MEPCA Magazine April 2023

Editor

Chris Callander chrisc@cimltd.co.uk

Publication Manager

James Davies jamesd@cimltd.co.uk 01795 509105

Account Manager

Hannah Moody hannah@cimltd.co.uk 01795 509115

Design & Production

Grant Waters Grant@cimltd.co.uk

James Taylor james@cimltd.co.uk 01795 509108

Credit Facilities Manager

Lauren Sharpe creditcontrol@cimltd.co.uk 01795 509103

Administration Manager

Natalie Murray admin@cimltd.co.uk 01795 509103

Sales Director

Tom Woollin tom@cimltd.co.uk

Chief Executive

John Denning jdenning@cimltd.co.uk

www.mepca-engineering.com

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With National Careers Week taking place recently, it’s no surprise that we have been hearing of projects designed to encourage young people into engineering careers. It is encouraging to see a growing number of initiatives such as those we cover this issue from Engineering UK, Imperial College London and the University of Sheffield’s Advanced Manufacturing Research Centre (AMRC). And while I can regularly report on initiatives from other organisations such as Primary Engineer, World Skills and Enginuity, it is essential to remember that the challenge of bringing more young people into engineering roles is not just the responsibility of educational institutions and the organisations set up specifically for that purpose.

Attracting young people into engineering roles is a shared responsibility of various stakeholders, including governments, educational institutions, engineering societies, associations, dedicated NGOs and, importantly, engineering companies themselves.

While governments play a vital role in promoting and funding engineering careers, educational institutions can design programs that are attractive to students, and engineering societies and associations can promote engineering careers, engineering companies must create a positive image of the profession by offering benefits and work environments that appeal to tomorrow’s workforce.

Engineering companies are central to developing and promoting innovative and exciting projects, offering hands-on experience, demonstrating clear career prospects, enabling flexibility and showing how their roles can positively impact society. And while it may not be the primary motivator, a competitive salary and benefits package can also attract young people to engineering roles.

Overall, prospective engineers need to see that the sector can offer them a combination of challenging and meaningful work, opportunities for growth, and work-life balance.

Of course, it is much easier for the major manufacturing and engineering companies to dedicate resources to promoting the sector, but there will be something every engineering-based company can do. And possibly the best place to start is to talk to the organisations already promoting engineering roles to see how they can help and how to get involved.

Chris Callander, Editor @Mepca-magazine

To subscribe to MEPCA visit our website www.mepca-engineering.com or scan the QR code.

Engineers making a difference

Two University of Sheffield AMRC Training Centre

alumnae feature in a new book that will be sent to every secondary school in the UK to inspire and excite young people about careers in engineering.

Beth Cousins, now a project engineer at the University of Sheffield Advanced Manufacturing Research Centre (AMRC) and Kate Todd-Davis, who works as a manufacturing engineer for Rolls-Royce, were hand-picked to appear in the book Engineers Making a Difference, alongside 44 other superhero engineers from sectors including construction, energy, transport, robotics, artificial intelligence and more.

The book, released just days before International Women’s Day, was penned by Dr Shini Somara, a mechanical engineer who is also a mentor at Imperial College London and a media broadcaster. Her love for engineering began in childhood, spending countless hours building things and pulling them apart to see how they worked – not to mention the curiosity she developed through watching her father, a mechanical and electrical engineer.

In the book, Beth, who works within the gears team at the AMRC, part of the High Value Manufacturing (HVM) Catapult, said that collaboration, creativity and

communication are essential in her job and that she loves the team of brilliant people she works with.

Kate, who uses old and new technologies as part of her day job, where she helps make parts for jet engines, finds her work fascinating and enjoys the hands-on approach to learning. In the book, she said: “At Rolls-Royce, the mindset is that apprentices are the future of the company, so we are always being taught new things and are given room to be creative.”

To help bring engineering careers into the spotlight further and reaffirm that anyone from any background can consider a career in engineering, the collaborators of Engineers Making a Difference, are sending out a school kit to every state secondary school in the UK, which includes two copies of the book, a teacher’s guide, 12 posters and a fourmetre-long timeline wall chart.

The project is supported by the Gatsby Charitable Foundation, set up by Lord Sainsbury to give charitable funding to science, education and art projects.

Collaborating on the project are Imperial College London, a global top ten university with a strong focus on STEM subjects, and What on Earth Publishing, a publisher of non-fiction books that engage the natural curiosity of young people.

The book can also be found at: bit.ly/ICLEMaD

Oscar win puts Made Smarter-backed puppet-maker in global spotlight

The puppet–maker behind the Oscar-winning animation

Pinocchio has praised the transformative impact of Made Smarter’s technology adoption programme.

Mackinnon & Saunders, based in Altrincham, collaborated with Hollywood director Guillermo del Toro to manufacture the miniature stars of the hit Netflix stop-motion animation.

Pinocchio is the first puppet that has been made using 3D-printed stainless steel. The innovation was made possible through the Made Smarter North West adoption programme, a government-funded initiative

to help SME manufacturers digitalise, decarbonise and drive growth through new technologies and skills.

Funding support and impartial expert advice enabled Mackinnon & Saunders to test and trial new 3D techniques with Laser Prototype Europe (LPE), a rapid prototyping service bureau based in Belfast.

On 12 March, Pinocchio followed up its incredible clutch of awards, including a BAFTA and Golden Globe, with the Oscar for ‘best animated feature’.

Commenting on the success Peter Saunders, Co-founder of Mackinnon & Saunders, said: “We are thrilled to have played a part in creating such a successful film which

has been watched and loved by so many.

“It means the world to our team to have worked on an Oscar-winning film. It is also testament to what can be achieved through programmes like Made Smarter, who gave us such valuable technical support and facilitated our exploration of this game-changing technology.”

Inspiring the next generation of engineers

EngineeringUK has launched a new careers resource designed to help entice young people into STEM careers.

‘From idea to career’ is a free, downloadable booklet for young people, teachers and careers advisors, which showcases the breadth of rewarding careers available in engineering and technology. From aerospace and energy to manufacturing and software design, the resource is designed to educate and excite young people about careers in 12 engineering disciplines.

The resource has been produced by EngineeringUK’s Careers Working Group - a collaborative group of careers, education, outreach and marketing specialists drawn from across the engineering and STEM community. The group produces a variety of free and interactive careers resources which are available to download on Neon, a website bringing together the UK’s best engineering outreach opportunities and inspiring careers resources in one place.

Eleanor Eyre, Head of Careers at EngineeringUK, commented: “There are so many exciting, rewarding and impactful careers within engineering and technology; however, young people often aren’t always aware that they exist. We’re delighted to have partnered with the engineering community, including over 25 professional engineering institutions, to create a resource showcasing the breadth and scope of engineering-related careers.”

The updated booklet also strongly focuses on environmental sustainability throughout – an area of particular interest to many young people. It showcases how careers in the 12 areas link to the UK’s net zero targets around carbon emissions and highlights how sustainability is a priority for every industry.

‘All routes into engineering’ is another impactful new resource – this 20-page booklet explains the different vocational and academic routes into the sector, including T levels, apprenticeships and degrees.

Find out more and download ‘From idea to career’ at: bit.ly/EUKIdea and ‘All routes into engineering’ at: bit.ly/EUKAllRoutes

Former Ford chair to lead advanced manufacturing centre

The Coventry-based centre for advanced manufacturing technologies, the Manufacturing Technology Centre (MTC), has appointed Dr Graham Hoare OBE to succeed Dr Clive Hickman OBE as its new CEO. Dr Hoare brings over 35 years of top-level industrial and commercial experience to the role.

Dr Hickman will retire as CEO of the MTC on 31 March, and, as announced last year, he will become Chair of the MTC board with effect from April.

Dr Hoare is a former Chair of Ford of Britain, having spent two decades with the carmaker in various senior roles. He began his career at Ford as director of powertrain research and advanced engineering at its US headquarters in Dearborn, Michigan. He was also the executive director of European powertrain engineering and director of global vehicle evaluation, and in 2018 was awarded the OBE for services to the UK motor

industry.

Previously, he was the chief engineer for transmissions and driveline at BMW and chief engineer, powertrain engineering, at Land Rover.

More recently, Dr Hoare briefly acted as interim CEO of Britishvolt, appointed to secure the future of the business, which has recently been acquired by Recharge Industries.

Dr Hickman, who has been CEO of the MTC since its creation 12 years ago, said, “I am delighted to report that the MTC is now a £120 million, 900 employee business with operations across the UK, and is supporting businesses large and small, regionally, nationally and internationally.

“I know that with his vast experience in the sector, Graham will propel the organisation to the next phase in our ambitions to become an even more integral and resilient member of the UK

manufacturing community. I wish him every success in the role.”

