Worldwide Engineering Magazine - May Issue

May Issue NSK Newark site implements rainwater harvesting

Titan Enterprises explains possible reasons for Flowmeter failure during installation

DER-IC Takes delivery of first Micro-Punch Sinter Press in the UK

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worldwide-engineering.com

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Finalists Announced for Plastics Recycling Awards Europe 2022

Print pre-sized labels from your phone

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Titan Enterprises explains possible reasons for Flowmeter failure during installation

Large laundry

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TorqSense transducers help to guarantee valve actuator performance

DER-IC Takes delivery of first Micro-Punch Sinter Press in the UK

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Major energy supplier revolutionises electrical maintenance inspections with partial discharge detection

Reciprocating action solves tough heat exchange challenges

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Motorcycle exhaust manufacturer takes brakes off innovation and growth with Made Smarter A manufacturer of high-quality motorcycle exhausts is unlocking its capacity to innovate and grow with the support of Made Smarter.

Fuel Exhausts, based in Kendal, is investing in a 3D scanner to capture digital versions of parts and components, 3D CAD software, and a 3D printer for producing prototypes of end caps and parts for exhausts.

The £30,000 integrated digital design solution, which has been match funded by the Made Smarter Adoption Programme in the North West, will enable the business to design and test product ideas in virtual reality before manufacturing them.

It will radically change the way the business operates, making the prototyping process 14 times quicker, increasing productivity, eliminating waste, reducing costs, and increasing profitability.

Meanwhile, 3D scanning technology will introduce reverse engineering

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of parts into the business, opening new markets.

The investment will also create two new production operative jobs.

Damian Turner, who runs the business with wife Louise, said: “We are a small but very dedicated team who strive to provide a fantastic product with second to none customer service.

“Over the two decades we have been trading, digital technology has moved to the forefront in many areas of manufacturing, with the support of Made Smarter we are ready to embrace the opportunity it offers to manufacture prototype parts and new products in-house and move into other areas of production for parts and accessories to complement our current range of exhausts.”

The 3D scanning technology will allow Fuel Exhausts to scan a motorbike to give it the capability

of reverse engineering of parts and components. It will also enable the business to test new products and design in a virtual environment, before using 3D printing to produce prototypes quickly and cheaply.

Donna Edwards, Made Smarter’s North West Adoption Programme Director, said: “We are delighted to be supporting Fuel Exhausts on its digital transformation. It is a superb example of a business using technology to transform how it designs, tests and manufacturers products.

“Fuel Exhausts is among hundreds of manufacturers in the region grasping the opportunities offered

by Made Smarter which include expert, impartial technology advice, digital transformation workshops to help take that first step to transform a business, a leadership programme, and funded digital technology internships.

I would encourage other SME manufacturers to do the same.”

NSK Newark site implements rainwater harvesting The Newark, UK manufacturing facility of bearing and linear motion specialist NSK has implemented a rainwater harvesting system that will reduce mains water consumption by almost 200,000 litres a year. The installation will also contribute to the reduction of local rainwater run-off, helping to avoid potential flooding in the region.

Based on the Stormsaver StormStation above-ground system, the installation centres on a large furnace building with a substantial roof volume and two large-diameter downpipes.

A dedicated NSK Automation and Sustainability engineer at Newark specified electronic valves within the downpipes that divert rainwater to a 10,000 litre tank (close to the size of a shipping container).

The tank is located in the central garden of the Newark site, on full display to employees as a feature of achievement. Offering integral filtration, UV lighting is also in

place to eliminate bacteria and fungal spores. The clean water is pressurised by two pumps and sent to three lavatory blocks in the site’s grinding department. This represents 40% of the lavatory facilities available to manufacturing personnel, serving around 140 employees over a threeshift pattern.

Commissioned in April 2022, the rainwater harvesting system saves the need to flush away almost 200,000 litres of potable water every year.

A further part of the project will be the site’s role as a test bed for smart meters. This soon- tobe-installed metering system will measure water in and water out, as well as electricity consumption.

Wider site metering will roll out later in the year.

Another important aspect of the installation involves the site’s proximity (less than 1km) to the River Trent. Any new buildings in the area, especially factory buildings, are subject to water management due

to the potential for local flooding.

If NSK wanted to construct a new building at its Newark site, it would have to feature flood prevention capabilities. This normally means water buffering, which is exactly the role of the new rainwater tank. With this thought in mind, the installation of additional tanks across the site will help to reduce water run-off locally, which would be beneficial for everyone in the region.

Such is the success of the project that it could prove the blueprint for other NSK plants in Europe.

Newark has already shared details of the system’s components, the capital investment involved and the savings. Further data will follow after the introduction of smart meters.

Moving forward, the site will continue introducing environmental initiatives, including low- flush lavatories and low-energy heating and lighting, as the company continues its global agenda in support of a more sustainable society.

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Finalists Announced for Plastics Recycling Awards Europe 2022 Winners will be announced at PRSE in Amsterdam on 23 June Shortlisted finalists in the Plastics Recycling Awards Europe 2022 were revealed earlier today in a livestream event. The winners of the seven award categories will be announced on 23 June, the second day of the Plastics Recycling Show Europe at the RAI Amsterdam, where all 45 finalists will be showcased.

“The number and quality of entries for this year’s awards has been outstanding, especially in the Household & Leisure Product category, ” said Ton Emans, President of Plastics Recyclers Europe. “All of the shortlisted products and projects are made in Europe and every product contains a minimum of 50% recycled plastics.

The success of these awards reflects the increasing collaboration we see along the whole plastics value chain from brand owners, packaging designers, raw material producers, equipment manufacturers and more.”

“Congratulations to all our finalists. The depth and diversity of projects and products prove the commitment to the recycling of plastics today,” said Matt Barber, Global Events Director, Crain Communications. “In the five years since the Plastics Recycling Awards Europe were founded, it is heartening to see just how extensively plastic products are now specifically designed to be recycled.”

Plastics Recycling Awards Europe 2022 Finalists: Automotive, Electrical or Electronic Product of the Year - plastic parts used in automotive and electrical products incorporating recycled material:

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- CEPLAFIB motorhome floor distance holders by AITIIP, ADRIA and TECOS

- Paclan For Nature - Good Karma bin bags by Cedo Folien und Haushaltsprodukte

- Coloured Recycled Material for Interior Trim Parts for Ford Transit vans by Ford Otomotiv Sanayi

- Reading eyewear by Euro-Optics

- Sustainable modular headliner for vehicle interiors and downstream recycling solutions by Grupo Antolin Building & Construction Product of the Year - interior and exterior construction products of all types: - ECO waste water traps by Jimten and Aliaxis - ECOSAN Structured Wall PVC Sewage Pipes by GROUP PLÁSTICOS FERRO - SOLAR HEAT panels made from recycled plastic, by MONTELLO & WET/ECOPIXEL - VORONOI plastic panels by Plastiz and Ser - a Sirmax Group CompanyArmaPET Eco50 by Armacell Benelux S.C.S Household & Leisure Product of the Year - covering all types of domestic and leisure goods with recycled content: - “ReCycle” Bike Bag by VAUDE , INTERSEROH & Fitcraft - DutchFiets bicycle by DutchFiets and Healix - EcoPackly collapsible storage container by FRATELLI GUZZINI

- Battigia sponge holder by VECA – A Sirmax Group Company - StepUp Pedal Bin by Brabantia - Tie Top High Performance Refuse Sack by Berry bpi - “My bottle, please” detergent refill system by CHT Germany - Kuniboo Beach Toy Set by Schwarz Group (PreZero Polymers AG, Kaufland Dienstleistung GmbH & Co. KG) and Mochtoys Plastic Packaging Product of the Year - judged on design innovation with recycled content and design for recycling:

