DEMM Engineering & Manufacturing February 2013

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No boundaries

How one apprentice sensed success

Energy efficiency Save power and money

Generators

Energy when you need it

Product watch What’s new this month

Electrical

Conference coming up

Maintenance matters What 2013 has in store

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The electrical and engineering calendar is already starting to take shape for the year, with the NZEI’s conference set for 8 & 9 March.

This year it is being hosted by the Auckland branch of the Institute, and I am sure it goes without saying that it will be both an interesting and worthwhile event for industry people young and old.

It also looks like health & safety at work will also come into focus this year as the Department of Labour canvasses the industry and gives a hint that changes are coming with the release of its Manufacturing Sector Action Plan.

As Craig Carlyle points out in his MESNZ column this edition, the stats around injuries and fatalities at work make for grim reading.

The bottom line is, everyone should be able to go home at the end of their shift in as fit a condition as they arrived. This is something we will be looking at in a future edition of Demm.

Also in this edition we feature Simon Holt. He completed his training as an engineer at the end of last year.

Profoundly deaf, he describes how, with the support of his employer, MiT, tutors and the usual amount of dedication, he is looking forward to not only a long career in engineering, but plans to give other people the confidence to follow his lead.

Thanks for reading, and make it a great month.

Steve Hart Editor

Contents 3 7 16 18 24 28 29 32 35 38 39 42 43

News Product watch Feature – Sensing success by Steve Hart Energy efficiency Motors and drives Air handling Pneumatics and hydraulics Maintenance matters Craig Carlyle – MESNZ Soap box Electrical technology Allan Hill - NZEI Generators

NEXT TIME In the next issue of DEMM, we’ll be covering food processing, safety at work, heat exchangers, automation & control and UPS..

The next edition of DEMM will be out 15 March Subscriptions: An 11-issue annual subscription in New Zealand is $59.00 (incl GST). Please call us for overseas rates.

COPYRIGHT: DEMM Engineering & Manufacturing Magazine has a copyright and may not be reproduced in whole or in part without the written permission of the publisher. Neither editorial opinions expressed nor facts stated in advertisements are necessarily agreed to by the editor or publisher. Whilst all efforts are made to ensure accuracy, no responsibility will be taken by the publishers for inaccurate information, or for any consequences of reliance on this information.

Editor: Steve Hart, Email: editor@demm.co.nz Advertising Frank Atkinson, Email: frank@adrenalin.co.nz Publisher: Cathy Parker, Email: cathy@adrenalin.co.nz Designer: Email: Rob@adrenalin.co.nz Subscriptions: subs@adrenalin.co.nz Proof reading: George Ward

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1

NEWS

Flat end to manufacturing year

Power to the people

The 2012 year ended flat for New Zealand’s manufacturing sector according to the latest BNZ - BusinessNZ Performance of Manufacturing Index (PMI).

The seasonally adjusted PMI for December 2012 was 50.1 (a PMI reading above 50.0 indicates that manufacturing is generally expanding; below 50.0 that it is declining). While this was 1.3 points up from November, the PMI averaged a generally flat value of 50.9 over 2012.

BusinessNZ’s executive director for manufacturing Catherine Beard said the December result was symptomatic of what manufacturers experienced in 2012.

“Five of the 12 months were in contraction, with only two months (February and May) showing any sufficient levels of expansion,” she says.

“However, despite the fairly unexciting result, comments by manufacturers remain more positive than negative, while we remain well ahead of where Australian manufacturing sits at present with all but two of their months in contraction.

“Also, the latest JPMorgan Global Manufacturing PMI for December (50.2) shows that what we are experiencing is really no different to other countries.

“This year will most likely present similar challenges for many manufacturers,

although the long awaited expectation of increased growth due to a slowly improving global economy, along with further upwards momentum in the Christchurch rebuild, should assist in driving up demand for products.”

BNZ economist Doug Steel says: “December looked a lot like 2012 as a whole for manufacturing – lots of ebb and flow.

For every indicator that looked to be doing a bit better, there seemed to be another one slipping the other way. At least productionwise, there looks to have been enough over the past three months for manufacturing to make a positive contribution to Q4 GDP growth.”

While all regions experienced a fall in unadjusted activity over December, the drop was more prominent in the North Island.

The Northern region (48.4) fell 8.2 points, while the Central region (46.3) fell 5.4 points to be both in contraction for the first time since April 2012.

In contrast, both regions in the South Island remained in expansion. The OtagoSouthland region (60.0) fell 5.0 points from November, while the Canterbury/Westland region (53.4) dropped 8.6 points.

Aggreko, the global leader in the supply of rental power and temperature control, has sent 10 generators to Samoa and Fiji to provide much needed alternative power following outages caused by Cyclone Evan which hit ground on 17 December 2012.

Destined for the main islands of both nations, six Aggreko 1250 kVA generators and one transformer will be shipped to Samoa; and four Aggreko 500kVA generators to Fiji. With many businesses and essential services without power as a result of the storms, the generators have been used to help the emergency efforts and restore local utilities.

Philip Lendich, area general manager of Aggreko New Zealand and Pacific Islands, says: “The Aggreko team in the islands worked hard to help the community while also supporting their own families.

“Our depot in Fiji was already working at capacity so we have shipped our most powerful units that are capable of supplying power to whole villages as they recover from the cyclone.”

Before being shipped the generators were serviced at the firm’s depot in Auckland.

Engineers are in demand

Floatless manhole prevents levitation

Structural engineers are among the candidates in demand in 2013 with employers starting to action their hiring needs for 2013, according to recruitment firm Hays’ first quarterly report of the year covering January to March.

The report shows that pockets of shortages for specific skills remain in some sectors, including construction and engineering, particularly due to the continuing work on the Christchurch rebuild.

“Certain sectors of the market have become dependent on international migration,” says Jason Walker, managing director of Hays in New Zealand.

“And we have seen that while employers are becoming more open to international candidates there are some serious hurdles for some sectors, such as engineering.

“However candidates already in employment are looking for better roles, highlighting there is continued confidence in the labour market, particularly for those whose skills are in demand.”

Kiwi firm Hynds has signed a partnership with Nippon Hume International in Tokyo for the introduction of a retrofitted Floatless Manhole system to New Zealand.

The system dramatically reduces earthquake damage, subsequent infrastructure repair costs, and is easily fitted to any existing concrete manhole at risk of floating during a seismic event.

Hynds will be working with councils and installers to progressively introduce this technology in to the New Zealand market.

Hynds is a privately owned New Zealand manufacturer and distributor of products for the management of water and water-based waste in the civil and rural infrastructure industry.

Established in 1973, the firm has become leaders in the supply of solutions for drainage, watermain, environmental, industrial and rural application.

TAG Oil committed to East Coast TAG Oil is to continue with the exploration programme underway in its East Coast permits following the decision by Apache to not proceed with its involvement in the permits.

Apache told TAG Oil that it won’t proceed to Phase 2 of the exploration programme.

TAG CEO Garth Johnson says: “We will continue with the work programme on the East Coast in the same careful, methodical and safe way that we have carried out our work programmes in Taranaki.

“We will also continue to work openly and constructively with local and central Government and with other key stakeholders on the East Coast.”

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February 2013

NEWS

Researchers show their metal The Waikato Centre for Advanced Materials held a symposium to showcase developments in titanium research and technology on 7 February. The event covered titanium alloy powder, metallurgy research, development and commercialisation.

Waikato University has a world-class titanium research team, and members used the event to present their research findings to fellow researchers and industry representatives from around the country.

Organiser professor Deliang Zhang says conferences such as this allows industry insiders to discuss key issues facing the industry.

He says the purpose of the symposium was to also showcase research results undertaken by titanium researchers.

Titanium has the highest strength-to-weight ratio of any metal, and is used for components and structural elements in the aerospace, medical and automotive industries and in the latest

Innovation and Technology at SouthMACH SouthMACH 2013 will bring together more than 120 machinery, equipment and manufacturing technology suppliers from all over New Zealand and Australia.

The event will feature a seminar programme that the organisers say will feature invaluable and quality information to all those involved in engineering, manufacturing and related sectors.

Registration is free and visitors will go into the draw to win one of five Macpac jackets worth $350 each. See www. southmach.co.nz

laptops and cellphones.

In 2010 the government invested nearly $8 million in the titanium industry, and opened a flagship facility for the Titanium Industry Development Association (TiDA) in Tauranga, aimed at testing new alloy materials and developing a national research and development strategy for titanium.

Waikato University professor Deliang Zhang.

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NEWS

Industrial robots multiply

RA David Hegarty appointment

There were an estimated 200,000 industrial robots produced worldwide in 2012. The majority of the manufacturing of these robots took place in Europe and Japan, where there is already a base of established industrial robot producers.

Between 2011 and 2016, the production of industrial robots in Asia Pacific (excluding Japan) is forecast to grow at a compound average growth rate (CAGR) of 9.6 percent, more than any other region in the world, with China set to contribute significantly to this growth. There are numerous influencing factors that may cause this figure to increase by a large factor.

Chinese industrial production has increased at a CAGR of approximately 14.5 percent over the past decade, and the country’s demand for automation has followed suit. In its recently announced five-year plan, it was clear the

Rockwell Automation has appointed David Hegarty as managing director Australia and New Zealand.

Following his appointment on 5 November 2012, Hegarty takes on a dual role as he will maintain his job as regional sales director.

Hegarty has been with the firm since 1999, and says that managing branches in Sydney and Brisbane has given him a broad understanding of the capabilities of the company and strong links to leadership in Australia, New Zealand and Asia.

He says a key challenge will be leading the company during a time of economic uncertainty in Europe and China.

“Many manufacturers and producers are moving their focus to productivity

country will seek to source goods from domestic suppliers rather than rely heavily on foreign imports.

The biggest news concerning the industrial robot market in China has been the announcement of Foxconn’s intention to deploy one million robots in its factories in the next two to three years, with intentions to sell onto the open market.

As the social demographic changes in China, businesses are finding it difficult to find low-cost labourers as more young people are furthering their education rather than taking vocational apprenticeships.

As more local robot manufacturers appear in China, alongside some of the more established names, it is clear that industrial robot production is set to increase more than in any other country in the world over the next decade.

Research into workplace distractions A University of Canterbury professor thinks distracting people with menial tasks while they work in high-risk environments will help them keep their mind on the job.

A University of Canterbury (UC) psychology professor is looking into improving worker performance in potentially dangerous environments by changing what they do during quiet period at work.

UC associate psychology professor Deak Helton is carrying out experiments to see if ‘guided distraction’ – a secondary task a person may do when there’s a pause in their main job – improves people’s performance in potentially dangerous high-risk environments.

Helton is a co-investigator for the Australian Research Council-funded project and is working with the lead investigator associate professor Mark Wiggins of Macquarie University in Sydney.

Helton says he and Wiggins are getting help from utility companies on both sides of the Tasman. He says the project will adopt a “novel strategy” to assist operators in highrisk automated environments, in order to maintain their performance in low workload situations so to reduce the potential for error.

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February 2013

David Hegarty, managing director Australia and New Zealand with Rockwell Automation.

in Australia and New Zealand,” he says. “As an industrial automation and information company Rockwell Automation has the opportunity to work with our customers to drive productivity in their businesses.”

New president for AMTI The Australian Manufacturing Technology Institute has named Paul Fowler (pictured) as its new president.

He will lead the institute’s continuing efforts to provide services around education and training, innovation and market access for Australia’s manufacturing businesses.

Titanium get $3 million grant A research group featuring the Titanium Industry Development Association, Industrial Research, GNS Science, University of Waikato and the University of Auckland, has been given a research grant.

The Ministry of Business, Innovation & Employment supported the group’s grant application that has a total value of $3 million a year, and is for an initial two-year period. Of this initial grant, $2.5 million is new financial investment.

The group’s projects will include research into advanced coatings and surface modification, selective laser melting, metal injection moulding, hotworking and cellular materials.

The partnership will be led by an industry advisory board, chaired by Jon Mayson. He was the chairman of NZTE, holds several directorships, and was previously the CEO for the Port of Tauranga.

NEWS

MHL show will be hotter than July The MHL Show returns to the ASB Showgrounds in Auckland on 3 and 4 July. The event runs in conjunction with The National Safety Show 13, the country’s largest dedicated workplace safety show, and will be held in pavilions one and two at the venue.

The material handling and logistics industry are showcasing the latest supply chain solutions, there will be more than 50 exhibits and a new forklift arena.

Register online for complimentary admission at www.mhlshow.co.nz

New deal for ENVCO

Scholarship for bright spark UCOL is playing its part in addressing the shortage of engineers by offering scholarships for the New Zealand diploma in electrical engineering in power specialisation.

The scholarship enhances UCOL’s Palmerston North based engineering programme and adds further incentive for students to gain qualifications in an industry desperate for job-ready graduates.

The successful scholarship applicants will be selected from full time students enrolled in year one of the diploma. The scholarship is offered in the form of free tuition fees for the first year.

Completion of the two year diploma opens up career opportunities in electrical and electronic design, industrial automation and control and power system design.

Applications for the scholarship close on 4 March 2013. For more information phone GO UCOL 0800 46 8265 or visit www.ucol.ac.nz.

Australasian company ENVCO Global – suppliers of environmental, agricultural and scientific measuring equipment – has been appointed official supplier, service and support agent for WTW Online Instrumentation, a world leading manufacturer of wastewater treatment technology.

WTW has had an international reputation for the design and production of quality water testing instrumentation world-wide for more than 55 years, and today provides some of the World’s broadest and most highly accepted product Lines for wastewater and drinking water infrastructure.

ENVCO Global Director Richard Morrow said that from 1 January 2013 the company will provide all sales and support for WTW Online Instrumentation, including servicing and maintenance services like membrane cap replacement and sensors.

WTW offers a complete line of pH/ORP, D.O., Conductivity, Nitrogen, Carbon, Phosphate and unique self-cleaning Turbidity instrumentation, as well as comprehensive accessories for the measuring and control of wastewater.

Rockwell conference is back The annual Rockwell Automation Software Technical Education (RSTechED) conference is returning to Melbourne, bringing together software technical experts, system integrators, machine builders and end -users at the St Kilda Novotel from 20-22 February.

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NEWS

Austech show stopper From 7 to 10 May 2013, Australia’s production technology providers will once again be presenting machine tools, precision tools, sheetmetal technology, automation equipment and much more at the Austech trade show.