Dr Graham Hoare OBE (right) succeeds Dr Clive Hickman OBE as the Manufacturing Technology Centre’s new CEO

Unlocking efficiency and productivity in manufacturing

Integrating robots into a control system offers a myriad of benefits, with increased efficiency and productivity being one of the most significant. Robots excel at performing repetitive tasks much faster than humans, leading to faster turnaround times and more efficient use of resources. Automation helps eradicate bottlenecks, reduces cycle times, and increases overall production capacity, resulting in streamlined manufacturing processes that minimise waste and maximise productivity.

Moreover, robotic automation ensures higher quality control by performing tasks with greater precision and consistency than human workers. Robots maintain strict tolerances, perform quality inspections and measurements and quickly identify defects, thereby reducing the risk of errors and enhancing product quality.

An easy way of integrating robots into

manufacturing lines is to implement a modular approach using motion control solutions — like Beckhoff’s Automation Technology for Robotics (ATRO) — so that machine builders can secure a complete automation solution from a single source. This technology is specifically designed for robotic applications, offering highperformance and precise motion control capabilities. The system consists of a range of hardware and software components that work together to achieve high levels of accuracy and repeatability in motion control. Using a motion control system to integrate robotics into a manufacturing line ensures that all software and hardware components are optimally matched, from the machine’s power supply to cobot-enabled modules, and all functions such as robotics, vision, safety, cloud robotics, and machine learning are fully integrated on a single control platform and architecture, enabling direct

combination with intelligent transport solutions.

The ATRO system is built on Beckhoff’s TwinCAT software platform, which provides a wide range of programming options and tools for motion control. This software platform allows for the creation of custom motion control algorithms, as well as the integration of other automation systems, such as vision systems and sensor networks. The software also includes a range of diagnostic tools for monitoring and troubleshooting the system.

www.beckhoff.co.uk

Non-contact linear encoders based around flexible product platform

SICK has expanded its proven, non-contact magnetostrictive linear encoder portfolio with the launch of a versatile product family for wideranging industrial applications. The DAX linear encoders precisely determine the absolute position of pistons in hydraulic cylinders, as well as reliably monitoring linear motion in many common industrial machines.

The DAX encoder represents an important milestone in the development of SICK’s encoder portfolio, opening up the availability of SICK’s magnetostrictive technology to industrial users for the first time.

The DAX offers a timesaving way for cylinder manufacturers, OEMS and endusers to access a reliable source of supply. The encoders offer space-saving benefits for new machinery, as well as backward compatibility with existing installations, and can be customised to work with all common

magnet types.

In just a few steps, SICK’s Online Configurator guides the user through the specification process to generate a part number and create an online order. Thanks to the platform concept of the DAX, application-specific versions can be generated quickly. There is also the flexibility of further customisation for new machine designs or to enable adaptation to existing machines, including where proprietary magnets are already in situ.

The DAX is being launched with three housing designs: one for integration into industrial hydraulic cylinders; a low-profile type with block magnets for mounting in tight installation situations; and a version with an integrated slider that guides the position magnet, easing the requirements on alignment during mounting.

Integration into existing or new machinery is straightforward using standard mechanical

interfaces. For electrical installation, the DAX product family offers a CANopen as well as an analogue output for either 0-10 VDC or 4-20 mA.

The DAX encoder family has industryappropriate measuring ranges for countless applications as diverse as packaging machines, wind, hydro and solar plants, wood processing machinery, or medical technology.

www.sick.co.uk

Cobot delivers class-leading speed, accuracy and safety

ABB has launched the SWIFTI CRB 1300 industrial collaborative robot, bridging the gap be-tween industrial and collaborative robots.

Combining class-leading speed and accuracy with ex-panded load handling capability of up to 11kg, the SWIFTI CRB 1300 can be used in a wide variety of production and product handling applications – from machine tending and pelletising to pick-and-place and screwdriving.

“Our customers are looking to robotic automation to make their processes more flexible, efficient and resilient, helping to counter labour shortages by enabling their employees to perform more value-added work,” said Andrea Cassoni, Managing Director for Global General Industry Robotics at ABB. “The latest addition to our SWIFTI family is a highly accurate, high

payload cobot that is up to six times faster than other robots in its class. This means it can be used by both SMEs and large manufacturers looking for collaborative automated solutions to achieve new lev-els of flexibility and productivity.”

Featuring a high-quality design backed by expert support, the SWIFTI CRB 1300 incorporates several features that can improve production efficiency by up to 44% compared to other cobots in its class. In a typical palletising application, SWIFTI’s speed and performance enable it to handle up to 13 boxes per minute compared to the nine boxes possible with other cobots in its class.

Powered by ABB’s OmniCore C30 and C90XT controller, the SWIFTI CRB 1300 is up to five times more precise than any cobot in its class, making it ideal for tasks requiring consistent accu-racy and repeatability. This, combined with a top speed of 6.2m/s, and payload options from 7kg

to 11kg and reaches from 0.9m to 1.4m, enables the SWIFTI CRB 1300 to perform a range of higher payload tasks including screwdriving, assembly, pick-and-place, and palletising. With pro-tection against dust and moisture (up to IP67), it can also be used in demanding environments, making it ideal for machine-tending applications.

go.abb/robotics

Easy to maintain IBC pump offers flexibility and lower cost of ownership

With many process fluids, chemicals and food stuffs being stored in containers, it’s not uncommon to have multiple barrel or IBC pumps onsite. With their role critical in delivering many processes, it’s important to consider the barrel pump’s total lifetime cost, which means not only considering the upfront cost, but also what is economical in the long term.

If you are considering your drum and IBC pumps’ total lifetime costs, if a process change could mean having to replace them before the end of their life, or if you are spending too much time maintaining them, the new modular VISCOPOWER was designed with exactly this in mind.

As processes are refined and the product improved, there are instances where a pump installed to perform a job is no longer entirely compatible with its modified application and needs to be replaced. The beauty of the

VISCOPOWER’s modular design is that you can simply change the screws, stators, motors or seals to adapt the pump to the new process.

Maintenance of wearing parts and cleaning, particularly in food processes, is a must. Thanks to its standardised clamp connections and fewer parts to remove, dismantling for cleaning and maintenance is up to 80% quicker with the VISCOPOWER than other barrel pumps.

The standardised clamp connection on the discharge means that all kinds of hose connections, outlet fittings, flow meters and bypass valves can be easily fitted to the pump.

The progressive cavity design makes the VISCOPOWER capable of high-pressure pumping up to 15Bar, solid handling up to 8mm, gentle pumping for shear-sensitive

media and transferring both low- and highviscosity fluids up to 100,000mPas. It has minimal dead space for bacteria to harbour, while electropolished surfaces and versions with a closed mechanical seal and FDA/3A approvals also make it an ideal solution for food and pharmaceutical applications.

www.castlepumps.com

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Navigating hazardous area safety requirements

Safety compliance expert and AEMT lecturer, Peter Rawlinson, looks at the key legislative requirements you may come across concerning hazardous environments, what they cover and how they relate to each other.

Before we get into specifics, it might be helpful to outline how different types of requirements compare briefly. A Standard is a technical specification covering aspects such as dimensions, capacity, ratings etc. It is not a legal requirement but is widely considered best practice.

A Regulation in EU terms is a piece of law universally applicable to all EU member states.

An EU Directive is a legislative act outlining objectives that all EU member states must translate into their national legislation.

A Statutory Instrument is similar to an EU Directive and is the principal form in which delegated legislation is made in Great Britain. Certification is the process of certifying that products, processes and people pass performance and quality assurance tests outlined in relevant standards and legislation.

The first acronym we will look at is IECEx, (International Electrotechnical Commission System for Certification to Standards Relating to Equipment for Use in Explosive Atmospheres). This aims to ‘facilitate international trade in equipment and services for use in explosive atmospheres, while maintaining the required level of safety’. The IECEx system started as a product certification scheme but has since expanded to cover personnel certification offering competence training for people working in explosive atmospheres.

IECEx has a broad global reach and is sometimes referred to as a passport scheme in so far as it is accepted by many countries prima facia, while some may accept it but require signing up to a local scheme.

Indeed, the IEC scheme is the starting point for the development of the standards for EX equipment, and use.

Because of its international scope, the Ex

Repair training offered by the Association of Electrical and Mechanical Trades (AEMT) follows unit Ex 005 of the IECEx Recognized Training Provider Programme (RTPP), which focuses on the BS EN IEC 60079-19 standard on repair, overhaul and reclamation of Ex equipment, alongside the BS EN IEC 60034-23 standard “Rotating electrical machines - Part 23: Repair, overhaul and reclamation”.