- Fully recyclable laminate tube with PCR by EPL Deutschland and Co. KG - Nivea Shower Crème Care bottles

by Beiersdorf & Morssinkhof Plastics Heerenveen - ProLiFEx rPEflex compostbag by Attero, Pokon Naturado, Oerlemans Packaging Group, TUSTI, Technische Universiteit Eindhoven and DOW - Recyclable collation shrink film with outstanding PCR content by Freiberger Lebensmittel, alesco Folien, and Borealis

- Lookin EVO bicycle saddle by Selle Royal and bage plastics

Product Technology Innovation of the Year - improving recyclability of plastic products or incorporating recycled materials in product production:

- N U K E R I N A S C O® chair by MEPOL - BRADO

- Nucleant nucleating additive for lightweighting by Ampacet

- HÅG Tion 2100 chair by Flokk

- Halogen-free polymer process aid for packaging and recycling market by Evonik Operations

- Caustic Washer for rigid and flexible flakes polyolefins by Krones AG

- K3® r100 separable carboard and plastic tubs by Greiner Packaging

- PolyPerception Waste Flow Platform by PolyPerception

- NextCycle IML labels by MCC Verstraete

- READY DEPACK TECNOFER depackaging system by TECNOFER ECOIMPIANTI

- Recyclable Mono PE shampoo Pouch by Procter & Gamble - Finish 0% Dishwasher Tablets packaging by Reckitt - “Future by Aptar” mono-material pump by Aptar Beauty & Home Recycling Machinery Innovation of the Year - increasing the efficiency and effectiveness of plastic recycling processes:

- Mistral+ CONNECT waste sorting system by Pellenc ST Plastics Recycling Ambassador of the Year - individuals who have made an outstanding contribution to European plastics recycling: - Pablo Urbano Villaescusa, COO, AUARA EMPRESA SOCIAL - Stijn Billiet, Director Global Sustainability, MCC Label

- VacuFil Visco+ fiber to fiber – inline recycling of post-consumer polyester (PET) fiber waste to highend filament yarn by BB Engineering

- Dan Jordan, Recycling Specialist, Summit Systems

- ZS-B MegaFeed by Coperion

- Robert Brüll, Head of Department Material Analysis and Characterization, Fraunhofer

- QualityON:Polyscan - Measuring the polymer composition directly during the recycling-extrusion process by EREMA Group - Gneuss MRSjump Extruder by Gneuß Kunststofftechnik - Greyparrot AI Waste Recognition System by Greyparrot

- Mik van Gaever, COO, Fost Plus The expert judging panel for the Plastics Recycling Awards 2022 includes four previous winners of the Ambassador Award: Flor Peña Herron, Senior Sustainability & Circular Economy Manager EMEA at Avery Dennison (2021); Professor

Kim Ragaert of Maastricht University (2020); Gian de Belder, Technical Director, R&D Packaging Sustainability at Procter & Gamble (2019) and Willemijn Peeters CEO of Searious Business (2018).

They are joined by Ton Emans, President of Plastics Recyclers Europe (PRE); Karen Laird, Editor of Sustainable Plastics and Rune Thoralfsson, Owner and Director of plastic film recycler Norfolier GreenTec AS. The Plastics Recycling Awards Europe are organised jointly by Plastics Recyclers Europe and Crain Communications, organisers of PRSE. Platinum sponsors of the 2022 Awards are EREMA Engineering Recycling Maschinen GmbH, Fimic SRL and Tomra Sorting Recycling.

The Plastics Recycling Show Europe is a free-to-attend exhibition and a conference designed specifically for plastics recycling professionals.

It brings together key players from the plastics and recycling sectors to showcase innovative technology, share best practices, network and do business. A broad cross-section of the industry is represented at the event including plastics recycling machinery and equipment suppliers, plastic material suppliers and compounders, pre-processors, plastics recyclers, waste management specialists and industry associations.

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ViewSonic’s X1000-4K LED soundbar projector scores iF Design Award for Smart and Minimalistic Design ViewSonic Corp., a leading global provider of visual solutions, has scored a prestigious honour at the iF Design Awards 2022 for the company’s innovative X10004K Ultra Short Throw Smart LED Soundbar Projector

and living spaces seamlessly, the X10004K is a combination of these efforts.

The projector combines phenomenal visual detail and an immersive audio experience in a sleek industrial design, transforming a tech device into a meaningful interior artifact.”

Selected from a field of more than 10,000 products from around the world, the projector won plaudits for its boundary-pushing design and advanced visual and audio capabilities.

The X1000-4K is the latest string of ViewSonic products to have been recognised at the iF Design Awards.

Previously, the company received accolades in 2018 for its M1 LED Portable Projector, in 2019 for its X10-4K, X11-4K Smart LED Projector, and in 2020 for the M1 mini LED Pocket Projector.

“We are incredibly proud to have received this recognition at the iF Design Awards 2022, especially given the competitive nature of the field this year,” said Dean Tsai, General Manager of Projector & LED Display Business Unit at ViewSonic. “ViewSonic has been working to reimagine what’s possible with projection solutions that can blend into consumers’ lifestyles

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The X1000-4K is an elegant solution for home cinemas — an aesthetically pleasing yet minimalist centrepiece that fits perfectly in a room. The iF Design Awards recognised the design as combining projector and soundbar in a package that blends interior

design elements with high-tech appeal and having blended geometric forms and fine detailing that embrace a convergence between device and living space.

The projector boasts 4K UHD visuals and 0.25 ultra short throw ratio that allows a 100” image to be projected from just 38cm away. It also packs in a 40W Harman Kardon soundbar that delivers an immersive sound experience.

Featuring industry-leading LED technology, the X1000-4K offers more than bright and vivid images but also a 30,000-hour lifespan — 6 times longer than traditional lamp-based units. Designed with an intuitive user interface, the projector features a range of smart features such as builtin WiFi for wireless screen mirroring, and Bluetooth connectivity for flexible audio needs.

Rohde & Schwarz enhances its digital training offerings through acquisition of The Technology Academy By integrating online training specialist The Technology Academy into the Rohde & Schwarz technology group, the T&M specialist takes its customer trainings further into the digital domain. Technology professionals worldwide get easy access to an extensive library of high-quality online courses in the fields of RF, wireless and microwave engineering technology, straight from industry experts.

Rohde & Schwarz announces that it has acquired UK-based The Technology Academy, a longestablished provider of online training courses in the fields of RF, wireless and microwave engineering technology. The Technology Academy is an ideal partner to expand the existing training offerings of Rohde & Schwarz and will play a significant role in increasing the company’s future professional services.

The Rohde & Schwarz Technology Academy combines the expertise and industry insights of the trusted T&M manufacturer – currently

providing live and virtual trainings from their in-house training center as well as on-site trainings for existing customers – with the web training expertise of The Technology Academy. A holistic portfolio of ondemand courses is available 24/7 to technology professionals with different experience levels. They will have easy, immediate access to a range of certified trainings, which offer in-depth expert knowledge and industry insights. Content is delivered in a practical and applicationoriented way, with a focus on clear explanations. Certificates are available for completed courses.

The main objective of the training offerings is to support technical staff in managing new challenges as well as staying up-to-date with the latest technologies. The webbased training format also allows both flexible and scalable learning paths. This combination of highquality training with insights from industry experts and simple access makes it easy for companies to find the right training options for staff while simultaneously addressing time and budget constraints.

Patricio Duenas, Vice President Sales and Market Segments Test & Measurement at Rohde & Schwarz, says: “We are excited to have The Rohde & Schwarz Technology Academy as part of our group of companies. Their holistic and high-quality technical courses perfectly complement our training portfolio. We look forward to creating additional training content to keep new and existing customers on top of the latest technical developments and help maintain their competitiveness.”

Dr. John Crute, founder of The Rohde & Schwarz Technology Academy, says: “After close collaboration with Rohde & Schwarz UK for more than 10 years, we are very happy to bring this relationship to the next level, making our training expertise available to a much wider global audience as part of the Rohde & Schwarz technology group.”

