electric injection moulding machines capable of handling more complex shapes and larger sizes. As a result, OEMs in this space are looking towards ‘high-cycle’ designs offering short processing times. Quicker, more frequent operation in turn demands the use of long-life ball NSK’sscrews.HTF-SRC series of high-speed, high-load ball screws (100-200 mm outer diameter) takes advantage of the new super long-life technology. Notably, the dimensions are completely interchangeable with NSK’s current equivalent models, so no machine design changes are
NSK has developed new technology that significantly extends ball screw life in highload applications such as injection moulding machines and servo presses. The latest super long-life ball screws from NSK offer up to twice the service life of conventional ball screws thanks to the optimisation of load distribution. Resource conservation through extended life and the downsizing of machinery is a further advantage.
www.nsk.comnecessary.
The technology will have particular appeal for machine builders transitioning to electric Bydesigns.developing special long-life technology that balances load distribution more evenly, NSK could extend the life of its ball screws up to twice that of conventional designs (application
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The new Bore and Keyway Machining Service encompasses horizontal and vertical adaptations. The service that is expected to have the greatest demand is machining customer bore and keyways into pilot bored products such as sprockets and couplings. Sprockets are stocked either pre-bored to receive a taper lock bush, or as pilot bored versions that can be machined with multiple bore Insizes.addition, a bespoke service is offered enabling modification to off the shelf products.
Buck & Hickman, the UK’s leading supplier of andmaintenance,industrialrepairoverhaul(MRO) products and services, has launched a new fast and flexible Bore and Keyway Machining Service. This latest addition to the company’s range of engineering services has seen new bore, keyway and grubscrew machinery installed, operated by experienced inhouse engineers. Now, Brammer Buck & Hickman can rework products to suit customers’ specific requirements and within a short time frame.
For more information, please go servicesuk.rubix.com/en/service/engineering-to
Brammer Buck & Hickman is part of the Rubix group, Europe’s largest supplier of industrial MRO products and services.
August 2022 - industrialdirector.com - 39
Darren Smart, Category Director - MRO at Brammer Buck & Hickman, commented: “Whilst we have been providing a basic Bore and Keyway Machining Service to customers, up until now this has been Byoutsourced.investing in state-of-the-art machinery, and staff training, we are delighted to bring this service in-house, for a far more flexible service and a considerably faster
Weturnaround.cannow meet customers’ bespoke requirements and specific tolerances, regardless of whether it is non-standard or has a slightly different fit.”
The new Bore and Keyway Machining Service joins Brammer Buck & Hickman’s range of engineering services which include specialist workshop, gearbox repair and other engineering services geared towards saving customers money.
•Reducesbalancing:neutral back flow, reducing power
Leads to Annual Savings of Almost £5000 for a Large Bakery
•Can damage equipment due to voltage drop
•Stablewastagevoltage levels on individual phases
•Cable damage due to excessive current on a phase Real-time data leads to real savings
IoT consultancy Smarter Technologies was approached by a large UK bakery to help them determine how much energy they were wasting through an imbalanced load. With multiple large ovens consuming a lot of energy, they knew that the savings could be significant—in terms of both energy consumption costs and the maintenance and lifespan of their equipment.
•Unequal distribution of single-phase loads •Asymmetrical three-phase equipment and •Unbalanceddevices faults •Damaged wiring, and more In short, as more is added to a system over time, the more likely that the installer is not aware of the operating power load and is simply fitting the equipment where there is space available in the fuse Phaseboard.balancing is very important to reduce distribution feeder losses and improve system stability and security. Here are some of the advantages of load
Understanding load balancing opportunities begins by having energy consumption data and the ability to analyse it. Smarter Technologies used its SmarterView platform to review of the electricity being used on site. The realtime data from the bakery’s smart meters is collected, displayed and analysed on the cloudbased SmarterView platform, which Smarter Technologies used to determine:
In evaluating the data, Smarter Technologies Energy management is becoming an increasingly important component of business strategy for today’s FMCG companies, aimed largely at reducing energy costs, improving sustainability, and achieving ESG goals. According to the 2020 Deloitte Resources Study, half of industrial companies report incorporating energy management at the corporate strategy
•Whetherchargingthere was sufficient power to support an electric oven (64KV power load)
•Reduces equipment damage
•Whether there was sufficient power to support EV
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But there’s an element of energy management that’s often overlooked when large FMCG companies are identifying ways to reduce energy costs and optimise consumption—energy load balancing.
