PACE Aug 2020

AUGUST 2020 | VOL.74 NO.4 | Est. 1953

INSIDE PACE

Instrumentation

Reliability & Safety

Sensors

AMS stays strong during the COVID-19 crisis

How innovation leads to productivity

A device for every application

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NEWS

Toxic water “cleaned” by electricity

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team of engineers at University of Sydney engineers are one step closer to cleaning up heavily contaminated industrial waterway streams.

Researchers from the School of Chemical and Biomolecular Engineering developed an electrochemical oxidation process with the aim of cleaning up complex wastewater that contained a toxic cocktail of chemical pollutants.

The process involved treating wastewater with electricity using specialised electrodes. They discharged electricity, then drove oxidation reactions near the electrode surfaces, transforming the organic contaminants into harmless gasses, ions or minerals.

The researchers hope the findings will help wineries, pharmaceutical manufacturers and other industries that must comply with strict wastewater regulations.

“Our study, published in Algal

Research, involved industrial wastewater that had been heavily contaminated with a cocktail of organic and inorganic species during a biofuel production process”, said Julia Ciarlini Jungers Soares, who is completing a PhD in Chemical and Biomolecular Engineering under the supervision of Dr Alejandro Montoya.

The wastewater, which contained carbon, nitrogen and phosphorus, was generated in a pilot plant, designed by the team for the production of biofuels using naturally abundant microalgae.

“We have employed an incredibly powerful process that eliminates even the most persistent non-biodegradable pollutants, such as pharmaceuticals and pesticides, as well as various classes of organic compounds that can be found in many industrial effluents,” she said.

“The process is relatively simple, does not require the addition of chemicals or severe operation conditions, and does

not produce additional waste streams.”

“Wastewater is a significant issue for our environment, as well as for many industries who use substantial volumes of water in their processes, such as in reactions, transport, and washing and cooling. Finding suitable solutions for reuse or disposal is often very challenging and costly.

“The electrochemical method that we used can be readily applied to industries that must comply with strict regulations for wastewater disposal, such as pulp and paper processing, wineries, as well as pharmaceutical production facilities.

“Worldwide, researchers are investigating methods for the development of biofuels from algae.

Developing alternatives for the treatment and reuse of this industrial effluent is a hot research topic and can bring opportunities for energy and resource recovery within a circular bio-economy framework.”

Julia Ciarlini Jungers Soares showcasing her work at the University of Sydney.

The team will soon carry out research focused on specific contaminants to better understand the chemical transformations that take place during electrochemical oxidation and will upscale the process.

A 2017 UNESCO report found that the opportunities from exploiting wastewater as a resource were vast, and that safely managed wastewater is an affordable and sustainable source of water, energy, nutrients and other recoverable materials. PACE

Boron Molecular, KISCO and CSIRO kick off partnership

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partnership between Melbourne-based company Boron Molecular, South Korean manufacturer the Kyung-In Synthetic Corporation (KISCO), and the CSIRO, is one step closer to developing the next generation of flexible phone screens and other high-tech products.

CSIRO and KISCO will both take a minority shareholding in Boron Molecular. The investment, announced in Seoul on July 9, will enable the continued growth of Boron the company’s manufacturing capacity in Australia, and use CSIRO technologies to open up global markets.

Boron Molecular managing director, Zoran Manev thanked the CSIRO for their long-term trust and support.

“Now with the manufacturing

capability, international reach and reputation of KISCO, we can offer CSIRO’s chemical technologies at scale to a global market,” he said.

Boron Molecular and KISCO will use a suite of CSIRO technologies to enable manufacturing of high purity precision engineered polymers for flexible electronics, and many other applications in health, industry and agriculture.

CSIRO Advanced Fibres and Chemical Industries research director, Dr John Tsanaktsidis said the partnership will see CSIRO continue to use its science to strengthen local businesses and create future industries and jobs.

“The new agreement will bolster Australia’s sovereign manufacturing capability, create local jobs and open

the door for Boron Molecular to further commercialise CSIRO’s technology in new global markets via KISCO’s international links and production capacity,” he said.

“Our partnership with KISCO and Boron Molecular builds on more 40 years of CSIRO’s technological leadership in chemical processing and polymers, which has led to Australia’s plastic banknote technology, extended wear contact lenses, biodegradable plastics for biomedical applications, and many other products.”

KISCO CEO and president, Dr Sung Yong Cho said they will initially focus on flexible electronics.

“We’re looking forward to making the first products from this new partnership available to Korean electronics companies this year,” he said.

CSIRO processes and technologies that Boron Molecular are commercialising include: • Flow chemistry – CSIRO is pioneering the use of flow chemistry in Australia and has helped Boron Molecular integrate this efficient, cost effective, waste-reducing technology into its operations. Flexible electronics are created using polymers made through flow chemistry.

• CSIRO’s reversible additionfragmentation chain transfer (RAFT) – enables the production of polymers that are designed with enhanced properties for a myriad of uses across health, industry and agriculture.

• Metal Organic Frameworks (MOFs) – used to absorb molecules and harvest water from air.

• MS3 art conservation resin. PACE AUGUST 2020 www.pacetoday.com.au 3

NEWS

$2.8 million funding for Automotive Innovation Lab Access Program, more expected

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eventeen Australian businesses will share almost $2.8 million in funding under Round 2 of the Automotive Innovation Lab Access Grants program. The government investment is expected to unlock a further $3.6 million in industry funding.

Minister for Industry, Science and Technology Karen Andrews, said the support would help companies undertake a range of design, prototype and testing activities to accelerate

getting their creative ideas to market.

“This investment in the automotive industry is more critical than ever, especially as the automotive industry looks to chart its COVID-19 recovery,” she said.

“We’re backing businesses who back themselves to expand their highvalue product offerings to local and global markets. This represent our Government’s ongoing commitment to supporting automotive manufacturing operations in Australia,

particularly in niche areas.

“Innovation and testing new ideas are key hallmarks of the nation’s advanced manufacturing sector and it is this Aussie ingenuity which is vital to growing our economy and creating jobs.”

Among the successful applicants is Adelaide’s Lightforce Australia, which is receiving $200,000 to develop a next generation driving light to improve visibility by integrating advanced sensors and controls to automatically

adapt to driving conditions.

