March 2024 www.mepca-engineering.com
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WORLD. LEADING. INDUSTRYSHOW.
CONTENTS 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 James Burke jb@cimltd.co.uk 01795 509115
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Design & Production Grant Waters grant@cimltd.co.uk James Taylor james@cimltd.co.uk Administration Manager Natalie Murray admin@cimltd.co.uk 01795 509103 Credit Facilities Manager Gwen Lee creditcontrol@cimltd.co.uk 01795 509103 Marketing Manager Lucas Payne lucas@cimltd.co.uk Sales Director Tom Woollin tom@cimltd.co.uk Chief Executive John Denning © 2024 TGM Publishing Limited,1st Floor, Saphir House, 5 Jubilee Way, Faversham, Kent, ME13 8GD. No part of this magazine may be reproduced or stored in a retrieval system or transmitted in any form – electronic, mechanical or physical – without express prior permission and written consent of the publisher. Contributions are invited and when not accepted will be returned only if accompanied by a fully stamped and addressed envelope. Manuscripts should be typewritten. No responsibility can be taken for drawings, photographs or literary contributions during transmission or in the editor’s hands. In the absence of an agreement the copyright of all contributions, literary, photographic or artistic, belongs to TGM Publishing Limited. The publisher accepts no responsibility in respect of advertisements appearing in the magazine and the opinions expressed do not necessarily represent the views of the publisher. The publisher cannot accept liability for any loss arising from the late appearance or non-publication of any advertisement.
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n this issue of MEPCA, we focus on machine building. A major drive in the machine building sector is to increase energy efficiency and reliability. As well as reducing costs, both of these areas can positively impact sustainability as energy usage and waste are reduced. But with modern society used to replacing things when they stop functioning rather than mending them, what is less commonly discussed is the ability to repair industrial machinery. This does look to be changing. In the last year or two, I have seen several businesses emerging with a focus on sourcing and selling used industrial components, such as variable speed drives, servo motors, PLCs, etc. Many electromechanical repair specialists are expanding their offer to include the repair of electronic elements of industrial machinery that would previously have been swapped out. And even where a replacement is the better option, such as replacing an older industrial motor with a much more efficient modern alternative, vendors are introducing mechanisms whereby the old obsolete equipment can be removed and recycled. These practices all align with the aims of a circular economy, a concept which has been discussed for some years now but, in my experience, is still not widely understood. There is still a way to go. The practicalities of some aspects, such as the recycling schemes, mean they are currently limited to larger-scale situations. Meanwhile, the design of legacy equipment means the cost of repair can limit viability. But we are on the right path, and as awareness grows, so will adoption. Plus, with legislation such as the Right to Repair, which while currently consumer focused can only be more widely implemented in the future, and requirements to report on Environmental, Social, and Governance (ESG) activity, a growth in demand for ‘circular’ solutions should make them more economical and, in return accessible. Enjoy the issue. Chris Callander, Editor
@Mepca-magazine
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CONTENTS Industry Partners:
FEATURES 12 OPINION BPMA
14-15 COVER STORY Hannover Messe
17 MACHINE BUILDING FOCUS Bosch Rexroth, Stego, British Encoder, BPX, OMRON, Oriental Motor and Schneider
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38 ROBOTICS FANUC, KUKA and Kawasaki Robotics UK
54 EVENT PREVIEWS Machine Vision Conference, Automation UK and the National Manufacturing Summit
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INDUSTRY NEWS
University opens world-leading virtual reality teaching facility
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his year’s cohort of secondyear Product Design and Manufacture students at the University of Nottingham are the first in the country to benefit from a brand-new virtual reality (VR) classroom that revolutionises the teaching of VR software. Based in the university’s Engineering Science and Learning Centre (ESLC), the classroom enables remote viewing and communication between lecturers and students in a way that’s never been done before. Containing 40, high image quality VR headsets, 35 of which are tethered overhead to individual high-power PCs with the remaining five consisting of more traditional desk-based systems with display screens, students can choose the way they want to learn and experience VR. In addition to the in-situ technology, 90 wireless headsets are available to loan to students. These can be used in any location so that they can continue their studies outside the classroom. Staff and students also have access to several 3D scanners and 360 stereoscopic cameras. Professor Joel Segal, Head of
Mechanical Materials and Manufacturing Engineering (M3) in the Faculty of Engineering, said: “While many universities, including us, have existing VR labs, these are nowhere near the scale of our newly unveiled facilities, which will provide our students with access to cutting edge tools and technologies unlike anything else on offer across the globe. The room can also be used flexibly for other teaching purposes as, when not in use, the headsets can be raised into the ceiling space. “We have a desire to be at the forefront of technology in teaching, and we’ve already been making strides in this area in recent years in our smaller VR labs. Now, however, we have the opportunity to take the lead in the UK and further build our reputation for
producing engineers that are ready to shape the real world.” Another aim of the facilities is to allow real-time collaboration across international campuses, as Nottingham’s Ningbo campus has its own VR lab so that students from across the world can work together in labs or in design-based exercises.
Some 80% of new Piccadilly line trains to be assembled in Yorkshire
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iemens Mobility is in the final stages of fitting out a new train factory in Goole, Yorkshire, where up to 80% of the new Piccadilly line Tube trains will be produced, up from a figure of 50%m and the first time Siemens Mobility will assemble trains here, in Britain. The factory, which is due to open this spring, is part of the wider rail village where up to £200 million is being invested, up to 700 jobs will be created along with to 1,700 opportunities in the supply chain. Once completed, the site will include assembly and commissioning halls, a train components servicing facility, a materials and logistics warehouse, and the Rail Accelerator & Innovation Solutions Hub
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for Enterprise (Raise), establishing Goole as a centre of excellence for rail technology in the UK. The components facility, which services motors, gearboxes and HVAC for Siemens’ UK fleets, one-quarter of UK passenger trains, and the Raise hub are already open. Rolling stock for the UK train market will be assembled at the factory, starting with new Piccadilly line Tube trains for TfL and all future UK orders, including the Bakerloo line trains, subject to TfL securing further funding from the Government to renew the life-expired fleet. The first Piccadilly line train has been delivered from Goole’s sister factory in Vienna and has been undergoing extensive testing by Siemens Mobility’s engineers
at its test track and climate chamber in Germany ahead of the first train arriving in London this summer. Transport for London (TfL) will then carry out further infrastructure testing and integration before the new trains start entering passenger service in London in 2025.
INDUSTRY NEWS
The Big Bang Fair returns
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he popular Big Bang Fair the UK’s largest celebration of science, technology, engineering and maths (STEM) for young people - is set to return this summer. The annual Fair, which is run by EngineeringUK, is designed to ignite a passion for STEM and showcase the exciting career possibilities in these sectors. Taking place from Wednesday, 19 to Friday, 21 June 2024, at the NEC in Birmingham, The Fair will welcome students aged 10 to 13 from across the UK. Schools and home educators can register for free tickets to attend at www.thebigbang.org.uk/the-big-bang-fair A diverse range of employers will come together at the 2024 Fair to bring engineering and tech careers to life – from the aerospace, rail and automotive industries to energy, healthcare and more. This gives young people the opportunity to meet STEM professionals, as well as join exciting live shows and inspiring career panels. There will also be plenty of hands-on activities to get stuck into, including testing their driving skills by putting powerful robots through a series of challenges, experiencing piloting a submarine, discovering how different materials are used in sports and space
exploration and much more. Given the UK’s acute skills shortage and ambitions to meet net zero by 2050, we urgently need more young people to progress into engineering and technology. STEM engagement activities such as this are vital for developing their awareness and interest in these careers – helping the sector to secure a skilled and diverse future workforce. Also taking place at the Fair will be the awards ceremony for the popular Big Bang UK Young Scientists & Engineers Competition. Winners will be announced,
including the crowning of the prestigious Big Bang UK Young Engineer, UK Young Scientist and UK Young Technologist of the Year, supported by Siemens. The Competition, which is free to enter, is open to young people in the UK aged 11 to 18 in state-funded education, who are home-educated or who enter as part of a community group. There’s still time for young people to get involved – with the Competition open for entries until 27 March and details can be found at www.thebigbang.org.uk/the-big-bangcompetition.