For further information on The Rohde & Schwarz Technology Academy and current training offerings, go to: www.rohde-schwarz.com

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Titan Enterprises explains possible reasons for Flowmeter failure during installation “Why Has My Pulse Flow Meter Sensor Failed?”

to fail suddenly, completely and permanently.

The majority of flow meters with a pulse output use a rotating element with internal magnets.

These magnets trigger a solidstate sensor giving a pulse output proportional to the liquid flow rate.

- Unregulated Power Supply: Exceeding the maximum 30Vdc to the Hall Effect sensor will damage the unit. A good quality regulated DC power supply is recommended for powering a pulse flow meter.

Titan Enterprises Ltd, who has been designing and manufacturing flowmeters for over 40 years, explains some of the reasons why these sensors might fail and what can be done to prevent damage that can lead to costly repairs and process downtime.

High quality Hall effect sensors are typically used within Titan’s pulse precision flow measurement devices. The sensors operate between 4.0Vdc and 30Vdc, however, there are a number of scenarios that will cause the Turbine and Oval Gear flow meters to fail, even though the installer believes the flow device has been installed correctly.

If a flow sensor fails, it may be for one of the following reasons: - Incorrect Wiring: Care must be taken when wiring the sensor power supply and pulse output of the flowmeter. The sensor is unable to cope with incorrect wiring reverse polarity or short circuiting can cause the sensor

- Electrical Interference / Voltage Spikes: Other connected equipment containing inductors (coils), or electromagnetic components (such as solenoid valves or pumps) can produce high voltage spikes when switching. These spikes can be a hundred to thousands of volts and if on the same circuit, will damage the flowmeter sensor beyond repair.

Electrical interference can also occur even without a direct connection if cabling is routed close to high-power equipment.

A failure mode that is commonly seen, is where a simple solenoid valve is operated on the same power supply as the flowmeter. When the solenoid de-energises in 1ms it produces a spike of 100s of Volts.

Some of this voltage spike feeds through to the sensor, momentarily exceeding the 30Vdc maximum of the sensor causing it to fail.

with Titan Enterprises observes: “The majority of damage tends to be caused during the installation of the flowmeter. Minor errors can result in a non-operational meter before the customer has even started, leading to costly repairs or replacements, as well as process downtime, that can be avoided.”

Titan Enterprises produce over 70,000 flowmeters each year that are used in a wide variety of industries, processes and applications, so troubleshooting for customers is not uncommon, particularly for those who are unfamiliar with Titan’s flow metering products.

Neil says: “Titan provides written data and instruction sheets with all our flow meters, and we have also published some installation tutorial videos to help our customers and prevent any mis-wiring that can damage the units.”

The following installation checklist will go a long way to preventing common causes of pulse flow meter sensor failure:

What can be done to prevent catastrophic failures in flow measuring systems?

Neil Hannay, Senior R&D Engineer

For further information on Titan’s flowmeter and instrumentation range or to discuss any process and technical issues, please contact Titan Enterprises on +44 (0)1935 812790 or sales@flowmeters. co.uk. Visit our website at www. flowmeters.co.uk/ 11

Answering customer-driven needs in miniature motor design and development From medical monitoring equipment to robots, miniature motors are integral to providing motion in space-critical, high performance applications. The design and manufacture of these motors takes cutting edge engineering expertise, while a keen understanding of customer requirements is essential when deciding which performance features must be developed.

Portescap’s ‘Voice of the Customer’ research ensures that it’s standard product platform is highly tuned to solve current customer needs – and that’s before the bespoke customisation begins.

Sunil Kumar, Product Manager at Portescap, explains why Voice of the Customer research is critical for optimising miniature motor design.

One of the most common requirements of an OEM design engineer is customisation flexibility.

Every application has different demands on the miniature motor

and motion control solution, which can seldom be completely fulfilled from a standard specification. For this reason, Portescap’s design approach has always included the widest range of customisation options. While the success of many customised designs means that they eventually become standard products among our miniature motor range, all customised development has to originate from a foundational technology platform.

Voice of the Customer

To arrive at these optimum bases of miniature motor development, customer input is vital. It’s important to maintain a clear vision of our customers’ landscape of competitive development.

Responding to the needs of the customer always remains the most important consideration. At Portescap, the framework we use to understand these insights most accurately is based on a process called the Voice of the Customer.

The final outcome is the generation of detailed product and solution design specifications, with significant input from our customers’ technical insights. Ultimately, these customer requests become key aspects of future product designs that are then developed by our engineers to solve complex problems for critical applications.

The Voice of the Customer process integrates years of design experience combined with real-life field application expertise to understand customer wants and needs, right down to the most detailed level. This includes collaborating with OEM design engineers, working alongside them as well as their end user customers, specific to industries and applications.

After detailed investigation, we need to understand the development path for the customer-inspired initiative. It’s crucial to know whether customer requests can work together and be aligned into a single product or solution. It’s also vital to determine whether a product concept is scalable and viable for manufacture to meet the price point that the market demands, and we achieve this understanding with the application of lean management principles.

For all new projects, we use the established stage-gate product development process.

The stage-gate process navigates a product idea from concept to business case to production, using a list of welldefined actions. Dedicated teams then take ownership of the product at each step, and a fundamentally important aspect

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is receiving user reviews and feedback throughout the entire development journey. The final result is a technology platform that is not only cost-effective for OEM integration but is also true to the customers’ initial design requests.

Applying customer insights to product design By listening to the customer to address their specific and developing needs, our Voice of the Customer process has delivered many innovative new motor platforms, all of which remain fully customisable.

A particular example is the development of brushless DC (BLDC) motors for robotic applications. As well as being robust, long lasting and able to operate at high speeds, they’re also small enough to fit into compact areas like robot joints.

With footprint being critical, user feedback led us to create a proprietary u-shaped coil with a much smaller size compared to those found within typical BLDC motors. The coil integrates larger copper fittings that enable higher performance

than a standard straight coil. It also has minimal iron losses, which means improved efficiency and cooler operation. This new design allows a two-pole motors, for example, to deliver 30% more torque compared to motors of a similar size with traditional coil design. Taking the design further, BLDC slotless motors that incorporate u-coils can be tailored for highspeed, high-torque or a balance of both.

Another common requirement for robotic applications received through the Voice of the Customer process is high dynamic response. Robotic grippers need a combination of fast, incremental precision that a stepper motor can provide, as well as the speed and acceleration typical of BLDC motors. A new way of achieving and combining the benefits of both motor types is by introducing a rare earth magnet, designed in a thin disc form. The result of this new design is increased step resolutions compared to permanent magnet stepper motors.

This is combined with significantly higher capabilities of acceleration due to low inertia, as well as greater top speed than conventional stepper

motors because of the new design’s shorter magnetic circuit which provides lower iron losses.

PSolving complex application challenges While low inertia disc magnet technology was developed as a result of Voice of the Customer research within robotics, it’s also a good example of how advances can be transferred to the benefit of wider applications. The low-inertia disc magnet technology can also apply to actuators, enabling quick linear acceleration and deceleration within one low-profile package, which saves process time. That means engineers can simplify their designs as they solve complex application challenges.

Robots can involve both linear and rotary motion. The challenge is that both modes typically require additional control components which expand footprint. However, we know from our research that recued size is a key attribute that customers need. As a result, our innovative development of the Dual Motion Can Stack Actuator allows simultaneous linear and rotary motion that combines two permanent stepper motors into one lightweight, compact package. The actuator design delivers pure linear motion in any direction without shaft rotation. It also achieves pure rotational motion, clockwise or anti-clockwise, with no shaft translation along its axis.

With this design, it’s also possible to combine linear motion and rotation simultaneously in any direction.