The ATEX directives are two EU directives describing the minimum safety requirements for workplaces and equipment used in explosive atmospheres, which must be applied in law by EU member states. There are, in fact, two directives. The ATEX ‘equipment’ Directive 2014/34/EU covers equipment and protective systems being used in potentially explosive areas. The ATEX ‘workplace’ Directive 1999/92/EC covers the minimum health and safety measures that need to be in place to protect people working in hazardous areas.

UKEX is a UK Statutory Instrument. This is a direct transposition of the ATEX equipment directive into UK law under the new postBrexit regime. This is driven in the UK by the UKEX AB (Authorised Body) group. The members of this group are also ATEX and IECEx certification bodies. It is in their interest for there to be ongoing alignment between the directives, and so it is unlikely that there will be a divergence between UKEX and ATEX despite the pending Brexit Bill and its impact on UK legislation.

DSEAR is also a UK Statutory Instrument and is a direct transposition of the ATEX workplace Directive into UK law. However, it also covers the requirements of the Chemical Agents Directive.

So, in essence, as far as regulation of hazardous area equipment and environments is concerned, IECEx is the starting point that enables the ease of

gaining ATEX and now UKEX. As such, if IECEx is amended, the amendments will automatically be adopted by the ATEX Directive and UKEX regulations by means of the acceptance of such amendments being “state of the art” for explosion protection.

Finally, you may come across CSA, UL or FM certification. This is a broad system to ensure the safety of products used in North America, including Canada, whereby an OHSA or SCC-accredited Nationally Recognized Test Lab (NRTL) can certify that a product complies with specific North American safety standards.

There are several standards which apply to hazardous areas under the North American system; for example, FM 3615, UL 1203, and CSA C22.2 No. 30 are the standards for Explosion-Proof Equipment, while UL 674 and CSA C22.2 No. 145 cover “Electric Motors and Generators for Use in Hazardous (Classified) Locations”. Some N American explosion protection standards are harmonised with the IEC, ATEX and UKEX systems, and others are not. In addition, the North American system follows a different environment classification system.

Manufacturers must step up use of digital technologies in supply chain monitoring

Make UK’s CEO, Stephen Phipson, explains why manufacturers are being urged to step up their adoption of digital technologies to monitor supply chains as part of efforts to build resilience in the face of permanent volatility in their markets.

The UK’s manufacturing base has enjoyed little respite since it came under siege at the start of the pandemic. Business conditions have evolved since that time, but often not favourably. While the end of the UK’s, and other nations’, pandemic lockdowns opened markets back up to trade, few predicted that global demand would exceed supply in such fashion as to hamstring the sector’s recovery.

With volatile pricing, unknown or unacceptable lead times and geopolitical sourcing implications, it’s little surprise that UK manufacturers have needed to place their supply chains under the microscope at extraordinarily short intervals. As manufacturers adapt at pace, supply chain uncertainty is growing.

Our most recent research with Infor finds that supply chain pressures will continue into the year ahead, with the overwhelming majority of companies reporting supply chain pressures in 2023 and looking ahead to 2024.

Resilience in supply chains is growing and driving new behaviours as recent pandemics and global trade disruption have taken their toll on confidence. Companies are focusing on building a resilient supply chain that can withstand these disruptions, manage the risk of further instability, and continue to function.

There is no one size fits all strategy that manufacturers are exploring, and each company will take account of several factors, including the complexity of supply chains as well as the distance from disruption. The most common trends include the diversification of supply, increasing stocking levels as well as shortening of supply chains, with a trend towards reshoring and nearshoring.

In research published in a paper titled ‘No weak links: Building supply chain resilience’, which we carried out with Infor and launched at the Make UK National Manufacturing Conference, 40% of manufacturers surveyed said that they had increased their supply from the UK. With a similar number saying they will do so in the coming year, the concept of reshoring is fast becoming a reality, and the intention is there in the year ahead.

While not fully defined, the concept of “friend-shoring” is also gaining international interest as rather than just focusing on bringing suppliers closer to home, companies focus on growing suppliers in markets which are considered stable, reliable and have shared objectives; in order words “, friendly”.

While it is likely to be a growing trend in the future as markets continue to be volatile and manufacturers are incentivised to look at their supply chains in more detail, there is currently limited evidence that this is leading to change today. However, given the pace at which the geopolitical situation is changing, especially with regard to countries such as China, it’s not too much of a stretch to imagine a scenario when sourcing components might become very difficult.

Supply chain monitoring is also firmly on manufacturers’ agendas, with 82% of manufacturers reporting that monitoring their supply chain is critical to their business.

However, there is a lag between citing its importance and using digital technologies that can help enhance supply chain monitoring. While manufacturers are dipping their toes in the water by using data analytics and dashboards, more sophisticated technologies such as AI and machine learning, which could be even more impactful, are yet to be considered overall.

There is a real missed opportunity here, and it’s vital that all stakeholders work together to help businesses understand the benefits.

And it’s not just the use of technology that is hampering the industry’s ability to truly unlock supply chain transformation. Age-old challenges such as lack of skills dominate, as well as companies’ inability to gain timely data.

The energy crisis, access to raw materials, labour shortages, input costs and wider supply chain disruption has created unprecedented times for businesses across the globe. UK manufacturers have prioritised keeping their heads above the water and continue to meet demand when supply-side constraints are making this challenging. However, with supply challenges set to continue, it is clear that companies are going to have to be adaptable, responsive and agile to keep their supply chain risk free.

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When standard does not suit, get an individual solution

With the introduction of its product configurator, in addition to the standard range for factory automation, process automation and safety technology, Automation24 now offers configurable products in its online shop.

The Automation24 configurator was specially developed to enable customers to configure products individually for their applications. All order-relevant information, such as price and delivery time, can be viewed directly at a glance. The articles can be found quickly and easily via the search or clear category structure at automation24.co.uk. The highclass technical support staff can also assist customers in the selection of products.

Automation24.co.uk is the first online shop on the British market where you can order configurable products and stocked standard articles in one shopping basket. Currently, you will find a wide selection of Endress+Hauser configurator products in the field of process technology. Additionally, you can source configurable safety edges and safety bumpers from ASO Safety Solutions. And more customisable manufacturer articles will follow soon.

One stop. Smart Shop.

The online shop www.automation24. co.uk is aimed primarily at small and medium-sized companies that cannot count on special purchasing conditions from manufacturers and wholesalers or only need a limited number of parts of an article. Since Automation24 offers a wide range of products, from sensors to control cabinets from many complementary categories, you will find complete solutions for your applications. Benefit from the range of devices from more than 60 different established manufacturers. The company is the price leader in many categories when purchasing small quantities. The prices of the products on offer are, on average, 24% below the manufacturer’s recommended prices and that from the first piece.

The Automation24 website is constantly being developed to ensure

the easiest process of buying and searching for products. Each product has a corresponding description and original photos created by Automation24 employees as well as documentation for download. The shop offers many features that make shopping easier, such as filters to search for products with similar parameters or suggestions for compatible accessories, product sets, everything with a one-page ordering process and much more. Thanks to the function to generate the offer directly from the website, you can immediately download it directly without waiting.

Thanks to the function to display the actual availability of products in stock, you can also get real-time information on delivery times for each product. Most orders are processed the same day the order is placed, which allows for fast delivery. An email and freephone contact number are available for technical and general questions about products. Automation24’s qualified engineers will assist you with technical support in selecting alternatives by choosing equipment that is suitable for the needs of your application.

Rapid dispatch thanks to stock in large warehouse

Automation24’s warehouse space is constantly expanding, allowing the company to stock more than 300,000 products for quick shipment on the day of your order. Order processing times are improved and enhanced by special machines, such as a cable cutter, which efficiently and accurately measures the quantity required at the point of purchase.

Choose from a range of over 7,000 branded products directly available in stock, or use the Automation24 configurator to configure the right product for your individual application. The Automation24 product portfolio includes many complementary categories, e.g. sensor technology, process instrumentation, industrial control and operation, safety technology, industrial network and communication systems, control and measurement technology, industrial lighting, protection, guidance and signalling systems, power supplies, as well as control cabinets, tools and drive technology.

New patents for ultrasonic flowmeter technology

Titan Enterprises has recently been granted additional patents for its ultrasonic flow technology used within its range of Atrato, MetraFlow and Process Atrato flow meters.

As a specialist liquid flow meter manufacturer, Titan first began developing a viable, accurate ultrasonic non-invasive small bore measuring device in 2001 as part of a longterm strategic plan. The work resulted in patented ultrasonic technology, which has since led to an expanding line of ultrasonic flowmeters and patents ranging from signal processing methodology to novel mechanical design.

Titan’s ultrasonic flow sensors use high-frequency sound waves to measure flow using the time-of-flight principle within the liquid in a small pipe. The ultrasound is injected with the direction of flow into the liquid by one piezoelectric crystal (the sensor) and is received by a second piezoelectric crystal further down the tube. These crystals then reverse the direction of the ultrasound in the tube, and both time-of-flight acoustic signals are measured. As one sound pulse is accelerated by the velocity of the liquid and the second retarded, the difference in the flight time is twice the fluid velocity, and as the dimensions of the flowmeter tubes are known, the volumetric flow can be calculated.