It is Australia’s premier advanced precision manufacturing and machine tool exhibition. The last Austech exhibition in Sydney, say organisers, proved that attendees weren’t just window shopping but were looking for the products and services on offer.

More than 50 percent of visitors to the 2012 exhibition found a particular product or solution to a manufacturing problem, and 36 percent say that they have made a purchase as a result of visiting the show.

Organisers say the event attracts more than 450 exhibitors and over 10,000 visitors every year.

Coming events The Advantage NZ Petroleum Conference.

28 April – 1 May, Sky City Auckland Convention Centre. www.nzpam.govt.nz

National Manufacturing Week 2013.

7 -10 May, Melbourne Convention & Exhibition Centre. www.nationalmanufacturingweek.com.au

SouthMACH 2013 29 & 30 May at the CBS Arena in Christchurch. www.southmach.co.nz

MHL 2013 Materials Handling & Logistics 3 & 4 July ASB Showgrounds, Auckland. www.mhlshow.co.nz

New Zealand Oil & Gas Expo 2013 11 & 12 September, TSB Stadium New Plymouth. www.nzoilandgasexpo.co.nz

SKF National Maintenance Engineering Conference 2013

Company fined after employee loses arm A Manurewa recycling firm has been fined $40,000 and ordered to pay reparation of $50,000 following an incident where an employee lost his arm in a baling machine.

The Manukau District Court heard in December 2012 that on 26 November 2011 a worker at General Recycle was operating a machine that baled plastic for recycling. After noticing an item of a different grade of plastic the worker attempted to retrieve it from the baling machine but caught his sleeve – leading to his arm being crushed as the baler operated.

MBIE Labour, general manager Northern, John Howard says: “The decision of the judge regarding the level of reparation makes it clear that this was an extremely serious incident and she commented that it would not be appropriate to reduce the award because of the financial state of the business.

“All too often employees are seriously injured at work, when it is their fundamental right to go home safe at the end of their working day.”

Every year employees across New Zealand are involved in accidents because of ineffective or non-existent machine guards.

Under the Health and Safety in Employment Act 1992 all employers have a duty to identify and take all practicable steps to ensure that their employees are not exposed to hazards in the workplace.

Howard says: “Health and safety inspectors are regularly investigating incidents where employees have been seriously harmed and in some cases received lifechanging injuries because of a lack of effective machine guarding.

“All the principles of machine guarding are well known and are easily accessible on the MBIE website. In addition, inspectors can offer specific advice if required.

“MBIE is committed to ensuring dangerous machinery is either replaced or made safe, and will not hesitate to take strong enforcement action to ensure this occurs.”

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February 2013

12 & 14 November, Novatel Rotorua Lakeside. www.mesnz.org.nz/nmec/ Send details of your industry event to Editor@DEMM.co.nz

Rockwell helps inspire young engineers Rockwell Automation has extended its support of the global FIRST (For Inspiration and Recognition of Science and Technology) program to New Zealand. This, says the firm, will open up new opportunities for school students aspiring to become engineers.

Rockwell Automation sponsorship of the FIRST program within New Zealand builds on a 10-year association between the two organisations in the United States.

“We are happy to be supporting FIRST locally – the organisation addresses the need for strong preparation in science, technology, engineering and mathematics to improve our communities, create jobs and educate tomorrow’s workforce,” says Matthew Treeby, commercial marketing manager, Rockwell Automation South Pacific.

Cleaning up at awards night Austrian based MAS, represented by local agent Koga Recyclingtech, was acknowledged at the 2012 Australasian Waste & Recycling Expo by taking first runner-up in the Best Innovation section of the EXPO awards Programme.

The award recognised the advanced technology in the MAS DRD (double rotor disc) combining waterless

cleaning and thermal drying for soiled plastics in one single machine, providing efficient and costsaving ‘drying and cleaning’ in one process.

Koga Group provides technologies to New Zealand for the sorting, shredding, recovery and recycling of waste materials into reuseable resources or process engineered fuels.

0927

PRODUCT WATCH

Machine parts with accuracy Okuma Japan has released the Multus B550, the best intelligent multitasking machine for working large complex parts.

A wide working range is achieved with Y axis travel of 520mm, comparable to that of machining centres.

The bed with Okuma’s traditional diagonal rib structure strongly resists bending and twisting, and a powerful turning spindle with of 37 kW output provides ample cutting power.

The milling spindle has the same 37kw output making this a versatile multi tasking solution. Large roller guides are used on the X, Y, and Z axes, and high accuracy machining of large parts is achieved with smooth movement and accurate positioning.

Use of the thermo-friendly concept minimizes thermal deformation of work pieces ensuring stable dimensional accuracies.

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For standard Variable Speed drive solutions, SEW-Eurodrive offers Movimot®, the ingeniously simple idea of combining a Geared Motor with an integrated frequency inverter.

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can be combined with all SEW motors & Gearmotors operates from any standard 3 phase power supply integrated motor control, protection and monitoring functions including motor brake if fitted

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INDUSTRIAL DRIVE TECHNOLOGY

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PRODUCT WATCH

Walk, talk and listen

Balancing act The most common cause of vibration in rotating equipment is imbalance.

Unbalanced components cause increased load on bearings and that inevitably leads to mechanical stress – resulting in costly mechanical problems. It can also contribute to increased energy consumption and reduced production time.

It is typically the displacement of the mass centreline from the rotors axis by an eccentricity in the distribution of the rotor mass that can cause components to become unbalanced.

Identifying the problem is easy. The faulty component can installed in a dynamic

balancing machine and by measuring the ‘heavy’ point in relation to the centreline, while the component is rotating, the required balance correction can be identified.

Vibration & Balancing Industrial services all industries – including manufacturing, production and maintenance. While most or its dynamic balancing is done at the firm’s Penrose facility, it also has the capability to provide onsite dynamic balancing for impellors, fans, and rotors etc that are difficult to remove from their operating positions.

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TSI 7575 indoor air quality meter Providing a comfortable, safe and healthy indoor working environment is an important concern, as part of an effective OH&S strategy.

Good indoor air quality increases concentration and productivity, which can also flow on to reduced absenteeism.

The latest TSI 7575 portable indoor air quality meter/logger simultaneously measures temperature, humidity, CO, CO2 and barometric pressure, and from that calculates dew point, wet bulb and percentage outside air.

The operating temperature range is 0 to 60°C with a ±0.5°C accuracy and relative humidity five to 95 percent, accuracy ±3 per cent. With a five line display information can be viewed instantly or it has logging capability to save up to 56,000 data points.

The user sets logging intervals from one second to one hour.

Software is supplied for downloading and reporting the data. It is both AC and battery powered.

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February 2013

D130208a

3M’s Peltor Lite-Com III system delivers high noise attenuation and with a radio built into the shell, it also provides effective and effortless short-range two-way communication.

A built-in active sound function lets you hear ambient sound, warning signals, machine sounds, conversation, etc. Weak sounds can be amplified, so you hear them better than you would without wearing hearing protectors.

Sudden impulse noises at harmful levels are immediately attenuated.

The right shell has a control panel with a large LCD display that shows your current settings.

An electronic voice tells you what settings you are adjusting, so you do not have to take off the headset to check.

An auxiliary input lets you connect a cellular phone or external com radio, regardless

of the frequency.

You can also connect a CD player or FM radio and listen to news and music. It operates on 69 channels in 433MHz band ensuring targeted communication for groups.

The Lite-Com III provides Class 4 protection and is available as a headband, neckband or helmet attachment.

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Smart transmitter improves efficiency Honeywell has launched a new range of SmartLine industrial pressure transmitters that it says will enhance communication abilities, improve operational efficiency and reduce lifecycle costs for process manufacturers.

In industrial process plants, field devices that measure pressure, f low and level are used throughout the manufacturing process to support safe and efficient production. Large industrial complexes can have thousands of these devices to support their manufacturing processes.

Honeywell SmartLine pressure transmitters make it easier to support field devices and promote plant reliability with their unique efficiency-enhancing features, such as a graphic display capable of showing process data in graphical formats and communicating messages from the control room.

SmartLine transmitters also feature modular components to simplify field repairs and reduce inventory required to make those repairs.

It communicates to all automation systems through open communication protocol modules and is integrated with Experion PKS and legacy DCS customers.

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D130208c

PRODUCT WATCH

Cushion those hard impacts Minimise maintenance cost, prevent downtime and stop accidents with Sentry Protection products from Ulti Group.

These impact-absorbing products – for columns, walls, pallet racking and corners – are made from semi-f lexible and stress-crack resistant plastics that cushion an impact before bouncing back into shape. Sentry Protection products have strategically placed pockets that are angled to def lect impact energy away.

Lavetia Flesher from DB Breweries says: “Our current experience with the Sentry Pro is excellent, I actually backed into one accidentally and found it was tough enough to bounce off and highlight that I was too close without damaging the rack.

“Visually it is bold and kind of makes a statement within our warehouse and it makes everyone aware of their purpose and further reduces the risk of people whom may otherwise be careless.

“I’m positive we have made a wise investment and will recommend them to others.”

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PRODUCT WATCH

Hammond “T” soft side enclosure Hammond Manufacturing’s new 1553T range of T cases is designed for use in a wide variety of hand-held instrumentation, data capture and controller application across all industries.

Initially available in two sizes, 165 x 80 x 28mm and 210 x 100 x 32mm, the enclosures feature recessed areas for keypads and displays and are available with our without a battery compartment.

Versions without a battery box have two removable end panels; the battery versions have a single panel at the top of the unit.

The battery box in the larger unit accepts 4 x AA or 2 x 9V cuboid batteries, 2 x AA or 1 x 9V in the smaller; connectors for both types are supplied.

The removable plastic end panels are easily machined to provide cut-outs to suit LEDs, connectors and switches as required.

Moulded in flame-retardant ABS, the units have a smooth curved shape that

fits comfortably into the hand. They are produced in light grey or black, both with over-moulded contrasting soft side grips as standard.

Both top and base are provided with PCB mounting standoffs and the two shells are assembled together with screws into brass inserts, allowing repeated access to the interior without degrading the closure.

• Go to www.demm.co.nz/enquiry quote: D130210a

Get the right deck

Keep it green Super Green Precision cleaner is a blend of grease-and ink-cutting, waterbased ingredients that is designed specifically for water based parts washing systems and industrial degreasing.

It reduces the concerns regarding combustibility, toxic odours, worker safety, atmospheric and environmental pollution and disposal.

The product contains corrosion inhibitors for aluminium and the degreasing ability of this product is enhanced by heating the working solution.

With more utility vehicles going onto New Zealand roads than ever before, the challenge is to select the deck that is best suited to your requirements.

“The preference by many Ute owners has been for traditional steel decks because they are perceived to be very strong,” says John Frear, GM – sales & marketing at Best Bars.

“But most people overlook the fact that an alloy deck is also designed and built strong enough to withstand the tough everyday usage it is likely to be subjected to around construction and other work sites. And due to their light weight they can carry heavier loads.”

Best Bars has designed a range of alloy decks that suit most one-tonne Ute models and variants from leading manufacturers. The alloy decks from Best Bars are tough and thanks to their durable, anodised finish, they won’t corrode, so will keep their looks for much longer. But the main advantage is their ability to haul extra loads.

• Go to www.demm.co.nz/enquiry quote: quote: • Go to www.demm.co.nz/enquiry D130210

Hammond Enclosures • ABS / Polycarbonate / Polystyrene • Diecast & Extruded Aluminium • Large stock range • Competitive prices

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February 2013

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Available from Hi-Q Electronics Limited

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www.hiq.co.nz

PRODUCT WATCH

Frozen raspberries without liquid nitrogen GEA Refrigeration Canada, formerly GEA Aerofreeze Systems, has introduced a new A series (Aerofreeze) IQF tunnel for freezing raspberries without the need for liquid nitrogen or cryogenic pre-crusting.

Raspberry processors have long faced challenges in maintaining the delicate attributes of the berry during the preservation process. Liquid nitrogen crusting freezers have been used in front of the traditional IQF raspberry freezer as the only viable method of conditioning the berries before deep freezing.

However, due to the high costs associated with the use of liquid nitrogen, fruit processors have been seeking out a less expensive solution.

“There is no other freezer currently available that can handle this type of product and deliver the required product quality. We’ve been working over the past several years to develop a freezer that meets the unique needs of this market,” says Robert Laflamme, president, GEA Refrigeration Canada.

• Go to www.demm.co.nz/enquiry quote: D130211

The heat is on From April new fire requirements come in force for interior surface linings and HVAC ducting – a group number system will be introduced to replace the SF1/SD1 system.

By installing NovaHush Panel Absorber in your building, you will have a product that meets the highest fire specification level for an interior surface lining.

The panel underwent the ISO 9705 fire test and achieved the highest fire performance rating, with a group 1S result. The amount of heat the absorber produced in the test was only 40 percent of the maximum permitted for Group 1. This means that it can be used in any interior surface lining application.

The absorber is polyester acoustic insulation made using fibres from recycled plastic bottles; it can be applied anywhere where the focus is to reduce noise.

•

Go to www.demm.co.nz/enquiry quote: D130211a

11

PRODUCT WATCH

Munching through waste NOV Mono, a designer and manufacturer of pumps, parts, grinders, screens and packaged systems, has a new addition to the TR Muncher range.

It is designed to meet on-site tanker discharge requirements and sludge/fat processing by protecting downstream equipment from blockages, while allowing quick and easy inspection and maintenance.

Shazad Ibnul, general manager, Mono Pumps (New Zealand), says downstream process requirements have changed due to the increasing installation of finer inlet screens, resulting in reduced particles and solids loading within the sludge treatment process.

“The TR Muncher specifically meets these changing requirements,” he says.

Installation of the TR Muncher is simple, with in-line f langes or the option of tanker coupling connections.

Quick release inspection covers allow in-situ replacement of the cutters

and these can be specified to 8mm, 5.5mm and 3mm thickness to match the optimum particle size for specific process requirements.

• Go to www.demm.co.nz/enquiry quote:

D130212

Passive junction box for better integration Turck has released a six-port M12 passive junction box, designed to integrate multiple devices into a single unit. Featuring a compact, low-profile design, the six-port model allows simple installation in diverse factory

LOOKING FOR NEW BUSINESS AND SALES ENQUIRIES? Contact Frank Atkinson Email / frank@adrenalin.co.nz DDI / (09) 477 0362

automation applications, ranging from packaging and automotive to material handling and mobile equipment.

