Cristian Son Tel: +39 027030631 c.son@tim-europe.com
Dear Readers,
Time flies, as you can always tell. You are holding the last issue of 2024 in your hands and my first year as editor in charge of IEN Europe is already coming to an end. I would like to take this opportunity to draw your attention to the March issue of IEN Europe, in which we will celebrate a milestone anniversary: 50 years of IEN Europe! Preparations for this special issue are already underway, but we don't want to reveal any more at this point.
k.petermann@tim-europe.com
Swiss power supply specialist Traco Power is also celebrating a special anniversary, as it will be celebrating its 80th birthday in 2024. To mark the occasion, we spoke to Florian Haas from Traco and learned a lot about the company's history. But of course he also looks to the future, because active change is the only way to keep Traco on course for the next 80 years. You will find the interview on page 8.
I would particularly like to draw your attention to the article on page 28, which deals in detail with the topic of energy efficiency and electric motors and shows how they can contribute to this. The article on page 22 also shows how resources can be conserved with modern concepts. Single-cable solutions for data and power supply contribute above all to clarity and faster commissioning in production, but also save copper and plastic thanks to fewer cables.
I wish you an interesting read and look forward to your feedback.
KayPetermann
Editor IEN Europe
Digital File Requirements available at: www.ien.eu/technical-guidelines/
A History of Power. Interview with Florian Haas, VP Global Marketing and IT from Traco Power.
Motors & Drives: Walking Naturally with an Artificial Foot. Newly developed prothesis assists users with motor power.
Motors & Drives: Motion Matters – A CNC Machine Is Only as Good as Its Servo Drives.
Products
&
Technological Integration and Logistical Advantages: A Partnership for the Future of RF Technology. Interview with Alessandro Gamorasca, Product Development Manager at
Safety Symposium to Celebrate 50 Years of Sella Controls
The HIMA Group proudly marked a significant milestone: the 50th anniversary of Sella Controls, one of its member companies since 2023. On October 9, 2024, a safety symposium was held in Birmingham to commemorate this achievement, honouring Sella Controls' journey from its modest beginnings to its status as a leader in safety and control systems. Sella Controls after a long-standing partnership, played a pivotal role in enhancing HIMA’s portfolio, especially in the railway sector, while also expanding the business in the process industry in the UK and Ireland. Over the past five decades, Sella Controls has consistently pushed the boundaries of innovation and safety, making significant contributions to projects across multiple sectors, including rail, oil and gas, and petrochemicals. Sella Controls acts today as the regional centre for the HIMA Group in the UK and as Global Center of Excellence for rail activities. It was an honour to have the family of one of the founders, Terry Lardner, at the celebrations. Trish Lardner, the wife of Terry, and their daughter Rachael attended the Safety Symposium in Birmingham, together with various customers, partners and friends of Sella Controls.
Takayuki Ito Elected President of the IFR
Takayuki Ito of Fanuc Corporation, who previously held the position of Vice President, succeeds Marina Bill of ABB who has served the rotating post since 2022. "I am proud to continue the work of my predecessor, Marina Bill, who has been a great ambassador for the world of robotics. We are witnessing rapid change in the automation of industrial and service sectors around the world." said Takayuki Ito.
New 200-mm Silicon Capacitor Line Opens in Caen, France
Takayuki Ito has a track record of more than 40 years in the robotics industry. He currently holds the position of Chief Technical Advisor at the Japanese robot manufacturer Fanuc Corporation based in Oshino, Japan. Since 1981, Takayuki Ito has worked at the Japanese robot manufacturer in various positions: In 1997, he became Executive Vice President for Fanuc Robotics in North America. He returned to the Fanuc headquarters in Japan in 2002, taking on the role of General Manager for the Robot Technology Center. The IFR’s new Vice President, Jane Heffner, has more than 20 years of experience in technology-driven industries, including automation, robotics, automotive, and aerospace. She currently serves as Vice President Global Sales at Mobile Industrial Robots (MiR), a leading manufacturer of autonomous mobile robots.
Murata Manufacturing Ltd has opened a new production line at its site in Caen, France, expanding the scope of its Integrated Passive Solutions offering. As originally announced in 2023, Murata has delivered on its commitment to build a new 200mm mass production line. The new line will strengthen Murata's silicon capacitor manufacturing capabilities. The Caen facility, which has been operated by Murata since the acquisition of start-up IPDiA in 2016, is a beacon of innovation and is home to over 250 dedicated employees who support the cleanroom, production line and all other key business functions. “The components created at our Caen site utilise highly advanced technologies for a wide variety of purposes. From the ubiquitous smartphones that contain hundreds of capacitors to vehicles that incorporate thousands, our products are foundational to modern technology. With the launch of this new line, we are continuing to invest in growing our production facilities and our local workforce,” said Norio Nakajima, President of Murata Manufacturing Co., Ltd. “It represents a significant step forward in our growth in the sector and demonstrates our determination to reinvest in the European electronics industry, well supported by Europe through the Chips Act and IPCEI initiatives.”
HMS Networks Acquires German Communications Specialist
HMS Networks AB has entered into a binding agreement with DOGAWIST-Investment GmbH to acquire 100% of the shares in PEAK-System Technik GmbH ("PEAK-System"). PEAK-System is a well-established German provider of industrial communication solutions and an expert in automotive communication technologies such as CAN and LIN. The acquisition will strengthen HMS' position in communication solutions for advanced engineering tools, test and control in the automotive, medical and transportation industries. HMS sees a number of synergies between the Ixxat business unit of HMS and PEAK-System. There is a lot of common expertise in automotive communication technologies such as CAN, CAN FD, LIN, Flexray and Automotive Ethernet, but with different applications and target groups. PEAKSystem is a well-established German industrial communication company offering both hardware and software for industrial and automotive communication. The company has been serving customers all over the world since the start in 1999. The headquarters, with product manufacturing and development, is located in Darmstadt, Germany. There is also a French subsidiary with an office in Maxéville, close to Nancy, France.
Effective M2M Orchestration Using SPE, IO-Link, and Sensor-to-Cloud
JUMO
Visit us in Nuremberg, Germany from November 12 to 14, Hall 7A, Booth 440
exclusive interview
A History of Power
On the occasion of the company's 80th anniversary, IEN Europe spoke to Florian Haas, VP Global Marketing from Traco Power about industrial power supplies and the demands they face now and in the future.
IEN Europe: Traco will be celebrating its 80th anniversary in 2024. What prompted the founder to set up the company in 1944 and what were the first Traco products?
Haas: Ever wondered what our grandparents’ weekend disco fever has to do with Traco Power’s legacy? Back in the day, the hottest discotheques were pulsing not just to the beat of the music but also to the rhythm of the most advanced Revox tape recorders, which were exclusively distributed by Traco.
Dr. Hans Caspar, great-grandfather of the current company owner, imported some of the world's first tape recorders. These were developed by Bush Development as the successor to the BK 40 dictation machine especially for the American market. The success with these devices failed, because they were unsuitable for the Swiss market not only because of their susceptibility to interference, but also because of their conception for 110 volts at 60 Hz. Until 1949 these devices were stored in the cellar of Mr. Caspar, until Mr. Ernst M. Egli established contact to Willi Studer. He was commissioned to convert the Soundmirror tape recorders for the Swiss market. However, Willi Studer decided to produce his own tape recorder and to construct it better from scratch.
IEN Europe: When did Traco start to focus on power supplies?
Haas: These tape recorders, integral to creating unforgettable nights of dance and music, required high-quality voltage converters and parts to keep the music playing. This need sparked Traco Power's journey into
DC-DC filters in the 1980ies.
Coin diameter: 31,45mm.
Picture: Traco Power
Haas, VP Global Marketing, Traco Power.
the niche of power supply solutions, setting the stage for our transformation from pioneers to industry leaders over the decades. A growing business developed from spare parts for these devices. Traco then made a real breakthrough with power solutions in the early 1970s. Since then, Traco Power has focused exclusively on this business.
IEN Europe: What is the current structure of the Traco Group and how many people work there? Is the founding family still involved with Traco?
Haas: The most important element of our success is our value proposition to our customers and partners. Not only our products, but also all our employees are reliable, available and agile.
This value proposition is based, among other things, on the fact that we are very lean and can therefore react and support quickly. Traco Power employs around 130 people at 5 locations in Switzerland, Germany, the USA, Ireland and France. Our employees work in development, product management, sales, marketing, IT and administration. For decades, we have been working with the selected production partners in Asia. At the beginning of this year, Traco Power was handed over to the greatgranddaughter of the founder and is still 100% family-owned.