•Longer cable life •Prevents fire and other accidents Unbalanced load effects: •Causes difference in voltage across the individual phases
•Unequal system impedances
Loadlevel.Balancing
What is load balancing and why is it important? Large commercial and industrial properties (where half hourly electricity meters have been installed) have what is called three-phase supply—the power comes into the property and is split into three further phases. This is unlike residential or small commercial outlets which have single-phase electricity. When electrical equipment is installed at a unit using a three-phase system, it draws power across the three phases to operate. In general, threephase load balancing is the ideal situation for any electrical system as it determines the quality of delivered electrical power. In a balanced system, the total active/reactive/apparent powers are simply the sum of their respective phase powers. Put simply, power delivered to the premises is ideal and 100% efficient with no losses. However, as businesses evolve and add to their loads, the electricity provision can become unbalanced, leading to inefficiencies. An unbalanced system has a negative effect on power quality of electrical power at the distribution level. The voltages are quite well balanced from the source (the electricity board), but the voltage levels in the building can become unbalanced due to:
About the author Matthew Margetts is Director of Sales and Marketing at Smarter Technologies. His background includes working for blue-chip companies such as AppNexus, AOL/ Verizon, and Microsoft in the UK, Far East and Australia.
The cost of the wasted electricity at the bakery has been estimated on a kWh unit charge of £0.15 (fifteen pence), although the actual cost/loss will proportionally alter based on the actual price the bakery is paying. The total cost of the supply imbalance over the two units is £4,973.91 per year. Data from Bakery Unit 1 Data from Bakery Unit 2 Conclusion As a result of the load balancing audit, the bakery was able to take remedial steps to balance its energy load and save close to £5000 a year. Although there are some initial costs to get the load balanced, these are still likely to be far less than the annual wastage.
About Smarter Technologies Smarter Technologies tracks, monitors and recovers assets across the globe in real time, providing asset tracking systems to the open market and fulfilling the world’s most complex asset tracking requirements. Our services cover a vast array of business sectors, products and equipment from container or pallet tracking to military-grade devices; and can be used across a broad spectrum of
Recovering the wastage reduces long-terms costs and improves the business’ carbon footprint, as electricity not being used by the ovens can be diverted to another use, such as electric vehicle (EV) charging. Rebalancing the load will allow Smarter Technologies to identify the extent to which EV chargers can be fitted, as the number of units and the available charge load and timings can only be confirmed once the true available capacity is Informationunderstood.onenergy load balancing is rarely surfaced, but understanding the utilisation of power in a business is as important as knowing the cost of energy—especially if it is being wasted and limiting the scope of operations. As the old adage goes, you can’t manage what you don’t measure, so having the accurate, real-time energy consumption data at the tip of one’s fingertips is a crucial piece of the puzzle when it comes to optimising energy management.
August 2022 - industrialdirector.com - 41 sought to identify patterns that demonstrated a consistent load difference between the phases in excess of 25%. To determine what power might be available, the team looked at how the operations of the business affect the amount of power required. It was immediately apparent that the electricity load is imbalanced. Besides being a significant financial cost, the unbalanced system also affected the availability of power to support wider initiatives. Calculating the cost of an unbalanced system
Asindustries.aleading IoT company, we also provide smart building solutions for modern businesses, offering wire-free, battery-powered and low-cost IoT smart sensor technology. Our solutions will put an end to scheduled maintenance and help businesses utilise their building’s efficiency, benefitting from real-time alerts and facilities management tools that will bring them into the 21st https://smartertechnologies.com/century.
While prosthetic legs enhance mobility for amputees, standard prostheses are passive, meaning that they are unable to provide the required feedback to enhance motor skills including balance. Now, microprocessors combined with miniature motion control technology are enabling dynamic prosthetic control, helping to emulate the human reflex loop and improve the wearer’s gait cycle. For lower limb amputees, prosthetics can be an effective way of restabilising mobility. Modern prosthetic legs are manufactured from lightweight materials that enable easier walking, and for some, can even make activities like running possible. Despite these advances, most prosthetic legs do not allow their wearers to move with a medically accepted normal walking pattern, known as the gait cycle. This can present challenges for balance, especially when walking on uneven ground or gradients, as well as the ability to quickly respond to changes in speed or Activedirection.prosthetics emulating the gait cycle
Taking a standard gait cycle, communication runs from the brain to the spinal cord and then on to the nerves and muscles. Around 20 times a second, reflex loop messages between the muscles, nerves and brain interact to control the required motor skills. Standard prostheses are unable to replace this closed reflex loop, so passive prosthetic limbs give a less natural sensation for the user, typically resulting in less effective mobility.