Most ultrasonic flowmeters can reliably measure fluids that transmit ultrasonic sound waves within a band (e.g. ±30%) around the speed of sound in water at 20°C. But if a fluid has significantly differing acoustic characteristics, for instance, viscous organic fluids or if measurement is at elevated temperatures, then the acoustic operational window can be missed by the sensors.

Titan’s proprietary Interface Software offered on the Atrato and MetraFlow overcomes this application challenge. The software functionality allows you to view the acoustic signal of the measured fluid in real time and, if required, move its position in the measurement window to ensure reliable flow measurement in the conditions of operation.

This increases the versatility of a single fluid calibrated meter to a much wider range of applications.

Ultrasonic flowmeters are the ideal solution for measuring low flow rates. Titan has developed several generations of ultrasonic low-flow meters based on its patented timeof-flight design able to measure the velocity of the fluid within the pipe. The very high signal-to-noise ratio from these devices has been widely proven to enable the metering of extremely low flows with great precision. The Atrato line of patented ultrasonic inline flowmeters consists of four models operating over a flow range of 2ml/min up to 20l/min. These low-flow ultrasonic flow sensors also offer excellent turndown (>200:1), repeatability (to ±0.1%), linearity and accuracy of better than ±1.0% of reading.

Titan’s ultrasonic flow devices are independent of Reynolds numbers and can therefore operate from laminar flow through to turbulent flow. This makes them highly

commercial, being able to accurately measure liquids ranging from water to high-viscosity oils. Being through-flow devices, they can also be tolerant to impurities in the system, which would cause havoc to meters with moving parts.

The rugged, clean bore construction of the Atrato and MetraFlow ultrasonic flowmeters make these devices ideal for almost any low-flow application, from research and development to industrial processes and even the metering of chemically challenging liquids. In addition, the Process Atrato, durably constructed from 316 stainless steel and PEEK, and incorporating Titan’s patented time-of-flight ultrasonic flowmeter technology, is specifically designed for use in demanding process and control environments. This meter is currently proving to be rock solid in tests within a totally unique environment - microgravity.

flowmeters.co.uk

Seamless communication from the field to the cloud

Industrial sensor technology specialist, Pepperl+Fuchs, explains how its IO-Link master with an OPC UA interface is supporting the growing demand for the seamless exchange of information between the field and the cloud.

Plants, products, and systems are becoming increasingly networked. This has resulted in a major effort to set machine-to-machine (M2M) communication standards. In recent years, one such standard has already established itself on the market: OPC UA. This cross-vendor, open architecture is designed for information exchange in industrial communication. In addition to M2M communication, the technology supports data and information exchange between machines and higher-level systems in Industry 4.0 environments. Pepperl+Fuchs presents the world’s first IO-Link master with an OPC UA interface that combines the architecture’s benefits in one device.

Seamless communication

OPC UA, short for Open Platform Communications Unified Architecture, enables the platform-independent, interoperable, and cross-vendor collaboration of machines in production and makes communication between machines and systems possible – both in closed networks and via the internet. OPC UA is more than just a communication protocol because the architecture also includes data models and interaction concepts. The interface is also scalable, which makes it suitable for both small- and large-scale infrastructures and supports use with mobile devices.

OPC UA is based on standards and guidelines that must be followed for compliant use of OPC UA communication. This way, the technology helps make processes in plants even more efficient while ensuring a seamless information exchange across all levels.

For the first time, Pepperl+Fuchs has incorporated OPC UA into IO-Link masters

and is now introducing the ICE 2 (EtherNet/ IP) and ICE3 (PROFINET) master series in addition to the ICE1 masters that are used for PLC-based systems and time-critical applications. Both new IO-Link master series come with an OPC UA interface and a realtime fieldbus protocol, making them an ideal solution for cloud-based applications that are less time-sensitive. With a completely webbased configuration concept that does not require additional software, they exemplify efficient commissioning and are an optimal solution for standalone applications with no superior PLC. All module settings can be saved as a separate file, so the configuration can be easily transferred to a new device (module cloning).

Simultaneous, interference-free communication via OPC UA and Ethernetbased fieldbus protocols also makes hybrid systems possible. In these cases, a PLC coordinates all time-sensitive applications and processes, while less time-sensitive, aggregated condition data is transferred to the cloud. Because of the MultiLink protocol,

users can simultaneously access the device via the PLC and the cloud.

Highlights of the IO-Link Masters with OPC UA interface include the crossvendor, platform-independent exchange of information (M2M communication), flexibility with both cloud-based and hybrid systems with a combination of PLC and cloud, a completely web-based configuration concept for user-friendly commissioning and a module cloning function which enables easy device replacement and plant expansion.

www.pepperl-fuchs.com

Compact safety light barriers for the food processing industry

Schmersal has developed a new series of safety light barriers suitable for hygienesensitive applications in the packaging and foodprocessing industries, such as milk and meat processing. With a diameter of 62mm and a height of 115mm, the singlebeam light barriers in the SLB series are extremely compact. This makes them ideal for thermoforming machinery for food packaging, cutting equipment, or other machinery with narrow installation spaces. Thanks to a sophisticated, detailed design, the SLB440 series achieves IP69 degree of protection and is thus protected against water ingress during close-range high-pressure and high-temperature spray downs. This means that the external and internal seals on this contactless active protective device (AOPD) meet very strict requirements and can withstand frequent

cleaning with alkali solutions, foam, hot steam or high-pressure jets.

The new AOPD product line has also been created based on hygienic design principles. The locking caps on the SLB440 are made of stainless steel (V4A), as are the cable inlet, pressure equalisation diaphragm and fastening parts. Made of polycarbonate (PC), the transparent protective tubes offer not only high resistance to cleaning agents but also withstand strong mechanical loads. If spray lances should accidentally strike the SLC440 IP69’s enclosure during pressure washing in food production, the safety and protection function will continue to work thanks to the robust protective tubes. The materials thus ensure higher process reliability and a lengthy safety light barrier service life.

The AOPD series features integrated evaluation with two safety outputs connected directly to the higher-level control

system. Additional features of this AOPD series are the integrated setup aid and straightforward connection option with M12 connectors (4-pole or 5-pole). Visitors to Hannover Messe in April can see the light barriers on stand D09, Hall 09.

www.schmersal.co.uk

KUKA robots on international tour

KUKA robots are demonstrating their capabilities by providing an innovative backdrop for Belgian artist Stromae’s spectacular international tour.

Stromae’s ‘Alors on danse’ brought him worldwide fame. Now Stromae, Belgian singer, songwriter, and composer, is continuing his Multitude tour in Europe from March to December 2023. On stage with Stromae are Ten KUKA robots that move oversized LED screens. A video that has now been released across the globe shows how this spectacular stage set came about.

“The stars of this show are obviously the robots,” Stromae pointed out in an Instagram video posted in July 2022, “they were the main inspiration of this show.” Ten robots – five hanging from the ceiling, five standing on the floor – shape the show with their specially choreographed movements. In some sequences, all the screens join together to form a kind of giant canvas, in others, they form an arc of images around Stromae and his musicians or shine down on them from above. Video sequences can be seen on them, as well as light installations and a Stromae avatar that dances in sync with the living artist.

On his official YouTube channel, Stromae has published a video illustrating how the partnership between the artist’s creative label Mosaert and KUKA came about. The video highlights the contrasts between dazzling international stage shows and German mechanical engineering at its best!

KUKA is the exclusive partner of Stromae’s Multitude Tour, and March 4 marks the start of the 2023 concert year for Stromae and his crew in Bordeaux, which will take them through various cities in France and then onto other European countries. There are local dates in Belgium in Brussels and Rotselaar, in the Netherlands in Amsterdam, in Switzerland in Geneva and Basel, in Germany in Cologne and Berlin, in Great Britain in London and in Italy in Rome. Throughout 2022, the Belgian

musician toured the USA and Canada, among other places. One highlight was his sold-out performances in New York on two consecutive evenings at Madison Square Garden, both with KUKA robots on stage, supporting the incredible stage show.

By the end of his two-year Multitude Tour, the robots will have been set up and taken down more than 90 times. The stage set is dismantled in less than 24 hours and reassembled in the next concert venue. This is only possible if both the robots and the entire team in the background are flexible. KUKAs France subsidiary did most of this job behind the scenes. They advised the artist in advance of what was needed, gave the whole plan a structure consummate with the intense show schedule and are now the first point of contact when the robots need servicing. Two additional KUKA robots are on hand in the background as contingency replacements, and KUKA system partner, Paris-based Vendôme Robotics, which managed the programming and choreography of the robots, will provide additional support where needed.