IEN Europe: Can you give our readers a brief overview of Traco's actual product portfolio and main markets?
Haas: We develop and distribute professional power supply solutions for
Florian
Picture: Traco Power
demanding applications.
The most important product categories are DC/DC converters from 1-300W and AC/DC switching power supplies from 2-1000W. In Ireland, we employ also a group of engineers who develop customized power solutions. Our products are the first choice for developers of applications in industry, medical technology, mobility/transportation and building automation.
Our product portfolio is also unique in terms of our performance promise of reliability and availability. Thanks to our decades of experience, our good relationships with developers and partners, and sophisticated data collection and evaluation approaches, we can maintain a rather lean product portfolio. This enables us to offer practically all our products from stock and for decades.
IEN Europe: High efficiency and thermal management are important issues for modern power supplies in general and especially when it comes to miniaturization in industrial applications. What is the role of GaN technology at the moment and what do you expect for the future?
Haas: GaN (Gallium Nitride) technology is critical for achieving high efficiency and better thermal management in modern, miniaturized power supplies. Compared to traditional silicon, GaN transistors switch faster and therefore reduces size of magnetic components like the transformer which is a size-determining component in switch mode power supplies. In addition, it also helps to reduce switching losses at certain topologies of power supplies and PFCs (power-factor correction), significantly boosting efficiency and reducing heat generation. Although faster switching may require slightly higher EMC measures, GaN transistors generally speaking help to solve thermal management challenges as well as allowing more compact designs.
Power supply manufacturers like Traco Power can integrate GaN technology to develop smaller, more efficient power supplies, meeting the rising demand for high-performance solutions in industrial, medical, and telecom applications. By using GaN, Traco Power can offer products with higher power density, lower energy losses, and improved reliability, ideal for space-constrained environments.
Engineers benefit from GaN’s improved efficiency by simplifying cooling requirements and allowing for more compact designs with higher power outputs. Additionally, GaN enables greater design flexibility by operating at higher frequencies and temperatures, empowering engi-
neers to create innovative, cutting-edge power solutions. GaN is transforming power supply design, offering new possibilities for advanced applications.
IEN Europe: Where do you see the particular technological challenges in the transition to an "all-electric society" and how can Traco contribute to the solutions needed?
Haas: The transition to an all-electric society faces several technological challenges, including reliable renewable energy generation, efficient energy storage, mobility, communication, entertainment and upgrading grid infrastructure to handle increased and highly fluctuating loads. Power conversion efficiency, electric mobility infrastructure, and stability in energy distribution are critical areas requiring innovation.
Traco Power can play a key role in addressing these challenges by offering advanced, reliable, highly efficient power conversion solutions that minimize energy loss. Their expertise in developing compact, reliable power supplies can support industries requiring stable power for electric vehicles, industrial and medical applications, and energy grids. Traco’s ability to offer also customized solutions positions them as a key contributor in optimizing power efficiency and stability. Through these innovations, Traco can help meet the demand for scalable, flexible power solutions, aiding the transition toward a sustainable, all-electric future.
IEN Europe: Is there a special/exceptional customer application that you can recall from the company's long history that was only made possible by Traco's contribution?
Haas: There are actually applications that run thanks to the contribution of our power supplies. Be it at an altitude of 10,000 meters below sea level, at -50°C in the Arctic, during a round-the-world flight in a solarpowered aircraft, or in basic research at universities, or even in particle accelerators.
For decades, developers worldwide have relied on our power supply products because, as already described, they do what they are supposed to do reliably for 20+ years, even under demanding conditions.
IEN Europe: Thank you for your insights and all the best for Traco's next 80 years of success.
65091 at www.ien.eu
Selection from the current Traco Portfolio of power supplies and filters. Picture: Traco Power
Traco Power Headquarter in Switzerland. Picture: Traco Power
10 motors & drives
Walking Naturally with an Artificial Foot
The newly developed D-Ankle prosthesis from Design Pro Technology makes this possible. Instead of the usual passive suspension at the foot components, the prosthesis assists its user by means of motor power. As is the case with a natural gait, the artificial foot is actively bent up and down with each step. The gait becomes more harmonious, more stable and less tiring. An intelligent controller finds the correct gait rhythm and a brushless motor from FAULHABER provides the necessary propulsion.
The loss of a leg or part of a lower limb can have many causes. With younger people, the cause is usually a birth defect or an accident. With older people, it is more often cancer, infections and chronic circulatory disorders; the latter is frequently triggered by diabetes. Millions of people are affected worldwide, mostly through the loss of the lower leg. From archeological finds in Egypt and China, we know that attempts to substitute missing body parts with prostheses have been made for at least 3000 years. Conventional prostheses can hardly be compared with the modern versions, as these have joints, controlling algorithms and spring-loaded elements made of high-tech materials. With their help, the gait pattern becomes much more natural. Some are even designed for maximum performance: athletes with amputations at the lower leg level who use carbon prostheses achieve outstanding times running over short distances. Ankle joint prostheses intended for everyday use therefore have a completely different design to the arched "skids" used in competitive sports. Usually mirroring natural anatomy, they consist of a lower leg component and a foot component, connected together by a joint. The passive artificial ankle joint ensures that the prosthesis always remains in a predictable position, however, it allows a very limited range of movement during locomotion.
As the foot recoils – during forward movement – the foot is pressed towards the lower leg; once the foot is kicked out, the elastic force returns the foot to a near perpendicular fixed starting position. "However, this fixed position does not correspond to the natural position of the foot during the transfer phase. There is a risk of the tip of the prosthetic foot
getting caught on the ground or on small obstacles," says Marcin Dziemianowicz. The engineer, whose focus is on biomechanics, founded Design Pro Technology in Białystok (Poland) in 2016 to find innovative solutions for such problems. With an interdisciplinary team consisting of engineers, orthopedic technicians, doctors and designers, the medical technology company develops and manufactures individual orthopedic aids that incorporate the very latest technology.
Active dorsal flexion to reduce tripping risk
With its new product D-Ankle, Design Pro Technology has created the first ankle joint prosthesis that actively moves the foot with a motor when walking and holds the foot in an anatomically natural position during the course of each step. Here, so-called dorsal flexion –the bending of the foot toward the tibia – during the swing phase is of crucial importance. "Increasing the distance between the tip of the toe and the ground decreases the risk of tripping," explains Marcin Dziemianowicz. "With a passive prosthesis, the wearer achieves this by making a circular movement with their hip or by lifting their leg higher. These compensatory movements are unnecessary with D-Ankle; walking becomes more natural and less tiring." When the prosthetic foot is set down on the ground, its mechanics will perform the natural change in angle during the support phase. DAnkle is the only prosthesis with active heelto-toe recoil functionality, including pushing off from the ground for the next step. Here, the motor-driven plantar flexion is activated, i.e. stretching in the joint. It also contributes to a harmonious gait and saves energy. Although the artificial hinge joint is unable to perform
the lateral movements that a natural ankle joint allows, they are made possible as passive deformation through the elastic material of the prosthetic foot – carbon fiber. As a result, the foot achieves full sole contact even on uneven surfaces.
The controller detects the gait rhythm
The integrated controller of the prosthesis receives signals from several sensors in order to distinguish between the different phases of a step cycle. A potentiometer measures the angle between the foot and lower leg; a bilateral pressure sensor measures loading at initial contact of the foot as well as unloading in the transfer phase. The accelerometer unit detects the overall movement including
Medical prosthetic foot powered by FAULHABER BP4 Series brushless motor. Picture: Faulhaber
FAULHABER BP4 Series brushless motor. Picture: Faulhaber
speed, foot inclination and path gradient.
"The algorithm merges the signals from few most recent steps and evaluates them," says Marcin Dziemianowicz, explaining the operating principle. "From this data, it derives the gait rhythm and the optimum foot position for each step phase. For example, the ankle joint is bent more when walking uphill than when walking on a level surface, and also the takeoff force is increased to make walking uphill easier. On downward slopes, it's the other way round so that the best possible contact between sole and ground can be achieved. Furthermore, a smartphone app can be used to adjust parameters such as take-off force, the sensitivity of the pressure sensor or the length of a step cycle phase."
