Worldwide Engineering Magazine - September Issue

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Featuring within this issue

September Issue

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Contents

Worldwide Engineering Magazine Providing timely industry news, exclusive features on advancing technology, equipment, materials, show previews, content marketing services for our valued clients and much more!

12 Microchip Announces High-Speed Devices The 2.0 interface standard was ratified last year

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SICK’s PBS Pressure Sensor

the PP20H pressure sensor with IO-Link

SICK has upgraded its pressure sensor, offering multifunctional PBS

The pressure sensor prevailed among the 17 finalists

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Micro Molding

Panasas Launches the New PanFS

Good micro molding partners should be fundamental

Dynamic Data Acceleration on the new PanFS® file system

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Pickering Interfaces

Electronic assemblies without PCBs

Fast turnaround, costeffective multiplexer

allows the user full, repeatable & safe control of a metal AM process.

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MAXXDRIVE® industrial gear units: Ideal for heavy-duty applications

MAXXDRIVE® industrial gear units from NORD DRIVESYSTEMS provide high output torques from 15 to 250 kNm and are ideal for use in heavy-duty applications such as agitators, belt drives, mixers, mills, drums or crushers. Thanks to the torsionally rigid onepiece UNICASE housing they achieve a longer bearing life than gear casings manufactured from jointed parts and ensure efficient power transmission and high tolerance for peak loads and impacts. Large lowfriction rolling bearings ensure extremely high axial and radial load capacities and a long service life. High-precision axis alignment ensures quiet running. NORD industrial gear units are offered as parallel gear units or as right-angle gear units and cover speed ratios from 5,54:1 to 400:1, as well as up to 30.000:1 with an auxiliary primary stage gear unit.

Mounting and fastening can take place on all six sides of the gear unit.

As standard, the series is equipped with a heavily ribbed UNICASE housing and an integrated axial fan. Due to the increased surface and the air guide covers, the cooling air flow is optimised and a very high thermal limiting power is achieved. In many cases, additional cooling is not required. Large roller bearings and centre distances increase the load capacity and service life of the components.

Economical modular system Based on the modular system, NORD plans complete and customised drive systems for heavy-duty operation. This way, attractive solutions can also be provided for price-sensitive industries. This is based on a comprehensive

MAXXDRIVE® XT for applications with high thermal limit powers NORD has developed its MAXXDRIVE® XT series 2-stage right-angle gear units especially for applications where low speed ratios in combination with high power performance is required.

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range of frequency inverters, motors, gear units and attached components like couplings, brakes, swing frames and many other options. For example, various versions of drive and driven shafts, mountings, sealing systems, back stops, auxiliary gear units, cooling equipment and sensors for condition monitoring (speed, temperature, vibrations, etc.) are available. For each application, respective features such as hydraulic couplings tailored to the particular process and gear unit, or Taconite seals that effectively protect shaft sealing rings against abrasive dust and corrosion, ensure smooth operation. installations as well as for decentralised, fullyintegrated drive units. www.nord.com

SICK’s PBS Pressure Sensor Has More ‘Plus’ Points

SICK has upgraded its pressure sensor offering with the versatile and multifunctional PBS Plus, combining electronic pressure control, measurement and realtime monitoring in one IO-Link enabled device.

The next-generation SICK PBS Plus combines application versatility and high-machine availability with an improved measurement capability between 0.4 and 1000 bar (gauge pressure). The high 0.5% accuracy, and a scalable analogue output with 5:1 turndown ratio, supports the ability to set even small measurement ranges to suit the application.

With IO-Link as standard, PNP/ NPN and analogue outputs available, the SICK PBS Plus can ably turn its hand to many process switching, measurement, and pressure data feedback duties.

The highly corrosion-resistant stainless-steel membrane and IP67 heavy-duty plastic housing make the PBS Plus a robust and economical solution for common process applications, such as measuring system pressure, hydrostatic level measurement or monitoring cylinder pressure in hydraulic presses.

“Many of our customers already appreciate the highly-visible on-sensor display of the SICK PBS together with the ability to rotate the device, so that the electrical connections, display

and control buttons can be aligned in the best orientation to suit the installation.

“The beauty of the PBS Plus is its versatility to be put to work on a wide range of duties for which previously it would have been necessary to order or store several different variants,” explains Darren Pratt, SICK’s UK. “With the easy configuration benefits afforded by IO-link, the PBS Plus can be simply adapted to many different measurement and switching requirements.”

pressure range of up to 0 to 25 bar, and vacuum measuring ranges available up to -1 to +24 bar, there is a PBS Plus for almost all applications. The pressure units on the display can be changed to psi, MPa, kPa, kg/cm2 as required.

For more information please contact Andrea Hornby on 01727 831121 or email andrea.hornby@sick.co.uk.

Visit website: www.sick.co.uk

The SICK PBS Plus pressure sensor also provides users with a wealth of additional data. It can send process data via IO-Link to the control as measured values in bar, as well as displaying and transmitting process temperature readings in °C. The sensor records and counts over-pressure events, as well as logging operating hours together with high and low pressures and temperatures. It therefore aids process resilience and provides valuable data for condition monitoring and predictive maintenance.

Set up of the PBS Plus is straightforward using the three push buttons and onsensor display. There is also no need to convert the IO-Link process data, as it is transmitted automatically as measured values. With a choice of gauge pressure ranges from 0 to 0.4 bar up to 0 to 1000 bar, absolute

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Wide range of compact, robust hand held case models from BCL Enclosures manufactured in UK for fast delivery The BC range of hand held boxes from BCL Enclosures, the specialist UK manufacturer of standard and custom plastic enclosures, includes a number of different models suitable for a wide range of applications these protective cases can be used for measuring instruments, wireless communication devices, control and data recording devices and many more.

The hand held case with battery compartment and belt/ pocket clip option, Model BC2, has an integral PP3 battery compartment with a removable cover and clip-in terminals supplied as standard. Four internal location pegs and sockets hold a PCB securely in place without the need for further fixings. The case is held together by two self-tapping screws concealed by the battery cover for a neat finish. The pocket/belt clip is supplied with each case and can easily be fixed to it with two supplied screws. Manufactured from ABS, standard colours are matt black, white or light grey, with other RAL colours available on request. The front of the case has feature panels which provide an excellent surface for customization such as company logos. The case measures 103mm high by 62mm wide by 23mm deep. Nominal wall thickness is 1.5mm.

A hand held case model, BC3, has a battery compartment and separate front cover model with an integral PP3 battery compartment accessible by a separate removable cover.

Again, the two main halves of the case are held together by two supplied self-tapping screws concealed by the battery cover.

The integral bezel and front cover can be removed for ease of manufacture. In moulded ABS, colours are high-impact matt black, white or grey with a polished front panel.

BC3 measures 118mm high by 66mm wide by 33mm deep.

Nominal wall thickness is 2.0mm.

Model BC5 hand held case offers a recessed front panel, battery compartment and a belt/pocket clip option.

The recessed front panel is suitable for a membrane-type keypad. The integral battery compartment is accessed by a separate removable cover and the two halves of the case held together with two concealed screws (supplied). There is also a handy optional pocket/belt clip supplied with the case that can be fixed in place with two screws. (The pocket clip BPC5 is also available separately). BC5 measures 92mm high by 63mm wide by 24mm deep. Nominal wall thickness is 2.5mm. BC5 is available in matt finish black only as standard, although RAL colours are available on request for both BC5 and BC3.

The final model in BCL’s range of hand held cases is an instrument or calculator case with a battery compartment, moulded from matt black or white ABS. The BC4 case has an integral battery compartment, with a sliding cover that will take two PP3 type batteries. Internal PCB pillars are provided in both halves of the case, which are securely held together with four supplied self-tapping screws.

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The final model in BCL’s range of hand held cases is an instrument or calculator case with a battery compartment, moulded from matt black or white ABS. The BC4 case has an integral battery compartment, with a sliding cover that will take two PP3 type batteries. Internal PCB pillars are provided in both halves of the case, which are securely held together with four supplied self-tapping screws.

At the window end of the case there is a removable panel for leads or a window for infra-red remote control applications.

Measurements are 154mm high by 81mm wide by 37.5mm deep at the upper end, tapering to 33mm deep at the lower edge. Nominal wall thickness is 2.0mm. The display window is 49mm x 20mm.

BCL Enclosures’ products are manufactured in the UK, which overcomes the supply issues often found with non-UK manufactured items. Products are available from stock or on very short lead times. In addition to the above hand held range, BCL Enclosures offers a very comprehensive range of plastic enclosures and power supply units. Advice on enclosure specification and a full gamut of custom and customization services are also available. For more information please visit: BCLEnclosures.com

Micro Molding — combining competencies and values of your chosen micro molder, because values will define the nature of the partnership that you will forge, and it will also allude to the levels of aptitude and working practices that will underpin your relationship.

The dichotomy is between core competencies and core values. The former you can buy.

The latter come from attitude, management and team ethos, and are driven by knowledge, passion, respect, morals, and reflect the beating heart of your micro molding partner.

Aaron Johnson, VP of Marketing and Customer Strategy, Accumold.

I cannot play the violin!

There, it’s out in the open, and I feel better for letting everyone know.

As a micro molding expert that is about to discuss with you the necessity of combining expertise and a suite of topend technology options when seeking precision molding solutions, why I hear you ask is this relevant?

Well, my lack of ability at playing the violin is a key failing if I am to play melodious music. And it is the defining factor whether you put a $10 violin from Walmart in front of me or a $1 million Stradivarius. Whichever violin I pick up, the noise will be the same. Awful!

The same is the case when looking at the art and science of micro molding. What differentiates a successful and market-leading micro molding company from a mediocre one is not the kit that resides in-house (anyone with a line of cash can buy good kit) , it is the inherent expertise in the micro molding team that is the

differentiator, and it is identifying the extent and power of this expertise that is crucial to partner selection and successful micro molding outcomes.

Core Competencies and Core Values I have made the point for a number of years now that the relationship between a micro molding expert and a customer should be a healthy, pragmatic, and in-depth partnership. When working on a micro molding project, it is unlikely that you will have the necessary technological infrastructure to undertake your own project in-house, so you lean on a company that has made the necessary investment in all the right tooling, molding, validation, and automated assembly technologies.

But what you are really seeking is access to the knowledge base that resides within your chosen micro molder’s team. Boil it all down, you need to make sure that your micro molding partner can push the parameters of what is possible and innovate on your behalf, not just flick a switch and hope for the best.

So it is that you are buying into and need to explore the values

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When it comes to marketing and image, in these days of easily created and slick looking websites and marketing materials, it is easy for middle of the road companies to present an image that flatters to deceive.

Let’s face it, spending a few hundred bucks you can have a world-class looking website that says all the right things.

But next time you search for a supplier and line up your top 10 websites, take a step back and have a real look. I will guarantee that the ones that are maybe not all they are cracked up to be list an impressive array of competencies, but you will see very little about the values of the company, its heritage, its beating heart, what is inherent in its DNA. It is my belief that values are what drive competencies.

It is the values inherent in a company that allows it to make and more importantly PROVE claims. Proof is everything, and to prove competence, you have to be able to demonstrate the correct ethos, knowledge, understanding, and values to achieve what in the micro molding world are often impossibly complex and testing manufacturing challenges.

Core Values for Micro Molding Success So, the time has come when you

have short-listed your potential micro molding expert. It looks as if they have the technological wherewithal to make and validate precision plastic parts.

Good start.

Now however comes the slightly less easy to assess and quantify aspect of your short listed micro molder. You understand that this company will be an integral part of your product development process, a true project partner, and so you need to get under the bonnet and in effect look into the whites of their eyes and work out what makes this company tick and how it works.

Of huge importance is an assessment of the knowledge that resides in the team, and here there are no short cuts.

Knowledge comes from experience, and experience comes from the number of years that your chosen micro molder has been at the vanguard of innovation in micro molding. If a company has three decades of experience molding in a variety of industry sectors it will be better placed to navigate the vagaries of your product development process than a company with less than 10-years experience, or one with a restricted knowledge of only one industry sector.

When micro molding, I have found that at every turn customers require smaller and smaller parts with more and more exacting tolerances, and very often there is a resignation at first meeting that they feel that maybe they want the impossible. Customers owe it to themselves to know that their chosen micro molding partner has the experience and understanding to go that extra mile and come up with solutions and optimal, timely, and costeffective solutions however challenging the application.

With the required knowledge set in the bank, a micro molder must then be able to exhibit a set of core values that motivate success. Every member of the

Accumold team, for example, signs up to and lives by the core values of the company that underpin and motivate everything that we do.

Without the right values, competencies and processes can be weak and produce suboptimal customer experiences and results.

Every member of the Accumold team is characterised by dedication and integrity. Each member of the team is defined by customers’ success, and each is dedicated to the provision of optimized solutions within budget and on time. Accumold’s team focuses ONLY on customer satisfaction, integrity meaning that every project we work on is characterized by an honest, pragmatic and collaborative working relationship with our customers. By doing this we add real and tangible value to a customer’s micro molding project.