Innovative Mechatronics Group in Victoria has been given $103,000 for its project to develop Australia’s first national-scale hybrid battery aftermarket service for the reuse and recovery of retired batteries from hybrid-electric vehicles.

The Automotive Innovation Lab Access Grants program is a key element of the Government’s $100 million Advanced Manufacturing Fund. PACE

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NEWS

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Electric vehicle fleets to back up the grid

Nissan Leaf vehicles will participate in an Australianfirst trial to show how EVs can contribute to energy security by injecting power into the grid.

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team from The Australian National University (ANU) will lead research into how electric vehicles (EVs) can support energy grids.

Fifty ACT Government Nissan LEAF EVs and one ActewAGL Nissan LEAF EV will take part in this ground-breaking study that will allow EV batteries to provide power into the grid, almost instantaneously when needed, to avoid blackouts.

Research lead Dr Bjorn Sturmberg from the Battery Storage and Grid Integration Program at ANU believes the project has the potential to enable a more resilient energy system with higher levels of renewable energy, like rooftop solar.

“We know V2G works in the lab but we need to demonstrate the reliability and viability of V2G services in the real world at scale,” he said.

“We need to prove the control,

coordination, and cybersecurity of the technology systems, as well as the crucial business and regulatory models to make V2G attractive to all stakeholders.

“As a stepping stone to the field deployment the project will leverage the state-of-the-art grid simulation facility at the ANU – the Distributed Energy Resources (DER) Lab. This will allow the charger to be rapidly prototyped to respond to the frequency disturbances that occur when the grid is on the brink of a blackout.”

The Australian-first trial will show how EVs can contribute to energy security by injecting power into the grid.

The two-year Realising Electric Vehicles-to-grid Services (REVS) project, recently announced by ARENA, aims to demonstrate the feasibility of vehicle-to-grid (V2G) services.

The ANU team is working to unlock the wider potential of V2G services by researching their social, technical and economic aspects.

This transdisciplinary approach addresses the shortcomings of previous trials.

The ultra-fast reactions of EV batteries make them extremely adept at balancing the grid, according to Sturmberg.

“One EV battery typically contains as much energy as an average household uses over two-tofour days and can react to events in a tenth of a second,” he said.

“If all of Australia’s 19 million vehicles were electric, they would store more energy than five Snowy 2.0s, or over 10,000 Tesla Big Batteries.”

It is hoped the research will help transform EV charging from a challenge for the grid into an asset that boosts energy reliability and security.

The REVS project is supported by $2.4 million funding by the Australian Renewable Energy Agency (ARENA), as part of ARENA’s Advancing Renewables Program. The consortium covers the whole electricity and transport supply chain, including ActewAGL, Evoenergy, Nissan, Sgfleet, JET Charge, ACT state government and The Australian National University.

The Battery Storage and Grid Integration Program, hosted at ANU, is jointly funded by the ACT Government under the Renewable Energy Innovation Fund initiative and the ANU. Established in April 2018, as an initiative of the ANU Energy Change Institute, the Battery Storage and Grid Integration Program consists of a collaborative community that researches solutions to real-world energy and associated systems problems in a holistic manner. PACE

An intelligent, performant and configurable LoRaWAN indoor gateway for smart IoT applications. The UG85 is based on the Semtech SX1301 chipset, allowing to operate on multiple channels at the same time.

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UC11-N1 LoRaWAN Sensor Node A battery powered LoRaWAN node with 2xGP10 and 2 analogue input external sensors.

SKU: ULC-015 Price: $258.00 ea + GST

Ultrasonic Distance/Level Sensor EM500-UDL is a wireless sensor compatible with standard LoRaWAN protocol. Combining with the advanced LoRa technology and 19000mAh battery provide years-long life.

SKU: ULC-016 Price: $746.00 ea + GST

AM100 Ambience Monitoring Sensor

This unit consists of multiple smart sensors that are built specifically for indoor ambient measurements of temperature, humidity, PIR and light.

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Arduino Programmable IO

DigiRail NXprog is an Arduino IDE programmable device that has analog and digital inputs and outputs and RS485 and Ethernet communication interfaces that meets the requirements for use in industrial environments.

SKU: SIG-130 Price: $469.95 ea + GST

2 x 250 Ohm Precision Resistors Dual 250 Ohm, 0.1%, 1W resistors, suitable for converting 4 to 20 mA loops to 1 to 5V on DIN rail mount.

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4-20mA Loop Powered 4 Digit LED Display The Loopview plugs inline with a DIN 43650 connector, 4 to 20 mA powered pressure transducer to display the current pressure.

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For Wholesale prices Contact Ocean Controls Ph: (03) 9708 2390 oceancontrols.com.au Prices are subjected to change without notice.

AUGUST 2020 www.pacetoday.com.au 5

NEWS

JCB creates excavator powered by hydrogen

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CB has developed the first ever hydrogen-powered excavator. The 20-tonne 220X excavator powered by a hydrogen fuel cell has been undergoing rigorous testing at JCB’s quarry proving grounds for more than 12 months.

JCB chairman, Lord Bamford said the company will continue to refine the technology with advanced testing of the prototype machine.

“The development of the first hydrogen fuelled excavator is very exciting as we strive towards a zero carbon world,” he said.

Lord Bamford’s son, Jo Bamford, spent 14 years at JCB before moving into the hydrogen sector, setting up Ryse Hydrogen and then buying Northern Ireland bus giant Wrightbus. He has won contracts to supply the world’s first hydrogen double-decker to cities such as London and Aberdeen.

“I truly believe hydrogen is the UK’s best opportunity to build a world-leading industry, which creates UK jobs, cuts emissions and is the envy of the globe,” Jo Bamford said.

Power for JCB’s prototype

excavator is generated by reacting hydrogen with oxygen in a fuel cell to create the energy needed to run electric motors. The only emission from the exhaust is water.

The development comes after JCB made manufacturing history last year by going into full production with the construction industry’s first fully electric mini excavator, the 19C-1E. JCB has also extended electric technology to its innovative Teletruk telescopic forklift range with the launch of an electric model, the JCB 30-19E. PACE

JCB’s first hydrogenpowered excavator.

Deakin has sustainable energy future with MREP2 wind farm

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eakin’s commitment to sustainable Victorian communities and mitigating the impacts of climate change is bolstered by its official membership of the Melbourne Renewable Energy Project 2 (MREP2).