With one or two discrete signals per port, the junction box is capable of providing up to 12 discrete signals— ensuring reliable connectivity for multiple devices. The junction box consolidates several discrete devices in an area to one device, which is then connected to a controller via a single cable. This eliminates each device requiring its own individual cable, delivering a more cost-effective, streamlined connectivity solution.

The model provides 2A of current per signal and up to 9A total current per junction box. For durable performance, the M12 passive junction box features IP67-rated ingress protection and reliably operates in temperatures ranging from -40°C to +85°C degrees.

“Offering f lexible integration capabilities, the M12 offers dependable connectivity performance in virtually any industrial or factory automation application,” says Jeff Schoenberg, Connectivity Product Manager, Turck.

• Go to www.demm.co.nz/enquiry quote:

D130212a

12

February 2013

Go anywhere flowmeter Krohne’s IFC 050 signal converter for electromagnetic f lowmeters, developed for the growing water markets worldwide, are designed to fit in any basic water or wastewater application.

The IFC 050 can be combined with Krohne’s Optif lux and Waterf lux series of electromagnetic f low sensors and can be used for raw water, potable water, wastewater and seawater.

In addition, its features match metering or leak detection in water distribution networks, agriculture or utility applications such as sprinkler/ irrigation, cooling or fire-fighting systems.

To suit the requirements of these applications, IFC 050 outputs reach from 4 to 20 mA HART, an active pulse output for driving e.g. an electromechanical counter up to an RS485 Modbus output for communication with microcontrollers and PLCs. As an option, the signal converter can be equipped with all three outputs.

Its electronics have an extra coating against condensed moisture for use in tropical areas. As an alternative to the display version, the blind version is the option for applications where the menu needs to be approached only once a time and a permanent display is not required.

• Go to www.demm.co.nz/enquiry quote: D130212b

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PRODUCT WATCH

Winding up cable makers The superconductor industry, in which New Zealand is an R&D leader, has the potential to deliver enormous energy and cost efficiencies to the conduction of electricity.

Integral to the superconductor revolution is Roebel cable, serving an emerging global cable market that is forecast to be worth hundreds of millions of dollars a year.

General Cable Superconductors, the only company worldwide that manufactures Roebel cable on a commercial scale, is benefiting from a new manufacturing unit that was designed and produced

by Lachlan Clelland, a Wellington Institute of Technology Bachelor of Engineering Technology graduate.

His Continuous Flexible

Lachlan Clelland.

Winding machine is already improving productivity according to General Cable Superconductors CEO Andrew Priest.

“We’re very impressed this idea has come from such a young engineer,” says Priest.

“The Continuous Flexible

Winding machine designed and produced by Lachlan is a world first. It has made the manufacture of cable more efficient and the process is less complex as a result.

“Lachlan has demonstrated an extremely high standard of multidisciplinary engineering.

Because of this, and the innovation and inspiration evident in this product, we have decided to recognise Lachlan with an award at the Wellington Institute of Technology.”

•

Go to www.demm.co.nz/ enquiry quote: D130214

Pop technology for Mac Valve

Exhibit at one of New Zealand’s largest engineering machinery and technology events!

Over 120 top industry suppliers will showcase their latest and most innovative products and services to the well respected engineering and manufacturing sectors, and you need to be there.

Book your site now!

Phone Trevor 09 484 1307 or visit

www.southmach.co.nz for more information and to see the latest exhibitor list.

29th – 30th May 2013 CBS Canterbury Arena Addington, Christchurch

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February 2013

While a spool design is typically used in piloted valves, the 26 Series from Mac Valves uses a poppet in the main body. This technology is known as a Pilot Operated Poppet (POP) design.

A standard spool type design has four seals (bore and end seals), while a POP design only has two (end seals), providing reduced friction in the main body.

This reduced friction results in greater repeatability over the life of the valve. Another characteristic of a traditional spool-type valve design is a longer stroke.

This is due to the spool having to travel out of the bore before air can f low.

A POP valve needs only to move off a seat for f low to be achieved, lending itself to additional speed when compared to a spool design.

Lastly, the 26 Series takes advantage of Mac Valves’ patented conical seat design.

These seats reduce wear in the main body, thereby increasing the life of the valve.

•

Go to www.demm.co.nz/ enquiry quote: D130214a

PRODUCT WATCH

Self-lubricating seal Rulon 641 is a combination of f luoropolymer and reinforcing materials that offer compliant bearing and seal material.

Developed to meet the demands of the food and pharmaceutical industry, it meets the requirements of FDA, USP Class VI, USDA and 3A. Rulon 641 is rated for 10-20,000 PV depending on operating conditions, speeds up to 500 FPM and loads up to 1000lbs, and temperatures from -240 to +288°C.

It is non-abrasive to soft hardware such as aluminium or stainless, white in colour for sanitary appearance and is not affected by clean down solutions or steam. The product has a low friction rating and is easy to install and remove.

Primarily used in dry conditions, it can work in wetted applications and in vacuum. Rulon 641 is self-lubricating so requires no lube and is virtually maintenance-free.

• Go to www.demm.co.nz/enquiry quote: D130215

Voltage sensitive relays for dual battery set-ups Narva’s 12V and 24V voltage sensitive relays are for people who have a dual battery set-up in their vehicles.

The relays are designed to sense the input voltage generated and automatically connect/disconnect the appliance at preset voltages, eliminating the possibility of discharging the primary

starting battery.

Constructed with a weatherproof body to the international IP65 rating and incorporating durable silver tipped contacts, the VSR units also feature surge protection, plus an LED indicator designed to alert the user when the relay is engaged.

Narva’s VSRs are ideal for dual battery set-ups as they enable two batteries to be charged at the same time, isolating the batteries once the vehicle is turned off, ensuring the starting battery is always charged and ready to go.

•

Go to www.demm.co.nz/ enquiry quote: D130215a

Now hear this The 3M Noise Indicator alerts users to potentially dangerous noise levels, helping identify areas where hearing protection may need to be worn.

Users simply clip the Noise Indicator to a shirt or jacket; its LED delivers a clear indication when noise levels exceed a potentially hazardous threshold.

A red flashing LED indicates noise levels are equal to or above 85 dBA –hearing protection may be required. Green flashing LED indicates noise levels are below 85dBA–hearing protection may not be necessary.

The 3M Noise Indicator’s small size and lightweight design make it ideal for workers in a variety of industries. With a rechargeable battery that operates for up to 200 hours

between charges, it’s an economical investment for use in an employee hearing awareness programme.

The NI-100 can be used as an effective training tool within a noise management programme and to help ensure workers know when and where to wear hearing protection.

Occupational hygienists and/or safety officers can also use it as a mapping tool to determine where noise studies are necessary.

•

Go to www.demm.co.nz/ enquiry quote: D130215b

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www.mhlshow.co.nz 15

FEATURE

Simon Holt at operates a milling machine at a workshop at the Manukau Institute of Technology. Photo supplied.

Touch sensitive student wants to help others Steve Hart reports on how a young apprentice has completed a four-year course in engineering despite being completely deaf.

Simon Holt looked like any other student as he operated a milling machine in a training workshop at the Manuka Institute of Technology late last year.

And while some of us might say he has achieved great things in completing his engineering training, he would prefer nothing much be made of his accomplishments.

Born profoundly deaf, he was first fitted with a hearing aid when he was 14 months old. But they caused more problems than they were worth, sending loud sounds into his brain.

“As I got older I stopped wearing them because they did not help me much, and I did not like the loud noises they made, especially at work – it hurt my head,” he says.

Simon has twin sisters who are also deaf, but has a brother who can hear.

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February 2013

At home his family mainly use signing to communicate – an official second language in New Zealand.

He has been a student at MIT for four

“It is not just sound that tells you something is wrong.

I can feel that it is different.”

Simon Holt, Calmac Engineering. years, attending night school and block release courses to complete his studies as part of an apprenticeship with Calmac Engineering in Auckland.

“I completed some courses at MiT evening classes and then Calmac offered me an apprenticeship through Competenz

which has worked okay for me,” he says.

“Competenz signed me off, so all I have to do is check I have the right number of credits for my course to be completely finished.”

At the time of writing, Simon was waiting to find out if he had gained a Level 3 Certificate in Maintenance Engineering and a Level 4 Certificate in General Engineering. But he is quietly confident there will be no surprises when the envelope arrives.

While other students in his year could listen to what tutors were explaining, Simon needed the help of a ‘signer’ – someone to translate what was being said into sign language for him.

“MiT has been fully supportive of me and I have always been provided with interpreters and note takers for all my evening and block courses,” says Simon.

“I think I do okay – open and accepting tutors make things better too.

“I lip read as well. I also think I focus on

FEATURE

the job because I can concentrate more, noises do not distract me.

“Overall there have been no real big challenges during my studies – I love the work. But sometimes not having access to an interpreter when required [can cause problems]. But not often, as I have great support at work and from others around me.”

Simon got the idea of becoming an engineer while doing work experience at the Kelston Deaf Education Centre – a residential school that provides services for deaf and hearing impaired children in Auckland, Northland, Waikato and the Bay of Plenty.

“I tried some different jobs, doing woodworking and working at a tyre shop,” he says. “Then I went to Calmac Engineering and really liked it there.

“They were happy to give me some holiday work and I just kept going back until a job came up. An apprenticeship was recommended by the firm after a year or so, and I decided it was a good thing to do. People knew I could do this job, and now I have the qualification to prove it.”

A lot of engineers will say there’s nothing like listening to a machine to know it is working and operating correctly. But Simon overcomes that with his sense of touch.

“Yes, sound does tell you these things but the machine also vibrates when things are not right,” he says. “I can feel the vibrations and know the machine needs to be looked at or checked.

“It is not just sound that tells you something is wrong. I can feel that it is different.”

Personal safety in a workshop is something Simon is well aware of, perhaps more than most – given a warning sound, or a yell from a work mate, will not attract his attention.

“I have health and safety inductions with all personnel at the place I go to work – with a sign language interpreter,” he says. “There is no difference for me being deaf, the rules are the same.

“People are told and can see I need the information differently. But once I am in the workplace people see there are no differences, I work safely and I am always careful and aware of what is around me.”

Simon plans to stay in engineering, but has ambitions to move into leadership, perhaps to mentor or train other young deaf people who want a career in the trade.

“I want to help them know that they can do this work too,” he says.

Simon Holt tried woodworking before settling on a career in engineering with Calmac Engineering in Avondale. Photo supplied.

How to engineer your career Ruth Tautari is one of 14 students in the final weeks of the inaugural three year Bachelor of Engineering Technology at the Wellington Institute of Technology. She is also a Lieutenant in the New Zealand Army based at Trentham, where she works giving support to the workshop that maintains the army’s vehicles.

“Most young girls don’t think about engineering as an option in terms of a career,” she says. “I’m here to show them it’s not only an option, but a great choice for women where you can get a degree and get a fantastic job, and yes, I am talking about engineering.”

Tautari decided to study engineering, majoring in mechanical, to enable her to provide more technical support in her role.

She admits to only having a patchy knowledge of physics and maths before formally studying engineering.

For her third year engineering project she designed a “suspend towing apparatus” for a Pinzgauer – a six wheeled medium all-terrain military vehicle.

WelTec has been awarded additional funding to meet the government’s call for more engineers

with 60 more places available on level 5 and 6 engineering programmes.

It is one of only two Institutes of Technology and Polytechnics nationally that offers all three majors (civil, mechanical and electrical) in the New Zealand Diploma of Engineering and Bachelor of Engineering Technology.

17

energy efficiency

Achieve energy efficiencies with advanced composites Composite materials have played a key role in reducing the weight of new aircraft so they are more energy efficient. The same philosophy has been applied to yachts and powerboats since the 1940s.

Composites are more durable than many other materials, have high mechanical properties, and can be tailored to an exact performance need.

This has made them the material of choice in an increasing number of applications.

Once the domain of ‘high end’ sectors (aerospace, marine, racing cars), composites are now used in agricultural machinery, medical equipment and sporting goods, as well as in the general manufacturing sector – for parts such as pipes and ducting, sewerage tanks, robotic arms, trailer beds and maintenance platforms.

This wider adoption is largely due to costs being driven down through improved processes and a better understanding of how to use the materials, thereby reducing the price gap between composite and metal construction, and making the composite route more viable.

Parts manufacturers around the world are now using advanced composites to broaden the design opportunities and improve the performance of components, as well as help their customers achieve production and cost efficiencies – and therefore ‘energy efficiencies’.

In its most basic form, a composite material is one that is composed of at least two elements working together to produce material properties that are different to the properties of those elements on their own.

This can cover a broad spectrum of materials, but is generally regarded as fibre reinforced plastics. This typically involves using fibres, (glass, carbon, aramid or a combination), together with a thermoset resin (epoxy, vinylester or polyester, or a combination), to form a tough, thin “skin”.

Structural core materials (foams, balsa, plastic/fabric and metallic honeycomb, felts and non-woven fibres) are often used to increase the stiffness of the panel by separating the skins, creating a light, strong, robust panel with excellent toughness and inherent insulation.

Using these materials it is possible to obtain just about any combination of properties you want – strength, stiffness, weight, insulation, corrosion resistance, thermal conductivity…

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February 2013

Compared to traditional materials such as concrete and steel, composite construction is relatively low weight for any given strength. This can offer reduced self-weight and reduced added structural weight to the existing structure, meaning easier handling and easier transportation.

Alternatively the stiffness to weight ratio allows larger components to be built. For example, a composite crop spraying arm can cover a larger distance more quickly than a traditional metal arm.

According to the World Corrosion Organisation, the annual cost of metallic corrosion could reach USD$2.2 trillion.

Advanced composites do not rust or corrode, and properly designed parts have a long service life, and minimum maintenance requirements compared with most other materials.

There are case studies of composite ductwork being in service in chemical manufacturing plants for more than 25 years. Composites are also creep and fatigue resistant – one reason why wind turbine blades are manufactured out of composites.

“There are further benefits to using composites,” says Sian Stimson of Gurit.

“Such as geometric versatility, insulation properties and reduced electronic interference. What is important to the end user will vary depending on the application.

“The culmination of these benefits, however, is a construction route that offers cost effectiveness and energy efficiencies over the life cycle of the project, and provides a solution that is often not practical or achievable in other materials.”