Setting the entertainment industry in motion

KUKA can provide the entertainment industry with innovative solutions that meet the sector’s specific demands. KUKA products feature at amusement parks, in creative art installations and at music venues and events.

To watch Stromae’s tour video featuring the KUKA robots, visit youtu.be/4T1814tHqYs

www.kuka.com

NCC

8-pole bayonet locking

> 5000 mating cycles

Panel mount parts unplugged IP67

Solder and dip solder contacts

www.binder-connector.co.uk

Real-time data monitoring ensures defect-free relays

OMRON Automotive Electronics Italy has upgraded its production line for Power and G8HN relays for the automotive market. The project, led by OMRON’s i-BELT Data Services team, has helped OMRON A.E.I. attain a quality rate of 100% on assembled parts, reducing costs associated with waste and additional checks, with a return on investment achieved after just one year.

The high quality standards demanded in the automotive industry require increased focus on efficiency and process repeatability when selecting the right technologies in the production of components for the industry. This is what led OMRON Automotive Electronics Italy (A.E.I.), a company that produces around 30 million parts for the global automotive market each year, to revise its manufacturing strategies using data analysis as a tool for smart, real-time management of critical process-based defects.

The first step of this strategic overhaul was to upgrade the Power and G8HN relays production line, an initiative supported by i-BELT Data Services, a technology service provided by OMRON’s Industrial Automation Business (IAB) division for everything relating to data acquisition and processing on board the machine.

Measuring the forces at play

The primary objective behind OMRON A.E.I.’s decision to upgrade its relay production line was to stamp out any inefficiencies that could result in batch defects and consequently cause financial losses and increase the risk of faulty parts reaching the customer. With support from OMRON IAB’s i-BELT Data Services, OMRON A.E.I. developed a new qualitycontrol model, which is no longer based on subjective intervention by downstream operators. Instead, the model is built on realtime analysis guided by intelligent systems able to eliminate any human error and faulty parts reaching the customer.

The engineers who worked on the project focused on the mechanical coupling of the plastic and metal components that make up the relays, known as caulking. This is the most critical part of the assembly process and is often the cause of faulty parts being supplied to the customer.

In the past, the qualitative check during this delicate stage of the process used to be performed by the operator, who carried out visual inspections based on statistics outlined in control plans to verify the correct appearance of a given component profile. However, this process didn’t allow for faulty components to be recovered. Instead, if defects were identified, production batches would be quarantined, checked a second time – costing both time and money – and would often then be scrapped.

OMRON A.E.I., therefore, decided to devise and implement a new control system based on measuring the caulking force in real time. The upgrade – made possible

thanks to OMRON AI NY controllers and components integrated within existing processes and interfaced with force sensors installed on the line – allowed OMRON A.E.I. to achieve a quality gate of 100% and establish a threshold to enable problems to be frozen as and when they occur. Therefore, in the event of coupling defects, the process stops instantly to allow operators to quickly find the best solution.

A process driven by data

The goal, with help from i-BELT Data Services, was to integrate the OMRON AI controller and the N.Y. controller within the process to achieve the required quality threshold, store data during production and ensure part traceability.

Data analysis proved critical to achieving all the targets set in the preliminary phase. The OMRON i-BELT Data Services team based in the Netherlands gathered every piece of data remotely from the sensors,

OMRON A.E.I. decided to devise and implement a new control system based on measuring the caulking force in real time.

CONTROL SOLUTIONS

including both those already installed on the machine and those fitted ad hoc to help monitor critical processes. This included the force sensor located on the caulking head, which was required specifically to measure the force exerted on the coupling.

Having the load cell connected to the A.I. controller allows OMRON A.E.I. to detect the different profiles of the forces at play in real time, as well as determine the level and value of the force capable of ensuring a quality rate of 100%. One of the biggest advantages of the A.I. controller is that it can synchronize with the machine and intercept data with millisecond precision. This means that the A.I. controller can detect irregularities very accurately as well as give immediate feedback. The result is an incredibly detailed view of the process:

“We know exactly what’s going on inside the machine,” explained the engineers at OMRON A.E.I. “Just as a doctor examines a patient, the controller allows us to detect the force profiles at play and to identify the actions to take in order to resolve a problem.”

Controlled quality equals reduced costs

By using the very best Industry 4.0 and A.I. technologies from the i-BELT Data Services team based on process monitoring, analysis, verification and validation, OMRON A.E.I. achieved every one of its goals during the assessment phase. Above all, OMRON A.E.I. attained a quality rate of 100% on assembled parts, which is a must in the automotive industry. This also enabled the Frosinone site to eliminate all costs associated with additional batch checks and wastage, with a return on investment achieved in less than 12 months.

Furthermore, in terms of big data, A.E.I. is now able to store all of the measurements within a database and reprocess them at any time. Going forward, managers at the company said the plan is for the same method to be extended to other products based on similar processes.

Finally, it’s also worth highlighting the sustainable benefits that come with the upgrade, including reduced energy consumption (electricity, water, gas), shorter working times and use of scrap parts and noble metals (copper, silver, brass).

According to managers at OMRON A.E.I., these results are fully in line with OMRON’s green vision and serve as an example for all companies seeking to improve their own manufacturing processes by focusing on data analysis rather than more costly investments in new hardware infrastructure.

www.industrial.omron.co.uk

Just as a doctor examines a patient, the controller allows the force profiles at play the be detected and identify the actions to take in order to resolve a problem.

Robotics software for everyone available online

Fuzzy Logic has announced the launch of its no-code industrial robot programming and simulation software, Fuzzy Studio, on its website.

Fuzzy Studio is a no-code software that enables nonrobotics experts to simulate and program industrial robots. It is universal, compatible with most robot brands on the market, and allows even those who lack expertise in robotics or programming to create, program, and simulate their own robotic cell. With the rise of robotics in the UK and EU, as a means to relocate production, the company believes Fuzzy Studio provides an easy and low risk solution for investment.

Fuzzy Studio comes in two licenses on the Fuzzy Logic website: the Fuzzy Studio Simulation license allows non-robotic users to create and preview a robotic cell in a simulated environment, while the Fuzzy Studio Production license provides all the tools necessary for the integration and operation of a real robotic cell.

Ryan Lober, CEO of Fuzzy Logic, said: “This online launch is the culmination of two years of Fuzzy Studio evolution built on deployment in production with our existing customers. Fuzzy Studio is now ready to be offered to a wider audience and is currently the most advanced and accessible industrial robotics software on the market.”

Today, solutions for creating robotic cells are often complex. With Fuzzy Studio, this process becomes incredibly simple and accessible. The software provides a wide library of robots and is highly compatible with 3D digital design formats (CAD). It enables the creation of an interactive virtual cell, which is intuitive and easy to handle for robotics novices. It offers anyone the opportunity to design, program, and simulate a robotic work cell for a fully functional real-time digital twin.

Optimising the cell

Fuzzy Studio includes a collision detection function to immediately validate cell sizing.

The positions of objects are configured and visible in minutes, and potential collision sources between parts of the digital twin are anticipated. Any object can be easily reconfigured in just a few clicks. When the positioning of an object is modified, the trajectories associated with that object are updated accordingly. Interactions are dynamic, and the feasibility of robot trajectories appears immediately.

Automatic trajectory generation

Robot trajectories require lengthy and complex programming by a roboticist. With Fuzzy Studio, these complex trajectories are automatically generated in just a few clicks through the 3D information of objects placed in the digital twin. On the contours of a part for deburring or its surface for sanding and grinding, the possibilities are endless and available to all. An unlimited number of waypoints can be added to these trajectories. This functionality offers order of magnitude time savings to users, as the generation of trajectories frees them from dependence on robotic experts.

With Fuzzy Studio, the basic specifications of a project can be validated

in just a few minutes instead of several weeks, and at a lower cost. Information on the sizing of the robotic cell is displayed for easy decision making before moving on to real-time control. Parameters can be quickly modified in the simulation, reducing the investment risks of a robotics project. These advantages are unique in the market and allow for a drastic reduction in investment risks.

Real-time execution

The Fuzzy Studio Production license includes the features of the Simulation license, with the addition of a connection to the robot for real-time control. This control validates all the hypotheses formulated in the simulated cell, including trajectories, implementation, and collisions in the real world. With fast simulation, the risk of error is reduced to almost zero. If a problem is detected, it can be easily corrected directly in the simulation.