Sporty drive with great endurance
The integrated drive ensures that the control signals are converted into the appropriate movement. At its heart is a brushless motor of the BP4 series from FAULHABER, the power of which is transferred to a lead screw. Motor and lead screw rotate in both directions and thus achieve active dorsal and plantar flexion of the foot. The high energy efficiency of the drive enables an operating time of 12 hours
on one battery charge. The motor also tolerates the considerable heat emission that can occur in everyday operation.
"Our objectives were altogether quite sporty," recalls Marcin Dziemianowicz. "The motor was to be able to emulate a jogging motion – with three steps per second, or three complete cycles of dorsal and plantar flexion. Furthermore, rapid changes in pace and direction were to be possible. For this application, you need very high speed and high torque in the smallest possible volume and with the lowest possible weight. We tried out various drive solutions from leading motor manufacturers. With FAULHABER, we not only found the most suitable product, but also received outstanding technical support."
After extensive and successful trials with test amputees, the foot prosthesis was introduced onto the market at the end of 2023. Its standard adapter allows it to be attached to any modular prosthesis stem. Individual prosthesis adjustment is carried out by an orthopedic technician. The height of the heel can be varied so that D-Ankle can also be worn in women's heeled shoes.
65135 at www.ien.eu
• Streamlined design, quiet and maintenance-free operation
• Unique combination with gas springs possible
• Application engineering for custom adaptation
• Extensive, proven experience in the automotive industry
• Exclusively in small quantities at ACE
Motion Matters – A CNC Machine Is Only as Good as Its Servo Drives
The precision of CNC machines is paramount for optimal results, emphasizing the significance of advanced servo motors in delivering precise force application. The reliability and precision of servo motors are indispensable to ensure that the CNC machine executes instructions accurately, meeting desired tolerances with optimal efficiency.
An example can be found in the offerings of MicroStep, a global manufacturer and supplier of CNC cutting machines, using cutting technologies such as plasma and oxyfuel, laser, and waterjet. For more than 10 years, MicroStep has been relying on servo motors and drivers of the MINAS series from Panasonic Industry and witnessed the constant technical upgrading of the drives. These constant improvements helped MicroStep with their regular technology migration to maintain the quality of their systems. After the MINAS A5, the company integrated Panasonic’s MINAS A6 servo drives into their machines. They are part of a highly dynamic servo driver family with a wide power range from 50W to 15kW and are suitable for many different areas of applications beyond CNC machines. Characterized by a compact but also robust design, the servo drivers and motors of the MINAS A6 series have been equipped with essential functions for damping resonance frequencies while eliminating vibration tendencies.
“We chose Panasonic Industry’s MINAS servo motor and drive solutions due to their proven reliability and high quality. The zero vibration of the servo motor series was a key factor for choosing them, as any spurious motion can impact the machining process,” comments Pavol Varga, Technical Director from MicroStep. In addition to the servo motors and drives being extremely precise and fast, Panasonic is a globally operating company with a long heritage in manufacturing and can guarantee the quality of its products and also the ontime delivery. “Working with a vendor of that caliber enables us to fulfill customer expectations, aided by a reliable support team with a high level of technical expertise,” adds Varga.
Another important aspect of integrating the MINAS servo motor and drive solutions into their CNC machines was the availability of higher-output motors that enabled MicroStep to extend their product portfolio upwards to more powerful systems and solutions.
Panasonic’s MINAS A6 servo motors and drivers
Heat-resistant seal
Since these systems are deployed in an industrial environment, it is also critical to ensure that the motors involved require little maintenance work and do not cause operational troubles. “Our servo motors of the MINAS family are protected by a dust-proof and heat-resistant oil seal made of a material with a high temperature resistance. Furthermore, the motors can be selected by type according to the operation environment. These features render our products ideal for production environments that are exposed to dust, heat and oil mist. Direct-mount connectors are used for the motor power supply and encoder input and output to improve the sealing performance so that the motor achieves an IP67 degree of protection”, remarks Stanislav Zaujec, Senior Sales Engineer from Panasonic Industry.
A constant process and a continued partnership
As MicroStep grew steadily and started delivering CNC cutting machines to customers all around the world, a reliable partner for motion solutions was needed. In 2013, Panasonic Industry started to provide MINAS A5 servo drives, which enabled MicroStep to meet their customers’ production demands. The high quality and especially zero-vibration of the servo drives convinced MicroStep to implement the Japanese technology into the CNC lineup. But not only the features and quality of the products convinced MicroStep to rely on Panasonic Industry. Thanks to a close contact with the local team, MicroStep also gets support with the design-in and implementation processes. Existing machines get regular updates, and the development of new solutions can be handled very effectively and quickly. “We are very content with the personal support we have experienced over one decade with Panasonic Industry and we are looking forward for an even longer partnership with them”, Alexej Makuch, MicroStep’s Managing Director sums up.
Looking forward
Integrating advanced servo motor and driver solutions like the MINAS series from Panasonic Industry can help ensure that precision applications like CNC machines and other advanced industrial solutions fulfill all of the demands for quality, performance, and reliability. Paired with a dependable pre- and aftersales service that supports with design-in, implementation, updates and trainings, MicroStep and Panasonic Industry are looking forward to working on new developments and projects together.
64962 at www.ien.eu
THE VALUE OF EXPERIENCE
Servotecnica, a company driven by innovation and known for developing high-quality motion control products, has come a long way in automation and robotics with its micromotors and slip rings. These components are essential for applications that require precise motion and reliable electrical connections through rotary interfaces.
For over 40 years, our passion and drive to innovate have guided the creation of top-of-the-line motion control products. This commitment has enabled us to bring about change in the automation and robotics markets. Our slip rings, and micromotors are the ideal choice for all applications requiring precise motion and reliable electrical connections through rotary interfaces.
Perfecting Productivity: Tripled Efficiency and Elimination of Defects
Steen-Hansen – a Norwegian manufacturer of fouling prevention and net protecting solutions for aquaculture use as well as of specialized industrial paint systems – has not only successfully overcome quality problems with its newly developed antifouling coatings, but also significantly shortened process times, simply by switching its production facilities to state-of-the-art mixing and dispersion technology.
Steen-Hansen has been a leading provider of antifouling coatings for nets in industrial fish farming for more than 30 years. Antifouling coatings reduce the growth of algae and other organisms on the nets, meaning they can be used for longer periods of time. In addition to conventional copper-based antifouling coatings, copper-reduced – not to mention completely copper-free and biocide-free coatings – are becoming increasingly important in the fish farming industry. SteenHansen is a pioneer in the development and manufacture of coating solutions like these with a reduced environmental footprint.
Innovative coatings call for new process technology
Manufacturer Steen-Hansen initially used dissolvers, which it also used for its copper-
based coatings, to make these innovative antifouling coatings. However, the company found that using conventional production techniques for copper-reduced or copperfree coatings resulted in quality deficiencies, since the long process times in the dissolver caused strong, undesirable foaming in the product.
Several factors were responsible for this foaming. On the one hand, powders contain a great deal of air. Even heavy powders such as titanium dioxide contain more than 75% air by volume. If this air is not fully substituted by liquid and separated, but rather dispersed together with the powder particles, this creates micro foam, which is exactly what happens in a dissolver process. Additionally, the fact that – in a dissolver – the powder is added to the open vessel from above leads
to the creation of vortexes, which introduce large amounts of additional air. Since SteenHansen‘s products are water-based, another factor is the process water foaming, regardless of the technology used.
Steen-Hansen managed to counteract this undesirable foaming by using defoamers, but only to a certain extent. This is why the company was looking for a way to disperse the powdered raw materials in a gentler, more product-friendly way, ultimately opting for the technology offered by mixing and dispersion technology specialist ystral. ‘ystral’s process engineering solution allowed us to overcome the quality problems and, at the same time, significantly shorten our production times,’ reported Stig Bjarte Fagerlid (plant manager at Steen-Hansen AS).
2019, the intense process steps of powder wetting and dispersion take place outside the vessel with the YSTRAL Conti-TDS inline powder wetting and dispersing machine, while the contents of the vessel are simultaneously mixed in a continuously homogeneous manner with a YSTRAL Jetstream Mixer.
Using the vacuum expansion method, the inline disperser achieves complete deagglomeration and wetting of the powder particles in a matter of microseconds. Due to an induction vacuum built up directly in the wetting and dispersing zone, the air contained in the powder is expanded many times over, enormously increasing the distances between the particles and allowing the particles to be completely wetted immediately, one by one, on contact with the liquid. The air contained in the powder is separated from the significantly heavier dispersion through the centrifugal effect of the fast-running rotor and coalesces to large air bubbles. These are then pumped to the process vessel with the liquid flow, where they can easily escape. There are no vortexes and there is no additional air intake during the entire process. This can help to significantly reduce the use of defoamers.