Manufacturers accelerate ESG strategies
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he UK has seen a 48% increase in the number of manufacturing firms setting ESG targets for their business, with around two-thirds (62%) now doing so (since 2021), according to a report from Make UK and Lloyds Bank. The in-depth report, which was based on a survey of 150 companies carried out between 13 September and 4 October 2023, looked at the progress, opportunities and challenges faced by UK manufacturing firms looking to improve their ESG strategies. It reveals that almost two-thirds of UK manufacturers (61%) say they expect to expand the scale of their ESG strategy in the next two years. Firms said the reasons behind this increase include increasing pressures from the labour market, government, investors, and customers. More than three-quarters (77%) of firms
are receiving ESG conditions or targets from their customers, but less than half (48%) said they have the resources required, highlighting a need for greater support for those companies. In addition, only one in four (27%) companies being asked to meet ESG requirements by their customers are getting support from them to do so. The report also reveals that businesses are accelerating the ESG requirements of their suppliers. Three-quarters (74%) of firms have built ESG conditions into their procurement strategies, up from two-thirds (66%) just two years ago. Yet,
four in ten (45%) are not aware of their suppliers’ performance against their targets. While one-third (35%) of manufacturers provide ESG support to their suppliers, UK manufacturing firms are two and a half times more likely to provide support to suppliers in pursuit of ESG targets than they are to receive it from their customers. The findings come as ESG transition plan disclosures, which include how firms identify, assess, and manage environmental and social related risks and opportunities, are set to become mandatory for many UK companies later this year.
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SOLUTIONS FOCUS
Compressed air monitoring “cuts costs by up to 30%”
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ICK has unveiled a pioneering compressed air monitoring system that accurately predicts where significant energy cost-savings can be made by fixing air leaks and removing wastage across entire production and logistics facilities. SICK’s Monitoring Box FTMg Premium is a digital and scalable service that can be used by production planners, energy managers and maintenance engineers to make compressed air cost savings of up to 30%, as well as to eliminate costly manual maintenance regimes. The enhanced digital Monitoring Box Premium service analyses and displays accurate data from SICK’s FTMg multifunctional flow sensors. Compressed air consumption data is visualised in easy-touse graphic displays, while alarms can be set up to alert when new leaks occur.
By comparing data from each measuring point, machine, and production line, cost drivers or overconsumption can be identified, e.g. by comparing a machine type with the same function on two production lines. Leaks and inefficiencies are easily eliminated, users understand their processes better and make aroundthe-clock decisions to optimise their energy usage. Production processes become more sustainable by reducing CO2 consumption and insights contribute towards ISO50001 Energy Management certification. Charlie Walker, Digital Solutions Consultant with SICK UK, explained: “Even if you walk around the factory today and identify and fix all your leaks, tomorrow there might be three more you will not have found. Now you can drill down using precise real-time data to discover exactly when, and
where, you are producing air and wasting it. “The system will tell you how much wastage is going on, and what that’s worth in real money. So, you know when to take action. Ultimately compressed-air costs could be reduced by up to 30% delivering a significant return on investment, while reducing your CO2 footprint and making servicing both more efficient and effective.” www.sick.com
One switch fits all – the new FlexFunction CTS safety switch
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igh locking force, a compact design and maximum flexibility are the hallmarks of the new CTS guard locking device. This safety switch is ideal for machines and installations requiring a high locking force in a limited amount of space. Measuring only 135 x 31 x 31mm in size, it delivers a maximum locking force of 3,900N for countless application options. The CTS can be installed in three different directions and is therefore suitable for both hinged and sliding doors. In addition, an escape release can be added at any time. Developed as a FlexFunction switch, in a single device the CTS also combines multiple functions that are otherwise available only in
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separate variants. With or without guard lock monitoring and with a high or low coding level for actuator code evaluation – the choice is up to the user with CTS. Functions are selected via the appropriate actuator. As with most Euchner switches, the CTS also features a variety of connection options.
All options remain open until setup because only then will the CTS be configured by the actuator. This is no obstacle to new applications, however, because the switch can be repeatedly reconfigured after a factory reset. All doors are open to you with this patented, one-ofa-kind EUCHNER FlexFunction system.
Simple integration Applications for the CTS include everything from separate operation and series connection to linking to a higher control system level. You can also combine the CTS with an Euchner IP-Link Gateway which additionally provides communication capabilities from Industry 4.0 applications, enabling comprehensive diagnostics. www.euchner.co.uk
SOLUTIONS FOCUS
Celebrating 30 years of innovation
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SI is celebrating 30 years of pioneering Silicon-onSapphire (SOS) technology in pressure transmitters and transducers. In the landscape of pressure measurement, SOS technology has been a game-changer, propelling ESI to the forefront of the industry. The year 1994 witnessed the birth of a cutting-edge approach, where the ingenious combination of silicon and sapphire substrate was integrated into the high accuracy HI2000 range. It not only offered exceptional stability and reliability but also paved the way for enhanced performance in various applications. The new Silicon-on-Sapphire sensor technology (SOS), with its unique properties, brought about a paradigm shift in the industry, setting new standards for accuracy and reliability. The combination of silicon grown onto the sapphire substrate provides a very durable and stable sensor that exhibits virtually no hysteresis. With its outstanding insulation properties, the
sapphire protects the strain gauge from electromagnetic pulse radiation and allows the sensor to operate over a very wide temperature range without loss of performance. It can endure high over pressures and provides superb corrosion resistance. The excellent elasticity of the sapphire ensures high repeatability which is a highly desirable characteristic for sensors. Over the past three decades, ESI’s SOS technology has found applications in diverse industries, ranging from aerospace and automotive to oil & gas and beyond. Available in pressure ranges from vacuum all the way up to 5,000 bar, the thin diaphragm of silicon on sapphire ensures minimal hysteresis and outstanding sensitivity, making it an ideal choice for critical pressure measurement requirements. Whether in the harsh environments of oil & gas processes or the precision demands of aerospace applications, ESI’s SOS technology has consistently delivered unparalleled performance. SOS technology has not just withstood
the test of time; it has thrived, evolving to meet the ever-growing demands of a rapidly changing world. ESI remains committed to pushing the boundaries of innovation, ensuring that the next 30 years will be marked by continued excellence in pressure measurement technology. esi-tec.com
New safety switch with rotating actuator head
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chmersal is set to launch four new electromechanical safety switches with separate actuators. The AZ215/AZ216 and AZ315/AZ316 switches handle safety guard position monitoring of sideways or rotating guard doors. Their stand-out feature is the rotating actuator head made from die-cast zinc, which can be easily rotated in 90-degree increments before installation. This allows the head to be approached from the side from four different directions, as well as from above. With this versatile approach position and the possibility of combination with different actuators, the AZ series offers maximum flexibility in installation, as well as a range of universal usage options to the user. The designer can use the AZ switch both for right-hand and left-hand designs on rotating and sliding guard doors. The plastic or metal switch housing is consistent in design and size with the PS
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215/216 and PS 315/316 series position switches, giving the AZ switches an equally compact design and easy integration into the surrounding construction. The small AZ215 and AZ216 switches are consistent with standard EN 50047, while the larger AZ315 and AZ316 switches satisfy standard EN 50041. In addition to the standard version with M20 cable entry and connection terminals, versions with four or 8-pin M12 connectors are also available, depending on the number of contacts. With the in-built 8-pin connector, AZ switches can be connected
to the SFB Safety Fieldbox. Device versions with three contacts in a wide range of combinations can also assume a signalling role in addition to their safety function. The connection terminals on the switch elements, which are rotated by 45 degrees, enable quick and easy wiring. www.schmersal.co.uk
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The first modular connector with a hybrid module configuration ■ Smaller and lighter connectors allow space savings of up to 50% ■ Compatible with components of the Han-Modular® series, the market standard for modular industrial connectors ■ Flexible and scalable to the respective need ■ Sustainability through consistent modularisation ■ Reduction of installation times by combining several individual connections
One Range. No Limits: www.HARTING.com/domino
OPINION
We still have a voice in Europe despite Brexit Wayne Rose, CEO of the British Pump Manufacturers Association (BPMA), shares some thoughts on the shifting legislative landscape impacting the pump sector in the aftermath of Brexit, highlighting some of the efforts undertaken by his organisation (and others) in ensuring a fair and equitable approach is adopted across the board.