The Fuzzy Studio Production license includes an I/O input and output module, which allows the behaviour of a PLC in the virtual cell to be easily simulated and programmed with simple functions such as generating a trajectory or launching a grip. This feature adds flexibility to robotic program architects. The use of the Production license also does not require any special coding skills. A simple click of a button in the software allows for real-time connection with the Fuzzy RTOS software installed in the robot bay, enabling real-time control of the robot.

www.flr.io

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M12 connectors expand automation capabilities

For signals, data, and electrical power, M12 type connectors have become indispensable interfaces for device connectivity. MEPCA found out how binder is supplementing its M12 lines with additional products that enable users of automation technology to achieve efficient, flexible, and error-free installation.

Leading supplier of industrial circular connectors, binder, has expanded several M12 series for automation technology with various products. Applications range from basic sensor/actuator cabling to industrial measurement and control technology as well as industrial Ethernet to autonomous robots or cobots. The product development was based on the requirements of the M12-relevant DIN EN IEC 61076-2 standard. It follows current trends with regard to miniaturisation, variability in use and cost efficiency.

Like all M12 series from binder, these products meet at least IP67 protection. They are mechanically robust, durable, and designed to be user-safe thanks to coding. Several shielded or shieldable product versions are available suited to applications in electromagnetically loaded industrial environments.

For the current year, binder has announced further new developments in the field of push-pull locking and M12 one-cable solutions.

M12 basics

Originally used primarily in vehicle engineering, M12 has become established since the 1980s as an extremely robust, reliable, and compact but also highperformance interface in automation technology. It is used in new machinery and systems as well as for modernising existing infrastructure. The more the Industrial Internet of Things (IIoT) prevails in modern factories and process plants, the more the number of networking-capable automation components rises – and consequently, the need for industrial interfaces of this kind.

Depending on the coding and design, M12 connectors can transmit signals, data, and, if required, electrical power between field devices, such as sensors, controllers, drives, and other network nodes. On the one hand, they are able to handle the high data rates of modern Ethernet networks. On the other hand, they can also supply components such as drives with high power levels. In order to make the best possible use of available installation space, it is advantageous to transmit data and electrical power via one and the same connector. Such hybrid solutions are becoming increasingly attractive but are particularly demanding in their technical implementation.

The A coding (for sensors and DC power) is available with three, four, five, eight and 12 pins. The B (for Profibus), D (for 100 Mbit Ethernet) and X (for 10 Gbit Ethernet) codings with four and eight pins, respectively, are suitable for data transmission at different transfer rates.

In the case of power supply, for example

for AC drives and frequency converters, S and K (for up to 630V(AC) at up to 16A) and, for example for DC drives or LED lighting, T and L (for up to 63V(DC) at up to 16A) apply.

All M12 connectors provide minimum IP67 protection against dust and water ingress. Special variants are also available in IP68 and IP69K for hygienically demanding applications. Depending on the design, the M12 connectors are intended for different application scenarios. Versions with special termination, such as crimping or wire clamp technology, are suitable for applications with vibrations. Others are suitable for outdoor use and, for example, resistant even to UV radiation. Depending on the application field, metal, plastic or stainless-steel housings are used.

M12 innovations

As field devices increase in functionality, their power requirements grow. In addition, the density of interfaces increases, which requires particularly compact connectivity

The M12 panel mount connectors with L-coding are suitable for hand, wave and reflow soldering on printed circuit boards. Photo: binder

solutions. For devices supplied with 63V(DC) at up to 16A, binder has expanded its M12 portfolio with panel mount connectors with L-coding and dip solder contacts. The space-saving 823 series products are suitable for manual, wave, and reflow soldering on printed circuit boards. Protected to IP68 when mated, they are designed for both front and rear panel mounting, with their sophisticated two-piece design helping eliminate potential failure sources. Because the mounting body is soldered to the PCB, but the flange housing

portfolio of ready-to-connect cables in the M12 segment includes a number of versions. Straight and angled products, as well as products moulded on one or both sides, with various codings and in different cable qualities, are available with three to 12 pins.

M12 outlook

binder is responding to the trend towards miniaturisation and reduced installation

range of applications enormously.

Additionally, binder has announced the

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Efficient, hygienic, compact. IE5+, the new generation of synchronous motors from NORD.

Pre-assembled, over moulded, and tested M12 connectors significantly reduce the installation effort. Photo: binder

Reliable data connectivity in demanding environments

The new Mini PushPull is a waterproof and dustproof version of the ix Industrial Ethernet interface, a perfect choice for fast and reliable data connectivity in demanding industrial environments and applications exposed to the elements.

Standardised according to IEC/PAS 61076-3-124, the ix Industrial mating face in the Mini PushPull stands for reliable transmission performance and optional power supply via PoE/PoE+. With a 30% shorter housing compared to the HARTING PushPull RJ45, users benefit from a miniaturised data interface for demanding applications. PushPull is the preferential device connection technology, offering outstanding robustness in combination with simple and process-safe operation in waterproof and dustproof design to IP65/ IP67.

Compact, robust jacks are available for device integration on the PCB, providing maximum stability with five THR shield contacts. The jacks are available in three different versions:

1. Horizontal jack

2. Angled vertical jack

3. Vertical jack

All jacks are optionally available in the A and B codings for Ethernet and signals. The data contacts are designed as SMD contacts. This allows device manufacturers to process the PCB jacks according to the normal reflow soldering process.

The Mini PushPull add-on housing, which fits all matching jacks, is mounted in front of a rectangular mounting cut-out during device integration and connects the PCB jacks, providing IP65 / IP67 protection.

To aid integration into control cabinets and terminal boxes, the portfolio includes PushPull panel feed-throughs in A and

B coding. These can be mounted quickly and easily in front of a rectangular mounting cut-out. They meet protection class IP65/IP67 thanks to the integrated seal, whilst matching dust caps seal unused connectors and device interfaces securely.

Securely contacted plug connections are the prerequisite for stable network systems. To ensure correct connections under challenging conditions, PushPull connectors are straightforward and intuitive in their operation. Secure locking is signalled by an audible click, and the connection is released by simply pulling on the ergonomically optimised housing. To prevent unintentional disconnection, the removal of the connector can be blocked by way of a security ring.

PushPull connectors are the ideal device

connection technology for all industrial electronics devices executed to protection classes IP65/IP67, from sensors to controls and industrial computers.

www.harting.com/UK

The easy to use, well protected and compact PushPull connector series from HARTING is expanding, as MEPCA discovered.

HARTING Mini PushPull ix Industrial field-installable and over moulded version.

The HARTING Mini PushPull ix Industrial has a 30% shorter housing than the HARTING PushPull RJ45.

Intelligent heat recovery reduces energy demand

In 2012, Fertigungstechnik NORD, a member of the NORD DRIVESYSTEMS Group, developed a concept for heat recovery on machine tools. Since then, the recovered energy has been used for heating production facilities and offices as well as for hot water production. NORD is continuously improving and expanding the system to become increasingly independent of fossil fuel sourced energy.

In Gadebusch, components for NORD drive solutions are produced, including housings, shafts and gearing components. The machines used for component processing generate heat, which had previously been dissipated directly to the environment via electrically powered cooling systems. This left resources unused, and in the summer months, the five production halls in Gadebusch became considerably hot. Therefore, in 2012, the company developed a heat recovery concept, which has since been consistently implemented.

The heat recovery was implemented using plate-type heat exchangers, which were coupled to the machines’ various cooling systems with matching consumption capacities. The internal machine circuits have thus been connected to an external

circuit, which – being a cooling water circuit – dissipates excess heat and feeds it into a central heat recovery system. Up to now, Fertigungstechnik NORD has connected more than 80 machines to the system, which is networked with the production department and the production hall ventilation. In the recovery system, two heat pumps generate hot water for heating the five production halls and several offices. In summer, the heat is dissipated from the production areas via three cooling devices.

Continuous refinement

Fertigungstechnik NORD has been investing in heat recovery since 2012. Currently, the production halls’ temperatures are held at approximately 28°C, even in summer. The system operates without additional heating when outdoor temperatures are above 0°C.

If temperatures drop below zero, the system also uses gas for heating to ensure a basic heat of 19 °C in the production halls and offices. Currently, Fertigungstechnik NORD saves approximately one third of its former consumption of 583,000 kWh of fossil fuel based energy. This corresponds to a reduced CO2 emission of approximately 117 t. In the current year, the shower water will also be heated with the residual heat from the production department to stop excess heat from dissipating into the environment during the summer. In the context of a complete bundle of measures, this once more shows that resource conservation, cost reduction and environmental performance are firmly established in the NORD Group’s future. www.nord.com

In 2012, Fertigungstechnik NORD in Gadebusch developed a heat recovery concept, which it implemented in three stages. The concept is continuously refined, allowing the company to become increasingly independent of fossil fuel energy sources.