One supplier for infrastructure technologies
Based on this experience, the company decided to install two more ystral process systems while modernising and expanding its production capacities. ‘We completely reorganised our production facilities as part of a relocation, and aligned our entire production infrastructure with ystral technologies,’ commented Mr Fagerlid. ‘ystral technologies allow us to fully automate our production processes. But, at our old site, we were unable to exploit this potential. So we used the move as an opportunity to comprehensively automate the peripheral devices of the ystral systems with powder and liquid handling.’ Whereas, at the old production site, the operators still opened bags manually and poured their contents into the ystral system’s powder hopper, now all the powder materials are fed from the silo to the ystral systems by means of a fully automatic chain conveyor.
At its new site, Steen-Hansen uses one system each for producing antifouling coatings containing copper, for making copper-free coatings, and for manufacturing industrial paints. A system consists of two process vessels with YSTRAL Jetstream Mixers, a powder vessel and the YSTRAL Conti-TDS inline dis-
perser, which is operated alternately on one of the two process vessels. While powder and liquid handling at Steen-Hansen is performed using a central control system, each system is fed from separate silos and tanks. This eliminates the possibility of the copperfree coating products being contaminated with copper particles, for example.
Fully automatic production
The YSTRAL Control System (YCS) Professional + – the ystral control system with the highest degree of automation – is used as the control software for the three systems. The operator starts and monitors the process using a graphical user interface, and dosing and feeding of the liquid components and solids is fully automatic. Every single process step is exactly reproducible, and creating new recipes is child’s play with the recipe handler.
By using modern mixing and dispersing technology and centrally controlled peripheral devices with automated feeding and dosing of powder and liquid components, Steen-Hansen successfully tripled its production capacity at its new site, all the while keeping its staff levels the same. The three ystral systems can be operated by just one employee. With the dissolvers previously used, the process often lasted one to two hours, but this was shortened to between 10 and 15 minutes with the ystral technology. While Steen-Hansen was barely able to meet the rapidly growing demand for its products with the production infrastructure it used previously, even in two-shift operation, it has now switched to one-shift operation in the new factory.
The significantly shorter process time also goes hand in hand with a considerable reduction in energy consumption - which is particularly important to Norwegian producer Steen-Hansen, since electricity prices are high in Norway. Measured in terms of electricity demand per litre of finished product, Steen-Hansen cut its electricity demand at the new site by about 75% –simply by using more efficient mixing and dispersing technology and energy-saving building technology.
NETZSCH is presenting a new version of the NEMO® MY magnetically coupled pump. In addition to the previously available version with a flexible coupling rod made of PA12, a versionwitharobustBorKjointisnowalsoavailable,which enablesawiderrangeofapplications. Themagneticallycoupled pumpishermeticallysealedandthereforeleak-free,which guaranteesthesafetyofallemployeesandthesystem.Thepump hasbeenspeciallydesignedforsaferandmoresustainable conveyingoffluidswithhighviscosity,suchasslurriesinbattery production.ThemagneticcouplingoftheNEMO®MYwasspecially developed. Comparedtoconventionalpumpswithmechanical sealsorothersealingsystemsitofferssignificantcostadvantages.
How Advanced Pressure Measurement Technologies Can Reduce Costs
Advanced pressure measurement technologies not only provide outstanding accuracy and reliability in chemical industry applications, but also help to minimise operational costs without compromising plant safety.
Chemical manufacturers depend on accurate and reliable pressure measurements in applications such as reactors, distillation columns, heat exchangers and storage tanks, to help optimise processes and ensure plant and worker safety. Some pressure measurement applications are relatively straightforward, which enables continued deployment of older and relatively basic instrumentation. However, in more critical and complex applications, the functionality provided by modern, advanced technologies create some significant benefits, including reduced costs and increased safety.
Distillation columns
For example, pressure measurements are vital for the operation of distillation columns, but the size of these columns can make it complex and costly to install and maintain measurement devices. For many years this application has relied on differential pressure (DP) transmitters in wet leg and dry leg systems. These devices, which use impulse piping as well as capillary-based solutions, are wellunderstood, but have certain disadvantages. For example, impulse lines are prone to plugging and can freeze in extreme cold, while DP transmitters with remote seals and capillaries have a limited measurement range and are difficult to install. Capillary systems are complicated to calibrate and maintain, have a relatively slow response time, and are sensitive to temperature changes, vibrations and physical stress. Capillaries are also fragile and prone to damage from physical impacts. If a seal is damaged, the complete capillary sys-
tem must be replaced, which makes inventory costs high. With all these challenges, the cost of installing a DP transmitter with capillaries can be five times higher than the cost of the device itself.
A better alternative is a measurement system based on electronic remote sensors (ERS), such as the Rosemount™ 3051S ERS System from Emerson. Rather than using a single DP transmitter with mechanical impulse piping or capillary, ERS systems use two pressure sensors connected with nonproprietary electrical wire that is immune to
the effects of temperature variations. The DP is calculated in one of the two sensors and transmitted to the distributed control system or a PLC using a standard two-wire 4-20 mA HART® signal. By removing mechanical connections, ERS systems not only provide a faster response time than traditional DP technologies but are also easier to install and maintain, thus reducing costs. Replacing difficult-to-install impulse piping with electrical wire makes installation quicker and 60% less costly compared to DP transmitters with capillaries. Additionally, while cold weather
The quick configuration of advanced pressure transmitters can lead to significant cost reductions at large chemical plants, where thousands of transmitters can be deployed. Picture: Emerson
Author: John van Gorsel, Emerson
Thousands of pressure transmitters can be deployed in a large chemical plant, so configuring them all can be time-consuming and costly.
installations of impulse piping and capillaries often require heat tracing or insulation to prevent freezing, electrical wire does not require heat tracing or insulation, which significantly reduces installation costs.
High pressure and vibration
In applications with high levels of pressure and vibration, mechanical instruments such as Bourdon tube gauges are typically used to provide pressure monitoring and control. These simple devices can be cost-effective in some applications but have limitations that make them less suitable for critical applications where high accuracy, real-time monitoring and data integration capabilities are vital. Extreme temperatures, humidity, vibration and shock can make Bourdon tube gauges difficult to read, possibly leading to inaccurate readings which could affect product quality and profitability. Bourdon tube gauges are also sensitive to overpressure and lack diagnostics, creating a safety risk for personnel. In challenging applications, they may require additional options such as syphons, seals and glycol fill, which raises costs. In addition, their components wear out over time, creating a high failure rate and necessitating regular maintenance and calibration. Furthermore, mechanical gauges provide only a visual display and lack digital output options, which means that time-consuming and error-prone manual readings are required.
To support increased reliability, electronic wireless devices, such as the Rosemount Wireless Pressure Gauge from Emerson, replace Bourdon tube gauges with a solid state pressure sensor based on piezoresistive technology. Wireless gauges provide correct pressure information even in highpressure and high-vibration environments, and reduce costs by delivering up to 10 years of maintenance-free operation. These devices feature a large dial, making it easy for personnel to accurately read pressure
levels, while a blinking diagnostics LED indicates that a device is operating correctly. In addition, WirelessHART® communication technology enables them to deliver reliable pressure readings and device health status back to the control room as often as once per minute, supporting the central logging of historical data, improved maintenance planning and reduced costs.
Safety
Safety instrumented systems (SIS) are another challenging and critical application, requiring high levels of accuracy, repeatability and reliability. Pressure transmitters deployed in SIS must be regularly proof-tested to verify that they are working correctly and comply with safety standards. Performing a proof-test has traditionally been a timeconsuming, labour-intensive and costly procedure. However, the latest devices provide guides to easily lead operators through a step-by-step process outlined by the transmitter’s software or a handheld communicator, which saves time and reduces both complexity and costs.
Poorly performing pressure transmitters can impact safety and operational efficiency, so issues need to be identified quickly. To enable this, advanced instruments feature built-in diagnostics to continuously moni-
tor electrical loops and impulse lines. Issues can then be identified and alerts transmitted quickly, enabling corrective measures to be taken before process quality is impacted. The early detection of issues also enables maintenance to be scheduled during planned downtime, to minimise disruption and avoid additional costs.