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or decades, the UK and its manufacturing industry aligned the vast majority of its product safety and certification protocols with that of Europe, ensuring that both elevated levels of compliance and fair competition were maintained across this vast trading block. In fact, drawing on the vast experience and technical expertise available through our extensive complement of trade bodies, institutions and world-renowned academia, the UK has been instrumental in devising much of the regulatory framework that exists today. Its influence has been profound and far-reaching, and contrary to some views, despite the complications brought about by Brexit, many of the UK’s trade bodies, including the BPMA, still maintain a considerable voice on the international stage. In the case of my own organisation, which represents the commercial interests of UK and Irish manufacturers and suppliers of liquid pumps and other pump-related equipment, it is itself a member of Europump, the European Pump Association, which represents 15 National Associations across the continent of Europe. Furthermore, as a founding member, the BPMA has representation on the main Europump Council, holds the secretariat of the Europump Marketing Commission, and enjoys strong representation on both the Standards and Technical Commissions. As such, and directly through this engagement, the BPMA is not only able to keep abreast of all applicable directives, standards and compliance matters relating to the manufacture and supply of pumps throughout Europe and the rest of the World,
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but it is also able to help steer, guide and question these important legislative activities. Navigating uncertainty: Going forward, the BPMA will continue to maintain ongoing discussions regarding the potential divergence of the UK from existing European standards and directives related to product certification. Insights will be provided on how the pump sector can effectively steer its way through the uncertainty brought about by these potential changes. The critical role of certification: Emphasising the significance of product certification, the BPMA will continue to highlight the potential implications for manufacturers, suppliers, and end-users. Key to this is advocating high-quality standards to ensure the continued reliability and safety of all pump products and their related systems. Industry advocacy and collaboration: The BPMA is committed to maintaining
a proactive role, along with other partner trade organisations, in providing the UK Government with substantial background information and market feedback to help ensure the long-awaited updates fully align with industry needs. As we navigate the evolving landscape post-Brexit, it is crucial for the pump industry to adapt to changing standards. At BPMA, we are actively engaged in providing insights to policymakers, both at home in the UK and within the EU, advocating for updates that will benefit the entire sector. Our collaborative efforts with fellow trade organisations underscore our commitment to ensuring a robust and progressive regulatory framework. For the benefit of our pump manufacturing members, we will continue to lobby all applicable persons and entities to ensure essential safety compliance, improved energy efficiencies, and fair and equitable trading opportunities.
COVER STORY
HANNOVER MESSE
energises a sustainable industry Key tasks facing industry today include improving competitiveness, protecting the climate and driving prosperity – and innovative technologies are crucial to meeting such challenges. Exhibitors at HANNOVER MESSE, running from 22 to 26 April this year, will demonstrate how companies can most efficiently use automation, artificial intelligence and renewable energies to achieve these goals.
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ccording to Basilios Triantafillos, Global Director of HANNOVER MESSE at Deutsche Messe AG: “Innovative technologies like those we see in April at HANNOVER MESSE are paving the way to a climate-neutral, highperformance industry. However, companies need guidance on how to apply automation, artificial intelligence and energy management concepts. Furthermore, bureaucracy and a shortage of skilled workers are limiting growth potential.” HANNOVER MESSE 2024 provides the answers to these challenges under the lead theme of “Energizing a Sustainable Industry.” Basilios continued, “The solution is a mix of new technologies, crossindustry collaboration and a clear political framework.” At HANNOVER MESSE, companies from the mechanical engineering, electrical engineering and digital industries, as well as the energy sector, come together to present their solutions for a greener future. More than 4,000 companies represent a united industrial ecosystem and demonstrate how automation, digitalisation and electrification can enable climate neutrality. Top industry trends at the fair include artificial intelligence, carbon-neutral production, energy systems, Industrie 4.0, Manufacturing-X, and hydrogen and fuel cells. Exhibiting companies include global technology enterprises such as Amazon Web Services, Bosch Rexroth, Google Cloud, Microsoft, Salzgitter AG, SAP, Schneider Electric, and Siemens as well as small and medium-sized enterprises such as Beckhoff Automation, EBM-Pabst, Festo, ifm electronic, igus, LAPP, Pepperl+Fuchs,
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Pilz, Q-CELLS, Rittal, Turck, and WAGO. Leading research organisations such as Bavaria Innovative, various Fraunhofer institutes, the Karlsruhe Institute for Technology (KIT), and Germany’s Ministry of Education and Research spotlight the current state of R&D and technology transfer. More than 300 industrial startups boost the focus on entrepreneurship and innovation. Green hydrogen is gaining more and more traction as governments and companies invest in projects to decarbonise sectors such as manufacturing and transportation. HANNOVER MESSE features roughly 500 companies from the hydrogen and fuel cell
industry, including more than 300 at the group exhibit Hydrogen + Fuel Cells Europe. Norway is the Partner Country at HANNOVER MESSE 2024. With the theme ‘Norway 2024: Pioneering the Green Industrial Transition’, the country will highlight its plans for converting to a low-carbon society and its key role in developing solutions within sectors such as renewable energy, carbon-neutral production, and the application of green and digital solutions. The Norwegian-German Energy Conference on 23 April examines a hydrogen economy that creates investment security for infrastructure, production, transport, storage,
COVER STORY and distribution. “Norway is honoured to be the Partner Country at HANNOVER MESSE. Norway’s highly skilled workforce, advanced industry and energy technology, and a high degree of trust and stability make us a key partner in the green shift and one of the world’s most attractive countries for business. We are thrilled to get this opportunity to showcase the Norwegian way of doing business and what Norway has to offer,” said Jan Christian Vestre, the Norwegian Minister of Trade and Industry. Norway has a rich industrial history and role as a reliable energy producer. This heritage, combined with its dedication to speeding up the green transition, will be beneficial as a Partner Country at HANNOVER MESSE, the world’s leading trade fair for industrial technology. Norway is fully integrated into the European internal market through the EEA Agreement, making trade and investment flow seamlessly between Norway, Germany and the rest of the European Union. Norway and Germany are key trading partners and have entered a strategic partnership on climate, renewable energy and green industry to cooperate even closer in the green transition. At the Norway Pavilion in Hall 12, top Norwegian companies will demonstrate products and solutions for the energy transition and a sustainable industry. The pavilion is an important focal point for the Norwegian presence at HANNOVER MESSE and hosts exhibitors from energy, process industry, battery/charging solutions, digitalisation and beyond. A networking program promotes collaboration between Norwegian and international businesses and presents business opportunities for foreign investors. The Norwegian-German Energy Conference on 23 April will complement the program. Two months before elections in Europe, the European Union will present itself at HANNOVER MESSE as a strong economic alliance. Ursula von der Leyen, President of the European Commission, will kick off the program with a speech at the opening ceremony on 21 April. The EU’s program during the fair includes the conference ‘EU as Home of Decarbonized Industry’ – where industry representatives can meet EU politicians to discuss topics such as the Green Deal – and the European Commission Pavilion. A shortage of skilled workers remains
a challenge in industry. ‘YOUR FUTURE’ is HANNOVER MESSE’s young talent initiative that encourages high school graduates, college students and young professionals to pursue careers in areas such as AI, engineering and robotics. The program consists of meetings with potential employers, guided tours to sponsoring exhibitors, information on apprenticeship and trainee programs, and networking with other participants. As well as sustainable industry, the topic of robotics is an integral part of HANNOVER MESSE. Robots of all sizes and shapes – from industrial robots and cobots right through to autonomous mobile robots – can be found throughout the exhibition grounds of the world’s leading trade fair for industry. A special highlight this year is the Application Park in Hall 5, which has a strong partner at its side in the form of the German Robotics Association (DRV). Among other things, the DRV has made it a mission to promote and foster the use of robotics in Germany. Given the shortage of skilled workers, there is undoubtedly potential in this direction, with Germany ranking fifth behind China, Japan, Korea and the USA in global comparison. “With the robotics experts from DRV, we have partners at our side with whom we will further build on the topic of robotics, in conjunction with that of automation, at HANNOVER MESSE. There is no better place in the world to showcase the diverse examples of robotic applications,” said Hubertus von Monschaw, Global Director of HANNOVER MESSE at Deutsche Messe AG. The DRV will be the exclusive partner of the ‘Application Park’ for the coming year.