• Go to www.demm.co.nz/enquiry quote: D130218

energy efficiency

ANZCO launches energy management programme One of New Zealand’s largest exporters is set to save more than $2 million a year and enhance its global reputation as a sustainable producer through a companywide energy management programme.

EECA Business is supporting the initiative over two years to help the firm generate long-term energy savings in its New Zealand plants.

With annual sales of $1.25 billion, ANZCO Foods processes and markets New Zealand beef and lamb products around the world.

The firm employs more than 3000 staff worldwide and has 11 meat processing plants in New Zealand.

This programme will target a reduction in its processing plant energy use by 25 GWh, returning ongoing annual savings of $2.45 million after two years.

EECA Business general manager Ian Niven says that making better use of its energy will provide far-reaching benefits for the company and congratulated the company on its vision.

“Globally New Zealand is recognised for sustainably produced, premium quality meat products. And energy efficiency

is one of the best ways to strengthen environmental credentials,” he says.

“By taking a lead in energy efficiency, ANZCO is making significant energy cost savings and signalling to its customers that it is committed to sustainable production.”

ANZCO managing director Mark Clarkson says the programme will deliver on many levels for the company.

He says: “Sustainability is key to the ANZCO brand and we are always looking for new ways to build on our reputation for environmentally responsible production, so reducing energy costs is a priority.”

The programme involves the establishment of a group-wide energy management plan, led by a team responsible for putting in place up to $5 million of identified energy efficiency projects.

With the assistance of one of EECA Business’ industrial programme partners, ANZCO will set up a system to help keep the programme on-track, measure efficiency outcomes, and develop case studies for a number of the projects.

Ian Niven says management commitment

Fuel cells about to get cheaper A new material for coating fuel cell bipolar plates, Ceramic MaxPhase from Swedish company Impact Coatings, is set to change the economics for fuel cells by significantly reducing manufacturing costs.

The cost for bipolar plates is currently one of the main obstacles to widespread commercialisation of fuel cell technology.

Ceramic MaxPhase provides an alternative to coating the metal bipolar plates with gold, the current method used to prevent corrosion of the plates.

“Cost-effective production of bipolar plates is one of the main elements needed for making fuel cells viable in the volume market,” says Henrik Ljungcrantz, CEO at Impact Coatings.

“Using a material that is far less costly than gold, but has similar physical properties, will help reduce the cost for fuel cell bipolar plates. We can today meet a coating cost of $5 per kW and expect to reach below the US Department of Energy 2017 target of $1 per kW, significantly ahead of time.”

Bipolar plates are used as anodes and cathodes in fuel cells, connecting several cells into a stack for the desired voltage. Because of the highly aggressive

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February 2013

environment inside the fuel cell, the plates are prone to corrosion.

Graphite, which is a corrosion-resistant material, has been used, but produces bipolar plates that are bulky and heavy.

Graphite plates are also difficult to manufacture at low cost and in high volume.

They are now being replaced by stainless steel bipolar plates, with a thin protective coating to prevent corrosion.

Ceramic MaxPhase is a corrosionresistant, electrically conductive ceramic coating that is applied by physical vapour deposition The material has been qualified for use in proton exchange membrane fuel cells (PEMFC) as well as direct-methanol fuel cells (DMFC) in tests exceeding 2500 hours.

The bipolar plates of stainless steel coated with Ceramic MaxPhase showed equivalent stack performance to gold plated bipolar plates during the tests.

The process and the material are now commercially available. A range of deposition systems for volume production is manufactured by Impact Coatings and a coating service is carried out at the company’s premises in Sweden.

is key to the programme achieving its objectives.

He says: “From the Board of Directors through to site operations, ANZCO leadership has indicated it wants to foster a culture of efficient energy use throughout the company.

“Such commitment is important to the success of making enduring improvements to energy management.”

EECA Business funding of up to $450,000 will be made available in stages upon achievement of various programme milestones.

• Go to www.demm.co.nz/enquiry quote: D130220

Make your power bills lighter LED is the most energy efficient choice you can make when it comes to lighting.

LEDs differ vastly from other forms of lighting. Traditional fluorescent and incandescent light bulbs are made of glass, operate at high temperatures, are inefficient and can flicker.

By comparison, LEDs are energy efficient and operate at much lower temperatures – meaning that little energy is wasted on heating the bulb as it creates light.

Immediate savings are made as the amount of light offered per watt is a lot higher than other lighting sources, while further savings can be made through the low running costs of LED lighting.

LEDs are small capsules or lenses that contain tiny chips. When they are placed on heat-conducting material, light is created.

Their long life means that less time is wasted changing bulbs, which for a business, can be a significant maintenance cost.

LEDs do not contain mercury or UV, are fully recyclable and turn on instantly.

Ecopoint’s range of LED lights give quality lighting with the added benefit of reducing the amount of power used for lighting by up to 70 per cent.

Its DALI dimmable tube, a replacement for a traditional fluorescent tube, features intelligent technology that automatically dims the light, offering even more savings.

• Go to www.demm.co.nz/enquiry quote: D130220a

energy efficiency

Industrial training courses from EECA

A good clean sound Energy Plant Solutions has supplied a number of acoustic cleaners for solid fuel boiler applications in New Zealand with extremely good results and very short payback times due to increased efficiency and reduced downtime.

Acoustic cleaners, otherwise known as sonic horns, operate by generating rapid sound pressure fluctuations. These pressure fluctuations are transmitted into dry particulate matter causing the solid particles to resonate and dislodge from the surface on which they are deposited.

Once dislodged, the materials fall, either due to gravity or they are carried away by the air stream within the process.

The powerful sound waves are produced when the short bursts of compressed air enters the unit’s wave generator and force the only moving part, a titanium diaphragm, to flex, creating the powerful “base” sound wave.

This “base” tone is then transmitted by a range of different bell sections into selected frequencies between 60 - 420Hz. Applications for the acoustic cleaners include boilers, superheaters, economisers, air heaters, duct work, electrostatic precipitators, filters, spray dryers, silos, hoppers, dry material bulk vehicles, and others.

• Go to www.demm.co.nz/enquiry quote: D130221

EECA Business works closely with the University of Waikato and EMANZ to develop and promote courses relating to efficiency in motor systems. Courses are designed for all businesses, auditors and service providers.

Webinars are a quick, easy and free way to keep up to date with the latest technologies.

These showcase studies and demonstrate how you can get started or improve your existing system. You can pick the topic you are interested, register and dial in from wherever you are. Each webinar is one hour long and is presented by Dr Martin Atkins, Dr Michael Walmsley and Dr James Neale from The University of Waikato.

A series of one-day workshops are being held to provide practical instruction to factory-based management and technical staff. All workshops are based on best practice energy efficiency opportunities for pump, fan and compressed air systems.

Attendees will leave with an ability to

identify system efficiency opportunities and to work confidently with skilled service providers to realise the efficiency opportunities available from the particular technology covered.

Webinar series includes: • 27 February: Process heat. Heat exchanger network design II – network modification • 13 March: Fan systems. Fan system control – do I need a tune up?

• 27 March: Steam systems. Water hammer – what it is and how to avoid it.

• 10 April: Compressed air. What is in my compressed air? The impact of the ambient environment.

• 2 April: Pumping systems. Pump system curves and the moody plot.

Best practice one-day workshops • 28 June - Fan Systems • 23 August - Compressed Air Systems • 30 August - Pumping Systems

• Go to www.demm.co.nz/enquiry quote: D130221a

Dim idea for LEDs Ecopoint’s latest LED lighting offering, the H-series tube, features DALI Dimmable technology and takes the significant power savings already associated with LED lighting to a whole new level.

DALI technology is one of the most advanced forms of energy efficient lighting technology available today. DALI technology is intelligent and has the ability to automatically control and dim each light when it senses there is enough natural, ambient light coming from an alternative source, such as a nearby window.

DALI stands for Digital Addressable Lighting Interface, and is fast becoming the standard for controllable lighting systems.

Ecopoint’s H-series DALI dimmable tubes feature intelligent brightness tracing and

breakdown feedback.

Ecopoint’s H-Series tube range is a direct replacement for the traditionally used but power hungry T8 fluorescent tube. Ecopoint’s tubes are simple to retrofit and once installed, offer energy savings of up to 70 percent. As well as lower energy costs, other benefits include its long life (50,000 hours plus), which will generate cost savings through reduced maintenance.

These lights have a wide range of uses; they are appropriate for office, retail, education, commercial and industrial settings; for new builds or upgrades of existing DALI installations.

• Go to www.demm.co.nz/enquiry quote: D130221b

Energy efficient sealed bearings SKF has launched its Sealed Energy Efficient deep groove ball bearing, the E2 DGBB, for applications in industries such as electric motors and twowheelers to industrial conveyors and water pumps.

“The deep groove ball bearing is a good example of a sustainable solution that saves energy in many different applications,” says Luigi Cavallero, Business Development Manager, Business

Unit Powertrain & Electrical and Two Wheeler, SKF. “Our products are suitable to meet the needs of the many energy saving programmes planned and implemented worldwide.”

The sealed E2 DGBB reduces friction by more than 30 percent compared to the SKF Explorer sealed DGBB. As a result the product significantly saves energy and reduces CO2. The new feature,

compared to the previously launched E2 performance class of bearings, is the addition of a seal that provides minimal interference between the inner ring and seal lip without compromising the performance of the sealing ability.

The SKF Sealed Energy Efficient deep groove ball bearing is available in sizes up to 52 mm outer diameter.

• Go to www.demm.co.nz/enquiry quote: D130221c

21

WHEN IT COMES TO MOTORS FORESIGHT IS MORE VALUABLE THAN HINDSIGHT

PLANNING FOR REPLACEMENT AND REPAIR SAVES YOU MONEY AND STRESS In manufacturing, motor failure is something to avoid.

But if it happens, you want to make the right decision on whether to replace or repair. What’s more, some motors could be using a lot in electricity because they haven’t been replaced soon enough.

Having a motor replacement and repair policy for your business ensures you’ll make the best decision, even when you’re under production pressure.

Take Tasman Insulation, for example. With 890 kW of motors at its Penrose plant, the company developed a motor replacement policy. Technical staff have clear guidelines so they can make the decision to replace quickly and easily. The firm is already making ongoing savings of $8,800 a year, which will soon increase

www.eecabusiness.govt.nz

EEC2659A_DEMM

to $10,000 after the next round of motor upgrades.

If the decision is to repair, Tasman uses quality-certified rewinders to ensure the best result.

Tasman Plant Manager Earl Ellis says: “Our motor policy sets out exactly when the optimum time to replace each motor is. It couldn’t be more straightforward to follow. We’ve already achieved excellent savings, and improved plant reliability.”

EECA BUSINESSTM endorses quality-certified motor rewinders. We also have programme partners who can help develop a motor replacement policy for your business and access any funding that may be available to you.

energy efficiency

PLAN AHEAD FOR MOTOR EFFICIENCY, MAKE USE OF OUR PROGRAMME PARTNERS FOR MOTOR REPLACEMENT POLICY HELP Demand Response Ltd - Wellington Contact: Gerald Crawford, 04 472 6061 Enercon Ltd - Christchurch Contact: Kees Brinkman, 03 384 7905 Energy NZ Ltd - Auckland Contact: Andy Logue, 09 909 0941

QUALITY CERTIFIED MOTOR REWINDERS CMG Electric Motors NZ Ltd - Auckland Contact: Ross McKandry, 09 820 3550 Electric Motor Solutions Ltd - Auckland Contact: Rich Noller, 09 274 7233 Gouk & Sullivan (1971) Ltd - Auckland Contact: Graham Gibbons, 09 573 1465 ABB Ltd - Waikato Contact: Clayton Eade, 07 849 3002 Greene Bros Ltd - Waikato 21 Bristol Place, Te Rapa, Hamilton Contact: Paddy Greene, 07 850 4109 CMG Electric Motors NZ Ltd - Bay of Plenty Contact: Mark Yeoward, 07 347 8624 Gouk & Sullivan Ltd - Bay of Plenty Contact: Steve Milbank, 07 323 7733 Hawera Rewinds Ltd - Taranaki Contact: Geoff Furborough, 06 278 4578 New Plymouth Rewinds Ltd - Taranaki Contact: Richard Lister, 06 758 2163 Elektron Motor Rewinders Ltd - Wellington Contact: Peter Alevizos, 04 237 8767 ABB Ltd - Christchurch Contact: Peter Wortley, 03 338 3787 Wallace Murray Electrical Ltd - Invercargill Contact: Hugh Murray, 03 218 6947

Guidance on essential maintenance for fluorescent light fittings The Lighting Council New Zealand recommends regular maintenance for the safe and efficient operation of fluorescent light fittings common in commercial properties. New guidelines issued to this end are designed to ensure efficient operation and reduce the risk of failure.

“All electrical technology generates heat, creating a fire risk if not properly maintained. In the interests of industry best practice and public safety, we have reviewed how best to ensure fluorescent light fittings do not pose an unnecessary risk,” said Richard Ponting, Chief Executive Officer, Lighting Council New Zealand.

Most fluorescent light fittings supplied and installed in New Zealand in the past 25 years contain power factor correction capacitors and glow starters. Regular maintenance, checking and replacement of these components is essential to ensure they operate safely and efficiently. Lack of regular maintenance or a failure to replace aged or damaged components, particularly capacitors, reduces efficiency and performance and may create a risk of failure.

It is recommended that commercial property owners take the following advice to appropriately maintain their fluorescent light fittings: At least every three years and whenever fluorescent tubes are replaced, fluorescent light fittings need to be checked to ensure that there are no signs of ageing or damage in any components such as capacitors, ballasts, lamp holders and starters.

Any capacitors, ballasts, lamp holders or starters showing signs of ageing should be replaced immediately.

Capacitors have a life span of between five to ten years.

They must be replaced at or prior to 10 years. Ensure that the replacement capacitors and ballasts meet the lighting manufacturer’s specification for the lamp in question.

Maintain a maintenance log and/or record on the component itself the dates it has been checked and the dates any components have been replaced.

Avoid the application of unnecessary external force when carrying out checks/maintenance. Do not use any components that are dropped or damaged.

Any light fittings that are subject to permanent or frequent external heat will require more regular checking and maintenance. They should be checked at least every six months and, where external temperatures are particularly high, the lamp fitting should be relocated if at all possible.

“Responsible commercial property owners/operators will already have robust plans in place for regular, routine maintenance. While regular maintenance of fluorescent light fittings does require a commitment from property owners, this should be viewed in the context of improved performance and risk management,” said Mr Ponting.