As a sustainability leader, the university will from July 1, 2020, start procuring 14 gigawatt hours of Deakin University has joined the MREP2 renewable energy project.

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renewable electricity per year through the Yaloak South Wind Farm at Mount Wallace, an hour west of Melbourne.

Deakin’s chief operating officer, Kean Selway said supporting the project and co-partners is a firm and considered step forward in the institution’s sustainability journey that will reap benefits.

“We are pleased to join the MREP2 membership, which progresses our commitment to economic, social and environmental sustainability and demonstrates our leading capacity to transition to cleaner energy,” he said.

“This is an important and very practical milestone in achieving our target of being carbon neutral by 2025, and contributing to a more sustainable future for the communities we serve, which we are very much a part.

“Our involvement enables us to power the innovative research, teaching and learning Deakin is renowned for at the Geelong Waterfront and Warrnambool campuses – and a portion

of the Burwood Campus in Melbourne.

Significantly, we will reduce emissions from these locations by 14,000 tonnes per year.”

Transitioning to 100 per cent renewable electricity is a key pillar of Deakin’s energy and emissions strategy.

In addition, procuring 14 gigawatt hours of renewable electricity per year through the wind farm will satisfy 25 per cent of Deakin’s total operational electricity requirements.

“Universities are in the privileged position of equipping the next generation of leaders, innovators and thinkers to understand the global climate challenges facing the world, and it’s important we lead with solutions that deliver community, economic and environmental benefits,” Selway said.

Deakin is part of a group of prominent Melbourne universities and businesses that has secured the MREP2 deal to power their operations with wind energy produced in regional Victoria.

Tango Energy will provide 110 GWh of renewable electricity per year to the purchasing group, over 10 years.

The purchasing group includes Deakin, RMIT University, Cbus Property, ISPT Property, Fulton Hogan, Citywide Asphalt, and Mondelez International. This new group includes 14 shopping centres, nine office buildings, seven educational campuses, and four manufacturing facilities.

MREP2 is the second purchasing agreement facilitated by Melbourne City Council through the Melbourne Renewable Energy Project. Combined with MREP1, the two projects represent the equivalent of a 5 per cent reduction in the city’s emissions, and a tangible shift towards renewable energy in the national grid.

The deal is equivalent to providing enough renewable power for more than 22,000 households a year. Combined with MREP1, it is enough power for 40,000 households a year. PACE

NEWS

Jane MacMaster new chief engineer at Engineers Australia

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ngineers Australia announced the appointment of Jane MacMaster to the newly created role of Chief Engineer in July.

CEO Dr Bronwyn Evans said the chief engineer will lead Engineers Australia’s engagement and policy discussion with industry, government, academia and other key stakeholders.

“The Chief Engineer will play an important part in delivering the organisation’s strategic vision and we are thrilled to have secured someone of Jane’s calibre,” Evans said.

“She will help ensure that Engineers Australia is well-positioned to provide

an extensive national recruitment process and commenced the role on July 15. PACE

financial services sector. Most recently she was Founder and Director of Ponder Enterprises, where she used her engineering skillset to address complex societal challenges.

MacMaster has a long association with Engineers Australia, including volunteer positions on the Accreditation Board and the Mechanical Engineering and Women in Engineering committees.

“Jane has a strong professional network that spans the industry, higher education and government sectors and I am confident she will make an immediate impact,” Evans said.

MacMaster was selected after

leadership for the profession in Australia in the crucial areas of infrastructure, energy, technology and climate change.”

MacMaster has a wealth of engineering experience gained in Australia and internationally, including senior systems and design engineer roles for BAE Systems Australia, for various aerospace and defence programs including a supersonic ship self-defence system project for NATO. MacMaster has postgraduate qualifications in International Relations and has previously worked as a Senior Strategy Advisor for the Department of the Prime Minister and Cabinet, and as a management consultant in the

Engineers Australia has appointed Jane Macmaster as new chief engineer.

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INSTRUMENTATION DISTRIBUTION

AMS covers a multitude of measurements through many applications and is a trusted partner in the industry.

Maintaining a wide offering to the market AMS distributes a good number of well-known instrumentation and calibration equipment brands to the Australian market. Peter Sims, analytical product manager from AMS Instrumentation & Calibration Pty Ltd shares his thoughts with PACE about its range and service offerings.

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MS Instrumentation & Calibration have been distributing a broad range of instrumentation and calibration equipment brands in its portfolio. Many of these manufacturers have been involved with AMS for many years and with some being loyal partners for 35-odd years. For these partner companies, AMS has been providing excellent service and giving them their best opportunities in the Australian market.

With an eclectic range of equipment that is sometimes seen as niche, Peter Sims, analytical product manager, said that AMS have to be better at what they do.

“Our company vision is key to how we operate – ‘AMS will be the trusted partner by providing unique expertise in offering engineering and product selection advice for instrumentation and calibration solutions’. All of our staff know that by heart and live it every day,” Sims said.

High-performing instrumentation equipment that AMS distributes include international brands like Beamex, 8 www.pacetoday.com.au AUGUST 2020

Fluid Components Inc, Bronkhorst, Azbil, Interface and McCrometer – all of whom are leaders in their chosen markets.

“These products are very broad. To name a few, we have liquid analysers from ElectroChemical Devices, portable combustion systems from Ecom, MTL Gas Analysers from Eaton and others.

Michell Instruments, whom we do distribution for as well, is a worldwide leader in the field of humidity and oxygen measurement. We have Ntron SIL-rated oxygen analysers and Optek who focuses on measuring process liquids through their interaction with light,” Sims said.

The increased market interest in analytical products

Through that broad array of analytical products, AMS covers a multitude of measurements through many applications. These applications extend to manufacturers who are looking for measurement applications for gases and liquids.

“AMS assists with anything from moisture measurements in gaseous

and liquid applications; the analysis of binary gases, oxygen in hazardous locations or where SIL2 rating is required; combustion oxygen and biogas monitoring,” Sims said. “Of course, some of these are best analysed via small sample system. AMS and our partners are also able to supply suitable packaged systems.”

Over the past six months, due to reduced staffing levels, Sims said that producers have looked to monitor more or upgrade their existing monitoring. During less challenging times, when there are adequate staff to manage a process, management often rely on consistency and “walk around” checks to ensure operations move along smoothly.