There, young robotics companies and startups, in particular, will present the diverse spectrum of possible applications for robots, as well as the interaction between humans, machines and artificial intelligence. Visitors can get a first-hand look at robotics-based automation and try it out for themselves. A highlight is the driverless transport systems, impressively demonstrating that drivers can be dispensed with in many areas of activity in the future. “This exhibition platform offers visitors to HANNOVER MESSE a unique opportunity to engage with new technologies and learn how robotics, AI and automation can help solve the enormous challenges facing industry,” enthused Helmut Schmid, CEO of the DRV.
HANNOVER MESSE HANNOVER MESSE is the world’s leading trade fair for industrial technology. Its lead theme, ‘Energizing a Sustainable Industry’, brings together exhibiting companies from mechanical and electrical engineering, the digital industry and the energy sector to present solutions for the future of manufacturing and energy supply. Leading topics include Industrie 4.0, Manufacturing-X, energy for industry, digitalization, artificial intelligence and machine learning, carbon-neutral production, and hydrogen and fuel cells. Conferences and forums complement the program. The next edition runs from 22 to 26 April 2024 in Hannover, Germany. To register your complimentary ticket, please use the ticket code u5meN. www.hannovermesse.de/en
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Focus On: Machine Building
MEPCA explores the latest topics in the machine building sector P28 – Breaking down the process of flexible manufacturing
MACHINE BUILDING FOCUS
Interlink system for high process reliability mk Profile Systems explains how its conveying solutions have provided an interlink system and stacking magazine for a manufacturer of office supplies.
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he office supplies manufacturer bought a new cutting machine for the production of files. The machine needed to be integrated into the production hall and linked to the existing conveyor system. It was essential that the cut blanks be stacked on the interlink system before being transported further. There was also a requirement to process different formats, from 616 x 318mm to 675 x 350mm in size. The cutting machine needed to run continuously and be capable of processing up to 100 blanks per minute. mk supplied the interlink system solution, which consisted of a stacking magazine, conveyor section and transfer so that it could connect to the existing conveyor system. The blanks fall continuously from the cutting machine into the stacking magazine. The magazine can be adapted to different formats using clamping levers. Once enough blanks are stacked, the first stack is transported onward. Meanwhile, the second stack begins to accumulate. The pawl for collecting the second stack must be extended within 0.6 seconds in order to correspond to the cycle time of the cutting machine. At the end of the line, the stacks are conveyed by means of a roller conveyor and a timing belt conveyor aligned transversely to the transfer onto the existing conveyor system. The transfer was provided with a cover that complies with accident prevention regulations. mk programmed the entire controller for the interlink system, including interfaces for the material flow. This element can, therefore, be operated independently and integrated into the customer’s higher-level safety circuit. The mk solution has provided the customer with a customised solution based on a well-engineered standard modular system. The system rewards them with high process reliability, and they have a reliable
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contact in mk to assist with all conveying tasks. The ZRF-P 2010 timing belt conveyor used in this solution is ideally suited for use as a dual line system for transporting heavy workpiece carriers and products with a rigid structure. The positive connection between the drive pulley and the timing belt ensures that the two conveyor lines are synchronised, making the system ideally suited to cycling operation. Various coatings on the surface of the timing belt ensure optimal gripping of the workpiece for a specific application. Combined with the wide range of different drive options, this makes the system the perfect basis for constructing complex interlinking and automation systems. A further feature of this conveyor system is the recirculation of the timing belt inside the profile frame. This provides a compact design and reduces the risk of accidents to a minimum. The profile also offers system slots (10mm slot width) on three sides for connecting
stands, side rails, sensors and stoppers. This solution also made use of mk’s RBT-P 2255 tangential chain roller conveyor. This roller conveyor is used wherever long conveying paths with a motorised drive mechanism are required. The conveyor is driven by a 0.5 inch chain, which runs within an enclosed, low-wear wear strip to tangentially drive the conveyor rollers from below via a sprocket wheel. This allows users to achieve conveying paths up to 10m in length and makes the system suitable for even dirty or oily environments. The chain tail is also equipped with idler pulleys supported by ball bearings for minimal friction losses. The tangential chain roller conveyor is available in both straight and curved configurations and can be combined with other roller conveyors (RBS and RBM). The longitudinal slots in the beam profiles can be used to attach side rails, stands, sensors and other accessories. www.mkprofiles.co.uk
AM-T100 3D CAMERA WITH SONY DEPTHSENSE TECHNOLOGY FOR THE AUTOMATION INDUSTRY. The AM-T100 Time-of-Flight camera (ToF) uses a Sony DepthSense™ sensor to create 3D depth images with millimetre accuracy. The ToF technology enables high-speed 3D imagery of the scene. With powerful IR illumination and a high image rate of up to 60fps at 640 x 480 pixel image resolution, the AM-T100 achieves a 67° x 51° field of view with a range of up to 6m. This camera can be used to support, box filling, stacking, volume detection and labelling in logistics and packaging as a means of boosting the efficiency and accuracy of processes.
SCHMERSAL | Enigma Business Park Malvern, Worcestershire, WR14 1GL
www.schmersal.co.uk uksupport@schmersal.com
MACHINE BUILDING FOCUS
Interface to the future A modern PLC with REST-API for a standard palletising system – this is what the robot automation company Robot ART was looking for. And it found it in the form of ctrlX CORE from Bosch Rexroth. We discover how the firm was won over by the openness and wide-ranging functions of the control platform and the common desire to produce more advanced robots.
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obot ART B.V. distributes Hyundai Robotics, Neura Robotics and Wepall smart palletising software in the Benelux region. The company also develops and produces a range of intelligent and intuitive entrylevel solutions focusing on robot automation. Naturally, it also provides service and support for system integrators and end users. Walter Nieboer, Application Engineer, Robotics, at Robot ART, explained: “Robot ART is a relatively new company in the sector and doesn’t yet have a closely-knit network of suppliers. We, therefore, used Google to look for a suitable partner. We’ve developed our own interface for our palletising system and were on the lookout for a control platform with a REST API. When we heard about the automation toolkit ctrlX AUTOMATION, we were immediately curious.”