These examples show how the Voice of the Customer process enables our engineers to understand the real needs of our customers and integrate them into our product development cycles. When our product developers move on to customise motors and control solutions for specific projects, Voice of the Customer research enables them to quickly and accurat3ely achieve a bespoke design that precisely matches the specification thanks to the customerinsight led technology foundation.

This in turn allows us to integrate new features into our standard product range that is in tune with current demand.

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Kollmorgen introduces a new generation of robot-ready frameless servo motors Kollmorgen, a global leader in motion control systems, today announced the new TBM2G series of frameless servo motors, introducing features that simplify the design of collaborative, surgical, aerospace and defense and other robots while delivering optimal performance in a lighter, more compact package. These new motors will complement Kollmorgen’s existing TBM and KBM series of frameless motors.

Resulting from several years of research, testing and customer feedback, the TBM2G series offers high-performance torque in an extremely compact electromagnetics package. These next- generation motors enable robots with lower joint weight, higher load-carrying capacity, improved energy efficiency, lower thermal rise, and faster, smoother movements.

Frameless torque motors typically deliver their best performance at low speeds but suffer at higher speeds. TBM2G motors remove this limitation through advanced windings and materials that deliver

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industry-leading power, torque and efficiency consistently across a wide speed range.

TBM2G motors also remove the sizing limitation that engineers often face when using off-the-shelf strain wave gearing, also known in the robotics market as harmonic gearing. The new TBM2G series motors are sized for a perfect fit with readily available strain wave systems, eliminating the need for extensive customizations that can increase engineering time and cost while potentially leading to supply and quality issues when robots enter full production.

The TBM2G series is available in seven frame sizes with three stack lengths each—a total of 21 standard motors that can be integrated directly into robotic joints and similar embedded equipment. Typical applications are collaborative robots in the 3–15 kg range, powered at 48 VDC and below. These motors are designed to perform at high speeds without exceeding the 80°C limit typically needed to safeguard humans

working in proximity to cobots and to prevent degradation of grease and electronic components. And they’re available with thermal sensor options to meet the requirements of drives and control systems used in the cobot market.

Kollmorgen is highly tooled up to deliver TBM2G motors globally, at any volume, with fast production times, reliable quality and local coengineering support.

“We’re excited to introduce new servo motors that significantly increase overall performance while reducing size in a wide range of frameless applications,” said Jeff Czarnecki, Vice President, Global Marketing at Kollmorgen. “And we’re particularly excited at the possibilities the TBM2G series opens up for robotics. TBM2G motors are a perfect fit for a new generation of high- performance cobots,” Czarnecki said. “They are truly robot ready.”

For more information, visit the TBM2G web page at www.kollmorgen.com/TBM2G.

Servomotors: powerful when the going gets tough Demanding tasks that require high torque are the DL4 servo motor’s primary discipline.

Particularly powerful and flexible in its connection to machine designs, the servo motor sets new standards. Luca Banfi, Sales & Marketing Manager at KEB Automation’s Italian partner company Brusatori, explains the special features of this “power package”.

What sets the DL4 motors apart from other servo motors?

DL4 servo motors are designed to fulfill very high torque requirements.

Compared to most of the motors on the market, they stand out due to their compactness and for the high nominal torques they can reach.

Furthermore, the customisation of these motors makes it possible to adapt them to most machines and obtain truly excellent performances. The possibility of having different shaft designs and different types of feedback allows these motors to be adapted to individual customer needs.

In which applications is the motor used and are there certain challenges for which it fits best?

The DL4 servo motors are particularly suitable for very stressful applications. In many cases, the environmental conditions and the operating cycle of the machine put a strain on the mechanical structure, bearings and windings. DL4 motors are designed to fit applications in different fields, from a wind turbine (pitch and yaw systems) to the machining of metals, wood and plastics. For example, in wood processing, the motors are subjected to constant high stress due to a combination of factors such as temperature and humidity combined with high torque requirements.

Which servo motor variants are available and what can users look forward to soon?

Starting from the mechanical variants available, the following solutions can be considered: mounting form B3 or B35 – smooth shaft, with key or splined. In some

cases, it is also possible to have a hollow shaft version. On the electrical side, different types of windings, thermal sensors and position sensors are available. Last but not least, there is the possibility of having motors with natural ventilation or servo ventilation – the latter guaranteeing very high nominal and peak torque levels.

Can you tell us something about the development history of the DL4?

The development of the DL4 motors started around 20 years ago, when the market was looking for machines with ever higher performance. At first, we started with the development of motors with good performances, after which the market made available components with increasingly better characteristics. From here, there was also the evolution of the motor itself allowed an important step forward.

Furthermore, the development of position sensors has made it possible to attain even better results in terms of the control of the machines where these motors are used.

Servo systems In combination with the KEB COMBIVERT F6 drive controllers (servo inverters) as well as assembled encoder/motor cables, power drive systems can be created with perfectly matched optimal speed and torque characteristics, as well as providing high efficiency and easy start up.

Brusatori Motori Elettrici is an Italian, family-run manufacturer of electric motors. Founded in 1953, the company manufactures synchronous, asynchronous, direct current and permanent magnet motor technology.

For more information on DL4 servo motors and COMBIVERT F6 drive controllers, please visit www.keb.co.uk 15

TorqSense transducers help to guarantee valve actuator performance Rotork Controls has established a global reputation for robust and reliable valve actuators, operating in some of the world’s most demanding and critical applications. Thorough testing of the motors used in the actuators is one of the keys to this assured performance, with TorqSense transducers from Sensor Technology playing a vital role in the test process.

Rotork is the world’s leading manufacturer of electric, pneumatic and hydraulic valve actuators and associated control systems, valve gearboxes and valve accessories.

The company’s electric valve actuator division offers an electrical solution to industrial valve control and actuation applications of virtually any size, description and complexity.

Its capabilities encompass actuators and control systems for new plants, plant extensions and upgrades, together with life-of-plant support.

The division’s unrivalled range of products offers a robust and economic solution for every valve duty and operating environment.

Rotork Controls chief development engineer Geoff Beeho comments: “If you look at something like an oil line, then any failure of the valve actuator could potentially be costing millions of dollars a day. We have to be able to guarantee the performance of the actuators in the most demanding conditions, so testing is vital.

TorqSense torque transducers from Sensor Technology are a key element of our test rigs.”

Companies and businesses around the world rely on Rotork actuators, in applications as diverse as power generation, water and sewage, industrial processes, subsea, marine, HVAC, incinerators and cement plants. Common features in many of these applications are challenging environmental

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conditions, extremes of temperatures, and high costs associated with any downtime.

Because of this, absolute reliability of the valve actuators is vital.

Rotork Controls designs custom actuator designs built around motorised gearboxes, using nonstandard open frame motors. “We use a variety of motors depending on the particular application, including DC motors, single-phase motors and three-phase motors, but we don’t rely on off-the-shelf products. Instead, we use open frame motors that we integrate directly into our own systems.

“Performance testing is very important,” he continues. “The duty cycle is atypical – our motors are not in continuous use, only running intermittently and for short period.

What is important to us is the short term ratings, and this data isn’t always readily available. We have to have performance data that will tell us exactly what we need to know about the motors in these most demanding applications.”

Rotork Controls designed its own rig to test the motors, with Sensor Technology TorqSense transducers at its heart. “We needed noncontact torque sensors in the rig.

The early design used magnetically coupled torque sensors but we were never completely happy with these. So when we upgraded the rig to be able to perform a wider range of tests, we took the opportunity to look around the market and we found the TorqSense transducers.”

“The TorqSense transducers immediately struck us as being a much more robust solution, better suited to handling the torques we were subjecting them to,” comments Beeho.

The common practices of overspecifying a motor that guarantee

reliable operation in standard applications simply don’t apply in valve actuation. “Motor sizing is critical,” says Beeho. “If we put in a motor that is too big, then we can risk damaging the valve. We can use motors that appear to be under-rated, but because our dutycycle is so short we can get better performance from the motor. But the performance data to support this sort of motor use isn’t always available, or isn’t always reliable, so we need to perform our own tests. We also need to know how our motors will handle extremes of temperature in given applications so that reliability is never compromised.