Mass deployment
Thousands of pressure transmitters can be deployed in a large chemical plant, so configuring them all can be time-consuming and costly. However, the Rosemount 3051 Pressure Transmitter from Emerson includes features that makes it easy to install, commission, configure, maintain and use. A user interface provides a straightforward, taskbased menu structure, enabling quick configuration in just a couple of clicks, saving a great deal of time and significantly reducing costs. The device offers Bluetooth® connectivity to reduce complexity further. This eliminates the need for a physical connection via a cable, which enables configuration and maintenance to be performed from a distance. This is especially beneficial if devices are installed on large storage tanks or distillations columns.
at www.pcne.eu
Next-Level Cabling: Less Effort, More Networking
For modern automated systems, those responsible are faced with the challenge of finding efficient cabling solutions that fulfil both the high performance and data transmission requirements. Traditional cabling systems often provide for separate cables for these purposes, which leads to increased effort and higher costs. One Cable Solutions (OCS) solve these challenges and thus also meet the growing requirements of the IIoT.
The classic cabling topology of most existing automated systems usually has separate cabling for power and signal or data transmission. The reason for this is that the requirements for the peripherals (cables, connectors, distributors) are different for the various applications. While cables for the power supply require large cross-sections for high currents, the focus for data transmission is on signal integrity and shielded cabling. The two cable harnesses are then typically brought together in the main control cabinet.
‘This cabling philosophy is quite demanding, as at least two cables per device always have to be laid in the field. With the increasing integration of IIoT-enabled devices - which always require a data interface - this approach is proving increasingly impractical. As a result, the need for more efficient solutions such as One Cable Technology is growing. These combine the functions of data transmission and power supply and significantly simplify cabling,’ explains Philipp Zuber, Product Manager at binder.
All-in-one solution reduces complexity and costs
The One Cable Solutions make it possible to transport both the power supply and data communication via a single cable. This has various advantages. One of these is the reduction in the work involved in connecting and laying cables and connectors. At the same time, material costs can be significantly reduced as fewer cables, cable routing systems and installation materials are required. There is also less need for
The PBC15 is equipped with 3 power contacts and 2 signal contacts in accordance with the design standard DIN EN IEC 61076-2-116 and is therefore particularly suitable for applications in the field of drive technology. Picture: binder
maintenance. The reduced number of cables also saves space, which is particularly beneficial in confined spaces. And the flexibility of the systems is increased as both power and data can be transported via the same cable.
Potential for many markets - already proven in drive technology
‘Theoretically, OCS is recommended wherever a high cabling effort is or can become problematic. This approach has already become established in the field of drive technology for automation. In the past, two cables were always run to servomotors: one cable for the energy and power supply and the second cable for the control and feedback of the encoder. Newer versions of servomotors only have a single cable connection. This is used to transmit both the power supply and the communication,’ says Philipp Zuber.
OCS technology is therefore particularly suitable for applications in which the cabling effort, the length of the cabling or the flexibility of the overall system play a major role. The solutions therefore also prove their worth in robotics, for example, particularly due to the reduced space requirements. In automation technology, they enable efficient connections of actuators and sensors at field level, which considerably reduces the amount of cabling required. There is also great potential in intralogistics and conveyor technology, particularly due to the long distances that have to be covered by the connecting cables.
The HEC connector for harsh environments is available in 3 different pole configurations, one of which is designed as a hybrid variant (4+3+PE). This contains 3 power contacts and 4 signal contacts for the transmission of power and signals via one cable. Picture: binder
Single-cable solution - various technological versions
OCS are based on various technological approaches. These include special cables and connectors as well as advanced protocols for data transmission. Hybrid cables combine lines for power and data in one physical cable sheath and are specially designed to minimise electromagnetic interference and ensure reliable data transmission. In the IT sector, Power over Ethernet (PoE) is a well-known example in which Ethernet cables transmit both data and power to devices such as IP cameras and WLAN access points. This principle is also used in industry, but usually only when the devices require lower amounts of power. In addition, many companies develop proprietary solutions and protocols to meet the specific requirements of their automation systems.
Challenges for connectors
However, the development of components for OCS is also associated with greater complexity in terms of construction and design - including for connectors, as Philipp Zuber knows: ‘As a manufacturer of hybrid connectors for OCS, our task is to minimise the complexity of connection and assembly. In doing so, we sometimes encounter challenges. The design of such a connector alone means that it consists of significantly more individual parts. The more components, the more complex the assembly and customisation. The task here is to find a user-friendly solution despite the complexity so that our customers can connect the connectors quickly and easily.’
Electromagnetic compatibility also plays a role here. The transmission of energy and data via the same cable can lead to electromagnetic interference, which can impair data integrity. It is important to ensure that the connectors are designed with high-quality shielding. These shields must be able to minimise electromagnetic interference in order to ensure reliable data transmission.
Compactness is also a challenge. Single-cable solutions must accommodate more contacts for power and signal transmission, often with shielding components. At the same time, the space requirement must not increase significantly. The development of such products requires a precise and efficient design in order to achieve maximum performance with minimum space requirements.
Single-cable solutions are particularly favoured in robotics and drive technology due to their space requirements. Picture:Sebastian/AdobeStock
Important component in terms of the IIoT
Phlipp Zuber attributes great potential to OCS - especially with regard to the digitalised and networked factory of the future: ‘Singlecable solutions will become increasingly popular in the course of the IIoT. This is because the smart factory requires high data transmission speed and reliability in order to ensure seamless communication between different devices and systems. Single-cable solutions simplify the infrastructure considerably. This also minimises the risk of errors and failures that can result from numerous separate connections. In addition, single-cable solutions support the modularity and flexibility of systems that characterise the IIoT, as they enable easier and faster scaling and adaptation.’
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Compact housing with axial connectors • Single- & multiturn with EHG Energy Harvesting generator • Robust magnetic or precise optical sensing • Environmental protection up to IP67
Creating AI-Based Service Revenue Models
IoT architectures remain heterogeneous despite standards like SMARC® and COM Express®. This complicates integration and increases costs. Middleware abstracts the complexities of hardware, operating systems, and protocols, reducing development time.
Author: Francesco Vaiani, Software Product Manager at SECO
IoT is advancing to a phase where OEMs create value through servitization, turning data from IoT devices into service-based revenue models like predictive maintenance and process optimization. In industries, AI and ML are integrated into operations, leveraging edge capabilities.
Developers of Product-as-a-Service (PaaS) face challenges with speed to market and cost reduction. Middleware like SECO’s Clea plays a key role in simplifying IoT platform integration, letting developers focus on building applications and monetizing data.
Middleware Solution
Clea integrates data orchestration with middleware, enabling AI model deployment at scale. Built on Kubernetes, it is cloudagnostic and simplifies device management through secure OTA updates. Clea also integrates with Google Cloud Services, enabling fast AI application development through the Clea App Framework.
The Clea suite comprises four core components:
• Clea Portal: A customizable front-end that supports service monetization with a billing framework for reselling applications via subscription models. It manages device access, data visualization, reporting, and user permissions.
• Clea Edgehog: A device-agnostic platform for managing IoT devices and fleets. It supports OTA updates, monitoring, geolocation, and file transfer.
• Clea Astarte: A comprehensive IoT middleware that handles communication between
devices and the cloud, offering tools for data orchestration and advanced use cases like data reduction. It includes SDKs that enable easy integration with edge devices, even microcontroller-based systems.
• Clea OS: Built on the open source Yocto Project, it offers a flexible and customizable platform that can be tailored to meet the specific needs of various hardware architectures and applications.
SECO is expanding its use of Google Cloud Marketplace for Astarte, enabling rapid software deployment without manual configura-
tion. Edgehog and Portal will soon be available, providing flexibility for developers.
Smart Factory Applications
The industrial sector, one of the earliest adopters of IoT technology, is now leading in AI adoption. AI in smart factories monitors machine data, detects anomalies, and predicts failures, enabling predictive maintenance and avoiding costly downtime. OEMs collect data from their equipment to offer value-added services like remote assistance and predictive maintenance to their customers.
Source: SECO
Clea is a comprehensive software suite for building IoT solutions that harness field data
Source: SECO
For example, SECO collaborated with a CNC hardware manufacturer to integrate smart sensors on one of their machines and connect them to Clea Edgehog. Using this infrastructure, SECO implemented an AI solution for remote monitoring, OTA updates, and predictive maintenance. This allowed the manufacturer to offer an annual maintenance contract to end users, creating a new revenue stream. Benefits included improved customer satisfaction, a 40% reduction in spare part delivery times, and a 10% reduction in spare part costs. Production quality also improved, with a 30% reduction in scrap.