Micro molding is Accumold’s absolute focus. The company has existed at the cutting-edge of micro molding for its entire 30-plus year history, and as such the company owns the space that other suppliers are trying to migrate to from the world of less exacting precision molding, where size and tolerance are less difficult.

Good micro molding partners should be seen to nurture the fundamental meaning of partnership. Results are always better when knowledge is openly shared throughout a team, and this also allows teams to be creative and find practical micro molding solutions for any application.

solutions that facilitate micro tool fabrication, validation (if a part cannot be measured to prove adherence to design intent then it is useless), and automated assembly.

With the requirement to mitigate risk of tolerance creep at every stage of micro product development, it is critical that micro molders have the technology to hand to undertake every stage of product development in-house.

True vertical integration as I have said many times is not just desirable but is in fact fundamental to successful micro molding outcomes.

Summary So what have we learned? First, I cannot play the violin!

Second, when embarking on a micro molding project you want to make sure that your chosen supplier not only has the best violins to hand, but they have the experience, knowledge, versatility, passion, drive, and enthusiasm to play them like a virtuoso. Values and competencies combine to make sweet music when micro molding. You do not want someone with no aptitude playing a great violin, and you do not want a virtuoso playing a Walmart toy. You want Yehudi Menuhin playing a Stradivarius.

Interrogate you micro molding partner carefully to ensure your projects hit the right note.

For more information, please visit: www.accu-mold.com

Core Competencies for Micro Molding Success To an extent I have played down or taken for granted the competencies that a good micro molder must be able to demonstrate. Micro molding involves much more than micro molding per se. It also requires expertise and technology

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Sensor applications in agricultural machinery

As part of the many sensor technologies now widely employed in smart farming, where sophisticated monitoring and control is now universally applied to optimise crop production, mobile agricultural machinery manufacturers are increasingly utilising precision sensors as part of the equipment and systems they produce to till, seed, and harvest crops to further maximise productivity. Variohm EuroSensor – a leading sensor manufacturer and a sensor component distributor – has successfully undertaken a number of applications with UK and European farm machinery manufacturers for position, load, pressure and temperature sensors with almost all of them installed in harsh outdoor environments where large temperature extremes as well as severe shock and vibration conditions exist - and upmost reliability is essential.

Applications range from angle sensors in sophisticated four-wheel steering systems that allow farm machinery to precisely manoeuvre in tight spaces for maximum crop yields to linear position and load sensors that are part of advanced mobile autonomous vehicles linked to the Global Navigation Satellite System (GNSS) for vehicle guidance and load weight measurement.

These various types of sensors serve numerous measurement tasks. Some are configured open loop with the position or load information simply fed to a visual display to allow manual operation of a process. Other automated and autonomous machine tasks involve the sensing component as part of closed loop systems where often multiple functions are synchronised, for instance with vision systems and linear motion positioners or rotary actuators for tasks such as in-row weeding or selective crop harvesting.

The high precision angle and linear position sensing technologies offered by Variohm include potentiometric based sensors where there is a physical contact between a conductive plastic track and wiper contact in a housed assembly. As the sensor is extended or rotated, the position information is provided as a linearly proportional voltage measurement.

For rotary angle sensing, Variohm offers two Hall Effect technologies where there is no contact between a fixed sensing element and a rotating magnet.

Whilst these sensor types do not differ in 1/4 the actual way the sensing takes place, they can be differentiated

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by the first ‘non-contacting’ type having an enclosed and housed assembly complete with bearings (so there is a degree of contact involved) and a second type of ‘touchless’ sensor where the sensor and magnet are supplied as separate components and mounted by the customer between the fixed and rotating components.

Variohm manufactures a range of Hall Effect angle sensors that are well suited to agricultural applications. Three mechanical design formats with encapsulated sensor electronics form the Euro-XP, XPD and XPK series. The XP and XPD are durable, housed versions featuring optional ‘U’ or ‘Spring’ shaft drives and a D-shaft drive respectively, both with flange mounting and integral bearings.

The third version, the Euro XPK, is a two-part ‘puck and magnet’ contactless design. Variohm’s comprehensive range of angle sensors also covers noncontacting sensor technologies with multi-turn capability so that, if attached to ballscrew or leadscrews for instance, they can be calibrated to measure travel length.

For linear position measurement based on a non-contacting measurement principles, magnetorestrictive technology and variations that offer added reliability are available.

As separate two-part rod and sensor components, they are assembled inside hydraulic cylinders (in-cylinder’) for position feedback or mounted alongside multiple cylinders typically for telescopic boom control. They are also available as especially robust housed components where a linear support bearing is used.

Clearly, as wear and working life are important aspects for agricultural, and many other mobile machinery applications, the sensors that necessitate contact between sensing elements are possibly less favoured than non-contacting and touchless sensors. Also, in terms of robustness, where the separate sensor and magnets can be epoxy-potted and effectively protected from air and liquid ingress, these technologies are perhaps favoured for the most arduous tasks where long life, low maintenance and best reliability can be assured.

Also for medium precision linear position sensing, and especially useful for long distance measurement, the cable extension sensor combines a rotary sensor on a cable winding drum and a spring-assisted winch mechanism. As the cable extends from the drum it rotates the shaft driving the internal

rotary sensor. The sensor technology used in the cable extension sensor can be potentiometric (sometimes called a string pot sensor) or incremental or absolute encoder.

Across this wide choice of position sensor types, accuracy, linearity, repeatability and other factors such as IP rating (up to IP69K), shock and vibration durability can be tuned to the application. The same applies for electrical input levels and electrical output requirements which cover analogue, ratiometric and many choices of digital output including CANopen, SAE J1939, SSI, and many more. Variohm also offers custom modification of electrical and mechanical interfacing to make customer installation as easy as possible.

Variohm’s wide range of pressure sensors are used in hydraulic systems as well as engine pressure measurement – from the sensor manufacturer’s comprehensive automotive industry offerings. Combined pressure and temperature sensors are usefully applied to process related tasks in crop storage, farm fertilizer dispensing machinery and hydraulic control management.

Load cells, from an extensive range of product types used

by the weighing industry and scale manufacturers, are in widespread use for bale weighing and load sensing for harvested crops in silos and mobile agricultural machinery. The load cells are well proven in similar applications in the construction industry, large commercial transportation vehicles and more. Variohm’s temperature sensors are extensively used by manufacturers of instrumentation systems for measuring ground temperatures and as part of other environmental measurement equipment.

With its longstanding distribution partnerships with several leading sensor manufacturers and wide application experience, plus design and assembly expertise and its own range of manufactured sensor products, Variohm EuroSensor offers complete sales and application support across a comprehensive range of sensor technologies for position, force, pressure, load, and temperature measurement in demanding measurement application across industry, motorsports and research.

For more information, please Vist: www.variohm.com Email: sales@variohm.com or call +44 (0)1327 351004

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Microchip Announces High-Speed CoaXPress® 2.0 Devices Until the 12.5Gbps CoaXPress 2.0 interface standard was ratified last year, machine-vision imagecapture solutions had replaced conveyor belts as the primary roadblock to achieving faster production-line throughput.

Now, Microchip Technology Inc. (Nasdaq: MCHP) has taken the next step toward realizing the full potential of CoaXPress (CXP) on the factory floor with the first single-chip physicallayer interface devices to include features that streamline machine vision system design, maximize transmission speed and simplify deployment in high-volume bottling operations, food inspection, industrial inspection and imaging applications.

“We have worked with the Japan Industrial Imaging Association (JIIA) standards organization and our lead customers to optimize our offering in conjunction with CXP so it fully exploits the specification’s benefits on the factory floor,” said Matthias Kaestner, vice president, Automotive Infotainment Systems business unit. “Our low-latency, lowpower transmission solutions integrate an equalizer, cable driver and clock data recovery into a single chip that enables camera and capture card manufacturers to deliver highspeed, high-resolution video and control signaling along with power over a single coax cable.”

Microchip’s EQCO125X40 family of CoaXPress devices is the first to implement the CXP 2.0 standard, starting from a new backward compatible design based on the specification, with an integrated clock data recovery (CDR) at all speed levels and a camera-side clock to support the demands of realworld environments. The devices significantly increase machinevision processing throughput by enabling cameras and capture cards to transmit four to eight times faster than alternative solutions. In addition, these

devices enable four times the cable/link distance with much lower power and near-zero latency.

The product family also increases design tolerances and flexibility by seamlessly locking on all frequencies at any speed, from CXP-1 to CXP-12, and eliminates the need for multiple channels by supporting 12.5Gbps of bandwidth over a single cable.

Broader cabling options ensure systems can be installed where needed and the integrated CDR improves jitter performance for the signal sent from the camera to the capture card.

The on-camera low-frequency clock recovery eliminates the need to program a separate clock in the FPGA. The integrated link signal integrity testing enables the system to perform real-time checks of cable link integrity before and during operations.

For card makers, Microchip’s new offering makes it easier and less expensive to develop more robust products that customers can deploy wherever they need them on the production line. The products enable presetup and real-time cable link quality tests to be performed, giving users more robust and comprehensive solutions to their challenges. They also have the option to scale up to 50 Gbps over multiple cables.

“Microchip’s new CXP-12 family provides our latest products with a compact and low component count single-chip equalizer solution which can therefore easily meet the CoaXPress return loss specification,” said Chris Beynon, CTO with Active Silicon. “The devices also have an elegant feature to allow real-time cable margin testing to detect aging or worn cables before any bit errors would be seen in normal operation.”

Microchip’s CXP devices enable manufacturers to get the same throughput from two ports on cameras and frame grabbers

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as they previously could with four. The devices can be used to retrieve a real-time lowfrequency clock at the camera side, which provides more accurate signal timing. The manufacturers can also use it as a cable repeater, further extending the distances over which the cameras can be linked. Their low power consumption makes them ideal for bringing to market smaller, better-performing imagecapture solutions that increase customer value yet are simpler and less costly to design.

In addition to providing key capabilities that Microchip believes will help to accelerate the adoption of betterperforming, lower-cost machinevision solutions in industrial inspection applications, the company expects that its CoaXPress 2.0 family will have an equally transformational effect on applications including traffic monitoring, surveillance and security, medical inspection systems and embedded vision solutions. The family is part of an extensive product portfolio spanning the requirements for creating total system solutions, including Microchip’s 12Gbps PolarFire field programmable gate arrays (FPGAs) that seamlessly support the CoaXPress protocol with minimal developer effort while enabling a low-power, low-latency and small-footprint solution.

For more information, please Visit: www.microchip.com

Working with Clwyd Compounders Elastomeric Compounding Specialists Clwyd offers industry leading support for all heat curable elastomers, in terms of quality, development and technical support, no matter the industry. Our team of five technologists and eight laboratory staff are on hand to work closely with our customers to give them the competitive edge, no matter what type of compound or volume required. They are backed up by a highly skilled manufacturing team, experienced in supplying quality consistent compounds and a laboratory with the ability to undertake extensive testing.

Trusted by Top Engineering Firms

Clwyd was approached to help develop a specialist compound for a nuclear submarine application. We worked very closely with the project team and a new material was developed, meeting both the specification required and the processing requirements. The development was completed on time and under budget.

The development was so successful that the project won the BAE Systems - Silver Award.

These awards are typically internal to BAE, however due to the extensive support that Clwyd delivered throughout the project, we had the honour of receiving it.

Clwyd has worked on a number of projects with Honeywell and to date, we are proud to be the only rubber compounder in the world approved as a Tier 1 supplier for safety critical rubber compounds.

Confirming Industrial Compliance Oil & Gas - RGD Resistant Compounds

Clwyd offers explosive decompression (ED) resistant compounds, which include FKM, FEPM (Aflas®), FFKM and HNBR. These compounds have been tested to ISO 23936-2 for rapid gas decompression (RGD) and are therefore ideal candidates to take forward for Norsok approval.

Food - FDA Extraction Testing Clwyd formulate rubber compounds to be FDA compliant to 21 CFR 177.2600 – Rubber articles intended for repeated use.

We have added on the ability to perform extraction testing in

both water and hexane to establish the extraction levels and therefore, give our customers confidence to take materials forward for FDA Certification or even USP Class VI.

Aerospace, Marine and Rail

Optimising Flame Retardant Compounds Clwyd Compounders Ltd has developed a range of flame retardant (FR) compounds that are suitable for testing to a variety of transportation related specifications. FR materials have always been in high demand within the rubber industry due to their application within transportation industries, but the performance of these materials can, at times, be lacking the required physical performance for the finished article.

Achieving optimum physical properties with FR materials is all about achieving the right balance between the level of flame retardancy required and material processability in production. This is the art that allows you to produce a part with optimal properties for your end application.

Based upon industry feedback, we have developed a range of FR compounds with EPDM, Silicone and Vamac in black and coloured formats that have all been formulated as halogen free and for low smoke, low toxicity (LSLT) requirements.