“With less staff, the measurements that were originally deemed as marginal or less critical, have become bottlenecks for them,” Sims said.

Previously less utilised instrumentation like dew point transmitters have now become much more critical. If there are personnel to manually visit, check drains and switch circuits, there is not much concern.

“Without manual checks from added hands, measurement becomes essential. Replacing old or uncalibrated devices have seen an increase recently.

As a result, we have seen strong sales with the Michell Easidew and their Service Exchange Program for annual calibrations along with their MDM300 portable dewpoint analyser,” Sims said.

Food and beverage

In the food and beverage sector, the Optek range of colour, turbidity and concentration analysers have seen growth in sales. In food and beverage, along with pharmaceutical applications, optical analysers can be applied to monitor the colour a process, for example red or green in edible oils, or reprocessed oils, or the clarity of sugar. They can also be used to monitor the turbidity of a beer or wine or when the CIP process has started to directly switch valves, all leading to better process outcomes by using in situ methods. Similarly, in a fermenter monitoring the growth of cells and finding the optimal point of harvest; or the separation process. In

INSTRUMENTATION DISTRIBUTION

pharmaceutical processes, UV is a very useful tool to monitor concentration of the dells of interest versus those of no interest. Targeting specific wavelengths can enhance yield and automate or just simplify operation.

Michell also find a niche in hydrocarbon dewpoint and water content of natural gas. These are two critical measurements for pipeline quality gas. The south-east of Australia’s reserves is in decline in guaranteeing quality supply which is essential for the pipeline owners and their users. Michell’s TDL600 (tuned diode array analyser) for moisture in natural gas features a class leading accuracy of +/- 1ppmv or one per cent of measured value and is designed to be as field serviceable as possible. Simple full module replacement makes service easy and site based. The objective is for users to retain the unit on site longer with a no return-to-base calibration after five years – a great saving of operating costs. “As the oil prices remains stagnant and we become nimbler, these are key needs. It also is much smaller and lighter than others thus allowing easy replacement of similar systems in the field,” Sims said.

Biogas

Prior to the country-wide lockdowns, Sims said that the biogas market was booming. There were a number of active projects where users wanted to monitor methane; carbon dioxide; hydrogen sulphide and oxygen out of a digesters or landfill.

“In the past, this market hasn’t been well serviced. Eaton’s MTL GIR6000 biogas analyser is a breath of fresh air – no pun intended – with some obvious advantages,” Sims said.

“Perhaps the lockdowns have taken our eyes off climate change and the events over summer, but as we once again try to reduce and use our waste, this type of analyser system will be in strong demand.”

Water monitoring

The demand for water monitoring devices is seeing strong demand. “Like other sectors, monitoring devices for water was either not used or obsolete. Innovative companies like ElectroChemical Devices In (ECD) who can supply a complete range of water analysers are now demand,” Sims said.

AMS’s partners have products that are well-differentiated and relevant for the market, hence the high demand.

Sims said that as we get through the COVID-19 pandemic, biotech applications are well covered by Optek’s equipment. These include the monitoring of fermentation, cell growth, filtration, etc – all are of great importance.

“Companies with these processes absolutely require solid, reliable and well supported equipment,” sims said.

“These clients want local support that is well educated, knowledgeable to the processes and applications but closely linked to the manufacturers. They want to know that support is close at hand if things go wrong, AMS are that trusted partner. “

Some partner standouts

There are some really well differentiated products that are distributed by the companies that AMS represents.

Michell’s TDL600 (tuned diode array analyser) for moisture in natural gas features a class leading accuracy of +/- 1ppmv.

Michell Instruments

Michell Instruments specialises in moisture and oxygen analysis and their Easidew Transmitter is ideal for the control of dew point in a process, but where precision is needed, such as calibration, their chilled mirror analysers are ideal.

Calibration for the Michell Easidew is done annually via a service exchange process that is simple, costeffective and efficient. Michell are also a fully qualified UKAS lab for moisture measurements. In addition, Michell have their own UKAS qualified calibration facility.

Optek

For over 30 years, German InLine process control solutions experts, Optek, is still at the forefront of online optical analysis. Their key market is the pharmaceutical industry.

“Here, often, the production is small, but the value of product is high,” Sims said. “One of Optek’s real differentiators is their easy of validation and sensor checking in situ.”

Optek’s key market is the pharmaceutical industry.

AUGUST 2020 www.pacetoday.com.au 9

INSTRUMENTATION DISTRIBUTION

Many of Optek’s sensors have a validation port included. A range of validation filters to calibrate the systems can be slipped into this. With colour and turbidity sensors, these are typically used for linearity checking of particular or broad wavelengths. However, for UV applications, where concentration is typically measured in a pharmaceutical plant, there are many filters that provide certainty.

For pharmaceutical companies, each batch of product are high in value. If one starts a batch not knowing what the primary measurements sit in relation to the true readings, the consequences could be costly – Optek’s products excel at mitigating these risks.

Eaton

“Our company vision is key to how we operate – ‘AMS will be the trusted partner by providing unique expertise in offering engineering and product selection advice for instrumentation and calibration solutions’.

All of our staff know that by heart and live it every day.” - Peter Sims, analytical product manager, AMS. Online analysers

In many instances online analysers provide almost instant payback to users. “We know that online oxygen is critical for the control of combustion efficiency in large boilers and furnaces,” Sims said. He singled out Michell Instruments’ XZR500 with its innovative solid-state reference and close coupled reduction system; Optek’s range of analysers that monitor colour, turbidity or concentration in liquids and some gases – extensively used in biotech applications and

Eaton’s MTL GIR6000 biogas analyser monitors methane; carbon dioxide; hydrogen sulphide and oxygen out of digesters or landfill.

Eaton/MTL’s GIR6000 for biogas applications is a modular system that can start small. It starts off just looking at methane and oxygen but can be expanded to H2S and carbon dioxide. In the not too distant future, gases such as hydrogen and carbon monoxide are expected to be added too.

“As mentioned earlier, the GIR6000 is that module replacement and upgrades can be performed on site, not needing a return to base process,” Sims said. “This is because returning this type of equipment, with cleaning and removal and shipping is expensive and very time consuming.”