The perfect solution Werner Knapen and Michel van den Elzen from Bosch Rexroth visited the company in Nieuwkoop and demonstrated the control platform ctrlX CORE. Robot ART owner Willem van Dam explained: “The system was the perfect solution. Not only does the solution meet all our requirements, but the PLC is also a decision for the future. The platform is characterised by openness and functionality. In the coming years, we’ll put together the perfect system to meet our needs and expand it on a modular basis.” According to Werner Knapen, software plays an increasingly important role when developing and building machines. He said:
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“That’s why we’ve developed an automation toolkit with hardware, software and services. It simplifies the world of automation and solves our customers’ challenges. ctrlX AUTOMATION removes previous boundaries. Our customers confirm this again and again.” At Robot ART, it quickly became apparent that the control system was the right choice. Walter continued: “We were immediately impressed – first with the virtual version and then with the physical ctrlX CORE. Setting up the EtherCAT was child’s play and we could communicate with our robot straight away. The control platform is extremely accessible, and working with it is fun.”
it is important to work with applications that can easily be used by humans and enhance robots. “Young employees want to work with modern methods and technologies, like a modern PLC. ctrlX AUTOMATION will help us to meet our ambitions and could even surpass them.” Apps from the ctrlX Store make it very easy to add new functions. Robot ART also intends to use ctrlX SAFETY to ensure the required machine safety – and that is by no means the end of the story. “Given the wide range of possibilities offered by Bosch Rexroth, we’d be negligent if we didn’t look at ways of optimising our machines on the drive level using the product group ctrlX DRIVE,” added Willem. “Whatever we want to add in the future, everything is possible thanks to the experts forum that has been set up by Rexroth, especially for this purpose.”
Let the future begin
Modern automation for modern people
Werner said: “Of course, I’m pleased that the users are so happy. They recognise the enormous possibilities that ctrlX AUTOMATION offers their company. I’m proud of this collaboration, which has come about in a relatively short time. It really enhances our network. After all, robots are the future. I’m sure we can learn a lot from each other and develop together.” Willem added: “We were in search of a platform that meets our needs. And we found what we were looking for. Thanks to ctrlX AUTOMATION, we’re ready for the next 25 years. Let the future begin.”
Because Robot ART is a company with many young employees, Willem believes
www.boschrexroth.co.uk
MACHINE BUILDING FOCUS
Monitoring load peaks with io-link current sensors MEPCA explores how the intelligent STEGO ESS 076 smart current sensor, equipped with an IO-Link interface, provides an effective solution for keeping a close eye on load peaks. Not only does it help in monitoring these peaks, but it also plays a role in enhancing overall energy efficiency.
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s industries embrace digitalisation, new and innovative ways to cut costs are emerging, and one key approach is through energy optimisation. A crucial aspect of this strategy involves closely monitoring instances of high energy demand. Unexpected spikes in electricity usage can result in significant additional expenses, particularly in energyintensive production settings. This is where STEGO’s ESS 076 Smart Sensor Current steps in.
Avoid unpleasant surprises For manufacturing companies, unexpectedly high electricity bills are among the most unwelcome surprises. December, in particular, can turn into a financial pitfall. Speaking of December, why is this month so crucial when it comes to the total cost of electricity consumption? The reason is that a high peak load in December can result in a subsequent increase in electricity costs for the entire year, imposed by the grid operator. But what if there was a way to avoid these unpleasant surprises? Combine the measuring of electricity consumption per machine and employing peak shaving, and you get a smart strategy to prevent peak loads and shield yourself from unwanted additional payments.
Monitor electricity in real time Current sensors like the ESS 076 offer straightforward real-time monitoring of power consumption in systems and machines. The potential for efficiency gains is significant, especially in energy-intensive applications. This becomes evident in a case study with STEGO client, LEGROM. Specialising in plastic injection moulding, LEGROM operates an extensive array of injection
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moulding machines, known for their high energy demands as they heat and process plastic granules under high pressure. In the past, the immediate or simultaneous activation of injection moulding machines at LEGROM resulted in unexpected additional electricity costs. Retrofitting the machines with a current sensor proved to be a much more cost-effective solution compared to dealing with additional payments. This is crucial, considering that in an industrial setting, these extra electricity costs can quickly escalate into five-digit euro sums.
Current sensors for the refit From the outset, LEGROM recognised that advancing energy flow monitoring would depend on peak shaving. Kim Waldmann, Managing Director at LEGROM and an industry expert in injection moulding, drew on his experience across various injection moulding companies to understand that information is the key resource for more efficient processes and risk mitigation. For LEGROM, the digitisation process was
carefully planned as a well-thought-out use case. However, the approach needed to be minimally invasive. An intelligent retrofit application for current measurement became crucial for the company’s operational technology (OT). Integrating sensors into the numerous machines in the injection moulding shop floor had to be quick and straightforward to minimise both time and complexity. The goal was to keep machine downtimes to a minimum to avoid disruptions to production capacity and productivity. Waldmann explained: “The integration of the STEGO current sensors was uncomplicated. We only needed to disconnect the machines from the power supply and route the live cable through the ESS 076. The sensor can measure up to 100A AC without direct contact, perfectly fitting our current condition monitoring needs. The sensors’ practical latching mechanism ensures secure and simple attachment to the power line.” www.stego-group.com
Enhance your Machine Interface with Pro-face HMIs and BPX
As a leading technical distributor of industrial control and automation products in the UK, we proudly offer the comprehensive Pro-face HMI range, ensuring our customers have access to cutting-edge technology, backed by unparalleled support.
At BPX, when it comes to HMIs we understand the importance of seamless integration and reliable performance. That’s why we’ve partnered with Pro-face, a renowned name in the industry known for their innovative solutions and exceptional quality. With BPX, you can trust that you’re getting access to the latest Pro-face HMIs, backed by our extensive technical expertise and unmatched customer service.
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Compatibility with Major Automation Manufacturers Whether you’re working with any leading automation brand, Pro-face HMIs seamlessly integrate with a wide range of PLCs, allowing for effortless communication and interoperability.
When it comes to enhancing your machine interface, Pro-face HMIs from BPX are the ideal choice.
Explore our Pro-face offer by visiting www.bpx.co.uk/pro-face or calling our Applications Team on 0116 299 9100 today!
MACHINE BUILDING FOCUS
Absolute vs. incremental encoders: know the difference British Encoder explores the difference between absolute and incremental encoders, and explains some of the considerations when deciding which type is right for your application.
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otary encoders sense changes in the position of a rotating shaft and then generate signals that send speed, direction and position information to a receiving device such as a counter, drive, or PLC. Rotary encoders come in two basic varieties: absolute encoders report the actual position of the shaft at a specific time, while incremental encoders indicate relative changes in the shaft’s position.