Image: NORD DRIVESYSTEMS

Paving the road to energy efficiency

The energy crisis makes one thing clear: It is not enough to just mount a photovoltaic system on your roof or subscribe to green power. Industry faces the challenge of reducing consumption in order to counter rising energy prices, reduce its carbon footprint, and, at the same time, be prepared for various taxonomies dictated by capital providers and/or governments. Solutions to these challenges are offered by HANNOVER MESSE, taking place in Hannover from 17 to 21 April 2023.

Potential energy savings are spawned by the interaction of IT and OT (operational technology). Smart Energy Monitoring from Hannover Messe exhibitor Baumüller, for example, helps users determine and subsequently optimise their carbon footprint. But most industrial users are still barely aware of many concealed consumption cases. Unregulated motors in pumps, fans, compressors or machines are still part of everyday life in many factories. Without control technology and the interaction of OT and IT, energy efficiency improvements are scarcely feasible. Direct current lines (DC), for example, are gaining importance. The advantage of DC is that frequency converters will become smaller, and the factory will become a “prosumer” – i.e. both a consumer and a supplier of energy. In addition, machines will communicate with the energy supply, or companies will build smart grids within the company – for example, to use employees’ e-cars as intermediate storage units. At the same time, customers are demanding greater system efficiency. A logistics centre doesn’t always have to run at 100% capacity when the machines know that a truck is stuck in a traffic jam. “To solve such tasks, you need domain knowledge. That’s what we have as automation companies, and that’s why many tech companies envy us,” explained Christian Wendler of the exhibiting company Lenze. He predicts a decade of automation.

The Energy 4.0 Conference Stages at Hannover Messe are dedicated to precisely these issues, providing an outstanding communication and competence platform for topics of an energy-intelligent, climate-friendly

and sustainable future. Here, industry thought leaders, first-rate experts and practitioners will present the latest trends and answer industry’s questions.

The many European automation companies are certainly also winners of the higher energy prices, because they have the technical answers for many applications – from storage solutions to speed control or DC networks. Energy conservation can only be achieved through the interaction of data, algorithms and physics. In addition, there is the factor of connectivity. Until now, energy data has been left out of the equation for many companies. But companies need to bring production and energy data together. Automation can help to conserve energy, water and CO2. One example is the Schaltbau plant. Both highly automated and with a DC power supply, it is expected to reduce costs by up to 35%. According to research conducted by Dr Mirjana Ristic of Bosch Rexroth within the framework of technology scouting surrounding DC technology and the results of the publicly funded DC-INDUSTRIE project, there is great potential for energy savings in this technology: “Industry consumes around 45% of the electricity in Germany, with drive systems accounting for around 70% it. If we start there, we can achieve major efficiency gains,” she explained. Within the German Electro and Digital Industry Association

(ZVEI), experts calculate an energy conservation potential of around 10%, with an estimated cost effect of approximately 20%. This is mainly due to savings involving AC to DC converters on motors. Average plant availability can moreover be increased to around 98%, according to the experts.

HANNOVER MESSE is the world’s premier trade fair for industry. Its lead theme, ‘Industrial Transformation – Making the Difference’, unites the display sectors of Automation, Motion & Drives, Digital Ecosystems, Energy Solutions, Engineered Parts & Solutions, Future Hub, Compressed Air & Vacuum and Global Business & Markets. The key topics include CO2-neutral production, energy management, Industrie 4.0, artificial intelligence and machine learning, and hydrogen and fuel cells. The exhibition program is complemented by a series of conferences and forums. The next edition will be hosted in Hannover from 17 to 21 April 2023. The Partner Country at HANNOVER MESSE 2023 is Indonesia.

www.hannovermesse.de

CHEMUK returns to the NEC this May

The CHEMUK 2023 EXPO, the UK trade show for process, control, and plant engineers, will return to the NEC, Birmingham, on 10 and 11 May this year.

Running as part of the trade event, The Chemical, Process & Plant Engineering Show will showcase the latest technology and specialist services to attending UK Plant, Process, Control & Engineering professionals from across the chemical and wider process industries.

Attendees will be able to discuss their requirements with hundreds of specialist engineering suppliers, including ABB, Borger, Burkert Fluid Control, EagleBurgmann Industries, Endress+Hauser, Gericke, HRS Heat Exchangers, KINETROL, RM Group, Siemens Automation, VEGA Controls Limited and many more.

Speaker Programme

In addition to the exhibition floor, visitors can attend any of the 40+ hours of keynotes, feature sessions, and panel discussions, running across the show’s five auditoriums and embracing some 150+ contributing speakers.

Highlights from this year’s programme include the IChemE Keynote Sessions, where three IChemE guest contributors will give keynote speeches. They are IChemE President, Professor David Bogle, from UCL, past President, Professor Jonathan Seville, Professor of Formulation Engineering at the University of Birmingham and IChemE Fellow, Professor Mercedes Maroto-Valer – Champion and Director at the Industrial Decarbonisation Research and Innovation Centre (IDRIC)

In the ABB Panel Sessions looking at Energy Management and Digital APM, ABB and invited industry experts will be examining these two hugely important topics. The first will discuss how managing your energy correlates to managing your business risk from current/future market forces and global events. Then the second will explore

how AI and Machine Learning improve business performance when applied to asset management.

The Process Intensification Network will be running two sessions. Part 1 will offer an introduction to Process Intensification by Prof. Adam Harvey, Professor of Process Intensification. Part 2 will explore ‘The role of Additive Manufacturing (3D Printing) in Facilitating Process Intensification’.

In the North East Pharmaceutical Manufacturing Showcase, the North East of England Process Industry Cluster (NEPIC) will bring together some key players from the North East pharmaceutical cluster to discuss the strengths of pharma manufacturing within the region. It will be joined by a number of NEPIC member companies to discuss their journeys within the sector, as well as key challenges, opportunities, technology trends and synergies with the chemical sector. A particular focus will be

placed on the role of continuous processing, as this is one of the key areas of innovation within the pharma manufacturing space. This will be a great opportunity to find out more about a regional sector that contributes to a third of the UK’s pharmaceutical GDP.

In addition, keynotes already confirmed to present this May include Richard Haldimann, Chief Technology & Sustainability Officer at Clariant, Professor Gill Reid, President of the Royal Society of Chemistry, Thomas Birk, Managing Director at BASF UK & Ireland plus, many more.

CHEMUK 2023 takes place on Wed 10 and Thu 11 May, 2023, at the National Exhibition Centre, Birmingham. The event opens from 9.30 am to 5.00 pm on day one and 9.30 am to 4.00 pm on day two. Free entry badges can be requested at the event website.

www.chemicalukexpo.com

Southern Manufacturing & Electronics sells out again

Pre-registrations for Southern Manufacturing & Electronics 2023 were the highest ever, and over

the three days in early February, 9,144 people visited the show.

At Southern Manufacturing & Electronics 2023, all 460 exhibitor stands were taken, on which 600 companies presented a vast array of high-technology mechanical, electrical and electronic components and assemblies, manufacturing and inspection equipment, controls and automation, engineering and business software, factory and workshop equipment, and a host of subcontracting and consultancy services. Most exhibitors were impressed not only by the number of visitors but also by the meaningful discussions and the high level of serious enquiries.

Hurco Europe, for example, booked more than 80 sales leads, 20% of them from new contacts. The company was promoting the latest features in its proprietary WinMax software, such as the Solid Model Import option that allows a user to create a program at the control directly from an STP file, with no need for CADCAM. David Waghorn, Managing Director, said, “Southern is proving to be a significant event for the UK manufacturing industry. Recent improvements to the road access and venue in Farnborough have guaranteed a better experience for exhibitors and visitors alike. We had no hesitation in rebooking the same space for 2024.”

LK Metrology was another exhibitor that was impressed with the show, as its stand generated considerable interest in the firm’s UK-manufactured coordinate measuring machines, as well as its portable measuring arms and accessories. Making its first public appearance was a new UKAS-certified gauge fixture holding length and form artefacts, which allows the inspection accuracy of any 3D measuring platform to be verified. Each CMM Checking Gauge (CCG) enables independent monitoring and verification of accuracy through regular intermediate

checks. Artefact measurement uncertainty is down to ± 0.01μm.

New on the 1st Machine Tool Accessories stand was the YS Modular System range from Japanese manufacturer Kitagawa. Usually fitted to lathes, they are now being offered for efficient static work holding on the table of machining centres. The pneumatically or hydraulically operated cylinders have multiple work holding options for pull or push chuck actuation and are rapid to set up for various production requirements. Cylinders with a standard mounting interface can be supplied to actuate 6-inch, 8-inch or 10-inch chuck sizes.

The Select Fiber laser was demonstrated to visitors by Coherent, which emphasised that choosing the right laser for a specific task, configuring the system and determining the ideal process parameters in this challenging environment requires specialised expertise and knowledge. The company is pushing the boundaries of what is possible in automotive, aerospace and electronics manufacturing applications.