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Previously less utilised instrumentation like dew point transmitters have now become much more critical.

online monitoring of many industries from dairy to petrochemical and water, where there are a vast array of other liquid analytical measurements such as: pH; conductivity; chlorine; specific ion; chlorine; specific ions; turbidity; and many more.

Getting the best support possible

AMS has supported Australian Industry for over 40 years. Dirk Kuiper, CEO of AMS and most of the staff at AMS have been involved in

instrumentation for a long time.

“We have a very stable team and the training at AMS has been second to none – Dirk wants his team to be supportive of our clients so that drives us to question and put customer service first,” Sims said.

In the current environment, Sims said that AMS was declared an essential service company as soon as the COVID-19 pandemic hit. About 80 per cent of their work was done from home, but a dedicated group travel into the office each day to look after the workshops and telephones and make sure products flow in and out as efficiently and effectively as possible.

“Although we have been locked down, our team have been called to make critical site visits,” Sims said. “As a mediumsized, independent company, we have found that our uniqueness and expertise has kept us busy with support, new enquiries and proactive activities.” PACE

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B E F EA TURED IN

Test and measurement instruments and devices are an integral part of monitoring and maintaning effective and safe operation of industrial processes and systems. Advances in smart sensor technology and the Industrial Internet of Things (IIoT) is transforming devices and what they can bring to operational management. Getting informed about what is happening next at the frontier of these developments will be crucial to those working in process control. The OctoberNovember feature of PACE magazine focusses on the latest in test and measurement technology across a variety of industrial sectors.

IF YOU’RE INTERESTED IN TAKING PART IN THE NEXT EDITION OF PACE, contact Danilo Cortucci at Danilo.Cortucci@primecreative.com.au

AUGUST 2017 www.pacetoday.com.au 1

RELIABILITY & SAFETY INNOVATION

Automatic lathe with six spindles wins gold vector award Two hundred and twenty-six entries from 32 countries were submitted for the 2020 vector award. During the jury meeting, which this year was conducted digitally for the first time because of the COVID-19, judges chose the most innovative applications in an online voting process. National sales manager, John Sharp, at Treotham Automation Australia shared his thoughts with PACE.

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igh speeds, long travels and compact installation spaces: every two years, igus GmbH bestows the vector award, with which fascinating and creative energy chain applications are honoured. This year, 266 entries from 32 countries were received.

The gold vector was won by the multi-spindle lathe of Gildemeister Italiana S.p.A. In a very restricted installation space, a total of eight harnessed energy chains guide cables and hoses reliably and safely.

Reduce lead times, set-up times igus awarded the green vector award for the first time. The prize went to sustainable drinks machine from Drop Water Co. and the sewage sludge turner from Huber SE.

and the effort required for process development and integration, and at the same time, do justice to the increasing degree of complexity involved: the new lathe from Gildemeister Italiana S.p.A., a subsidiary of DMG Mori AG, fulfils these requirements.

The heart of the machine is the spindle drum, with six spindles for simultaneous machining of several workpieces. The drum moves the workpieces to the tools quickly and very precisely. It only takes 0.65 seconds for one of the six spindles

to travel to the next position. For spindles to return to the starting position after machining has been completed in the six stations, the drum has to turn 300 degrees in reverse.

Treotham Automation Australia national sales manager, John Sharp, said the entries for 2020 showed how innovation leads to productivity.

“The automatic multi spindle gives the manufacture the ability to have flexible production on several work pieces at the same time, all contained in one dense

machine,” he said.

For this, the unit, which weighs over three metric tons, only needs one second. The biggest challenge: a safe energy supply system for all six spindles. The solution: a unique energy supply system that rotates with the drum and enables the linear movements of the spindle drums.

A total of 8 igus energy chains, 64 cables and 73 hoses are used in the automatic multi-spindle lathe.

An application for which Gildemeister Italiana has now won the gold vector and 5,000 euros in prize money. Awarded every two years, the prize is given for fascinating and spectacular energy chain applications. The jury consists of representatives from specialist journals/publications, as well as from the areas of industry and research.

Silver and bronze go to Austria and Germany

The silver vector award goes to AlpinaTec GmbH from Austria and its work on the GESTRA project for the Fraunhofer Institute. GESTRA is a radar-based system that is used to search for and map space debris. A complex rotary energy supply system specially designed for the azimuth axis and a two-sided double chain system for the elevation axis are used.

The bronze vector award has been won by Grenzebach Maschinenbau with its stir friction welding machine.

The energy and media supply components within the welding head as well as the adjacent construction all had to be flexible. For confined installation spaces, the coupling of a twisterband with an R4 energy chain proved to be a creative and fail-safe solution.

12 www.pacetoday.com.au AUGUST 2020

RELIABILITY & SAFETY INNOVATION

Premiere: Green vector award for sustainable products

Sustainability is very important to igus. For example, igus has been taking back used energy chains and recycling them since the end of 2019. For this reason, the jury also wanted to bestow an award for especially sustainable energy chain projects.

Sharp said it was important to foster green initiatives through the vector awards, and importantly, allay fears of plastic use.

“Since igus are primarily a plastics technology company they are mindful of the sometimes misplaced fear of the word plastic,” he said.

“Often plastic in the industrial setting is by far the greener option in terms of energy used in manufacture compared with steel and problems associated with oils for lubrication of steel parts and the product life cycle in general.”

The green vector award includes prize money of 1,000 euros and

The golden vector award goes to Gildemeister Italiana for complex integration of an energy chain system in a multi-spindle lathe.

goes to the company Drop Water in the US and the German company Huber SE. Drop Water received the prize for an automatic machine that fills biodegradable containers with beverages at the press of a button.

The water for the beverage does not have to be transported as the automatic machine is connected to a water source.

“Often plastic in the industrial setting is by far the greener option in terms of energy used in manufacture compared with steel and problems associated with oils for lubrication of steel parts and the product life cycle in general.”

A harnessed readychain ensures that the cables of the linear robot used are guided safely and reliably. In a water treatment plant in Egypt, Huber SE, the other winner, relies on solar energy to dry sewage sludge. Dewatered sticky sludge is reduced in mass and volume to about a quarter by solar drying and transformed into

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a granular material.

The plant will be used for the treatment of drinking water for 500,000 people drawn from the polluted Bahr El-Baqar canal system.