For further detailed information, including what to look for in checking for signs of ageing or a need to replace components, go to www.lightingcouncil.org.nz/bulletins

EEC2659B_DEMM

23

motors and drives

Speed or power – you choose Brett Motum compares DC motor driven actuators with linear DC motor actuators, to weigh up their individual merits and shortcomings.

Factory automation and robotic application engineers are often faced with the challenge of requiring fast, accurate and powerful linear actuation within a small allocated volume. The two most commonly available technologies are rotary DC motor driven actuators and linear DC motor actuators.

There are of course advantages and disadvantages with all technologies and they are sometimes easily overlooked.

This short summary contains some common considerations.

Linear motors An easy way to think of a linear DC motor is to take a standard DC motor and lay it out flat. For example: A line of motor stator coils over or along which is passed the permanent magnet sliding actuator. They can also be manufactured as a rail of magnets with a moving coil.

These can be flat or circular shapes.

Advantages The main advantage of a DC linear motor is speed. Smaller and high quality units can achieve outstanding acceleration rates.

The other advantage is operational life.

Because there is no gearing and the only friction points are the required linear guides, the lifespan is therefore relatively long.

Disadvantages Linear DC motors have a very low force or in particular a very low speed force gradient compared with DC linear actuators. Of particular importance is the need to compare the same figure.

Manufacturers from different parts of the globe often use a completely different standpoint from which to select catalogue ratings related to force.

Peak force, stall force, rated force, holding force, back driving force to name a few. The most comprehensive test is to use a force gradient. This can be calculated or informative companies will supply you with the figure representing metres per second per Newton (m/s/N).

The gradient of this speed force line

24

February 2013

An OEM linear actuator.

In this comparison we are looking at DC motor driven linear actuators only.

These are supplied in many forms from inline OEM style units to off the shelf self-contained units. In the interest of fairness we should also do a quick comparison within this sub category.

on hospital beds and low duty cycle applications that seem at first glance to be a good solution. However, they are bulky and inefficient compared to an OEM style spindle drive.

The low cost DC motors commonly used in this style of actuator can have quite high radial load applied from the belt and pulley mechanism. This can result in pre-mature failure of the motor bearings.

Because this application note is written for automation and robotic design engineers we can assume the OEM style will be far more applicable in terms of space, power, efficiency and reliability so we will make a comparison of advantages and disadvantages between the OEM style actuators and linear motors.

OEM units

Advantages

These are units that are designed specifically for integration into a product being developed from the ground up, where the actuator section of the unit becomes part of the product itself. This is done in the interest of keeping the overall size and weight to a minimum.

This could be a system as simple as a DC motor driving a threaded section using an actuation nut or a more robust design of an integrated ball screw, thrust block, DC motor, gearhead and encoder assembly.

DC motor driven actuators can produce much higher forces per volume than linear motors.

The nature of the thread or spindle section gives both self-locking and free running options.

High efficiency is possible. particularly with the recent advances in ceramic and other high grade running materials.

Controllability is very easy with the simple mounting of standard encoders on the rear of the motor. Combined with the gearing ratio and the thread pitch this gives a very high positioning resolution from standard motor position controllers.

Cost: One must compare the additional system components required for the same overall result. Linear encoders, linear guide rail, limit switches etc. are typically required with linear motors.

Much of this additional cost can be avoided with integrated OEM style units that do not require all of these add-ons.

represents how much the unit slows down for every Newton of load that is applied and this is a true test of its strength.

The second disadvantage is current draw. Because linear motors are a direct drive solution and there is a higher level of current rise with the required feed force, a geared solution will be proportionally lower.

Linear actuators

Self-contained units These are commonly available linear actuators that typically have a DC motor mounted beside the threaded section that is driven by a belt and pulley. The threaded or spindle section is contained in a tube. A fixed nut is connected to an overtube that pushes an actuation rod in and out.

These are bolt on units typically used

motors and drives

Disadvantages The main disadvantage of a DC linear actuator over a linear motor is speed. Top speeds of around 180 to 200mm/s are typical.

The second main disadvantage is integration. In order to reduce the overall machine size and by design,

the fixation of the spindle nut is part of the application load itself and as such a certain level of system design and integration is required from the customer.

This short document touches only on some of the issues considered in complex design projects and the detail needs to

be thoroughly investigated before the purchase of a product. This highlights the importance of dealing with a supplier with worldwide representation, data sheets that you can trust and a willingness to customise the product for the application requirements.

Brett Motum works for Maxon Motor.

Direct import transmissions EQM Industrial has a selection of the world’s best transmission products imported directly from companies such as ABI, Dagu, Challenge and STM. To make it easier for engineers, the company’s website lists products within each brand along with vital information on ratios and sizes.

The ABI Stainless Steel Gear motors, manufactured in the Netherlands, are top of the line and well suited for the food processing sector because they can withstand high water pressure (1400PSI) and incredibly hot water (maximum 80°C).

If you are in need of a low voltage battery powered motor to power your machine, the firm says you can’t ignore the high quality Dagu low voltage motor range.

These 12, 24 & 180v DC motors are designed and manufactured in Italy. They are ideal for any portable and remote device including mobile trolleys and carts, marine industry equipment and airplane accessories.

EQM also stocks a full range of STM gearboxes interchangeable with other brands and features an input coupling system that eliminates fretting in the

keyway, as well as allowing it to be easily assembled or disassembled.

EQM Industrial has a wealth of experience in the industry and provides a complete service - from importing, distributing and assembling to

manufacturing and offers a wide and innovative product line of easy to use equipment, new technologies and turnkey easy to install packages and systems.

• Go to www.demm.co.nz/enquiry quote:

D130225

25

motors and drives

Tsubaki GT4 Winner drive chain lasts longer Industries that are exposed to harsh environments can be extremely hard on drive chains. Abrasive dust particles infiltrate the chain links and cause corrosion of the chain’s internals that leads to elongation and eventual failure.

Tsubaki claims its BS chain offers 45 percent less elongation than competitor products in such environments.

The firm says one of Europe’s largest producers of asphalt for road construction found that the roller chain it used to drive its conveyors tended to have “exceptionally short service periods” before replacement was needed.

Standard 16B chain was used to reduce purchasing costs, but the regular downtime and maintenance requirements meant that the total cost of ownership

remained high.

Tsubaki, the world’s largest manufacturer of roller chain, suggested its BS/DIN premium chain GT4 Winner as an alternative. BS chain GT4 Winner is one of the most advanced chains that Tsubaki produces, and boasts four key features that are designed to reduce wear and chain elongation.

1: Lube-grooved (LG) bushes hold oil at the point of contact that provides an internal reservoir for lubricant where the chain needs it most.

2: Seamless and perfectly cylindrical bushes result in both better contact between the pin and bush and improved lubricant retention.

3: Centre sink rivets – for easy disassembly – which are designed with markings to identify pin rotations caused by chain overloading.

Power Transmission “PACKAGED” To Suit Your Needs

Worm Gear Motors and Worm Gear Reducers

• Modular design with ISO standard flanged input together with output flanges, torque arms, plus simple connection of multiple staged reductions • 100% compatible with ISO flange mounted motors • Lightweight aluminium design • Available in 10 sizes with power ratings .09kW - 15kW and ratios of 7.5:1 to 6,400:1

RR Fisher & Co Ltd R PO Box 23293 Auckland

Auckland Ph: 09 278 4059 Fax: 09 279 8286 Christchurch Ph: 03 377 0025 Fax: 03 377 0086

26

February 2013

4: Ring coined connection links allow the chain to be specified up to its full kW rating; unlike the typical standard slip-fit connecting links used by competitors which are usually much weaker than the base chain.

Tsubaki compared its chain against the one that had been used at the site and a premier chain from the same manufacturer which uses chrome bearing pins for increased wear resistance. The chain was left in operation for 1750 service hours prior to measuring for elongation.

It found the competitor’s

premium brand had suffered 3.3 percent elongation while Tsubaki’s GT4 Winner was only 1.9 percent: this equates to 42 percent less elongation for GT4 Winner.

In comparison to the original chain – which had suffered from 3.5 percent elongation – Tsubaki’s solution was shown to offer 45 percent less elongation, a significant improvement and one that could double the service life of the chain, making it economically a far more beneficial product.

•

Go to www.demm.co.nz/ enquiry quote: D130226

Impressive all round axial flux BLDC motor The ImPress motor is the latest generation axial flux brushless DC motor from Regal.

Designed for direct drive blower and fan applications it is suited for markets including gas heaters, condenser motors, evaporative air conditioners and other air movement applications.

The ImPress technology has its origins in the motor developed for use in the Australian solar car Desert Rose from Charles Darwin University.

Included among several awards was the General Motors award for technical innovation, won in the World Solar Challenge.

The axial flux motor technology is also sold by Regal in the water pumping industry.

ImPress provides higher efficiency, lower operating costs, noise and CO2 emissions in a smaller, more compact package.

With advanced features such as airflow control, the motor can provide improved indoor air quality, energy savings, reduced noise and comfort for the end user.

• Go to www.demm.co.nz/enquiry quote:

D130226a

motors and drives

Time to belt up Gates’ most powerful synchronous belt, the Poly Chain GT Carbo, has been designed for optimum performance on high torque, low speed and high speed drives in any industrial application.

The lightweight belt features power ratings of up to 30 percent greater than previous constructions and still maintain the long service life.

The belt’s construction is “innovative and state-of-theart” says the firm. With a polyurethane compound for the body and teeth, the belt is “super tough and virtually immune to abrasion and chemical attack”.

For roller chain

applications, belts can do away with the maintenance of retensioning and lubrication, while delivering power capacities exceeding those of equivalent width and pitch standard roller chain drives.

•

Go to www.demm.co.nz/ enquiry quote: D130227

Belt handles more horsepower Gates’ highest-performing V-belt, Predator, has equal or greater horsepower capacity than a standard V-belt in half the width and weight, says the firm.

Using a thinner belt such as the Predator allows for narrower pulleys, which can minimise overhung load, extend bearing life and drastically reduce downtime and maintenance costs.

Designed for the toughest, dirtiest and most aggressive applications and environments, the belts have the “highest power density of any V-belt”, and – says the firm – stretch dramatically less than standard construction belts.

From 0.37kW up to 4kW, the Sew Movimot integrated frequency inverter is built into the terminal box of the motor or brake motor providing simple operation.

“That’s why they’re ideal for use on problem drives requiring high-impact strength and load-carrying power,” says Gates.

The drives have been used in the toughest applications in agriculture, forestry, mining, construction and manufacturing.

Gates says its maintenance free belt can handle up to 2.2 times more horsepower than the equivalent size standard V-belt.

Enjoy the power and the control Movimot geared motors – motors, with or without brake option – puts the motor control functionality on the machinery being driven, not in the switch cabinet.

This provides the user with such benefits as simple installation, open loop vector speed control, full on-board motor protection and complete electromagnetic compatibility without special cabling requirements.

For drives of up to 4kW inclusive, this innovation

from Sew-Eurodrive has found wide acceptance throughout New Zealand.

Each Movimot installation typically has an optional on-board keypad or a cabled remote keypad.

The flexibility of decentralised drive installation makes it easier for the system operator whenever the machine has to be reconfigured or expanded to meet new requirements.

•

Go to www.demm.co.nz/ enquiry quote: D130227b

RED POWER The only maintenance-free V-belt

•

Go to www.demm.co.nz/ enquiry quote: D1302227a This means no further re-tensioning for the service life of the belt.

• Highest on-going drive efficiency (97%) due to tension being retained.

• Close length tolerance of +- 2mm up to 5000mm length.

• No need to match belts.

• Higher power transmission capability than standard wedge belts.

• Robust, problem-solving belt with a proven long service life in the NZ market.

The new RED POWER 3, available progressively during 2012, will offer even higher power transmission capability.

Available from:

TRANZ CORPORATION LTD

343 Church Street, Penrose, Auckland 1061, New Zealand P.O.Box 12320 Telephone: 09 634 5511 Fax: 09 634 5518 website: www.tranzcorp.co.nz | email: sales@tranzcorp.co.nz

27

AIR HANDLING

Absolutely anything you need for Dust and Fume Extraction New Zealand

DUCT & FLEX Flex

In-stock for overnight delivery

•

Lessons learned from European manufacturers Modular Duct

Dust Storm Filters

Fans

European Quality Fume Arms

Freephone 0508 NZ DUCT (0508 69 38 28) 13F Saleyards Road, Otahuhu, Auckland Ph: 09 276 8020 Fax: 09 276 8070 Email: info@nzduct.co.nz

www.nzduct.co.nz 28

The first thing Bernie Klaver, senior engineer and workshop manager at Unitech Industries in Auckland noticed about his new mobile extraction arm was the lack of “The problem we have is that the work we do extremely varied, but includes a lot of aluminium grinding, welding, plus general metal work, says Klaver.

“To improve conditions in the entire work shop would be difficult to solve with a fixed extraction system.”

Klaver asked NZ Duct & Flex about the European manufactured Fume Cube and says he was impressed with it from the moment he saw it.

“With the locking castors it’s easy to reposition the unit to where we need it,” he says.

Henderson based Unitech Industries manufactures products such as infant formula, micronutrient premixes and animal nutritional products, across the Asia Pacific region.

Geoff Ebdon of New Zealand Duct & Flex says the firm’s Fume Cube is an ideal solution for smaller work shops or schools where continuous filtration is not required.

The Fume Cube unit features a 160mm self supporting fume arm, a wire mesh pre-filter, a fine filter and a fan producing 1000m³ an hour at the hood. Go to www.demm.co.nz/enquiry quote: D130228

Widest Range Baghouse Filters

Quietly cleaning the air

February 2013

Geoff Ebdon from NZ Duct & Flex makes a point of visiting his European supplier factories every 18 months.

He has just returned from Denmark where JKF Industri has its factory.

JKF Industri has been manufacturing modular ducting for nearly 60 years and the product has been available in New Zealand for more than 25 years.

The firm has a full range of dust extraction systems, fans and associated products made from galvanised Swedish steel to ensure items in its modular duct range ‘last longer’.

During a tour at the firm in January, Ebdon saw Super Blower filters and DustStorm units capable of dealing with air volumes from 10,000 to 100,000m² an hour.