Cleaning systems company MecWash featured its new MWX300, offering highpower cleaning in a very small footprint, including flood, spray and ultrasonic wash and rinse plus hot air and vacuum drying in a single chamber. Controls and Automation specialist Carlo Gavazzi made its debut appearance to explain the firm’s factory automation expertise, notably by introducing intelligence into processes using IO-Link sensors, digital solid-state relays, motor softstarters and energy management.

Unitemp, a specialist environmental engineering company that offers testing equipment for tough working conditions involving high temperature, humidity, vibration or acceleration, was on hand to promote its chambers with capacities from a few litres to several hundred cubic metres. The company also specialises in the design, installation and commissioning of modular custom environmental rooms.

Starrag UK was promoting its huge range of machine tools encompassing the Berthiez, Bumotec, Dörries, Droop+Rein, Ecospeed, Heckert, Scharmann, SIP and Starrag brands. A particular focus was the low-cost Heckert H65 compact, 4-axis machining centre. Occupying a footprint of just 24m2, it offers metal cutting speeds up to 30% faster than comparable models in its class. X, Y, Z travels are 850 x 1,020 x 1,000mm, and the 630 x 500mm twin pallets are each able to accommodate loads of 1.5 tonnes. The machine also boasts traverse rates of up to 80m/min.

Southern Manufacturing & Electronics 2024 will be held from 6 to 8 February. Further information is available on the show website. www.industrysouth.co.uk

The networking exhibition for the lifting equipment industry

Sponsors and Partners: Hosted by:

Packed show floor of lifting equipment and services

FREE TO ATTEND FOR USERS AND BUYERS OF LIFTING EQUIPMENT ACROSS MULTIPLE MARKETS

Fusion promotion offers huge savings on hundreds of items

Automated end-of-line packaging within reach of everyone

On 28 and 29 March at the 2023 Robotics and Automation show, end-of-line packaging specialist Brillopak will show its technology and automation architecture approach on stand r602. Visitors will see how it can help companies weather the perfect storm caused by labour issues and compounded by a need for faster return on investment.

The company’s BR2 PunnetPAKer and the single-cell UniPAKer have proven to be excellent initial installations for companies looking to take their first steps on their automation journey.

Visitors will see how Brillopak scopes out projects and creates architectural plans based on the ‘big picture’ before highlighting ways that phased installation of robotics/automation can spread and offset costs.

www.brillopak.co.uk

Highly efficient IE5+ synchronous motor

Carl Kammerling International has announced the return of its ‘Fusion’ promotion, offering discounts of up to 85% and deals on more than 200 product lines.

Fusion 2023 will reward merchants and wholesalers with huge discounts and incentives across products from C.K Tools, C.K Magma, C.K Classic, Avit and Kasp. After making an initial sign-up purchase of just £300, deals will be applied to every order, and all orders benefit from free delivery.

Running across much of its core range and a selection of new products, this year’s promotion has been devised to boost retailers’ bottom lines early in the year, setting them up for success throughout 2023.

Sion Lewis, Trade Marketing & Comms

Lead at CKI, says: “Our Fusion 2023 promotion offers some massive savings and amazing opportunities. These are unbeatable prices on quality, reliable tools from trade professionals’ trusted brands, and they’re coming at a particularly tricky time.

Fusion 2023 will run from 1st Feb to 27th May. It will be supported by a significant marketing campaign, with a wide array of POS and a promotional trade brochure.

Contact the CKI customer services team on 01758 704704 to sign up for the promotion today.

bit.ly/CKFusion

NORD sets new standards with regard to energy efficiency with the IE5+ synchronous motor, which achieves an efficiency of up to 95%. Thanks to permanent magnet synchronous motor technology (PMSM), it achieves this high efficiency relatively constantly over a wide speed and torque range and also provides very good energy consumption performance in partial load and partial speed ranges. This means that it even surpasses the highest defined energy efficiency class IE5.

Due to its wide power range, the IE5+ also contributes to reducing the Total Cost of Ownership (TCO) beyond the energy efficiency by enabling version reduction in an overall system.

www.nord.com

Industry firsts from warehouse management system

Supply chain solutions provider TouchPath claims several industry firsts centred on performance optimisation with the latest version of its ‘Touch WMS’ warehouse management system.

Advanced drag and drop load planning now ensures that pallets are loaded onto a trailer in the correct sequence.

The Touch WMS ‘power picking command centre’ is now highly granular, allowing individual picks to be assigned to an individual picker while tracking their real-time progress on a dedicated screen.

Touch WMS supports the full range of warehouse processes and can now be integrated with several leading ERP systems.

www.touchpath.com

CONNECTIONS

3D Print Manufacturing

Midlands 3D Printing

Units 6-7 Emerald Way, Stone Business Park, Stone, Staffordshire, ST15 0SR

T: 01785 594389

E: sales@midlands3d.com

W: www.midlands3d.com

Anti Vibration Products, Mounts & Bushes

Fibet Rubber Bonding (UK) Ltd

Unit 9 Dale Mill, Hallam Road, Nelson, Lancashire, BB9 8AN

T: 01282 878200

E: sales@fibet.co.uk

W: www.fibet.co.uk

Control Systems

Beckhoff Automation Ltd

The Boathouse, Station Road

Henley-on-Thames, Oxon RG9 1AZ

T:+ 44 (0)1491 410539

E: info@beckhoff.co.uk

W: www.beckhoff.co.uk

Dust & Fume Solutions

Impact Technical Services

3 Kingsley Street, Leicester, LE2 6DY

T: 0116 244 8855

E: enquiries@impactts.co.uk

W: www.impacttechnicalservices.co.uk

Flow Meters

Titan Enterprises Ltd Unit 2, 5A Cold Harbour Business Park, Sherborne, Dorset, DT9 4JW

T: +44 (0)1935 812790

E: sales@flowmeters.co.uk

W: www.flowmeters.co.uk

High Shear Mixing Equipment

Silverson Machines Ltd

Waterside, Chesham, Buckinghamshire, HP5 1PQ

T: +44 (0)1494 786331

E: sales@silverson.co.uk

W: www.silverson.co.uk

Industrial Communications

Brainboxes

T: + 44 (0) 151 220 2500

E: sales@brainboxes.com

W: www.brainboxes.com

Industrial Fans

Axair Fans UK Limited Lowfield Drive, Wolstanton, Newcastle-under-Lyme, ST5 0UU

T: 01782 349 430

E: aj@axair-fans.co.uk

W: www.axair-fans.co.uk

Machine Safety

Schmersal UK Ltd

Sparrowhawk Close, Malvern, Worcestershire, WR14 1GL

T: 01684 571980

E: uksupport@schmersal.com

W: www.schmersal.co.uk

Pipework Systems

Jacob UK Ltd

Laundry Bank, Church Stretton, SY6 6PH

T: 01694 722841

E: sales@jacob-uk.com

W: www.jacob-group.com/uk

Robotics & Automation

KUKA Robotics UK Ltd

Great Western Street, Wednesbury, West Midlands, WS10 7LL

T: 0121 505 9970

E: sales.uk@kuka.com

W: www.kuka.com

Rotation Monitoring Equipment

Rotech Systems

Unit 57, Canal Bridge Centre, Ellesmere Port, Cheshire, England, CH65 4EH

T: +44 (0)151 356 2322

E: sales@rotechsystems.co.uk

W: www.rotechsystems.co.uk

Sensors

Carlo Gavazzi UK Ltd

4.4 Frimley Business Park, Frimley, GU16 7SG

T: 01276 854110

W: www.carlogavazzi.co.uk

IFM Electronic

Efector House, Kingsway Business Park, Oldfield Road, Hampton, Middlesex, TW12 2HD

T: 020 8213-0000

E: enquiry.gb@ifm.com

W: www.ifm.com

Test & Inspection

Cupio Services Ltd

T: 01256 262800

E: info@cupioservices.co.uk

W: www.cupioservices.co.uk

Interested in advertising within future issues of MEPCA?

Please call 01795 509105 or email hannah@cimltd.co.uk for more details.

Accurate detection of actuating parts for harsh environmental applications

ICF Series: Full metal inductive sensors with IO-Link communication and available in M12, M18 and M30 robust stainless-steel housings.

• Pressure resistance on the sensing face up to 260 bar for M12, 200 bar for M18 and 100 bar for M30, thanks to one-piece stainless-steel housing

• Extreme mechanical performance: 25 g vibration resistance, 100 g shock resistance and 40 g continuous shock resistance; IK10 mechanical shock resistance (EN 50102), 1 J impact resistance (EN 60068-2-75)

• cULus and ECOLAB approved, IO-Link communication V1.1

• Extended operating temperature range: -40 to +85°C.

Resistant to short exposure (15’) at 100°C for cleaning process

• IP68 and IP69K protection

• High switching distances: 4 to 22 mm