For the dependable supply of power and energy to the automatic machine, igus energy chains with chainflex cables are used in 128 units over a travel of 100 metres. PACE

MANAGEMENT >> TECHNOLOGY >> SOLUTIONS AUGUST

2020 | VOL.74 NO.4 | Est. 1953

AUGUST 2020

INSIDE PACE

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Reliability &

Safety How innov ation to productivity leads

Sensors

A device for every applic ation

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PACE delivers in-depth technical articles covering topics such as process control, automation, sensing, instrumentation, fluid handling, test and measurement, and network & communications.

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SENSORS VEGA is the only supplier on the market that has a solution with ceramic sensors in its portfolio.

As easy as child’s play VEGA has consistently come through providing the market with instrument updates. The VEGABAR 80 series represents a systematic further development of the concept and products.

W

ith the introduction of the plics family around 10 years ago, VEGA turned the vision of simple, standardised measurement of level and pressure into reality.

The clear structure of the new VEGABAR 80 series ensures easy selection when looking for the right instrument for a particular application. The new handling with “quick start” procedure allows fast, simple and reliable setup and commissioning. What is more, the integrated diagnostics system now makes really fast maintenance and servicing possible.

and ceramic measuring cells in recent years.

The biggest leaps in technology, however, are being experienced by the ceramic measuring cell CERTEC. This is the core technology for VEGA. Only a few suppliers have ceramic-capacitive cells in their portfolio, and fewer still have the know-how to produce them themselves. Eighty per cent of all units sold operate with ceramic sensors. In principle, both technologies can be used in the majority of applications. But VEGA is firmly convinced that in many cases ceramic is the better technology, because it is more robust and durable.

The VEGABAR 80 product line-up – making three from five

Being shock-proof

With the new VEGABAR 80 series, all conceivable applications can be covered with only three process pressure transmitters – The all-rounder VEGABAR 82 with ceramic measuring cell, which can cover 80 per cent of all applications.

VEGABAR 83 with metallic measuring cell, the first choice for high pressure applications. The classic VEGABAR 81 with chemical seal, which is always deployed when high temperature and/or chemical resistance is required.

Ceramic versus metallic A lot has happened in the development of both metallic

14 www.pacetoday.com.au AUGUST 2020

Of course, there are two sides to every coin. Ceramic measuring cells have many advantages, but also some weaknesses, e.g. their susceptibility to thermal shock and moisture. Through intensive further development of CERTEC, both of these problems could be significantly reduced or even eliminated altogether.

Equipping VEGABAR 82 with temperature shock compensation resulted in a technological masterpiece and patent for this worldwide innovation has already been applied for.

When sudden temperature changes occur, it can take several minutes before sensors with ceramic measuring cells begin delivering

reliable readings again. Users often did not know that a sensor was experiencing a temperature shock and transmitting incorrect values.

With the ceramic measuring cell in VEGABAR 80, customers can be absolutely sure that they are getting correct measurement data. Because now, even very fast temperature changes cannot affect the pressure measurement.

And this is how it works – in addition to the usual temperature sensor on the backside of CERTEC, there is a second sensor in the glass joint directly behind the ceramic diaphragm – this sensor is mounted in an extremely technically challenging process. Due to its exposed position, it doesn’t miss even the slightest temperature change. Any thermal shock is fully compensated by means of a sophisticated algorithm.

A side benefit of the second sensor directly next to the process is a temperature measurement of exceptionally high quality, with an accuracy of ± 2 K. Earlier versions of the measuring cell could also output a temperature signal, however, due to its slowness the sensor was only suitable for storage tanks, which normally have a relatively stable temperature. So now, in many applications, installation of a separate temperature sensor can be eliminated.

NAMUR has already commented very positively about this feature.

No problems with moisture The typical moisture sensitivity could also be significantly lowered. The problem with the naked electrodes of capacitive systems: ingressing dielectric fluid, such as water, changes the dielectric constant and the capacitance, and thus the pressure reading. However, the instrument cannot distinguish the reason for the change in capacitance. The solution: in the new instrument generation, VEGA has applied a measurement and a reference capacitor and covered the entire surface of the measuring cell with a thin layer of glass. Since due to the glass passivation there is no longer any contact with the medium, the dielectric constant in the entire system changes, that is for both the measurement and the reference capacitances. A coefficient is formed from the two values and computationally balanced for the measuring result.

Outstanding properties

Another special feature of the VEGA ceramic is its high overload resistance of up to factor 200 – more than double what other ceramics are able to provide.

Progress has also been made with regard to the temperature range.

120°C was previously the limit with the standard version, but CERTEC can now withstand temperatures up to 130°C. These additional 10°C are especially interesting for the food and pharmaceutical industry because, in

SENSORS

VEGABAR 80 customers can be absolutely sure that they are getting correct measurement data.

many cases, customers no longer have to buy the high-temperature version for their sterilisation processes.

Application temperatures have increased in relatively small steps, but when it comes to extending the measuring ranges, one could rightfully say that we have put on a pair of proverbial “seven-league boots.” VEGABAR 82 boasts a tiny measuring range of only 25 mbar (previously 100 mbar). And that completely without electronic turndown. In this area, too, we are in the lead – there has never been anything like it before. The measuring range has also significantly increased in the upward direction, from previously 60 to 100 bar. This has clearly extended the application limits. Customers will thus be able to solve even more applications with the standard VEGABAR 82 sensor in the future.

Applicable to any situation

CERTEC is the only ceramic measuring cell on the market that allows absolute front-flush mounting,

as its radial seal is recessed and protected from the medium. It can bring this advantage to bear especially in abrasive applications. Not without reason is it used worldwide in the paper industry in more than 40,000 measuring points. Buildup is also a thing of the past. The sensor simply cleans itself in the flowing medium.

Safe, reliable operation

Another key topic – Second Line of Defence. This feature is absolutely indispensable, e.g. in phosgene applications, in order to prevent the highly toxic medium from penetrating into the terminal compartment and endangering people and the environment. At present, customers have to resort to encapsulated absolute pressure transmitters with special chemical seal assembly. Now there are alternative solutions from VEGA. The VEGABAR 82/83 is a fully welded sensor module with a second line of defence, which, in combination with climate compensated electronics, can reliably and accurately measure

relative pressure even in such applications. This unique innovation allows very high measurement accuracy to be achieved also with small process fittings.