The differences Both types of encoders are somewhat simple electromechanical devices, and they operate on similar principles. Each time the shaft rotates past a certain position, a sensor in the encoder registers this movement and sends either a digital signal or an electrical pulse through an output channel. Absolute rotary encoders assign a unique code to each indicated position on the shaft, allowing them to identify the position of the shaft at any given time. For example, an absolute encoder with a resolution of 8 bits (1024) will report 1024 unique shaft position values with each rotation. Incremental encoders, on the other hand, produce an output signal, or pulse, each time the shaft passes a specified angle – the number of pulses in each time span is enough to measure the shaft’s change in position and its speed but does not specify the shaft’s position at any given time. An encoder typically includes a marked disk connected to the shaft and a fixedposition receptor. As the shaft rotates, the disk passes output channels mounted on the receptor. More channels allow for greater resolution or more precise measurement of the shaft’s position and speed. Some absolute rotary encoders have 400 or more channels. Incremental encoders typically have one
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or two channels, along with an index or Z channel. With one channel, the encoder can count the number of rotations the shaft makes over time but cannot determine its direction. With a second channel, typically set at 90 degrees from the first, incremental encoders can also relay directionality. If the system loses power, an absolute encoder can resume functionality immediately upon powerup. An incremental encoder, though, cannot begin relaying usable information until the shaft has made at least one turn. For some applications, this isn’t good enough. For those cases, incremental encoders can include an additional channel, or Z channel, which serves as an index of the shaft’s position.
Which type is right? For some applications, like the precise orientation of radar or other sensing systems, there is no real debate: absolute rotary encoders are a must. For other purposes, including the simple measurement of shaft rotation speed, you may have an honest choice to make. The difference can often be measured in stability and cost. Absolute encoders are uniquely able to begin operation immediately when a system is powered up. This lends them a degree of stability unavailable to incremental
encoders. By the same token, their design gives absolute encoders something of a built-in failsafe. By incorporating many more channels than incremental encoders, absolute encoders benefit from an inherent redundancy: if one channel stops working for whatever reason, the system can still function normally. If the same happens to an incremental encoder, it will lose either its indexing functionality, its directionalsensing capability, or its ability to generate any useful information. Absolute encoders, in other words, can be fixed or replaced on operators’ schedules. Incremental encoders typically require immediate shutdown and replacement when they go bad. That’s just one of the ways that incremental encoders may cost more in the long run than their absolute counterparts. The upfront cost typically favours incremental encoders by a wide margin. Absolute encoders simply contain more components to ensure higher resolution, and this means a higher up-front investment. But maintenance issues and downtime, along with the need to reinitialize incremental encoders each time the system regains power, may lead to performance losses, which result in a higher overall cost option. www.encoder.co.uk
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MACHINE BUILDING FOCUS
Still plotting a path to Industry 4.0? Guy Collins from specialist automation and control distributor BPX outlines the value of having a well-chosen, trusted guide on the journey to implementing Industry 4.0.
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or all the talk of Industry 5.0, just implementing Industry 4.0 remains a difficult challenge for a lot of manufacturers. Often, their business is successful, but the attraction of bridging IT and OT in a seamless, digitised way to deliver intelligent insights, autonomous decision-making, and improved productivity remains tantalisingly out of reach. The inevitable focus on the core business makes it difficult to devote resources to the requirements and challenges of deploying datadriven, smart manufacturing technologies to boost agility and competitiveness. Although the answer is perhaps that the move to smarter manufacturing is not a leap but a series of well-judged smaller steps towards an end goal, many companies will need guidance to determine how to make those steps without disturbing existing processes or introducing new risks. They need a knowledgeable partner, offering the best routes and warning of the perils of the journey. A well-chosen guide should demonstrate an understanding of the environment and know the intricacies of blending IT and OT to develop a roadmap tailored to a company’s specific vision, constraints, risks, and requirements. That trusted advisor should be able to help in three essential ways. Learn the terrain – assessments are key: Smart manufacturing implementations should start with an assessment to learn the environment and understand the level of digital readiness. A typical assessment reveals critical information about the path ahead: • The current state of automation and connectivity. • The available technical skill set of existing staff. • Challenges and needs related to data exchange with customers and suppliers. • Responsiveness of the manufacturing process to customer demands and changing market dynamics.
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Assessments help determine the capacity of important systems such as Manufacturing Execution Systems or Enterprise Resource Planning platforms. What could be the benefits of artificial intelligence (AI) or augmented reality (AR) implementations? What about a customer’s environmental, social, and governance (ESG) status? How can sustainability and energy consumption goals be met? Looking into all these areas is essential to mapping out the digital journey. Act as interpreter – bridge the gap: Experienced guides also serve as valuable interpreters. IT and OT teams have historically worked independently with little interaction, speaking different languages, working with different equipment, and approaching challenges with different mindsets. Convergence creates the need to bridge these teams so each can understand the other’s priorities, challenges, and goals. Only by getting both teams on the same page can an organisation successfully move forward with planning and execution. Follow the best path – plan a stepby-step route: A guided path to intelligent manufacturing may be preferable for many organisations. A company may need to go through Industry 3.1 and 3.2 before ascending to 4.0. An experienced technology advisor will
plot a step-by-step route that may start, for example, by placing Industrial Internet of Things (IIoT) sensors on existing manufacturing motors and drive systems to begin collecting shop floor data. Information collected can show how to improve maintenance efficiency and reduce energy consumption. A quick, early ROI win can help make the case with management for further technology investment in areas such as AI and advanced robotics. A progressive approach helps to educate all of those involved on the steps to take next so they can make well-informed investments.
A pathway to digitisation At BPX, we take our role as a technology guide seriously. Our motto is “Help to Choose, Help to Use.” We apply a halfcentury of industrial automation experience to help our customers select the right products and solutions for their applications and ensure they can optimise the value they get from their investment. We leverage our trusted relationships with leading suppliers such as Schneider Electric, Mitsubishi Electric and Omron to help our customers plot their best route to Industry 4.0. www.bpx.co.uk
Flexibility to help manufacturing flow Create personalised products for your customers with flexible industrial automation solutions that adapt to your changing needs. #MakeitFlexible
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MACHINE BUILDING FOCUS
Breaking down the process of flexible manufacturing John van Hooijdonk, Industry Marketing Manager at OMRON Europe, explores what is involved in moving to a more flexible manufacturing approach, outlining what is involved at three key workflow stages and the key benefits that can be realised.
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he fast-moving consumer goods market is experiencing a transformative shift driven by factors such as consumer empowerment, customisation demands, health-conscious preferences, veganism, ethical concerns, and sustainability. We expect that it will undergo more changes in the next decade than it has in the previous 50 years. This necessitates the adaptation of production and supply chains to meet emerging trends. The future of fast-moving consumer goods factories will likely involve smaller, smarter facilities with autonomous movement of goods and interconnected systems.
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Machines, whether standalone or interconnected, need to be more flexible than ever before to ensure the timely supply of appropriate materials and packaging. Production has to be more agile, increasingly producing retail-ready items with a high mix-low volume approach with zero recalls. The question is how to realize this with minimal cost and fast ROI.
Workflow in three levels To achieve the optimal solution with maximum flexibility, it is important to consider various factors. A practical approach, like the one employed by OMRON, focuses on optimising processes
to minimise disruptions. This involves breaking down the workflow into three functional levels. Level 1 - For the machine. Before reaching the production line and machine level, the emphasis needs to be on enabling flexibility in the production line, thanks to just-in-time delivery of consumables, optimising the transport of goods, boxes, and pallets, as well as managing halfproducts, waste, and unused consumables. The goal is to avoid storing consumables and half-products on the shop floor. Level 2 - At the machine. At the machine level, the focus shifts to automating material verification and feeding processes, replacing
MACHINE BUILDING FOCUS manual feeding activities with automated ones, conducting quality assurance on packaging materials, and ensuring package integrity after packaging. Level 3 - In the machine. In the machine itself, all functions, such as machine control, motion, robotics, sensing, vision, and safety, are automatically aligned. This ensures that tasks like filling, capping, tray loading, seaming, sealing, and labelling are executed as quickly as possible, thereby enhancing overall efficiency.