The TorqSense transducers allow us to make all the required tests.”

An advantage of the TorqSense transducers in the Rotork test rig is that they provide both analogue and digital outputs. “This has proved to be a real bonus,” says Beeho. “Not only can we use one output to check the calibration of the other, but it also means we have the flexibility to use both outputs performing different tests. For example, we might use the analogue output to feed torque and speed data into the power analyser during a performance test, and then use the digital output for a temperature test. Here, we run the motor for 15 minutes at constant torque and see how hot it gets. The output from the TorqSense transducer allows us to close the loop so that we can keep the torque constant.”

In any application, the fundamental considerations are the actuator’s ability to overcome the resistive forces of the valve, and the dynamic performance requirements to enable the valve to adequately meet the process demands. With its comprehensive testing procedures built around the TorqSense transducers, Rotork Controls has the confidence that its electrically operated valve actuators will always meet the application requirements.

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Major energy supplier revolutionises electrical maintenance inspections with partial discharge detection Kenter, a Dutch energy metering and management company, detects partial discharge using Fluke’s ii910 Precision Acoustic Imager to prevent the degradation of medium voltage applications which can impact SMEs and large multinational organisations Kenter, a leading Dutch energy metering and management company with more than 30,000 customers, has transformed maintenance inspections through the fast and safe detection of partial discharge. Left undetected partial discharge can cause degradation of medium voltage installations which pose significant safety, efficiency and financial risks that are critical considerations in maintenance inspections.

Kenter is part of Alliander, the largest energy network operator in the Netherlands, and works to install, rent and maintain safe and reliable energy supplies to a wide range of businesses from

small family-run bakeries through to electric vehicle manufacturers and large multinational chemical companies. Kenter offers innovative energy supply and measurement solutions to aid companies wanting to optimise their energy consumption. The company’s team of 300 maintenance specialists have greatly improved the speed and accuracy of scheduled maintenance inspections using an innovative handheld tool, the ii910 Precision Acoustic Imager from Fluke.

Partial discharge is typically caused by a minor defect which can result in thousands of smaller repetitive electrical discharges.

The phenomenon often occurs around insulation on pieces of equipment, such as high-voltage lines, transformers, turbines, busbars and the inside of cabinets, and can impact energy supply due to mechanical, heat, and chemical damage to insulators and conductors.

Managing maintenance schedules

The Fluke™ ii910 Precision Acoustic Imager allows maintenance engineers to quickly scan a customer’s electrical assets from a safe distance whilst operational, and immediately identify areas impacted by partial discharge.

The image can be quickly analysed to detect the type of partial discharge, enabling the team to undertake appropriate maintenance. Users benefit from the tool’s ease-of-use, speed and accuracy, while customers can continue operations during maintenance inspections without the need for a plant shut-down.

Kenter provides 24/7 maintenance on the equipment required to deliver a safe and reliable power supply to customers nationwide. This service includes scheduled maintenance cycles which typically occur every three, five, six or 10 years. During scheduled maintenance, Kenter looks to coordinate a series of works to minimise disruptions to operations,including checking for partial discharge.

Fast and accurate inspections

According to Martin Damen, Technical Engineer Manager at Kenter, Fluke’s ii910 Precision Acoustic Imager has revolutionised maintenance inspections and is a critical tool for maintenance.

“Being able to scan a whole installation in one go is a real game changer in regard to how quickly we can identify a partial discharge issue,” he said.

Dirk Kwik, Team Manager Service and Maintenance at Kenter, agreed: “Our engineers are focused on identifying issues and undertaking maintenance as quickly and safely as possible to minimise disruption to our customers’ businesses and avoiding costly unscheduled downtime.”

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Benefits in application A recent review at a customer’s site using Fluke’s ii910 Precision Acoustic Imager showed partial discharge was occurring on the switchgear installation. This had not been detected by staff as there was no distinctive smell or sound during the interim review and no malfunction issues had been reported. The customer was also reluctant to shut down operations for assessment using an oscilloscope. Failure to identify this issue could have significant consequences due to the ultimate risk of the switchgear failing. According to Damen, the cost to replace the switchgear could be in the region of €30,000 – and that’s without assessing the potential damage to the customer’s reputation, who work to tight deadlines, as a result of their business being offline.

The ii910 device has helped Kenter’s management team to deploy their workforce more effectively. More than 18 engineers are now fully competent using the ii910 with online training being rolled out to the national engineering team. The complexity of operating an oscilloscope resulted in a significantly higher amount of time required to train engineers to accurately detect partial discharge.

Innovative detection of partial discharge The ii910 Precision Acoustic Imager was developed to help engineers quickly identify and locate partial discharges. The innovative detection tool has a seven-inch LCD touchscreen which overlays a SoundMap™ on a visual image for rapid identification of discharge or leaks between frequencies of 2-100 kHZ. The ii910 provides video recording of up to five minutes and has a battery life of at least six hours.

“The Fluke ii910 Precision Acoustic Imager was developed with the enduser in mind,” comments Tako Feron, Product Manager Acoustic Imaging at Fluke Corporation. www.fluke.com/en-gb/product/ industrial-imaging/precisionacoustic-imager-ii910

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Moxa launches E1 Mark and EN 501214 compliant robust computers for intelligent transportation applications For modern transportation systems, maintenance is always crucial if you want to bring a safer overall transport experience to passengers. To save on maintenance efforts, Moxa, an IRIS-certified railway communication solution provider, has launched the V2403C Series, a new series of robust industrial computers that comply with the E1 Mark, ISO 7637-2, and EN 501214 standards for vehicular and wayside applications.

Versatile Design to Strengthen Reliability in Transportation Infrastructure Drawing on Moxa’s extensive expertise in building robust computing platforms, the V2403C Series operates in a wide range of operating temperatures for deployments in harsh environments, which require high computing power and reliable wireless connectivity. As a field-ready solution, the V2403C computers are built around an Intel® CoreTM i7/i5/i3 or Intel® Celeron® highperformance processor and come with up to 32 GB RAM, one mSATA slot, and two hot-swappable 2.5inch SSDs for storage expansion.

Embedded with two mPCIe slots for I/O expansion, the ultra-compact fanless computers support multiple displays in the control room for local monitoring of status and real-time control.

Robust Industrial Computers for Rugged Operating Conditions Wayside and vehicular applications require robust computers with expansion capabilities to connect sensors, cameras, and devices that use Wi-Fi and cellular technology.

Furthermore, the design must handle “dirty power” during engine starts and shutdowns with a graceful 20

shutdown mechanism in place to preserve system stability and lifespan of batteries. Compliance with E1 Mark, ISO 7637-2, and MILSTD-810G requirements protects the V2403C computers from shocks and vibrations that are common in transportation applications.

The V2403C computers are also compliant with the EN 50121-4 standard for wayside applications.

To provide reliable transportation and ensure passenger safety, the V2403C computers come with power ignition control that protects equipment against unstable power. The combination of high performance, rugged design, compact size, wireless connectivity, and enhanced security makes the V2403C Series a perfect fit for mission-critical, heavy-duty wayside and vehicular applications.

processor • Configurable power ignition delay to protect equipment - Higher cybersecurity awareness with optional TPM module - Compact yet robust design with sufficient interfaces for wireless expansion - MIL-STD-810G compliant for protection against shocks and vibrations • E1 Mark* compliant for vehicular applications - Compliant with ISO 7637-2 requirements - Compliant with EN 50121-4 for wayside applications - -40 to 70°C (-40 to 158°F) widetemperature models available • Microsoft Azure and AWS certified for IoT applications

V2403C Series Highlights - 7th Gen Intel® CoreTM i7/i5/i3 or Intel® Celeron® high-performance

www.moxa.com/en/products/ industrial-computing/x86computers/v2403c-series

Print pre-sized labels from your phone Brady Corporation’s new M211 Label Printer is a lightweight, sturdy and wearable device that prints both presized and continuous labels to identify cables and components. It can create even complex labels that can all be designed, printed and previewed from your phone.