Leveraging the Power of IIoT
IoT devices, combined with AI, transform data streams into actionable insights that drive operational efficiency and productivity. With platforms like Clea, developers can bypass the complexity of integrating IoT infrastructure and focus on value creation. In the context of a smart factory, these insights can lead to predictive maintenance, optimized processes, and increased shareholder value.
Simplifying Development
Clea’s components streamline the development of IoT-based services, especially AIbased applications. Middleware abstracts the underlying complexity of IoT systems,
including hardware, protocols, and operating systems, allowing developers to focus on building solutions that deliver tangible business value.
Clea integrates seamlessly with cloud platforms and offers developers the ability to deploy and manage applications easily. By reducing the need for specialized knowledge of various IoT architectures, Clea minimizes development time and costs, speeding up the path to market for AI-driven services. SECO’s strategy includes making Clea components available on Google Cloud Marketplace, empowering developers to quickly deploy solutions at scale.
Expanding Impact with Google Cloud Marketplaces
Google Cloud Marketplace serves as a vital distribution channel for SECO’s IoT middleware components. Developers can deploy Astarte, Edgehog, and Portal quickly, bypassing manual configuration, and leveraging the reliability and scalability of Google’s cloud infrastructure. SECO’s strategic approach focuses on making all Clea components available on Google Cloud Marketplace, ensuring developers can use them according to their specific IoT deployment needs, whether collectively or individually.
By simplifying the software distribution pro-
cess, Google Cloud Marketplace allows developers to efficiently manage complex IoT applications and focus on building innovative, AI-based services. This strategy aligns with SECO’s goal of supporting developers as they build value-added services, enabling them to monetize their IoT installations and optimize operational efficiency.
AI and IIoT: A Competitive Advantage
As AI integrates with IIoT, companies improve operational efficiency, reduce downtime, and enhance product offerings. Predictive maintenance is one example of how AI can optimize operations, cut costs and generate new revenue streams through service models.
Clea helps OEMs capitalize on IoT data. Its data orchestration, device management, and AI deployment capabilities allow developers to create customized applications that deliver business benefits. The flexibility of Clea’s cloud-agnostic design ensures smooth integration with existing infrastructure.
Driving Value
SECO’s Clea platform is designed to help businesses unlock the full potential of AI and IoT, enabling them to transition to service-based revenue models. By abstracting the complexities of IoT architectures and providing tools for rapid AI deployment, Clea reduces the time and cost required to bring innovative products and services to market. SECO’s ongoing investment in the Google Cloud Marketplace further supports developers by providing easy access to Clea’s modular components, facilitating the creation of scalable, AI-driven applications that meet the specific needs of industrial IoT deployments.
In summary, AI and IIoT offer substantial opportunities for manufacturers to enhance operations, generate new revenue streams, and create value for both customers and shareholders. Clea, with its robust middleware and cloud integration, serves as a powerful tool for developers looking to build AI-based applications and services. SECO’s strategic vision positions it as a leader in enabling businesses to harness the power of AI and IoT to drive future growth.
65138 at www.ien.eu
Using AI to reduce warranty costs and drive revenue from CNC operation.
Integration of Opc UA Information Modeling Into Edge Product Range
Advancement for more seamless integration, data exchange, and control in Industrial IoT (IIoT) applications.
Softing Industrial announces the integration of OPC Unified Architecture (UA) Information Modeling into its edge product range as well as the Secure Integration Server (SIS). This OPC UA Information Modeling including the support of OPC UA Companion Standards provides a structured way to represent machine data, making it easier to interpret and share across different systems.
This standardized model enables real-time management and monitoring of digital representations of physical assets, such as machines and sensors.
This is essential for optimizing workflows, improving decision-making, and supporting predictive maintenance.
The integration opens a new dimension of opportunities for manufacturers and industrial operators. Key advantages include:
• Interoperability: A standardized information model makes it easy to connect various devices and systems across different vendors and protocols.
• Simplified Data Handling: Structured and unified data models make the extraction, interpretation, and transfer of machine data much more streamlined, facilitating seamless IIoT integration.
• Enhanced Security: Coupled with the OPC UA Security Functionality, this integration ensures that the data exchange between machines and systems remains secure and compliant with industry standards.
• Improved Efficiency: By using a single framework for data transfer and device interaction, operators can reduce the time and effort required for configuration, data interpretation, and overall system integration.
• Scalability: The integration enables easy scaling of industrial applications, as operators can standardize machine data handling across numerous devices and systems with minimal disruption.
Softing Industrial’s edgeConnector products enable seamless communication between control systems and the cloud, playing a crucial role in connecting operational technology (OT) and Information Technology (IT) systems in IIoT environments. These connectors offer reliable data collection from field devices and control systems, which can then be transferred to cloud platforms for further analysis and optimization.
The edgeGate further enhances this process by providing robust gateway functionality, ensuring smooth and secure data flow between OT systems and cloud or enterprise
applications. It offers built-in features for protocol conversion, edge analytics, and data aggregation.
The Secure Integration Server from Softing Industrial is designed to ensure secure, reliable data transfer between machines, devices, and IT systems. By using state-ofthe-art encryption and security protocols, it safeguards critical machine data from unauthorized access and cyber threats, while also supporting a flexible, scalable integration of IT and OT environments.
This move marks another significant step forward in Softing Industrial’s commitment to providing state-of-the-art solutions for Industry 4.0 and the future of digital industrial operations.
Technological Integration and Logistical Advantages: A Partnership for the Future of RF Technology
Alessandro Gomarasca, Product Development Manager at Servotecnica, discussed with our editorial team a distribution agreement that promises to integrate skills and technologies, opening new horizons in the European market.
IEN Europe: Can you give us an overview of Diamond Antenna and Microwave, including a brief history and a description of their main production?
Gomarasca: Diamond Antenna and Microwave is an American company located near Boston, Massachusetts. Historically, the company has specialized in the production of rotary joints for RF (radio frequency) transmissions, which remains their core business. These joints can be either contact-based or contactless and find application in various markets, including antennas and radar. Diamond focuses on four main sectors: the
defense sector, which includes the use of rotary joints and radar antennas on military platforms; the commercial sector, which involves antennas and radars used in maritime or land applications; the air traffic control (ATC) market, where the joints and antennas are used in airport radar systems; and finally, the space sector, where Diamond has long been present, although we are only now beginning to develop this market in Europe. In this area, the rotary joints are used in spacecraft or satellite antennas.
Diamond Antenna is considered a leader in the field, with few competitors worldwide.
There are only a handful of manufacturers at this level in the United States, and even fewer in Europe. There are also Asian manufacturers, but they usually work on lower-tier components. Diamond, on the other hand, is among the top three global manufacturers in terms of product quality and technology.
IEN Europe: How did the collaboration between Servotecnica and Diamond Antenna begin about, and what led to this partnership? Gomarasca: Servotecnica has operated since its inception in the four key sectors mentioned earlier and has a well-established expertise in electric slip rings, which is the rotating collector for transmission electrical signals or fieldbus, based on physical contact. About 15 years ago, we started collaborating with other companies specializing in collectors for fluid passage, such as water and gas, and in collectors for optical fiber signals. The only area missing from our portfolio to offer a complete range of technological solutions was RF technology, the transmission of radio frequency signals. During our scouting activities, we identified Diamond, a company we already knew. Thanks to this agreement we have been able to complete our technological offering, integrating their expertise in RF joints with our electric, hydraulic, and optical fiber technologies, thus making our offering broader and more versatile for our customers.
IEN Europe: What are the strategic advantages of this distribution contract for Servotecni-
Alessandro Gomarasca, Product Development Manage, Servotecnica. Picture: Servotecnica
ca, especially from a technical and logistical perspective?
Gomarasca: This agreement with Diamond offers Servotecnica several competitive advantages. In addition to completing our technological range, we can support customers commercially and technically more effectively. We have qualified technical staff capable of interfacing with customers to understand their needs and resolve any issues, both through technical analysis on damaged products and by intervening promptly in the field. Moreover, many of Diamond’s products are large and high-value units, such as antennas that can measure up to one and a half meters or more. In case of maintenance or failure, disassembling and shipping them to the United States would involve significant logistical costs and waiting times. Thanks to our operational base in Italy, and potentially extended to the rest of Europe, we can intervene quickly, reducing these times and simplifying operations, including bureaucratic processes. In particular, some of these units are subject to export licenses, which makes internal management within the European Community much easier compared to exporting material to the United States.