For the machine Designing, building, and optimising a process and packaging line requires expertise and experience to ensure maximum benefits from an investment. Enhancing line performance by optimising the flow of goods and consumables on the factory floor and adjoining storage areas is key. The use of autonomous mobile robots (AMRs), collaborative robots (cobots), and traditional industrial robots is becoming increasingly common in factories. Mobile robots are replacing traditional conveyor systems, aiming to create a flexible and continuous production process that can accommodate customer-specific manufacturing needs while minimising the reliance on rigid and maintenance-heavy conveyors. This shift not only improves agility but also reduces scrap, contamination risks, waste, and losses. Maintaining interconnectivity among production processes is crucial to ensure uninterrupted flow. Collaborative and flexible transport and transfer solutions, such as those offered by OMRON and its partners, can be tailored to specific production environments. These solutions involve tasks like transferring work-in-progress (WIP) stock between locations or rework areas, guided by fleet management systems. By leveraging expertise and innovative solutions, manufacturers can achieve greater flexibility, optimise production processes, and enhance overall line performance. The focus is on tailoring solutions to meet specific requirements and improve the efficiency of the production environment.
At the machine Mastering optimal replenishment is an important element in improving Overall Equipment Effectiveness (OEE), eliminating waiting time, and minimising intermediate
stock on the factory floor. This concentrates on package and container loading as well as the efficient output of finished goods. The objective is to ensure timely and direct material feeding without any manual intervention, thus eliminating line starvation and reducing the chances of errors. To control conveyor systems effectively without causing damage to products, automatic position control of goods on the conveyor is essential. For example, OMRON’s Sysmac control platform offers Smart Conveyor Function Blocks (FBs) dedicated to spacing and positioning products on the conveyor. This feature enables precise control and alignment of goods, optimising conveyor operations without compromising product integrity. Collaborative robots, or cobots, can significantly improve material feeding processes. These robots can pick up packaging materials like cartons and place them directly onto conveyor belts or into packaging machines. This eliminates the need for manual unloading of consumables and greatly enhances efficiency. By incorporating cobots into operations, manufacturers can ensure the safe and damage-free handling of products, resulting in smooth line throughput, reduced scrap, and prevention of damaged products from entering downstream processes. Advanced control systems, automation, and collaborative robot technologies can optimize material feeding processes. These solutions help minimize human error, enhance overall line efficiency, and achieve seamless and precise handling of materials. This not only safeguards product quality but also maximizes the throughput of a production line.
In the machine What happens within the machine? Efficient handling of products is crucial for maintaining throughput and preparing them for downstream processes. Delta-style robots, along with smart conveyor tracking capabilities, are ideal for fast, accurate, repeatable, and efficient handling, such as precise pick and place operations. Software can optimise flow rates and recipe handling, ensuring seamless integration and operation. With one controller that handles motion, vision, safety, and robotics, OMRON provides a comprehensive solution for streamlined machine functionality. When considering machine throughput, speed is important but not the sole determining
factor. By integrating product orientation, sorting/grading, and picking and placing within the machine, valuable time and resources can be saved. This reduces changeover time and enhances overall efficiency. Seamless transformation and changeover processes rely on the alignment of sensing, control, motion, safety, and robotics. However, as systems become more interwoven, machine settings become more complex. Decentralised robot and PLC programming can lead to issues such as a lack of real-time communication between devices and the need for dual programming and debugging. Complex production lines often require independent modification of both PLC and robot programs, followed by recommissioning. To address these challenges, OMRON offers a more convenient solution that revolves around one controller, one piece of software, and one connection. A modular and scalable architecture is crucial for flexibility and adaptability. OMRON’s Robotic Integrated Controller (RIC) significantly reduces changeover time for the entire production line. The Recipe Manager simplifies the creation of manufacturing recipes and product variants, while visual monitoring facilitates easy modifications. The RIC synchronises automation technology, enabling manufacturers to improve speed, accuracy, and efficiency, simulate entire production lines, simplify maintenance, and reduce time-to-market.
The benefits The automation of production processes for flexible manufacturing offers numerous advantages, including: • Faster product changeover capabilities, which enable quick adjustments and modifications to production lines, reducing changeover time and optimising performance • Improved tracking and analysis, which provides valuable insights for continuous improvement and workflow optimisation. • Increased employee satisfaction thanks to a focus on value-adding tasks and more strategic and creative work By leveraging the benefits of automated flexibility, companies can achieve greater operational efficiency, employee safety, cost savings, product innovation, and improved competitiveness. bit.ly/OMRONmif
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Coming together to provide a lasting alternative solution In a strategic move that fortifies its position as a leader in the motors and drives industry, Oriental Motor has recently inked a significant UK distribution deal with Swedish-owned OEM Automatic.
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he partnership between Oriental Motor and OEM Automatic is poised to have far-reaching implications, offering enhanced support to customers, particularly in scenarios where sourcing or replacing AC or Brushless DC (BLDC) motors has proven challenging, especially since Panasonics’ withdrawal of its AC and BLDC product from the market. OEM Automatic, a distinguished specialist supplier, stands to benefit immensely from the expansion of its product portfolio with the addition of Oriental Motor’s comprehensive range. The move is especially crucial in scenarios where AC or BLDC motors have been discontinued, providing customers with viable alternatives and ensuring seamless operations without disruption. “What is really exciting for us is that we’re seeing lead times halved from what is an average of eight to 12 weeks; that is a massive shift that can only be good for the market,” said Nik Page, the Motors Business Area Manager at OEM Automatic. “Customers can get products quicker than they’ve ever been able to.” Oriental Motor’s extensive product line spans an array of cutting-edge technologies, ranging from the intelligent stepper and servo motor range (AZ series) to open-loop stepper motors with drivers (PKP and CVK Series). The inclusion of AC input BLDCs (BLE2 series and
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BMU Series), DC input BLDCs (BLH and BLV-R series), induction motors, reversible motors, IP67-rated motors, and various actuators further solidifies Oriental Motor’s commitment to delivering innovative solutions for a diverse range of applications. Mike Larsen, the UK Divisional Manager at Oriental Motor, expressed enthusiasm about the collaboration, highlighting the strategic significance of partnering with OEM Automatic, a major player in the distribution landscape. He identified that this venture would not only provide OEM Automatic’s customers with access to a broader range of high-quality products but also serve as an opportunity to introduce Oriental Motor to a new audience of engineers. Nik Page echoed Larsen’s sentiments, emphasising the expansive nature of this collaboration. He
sees this partnership as a pivotal move that expands their current offerings and positions OEM Automatic firmly within the domain of control and automation. Nick believes that this partnership with Oriental Motor’s products and systems aligns seamlessly with the evolving needs of his company’s customers, both present and future. Adam Porter, Product Group Manager at OEM Automatic, went on to say: “Thanks to the large product offer Oriental Motors brings, we are able to develop and evolve with our customers, providing solutions today and into the future”. This exciting new distribution deal between Oriental Motor and OEM Automatic is a strategic alliance that holds promise for the industry. With Oriental Motor’s cuttingedge technologies and OEM Automatic’s established position as a specialist supplier, this collaboration is poised to usher in a new era of innovation and support for customers in the dynamic field of motors and drives. Oriental Motor, Japan’s oldest motor manufacturer, has been in business for around 130 years and boasts a rich legacy of over 70,000 products specialising in various motor technologies. Since its entry into the European market in 1982, the company has played a vital role in the region’s motor manufacturing industry. In the UK specifically, Oriental Motor has been a trusted source of high-quality Japanese motors since 1996. www.orientalmotor.eu/uk
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Oriental Motor (UK) LTD www.oriental-motor.co.uk – info@oriental-motor.co.uk – 01256 347 090
MACHINE BUILDING FOCUS
Creating value in machine building through robotics The highly competitive world of machine building requires constant innovation to meet the everchanging needs of end-users. Jocelyn Golding, OEM Industrial SI & IAD Channel Manager at Schneider Electric, explains how innovative robotic deployment, backed by a strong partnership between OEMs and robot suppliers, can rise to the challenge.