Label with your phone The new M211 Label Printer can easily be clipped to any belt. It connects seamlessly to smartphones via Bluetooth and is driven by Brady’s Express Labels App. The app allows to quickly design, preview and print labels and to integrate data from spreadsheets. No other phone driven label printer today matches the label design possibilities of the M211. In addition, designs can be saved and shared between colleagues, either in the field or at the office.

Tested, quality labels Quite unique for an entry-level portable label printer, is the M211’s ability to print on both continuous and pre- sized labels. Brady offers M211 users 90+ different label cartridges to choose from. These include general purpose and dedicated labels, designed for reliability in specific applications. Brady has technical data sheets with label test results that evaluate adhesion to various types of flat and curved surfaces, and label print resistance to humidity, abrasion, heat, cold, weathering and other influences.

Resilient and easy to use The new M211 Label Printer prints up to 300 labels on a single battery charge. Yet the system weighs only 0.5 kg, and has a compact design to make it extremely wearable. At the same time, the M211 is a tough device.

Tests indicate the tiny printer survives 1.8m falls, 110 kg crushes and military specification shocks. Next to its ability to survive almost any job site, the M211 features ‘drop-lock-print’ label cartridges designed for swift ‘on-thejob’ consumable switching. www.bradyeurope.com.

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Large laundry Intelligent robotics for laundries closes automation gap The textile and garment industry is facing major challenges with current supply chain and energy issues. The future recovery is also threatened by factors that hinder production, such as labour and equipment shortages, which put them under additional pressure. The competitiveness of the industry, especially in a global context, depends on how affected companies respond to these framework conditions. One solution is to move the production of clothing back to Europe in an economically viable way.

Shorter transport routes and the associated significant savings in transport costs and greenhouse gases speak in favour of this. On the other hand, the related higher wage costs and the prevailing shortage of skilled workers in this country must be compensated.

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The latter requires further automation of textile processing.

The German deep-tech start-up sewts GmbH from Munich has focused on the great potential that lies in this task. It develops solutions with the help of which robots similar to humans - anticipate how a textile will behave and adapt their movement accordingly.

large- scale industrial laundries, the unfolding process. Although 90% of the process steps in industrial washing are already automated, the remaining manual operations account for 30% of labour costs. The potential savings through automation are therefore enormous at this point.

Application

The German deep-tech start-up sewts GmbH from Munich has focused on the great potential that lies in this task. It develops solutions with the help of which robots similar to humans - anticipate how a textile will behave and adapt their movement accordingly. In the first step, sewts has set its sights on an application for large industrial laundries. With a system that uses both 2D and 3D cameras from IDS Imaging Development Systems GmbH, the young entrepreneurs are automating one of the last remaining manual steps in

It is true that industrial laundries already operate in a highly automated environment to handle the large volumes of laundry.

Among other things, the folding of laundry is done by machines.

However, each of these machines usually requires an employee to manually spread out the laundry and feed it without creases.

This monotonous and strenuous loading of the folding machines has a disproportionate effect on personnel costs. In addition, qualified workforce is difficult to

find, which often has an impact on the capacity utilisation and thus the profitability of industrial laundries. The seasonal nature of the business also requires a high degree of flexibility. sewts makes IDS cameras the image processing components of a new type of intelligent system whose technology can now be used to automate individual steps, such as sorting dirty textiles or inserting laundry into folding machines.

“The particular challenge here is the malleability of the textiles,” explains Tim Doerks, co-founder and CTO. While the automation of the processing of solid materials, such as metals, is comparatively unproblematic with the help of robotics and AI solutions, available software solutions and conventional image processing often still have their limits when it comes to easily deformable materials. Accordingly, commercially available robots and gripping systems have so far only been able to perform such simple operations as gripping a towel or piece of clothing inadequately. But the sewts system VELUM can provide this. With the help of intelligent software and easy-to-integrate IDS cameras, it is able to analyse dimensionally unstable materials such as textiles. Thanks to the new technology, robots can predict the behaviour of these materials during gripping in real time. It empowers VELUM to feed towels and similar linen made of terry cloth easily and crease-free into existing folding machines, thus closing a costsensitive automation gap.

The software suite developed by sewts combines commercially available robots, grippers and cameras into an intelligent system. In the search for the right camera modules, several criteria were decisive for the Munichbased company in addition to uncompromising industrial suitability: “We need a 3D camera that is costeffective because we use two to three 3D cameras depending on the system configuration. In addition, it mustabove all ensure high accuracy of the depth data,” explains Tim Doerks.

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“Beyond that, we need 2D cameras that are light sensitive, deliver high dynamic range and are suitable for use in a multi-camera system.”

The founders found what they were looking for in the IDS portfolio: For the VELUM multi-camera system, the choice fell on the new Ensenso S10 3D camera as well as models from the uEye CP camera series.

Their task is to identify, both in 2D and 3D, interesting features and gripping points of the textiles that are fed into the system after washing and drying in an unordered manner in a container or on a conveyor belt. The shape and position of the individual objects cannot be predicted. The cameras capture the different textures of the materials. They distinguish which hems there are on a towel and where corners are.

We match the images from the 2D and 3D cameras to have a higher 2D resolution together with the 3D data. So we use the respective advantages of the 2D camera, in this case the higher resolution, and the 3D camera, i.e. the precise depth data”, Tim Doerks, co-founder and CTO at sewts mentiones. Equipped with a 1.6 MP Sony sensor, the Ensenso S10 uses a 3D process based on structured light: A narrow-band infrared laser projector produces a high-contrast dot pattern even on objects with difficult surfaces or in dimly lit environments. Each image captured by the 1.6 MP Sony sensor provides a complete point cloud with up to 85,000 depth points. Artificial intelligence enables reliable assignment of the laser points found to the hard- coded positions of the projection. This results in the robust 3D data with the necessary depth accuracy, from which VELUM extracts the coordinates for the gripping points.

The complementary GV-5280CPC-HQ industrial camera with GigE Vision firmware is equipped with Sony’s IMX264 2/3” global shutter CMOS sensor. It delivers nearnoise-free, high-contrast 5 MP images in 5:4 format at 22 fps at full GigE speed in applications with fluctuating lighting conditions.

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The uEye CP camera offers maximum functionality with extensive pixel pre-processing and is perfect for multi-camera systems thanks to the internal 120 MB image memory for buffering image sequences. At around 50 g, the small magnesium housing is as light as it is robust and predestines the camera for spacecritical applications and for use on robot arms.

Software Depending on customer requirements or configuration, two to three uEye 2D or Ensenso 3D cameras are used - both models can be seamlessly integrated into VELUM. “We are experts in preparing the generated data, which is especially important when working with 3D point clouds. This pre-processing is an important component of our systems in order to generate suitable input for our artificial intelligence,” Tim Doerks emphasises. The AI developed by sewts processes the data supplied by the uEye CP or Ensenso S cameras. The intelligent software analyses the topology of the textiles using features such as the course of the seam, local elevations or the relative position of seams, classifies them according to textile type and class using various textures and embroidery patterns and translates these findings into robot commands.

The data is processed via Convolutional Neural Networks (CNN) and classical image processing. “We use IDS peak, the software development kit from IDS. We connect to our system via Python and the IDS Library,” reveals Till Rickert, co-founder and CPO of sewts. “The added value of the IDS software package for us lies primarily in the ease of calibration and integration into our High Tech Vision System,” he continues.

“AI is at the core of our technology.