The transportation industry can benefit greatly from having compounds available to them that are composed of the optimum balance of FR fillers and additives to create an LSLT compound that meets the desired transportation related specification whilst having superior physical properties compared to commercially available materials.

As part of this project, Clwyd Compounders Ltd has developed a black 70 shore hard EPDM which is fully approved to EN 45545-2 R22 HL2. Several other FR compounds have also been developed, suitable for rail, aerospace and marine applications.

Clwyd have recently developed compounds to produce novel properties such as; Light-Weighting, Low Friction, RF Shielding and Heat Dissipation.

To find out more please visit: www.clwydcompounders.com, call +44 1978 810 551 or email us at sales@clwydcompounders.com

Pickering Interfaces launches turnkey LXI microwave switch and signal routing subsystem service

Fast turnaround, cost-effective multiplexer, matrix and complex routing solutions, ready-to-use out of the box Pickering Interfaces, the leading supplier of modular signal switching and simulation solutions for use in electronic test and verification, launches a new value-add turnkey LXI microwave switch and signal routing subsystems service. This new service delivers customengineered solutions created to customers’ specifications.

These integrated microwave test packages include switches, a dedicated soft front panel, all the wiring and more in a suitable enclosure. They are supplied fully tested, with full documentation and a three-year warranty.

The service provides compact, rack-mounted, multiplexer, matrix and complex routing designs based on an industrystandard LXI/Ethernet interface, designed and manufactured by Pickering’s team of switching experts. Solutions are available

with bandwidths from DC to 67 GHz @ 50Ω, with terminated or unterminated options and bandwidths up to 2.5 GHz @ 75Ω.

These cost-effective microwave switch subsystems are available on a fast turnaround. They are fully documented to ensure performance repeatability when ordering additional systems. The subsystems also include a familiar programming environment using Pickering’s standard switch API that supports all major test programming languages and helps to accelerate software integration. For complex subsystems, Pickering’s Switch Path Manager signal routing software can be used to significantly reduce integration time.

Comments Keith Moore, CEO, Pickering Interfaces: “This is an exciting new addition to our product offerings. More and more, our customers ask for out-of-the-box solutions that are complete and ready-to-run

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with minimal fuss and set-up time. We have the expertise and ability to turn your high-level requirements for a microwave switching subsystem into a fully integrated solution.

You provide us with your unique configuration and specifications—our engineers will work closely with you to provide a well-defined and supportable end product— delivering everything a microwave test engineer needs to get a complex microwave test system up and working the first time.”

Also, Pickering can turn a custom design into a ‘commercial-off-the-shelf’ (COTS) product, offering product support for more than 15 years.

More details can be found at www.pickeringtest.com/ or call +44 (0)1255 687900

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Ixthus Instrumentation offer complete support and calibration services for RIFTEK railway transport measurement instruments world-wide and are characterised by their compactness, durability, portability and reliable use in particularly harsh environments.

Most instruments can be used in-situ with no need for wheelset removal and with battery powered devices offering up to 1000 measurements between recharge.

Complementing its comprehensive range of optoelectronic measurement equipment and systems used across industry and research, RIFTEK LLC design and manufacture dedicated gauging instruments for the maintenance and in-situ inspection of safety-critical dimensional characteristics for all types of railway transport. Covering precision measurement of wheel profile and diameter, rail track and brake profile, back- to-back wheel distance in addition to specialised systems for wheel set geometrical parameters, these world- class instruments include portable laser-based hardware with integral displays, Bluetooth® and USB enabled devices for use with dedicated PDA dataloggers, and free PC software for data acquisition. RIFTEK, an ISO 9001:2015 certified company, is represented exclusively in the UK by Ixthus Instrumentation with complete support that includes instrumentation system design and application assistance as well as a comprehensive calibration service for RIFTEK’s standard rail transport measurement instruments.

RIFTEK’s range of rail transport gauging systems are used in more than 60 countries

The comprehensive range includes the IDK series wheel diameter gauge for rolling circle 1/3 measurement between 600 mm to 1300 mm using the ‘three points’ technique with a resolution to within 0.01 mm - made directly on the rolling stock without wheel set roll-out.

The IDK-BT option features a Bluetooth interface for transfer of measured parameters directly to an optional PDA or for a PC based wheel set wear database management system. More compact versions are also available for smaller tramway wheels and for measurement in areas with restricted space.

RIFTEK’s IKP-5 series wheel profile gauges are available for standard wheels or as shortened and super-short versions for tramway wheels.

With Bluetooth, PC software and an optional operator PDA the IKP-5 offers setting of measured and calculated wheel flange parameters including flange height, thickness and slope, wear parameters, angular profile parameters and more. Data is easily synchronised to external PC storage for wheel sets wear data processing and analysis.

Similar operational features are available for rail track profile measurement with the PRP series profilometer.

Its laser measurement head is mounted on an adjustable frame (with optional motorised linear translation) for full profile scanning results and graphical image visualisation of the combined actual and ‘as new’

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cross sections displayed and recorded for further analysis.

Other products include the IMR series back-to-back distance gauge for measurement of railway, metro and tram wheels distances without wheel set roll-out. The IMR-series is a more compact tool for back-to back wheel distance measurement featuring a single laser scanning head. RIFTEK also supply various rail vehicle disc brake measurement devices that feature non-contact laser sensors and scanning heads.

For contactless automatic realtime measurement of wheel set geometrical parameters, RIFTEK’s 3DWheel series employs a combination of 2D laser scanners mounted on the side of the track that are calibrated into a common coordinate system. As the laser sensor detects a wheel passing through, the measurement cycle records the wheel profile in several sections with the results transferred through Ethernet to a control computer for profile reconstruction, dimensional calculation and wheel-set wear evaluation. The same 2D scanner can also be utilised for rail-head 2/3 scanning for wear and correlation.

Ixthus Instrumentation are on hand to assist users for the operation and training for all RIFTEK rail transport gauging systems and other specialised optoelectronic measurement instruments.

For further information please call: +44 (0) 1327 353437 Email: info@ixthus.co.uk or Visit: www.ixthus.co.uk.

PP C&A celebrates 30,000 ‘control systems’ milestone with Mazak UK that can arise if the customer is having to manage this. Vendor reduction and rationalisation is a big driver.

“30,000 control systems to exacting global standards is some achievement and we look forward to the celebrating future milestones together.”

One of the UK’s leading strategic manufacturing outsourcing specialists is celebrating a major milestone this month, when it delivers the 30,000th control system to Mazak UK. PP Control & Automation has been working with the global machine tool builder for more than 27 years and the latest partnership has seen it play a key role in the design and production of the new CV5500, a fully simultaneous 5-axis machining centre.

The company, which employs over 200 people at its state-ofthe-art facility in Cheslyn Hay, used its expertise to support the design and build of a new configurable control system and interconnectivity solution that would facilitate both the efficient build within PP C&A and the simple and effective integration when building the machine tools at Mazak’s facility in Worcester. This was even more challenging when you factor in the need to achieve a highly competitive price point that would allow it to successfully launch a world class machine for target markets across Europe.

“The relationship dates back to 1993 when Japanese senior management team saw something ‘different’ in our approach and a company-wide focus on quality, resulting in

the placement of the very first order,” explained Tony Hague, CEO of PP Control & Automation “As the years have gone by, the relationship between the two businesses has become more interlinked, with PP C&A increasingly invited to be involved in the design stage of new machine builds to support ‘Design for Manufacturing (DFM)’ and to understand how more specification can be added easily to new models.”

He continued: “For this project, our engineers worked closely with Mazak from the outset of the concept, looking at ways in which we can add value, eliminate unnecessary costs and standardise the build process, whilst still being able to deliver greater scope for the customer to configure machines.

“We are also now taking full responsibility for total supply chain management, including working with multiple Japanese manufactured parts to ensure that we reduce the hidden costs

Despite the UK’s largest industrial show being cancelled due to the Covid-19 pandemic, the latest technology has been universally acclaimed by industry and is expected to be one of the Worcester-based firm’s most popular machines with significant sales already secured.

PP C&A’s dedicated manufacturing and assembly cell has played a key role in the successful introduction of this model, on-time and at a cost point that works for both the customer and the end-user.

Mazak UK Engineering Director Dave Fisher was delighted with the outcome: “PP C&A is one of our critical partners, supporting our ever-changing needs in both engineering and production.

“The relationship works because we both bring our own areas of expertise to the table, challenging and developing ideas that deliver mutual benefits and unrivalled machining performance for our customers.”

Alan Mucklow, Managing Director UK & Ireland Sales & Service Division at Mazak, went on to add: “The CV5-500 is the latest in a long line of Mazak machines to have been fully designed and built in the UK. Not only does it set a new benchmark in British machine tool building, but it breaks the mould for the compact, fully simultaneous 5-axis machining category as a whole.”

For more information, please visit: www.ppcanda.com

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Digital and analog interface benefits all at once thanks to Dual Channel for both absolute and relative pressure measurement.

Enhanced process efficiency thanks to fusioned sensor data IO-Link allows for mutual and bidirectional sensor communication via the controller. This way, every sensor can utilize the measured values of other sensors to solve complex measuring tasks or for optimization of processes and production flow.

Digital communication opens up many opportunities – but only sensors that reliably deliver precise measured values offer real added value by IOLink. Well established and appreciated by many users, both pressure sensor PP20H and CombiLyz AFI conductivity sensor excel by outstanding measuring performance and IO- Link interface, but now they offer even more interesting features such as simple and fast parameterization- even during operation. This way, secondary data like different process data output simultaneously or diagnostic data only accessible this way can be communicated from sensor to controller or even retrieved from the sensor memory if required. Further to the digital interface, the sensors also provide one or more conventional analog outputs for maximum user flexibility.

Dual Channel - analog and digital interface in a single sensor Dual Channel enables analog as well as digital sensor operation or both at the same time - this way, Baumer process sensors such as conductivity sensor CombiLyz AFI and pressure sensor PP20H work both in conventional control topologies

and digital IO-Link control environments. In process automation, the proven analog interface is helpful for sensor integration into existing control concepts. Nevertheless, in sensor commissioning, IO-Link advantages such as easy and fast parameterization or access to secondary data are a valuable help. For process control, parallel readout of conductivity or pressure value is enabled via 4...

20 mA analog output.

More information, more process effectiveness IO-Link provides access to valuable secondary data: process data including sensor temperature respectively process temperature of PP20H. Such information allow for interesting conclusions, e.g. unusual temperature rise in containers or pipes. And, such data are basic for predictive maintenance. CombiLyz AFI conductivity sensor delivers information on media concentration in addition to media conductivity. By doing so, the medium in process and its concentration is precisely identified. Pressure sensor PP20H delivers ambient pressure information in addition to process pressure. Therefore, the sensor can be deployed

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Using conductivity sensor AFI for example, transmission of the measured temperature value would reduce response times of temperature compensation to 15 seconds or even completely circumvent them. In level detection in closed tanks, two fusioned pressure sensors enable direct indication of the filling level.

The head pressure sensor transmits the measured value to the pressure sensor at the tank bottom for zero point adjustment. This way, the actual pressure is determined.

With CombiLyz conductivity sensors and PP20H pressure sensors now featuring this digital communication interface, Baumer further adds on their portfolio of IO-Link process sensors. And, solutions for flow and level detection using this digital communication standard are also available. Further information here: baumer.com /io-link-process-sensors

Emerson’s new laser welder enhances manufacturing capabilities The BransonTM GL-300 is a highly flexible quasisimultaneous plastic joining solution, designed to deliver efficient high-quality welds in a wide range of applications and help manufacturers to increase production efficiency.

Emerson has launched a new laser welder platform that provides high mix and batch manufacturers of plastic components with greater production capability, without compromising product quality or performance. The BransonTM GL-300 is a highly flexible quasisimultaneous plastic joining solution, designed to deliver efficient high-quality welds in a wide range of applications and help manufacturers to increase production efficiency.

Manufacturers increasingly need machines and processes that can be quickly and costeffectively adapted to changing

production demands and specifications. For low volume, high mix manufacturers especially, flexible welding solutions that allow faster production start-up, provide a critical advantage. The Branson GL platform meets this need by combining highly efficient and accurate welds with costeffective and easy-to- change tooling that enables faster setup and adjustment for changing product specifications.

Manufacturing capability is further enhanced by a range of unique features including a high-quality scanning system, easy-to-use HMI, large (300mm x 300mm) weld area, multiple weld modes, variable spot size as low as 0.5 mm and an adjustable laser power source height. These enable the Branson GL-300 to support applications with different materials, application sizes and production speeds.

“For batch manufacturers looking for more efficient production processes, quasisimultaneous laser welders provide a very flexible, costeffective joining solution,” said Priyank Kishor, global product manager for Branson products at Emerson’s Automation Solutions Business. “The Branson GL-300 extends this flexibility by enabling the assembly of a broader range of components, helping to increase manufacturing capability and profitability.”