Reliable and stable measurement data are the most important feature of a pressure measurement setup.

VEGABAR 80 with SIL differs from a standard instrument both in hardware and in software.

VEGABAR 80 with SIL is a separate instrument developed according to the guidelines of IEC 61508. In single-channel systems VEGABAR 80 can be implemented up to SIL2, and in homogeneously redundant systems even up to SIL3 via the software.

Electronic differential pressure

An innovative software and hardware concept makes it possible to combine any two instruments from the VEGABAR 80 family, whether all-rounder, high-pressure or high-temperature sensor, into an electronic differential pressure system. What does this mean in

practice? For example, the customer only has to take a VEGABAR 82, a standard instrument that he has in stock anyway, order an additional sensor, select the “slave” electronics version and connect them together.

Users benefit from simple selection, identical adjustment and operation as well as simplified stocking.

VEGA gets positive feedback again and again on the simplicity and ease of use of its classic differential pressure system. These features have been systematically improved and further developed in the VEGABAR 80 series.

Further advantages of the electronic differential pressure system: There are no oil-filled capillary tubes that need to be insulated – usually at great cost – to avoid environmental influences such as temperature changes or strong vibration and the resulting measurement errors. And oil-filled chemical seal assemblies are usually quite expensive. An electronic differential pressure system is in many cases not only a simpler solution but also a more cost-effective one. PACE AUGUST 2020 www.pacetoday.com.au 15

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NEW PRODUCTS

Starter kit 4-port IO-Link master with IoT core and MQTT interface The robust components IO-Link temperature sensor, plug-in power supply with interchangeable adapter, Ethernet and sensor cable ensure fast and user-friendly connection of the automation technology to the IT world.

• 4-port IO-Link master with IoT core and MQTT interface • Start-up package for IoT applications for download • IO-Link parameter setting software “LR DEVICE” on USB stick • Including IO-Link temperature sensor, plug-in power supply with interchangeable adapter, Ethernet and sensor cable.

Starter kit IO-Link master With this starter kit you can immediately try out the IoT core interface of the IO-Link master on your desk.Connect the IO-Link temperature sensor to the IO-Link master and transmit the value of the sensor to different IoT software environments via TCP/IP JSON or MQTT. This is how you easily connect robust components from automation technology to the IT world.

Start-up package for IoT applications for download In this IoT start-up package, you will find practical examples on how to simply read and process temperature values with an internet browser, Excel, Postman or NodeRed. Advantages and customer benefits IoT core interface for the IT world The IoT core allows access to all data ranges of the IO-Link master and sensors. Established HTTP calls and JSON commands allow reading or writing of information. Connection to the IT world is made via the IoT core interface. In addition, ifm offers further IO-Link masters with different fieldbus interfaces for the automation level.

Display measured values in the internet browser or in Excel The quickest and simplest HTTP call can be made using an internet browser or Excel. The start-up package contains a small example of how you can display the temperature value in every internet browser.

You can also record temperature values in Excel for subsequent analysis and optimisation of your installation.

Sensor configuration with LR DEVICE The intuitive software finds all IO-Link masters in the network and creates an overview of the whole plant. In addition, all sensors connected are indicated with the respective parameters. This means that parameter setting of all sensors in the system is possible from one central point.

Easy sensor connection The sensors and actuators are connected via standard M12 connection cables without screening. Up to 4 IO-Link sensors can be connected and supplied with a total of up to 3.6A. The cable can be up to 20m long.

Secure digital data The sensor data is transferred digitally. Unlike analogue signals, contact resistance and EMC interference cannot corrupt the signals.

Company: ifm efector Phone: 1300 365 088 Web: www.ifm.com/au/en

C7015 ultra-compact industrial PC enables direct integration into machine environments With the new C7015 ultra-compact Industrial PC, Beckhoff combines its extensive expertise with PC-based machine control and IP 65/67 components. The result is an Industrial PC (IPC) designed with IP 65/67 protection for direct installation on the machine or other equipment. The edge device is ideal for decentralised installation and provides powerful multi-core computing performance. When used as a full-fledged control computer, the device also reduces the required control cabinet space. This simplifies machine design as well as subsequent system expansions.

Decentralised machine control with EtherCAT P The IP 65/67 IPC also serves as a highly functional machine controller.

Installing it directly in the field can save valuable electrical cabinet space.

This reduces machine footprints significantly, especially when combined with other Beckhoff components with a high protection rating, such as the AMP8000 distributed servo drive system and the EPP series of EtherCAT P I/O modules. These solutions can vastly simplify machine design while also minimizing the effort of subsequent system expansions, such as the addition of an energy data acquisition system.

The C7015 ultra-compact IPC, which measures 85 x 167 x 43 mm, is an economical yet high-performance IP 65/67 device designed for installation within machine environments. The space-saving, fanless device is universally suited to high-performance automation, visualization and communication purposes. Its applications range from classic machine control to the decentralized edge computing utilised in advanced Industrie 4.0 concepts.

The integrated EtherCAT P connection of the C7015 creates a range of new options for efficient sensor/actuator connection via the IP 67-protected EPP modules. In this way, even complex diagnostic or condition monitoring tasks can be decentralised and supported with minimal installation effort, for example. For that purpose, a special mounting plate enables direct attachment of an EPP module to the C7015. If required, additional EPP modules can be flexibly connected via EtherCAT P for specific applications.

High-performance edge device The C7015 is equipped with a powerful Intel Atom multi-core CPU with up to four processor cores. Compared to conventional ARM-based edge devices, it is able to support far more demanding applications as well as decentralised data pre-processing and the acquisition of large data volumes. The device housing with IP 65/67 protection rating is another feature that makes the C7015 ideal for use in modern edge applications, even in harsh production environments.

Company: Beckhoff Phone: (02) 8069 2333 Web: www.beckhoff.com.au

AUGUST 2020 www.pacetoday.com.au 17

NEW PRODUCTS

Close to the process with distributed automation Are you looking to automate your plant with a closeto-process and secure method? Bürkert provides the support you actually need thanks to its ideally matched and compact solutions.

The new valve island field module Type 8653 AirLINE Field makes an important contribution to decentralised automation, without the requirement of a control cabinet.

Discover just how easy it is to combine our wide range of components and integrate valve islands, control cabinets and process valves into an automation system that is fit-for-purpose for your production facility.