Intelligent algorithms are needed to build adaptive systems that can cope with non-deterministic automation processes. That’s why we use the latest findings from AI research, refine them for our needs and finally put them together

into a big whole,” adds Till Rickert.

It receives various sensor data (e.g. optical information), draws conclusions from them on a humanlike cognitive level and translates them into robot commands. In this way, systems like VELUM perform tasks that previously required the human mind. This is exactly what sewts’ corporate philosophy is all about: “Our goal is to transform complex manual work into smooth automation”.

Outlook With systems like VELUM, laundries can significantly increase their throughput regardless of the staffing situation and thus increase their profitability. “By closing this significant automation gap, we can almost double the productivity of a textile washing line,” assures CEO Alexander Bley.

IDS cameras can also be used for clothing such as shirts and trousers in the future. “It is important to understand the properties of these materials in order to implement robust processes. We achieve this through sophisticated material simulations. In order to simulate the behaviour of textiles, we create special FE simulations using the finite element method,” explains Alexander Bley. But the Munich-based company has an overarching vision: “We want to make it possible to automate the production of clothing and move it back to the point of use in a cost-efficient way. In this way, we shorten transport distances, create more reliable supply chains, save CO2 emissions and combat the problem of overproduction.”

Additionally applications with materials that are not textiles are also planned for the future.

There are many potential use cases for technologies like these, and image processing will always play a significant role. Artificial intelligence will accelerate this development.

Cameras Ensenso S: 3D laser point triangulation with artificial intelligence

- Ultra-compact and cost-efficient - High 3D data rate and accuracy through AI support - Robust 3D data even in low ambient lighting - Structured light with AI-based laser dot pattern triangulation - Suitable for applications in logistics automation, robot vision, obstacle detection, monitoring and horticultural automation, etc.

Incredibly fast, incredibly reliable, incredible sensors: The uEye CP - Interface: Ethernet - Model: GV-5280CP-C-HQ - Sensortyp: CMOS - Sensor type: CMOS - Manufacturer: Sony - Frame rate: 24.0 fps - Resolution (h x v): 2448 x 2048 - Shutter: Global Shutter - Resolution: 5.01 MPixel - Dimensions: 29 x 29 x 29 mm - Weight: 52 g - Connector: GigE RJ46, screwable - Applications: e.g. industrial image processing, mechanical engineering, surface inspection, medical technology, traffic & transport, quality assurance, etc.

Client Founded in 2019, Munich-based sewts GmbH is a provider of innovative control and image processing software that pushes the boundaries of robotics when processing easily deformable materials. sewts has developed a unique technology that uses high-precision finite element method (FEM) simulations to efficiently train machine learning algorithms.

The intelligent software solution enables countless applications in industrial automation, such as the processing of textiles in industrial laundries or the production of clothing, but also the handling of foils, cables, deformable plastic parts and many more. www.sewts.com 25

DER-IC Takes delivery of first Micro-Punch Sinter Press in the UK Inseto, a leading technical distributor of equipment and materials, has supplied Driving the Electric Revolution Industrialisation Centre (DER-IC) North East with equipment to enhance its power electronics, machines and drives (PEMD) capabilities. Of the equipment supplied, an AMX P100 sinter press is the first micro-punch machine to be installed in the UK and will enable the manufacture of high-reliability high-power modules.

Sintering is a manufacturing process that combines pressure (mechanical force) and temperature to bond materials using a sinter paste. The process is increasingly required for the packaging of high- power semiconductor modules that incorporate silicon carbide (SiC) dies which, when channelling high currents, can produce heat at temperatures far higher than the melting point of solder

(as traditionally used for conductive die-attach).

As for the AMX P100’s ‘micro-punch’ capability, this relates to how most sinter presses use a flat, single punch to apply force to the top of the dies. But if the dies are of different thicknesses, the same force cannot be applied across all. This means there is a risk of voids forming in the sinter paste beneath thinner dies which in turn can result in failures in the field because of the high voltages and currents being switched. The AMX P100 can apply equal force to all dies, irrespective of their thickness.

Professor Derrick Holliday, Technical Director for DER-IC North East comments: “The drive by industry to create highly efficient, power dense and integrated power converters places increasing demands on power semiconductor switching devices. Manufacturers must be confident that products operating

under these demanding conditions, particularly in safety-critical applications, are reliable. By ensuring the highest integrity bonds, this advanced sintering technology will facilitate the development of novel and advanced semiconductor packages and converter topologies, as well as supporting broader power switching device research, by both industry and academia.”

Inseto has also supplied DER-IC North East with two other pieces of equipment that will be used within the new facility for the manufacture of power modules and packs, as well as other components needed for PEMD. The first machine is a Kulicke & Soffa Asterion hybrid wedge bonder. Features include an expanded bond area, robust pattern recognition capabilities and extremely tight process controls. Together, these features deliver heightened productivity, bonding quality and reliability.

The second machine is an Amadyne FAB1 (flexible automatic die bonder). It is a modular micro assembly production platform designed for complex high mix and high-quality products. Features include short setup times (i.e. fast product changeovers, ideal for prototyping and process development) and remote system support / diagnostics.

Rachel Chambers, DER-IC North East Chief Operating Officer, comments: “It’s critical for us to ensure we provide best-in-class equipment and capabilities to support companies on developing, prototyping and scaling up their manufacturing processes. The sintering equipment in particular will give those using our facilities accesses to advanced manufacturing capabilities, and my team and I are looking forward to working closely with Inseto in helping all users meet their PEMD goals.”

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Teledyne FLIR helps to keep airspace surrounding Swedish critical infrastructure free of drones Teledyne FLIR successfully completed an installation of a long-range drone detection system for a critical infrastructure site in Sweden. A smart slew-to-cue system, combining radar, thermal imaging and visual sensors, makes sure no unmanned aircraft system goes undetected.

The FLIR Ranger HDC MR uses thermal imaging technology to detect threats in all conditions, including nighttime, low-visibility, and poor weather such as fog, rain, and clouds.

As drones are becoming commercially available to a wider audience, effective drone detection and monitoring has become increasingly important, especially for critical infrastructures and sites, such as power plants, utility centers and airports.

However, effective and accurate drone detection is challenging. In contrast to land-based monitoring and detection, aerial detection has a much wider, dome-shaped area to cover, with no real reference points.

In addition, today’s drones are fast and small, and they can demonstrate erratic flying behavior. Visual detection systems have an additional challenge, in that they need to detect objects in variable sky and weather conditions.

Drone detection for critical infrastructures Teledyne FLIR recently provided a robust drone detection system for a Swedish critical infrastructure customer. The project – completed early 2022 – was also made possible by Teledyne FLIR’s longtime distributor and integration partner CCTV-Systems AB, a company which has been in the video

surveillance systems business since 1982. Just like Teledyne FLIR, CCTVSystems AB has vast experience in providing threat detection systems for industrial and security sectors all over the world.

Teledyne FLIR offered an integrated drone detection system based on radar and a combination of thermal and visible sensors. The system uses a so-called slew-to-cue feature, where a radar will continuously scan the sky, detect the drones from a long distance and automatically point the FLIR PTZ camera to the exact position of the detected drone, whereupon the camera will continue to track the moving object using its pan/tilt mechanism.

Integrated drone detection system “Today, Teledyne FLIR is the only company that can provide a total, integrated solution for this application,” says Johan Eklund, Managing Director at CCTV-Systems AB. “The company’s radar, dual thermal and visible PTZ system, and software platform are all seamlessly integrated to provide a highperformance surveillance system.

And what’s more, all of the system’s components have been thoroughly tested and proven in the field.”

“We are very fortunate to have such a dedicated and skilful partner in CCTV Systems AB,” says William Turner, Northern European Sales Manager at Teledyne FLIR. “In order to satisfy the complex requirements of a demanding client, this project cut new ground and called for high levels of technical expertise and customer commitment from Johan and his team.”