IDS to offer 20.35 MP IMX541 sensor from the Pregius S series from September IDS integrates the highperformance, extremely high-resolution sensor IMX541 from the Pregius S series into the versatile uEye SE camera family. Thanks to its compact 1.1” format, the 20.35 MP CMOS sensor is compatible with C-mount lenses. The industrial cameras feature a practical USB3 Vision interface, deliver 20 fps and will be available from September either as board-level models or with a robust metal housing.

Pregius S – the fourth generation of extremely powerful CMOS image sensors from Sony – makes BSI (“Back Side Illuminated”) technology available for the first time in global shutter sensors. The benefits are smaller pixels (only 2.74 μm, which allows a significantly higher pixel density), higher resolution and also improved quantum efficiency and sensitivity. The new camera models deliver

outstanding image quality that leaves nothing to be desired even in demanding machine vision applications such as surface inspections, detailed image evaluation in medical technology or use in the traffic sector. Anyone who values highresolution images – for example to detect even the smallest material defects – will hardly be able to overlook these sensors in the future.

similar high- resolution, but large-format sensors, for which F-mount lenses are usually required. With the uEye SE models, C-mount lenses can be used – which means considerable cost savings.

Thanks to the USB3 Vision interface, the cameras are also uncompromisingly Vision Standards-compliant and can therefore be used comfortably with IDS peak, for example. The free SDK is characterized by an easy-to-use programming interface developed by IDS. Users no longer need to work directly with GenTL and GenAPI. Convenience classes help to reduce programming effort and thus minimize potential sources of error.

For more information please visit: ids-imaging.com or call +44 1256 962910

The compact industrial cameras are therefore also a sensible alternative to cameras with

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Schaeffler provides custom rotating direct drive motor for one of the world’s largest reflecting telescopes

- Schaeffler has supplied a custom direct drive motor solution for a giant reflecting telescope in The Canary Islands - The drive solution from Schaeffler ensures the precise positioning of the telescopic camera and regulates its speed - The compact, segmented design of the motor cut transportation and mounting costs, while optimising system performance and maintenance Schaeffler has provided a rotating direct drive motor solution to a giant telescope located on La Palma in the Canary Islands – one of the world’s largest reflecting telescopes.

Astronomers and astrophysicists researching outer space rely on high performance telescopes to closely observe galaxies far away. When looking to the stars and exploring planets, black holes and other distant celestial bodies, the first thing to do is find a high vantage point.

Nowhere else in Europe is the night sky so dark and clear as it is when viewed from the Roque de los Muchachos ridge on La Palma, which rises to a height of almost 2,500 metres. This offers professional stargazers ideal research conditions thanks to the Atlantic island’s extremely low levels of light pollution.

This remote location is home to a dozen different observatories and therefore offers astronomers from numerous different countries an infrastructure found almost nowhere else in the world. Of all the observatories located on the Roque de los Muchachos ridge, the Gran Telescopio de Canarias (GTC) stands out the most. With its 36 reflectors and a diameter of 10.4 metres, the silver-coloured steel structure is one of the world’s largest reflecting telescopes. The GTC, which was opened in 2009 at a cost of 80 million euros, weighs around 300 tonnes and has already spotted more than 2,000 planets and discovered galaxies far away.

High precision movements Giant telescopes such as the GTC operate with extremely high precision. Scientists observing the stars at night or in the early hours of the morning, rely on long exposure times, which means the telescope must be able to move with millimetre precision – an immensely challenging task given the enormous weight involved. Schaeffler has already proved its expertise in this sector in 2015 when the company supplied a torque motor for a satellite observation station in Changchun, China, which is part of the National Astronomical Observatories belonging to the Chinese Academy of Sciences.

Expertise from the Industrial Drives division Schaeffler Iberia contributed its specialist engineering expertise in industrial drives to this latest project on La Palma and was involved in developing an instrument rotator for one of the GTC’s focal stations, known as the Cassegrain Focal Station (CG-Set). IDOM, a Spanish company that provides engineering and architecture services, was commissioned to develop this new CG set.

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Due to a positive experience during its long-standing collaboration with Schaeffler Iberia in various projects, IDOM decided to involve Schaeffler in the development of the instrument rotator drive.

The instrument rotator is an important high precision mechanism in the telescope and controls the focal tracking and rapid positioning system that rotates the two-tonne telescopic camera with outstanding eveness throughout the entire observation in order to ensure its perfect alignment with the heavens from start to finish. In this specific case, Schaeffler’s special drive solution not only had to ensure the system’s ability to precisely position the camera and regulate its speed, but also had to feature a compact, lightweight instrument rotator.

Benefits of the Schaeffler solution Schaeffler devised a special solution that optimally suited the application requirements. A segmented, slotless RMF torque motor was developed for the drive of the instrument rotator.

Assistance was also provided by Schaeffler during the mounting process in order to determine the motor’s control parameters.

The direct drive from Schaeffler Industrial Drives is characterised by its highly dynamic yet very even motion, which also takes place with a high level of energy efficiency. The special motor, which is more than two metres in diameter, was developed and built based on a proven drive concept from machine tools for grinding operations that was adapted for the telescope.

For more information, please visit: www.schaeffler.com Contact: info.uk@schaeffler.com

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New CICV Forum animations remind public to play their part and let construction workers do their jobs safely “We must continue with this level of co-operation and collaboration and remind the public of the part they have to play as we move forward with Scotland’s recovery.”

The latest campaign reinforces the Forum’s reputation for proactive innovation throughout the Covid-19 crisis, during which it’s become the first port of call for clarity of advice.

The Construction Industry Coronavirus (CICV) Forum has launched a colourful new social media campaign reminding the public to let construction workers do their jobs safely as Scotland strives to rebuild the sector.

“However, they must be allowed to carry out their tasks effectively and the public can play a hugely important role by supporting and respecting them and letting them do their jobs as they take on this mammoth task.

Released under the theme of #RebuildingTogether, the latest initiative uses two short animations to highlight the need for co-operation and respect for workers operating in difficult circumstances.

“This new campaign emphasises the Forum’s message that we’re all #RebuildingTogether and that it’s important that everyone takes personal responsibility for their actions in the interest of themselves, their colleagues and the wider community.”

The clips, designed to be shared on social media, feature workers called ‘Paul’ and ‘Gill’ who put a strong emphasis on physical distancing and letting workers do their jobs safely.

To help the public feel more confident about commissioning work, the campaign is also accompanied by a downloadable PDF leaflet that sets out clearly what workers and clients are expected to do – and not do – throughout projects.

Forum Chair and SELECT Managing Director Alan Wilson added: “Since the start of the CICV Forum, it’s been extremely heartening to see how people across the industry have pulled together to get us through.

Rebecca Crosland, Health and Safety Advisor at the Building Engineering Services Association and Chair of the Forum’s Health and Safety subgroup, said: “Contractors and operatives have been extremely responsive to guidance aimed at safe working as we enter into new phases of the return to work.

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Made up of more than 60 trade associations, private companies and professional bodies, the Forum recently welcomed its 100th individual member as it continues to advise and inform the industry and public alike.

Since its creation in March, the Forum has drawn on the collective expertise of its members to maintain a steady supply of information and practical advice to the sector as well as carrying out surveys, hosting webinars and making appeals to Government Ministers.

In the last month alone, it has issued seven health and safety advice documents, updated its operating guidance and reminded construction workers to observe physical distancing in their social lives too.

For more information please visit: cicvforum.co.uk/

Volkswagen Chooses FERODO® Brake Pads for 2020 Golf VIII

FERODO® disc brake pads have been selected as original equipment (OE) for 2020 Volkswagen Golf VIII hatchbacks, bringing the brand’s “Power of Performance” to the latest generation of one of Europe’s best- selling passenger car models. FERODO for more than 100 years has been a preferred partner to vehicle manufacturers around the world.

The latest FERODO OE brake pads are engineered and tested to provide powerful, precise, quiet stopping performance and long pad and disc life under a full range of operating conditions. FERODO will soon extend this OE expertise to the replacement market with the introduction of Eco-Friction® brake pads for the Golf VIII. EcoFriction technology features low- to zero-copper formulations that reduce heavy metals and emissions – resulting in pads that are green, safe and which provide outstanding stopping performance.

As a leading OE supplier, FERODO conducts up to a full year of testing to validate each new friction formulation in nine key performance areas: pressure, speed and temperature sensitivity; light and heavy fade; thermal conductivity; judder; noise; and pad and disc life. Other test protocols, including ECE R90 testing utilized by many competing manufacturers, require fewer than 10 hours of validation covering just three performance characteristics.

“Vehicle manufacturers recognize that FERODO brake pads contribute to a superior

driving experience through outstanding stopping performance, safety and reliability,” said Silvano Veglia, Director Product Management FERODO, DRiV Incorporated. “At the same time, our status as a leading OE supplier – combined with full in-house production, a history continuous innovation and our extensive technical support capabilities – make FERODO the right choice for brake pad replacement throughout the life of a vehicle.”

To learn more about FERODO OE and replacement brake pads and related products, visit: www.ferodo.com.

Never miss an issue - Subscribe for FREE Worldwide Engineering Magazine | 23

Record working dimensions for the new XXL-Box

“After the huge success of the L-BOX and XL-BOX, our compact marking stations, we have been asked on numerous occasions to offer a larger workspace in order to be able to mark large parts”.

These are the words of Eric B. Marketing and Sales Director at SIC MARKING, world leader in industrial traceability, to justify the launch of the new XXL-BOX Laser Marking Station.

in the realisation of tailor-made solutions:

Available in 3 basic sizes at a very competitive price, the XXL-BOX perfectly complements SIC MARKING’s laser workstation wide range of products, which makes it possible to meet all customer requirements in terms of cabinet size.

“The XXL-BOX is ideally suited for the classic use of its large working volume, but also enables the project manager at SIC MARKING to offer tailor-made solutions for more complex large-volume marking applications. As Project Manager, Nicolas E. highlights the flexibility of this new product through a large number of accessories. “Automatic threedimensional axis, automatic loading system, loading drawer or turntable are just a few examples of the applications proposed by our technical teams to meet our customers’ needs”.

As its name indicates, the new XXL-BOX station offers record working dimensions (up to 520 mm high) as well as great modularity thanks to its 3 standard models (800, 1200 and 1600 mm wide) and its numerous accessories. The strength of this new product also lies in its ability to adapt perfectly to different customer requirements, illustrating SIC MARKING’s extensive know-how

Requested by a large number of customers, the new XXL-Box Laser Marking Station has met a great success with ETIs and large companies manufacturing large parts or sub-assemblies such as shafts, valve or pump bodies, crankcase, exhaust components but also bodywork sub-assemblies. It is not surprising to find it in the sectors in which SIC MARKING is already active: Automotive,

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Aeronautics, Industrial Vehicles, 1/2 Hydraulics, Oil & Gas...

As a result, the international French group had the opportunity to prove all the qualities of its new product by taking up the challenge offered by a major German automotive supplier. The company wanted to mark a Datamatrix code on gearbox prototypes. The solution provided was an XXL-BOX laser marking station, with a 5-axis laser that made it possible to achieve a marking window of 900 x 500 x 500 mm. The project was the result of a technical and commercial cooperation between the headquarters and SIC MARKING GMBH (the group’s German subsidiary) and highlighted the great adaptability of this new product to customised requests and the group’s ability to monitor projects at an international level.

For more information please visit: www.sic-marking.co.uk Email: salesuk@sic-marking. com or call 0044 (0) 1926 830372

NORDAC PRO SK 500P: The latest generation of control cabinet inverters

The new control cabinet inverters cover rated motor powers from 0.25 to 5.5 kW and feature ultimate levels of connectivity, functionality and versatility. Various device versions can be optimally allocated to various application requirements. Plug-in control, safety and option modules ensure maximum flexibility and the compact book-size design format enables space-saving installation in control cabinets.

Integrated multi-protocol Ethernet interface NORDAC PRO SK 500P is the new generation of control cabinet inverters. The series is equipped with an integrated universal Ethernet interface that enables the use of the major real-time Ethernet standards via one single interface. Whether for Profinet, EtherNet/IP, Powerlink or EtherCAT, the required protocol can be easily set by means of parameters.

Voltage-free parameterisation via USB port The future-proof nature of the modular series is shown by its modern connectivity such as the use of an SD memory card as a storage medium for parameters, as well as a USB interface which enables “in the box” parameterisation of the inverter when the power is switched off.

It also provides a CANopen

interface, five or six digital and two analogue inputs, two digital and one analogue output, two potential-free multi-function relays, an HTL / TTL incremental encoder interface as well as a universal encoder interface which enables connection of SIN/COS, BiSS SSI, Hiperface and EnDat encoders.

One NORDAC PRO SK 550P highlight is the integrated multichip for Industrial Ethernet that enables the use of the most important real-time Ethernet standards via a single interface.

Multi-encoder interface for multiple axis operation The NORDAC PRO SK 500P can read out up to four encoder systems simultaneously and can therefore control several motors in positioning mode.