“These are the sort of air volumes commonly required for European and Asian manufacturers, all fitted with the most advanced explosion venting systems available

Geoff Ebdon with Jkf sales manager Morten Ostergaard and design engineer discussing the Perspex walled filter in action.

and meeting all world environmental standards,” he says.

“It’s now, in Europe, impossible to sell an extraction unit without an ATEX approved explosion membrane that protect employees in the event of a fire or explosion. These are placed on the top of the filter units so any explosion is directed upwards.”

Ebdon says new products are continually being developed as energy consumption and running costs play an ever greater part in the product selection procedures of customers.

•

Go to www.demm.co.nz/ enquiry quote: D130228a

Pneumatics-Hydraulics

Powerpack delivery ticks all the boxes For a large offshore power generation project, Hyspecs supplied five hydraulic powerpacks, 20 cylinders, interconnecting pipework and assisted its customer on-site to pass factory acceptance tests.

Hyspecs’ powerpacks were designed, manufactured, third-party inspected and tested in-house at its premises in Dandenong, Victoria, before being shipped to Thailand for testing. Once they got the all-clear, they were sent to the customer in Oman where they were installed.

Because the application is power generation, the hydraulic design and component selection was critical to give long-term reliability and offer failsafe operation.

Hyspecs’ staff used products from its established

suppliers such as EPE, Eaton, Hydraforce and OMT, firms that meet the quality and performance criteria required for this application.

Custom manifolds were designed and manufactured by sister company Hytech (Hyspecs Technologies) in New Zealand and used to reduce pipework complexity and the likelihood of leaks.

Each power unit features two variable displacement piston pumps, proportional control valves, six accumulators fitted with fluid and gas safety reliefs, off-line filtering and cooling, pressure and return filters, custom designed manifold blocks and a stainless steel reservoir.

A full array of sensors ensures the powerpacks are protected from overheating, low oil level, excessive

Greg Loel, Hyspecs’ operations facilitator in Melbourne, stands next to a powerpack.

pressure, filter blockage and incorrect ball valve operation.

Each hydraulic cylinder was fitted with counterbalance valves directly mounted on the ports so that a hose failure would not cause

uncontrolled movement, the counterbalance valves were tuned to the system to ensure smooth and stable operation in all modes of operation.

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Go to www.demm.co.nz/ enquiry quote: D130229

P NZ’s leading ROTARY SCREW COMPRESSOR Hyspecs’ hydraulic powerpack next to the machine it will be controlling in Oman – a damper for the gas turbine for a power generation plant.

Pneumatic aeration for dry products Solimar Pneumatics designs and supplies aeration devices and discharge aids for storage silos, weigh hoppers, filters and bulk tankers.

Its experience in the discharge of dry products has made the firm a recognised leader in the industry.

Solimar’s Silo Fluidiser helps to discharge dry products such cement, f lour, feed and lime. Instead of

only aerating the product like fabric aerator pads, the Solimar Fluidiser uses air movement and vibration to facilitate the f low of dry bulk materials.

The air movement from the f luidiser sweeps the product off the silo wall and allows for even f low to the discharge outlet.

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Go to www.demm.co.nz/ enquiry quote: D130229a

specialist . . .

7.5 - 280kw, 36 - 1285cfm Electric stationary, diesel portable Fixed speed, VSD Lubricated, oil free Complete compressed air systems

. . . screwing down your cost of compressed air Contact us now: 0800 555 018 info@industrialair.co.nz

www.industrialair.co.nz

‘YOUR LEADING ROTARY SCREW SPECIALIST’

29

Pneumatics-Hydraulics

Integrated pneumatic actuators A high-performance range of pneumatic cylinders designed to reduce energy usage and operating costs for OEMs and end users in a range of processing applications is now available.

Conventional pneumatic control involves an arrangement of valves or valve islands, actuators, flow controls and sensors, along with connectors and fittings. In typical applications, up to 13 different components can be required for each actuator function.

This complexity presents some intrinsic disadvantages and performance constraints. The IVAC (integrated valve and actuator control) has been developed as an integrated unit that combines the valve, flow controls, cushioning and sensors in a single actuator package.

IVAC is a weight and space-optimised actuator, suitable for a range of bore sizes from 40 to 80mm, with an integrated valve and magnetically operated switches for complete actuator control.

Able to be retrofitted or integrated

within new systems, each unit requires only one pneumatic and one electrical connection, eliminating the need for multiple valve islands, components, tubing and accessories.

Of particular importance to OEMs and end users is that the IVAC conforms dimensionally to ISO / VDMA mounting dimensions.

The energy savings are obtained by excluding the need for pneumatic piping between the conventional type cylinder and remotely mounted conventional control valve.

In conventional systems the compressed air usage in both ‘in stroke’ and ‘out stroke’ pneumatic piping consumes significant compressed air energy in high cycling applications, or where the valve is mounted some distance from the conventional cylinder. The IVAC valve is integrally mounted within the cylinder producing

Energy-saving IVAC cylinder.

the savings.

A number of options and varieties are available including cleanline versions for industrial cylinders, industrial slave cylinders and easy washdown, helping OEMs comply more easily and cost effectively with hygiene regulations.

The design of the integrated actuator is based on modularity to allow all components to be easily assembled and disassembled.

The IVAC’s modular concept includes a special solenoid pilot module which is placed directly at the end of the actuator barrel, and the integration of a pneumatic interface, position sensing, display for status and M12 electrical connection.

• Go to www.demm.co.nz/enquiry quote: D130230

Rotork acquires Fairchild Industrial Products

The power to deliver Electric powered hydraulic rebar cutters are now available for both, purchase or hire from Hytools NZ. These portable rebar cutters can cut rebar, whether deformed or not, from 4mm to 32mm across the range of cutters available.

The DC20 rebar cutter, for instance, will cut up to 20mm rebar and does this at a rate of three to 3.5 seconds per cut.

30

This tool weighs 13kg and is available either with a top handle for bench cutting or a rear handle for dropping into a trench. Also available is a cordless range for both 16mm and 20mm rebar.

Full service, backup and spare parts are available for this new range of products as well as cutting block replacement sets.

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Go to www.demm.co.nz/ enquiry quote: D130230a

February 2013

Rotork, the actuator manufacturer and f low control company with offices in Wellington and Auckland, has bought Fairchild Industrial Products, a manufacturer of pneumatic controls and power transmission products based in North Carolina, USA. Fairchild manufactures a range of market leading regulators, boosters, relays and transducers. The products are used in a wide variety of applications that require precision control of pneumatic devices and motion control equipment.

As well as oil and gas applications the company also benefits from orders in pharmaceutical and biomedical equipment, tyre manufacturing machinery, robotics, food processing and chemical manufacturing applications. The company has offices in China and India with a presence in Mexico, Russia and Brazil.

The acquisition of Fairchild is in line with Rotork’s strategy of strengthening its presence in the global flow control market, as part of which the Group also announces the creation of a new division, Rotork Instruments.

Rotork Instruments will focus on developing further opportunities in the flow control market; in particular, products associated with flow and pressure control and diagnostic and information gathering technology.

Fairchild will be the first company within the Rotork Instruments division.

Rotork Group CEO Peter France, says: “The acquisition of Fairchild will strengthen our presence in the global flow control market and, in forming the basis of new division, Rotork Instruments, will broaden the scope of the Group’s activities.”

The magazine behind nz’s exporT drive

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www.exportermagazine.co.nz

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www.exportermagazine.co.nz/digital 31

MAINTENANCE MATTERS

SKF food grade chain oils SKF New Zealand has launched a new range of food grade chain oils.

The food and beverage industry is a challenging market where production efficiencies need to improve together with safety and cleanliness.

SKF, with its new food grade chain oil product range, can help manufacturers reach their targets. Selecting the right chain oil for the application can bring multiple benefits: • Improved chain life.

• Improved processing efficiency.

• Reduced maintenance costs.

• Improved safety.

• Ease of handling.

“Health concerns are rising regarding

the usage of inappropriate chain oils in manufacturing of various food-type products,” says SKF. “It is of great importance to bring the awareness to our customers of all the possible risks related to it.”

Some typical applications in food and beverage sector include bakery ovens (pizza, pastry, bread manufacturing), proofers, pasta driers, beverages and confectionery industry

(bottling, manufacturing of sweets) and industrial meat processing.

•

Go to www.demm.co.nz/enquiry quote: D130232

Chuck delivers high speed machining

RFID For Tool Tracking Keeping track of your tools is not likely to be one of your favourite tasks, but it is a necessary one.

It used to be tricky to keep tabs on who had which tool, and whether they had returned it or not. But that has all changed with the introduction of Omni-ID’s new miniature UHF RFID tags, designed specifically for mounting on (and tracking) your tools.

All that is required is a unique RFID ID badge for each worker, and an RFID reader/ antenna system mounted in the throughway into the tool storage area.

RFID works on proximity, so whenever a tool passes through the RFID “field” the system reads the the member of staff’s tag and then whatever tool tags are also in range.

The tools are then associated with the worker until they return the tools and leaves the tool storage area empty handed, or with different tools.

•

Go to www.demm.co.nz/enquiry quote: D130232a

32

February 2013

Seco’s collet chuck EPB 5672 is used for highperformance, high-speed machining. It offers a maximum run-out of three microns at a tool length that is three times the outer diameter (3xD), up to 50mm. This is 40 percent lower than the earlier D-type (5872), which is currently being phased out by the firm.

EPB 5672 is designed to maximise the clamping force and spread it equally over the tool shank along the full length of the collet, making high-performance cutting tool use possible.

It also reduces the risk of tools being pulled out of the chuck.

The high and even pressure on the tool shank is achieved through a combination of design features. One is that the clamping nut has a strong trapezoidal thread to push the collet firmly down in its pocket.

There is also a completely new type of functionality between the nut and body: two cylindrical guiding surfaces on both sides of

the thread.

In classic types, the clamping nut is only in contact with the body via the treads. In this case the nut has double functions; the thread pushes the collet into the body while the two cylindrical guides keep the run-out down.

That is one reason behind the three-micron run-out that characterises EPB 5672. Another is the cylindrical shape of the nut and body without any asymmetric parts. This creates a well-balanced tool assembly for high-

speed machining, where the slick round collet nut is tightened using a roller spanner.

The front-end can handle up to 80,000 revolutions per minute (rpm), but the actual maximum is often limited by the type and size of back-end taper.

All in all, says Seco, this adds up to a rigid collet chuck with low tool deflection, suitable for modern cutting tools.

•

Go to www.demm. co.nz/enquiry quote: D130232b

MAINTENANCE MATTERS

Vibrating wire strain gauge New from Bestech is a range of vibrating wire strain gauges and sensors for geophysical applications – where the prime requirement is to monitor changes in structural integrity and stress over long periods of time.

Existing applications include the monitoring of stress and crack propagation in dam walls, tunnels, bridges, large diameter pipes, embankments, and mounting pads for heavy machinery and high voltage pylons.

The Encardio-Rite vibrating wire technology is ideal where it is necessary to run long cables between the sensor and the controlling instrument.

Changes in cable resistance and conductivity due to temperature and moisture ingress have no effect on the integrity of the frequencybased signal where it can also be used for embedment in soil or concrete.

All Encardio-Rite EDS-20V strain gauges supplied by Bestech Australia comprise a pretensioned high tensile steel wire strain gauge element with thermistor temperature sensor as to measure temperate changes at the same time, and a permanent magnet and induction coil assembly.

Both components are factory sealed to prevent the ingress of water, corrosive substances and gasses. The induction coil assembly is either mounted over the strain gauge assembly, or both components form one assembly.

To complete a basic system, a vibrating wire strain indicator, such as the Encardio-Rite EDI-51V, is connected by a four core screened cable to the induction coil assembly to display measured strain

that is proportional to the frequency output.

Multichannel signal conditioners are also available.

At preset time intervals, the EDI-51V sends an impulse via a four core screened cable to the magnet coil assembly. The induced electromagnetic pulse then ‘plucks’ the magnetic wire of the strain gauge where a natural frequency of vibration is created. On the principle that the square of the resonant frequency of the wire is proportional to the stress applied to the wire, any movement in the structure that affects the stress applied to the gauge causes a change in its resonant frequency.

The induction coil senses the ‘new’ frequency and transmits it as the signal back to the EDI-51V or other Encardio-Rite vibrating wire instrument. The instrument then converts the frequency to microstrain based on the above principle, displays and logs the measurement, and outputs the data via an RS232 interface.

Proportionate to the tension, the wire resonates at a frequency ‘f’, and the strain applied on the strain gauge can be determined.

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33

MAINTENANCE MATTERS

Plastic cribbing for load safety A safety initiative by CablePrice NZ has seen it introduce plastic cribbing blocks designed to improve safety when stabilising heavy loads after they have been lifted for maintenance and access.

The Enerpac plastic cribbing system – developed as a more stable, longerlasting and easily cleaned alternative to wooden blocks – was provided by Enerpac distributor Jonel Hydraulics.

The blocks feature an aggressively patterned slip-resistant pyramid locking surface for stable cribbing, chocking and shoring. Unlike wood, plastic offers a predictable and high load capacity that deforms only slowly under extreme load, because of the homogeneous material used.

“We have had up to 30 tons sitting on them – we use them for everything.

It is all about safety,” says CablePrice Rotorua equipment workshop team leader, Chase Murphy.

“Previously we used wooden blocks, but this is the way of the future for an industry leader. Sometimes we could hear wooden blocks cracking under load. We are always obsessed with safety, so we sought a better way to ensure it when lifting up machinery for service inspection and maintenance,” says Murphy.

Enerpac NZ territory manager Neville Stuart says that after he went on-site to demonstrate the blocks, CablePrice ordered 24, which can support up to 60 tons in two-box cribs and 100 tons in three-box cribs.

The cribbing systems complement Enerpac’s broader ranges of lifting and load handling technologies including heavy duty load skates, low clearance machine lifts and vertical lifting wedges requiring only 10mm tip clearance to

apply 700 bar hydraulic force.

Enerpac is a global leader in high-force tools and 700 bar hydraulic equipment used in industrial markets, where its technologies are used to safely hoist loads as large as turbines, ships, railway locomotives, bridges, mining shovels and entire buildings.

“Our total ranges are keyed to safety and cost-efficiency, which is the case with plastic cribbing systems being used when maximum crib stability and material durability is required by industry leaders such as CablePrice NZ,” says Stuart.

“Enerpac’s cribbing system won’t splinter, doesn’t absorb most fluids (subject to chemical compatibility tests) and can be used for interlocking box cribs, parallel cribs and triangle cribs.”