The advantages: • Shorter distances than with a central solution save energy and operating costs • Compact solution with a control cabinet or standalone field module • Fast and simple integration due to compatibility with all common communication standards • The components are robust and safe to clean and therefore ideal for use in cleaning applications When will you commit to the concept of distributed automation?

If the plant configuration demands densely arranged valves or plant sections need to be configured flexibly, distributed automation is the ideal solution for you. The individual components such as the control cabinet or field module and process valves are ideally matched, and this simplifies the planning and engineering work required thanks to their intrinsic compatibility and the fact that the whole platform is pre-calibrated.

Extending the solution is always a quick and easy option.

4. Well protected against corrosion and unauthorised access Bürkert device solutions are compact and available as a control cabinet or a stand-alone field module. The components are robust, easy to clean and yet protected against unauthorised access.

Guarantee process reliability and product quality Is fast switching the most important thing for you? The innovative Bürkert valve islands AirLINE Field can be installed directly next to the process. Due to the smaller pneumatic distances, your valves switch faster and you also save on compressed air and energy. Distributed control enables you to quickly and accurately identify faults and to switch off individual modules instead of the whole plant. This saves both time and money.

The valve islands AirLINE allow valves to switch faster They are easy to install, maintain and ensure reliable processes: The valve islands AirLINE reliably control process valves and other actuators, clearly show status and diagnostic information on the LC display and transmit this information to higher-level controllers.

Check valves in the exhaust air ducts make sure there is no unplanned actuation due to pressure peaks. In short: The valve islands AirLINE guarantee maximum process reliability.

The benefits of distributed automation

All Bürkert valve islands and pneumatic field modules are ideally matched and communicate reliably with each other. Due to this intrinsic compatibility, the amount of engineering effort needed for planning, installation and operation remains low.

1. Highest level of reliability for all plant processes With Bürkert valve islands you always have a clear overview of the device status – for fast monitoring and diagnostics. Thanks to the redundant ring topology and protocols, your processes always run reliably, and you avoid unwanted valve switching.

2. Extensive flexibility for your plant Bürkert valve islands can be installed directly in the field since they adapt to various set-ups. Needless to say, they support all important fieldbus protocols and can be connected to the Bürkert device platform EDP. 3. Simple start-up and fast maintenance The valve islands can be installed quickly and flexibly on the wall or on a standard rail. With a visual position indicator and a robust manual override, they are easy to operate and maintain: Rely on preventive and wear-optimised maintenance.

18 www.pacetoday.com.au AUGUST 2020

1. A irLINE Field can be connected to other higher-level controllers (PLCs) via the fieldbus gateway Type ME43 (stand-alone).

2. A irLINE Field can be connected to other higher-level controllers (PLCs) via the valve island Type 8652.

Fast start-up, comprehensively documented Fast response and delivery times, support and assembly services ensure efficient installation. The plug-and-play solutions can be configured quickly and easily, they are fully inspected and documented and thus allow for immediate start-up.

Company: Bürkert Phone: 03 9017 8225 Web: www.burkert.com.au

NEW PRODUCTS

ICP Electronics Australia presents iEi’s RACK-500AI-C246 5U artificial intelligence system ICP Australia introduces iEi’s RACK-500AI-C246 5U AI system with Intel Xeon E-2176G CPU (3.70 GHz, Hexa Core, TDP 80W) with Intel C246, pre-installed 16GB ECC DDR4 memory, HDMI, Dual Intel PCIe GbE, USB 3.2, iAMT, w/ 1 PCIe x16/x4 Slot BP and FSP350.

The RACK-500AI-C246 AI Compact Embedded System is powered by the Intel Xeon E-2176G processor. It is designed for Harsh Environment applications and supports Wall Mounting method.

RACK-500AI-C246 provides one PCIe x16 slot and one PCIe x4 Gen3 slot for building AI applications by installing iEi Mustang accelerator cards. Its I/O interfaces includes two USB 3.2 Gen 1 ports, two USB 2.0 ports, two GbE, and one HDMI. Features: • i ntel Coffee Lake C246 chipset with Intel Xeon E-2176G CPU (3.70 GHz, Hexa core, TDP 80W); • 1 x front-accessible 3.5” and 1 x 3.5” HDD drive capacity; • I ntegrated one PCIe x16 and one PCIe x4 Gen3 expansion slot (support maximum length 338mm PCIe add-on cards); and • great flexibility hardware expansion.

Company: ICP Electronics Australia Phone: (02) 9457 6011 Web: www.icp-australia.com.au

Katronic with Profibus PA – More than just a Clamp-On Flowmeter Katronic’s sophisticated KATflow 150 and KATflow 170 clamp-on, non-invasive flowmeters are now available with Profibus PA digital communications, providing plant operators with another piece of the Industry 4.0 jigsaw puzzle.

Company: AMS Instrumentation & Calibration Pty Ltd Phone: (03) 9017 8225, or (NZ) 0800 442 743, Web: www.ams-ic.com.au

Katronic equipment has always communicated the basic process measurements, along with maths functions to deliver relevant information to the user to aid decision making, but the addition of digital communications such as Profibus PA means that a wide variety of process variable data can be delivered simultaneously, allowing more sophisticated choices to be made, driving asset management and predictive maintenance so that users can schedule manpower more effectively and maximise plant uptime.

Industry 4.0, IIoT, plant digitalisation all hangs on the ability to gather and make sense of data. Katronic delivers a non-invasive, clamp-on device that can be easily added into the process without disruption or downtime and collects data on every aspect of the flow; from basic measurements such as flow volume, flow velocity and temperature to the way that the flow rate varies with the operation of other plant infrastructure like valves and pumps, even variations in the speed of sound through the fluid can be logged, allowing plant operators to build a picture over time. Changes in operational profiles can be tracked, actions taken, and maintenance prioritised, maximising uptime, increasing efficiency and reducing costs.

AUGUST 2020 www.pacetoday.com.au 19

We bring colour into view!

Compact pressure sensors and switches with 360° custom-colour status display

256 colours Individually selectable: Measurement in progress Sensor switching Process malfunction

15 cm

Compact design

Hygienic adapter system

Adjustment via smartphone

$ 547 VEGABAR 39 Clamp 1"

www.vega.com/vegabar