Together with features such as the integrated PLC for motor- related motion and logic control, a 200% overload reserve for perfect torque and speed performance as well as sensorless current vector control for asynchronous and synchronous motors (open loop and closed loop), it is a genuine all-rounder. The integrated brake chopper for 4-quadrant operation is a part of the basic equipment for the entire series, as is motor brake management, which is important, e.g. for lifting gear applications.

NORD supplies the inverters with integrated STO and SS1.

Industry 4.0 READY! The integrated PLC processes the data from sensors and actuators and can autonomously initiate control sequences, as well as communicating drive and application data to a control centre, networked components or to cloud storage. This allows continuous condition monitoring and therefore forms the basis for predictive maintenance concepts as well as optimum plant dimensioning.

Intelligent, communicative and easy to connect: With the NORDAC PRO SK 500P, the NORD DRIVESYSTEMS range includes future-proof and userfriendly frequency inverters for control cabinets. The overall concept has been revised, so that the inverter series provides a new future-proof platform which promises many years of power and performance from NORD. The new series is of course downwardly compatible with the current SK 500E series.

For more information please visit: www.nord.com Email: sales@nord.com or call +44-1235-534404

Worldwide Engineering Magazine | 25

THE VALUE OF VALIDATION

Validation exists to ensure that injection moulders have a stable and dimensionally centred process. However, it shouldn’t be regarded as a tick-box exercise just for medical moulders to test their tools to satisfy the FDA or other regulatory bodies. Nigel Flowers, Managing Director at Sumitomo (SHI) Demag UK explains how validations can help to de-risk projects, avoid costly product recalls and cosmetic product defects.

The validation rules, amended in 2015 by the European Commission, continue to apply today. From a UK perspective, it is highly likely that these EU standards will continue to be accepted until UK standards have been developed. CE marking is a case in point, and will be accepted for the foreseeable future.

Governed by EudraLex Good Manufacturing Practice (GMP) Volume 4, the latest version of Annex 15 - Qualification and Validation - requires manufacturers to ensure that “critical aspects” of

their operation are validated throughout the product lifecycle. This includes any changes that could impact a product’s quality.

Closely mirroring the FDA’s lifecycle approach, Annex 15 also places a greater emphasis on risk management to reflect today’s manufacturing and regulatory environment.

For any manufacturer of pharmaceutical components, zero defects remain the target.

In the medical industry, there’s no wiggle room. You can’t shift the parameters to suit. Those producing a medical device or a sterile implant, nothing less than 100% quality is acceptable.

More than good business practice From a moulder’s perspective, validations can address profitdriven challenges and design out production weaknesses.

Functional tests can help operatives better understand what drives the machine, how fast it goes and the consequences if manufacturing

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procedures are not correctly followed.

There are three key phases to process validation, categorised as Process Design, Process Qualification, and Continued Process Verification. These reflect the focus on the manufacturing lifecycle and the need to provide scientifically sound data to verify that the injection moulding processes start and continue to remain stable. Every stage of each injection moulding cycle must be documented.

The Process Design stage starts by examining if the machinery is of an appropriate size in relation to shot size and tonnage. It also checks that equipment is properly calibrated.

During Process Qualification, the range of process parameters is then established. This involves conducting a selection of statistical and dimensional studies to identify and investigate any deviations in the process. A process is not considered as validated if the variations have negatively

impacted the finished product in any way.

The final validation phase Continued Process Verification - focuses on demonstrating that the process is consistently stable. It involves simulating different production runs using the same production equipment and the processes routinely performed, ensuring repeatability of the set-up conditions throughout the machine’s full lifecycle.

In accordance with ISO 13485 standards, ongoing documentation of the injection moulding process needs to be maintained. This is a continuous process. When machine settings are adjusted to compensate for changes in the environment or to address moulding issues e.g. pulling, distortion, or aesthetic defects, it will trigger a re-validation exercise. So too would major repairs, changes, or improvements to the mould tool and machine. The cost and time implications each time a moulder repeats this validation process can be extensive.

Although not a prerequisite for all sectors, validation is essential

within the pharmaceutical industry and is a good business practice for a large number of mass manufacturers of injection moulded medical components.

Think of it as a long-term investment. Essentially, it’s a risk assessment which, when executed professionally, can deliver efficiency gains and save your business time, money and resources by ensuring product integrity and reducing scrap volumes.

tools in a simulated application centre. Sumitomo (SHI) Demag has facilities in England, Germany and recently opened a new medical test cell in a new Research & Development hub in Ireland. “Seeing how an application performs in realistic process conditions not only helps moulders to make a more informed investment decision, it can also help to derisk and speed up the delivery of projects,” ends Nigel.

Who performs mould tool validations?

For more information please visit: uk.sumitomo-shi-demag.eu

Usually conducted by an engineer, the actual validation usually takes longer than actually building the tool itself.

For this reason, the validation is often partially completed at the toolmakers’ facility by a senior engineer from the company.

The key reason for this is issues can be addressed on site, rather than shipping a heavy tool back and forth. The final phases of the validation will be completed in-house on the specified equipment.

It can also be beneficial for injection moulders considering new machinery to test moulding

Worldwide Engineering Magazine | 27

An innovation with added value – the PP20H pressure sensor with IO-Link wins the Innovations Showcase Award step: “We are planning additional functions based on IO-Link.”

The pressure sensor prevailed among the 17 finalists due to its condensate-resistant silicon measuring cell, exceptional precision across the entire temperature range, and IO-Link interface. “An IO-Link interface is the latest trend in the sector and we have incorporated this technology in our PP20H,” says Baschar Al Hammoud, product manager for pressure sensors.

However, in true Baumer style, the company did not settle for that without offering its customers extra benefit – in addition to the digital IO-Link interface, the PP20H also offers an additional analog output.

Baschar Al Hammoud explains, “With this combination, the PP20H offers users more flexibility than any other pressure sensor.”

This way, during commissioning of the sensor, users can benefit from all IO-Link advantages, which considerably simplify sensor parameterization while still allowing process control by the sensor via the 4 ... 20 mA

analog output. Furthermore, the IO-Link makes it possible to call up additional process data such as the pressure of the measurement cell or the temperatures of the pressure sensor and the microchip in the central processing unit. Access to this information allows for interesting investigations: for example, whether an unusual temperature rise has occurred in a container, which may indicate a defect or faulty dosage of the ingredients in a tank. As high temperatures may decrease the service life of the sensor or other system components, this may indicate the need for preventive maintenance – one of the promises of Industry 4.0. Of course, the PP20H series offers all the advantages of IO-Link, such as quick parameterization during operation and prior to installation. Even more, a new sensor easily learns the parameters of the old sensor via the master and is immediately ready for operation upon installation. For Baschar Al Hammoud, this is only the first

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The PP20H also exceeds all standards also in terms of robustness. Its measurement cell is completely sealed even during relative pressure measurement. This prevents the entrance of warm and humid ambient air, which may precipitate with low process temperatures. This is the case, for example, in milk or ice cream processing. At the same time, the sensor must be somehow “open” to the surroundings because the sensor will also determine the difference to the ambient temperature. The Baumer engineers devised a unique technical solution for this challenge – they placed a barometric pressure sensor in the back of the housing that can measure the reference pressure of the environment via an opening. This way, the actual silicon measurement cell in the front remains hermetically sealed. The PP20H is therefore not only suitable for CIP (Clean in Place) and SIP (Sterilization in Place) processes, but also for sudden changes in process media temperatures.

More information available at: www.baumer.com/pp20h

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Kennametal introduces the eBoreTM Fine Boring System Digital-ready boring tools enable precision adjustment as easy as 1, 2, 3. eBore Universal: one head, multiple configurations, large diameter and boring depth range. The eBore digital display allows precision adjustment on the spindle, reducing setup time and idle time.

Boring small and very large diameters The eBore product line consists of 4 types of tools, all of them feature through the tool coolant, covering the following diameter range:

Kennametal has introduced a new line of digital-ready fine boring tools that make precision adjustment easy, enabling more productive, predictable, and accurate boring. The eBore Fine Boring System consists of cutting units to cover a diameter range from 6 to 1020mm (0.236” to 40.157”) and an optional digital display that makes precision adjustments as simple as turning a screw—and costly mistakes a thing of the past.

“For many workpieces, the boring operation is often the final step, and a simple mistake can lead to scrapped parts. The Kennametal eBore fine boring system does away with the traditional ‘count the graduations’ approach to boring and reduces costly mistakes,” said Global Product Manager Marcus Paul. “We’ve found there’s tremendous operator acceptance due to its simplicity and ease- of-use. And because the same eBore digital device can be used across multiple types of tools and on various machines, it’s easy on the tooling budget as well.”

Offering no-mistake adjustments and accuracy to within 2 microns, Kennametal’s eBore digital device is an optional—though extremely useful—part of the Kennametal Digital Boring System

Ease-of-use With Kennametal’s digital eBore digital device, dialing in a tight bore and losing count of how far the adjustment screw was turned is a thing of the past.

With an adjustment accuracy of 0.002 mm (0.00008”), the chip and coolant-resistant device contains a glass-scale that keeps track of boring bar movement.

Simply snap it in place, turn the boring head’s adjustment screw by the desired amount, and the tool is ready for the next boring operation.

With eBore, there is no need to remove the boring head from the spindle for adjustment nor to count graduations or take notes. Concerns over backlash and movement due to overtightening of the boring head’s locking screw are a thing of the past, as are endless test cuts and “sneaking up on the bore”. The result is less scrap, less downtime, and faster setups.

The device shuts off automatically after 30 seconds and provides more than 5,000 adjustments between battery changes. And if you forget to remove the boring head before turning on the spindle, a ball and spring clamping mechanism releases the display automatically at 500 RPM, preventing potential injuries.

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-eBore Universal Tool - 6-152mm (0.236”-5.984”) -eBore Fine Boring Tool - 20205mm (0.787”-8.071”) -eBore Bridge Finishing Tool 200-1020mm (7.874”-40.157”) -eBore Twin Cutter Roughing Tool - 19.5-1020mm (7.677”40.157”)

eBore Tool types from left to right: eBore Universal, eBore Fine Boring, eBore Bridge Tool. eBore Twin Cutter.

Built on simplicity, the eBore system comes with Kennametal’s KM quick-change interface and can be easily adapted to HSK, PSC, KM4X, and steep taper spindles.

For more information please visit: www.kennametal.com

Rohde & Schwarz presents a new Q/V band RF upconverter or testing satellite payloads

To enable continually higher data rates for end users of satellite links, satellite operators are using higher frequencies, such as the Q/V band, where larger bandwidths are available.

The new R&S SZV100A RF upconverter from Rohde & Schwarz now offers a solution for testing broadband transponders in the payloads of very high throughput satellites (VHTS).

With its 2 GHz modulation bandwidth, the R&S SZV100A covers the entire frequency range from 36 GHz to 56 GHz. Munich, August 10, 2020 — The Q/V band offers larger bandwidths for feeder links to satellites, making it ideal for the implementation of upcoming data links with high bit rates. This includes future communications and cellular backhaul networks that can provide end users with large volumes of data. Operators of conventional geostationary satellites as well as LEO satellites in the new space environment are discovering the advantages of these new satellite bands.

High demands are placed on microwave components in the Q/V band, which means they must undergo extensive testing during development and verification. Amplifiers, converters, receiver modules and complete satellite payloads are just a few examples of components that have to be tested in the Q/V band.

Especially for satellite payloads, test equipment must meet very high requirements for signal quality. Together with the R&S SMW200A vector signal generator, the R&S SZV100A Q/V band RF upconverter provides continuous coverage of all satellite bands from VHF to V band as well as the frequency bands for 5G in the Q/V band.

The test setup consists of the R&S SMW200A vector signal generator, the R&S SMA100B RF and microwave signal generator, and the R&S SZV100A Q/V band RF upconverter. With its outstanding RF performance, the R&S SMW200A delivers the modulated broadband IF signal with bandwidths up to 2 GHz,

while the R&S SMA100B provides the high-precision LO signal.

The maximum output power of the R&S SZV100A is as high as +16 dBm (at 1 dB compression point).

The compact housing design, low weight and mounting points of the R&S SZV100A allow mounting as close as possible to the DUT, for example on the outside of a thermal vacuum chamber (TVAC). The distance between the IF source or LO source and the R&S SZV100A can be as much as 10 meters, allowing an optimized test setup.

The upconverter and the signal generators can be operated remotely with a PC software over a LAN connection. The R&S SZV remote control software enables simple and convenient configuration of the entire device setup.

The R&S SZV100A is now available from Rohde & Schwarz.

Visit: www.rohde-schwarz.com

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Panasas Launches the New PanFS with Dynamic Data Acceleration Technology to Support Diverse and Changing Workflows in HPC and AI Panasas® today released Dynamic Data Acceleration on the new PanFS® parallel file system, a proprietary software feature that delivers predictable high performance by automatically adapting to the changing and evolving small file and mixed workloads that dominate today’s HPC and AI landscape.

itself year after year in pursuit of scientific or engineering advancement. Now data science and machine learning have also broadened the aperture of the types of workloads administrators have to manage.