Available in three sizes of cribbing blocks and two sizes of wedges, the system, made from recycled plastic, is

MSA’s new Galaxy GX2 automated test system provides advanced safety management and effortless operation.

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34

February 2013

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Enerpac cribbing block systems from Jonel Hydraulics supporting a CablePrice tracked vehicle.

Gas testing made easy

•

available in different combinations of wedges and blocks in nylon carrying totes.

CablePrice, a subsidiary of Hitachi Construction Machinery, is the country’s only authorised dealer for Hitachi construction machinery, Scania trucks and buses, and John Deere construction and forestry equipment.

MAINTENANCE MATTERS

2013 – the year of change from the top By Craig Carlyle, secretary MESNZ. From the Maintenance Engineering Society’s (MESNZ) point of view, 2013 promises a year of change to policies affecting industry.

MESNZ education spokesman Bill Sole has already provided a concise précis of changes signalled by the Ministry of Education, (DEMM, January 2013). Industry training, the apprenticeship system and the supply of tradesmen are all core topics for the society, representing businesses and engineers at the coalface of the topics.

While no timeline has yet been published for the publication of the MOE’s position, as detailed summary of the industry training review is available on the MOE website (http://goo.gl/ ORDH5).

The Department of Labour (DOL) meanwhile, has also been active in taking a hard look at our health and safety performance, canvassing industry and signalling change with the release of the Manufacturing Sector Action Plan to 2013.

This is a paradigm shift from 2008, when the MESNZ’s own study into New Zealand’s performance (read – death and injury stats 38 percent worse than 1992) seemed to be a dissenting voice in the face of the health and safety industry machine.

The Action Plan pulls together stakeholders from ACC, ITOs,

organisations, (HERA, Competenz, Meat Industry Assoc., etc), unions, and several interested companies, (Fonterra, Impac, etc).

Action Plan priorities are seen as machinery, vehicles, at-risk groups and data gathering and the document goes on to establish goals and achievement approaches for each priority. While the makeup of the stakeholders is somewhat skewed; it certainly would benefit from a higher representation from SME’s (Small to Medium Enterprises), particularly those demonstrating real success in managing health and safety, the document is significant in light of increasing dissatisfaction with suffocating health and safety management, continued high profile failures and the DOL’s own woes and resourcing issues.

MESNZ has pledged its commitment to participating in any initiative that will make health and safety management simple, achievable for management and effective for employees.

In both education and health and safety, the changes are understandably a fraction of what the MESNZ has called for, but it is change, and change in the right direction. Most important is the recognition by Wellington that change is needed in topics that the society

previously was a lone (and embattled) voice in. For our engineering members, it goes to prove that your voice can be heard.

At a more practical level, the MESNZ is busily firming up the schedule for its 2013 Network Evening series. It offers opportunities across all regions to check out exciting and inspiring companies in a relaxed after work environment. While late summer fixtures are still being detailed, June will see MESNZ at the V8 Super Tourer workshop of East Tamaki’s M3 Racing. This multi faceted operation based around the preparation and maintenance of Super Tourer cars for Greg Murphy, Paul Manuell and Paul Morris will satisfy the interest of anyone with even a remote interest in motor racing and Lean operations.

Check the MESNZ website for details; mesnz.org.nz/network-evening/ but numbers are limited, so reserve your place early. As with all the Network Evenings, there is no attendance cost.

While on the MESNZ website, check out the 2013 SKF National Maintenance Engineering Conference page, at mesnz.org.nz/nmec/. The site has been updated with the conference and registration details for the November 12-13 event at Novotel Rotorua and will be continuously updated as the year progresses.

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www.skf.co.nz 35

MAINTENANCE MATTERS

Time on our hands Nick Inskip, industry development general manager at the Heavy Engineering Research Association says the GFC means companies have the capacity to develop new products

The Heavy Engineering Research Association interfaces with the sharp end of high value manufacturing, which provides a unique insight into what happens in industry in relation to the current effects of the Global Financial Crisis (GFC).

There is an increasing focus on what has been called the jobs crisis as evidenced by the [October 2012] Jobs Summit held in Auckland, which HERA participated in as part of the business panel.

One thing that characterises our industry is that many of the jobs are relatively skilled and high paying, so with the significant downturn caused by the GFC, many companies had to look carefully at their workforce.

We saw some shedding of lower skilled staff and significant cuts in overtime but generally industry tried to maintain their staff. To do that they typically started accepting work that they usually wouldn’t bid for, with very tight margins and many took on jobs that barely covered costs in order to maintain their staff.

In context, the number of tonnes processed through our industry dropped

Coming up in the March 2013 issue S Food process industry

SSafety in the workplace

SHeat exchanges SAutomation and control

SUPS Deadline editorial 15 February Deadline advertising 22 February

36

February 2013

by 38 percent between 2008 and 2010 in terms of tonnes of steel, and has recovered in the last two years but is still 26 percent down.

What this means is that our high value manufacturing companies have capacity and capability. What they need to do is develop new products, and then get those products to export markets.

That will give them growth, it will drive the country’s growth and that will create good quality jobs and provide future jobs for our children.

What we need to drive the creation of quality jobs is serious growth in high value manufacturing. I see three ways of driving that:

If we don’t invest now, our children will be sitting at another job summit in 20 years time 1) We need to recognise that all companies are not equal and identify those who are, or want to be, involved in exports of high value products – and then provide serious support, cognisant that they do not have the margins to go it alone.

2) We recognise the need to have large New Zealand companies, including state- owned enterprises, accept that they have an important role as New Zealand corporate citizens to work with local suppliers to develop superior products for their needs, which the local suppliers can then take to export markets. This is called lead user innovation and is a key component of the UK governments procurement processes. It is critically important here because New Zealand is far from markets, and companies have to be able to demonstrate technologies before they can sell them offshore.

3) We recognise that in our country, governments in one form or another are major purchasers of products and

Nick Inskip is the industry development general manager at the Heavy Engineering Research Association.

services, and that pressure to cut costs means the development of an emerging culture of cheapest product at any price.

The reason I say at any price is that the cheapest, where it is imported, often does come at a big price to local jobs and a big price to our economy in terms of adding to the trade deficit. Often the products are inferior to what could have been purchased here and purchasing offshore makes it difficult to maintain strategically critical capability in New Zealand.

Finally, what we need is a compact between everyone and anyone who can turn this country around. A compact between government, SOEs, industry, unions and researchers to help build a solid high value manufacturing sector without excuse or compromise.

It’s the only way to generate the serious growth that provides jobs and stimulates the pathways for skills development.

If we don’t invest now, our children will be sitting at another job summit in 20 years time, having the same debate again. It’s our responsibility so let’s do it.

MAINTENANCE MATTERS

Specialty lubricants for machine tools Synthetic lubricants can help minimise machine tool’s life cycle costs by extending costly relubrication and oil change intervals, or even by enabling lifetime lubrication.

Empirical studies show that as much as 70 per cent to 85 per cent of a machine’s life cycle cost is already determined during its design stage.

It is at this point that lubricants, which are often overlooked due to their presumed minor role, are in fact of extreme importance: Synthetic speciality lubricants have in many cases proven to extend relubrication and oil change intervals.

Quite often, they can even enable lifetime lubrication in an application. At the same time, speciality lubricants can enhance machine performance in terms of improved precision, extended production output or reduced reject rate.

More of today’s machine tools contain low-friction linear guides, rather than conventional slideways to enable positioning of the work piece and/or tool.

Motion is normally achieved via ball screws.

The linear guides are designed as flat guides or profiled rails incorporating recirculating balls or rollers.

The specific requirements to be met by these components – which also influence

the selection of lubricant – are: • High precision • High reliability • Low vibration, no stick-slip • High speeds • High acceleration leading to high dynamic loads A multitude of influencing parameters play a role in the construction and operation of machine tool drive systems: type of linear guide, friction bodies and seals/caps, operating conditions, useful life of the lubricant and relubrication and other external influencing factors.

Considering the design of internal and external seals, cage guides, lubricant reservoirs and lubricant feed lines it becomes obvious why the lubricant should be considered an important machine element in its own right early in the machine design stage.

Considering the system as a whole, the high requirements to be met by linear guides result in equally high requirements to be met by the lubricants:

Good anticorrosive behaviour and demulsifying ability enabling resistance to media, and especially to cooling lubricants • Dampening of vibration or shocks, which is important e.g. for the machining of grey cast iron • Wear protection also under micromovement conditions • Low friction enabling easy start-up • Additional sealing properties when operating in contaminated environment • Good compatibility with plastics, elastomers and other lubricants It is not uncommon for lubricants, which are normally considered low-priority ‘C’ components, to assume an ‘A’ function with a positive effect on machine tool TCO. To fully use the potential provided by optimised lubrication, a global approach is indispensable for any solution development.

The lubricant should be considered as a machine element already at the design stage of the machine tool / component, the performance of the lubricant, its application and dosage should also be taken into account.

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37

Change is not always a good thing

Craig Carlyle of Maintenance Transformations wonders why fewer trainees are arriving on the job with the basic skills needed to learn.

At a social function during the summer break I heard a lady extolling the virtues of her daughter. My disinterest perked up when her conversation turned to the new ‘i-learning’ class at her school.

Mum waxed on about the new iPad that was central to this education initiative and told anyone who’d care to listen that her child had already learned to play music thanks to the GarageBand app.

I invited the young child to show us her music skills on a guitar resting in the corner. No prizes for guessing the result…

I hate to spoil the party, but no ‘app’ is going to provide a better appreciation of music – or provide a worthwhile foundation in music skills – than handson learning.

Technical training Putting our engineering hats on, consider the demise of the secondary school technical training of last century.

Our education system unleashed unsuspecting children into metalwork, woodwork, cooking and sewing classes under the baleful stare of grumpy expractitioners with a death wish to inspire new generations.

Lathe chuck keys flew across rooms, disasters exploded from ovens and parents were confronted by tragic but well-intentioned ‘projects’. While the results were often lamentable, generations of youths were inspired (or not) by the experience and gifted with basic understanding and skills.

Unfortunately, careers are not built on leaving well alone and some bright spark came up with a whole new concept for technical training.

Someone suggested we remove the teacher to a central location where he can observe the students, place them into working groups and get rid of the nasty doing stuff.

Sound familiar?

Is it any wonder that we now have a problem identifying and inspiring potential trades staff and steering them towards a technical career?

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February 2013

The inspiration, the chance to have a go, and the humble beginnings of core skills are all missing. Technical or trades careers are portrayed as ‘unsexy’ in favour of the rush to university. If you are not good at making career decisions, go to Uni. Those who do make it into real trade training are missing so much elementary exposure that lesson one is often how to hold a file, a skill previously taught at intermediate school.

If we were to measure the outcomes of the Tomorrow’s Schools’ initiative on hands-on skills, literacy and numeracy against those of the previous system, trades tutors dealing with the result will tell you very clearly, we have gone backwards.

This is just new-think at secondary schooling level. I have not even touched on tertiary level and the ‘experts’ who informed me that replacing block courses

with centralised unsupervised e-learning rooms would be more effective. When I was at school, we called that ‘detention’.

Spin New Zealanders are very good at accepting spin, we are a marketer’s dream.

Computers and new technology can be wonderful things when used appropriately.

However, in industry, education and households, we are sometimes in such a rush to join the crowd that we ditch our previously learnt business, education and parenting lessons.

Melding the appropriate application of technology with proven systems, processes and experience takes real skill.

Until we learn to unravel what we hear, break it down into measurable outcomes, work out who has their trotters in the trough and learn how to say ‘no’, we will continue to endure generations of new-think.

Want to have your say about some aspect of the engineering and manufacturing industry? Email your views in 450 to 550 words – to Editor@Demm.co.nz

Power when you need it The Ablerex uninterupted power supply (UPS) range is a solution for mission critical users who demand high reliability, availability and performance for critical electronic equipment and computer loads.

Ablerex UPS’s feature double conversion true online technology, field-proven full digital signal processor (DSP), and use patented inverter control technology.

With a pure sine wave output for compatibility with all kinds of loads, this range also feature unity input power factor to meet today’s standard for energy saving and reflected harmonic pollution, an eco mode for high efficiency to save power, zero or near zero transfer times to prevent load interruption, and the i-batt feature to prevent deep discharge of batteries.

The UPS’s can be either tower or rack mount configuration and come standard with monitoring and shutdown software.

Network monitoring is available via optional SNMP cards and the user can be alerted via SMS and email to issues on their network.

Extended runtimes are no problem with the addition of matching battery cabinets and maintenance is a breeze

with a modular system design and hot swappable batteries.

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The power to protect It can often be difficult to source power protection or a backup solution based in a harsh environment.

Either an uninterrupted power supply (UPS) cooled with fan acts like a giant vacuum cleaner, sucking in factory or work site contaminants straight onto circuit boards drastically shortening its life, or you need to invest in creating a more sterile environment to enclose this equipment.

Socomec now have a solution with its Masterys IP+ range of UPS’s ranging from

10 to 80kVA. These units enjoy features including isolation transformer and integrated batteries, robust enclosure, IP31 & IP52 protection with replaceable filters as well as double the UPS international standard for EMC immunity.

These are generator compatible and due to IGBT rectifier have input power factor >0.99 & input current harmonic distortion <3 percent.

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Kontron V Panel Express now a single system The Kontron Panel PC family V Panel Express is now available with the Intel Core i7 dual-core processor.

While increasing the performance, the system remains fanless – positioned for use in harsh environments.

Kontron says operating as a combined real-time control and visualization system for industrial imaging helps eliminate the need of buying two systems, saving businesses money.

The Kontron V Panel Express features a processor with 2.2 GHz (2.9 GHz in turbo mode) and up to 8 GB DDR3 memory.

For applications with less performance demands, a version is available with the 1.4 GHz Intel Celeron 827E single-core processor.

The integrated range of interfaces suitable for industrial deployment includes five USB (1x front, 4x rear), one LAN 10/100, one LAN 10/100/1000, two RS232 and one DVI-I. In terms of storage media, either up to two SATA hard disks or especially robust compact flash media can be housed.

Shock, vibration and temperature resistance are standard features of the

Panel PC family. The same is true for its protection against electromagnetic interference, often found in industrial environments with electric motors.