The system includes the FLIR Ranger R8SS-3D radar, which can detect objects within a three-kilometer

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range and track up to 500 drone targets simultaneously, while effectively filtering bird detections.

The R8SS-3D provides complete hemispherical detection and is able to monitor the coverage area four times per second, run 24/7, and detect all ground and aerial threats in virtually any climate, day and night. Radar detections are continuously tracked with the FLIR Ranger HDC MR, a high-definition mid-range surveillance system which uses thermal imaging technology to detect threats, even in conditions where visibility is poor, at night or in degraded weather conditions, such as fog, rain and clouds. Everything the system picks up is monitored through FLIR’s Cameleon software platform. This software enables operators to control the surveillance system and share all detector information with other agencies.

Maximum detection accuracy From the project onset the enduser’s minimum requirement was to obtain 100% accurate classification at 500 meters. Teledyne FLIR was able to far exceed this requirement thanks to thorough tuning and calibration, and to the system’s superior optics and highperformance radar capability.

Teledyne FLIR also ensures that the system can operate with maximum uptime, not considered a luxury for a critical infrastructure where 24/7 situational awareness is always needed. The system makes use of an uncooled thermal sensor, which requires minimal maintenance leading to practically zero downtime.

On the other hand, a cooled camera would require periodic replacement of the cooling elements.

“This system is an ideal configuration for any critical infrastructure site that wants to keep its airspace free from threats and that needs 24/7 decisionmaking support,” says Eklund. “The system we installed in Sweden could also be used as a reliable, mid-range drone detection system for airports, refineries, nuclear plants, utilities and more.” www.flir.com/discover/security/ cuas-application-spotlight/ 29

Reciprocating action solves tough heat exchange challenges

By Matt Hale, International Sales & Marketing Director, HRS Heat Exchangers Scraped surface heat exchangers have been used for difficult heat transfer applications involving viscous fluids or where fouling is an issue, such as evaporation processes.

The most common type of scraped surface heat exchanger (SSHE) uses a rotating shaft with blades or augers which scrape the surface of the tube.

The popular HRS R Series is based on this approach. However, the design is not optimal for every situation, and so HRS developed the Unicus Series of reciprocating scraped surface heat exchangers.

The HRS Unicus Series is specifically designed to provide the improved heat transfer of a traditional SSHE,

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but with a gentle action to preserve the quality and integrity of delicate food products such as cheese, yoghurt, ice cream, meat paste, and products containing whole pieces of fruits or vegetables. Over the years, a number of different scraper designs have been developed, meaning that every application, from processing curds to heating sauce or pasteurising fruit compotes can be handled in the most efficient yet gentle way possible. Other applications where the Unicus Series has been beneficial include handling meat slurry and mince, and processing yeast-malt extracts.

The hygienic design uses a patented stainless-steel scraping mechanism which moved hydraulically back and forth within each interior tube. The movement

performs two key functions: it minimises potential fouling by keeping the tube wall clean, and also creates turbulence within the material. Together, these actions increase the rate of heat transfer in the material, creating a highly efficient process which is ideal for viscous and high fouling materials.

Since they are controlled separately, the speed of the scrapers can be optimised for a particular product being processed, so that materials which are susceptible to shear stress or pressure damage (such as creams and custards) can be handled delicately to prevent damage while still providing high levels of heat transfer. The Unicus Series has proven particularly useful in handling viscous food products

where texture and consistency are important attributes. For example, some creams or sauces may shear when subjected to excess pressure, making them unusable. The Unicus means that effective heat transfer can be carried out at low pressures which overcomes these problems.

Each Unicus SSHE consists of three elements: a hydraulic cylinder and power pack (although in smaller units a pneumatic cylinder can be supplied instead), a separation chamber to ensure hygiene and preserve product separation from the motor, and the heat exchanger itself. The heat exchanger consists of a number of tubes, each of which contains a stainless-steel rod to which the appropriate scraping elements are fitted. Using a range of food-safe materials including Teflon and PEEK (polyether ether ketone), these provide different internal geometry setups according to the application, such as 120° scrapers for large particulates and 360° scrapers for viscous fluids without particulates.

The Unicus Series is also fully scalable by increasing the shell diameter and adding more interior tubes from a single tube up to 80 in one shell. A key feature is the specially designed seals which separate the inner tube from the separation chamber, tailored to the product application. These seals prevent leakage of the product and ensure internal and external hygiene.

A standard range of models for food processing provide heat transfer areas from 0.7 to 10 m2, while larger models up to 120 m2 can be made for specific uses.

One area where the Unicus Series excels is in evaporation applications, where the prevention of fouling is particularly important. HRS has a specific version of the Unicus for use in evaporation units where volume reduction of the material is essential. The scraping action keeps the heat transfer surfaces clean so that Unicus evaporators can concentrate materials to a level that is unattainable using traditional technologies. Unicus evaporators can be used in multi-effect setups or in combination with mechanical vapour recompression.

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Sprint Power forms pioneering battery technology collaboration with AMTE Power Sprint Power has teamed up with AMTE Power and Eltrium to accelerate the development of next-generation battery technologies to meet the growing and complex needs of the electric vehicle (EV) market.

The collaboration, which will commence in 2022, will aid global car makers and start-ups as they ramp up development of hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs) and battery electric vehicles (BEVs).

The group will provide OEM customers with an end-to-end solution for battery systems development, manufacturing and supply. Sprint Power is an established global leader in realising breakthrough technical developments in power electronics,

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battery management systems and battery module and pack design, while AMTE brings its rich experience in battery cell technology and production.

Completing the partnership is Eltrium’s battery module and pack manufacturing capabilities.

market EV applications as well as high-performance projects. The scope of the partnership will cover automotive, marine, aerospace, commercial and off-highway vehicles.

The group is ideally placed to help the EV industry navigate new rules of origin. Legislation coming into force in just two years’ time will stipulate that batteries need to contain up to 50% of locally sourced materials – be that from the UK or the EU. With all three organisations based in the UK, the partners offer OEMs an immediate solution to this looming regulatory change.

Sustainability will be at the heart of Sprint Power, AMTE and Eltrium’s approach. Critical systems, components and subsystems – including all cells, modules and packs – and production processes at Eltrium will be designed for second-life battery reuse and recyclability.

Next-gen battery systems will be designed and optimised for mass

Unwavering focus on sustainability

Richie Frost, Founder and CEO at Sprint Power, said: “Our new collaboration agreement with AMTE Power and Eltrium will deliver a

game-changing support network to how next-generation battery tech – from the initial planning and design stages through to start of production – is undertaken within the industry.”

“By teaming up with AMTE Power and Eltrium, we have leapt forward to be right at the vanguard of battery technology development. We offer the industry complete bespoke solutions, tapping into our unmatched tech, engineering and production expertise.”

“As the EV market grows and OEMs come under increasing pressure to meet new and challenging demands, including tough legislation, Sprint Power along with AMTE Power and Eltrium will be on-hand to boost programmes, enhance development and optimise battery technologies.”

Fergal Harrington-Beatty, Head of Electric Vehicles at AMTE Power, said: “There is huge potential for growth in the EV market as the government gears up for its 2030 deadline to end the sale of petrol and diesel cars. A reliable and secure supply of battery cells that can hit the right performance for OEMs is absolutely vital to underpin that growth. With Sprint and Eltrium, we’re developing the essential blend of technology, engineering expertise and manufacturing know-how to deliver for them.”

Sprint Power and AMTE Power are also working together on Project CELERITAS, a £9.7 million UK government-backed project to develop ultra-fast charging cells and battery packs for battery electric vehicles (BEVs) and fuel cell hybrid electric vehicles (FCHEVs). The project, headed by the UK’s Advanced Propulsion Centre (APCUK), also includes BMW, bp and Clas-SiC. More information is available via the Sprint Power website: www.sprint-power.com

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