A high-performance storage system has to be able to incorporate and adapt to this kind of dynamic environment.”

Inconsistent performance and lack of adaptability in the face of change has been a major headache for both application users and storage administrators. PanFS with Dynamic Data Acceleration is the remedy to this headache and the answer to HPC and enterprise IT organizations who are looking for a highperformance plug-and-play storage solution that keeps up with their pace of change.

What is Dynamic Data Acceleration?

“Diversity and change are the major watchwords in HPC applications today,” said Addison Snell, CEO at Intersect360 Research. “Technical computing has always raced to outdo

PanFS with Dynamic Data Acceleration takes the complexity and manual intervention of tiered HPC storage systems off the system administrator’s hands, maximizing the efficiency of all storage media in a seamless, total-performance system that automatically adapts to changing file sizes and workloads. In this integrated system, NVMe SSDs store metadata, low-latency SSDs store small files, and large files are stored on low-cost, high-bandwidth HDDs. By dynamically managing the

movement of files between SSD and HDD, and maximizing the full potential of NVMe, PanFS delivers the highest possible performance for HPC and AI workflows.

The difference between PanFS with Dynamic Data Acceleration and other HPC storage systems All other parallel file systems require clumsy tiering and/or manual tuning to compensate for specific workload characteristics and changes. The approach of piecing together various tiers to achieve performance leads to a level of complexity and inconsistent performance that negatively impacts productivity and increases overall costs. In contrast, PanFS with Dynamic Data Acceleration automatically adapts to changing file sizes and workloads without tuning or manual intervention, delivering a consistent and fast totalperformance HPC storage solution.

For more information please visit the website: www.panasas.com

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Get back to school safely with Agrippa record the specific sound of a fire alarm in order to release the door in the event of a fire. The devices can also be programmed to automatically close doors at the end of the school day, or manually closed by pressing the auto-release button. The position of the device at the top of the door ensures that it will remain open until manually closed by an adult, preventing the risk of younger children catching fingers in heavy doors!

Improving air ventilation

This week marks the launch of the Government’s ‘Back to School Safely’ campaign following the announcement that all educational facilities will reopen from the beginning of the autumn term.

Following the opening of nurseries, schools and colleges, the government has advised schools to implement a range of protective measures in order to mitigate the risk of the virus being spread. The six preventative actions which have been outlined by gov.uk and Public Health England are: 1) Minimise contact with individuals who are unwell by ensuring that those who have coronavirus (COVID-19) symptoms, or who have someone in their household who does, do not attend school 2) Clean hands thoroughly more often than usual 3) Ensure good respiratory hygiene by promoting the ‘catch it, bin it, kill it’ approach

4) Introduce enhanced cleaning, including cleaning frequently touched surfaces often, using standard products such as detergents and bleach 5) Minimise contact between individuals and maintain social distancing wherever possible 6) Where necessary, wear appropriate personal protective equipment (PPE) The Agrippa range of door holders and closers can directly support schools to meet the Government recommended preventative actions by: Removing the need to touch door handles Despite best hand washing and cleaning efforts, the frequent and inevitable use of door handles presents a potential hot spot for the transmission of infection. The Agrippa range allows any internal door to be safely and hygienically retained without compromising fire safety with the use of illegal wedges. The Agrippa devices

Ensuring good air circulation by opening windows and doors prevents the build-up of stagnant air and reduces the risk of coronavirus spreading. While it can be tempting to prop open a fire door with a homemade wedge or heavy item, this puts lives at risk. It is critical that fire doors are held open by a device which will automatically release in the event of a fire and is approved to European standards.

Improving visibility in corridors to help maintain social distancing Holding open internal doors improves visibility and allows social distancing to be maintained when walking through corridors or entering and leaving a room. Retaining the fire doors tightly against corridor walls, the wire-free and battery powered Agrippa range is a perfect solution for schools as it maximises the space available and will not release if the door is knocked by passing students, helping to prevent wear and tear to expensive fire doors.

To learn more about how Agrippa can support your COVID prevention strategy, visit www.geofire.co.uk/agrippacovid19-solution/

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Two new models complete Verlinde’s range of Stagemaker hoists

After two years of technological design and an alignment of production with market requirements, Verlinde announces the widening of its new range of Stagemaker electric chain hoists dedicated to the entertainment industry.

The new Stagemaker SL5 and SL10 models with their load capacity of 500 kg to 1000 kg (1 fall) and 2000 kg (2 falls) integrate Verlinde’s latest technological developments: innovative design, toughness and enhanced power ensuring faultless reliability while complying with international standards.

From the first model with its reverse-purchase block system launched in 1975 Verlinde’s Stagemaker range has enjoyed an excellent reputation worldwide in the entertainment industry and show business.

Boasting an entirely ergonomic design, Stagemaker hoists are the only models available on the market fitted as standard with double brakes, retractable handgrips and protective rubber pads.

The new SL5 and SL10 models will furthermore ensure IP66 protection, a rating currently being certified for the motor as a whole. The hoist shell is protected by a 70μm black epoxy powder coating enabling resistance to extreme environments (-10C° to +40 C°).

Two versions of the SL 5 and SL 10 models are available: (A) with forward voltage and (B) with low voltage. These 2 new lifting units are upgrades on the previous SR5 and SR10 versions and so

Enhanced safety The new SL models are D8+ compliant as standard with SPQ2 (code of practice): the positioning of the clutch in the gear box ensures load holding by the brake whatever the operating conditions of the hoist. The CHAINFlux chain guide enables greater flexible horizontal flow of the chain on output from the lifting load wheel. The equipment used provides furthermore a remarkable friction coefficient facilitating passage of the chain on ejection. The LimitFlux electromagnetic limit switches are provided as standard on all B-type hoists in the Sl range.

This system enables the high and low positions of the hook or hoist to be controlled with halflink chain precision. Travel limit switches are adjusted by moving two rings along the hoisting chain.

Ease of use and ergonomics Like the whole Stagemaker range, models SL5 and SL10 are fitted with PerfectPush, a 5-pocket hoist load wheel concept designed to enhance chain guidance and prevent the polygon effect. Operation in standard self-climbing configuration or in industrial suspension hoist configuration is achieved without any modification by simply turning the chain bucket. The lifting motor provides a wide range of constant running speeds with or without load: SL5 and SL10 are available as standard with the conventional 4m/min but can also be supplied at speeds of 8m and 16m/min.

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The design with its unobtrusive lines provides Stagemaker SL excellent integration in its operating environment (lighting, sound system, etc.).

Another appreciated aspect of this discretion is its operational silence (60 dBA). The lifting hook and transportation handles integrate an ergonomic rubberized gripping system.

The two retractable handles were integrated in the hoist shell when it was designed with the aim of facilitating its transportation. The high capacity, heavy duty, black canvas (1100 denier) chain bucket is removable and reversible.

Economical hoists The ease of access to the torque limitor, electrical components (Plug & Play) and to the fuse together with rapid removal of the motor facilitate maintenance operations. What is more, brake linings can be inspected visually.

Verlinde constantly upgrades its hoists in alignment with current technologies and worldwide regulations. SL models comply with the following standards: CE, DIN, CSA and EAC. For more information please visit: www.verlinde.com

Compact inspect systems become the ‘New Normal’

When it comes to buying criteria for inspection equipment, whilst commercial viability will always make or break decisions, the COVID-19 crisis is pushing spaceoptimised design and remote diagnostics to the fore.

Footprint has long been a consideration when choosing packaging and processing equipment – factory space is at a premium and the everincreasing cost of real estate means each cubic metre has to be maximised.

In production and packaging facilities where every inch counts, establishing new practices that will enable factory personnel to work safely during the COVID-19 pandemic is a huge challenge. Preventing the spread of the virus within the workplace is all about creating distance and physical barriers between workers, but space is in short supply in most facilities.

Moving people, not machinery Redesigning factory layouts is not easy, requiring considerable investment. However, producers have a duty of care to operators to ensure they are working in a safe environment. Rather than reconfiguring production line layouts, companies are looking at how they can redeploy and organise operators in a safer way, for example, by altering shift patterns. In other words, the focus is on moving people rather than machinery.

As factories adapt to these new ways of working, Phil Brown, Managing Director of Fortress Technology, expects equipment compactness to become even more important.

“From a factory floor perspective, adapting to COVID-19 is all about creating space. Smaller footprint equipment creates more space for people to move around without being restricted to certain pathways,” he says.

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Combi systems come into their own One of the ways in which companies can save line space is to opt for a combined checkweighing and metal detection system – mounting these systems on the same conveyor results in a far smaller footprint than stand-alone units would occupy.

Combi metal detector/ checkweighers are not a new concept, but last month [May], saw Fortress unveil its first ever offering in the space under the Raptor marque. Developed in collaboration with Sparc Systems, the integrated system delivers hygienic and userfriendly operation on a compact footprint.

The machine’s footprint has been minimised via several design features. Clever configuration of the reject mechanisms, for example, means that they occupy 50%

less space than a conventional design.

“You can’t get away from the fact you need separate rejects for weighing and metal as the rework required for rejected products is very different.

However, we have designed the system with opposing rather than end to end rejects, reducing the length of the reject system from one metre to 500mm,” explains Brown.

“500mm might not sound like a lot of space, but it can be the difference between a safe working space and one that doesn’t meet requirements.

Also, if you equate it to the amount you are paying per sq ft, it translates to a tangible cost saving,” he adds.

Another way in which the Raptor Combi system can offer space-saving advantages over rival systems is through the flexibility this platform offers.

Whilst Fortress manufactures a standard Raptor system for

customers wanting a short lead-time system for handling products up to 400mm in size and up to 8kg in weight, it will also manufacture custom systems for smaller products and space-restricted areas.

“A lot of our competitors will just produce a standard system that can accommodate any product up to 500mm. However, if you are running a 250mm product, you don’t need such a long system. In that situation, we can engineer the system down to 1.2m instead of supplying a standard system that is 2m in length,” says Brown.

One scenario where spaceoptimised combi systems can really come into their own is on labour-intensive ready meal lines, where multiple components are added manually. Here, where individual working space can’t be maintained, factories have had to install physical screens to separate operators. Either solution increases the line space

required to safely perform this operation, so downstream equipment space savings are needed to free up space.

Distanced diagnostics As well as creating a further driver for more compact systems, the COVID-19 pandemic is accelerating adoption of remote access functionality on inspection equipment.

“Most modern metal detectors and checkweighers have inbuilt remote diagnostics but until now this function has been under-utilised. However, recent months have seen it taking on increasing importance as companies seek to protect staff and reduce travel and face-toface contact,” notes Brown.

There are several reasons for this shift in behaviour. Some areas of the food industry have faced unprecedented demand in recent months as consumer spending has shifted from the out of home hospitality sector to retail grocery, and supermarkets have grappled with unpredictable purchasing behaviour and patterns. Issues with equipment have had to be resolved as quickly as possible, with minimal disruption and person-to-person contact. In these circumstances, remote troubleshooting is the ideal solution, and even if the issue cannot be resolved remotely, it can serve as a first line approach, arming engineers with valuable information so that site visits can be as brief as possible.

Now that companies have started to realise the benefits of remote assistance, Brown believes it is unlikely that the industry will revert to a more traditional face-to-face approach and that it will be a focus for innovation in years to come.

For more information Email: Info@fortresstechnology.com visit: www.fortresstechnology. com or call +44 (0) 1295 256266

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Recycling plant saves over €50,000 per year with NSK mounted bearings use in unfavourable application conditions, such as conveyors for the recycling, quarrying, steelmaking and agriculture industries. Importantly, the components are easy to install thanks to design details like solid housing corners that provide an optimal hold for positioning pins, and a centre mark for simple alignment. Maintenance is also straightforward due the precision-engineered split housing that ensures easy bearing replacement. Relubrication is possible via two boreholes.

A recycling plant that was experiencing regular failures of mounted bearings on the conveyor of an optical sorting machine is enjoying major gains following the switch to NSK SNN series plummer blocks fitted with NSKHPS spherical roller bearings.

Thanks to the reduction in replacement bearing costs, breakdowns and maintenance, the facility is saving €51,174 per annum.

The problem at the recycling plant came to light soon after installation. Within just three months, five bearing failures had been recorded. Keen to resolve the issue, which was proving expensive in repairs and downtime, the facility’s management team invited NSK to perform a comprehensive application review.

As part of its AIP Added Value Programme, NSK’s team of specialist engineers soon determined that vibration and lubrication issues were causing the bearing to fail prematurely.

Specifically, vibration in the application was causing the grub screws to loosen, resulting in the shaft spinning in the bearing’s inner ring. It was also noted that the type of mounted unit being used had no grease escape path, leading to excessive grease build up and high heat levels.