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39

Team Singer win EECA’s 2012 excellence award The challenge was to optomise the lighting in an existing lecture theatre in one of New Zealand’s widelyacknowledged and most-prestigious modern pieces of architecture, the Owen G Glenn building, home of the University of Auckland’s Business School.

The fact, a now-familiar combination of the Singer Group – which has been involved with the facility from the planning stages right the way through to today – and 0800 SAVE ENERGY was able to bring that off, and some, has been recognised with the award of the EECA 2012 Excellence Award for Energy Efficiency.

Installed lighting seldom, if ever, has the luxury of being isolated or independent from other building services; and so it proved here – bringing an additional challenge.

Designers also had to work around the lighting’s inf luence on air-return for the HVAC system, since the ref lector panels in the original system obstructed return-airf low, such that HVAC technicians struggled to balance and optimise the system’s operation. (Solved with the installation of tuneable airreturn vents, with a vertical adjustment of the acrylic diffusers.)

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February 2013

Then came the bottom-line test: the upgrade had to be funded out of typically tight maintenance budgets, given the building was far too new for there to be allocated funds for renewal or remedial works.

“The project brief was not a simple one,” says Emmett Mackle, Facilities Manager, the University of Auckland, “and required solutions to glare and reliability issues.”

The solution, derived by the team engineers, identified an alternate resolution – which not only addressed the above concerns, but also, importantly, extracted cost-efficiencies and savings, by reducing energy consumption.

The team had to focus on a system approach too, since the site called for multiple, lamp-length configurations, in addition to supplementary mounting and finishing hardware.

Alistair Mander, Singer’s Technical Services Manager, who took over the team leadership between Singer and the university, from Rob Stirling (leader of the team from the initial installation, through the establishment of a specialist Computer Centre, one of the biggest in the country at the time, and troubleshooting the likes of

harmonics in AV equipment), values the relationship he has inherited.

“I am always aware that this is a cherished and established relationship that I’m now responsible for. I see my duty and responsibility to follow the Singer philosophy to ‘Build, Maintain and Optimise’ enduring relationships, based on trust and mutual benefit. And since we are a service provider, I know which way that ‘balance’ needs to be tilted.

“That’s where another of our principles, form and function come into consideration too, since this prestigious building needs to be not only environmentally friendly, but provide the optimum conditions for higherlearning, at all times,” says Mander.

Singer turned to their regular working partner, 0800 SAVE ENERGY to “work jointly on a major rethink in the lighting design and implementation, offset as much as possible by energy-efficiency and maintenance simplification”, while customising a product which conformed to the university’s requirements.

“We quickly realised complex performance and aesthetic requirements could not be met by an off-the-shelf product, so the joint U of A/Singer/0800 team committed to a ‘high-efficiency, bespoke luminaire

solution’ – one we like to think did the business,” says Mander.

Trevor Murray, Executive Director of Enlightenz and 0800 SAVE ENERGY takes up the story.

“The original design architects clearly had a vision of an unobtrusive, indirect lighting theme which provided low-glare, functional light for both presenters and audiences alike, while also drawing attention to and accentuating the series of layered ceiling elements.

“The forward-facing ceiling-wash illumination f looded presenters and reduced the audience to a ‘sea of silhouettes’ and the light ref lected down to the seating was so weak that high-wattage downlights had to be installed, at additional expense, before the building could be handed over.”

Mander says that by following the Singer dictat of ‘Root Cause Analysis’ (RCA), in such circumstances, it became clear the basis of the substandard lighting levels was due to there being no integrated optical control of the different lighting systems; leading to a clash rather than a harmony of outputs.

“The dimmable, continuous-line fixtures also suffered from overheatingrelated reliability problems. The luminaires dimmed via a proprietary protocol, which conf licted with the master DALI control system and caused constant programming headaches. This has been eliminated.

“It didn’t help either that with ceilings more than seven metres above f loor lever, at the highest point, scaffolding is an expensive but essential part of any maintenance operations.

The focus had to be placed on cutting unplanned maintenance to the minimum,” Mander says.

Since the building was well-used, there was no chance for the designers to have the luxury of test-fitting multiple prototypes to prove the design.

“In the end,” says Murray, “we came up with a concept to rationalise the two existing lighting components – the indirect ceiling wash from the continuous lines and direct illumination from the downlights – into a single luminaire system.

“Low-glare optics for the direct component were needed to support the audience’s visual comfort, while diffused indirect light would ‘accent’ the ceiling elements without glare to presenters.”

The team, in deliberations with the university’s Mackle and Denis Agate, its Energy Manager, agreed that it was important to retain and reinforce the original ceiling design concept, using continuous parallel linear ceiling elements; so the new solution had to deliver within those constraints.

Trevor Murray again: “This task became a lot more complicated when prototyping revealed significant inconsistencies in the nominally straight and level ceiling surfaces; requiring f lexibility to accommodate both horizontal and vertical deviations of up to 30 mm, yet still appear seamless along the ceiling interface.”

The final word is with the university’s facilities manager, Emmett Mackle.

“The implementation of these upgrades was as challenging as the design problem. 0800 SAVE ENERGY and Singer cooperated well to make use of the limited maintenance windows available during semester breaks.

According to Mackle, ‘the project has been an overwhelming success’, with both teaching and maintenance staff ‘delighted with the results’.

“The lighting performance has improved dramatically.

“We believe the results achieved in the upgrade of the Owen G Glenn lecture theatre lighting are exceptional, especially given the constraints their designers had to accommodate. Their work has done more-than-justice to our f lagship auditorium facilities,” says Mackle.

Efficiency in “High-lights” Removed 2 x 42W down-lights delivered a considerably reduced lighting load .

Optical efficiency in replacement luminaires means they never operate at full output (even in ‘welcome’ mode) giving further energy and maintenance savings.

Singer’s rapid-mount fixing hardware and 0800 SAVE ENERGY’s Ensto’s plug-and-play wiring system, minimised on-site and premium scaffolding time.

0800 474 643 www.singergroup.co.nz

41

NZEI’s conference 8 & 9 March 2013 Allan Hill, national secretary/manager NZEI. The planning for the NZEI Inc’s annual conference, which is being hosted by the Auckland branch, is progressing extremely well, and some very respected speakers will be presenting during the technical forum Session on day one at the Manukau Institute Of Technology.

The following well-respected trade exhibitors have registered their interest in setting up trade display booths for day one and to provide support to the NZEI Inc for the conference.

• Omron NZ. • Pilz NZ. • Eurotec • Schneider Electrical.

• Ellis & Co. • Jackson Electric.

• Sulco Tools.

• NHP NZ.

Day 1: 8 March - Technical Forums Venue – Block D at the Manukau Institute of Technology (MIT), Otara Road, Entrance through Gate 5

Day 1 Programme 10:00 – 10:30 Registration and morning tea.

10:00 – 16:00 Trade displays.

10:30 – 11:00 Conference opening by NZEI INC. President and MIT Dean 11:00 – 12:00 Speaker from DoL/MBIE , Gerry Ryan, senior advisor high hazards electrical.

12:00 – 12:30 Lunch.

12:30 – 13:00 Crombie Lockwood will speak about SparkProof tailored electrical insurance.

13:00 – 14:00 Speaker from New Zealand Standards, John Kelly, senior manager electrical.

14:00 – 15:00 Speaker from Energy Safety, MBIE, Peter Morfee, principle technical advisor.

15:00 – 16:00 Speaker from Electrical.

Workers Registration Board, MBIE, John Sickels, registrar.

16:30 – 19:00 BBQ at MIT.

Day 2: 9 March 2013 - formal part

Last year’s conference was held in Wellington. Photos / supplied.

10:00 – 12:00 AGM/conference.

12:00 – 12:45 Lunch.

13:00 – 16:00 Conference continues.

16:15 – 18:00 Post conference council meeting.

19:00 – 21:30 Dinner and investiture of officers.

For information about the conference contact:.

Gerry Ackerstaff, 2013 Conference Secretary/Treasurer.

Ph: (09) 296 1016, mob: (021) 171 8218 Email: ackers_195@gmail.com.

Venue – Airport Gateway Hotel, 206 Kirkbride Road, Mangere.

New Zealand Electrical Institute Inc. PO Box 64-258, Botany, Manukau 2163 Phone: 09 271 1901, Mobile: 021 613 448.

Day 2 Programme

Email: nzei@xtra.co.nz

09:30 – 10:00 Morning tea – meet and greet.

42

February 2013

generator

Power where you need it

Quiet power The Kubota diesel generator product line-up has gained worldwide recognition as the premier generators in the marketplace.

The pairing of the ever-reliable Kubota diesel engine with top quality alternators has resulted in a product line-up that is the most sought after in the under 30 kVA class. The Lowboy Series II is the highest selling Kubota generator in New Zealand. Built for the discerning owner who requires reliable power delivered from a small, quiet unit, the Lowboy II Series is the solution.

These units are available in single phase, 6 and 9kVA ratings. Measuring a tiny 1075mm (GL6000) and 1285mm (GL9000) L X 607mmW X 696mmH opens up a range of applications.

The Lowboy Series II generators achieve their compact design and superior performance by direct coupling the alternator to the engine which also means there is no drive belt to adjust.

The use of a larger capacity radiator with oversized muffler plus a low fan

speed ensures minimum operating noise levels. A matched air cleaner hose further reduces noise to make sure these generators are the quietest available.

These generators are designed with space in mind with quality features that we have come to expect from the world’s largest manufacturer of diesel engines up to 100HP. From keeping your ice-cream cold in your custom built van to supplying back up or emergency power to your household, the Lowboy Series II applications are endless.

•

Go to www.demm.co.nz/enquiry quote: D130243

Inverter generators have been on sale for a decade, creating a quieter, lighter weight and more economical genset.

The Kipor Diesel Inverter series feature a digital display with advanced remote control function enabling them to connect to offthe-grid systems or auto start and stop controllers, opening up the world for economical automated power supply.

The first model to be released was the ID5500, now in its second version, a 5500W single cylinder air-cooled generator, which allows fuel consumption of less than 1L of fuel an hour at low loads.

The newly released ID10 inverter generator features a three cylinder water-cooled diesel engine, which can vary its engine speed from 1700rpm to 2700rpm depending on load to a maximum of 10.5KW.

• Go to www.demm.co.nz/enquiry quote:

D130243a

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generator

MPower teams up with Pramac A strategic alliance has been formed with Pramac, a world-class European generator manufacturer, for MPower to market Pramac’s range throughout New Zealand, PNG, the Pacific Islands and Australia.

The alliance, which started in January, will build on MPower’s expertise and reputation for supplying reliable and dependable power systems, and will form the basis of an expansion of its standby and portable generator activities.

MPower is committed to supporting the existing and established Pramac dealer and sales network and will be seeking to further enhance the success of Pramac in this region.

MPower also assemble and distribute Advanced Power Portable generators ranging from 2.5kva to 15 kva and has just release Mine Specification generators.

•

Go to www.demm.co.nz/ enquiry quote: D130244

Advanced Power’s mine generators Advanced Power has released a new range of portable 3000rpm Kohler powered diesel ‘mine specification’ generators for use in rough mining conditions.

The sets are designed and built to withstand the rigors of site work, where portable power is required. This has a standard fitment of options that will allow the sets to be used in most industrial/ commercial applications.

All sets in this range come with a rated central crane lifting point, lockable battery isolator, 300mm earth stake, Gel SLA battery and European Linz alternators as standard.

All units are Spinefex Lifeguard equipped. Fitted with type rated high visibility yellow fibreglass boards with lockable polycarbonate breaker covers, individual RCDs per outlet, emergency stop button and auxiliary push to test outlet.

The generators sit inside a galvanised containment tray to eliminate substrate spilling or contamination that could be caused from oil or fuel spillage during filling or servicing.

If rolling portability is required, then a high

clearance heavy duty puncture resistant wheel kit can be fitted in lieu of the containment tray, giving plenty of rough terrain access for the roughest of sites.

•

Go to www.demm. co.nz/enquiry quote: D130244a

Flexibility for emergency lighting With a width of 5.2 mm, Phoenix Contact’s compact PTB 2,5 three-level terminal blocks provide high flexibility when wiring emergency lighting. In commercial buildings, standard lighting is often also used as emergency lighting, which provides flexibility, for example, when modifying building utilization.

Luminaires can be connected using just two three-level terminal blocks, reducing space requirements by up to 50 percent. Two bridge shafts per level make it possible to daisy-chain the DALI bus using the jump-over bridging.

In addition, it is possible to combine the potentials of the specified lamps for the emergency lighting. Since the bridge shafts are located on the inner side of the control cabinet, it is possible to select the luminaires at any time without a lot of wiring work.

The potentials of the luminaires can be protected at 250 V using 10 A 5x20 mm fuse inserts. Using a nested configuration, the fuse plug can be inserted into the universal disconnect zone of the narrow 5.2 mm three-level terminal block. Feed-through and knife-disconnect terminals with the same contours extend the range of potential applications.

• Go to www.demm.co.nz/enquiry quote:

D130244b

Read an article in this magazine Fanless CX9020 PC controller The CX9020 embedded PC from Beckhoff represents a compact and want to know more? and state-of-the-art PC control. The fanless CX9020 is equipped It's simple, fill out the form and fax it in to 09 478 4779 or mail it to: DEMM Engineering & Manufacturing reader enquiry, Freepost 4359, PO Box 65 092 Mairangi Bay, Auckland 0754, or for quicker results go to

www.demm.co.nz/enquiry or email frank@adrenalin.co.nz Reader reply form Reader enquiry number:________________________________________________________ Name:_____________________________________________________________________ Your business name:__________________________________________________________ Position:___________________________________________________________________ Phone numbers:______________________________________________________________ Email:_____________________________________________________________________ Postal _____________________________________________________________________ ________________________________________________________________________

with a 1GHz ARM Cortex A8 processor, 1GB RAM and is suitable for a wide range of PLC and motion control applications in small and medium-sized machines, systems or buildings.

The embedded PC integrates a CPU, numerous IT connectivity solutions and optional interfaces, a power supply and a direct I/O interface for Beckhoff I/O systems, all in a compact housing.

In combination with the TwinCAT automation software platform the CX9020 system becomes a high-performance PLC and motion controller that can be used with or without visualization.

The CX9020 operating system is Microsoft Windows embedded compact 7. The extended operating temperature range between -25 to +60 degrees C enables application in demanding environments – covering a wide range of manufacturing facility types and outdoor applications, including wind turbines and solar power plants.

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44

February 2013

D130244c

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