Active prosthetic legs rely on hydraulic dampers throughout the gait cycle. This includes the stance phase when the foot is in contact with the ground, as well as the swing phase when the leg follows through. Hydraulic control is required to optimise motion and balance, particularly through the swing phase where the prosthetic limb must be slowed in preparation to support weight and enable propulsion.
Now, prosthetics have an active capacity that emulates the natural gait cycle more closely. Sensors placed in the knee and/or ankle are connected to a microprocessor embedded within the prosthetic leg. This creates a closed feedback loop with various conditional inputs used by the microprocessor to control integrated hydraulics that replace some of the human motor functions. The result is a more natural and effective response. Wearers of active prosthetic legs have reported increased mobility, balance, and a more natural gait, as well as regaining other skills such as walking backwards. Miniature DC motor technology
Intelligent Prosthetics Increase Mobility Through Miniature Motion Control
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The microprocessor receives live data from high resolution angle and pressure sensors, using this information to command the hydraulic damping system. The system’s spring forces are actuated in real time thanks to high performance miniature DC motors. To emulate the natural gait cycle as closely as possible, smooth control is imperative. As even minor elements of the jittery, cogging effect sometimes present in iron core motors would impede natural control, instead a coreless brushed DC motor with precious metal commutation is the optimum choice. A design such as Portescap’s 13N motor is capable of providing 3.3 mNm of smooth, continuous Designtorque. advantages for the real world
August 2022 - industrialdirector.com - 43 Light weight is also essential as excess affects prosthetic performance and makes wearing the device more tiring for the user. In addition, a small motor formfactor is required to integrate within the prosthetic and accommodate the adjoining gearbox. Used to control motor speed, a gearbox such as Portescap’s R13 planetary design is also combined with a magnetic encoder that provides data feedback for gait cycle control. With a diameter of 13mm, Portescap’s 13N motor is up to 30% smaller than other designs for the equivalent power density. Power to the active prosthetic system is provided by an integrated battery, so for prolonged use, motor efficiency is key. Coreless brushed DC motors operate with a low current draw and remove the possibility of iron losses. Typically, the coreless brushed DC motor can endure a day’s use before recharge, such as the Portescap 13N that operates at 75% efficiency. Living with the prosthetic also means that motor operation has to be low noise, another advantage of the coreless brushed design with smooth bearing
AsFutureassembly.developmenttheactiveprosthetic limb enables its wearer to engage in activities using greater mobility, the device also has to be rugged. Coreless brushed DC motors operate across the required extremes of cold and heat and are sufficiently resilient to endure the shocks and vibrations of the most demanding environments. An active prosthetic limb can last for around 5,000 operational hours, equivalent to around two years.
As active technology enabling improved mobility for amputees is advancing, miniature motor manufacturers like Portescap are working with prosthetic developers to create customised solutions. Development in microprocessor technology, alongside miniature motion control systems, is helping create a more able world. Image Captions: Image 1: Modern prosthetic legs are manufactured from lightweight materials that enable easier walking, and for some, can even make activities like running possible. (Image Source: AdobeStock_232970923) Image 2: Portescap’ s 13N coreless brushed DC motor (left) in combination with the R13 planetary gearbox (right) provides high power density and efficiency to extend battery operation for active prosthetic limbs.
Image 3: A coreless brushed DC motor, gearbox and magnetic encoder create a durable and compact assembly that can easily fit into the PortescapAboutprosthetic.Portescapoffers the broadest miniature and specialty motor products in the industry, encompassing coreless brush DC, brushless DC, stepper can stack, gearheads, digital linear actuators, and disc magnet technologies. Portescap products have been serving diverse motion control needs in wide spectrum of medical and industrial applications, lifescience, instrumentation, automation, aerospace and commercial applications, for more than 70 years. Portescap has manufacturing centers in the United States and India, and utilizes a global product development network with research and development centers in the United States, China, India and Switzerland. For more information, visit www.portescap.com