Following the observations, NSK recommended using NSKHPS (High Performance Standard) spherical roller bearings mounted on adapter sleeves in an SNN plummer block housing. The adapter sleeve locking method means that the bearing cannot become loose on the shaft, even with vibration present. Furthermore, NSK SNN plummer blocks are provided with a grease escape hole as standard, meaning excessive grease accumulation is avoided.

No bearing failures have been recorded since the NSK solution was implemented.

With its modular SNN series, NSK offers plummer blocks that have been developed for

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Further benefits of SNN series plummer blocks include high rigidity (to minimise deformation of the bearing seat), good heat dissipation and a comprehensive range of sealing arrangements to match all needs. In addition, the same housing can be used with double row spherical roller bearings or double row selfaligning ball bearings. Mounted units in the SNN series can be supplied for shaft diameters from 20 to 140 mm.

The NSKHPS spherical roller bearings used at the recycling plant are suitable for high speeds and loads. Available with a steel or brass cage, product features include optimum raceway design and surface finishing, as well as temperature stability up to 200°C. Importantly, NSKHPS bearings offer 25% higher dynamic load rating, up to 20% higher limiting speed and up to twice the operating life.

In combination with the SNN series plummer blocks, NSKHPS bearings have enabled the recycling plant to go from 10 breakdowns a year, to none.

For more information please visit: www.nsk.com/products/ bearingunit/ball/index.html

UniPAKer variations make robotic crate packing as easy as 123

Brillopak has developed its award-winning UniPAKer robotic crate packing platform with the introduction of single and triple-head versions of the system, following the success of its dual robot cells in fresh produce applications.

The ability to incorpo-rate one, two or three parallel arm delta robots into a single crate packing cell ena-bles the design of flexible systems that strike the optimum balance between speed and gentle handling.

“Whilst delta robot heads might boast mechanical speeds in excess of 120 picks per minute, such high speeds can only be achieved in real life on very straightforward crate/ case packing applications such as packs of biscuits. It is very unlikely that any packaging automation supplier who is handling delicate or awkward products like flow-wrapped apples, bags of carrots or traysealed meat would be able to achieve anything close to those kinds of speeds without damaging the product in the process, it simply isn’t possible,”

says Peter Newman, Technical Director at Brillopak.

He continues: “That is precisely the reason why we have developed single, dual and triple robot configurations for our UniPAKer packing system – to help our customers meet their performance and payback objectives without making false promises.”

Working on the premise that most fresh produce packs – whether punnets of soft fruit, bags of sprouts or flow-wrapped packs of peppers – can be packed into crates using a single robot head at speeds of 30-40 packs per minute, the UniPAKer can double or triple those speeds to achieve a customer’s target by adding a second or third robot. Each ro-bot takes it in turn to take a pack off the infeed conveyor and position it precisely in the crate, so the desired crate presentation is achieved twice or three times more quickly than with a single robot. To maintain a compact footprint, simplify operation and minimise capi-tal outlay, the entire system is centrally

controlled and the robots share a vision system, infeed and outfeed, regardless of whether it is a dual or triple configuration.

The 70-80 ppm speed capabilities of the dual-head UniPAKer are the perfect match for flow wrapping lines handling fruit and veg such as apples, sprouts, tomatoes, peppers and pears, with or without a supporting tray.

When three heads are better than two The triple-head system has been conceived with difficultto-handle or bulky products in mind. Brillopak is currently building its first triple-head UniPAKer cell for a supermarket customer with the goal of packing bags of carrots into plastic retailer crates at speeds of 100 ppm.

For more information, please visit: www.brillopak.co.uk/

Worldwide Engineering Magazine | 39

NORD drive solutions for the bakery industry

With its lightweight, corrosionresistant gear units, smooth surface motors, frequency inverters and motor starters in wash-down-optimised aluminium housings, NORD DRIVESYSTEMS is a powerful partner for hygiene-friendly drive systems in the bakery industry. Strong and robust drive solutions for mixing and agitation processes extend the drive technology specialist’s portfolio.

Whether agitators, conveyor systems, weighing and filling plants or packaging machinery: NORD DRIVESYSTEMS offers efficient and hygienic drive solutions for the bakery industry that meet stringent requirements on hygiene, reliability and durability. The manufacturer’s innovative inverter technology guarantees high positioning accuracy and reliable implementation of dynamic sequences. The drive units can be controlled individually, for example, to regulate kneading and conveyor speeds and to prevent blockages or control the dough process. Due to their modular

structure, the drive units are also service- and maintenancefriendly.

Corrosion protection in demanding environments The nsd tupH surface treatment provides an outstanding anticorrosion treatment for gear units, smooth motors, frequency inverters and motor starters in wash-down-optimised cast aluminium housings. nsd tupH drive units are a robust and durable alternative to painted geared motors or stainless steel drive units. A respective treatment is available for all NORD products made from aluminium. In nsd tupH aluminium drive units, all DIN and standard components, including drive shafts, are made from stainless steel. The fanless smooth motors do not spread germs and run very quietly.

Strong drive packages for mixer applications MAXXDRIVE® industrial gear units from NORD DRIVESYSTES ensure reliable operation in industries using mixing and agitation processes even under

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extreme conditions and offering high output torques up to 282 kNm, along with quiet running and long service life.

The compact combination of MAXXDRIVE® industrial gear units, the new SAFOMI IEC adapter and an energy-efficient electric motor from NORD is the best choice for mixers and agitator applications to reduce the number of wearing parts and attached components.

The SAFOMI adapter combines the functions of a standard IEC adapter and an oil expansion tank in one single component.

Its use on the agitator drive increases operational reliability and lowers maintenance efforts.

Oil tanks and hoses as well as the radial shaft seal between gear unit and IEC cylinder are not required. The SAFOMI adapter is available for parallel gear units in sizes 7 to 11 (output torques from 25 to 75 kNm).

For more information please visit: www.nord.com

Sumitomo (SHI) Demag stays on ‘multi’ trend

Multi-component manufacturing to the injection moulding world is what flares are to the fashion world. Both have been around for a long time and their popularity ebbs and flows. And just as wide legged trousers made a comeback on the catwalks in 2019, so multicomponent moulding is currently undergoing a surge in popularity, as it evolves in new directions.

According to the latest report issued by Transparency Market Research, the global market for multi-component moulding is anticipated to reach US$ 11.58 billion by 2024 .

Automotive industry in the driving seat The automotive industry commands the lion’s share of the market, accounting for approximately 30% of European demand for multi-component parts. This sector looks set to remain strong, driven by advancements in touchscreen electronics and the advent of sophisticated multi-face

tooling that allows for in-mould finishing and assembly.

The trend here is towards producing a single component that would have historically required several separately moulded parts and off-mould processes. For example, by combining multi-component moulding with touchscreen technology, a car dashboard can be moulded as a single element with the HMI functionalities sandwiched between the plastic.

As well as looking smart, this reduces the cost of production by eliminating the need for laser cutting, etching etc.

Another example of a growing automotive application is the production of the bezels that surround satellite navigation systems. The electronic touchpad for the ‘sat nav’ is laid inside the mould, then trimmed and tested ready to go straight into the vehicle.

But although automotive parts account for the majority of applications, other industries – medical devices, consumer goods, packaging and

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electronics – are predicted to experience the biggest growth in multi-component moulding over the next five years.

Aesthetic appeal and functionality In FMCG manufacturing, multicomponent moulding appeals to brand leaders seeking innovative and creative ways to integrate multiple colours, resins and sensory features into products, in order to provide differentiation. Combinations of materials, such as silicones and thermoplastics, PP and opaque thermoplastics like ABS, or hard plastics with a soft-touch material, are especially popular in the personal care market.

Some of the most common examples include disposable razors, toothbrushes and bottle caps.

However, as sustainability has climbed the corporate agenda, interest has shifted away from multi-material moulding and towards multi-colour moulding, as this enables the production of fully recyclable mono-material components. Some brands in

the premium spirits space have adopted this approach.

In the medical device segment, the driver behind multicomponent moulding is creating precision moulded products with specific physical properties and functionalities.

Adding a sealing solution, for example diaphragms, O-rings, gaskets and lip seals, to a medical component is critical to ensure resistance to potentially harmful and toxic chemicals and prevent cross contamination risks.

Filling a gap Sandwiching applications that go beyond burying low cost scrap material within a part are another major growth area. From a circular economy standpoint, sandwich moulding offers options to integrate recycled materials for the inner part of the component.

Examples include the trays used for protecting kitchen appliances during transit or for transporting automotive parts around a factory, with a filling from lower value recycled material.

As rising demand for recycled materials closes the price differential with virgin materials, moulders are looking to other ways of filling the cavity. The use of gas injection to hollow out the centre of the product, for example, makes it easier to recycle, plus there is the cost benefit that comes from a reduction in weight, material usage and cycle time.

Pros and cons Injection moulders are realising how much they can save by producing a finished part in the mould without the use of downstream equipment that takes up floor space and is expensive to buy, operate and maintain. In its most basic form, multi-component moulding removes the ‘assembly’ stage, whether clipping or gluing, reducing assembly costs by up to 20%. The fact moulding

takes place within one cycle also means it is more productive than conventional moulding – total manufacturing cycle time may be trimmed by up to 20% due to less handling of the part.

However, there are downsides to multi-component manufacturing. Capital investment is higher than with a standard press. This is partly because many multicomponent or co-injection presses are customised, making them more expensive, but also because tooling costs are higher due to the complexity; it is more difficult to repurpose the mould for different products than it is with a standard injection moulding process. In addition, the product design process and operation of the machine are far more complicated for multicomponent products.

Many of the disadvantages of multi-component manufacturing stem from the fact it has historically been performed on hydraulic machines. These are difficult to configure for different materials - the pump system may have to be changed, for example.

They are also heavy on energy consumption as the hydraulic

motor is connected to an electric power unit that works at maximum power in every phase of the moulding process.

All-electric has the answers All-electric multi-component systems are starting to emerge as a viable alternative, offering speed, precision and energy efficiency advantages over their hydraulic counterparts.

When working with two materials, perfecting the injection process control is even more critical given that a second material is being injected on top of the first shot.

All-electric machines use servo drives, enabling moulders to achieve greater precision and repeatability. For example, servo technology is critical for the smooth and fast rotation of the mould between the injection of the first and second material in order to ensure components are perfectly positioned to receive the second shot. Ultimately, this more precise operation translates to shorter cycle times compared to hydraulic concepts.

For more information, or to get in contact visit: uk.sumitomo-shi-demag.eu/

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FPT Industrial promotes the O’ Porto Rotondo Offshore Classic Edition

The O’ Porto Rotondo Offshore Classic Edition “Powered by FPT” was held in the waters of Porto Rotondo in Sardinia, from August 20 - 22. This prestigious, deep-sea fishing competition for imperial needlefish, was promoted by FPT Industrial.

The competition - organized by the Porto Rotondo Yacht Club Fishing Division - saw 14 boats with about 50 crew members battle it out, all united by their passion for the sea and sport, as well as by their desire to support the research and study of the imperial needlefish. FPT Industrial recently signed a partnership agreement with the Fishing Division of the Porto Rotondo Yacht Club and decided to support this top-level competition as a technical partner. It is the only Mediterranean tournament that is exclusively dedicated to the imperial needlefish and represents an ideal venue for marine engines to promote the performance characteristics that are required for this type of activity, such as power, durability, and low fuel consumption. During the

event, FPT Industrial gave a competition kit consisting of environmentally friendly items to all participants.

The trolling technique involves long hours of navigation, during which the imperial needlefish are hunted down with the help of the most modern fish finders. This phase is interrupted without warning at the moment of hooking and fighting.

Therefore, the engine must first have the responsiveness and speed to arrive quickly, and in time, at the competition area and then subsequently, ensure a more constant, regular, and efficient pace at the various trolling speeds. It should also be able to stop quickly and be able to appropriately follow the catching phase of the needlefish to avoid losing the fish and to attach the satellite tag linked to the Mediterranean Spearfish Project of the IGFA (International Game Fishing Association).

The imperial needlefish, a migratory pelagic species related to the marlin, swims in deep waters where it hunts for bluefish, such as anchovies,

sardines, and sardinella. It can reach two meters in length and 30 kilos in weight. At the end of a head-to-head that kept the fans on the edge of their seats, the race was won by the Velociraptor crew on the Tiara 42 boat, with four imperial needlefish. Sandro Onofaro, European sea fishing from a boat record holder and Director of the YCPR Fishing Division, the fishing division of the Porto Rotondo Yacht Club, presented the awards. “It was an honor for me to recognize, together with FPT Industrial, the participants in this tournament that combines sport and scientific research in what is the most important offshore trolling event of the 2020 season in Sardinia and, I would even dare to say, at an international level,” confirms Sandro Onofaro.

From 42 hp up to 1,006 hp, transmissions with maximum torque of 200 Nm up to 500 Nm, front and rear axles from 2 to 32 ton GAW (Gross Axle Weight).