IEN Europe: Does this collaboration allow you to access new markets compared to those you have already reached in the past?
Gomarasca: Yes and no. Certainly, the market we are focusing on the most, and where Ser-
votecnica was previously underrepresented, is the space sector. Previously, we didn’t have suppliers for this sector, but through market analysis, we identified strong growth potential. The launch of satellites has become simpler and more accessible, and more and more customers, including our historical partners, are exploring this sector that was not so developed in Europe until recently. We have already started some projects and received orders in this area, where the technological competition is even higher compared to the traditional industrial market.
Thinking about developing technology from scratch for space applications would require timelines that are not compatible with current market demands, which require immediate solutions. Thanks to Diamond, we now have access to this market, representing a new growth opportunity.
In addition, the partnership allows us to offer a unique proposal: we now have all four of the main technologies for rotary joints and can provide an integrated solution to our customers. Even if the components come from different suppliers, including Diamond, the customer has a single point of contact, Servotecnica, for all technologies. In the event of problems, the customer does not have to worry about identifying which joint or technology needs intervention, as we manage the entire process, ensuring an efficient and complete service. This integration represents a distinctive offering in the market, as the
7 Channel Rotary Joints. Picture: Diamond
technologies involved are very different from one another.
IEN Europe: The integration of technologies is one of the main advantages of this partnership, right?
Gomarasca: Exactly. It’s essential to combine the different solutions and have a local base in Italy, or at least in Europe, that can provide technical support and operate directly on the products, whether for maintenance or analysis. Joints generally require regular maintenance. They are devices that operate continuously, like airport radars, active 24 hours a day, and their reliability is crucial; they cannot afford to fail.
In addition to maintenance, another significant advantage concerns the commissioning of complex joints. In these cases, the customer requests to accept the product at the supplier's site. Before shipping the piece, the customer themselves participates in the tests, verifies the specifications, and all this is much easier to organize here in Italy compared to sending technicians to the United States. Not only is time saved, but costs are also significantly reduced.
IEN Europe: What are the next steps to optimize this collaboration from a technical point of view?
Gomarasca: We are currently already able to provide technical support for the products and manage all logistical aspects, but we are
exclusive interview
structuring ourselves to further expand these capabilities in the next 12-18 months and to be able to manage maintenance, qualification, and acceptance of the joints on-site. This requires acquiring specific tools, which are different from those we usually use on our products. A know-how we will achieve through training courses, which we are investing in, structuring so that Servotecnica technicians will directly attend at Diamond, who will subsequently send their experts to Italy to verify that the tests are carried out according to their standards.
IEN Europe: So, this partnership makes you the exclusive point of contact and distributor for Diamond in Italy and, prospectively, also in Europe?
Gomarasca: Exactly, we are the exclusive distributors for Diamond Antenna in Italy, and we are structuring the same network across Europe. We have already mapped out the clients and are working to expand the sales network, aiming to position Diamond as a major player in the European market. At this moment, we are focusing on companies that can benefit from RF technology, such as those active in the space sector, ATC, defense, and navigation. In particular, Diamond’s technology offers the opportunity to provide support for highquality and high-value components. We aim to create synergies with our customers, not just selling the product but also accompanying them through all project phases, from conception to installation and beyond.
The expansion with Diamond’s unique technology will allow Servotecnica to expand their product range and offer comprehensive services.
Picture: Diamond
IEN Europe: In the coming months, the focus will be on integrating the technologies and skills. How will Diamond’s products integrate with Servotecnica’s existing product lines?
Gomarasca: As mentioned earlier, Diamond has a unique technology, particularly in the space market, which Servotecnica didn’t have until now. The commercialization of our first RF rotary collector will allow us to significantly expand our product range, responding to the needs of some existing customers interested in this technology.
Diamond is a well-recognized brand in Italy, even though its main market is in the United States, where they sell most of their products. However, in our sector, they are known both for their brand and for their innovative technologies.
IEN Europe: What do you think about the future of Servotecnica and this partnership?
Gomarasca: The prospects are very promising, as we now have access to new technologies and markets, and our ability to offer a comprehensive service to customers differentiates us from the competition.
The synergy between our skills and those of Diamond will allow us to tackle more ambitious challenges and grow further in the European context. It will be interesting to see how these opportunities develop in the coming years and to work with in tandem with Diamond to realize them.
IEN Europe: Thank you for these insights.
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Radar station at Bremen airport.
UNMANAGED16-PORTETHERNETSWITCH
ForMission-criticaloperationsinharshenvironments
Red Lion® is pleased to announce the launch of the N-Tron® NT116 unmanaged industrial Ethernet switch. The NT116 is designed for industrial applications that require reliable performance for missioncritical applications in harsh environments. The NT116 unmanaged switch provides exceptional reliability and performance for data acquisition,EthernetI/Oandprocesscontrol.Housedinarugged industrialmetalenclosure,theunitiscompactinsizeandfeatures 16high-performancecopperports(10/100BaseTXRJ45).The NT116offershighshockandvibrationtolerance.Allportshave built-inESDandsurgeprotection.UsersbenefitfromanexceptionalMTBFratingof1.2millionhours.Allthisinaslim,space-saving designthatoperatesfrom-40°Cto85°C. TheNT116supportsfull wirespeedcommunicationswithupto3.2Gb/sthroughput.Ituses store-and-forwardtechnologyandsupportsfullandhalf-duplex operation.Two10-49VDCpowerinputsareprovidedforredundancy. InadditiontoIEEE802.3complianceandmarine,railway androllingstockcertifications,thenewswitchhasULOrdinaryand HazardouslocationsaswellasATEXandIECExcertifications. Its ruggedandhardeneddesignprovidesthedurabilityandreliability neededtowithstandextremeconditions.
Reduce Industrial Emissions With Two Words: Motor Efficiency
Combating climate change is a serious challenge, with a nearly overwhelming array of issues to overcome. Sustainability-minded people do their best to lessen their personal carbon footprint by using public transportation, driving an EV, cutting back on energy usage, etc. But the biggest culprit in carbon emissions is actually industry, representing an estimated 23% of all greenhouse gas emissions in the U.S as the U.S. Environmential Protection Agency published.
Author: Maurice O'Brien, Strategic Marketing Director for Industrial Automation, Analog Devices
Fortunately, the industrial sector represents a unique opportunity to address key sources of emissions at scale, and there is ample incentive to take corrective action thanks to cost savings, evolving regulations, and a need for more resilient energy grids. It has been estimated electric motors represent approximately 70% of industrial electricity consumption as they drive pumps, fans, compressed air systems, material handling, processing systems, and more. This makes motors an especially promising opportunity to address carbon emissions through technologies that allow them to perform much more efficiently, particularly for large-scale manufacturers willing to invest in retrofits that drive energy efficiency.
Reducing carbon emissions is a globally significant challenge, reflected by its inclusion
in the Paris Agreement. The Agreement aims to limit global warming to 1.5°C by 2050, requiring an approximately 70% reduction in CO2 emissions from 2018 levels.
Meeting the challenge of a 1.5°C target will require a shift in investment away from fossil fuels and toward energy efficiency, renewables, and nuclear power as well as carbon capture, utilization, and storage (CCUS) along with other low carbon areas. However, while renewable energy gets much of the attention, Analog Devices sees gains in energy efficiency as perhaps even more critical. By increasing efficiency and mitigating demand on the energy grid, manufacturers may be able to increase resilience, generate cost savings, and reduce emissions in their operations.
Chart 1 shows a path to the 1.5°C target by reducing CO2 emissions to under 10 Gt by
2050, as covered in World Energy Outlook 2019. This study includes two major sections. The first is the Stated Policies Scenario, which considers only specific policy initiatives already announced. The second is the Sustainable Development Scenario, which describes a pathway that enables the world to meet climate, energy access, and air quality goals, and is fully compliant with the Paris Accords. At the same time, it maintains a strong focus on the reliability and affordability of energy for a growing global population. Notably, the largest opportunity to reduce CO2 emissions identified as part of the Sustainable Development Scenario is gains in energy efficiency, representing 37% of the Sustainable Development Scenario’s reductions relative to the Stated Policies Scenario.
Increased efficiency = increased deployment of motor drives
With energy efficiency as a centerpiece to combating emissions, it’s imperative that technologists and manufacturers identify where they can make a practical difference, and electric industrial motors are a perfect starting point.
The most basic and lowest efficiency motion solutions operate in an either on or off position, applying one level of output regardless of changes in their task’s requirements. They are based on a grid-connected or AC-powered, 3-phase motor that uses a switchgear to provide on/off control and protection circuitry. However, through the use of variable drive technology, motors are able to better match output with the load requirement. Deploying
more high efficiency motors and drives, and embracing digitalization represents a tremendous opportunity as the world seeks to achieve greater energy efficiency and cut CO2 emissions.
By adding technology including a rectifier, DC bus, and a 3-phase inverter stage, it becomes possible to significantly reduce energy consumption by running the motor at the optimum speed for the load and application. De-
Higher motor efficiency means lower emissions. Source: International Energy Agency
pending on the motor and application, adding an inverter or drive to an existing motor can reduce power consumption between 25% and 60%. For higher performance motion control applications, a VSD enables accurate torque, velocity, and position control. To accelerate the deployment of higher efficiency motordriven systems, the International Electrotechnical Commission (IEC) has contributed to the definition of energy-efficient electric motor standards. This includes the IEC 60034-2-1 test standard for electric motors and the IEC 60034-30-1 classification scheme comprised of four levels of motor efficiency (IE1 through IE4). These standards have made it easier to compare efficiency levels between motor manufacturers and have provided a reference for governments to specify the efficiency levels for their minimum energy performance standards (MEPS). As regulators pursue options for reducing energy consumption and emissions, ADI expects that the use of these standards will drive continued investment in more efficient motor technologies.
Motor-driven systems integrate advanced sensing, signal processing, edge AI, and connectivity solutions to create motion data and insights at the Intelligent Edge.
Key technologies to allow efficient motor operation in the industry.
34 energy efficiency
Semiconductor technology is a significant facilitator of the energy efficient transition enabling modern drives. Leaders like ABB and Analog Devices are investing in the development of energy efficient technology, solutions, and products for motion applications. There is an expectation that advances in motor design alone will not guarantee optimal energy efficiency. As a result, leaders like ABB are pursuing developments in advanced motor drives including control algorithms, optimal switching frequency, and digital modeling. This breadth of technologies is a critical requirement for life cycle management of motor-driven systems—from design, modeling, and dimensioning to powertrain optimal operation and control. Digitalization and artificial intelligence will contribute to the enablement of energy efficient motor-driven systems that are required for a more sustainable manufacturing future.
Digital transformation delivers increased manufacturing efficiency
However, the opportunity for more energy efficient motor operations is not limited to just the motors themselves. VSDs use data from voltages, currents, position, temperature,
power, and energy consumption combined with external sensors that monitor vibration and other process variables. With a converged information technology/operating technology (IT/OT) Ethernet network, the various data captured from motion applications are networked together communicating data and insights to cloud-based data storage or onpremises storage, making them more accessible and actionable thanks to powerful cloud computing and artificial intelligence (AI). This opens the possibility for more scalable optimizations of manufacturing flows, reductions in energy consumption, and lowered CO2 emissions in manufacturing. Moreover, the use of these motion insights extends equipment lifespans, improves manufacturing quality, and reduces unplanned downtime and material wastage while increasing safety in manufacturing plants.
Another critical capability is identifying deployed motors that operate too near to or slightly above their rated output, which may result in increased electricity consumption and potential lifetime issues. In a large manufacturing installation with several hundred to several thousand motors deployed, digital transformation strategies are especially cru-
cial to identifying these opportunities for reducing electricity consumption and CO2
An ecosystem solution on the path to net zero
The path to reducing emissions is complex but could create new opportunities for industrial manufacturing companies to embrace new technologies that accelerate lower carbon manufacturing. It is anticipated that increased industrial activity will nearly double the demand for motor systems by 2040. Therefore, the CO2 reduction impact and the opportunity for new higher efficiency motordriven systems are expected to increase significantly.
Key for manufacturers will be how they partner with companies within the ecosystem, as a variety of experience and connections will be important for deploying more energy efficient motor technology at scale. The scope of the challenge is significant, but collaborating with the right players in industry, technology, and government will be important to achieving energy efficiency goals in industry and our world.
65140 at www.ien.eu
Picture: iStock - 1493827672
Medium Voltage, SpeedControlled Motor Will Facilitate a Low Carbon Society
The new MV Titanium compact motor and control concept offers game-changing savings of up to 40 percent for energy-intensive sectors looking to slash emissions, like power, renewables, and mining.
Heavyweight industries like power, renewables, processing, mining, cement and many others are undergoing a pivotal shift towards low- or no-carbon operation. These sectors all come with their own decarbonization challenges, which require specific solutions for their fans, pumps, compressors, and other mission critical equipment. A common thread connecting them is their reliance on large, megawatt-scale motors. In fact, these motors account for 10 percent of the world’s total electricity demand. So, enhancing their efficiency could significantly reduce emissions and help industries decarbonize more effectively.
Energy efficiency measures, such as speed-controlled motors, have gained significant traction in low voltage applications. But very large motors have so far been left behind due to initial cost and complexity, with only 10-15 percent globally estimated to be currently connected to a drive. ABB has addressed this challenge by developing a groundbreaking con cept — the MV Titanium, the world’s first controlled medium voltage (MV) motor in the 1-5-megawatt (MW) range to incorporate a variable speed drive (VSD) in one easy-to-specify and -install package.
Saving on capital costs
The MV Titanium concept addresses the main perceived obstacles related to installing a drive with a large motor: not only the initial cost of a sepa rate drive, but also its associated electrical house (e-house), transformers, switchgear and cabling. These factors all multiply the capital cost and increase the complexity of installation, especially on existing sites where space is at a premium.
This all-in-one concept will offer energy savings of up to 40 percent for pumps, compressors, fans and other applications across multiple industries. For operators, the payback period is compelling — typically 1-3 years. Furthermore, the potential global savings in energy costs and reduced CO2 emissions are huge. If we retrofitted the entire installed base of an estimated one million motors, it would be like taking just over 1000 coal-fired power stations offline.
64956 at www.ien.eu
energy efficiency
High-Definition Oscilloscopes
For high-precision and high-speed measurement of complex waveforms.
Yokogawa Test & Measurement Corporation announces the release of its DLM3000HD series high-definition oscilloscopes supported by new IS8002CDV Classic Data Viewer (CDV) software. The compact and lightweight multichannel DLM3000HD meets market demand for high-precision, high-speed measurement of complex digital waveforms during inverter/motor development and testing. With a lineup spanning 500 MHz and 350 MHz frequency bandwidth models, the combination of proprietary low-noise detection and high resolution allows technicians to perform studies in minute detail, faster than before.
Development Background
Building on the existing DLM3000 mixedsignal oscilloscope series launched in 2018, Yokogawa applied its 100+ years of expertise and innovation in measuring instrument technology to develop the DLM3000HD. The product stems from requests made by customers for a lightweight, compact oscilloscope with higher precision and rapid start-up speed that supports the ongoing requirement for more energy-efficient and sustainable motors and inverters. Adopting the DLM3000HD to capture highly accurate voltage and current waveforms with high sample rates addresses the capabilities of electric motors and drives to ensure efficiency in transportation sector applications, for example. Another development driver is next-generation power devices deploying silicon-carbide (SiC) technology, which can switch on and off in a few nanoseconds. Oscilloscopes offering bandwidths of 350 MHz or greater are necessary to capture the fast rising and falling edges of the transient (high-intensity voltage spike during switching). Thanks to its
multi-channel measurement, wide bandwidth capabilities and vastly improved vertical axis resolution the series steps up to the challenge of performing high-precision parameter measurements, statistical analysis, and real-time mathematical functions.
Features
In comparison with the existing DLM3000, resolution some 16 times greater (12 bit) in the vertical axis captures waveform overshoot and ringing for more accurate observation of tiny changes in high-speed signals. A long 1 Gpoint memory (double the 0.5 Gpoint memory of the DLM3000) supports the development and evaluation of next-generation inverter devices by recording multiple channels simultaneously, greatly increasing work
efficiency. Engineers can make accurate observations of subtle changes in measurement target signals over a long period of time (even at high sample rates up to 2.5 GS/s), confirm signal waveforms, and detect signals causing unexpected anomalies.
Another unique feature of the DLM3000HD series is the pioneering auto set-up function for in-vehicle serial bus development and evaluation, a capability that is also possible during post data acquisition analysis. This time-saving function, which automatically configures the optimal bit rate and threshold level, accelerates the delivery of secure, reliable measurement results in the automotive industry. 65076 at www.ien.eu