FPT Industrial offers the most complete Natural Gas engines line-up on the market for industrial applications, including engine ranges from 136 hp up to 460 hp. This extensive offer and a close focus on R&D activities make FPT Industrial a world leader in industrial powertrains.

For further information, visit: www.fptindustrial.com.

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Vert’s reduced rate Compressor hire scheme offer is first taken up by Stirling fish vaccination business Aqualife Vert Technologies, the Edinburgh-based advanced compressor manufacturer which at the onset of the Covid-19 lockdown introduced a free compressor loan scheme to hard pressed businesses, has launched a new reduced-rate hire scheme initiative to support businesses looking to kick-start their activities but unwilling to invest in new kit. And already, Stirling-based fish vaccination business, Aqualife Services Ltd, has taken up Vert’s new offer to help it with new product development without the need to invest in new equipment at an uncertain time.

Aqualife is the world’s largest fish vaccine delivery company and since 1996 has been leading and pioneering farmed fish health and welfare. From its bases in Scotland and Norway, it works with aquaculture clients across the world to set industry benchmarks for quality, safety, and hygiene. Its teams have vaccinated more than 800 million fish to date, that is, over £10 billion of fish kept healthy and disease free.

It offers, too, a range of training courses and a variety of fish care and handling services.

of compressors to SMEs which, like Aqualife, need to kick-start their businesses without having to incur fresh capital expenditure. “‘We are happy to support other SMEs with our compressors over the next few months to help keep their business working. We are flexible and open to discussions as to how we can play our part.”

Kristian Clezy, Aqualife’s Head of Engineering, said: “we needed a source of compact, quiet, low- vibration air to reduce stress on fish during the vaccination procedure and to help create a pleasant working environment for the operators of our new semi-automatic fish vaccination solution. “We first saw the A150 compressor in action at Vert’s Stirling University Innovation Park roadshow event in February and were impressed by the low noise and vibration of the compressor, as well as its ability to run continuously with a 100% duty cycle.

“Vert’s loan offer has allowed us to continue to focus on new product development which otherwise may have slowed as we come out of lockdown, so we are grateful for its commercial support through these tricky times.” Vert CEO, Phil Harris, said: “We are in the happy position of having the capacity to hire out a small number

The Vert CRC technology has won multiple awards since the first working prototype was produced and has been described as the biggest advance in the compressor industry in 40 years.

The company now collaborates with global OEMs to integrate its unique technology into new applications in sectors such as refrigeration, heat pumps, cooling and expanders. The core CRC technology is also integrated into a Vert branded compressor range which offers a portable, low noise & vibration, 100% duty source of compressed air which is ideal for hand held tools, fibre optic cable blowing and decentralised air provision. Vert employs 14 people at its Manufacturing and Design centre on the southern edge of Edinburgh.

For more information, please visit: www.vertrotors.com/

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Stability & Flexibility: A new paradigm for eBeam Metal AM Lacking Stability

Introduction Additive manufacture (AM), and in particular the powder bed fusion (PBF) process, has offered hope to manufacturing industries needing to meet the environmental and economic targets of global industry sectors and the corresponding guidelines and regulations.

Indeed, AM offers a disruptive capability in this regard but user uptake has been slower than envisaged as difficulties with its implementation have surfaced time and again and more traditional production technologies have won the argument.

AM is no different to any other manufacturing process that relies on the interaction between a manufacturing system and the material of the product being manufactured.

For that interaction between the system and the material to be simultaneously understood, repeatable and to deliver the required output; clear and consistent knowledge of both the system and the raw material is essential. The process owner has to bring these two halves together to ensure the whole.

Wayland Additive understands this need from the user’s perspective and has made it its mission to develop a machine

that allows the user full, repeatable and safe control of a metal AM process.

To do this, two things are essential in the machine architecture: • It must present to the user a stable platform (machine and process material).

• It must also be capable of great flexibility and control to accommodate the wide range of user applications.

However, stability and flexibility have not always comfortably complemented each other in the field of AM. Wayland Additive is operating to break this barrier down.

Focusing on eBeam The physics of the electron beam (eBeam) process is ideally suited for AM. Electron beams have been used for decades in precision welding, in scanning electron microscopy and in the semiconductor industry for mask manufacture and direct writing of nanopatterns onto resists — with each application putting its own unique demands on the technology. Feature size and process capability is a function of the alliance between the raw material (or in the case of electron microscopy, the sample) and the machine. AM is no different.

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When the Wayland team first closely reviewed additive processes (back in 2015) we were struck by the lack of stability, exhibited both in the machines and the output. Our attention turned to the PBF (powder bed fusion) process, where laser and eBeam machines were operating and where repeatability from part to part and from build to build was lacking at the system level and from part to part at the output level. This was a consequence of both process issues and the constraints of existing machine capabilities. Each of the two competing energy sources brought their own unique challenges for users looking to achieve successful outcomes.

With the laser PBF process residual thermal stress, soot contamination, low productivity, the challenge of process monitoring, limited part volume and limited process control parameters restrict the process dynamics and the optimisation options that are available to the user. This in turn has led to machine makers and customers turning to material scientists to develop new materials dedicated to the AM process, in an attempt to overcome such limitations. It is interesting to note that huge sums of money are now being spent in the industry trying to develop “forgiving” materials in order to get around the issues presented by both laser PBF and traditional eBeam PBF systems.

This may be one way of solving the problem but the strategy of relying on bespoke materials for targeted applications may further add to the cost of AM. Powder producers need to be able to produce large volumes in order to reduce costs, rather than providing a wide range of specialist alloys.

With the eBeam process, the problem of powder charging — that alliance between the machine and the material

at the aspects that dictate basic machine stability: such as high voltage performance; vacuum integrity and cleanliness; electromagnetic shielding; beam deflection capability, distortion corrections and noise, but also at the limiting process issues (i.e. powder charging) and thereby develop a system that offers the user a stable yet broad process window for product development across a breadth of materials.

— meant that the process stability and breadth were immediately and severely compromised. With a background in electron beam systems the Wayland team reviewed the state-of-the-art and immediately set about removing the constraints from the eBeam process, believing that the physics of the process is fundamentally more favourable to AM in the following ways: • The energy transfer from the electron beam to the powder is a kinetic process • Extremely fast deflection speeds can be achieved as there are no mirrors to manipulate • The incident power on the powder bed is easily measured and controlled • There are no optical surfaces between the electron source and the powder bed to contaminate and deteriorate with time • The process can run hot and so take place above the annealing temperature of the process material, resulting in stress free parts with less post processing • The process takes place in a vacuum so powder contamination and oxidation is reduced and powder life extended • In-process monitoring can take place using a range of photon and electron detectors and systems.

Electrons have an inherent advantage over photons in that they are charged particles, which means that the beam can be deflected, focused and corrected very rapidly, without any physical contact, scattering or absorption. Within the context of AM to date, however, this has also proved to be a disadvantage. When charge particles are incident upon insulating materials, they tend to adhere and build up a surface charge. When this happens during the metal eBeam AM process (where the accelerating potential of the electrons is many thousands of volts and metal powders tend to have an insulating surface oxide layer) a considerable potential can build up on the powder bed, until the powder particles are caused by Coulomb forces to repel each other and a “smoke event” occurs. When this happens, the particles become free flying within the chamber and the build is violently terminated, potentially to the detriment of the machine as well as the build. This build-up of charge occurs very rapidly and has to be managed throughout the build process in order to reliably complete a build.

The user will no longer walk the tightrope of compromise, rather hasten along a stable path of product development. The latter achieved by overcoming the charge accumulation of electrons on the powder bed, without the need to pre-sinter the powder, thereby creating a stable process that allows the capability of the electron beam to explore/exploit the material properties of the metal and to manipulate the thermal rates of change within the melt pools.

The NeuBeam process and the new Wayland system has been designed from the bottom up and incorporates many years of learning from the semiconductor industry — a hard task master. The team listened to the experiences of users of metal AM platforms and in so doing realised that they did not need to invent a new wheel but rather adapt an existing and sophisticated capability built on hard won knowledge from another field (the semiconductor industry). By combining these experts with long-term AM industry insiders it was possible to rapidly develop both the machine and the processes and so the marriage of machine and process was established from the beginning.

For more information please visit: www.waylandadditive.com

NeuBeam Ensures Stability is Built-in The electron beam and charged particle physics and engineering expertise gathered at Wayland has allowed us to look not only

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Electronic assemblies without PCBs

Laser direct structuring (LDS) is a special success story. For almost 20 years, it has been possible to apply electronic conductor paths directly onto plastic parts during series production.

Laser Direct Structuring (LDS) - The structure of the conductor path is applied using the LDS process.

LDS enables electronic assemblies to be made in flexible geometric shapes. Smart phones, hearing aids and smart watches are becoming smaller and more powerful thanks to this process.

LDS enables the production of electronic assemblies with flexible geometric shapes. This process enables electronic products (such as smart phones, sensors or medical devices) to become even smaller and more powerful. Automated manufacturing processes also make this process more economically attractive.

There is less and less space available for electronic assemblies, so solutions

are needed which replace conventional printed circuit boards. LDS enables further miniaturisation and makes increasingly complex geometric designs possible. This is a stable and reliable process that has established itself in qualitycritical sectors such as medical technology or safety-relevant components for the automotive industry.

The LDS process enables three - Dimensional assemblies Direct laser structuring enables 3D-MID (Mechatronic Integrated Devices) assemblies to be produced. When using 3D-MID, electronic components can be fitted directly onto a threedimensional base body, without circuit boards or connecting cables. The base body is manufactured using an injection moulding process, whereby the thermoplastic material has a non-conductive, inorganic additive.

The additives in the material are “activated” by direct laser structuring so that the plastic material can accommodate the electrical conductor paths.

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The laser beam writes the areas intended for the conductor paths and creates a microrough structure. The released metal particles form the nuclei for the subsequent chemical metallisation. In this way, the electrical conductor paths are applied to the areas marked by the laser. The other areas of the three-dimensional base body remain unchanged. The plastic component can then be assembled in standard SMD processes similar to a conventional PCB. It is also suitable for soldering in a reflow oven.

Versatile application of laser technology HARTING 3D-MID AG is the largest supplier of 3D-MID components outside of Asia. HARTING uses highperformance laser systems for the LDS process, with three lasers working in parallel, each offset by 45 degrees. Thanks to an additional axis of rotation, components can be processed by the laser simultaneously from all sides (360 degrees). This technology enables flexible

geometric shapes, such as reflector shells or LED lights, to be made. Despite the minimal conductor path thickness of 16 to 20 μm, the conductor paths are still suitable for demanding automotive components or for applications with currents up to 10 A – for example for heating coils in cameras which are used to prevent the optics from fogging up.

Dimensioning and positioning - Minimum distances between the conductor paths (a): 50 – 150 μm. Minimum width of the conductor paths (b): 50 – 150 μm Radius (r): 0.2 mm Frequent changes during the electronics development phase or new components with modified dimensions can lead to costly adjustments during conventional PCB production.

The laser layout, in contrast, can be adapted very flexibly by using the parameters of the laser’s control software. No changes in the injection moulding are required for this.

The production of prototypes using LDS is also easier compared to conventional processes. HARTING can produce the plastic base body using LDS-compatible material and 3D printing. Injection moulding can also be used with inexpensive prototype tools.

- The improvement of the optics enables the use of a laser with a diameter of 100 μm and a laser with a fine focus of 50 μm for processing even smaller structures.

HARTING is the only 3D-MID manufacturer in the world that has a laser system with three fine focus optics of 50 μm. Even smaller conductor path gaps can be achieved thanks to this fine focus laser. Thus, many conductor paths can be created on the same component and a higher packing density can be implemented. This is used for safety technology, among other things, because the closely spaced and intertwined conductors are capable of triggering safety alarms from even the smallest physical interference.

Advances in materials and economics Only specially selected thermoplastics are certified for the LDS process; these are available from stock. The process can be further improved with customer-specific adjustments to the plastic material: - HARTING uses a process which adds LDS additives to non-certified materials to make them MID- compatible. range.

- Specific RAL or Pantone colours can be achieved with MID plastics by using colour pigments and special LDS additives - By selecting suitable additives, special RF characteristics can also be implemented, depending on the frequency Component carrier Electronic components – such as LEDs, ICs, photodiodes and sensors – can be attached directly onto the component carrier. The assembled component carriers can then be processed as standard SMD components.

More growth for 3D-MID Security caps for payment terminals - The 3D-MID caps protect the electronics from unauthorized access both mechanically and electronically. A highly precise meandering structure detects every access, no matter how small, and consequently prevents theft.

For more information, please visit: www.harting.com/3D-MID

New trends in the LDS process - Several aspects of LDS technology have been improved and further developed over the past few years.

- The working area of the laser has been enlarged from 160 x 160 x 80 mm to 200 mm x 200 mm x 80 mm, thus enabling a higher packing density and the processing of even larger components.

- The working speed of the laser can be doubled to 4 m/s by optimising the servo units and mirrors which guide the laser beam, thereby significantly reducing the processing time.

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