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he world of machine building is fiercely competitive, demanding perpetual innovation to cater to the ever-evolving requirements of end-users. End-users are coming from a perspective of cost reduction, effective usage of resources, and energy reduction, and OEMs can take the opportunity to meet those needs with the additional value of creating more sustainable operations through innovative robotic deployment. At the design level, with the right partner, OEMs can create an energyefficient machine that offers cost savings and delivers value throughout the entire lifecycle of an asset. End-users are not only able to manufacture at higher volumes with consistent output, but they can even address wider industry topics like labour shortages and the growing skills gap through their robotics choice, and that process starts with the OEM.
Building flexibility Selecting the right robotics partner is pivotal for OEMs seeking to foster innovation. An IoT-ready platform encompassing robotics, simulation, automation control, software, and digital services, like the EcoStruxure Platform from Schneider Electric, is essential. The reason this is so integral is because it ties directly with the benefit of high payoff at every stage of the lifecycle, providing OEMs with the flexibility to keep serving clients long after the product is delivered. OEM partners of Schneider Electric utilising the EcoStruxure Platform can benefit from a level of interoperability, something that can help elevate a business in a crowded marketplace.
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As is well known in the sector, modern facilities are filled with assets from varying suppliers, often each with its own software platform. This creates a challenge for end users who are looking to innovate, as any additional technology they bring to a production line creates another information silo. Choosing a platform built for interoperability future proofs the needs of the customer and positions the OEM as a trusted advisor. Moreover, this means that long after an asset has been deployed, OEMs can offer routes for improvement through robotics in a simulated environment that takes into account all assets of a facility without any disruption to production, turning an OEM from a supplier into a partner. Reaching this partnership status with endusers requires OEMs to align themselves
with a strong digital transformation and advanced automation partner. With the right robotics and automation partner, OEMs benefit from a portfolio of solutions that can essentially meet any end-user need, now and in the future, making them invaluable in future innovation. For example, an end-user may be struggling to hire the next generation of operators due to the growing skills gap. As time goes this issue can become critical and with a traditional supplier relationship this issue would be far removed from the realms of an OEM. Now, with a robotics partner, that same OEM can proactively approach the issue, showing how specific robot solutions can close the gap in labour shortages and provide a pathway to upskill existing members of the workforce into
MACHINE BUILDING FOCUS supervisory roles. The added benefit of the IoT-ready platform approach means this can be presented with no risk while meeting the specific needs of the end facility, which ultimately enhances the OEM’s business value to the end user.
Links in the chain OEMs can reach this level of future-ready machine building with collaboration. The chosen robotics partner must offer efficiency, streamlining the entire information-gathering process in a single portal with curated content specific to the OEM’s specialities. The mySchneider Portal is a personalised digital experience that provides a onestop-shop for all facets of robotics and automation products, offering a simple selector that instantly identifies the right solution with a quick and easy process for managing orders. With personalised support and accessible expertise, OEMs can future-proof their own business in terms of supply chain security. Recent global events have shown how important it is to have a robust supply chain
that can be trusted, as without the right robots or cobots, OEMs simply won’t be able to meet the needs of digitally advancing end-users. Collaboration between OEMs and robotics suppliers is a two-way street. Collaborative work enables suppliers to gain invaluable insights into OEM operations, leading to the development of superior products and solutions. This, in turn, results in a more efficient and innovative sector benefiting everyone involved. OEM partnership with robotics suppliers delivers value throughout the entire lifecycle of an asset, but also across the entire supply chain, leading to a more efficient and innovative sector for everyone within it. Schneider Electric is constantly looking beyond the norm to provide innovative solutions like the EcoStruxure platform and mySchneider Portal and to OEMs in unlocking the full potential of their business while learning and growing together to reach a more innovative sector.
There is no one in the entire supply chain of manufacturing that knows more about meeting the needs of end-users than OEMs, and there’s no one who understands the capabilities of assets better than the supplier. Bringing these two distinct sets of expertise together through partnership delivers immense value both in the short and long term. Integrated robotics solutions can help OEMs stay ahead of the competition with higher productivity, quality, workforce safety, and lower costs. bit.ly/seFoA
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DRIVES, MOTORS & CONTROLS
Synchronous reluctance motor gains liquid cooling ABB has achieved what it says is a world first for its IE5 SynRM (synchronous reluctance motor) series with the launch of a new version that combines the benefits of ultra-premium energy efficiency with highly effective liquid cooling. According to the company, the new design sets a new benchmark for high power output and reliability in a compact footprint.
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ustomers can use IE5 SynRM Liquid-cooled motors to save energy costs and cut emissions in new projects or as a drop-in replacement for less efficient motors. They are ideally suited to a wide range of industries, including marine propulsion, rubber and plastics production, and food and beverage. A major advantage of the IE5 SynRM Liquid-cooled motors is that they are much more efficient than the traditional liquidcooled induction motors in current use and offer significant potential for upgrading with energy-saving technology. Energy efficiency is crucial to optimising the total cost of ownership (TCO) of an electric motor because the cost of the energy to run it throughout its life accounts for around 97% of a motor’s TCO, with the purchase cost accounting for about 2%. IE5 motors have 40% lower energy losses than commonly used IE3 motors. This often makes the payback time for selecting an IE5 instead of an IE3 motor less than one year. Reliability is improved by highly effective cooling combined with the cool SynRM rotor and cooling ribs on the bearing assembly that reduces the operating temperature of the bearings. This helps to increase the lifetime of this key component and reduce maintenance needs. The motors are robust, with tight seals to keep out moisture, dirt and dust and a smooth outer surface to prevent dust buildup. This makes them perfect for demanding applications that re-quire high power density where space is restricted, such as marine propulsion systems and thrust-ers. Furthermore, the motors do not need fans or ventilation, so they do not disturb the
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surround-ing air or release heat into the local environment. This is a major benefit in processes that are im-pacted by airflow, such as rubber and plastics production, and food and beverage applications like chocolate conche machines. With no fans, the motors also enhance the working environment by reducing noise levels. Stefan Floeck, Division President IEC Low Voltage Motors at ABB, said: “ABB pioneered both SynRM technology and liquid cooling for induction motors. Now, we have brought them togeth-er in our IE5 SynRM Liquid-cooled motor that enables customers to enjoy the benefits of ultrapremium efficiency in an even wider range of applications. It is yet another world-first for this series following the launch of our IE5 SynRM Increased Safety motor for hazardous areas.” The high power output of the liquid-cooled
motor offers increased design flexibility. It can ena-ble a machine to be upgraded to deliver a higher power output within the same footprint, or it can allow for a more compact installation footprint while still providing the same output. The IE5 SynRM Liquid-cooled motors are significantly lighter than competing designs, making them easy to handle and install. A 240 kW IE5 SynRM motor in frame size 315 weighs 870kg, this is almost half the weight of a corresponding IE3 induction motor. IE5 SynRM Liquid-cooled motors are available in frame sizes IEC 200-315 in aluminium frames, with steel available on request. The versatile design enables the motors to provide exceptional performance over a range of powers from 37 to 710kW at 400V. new.abb.com/uk
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MACHINE BUILDING FOCUS
Miniaturised modular connector designs Connector specialist HARTING outlines a series of smaller, lightweight connectors designed to support the modern trend towards machine and equipment miniaturisation.
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evices such as sensors, cameras and automation equipment are rapidly decreasing in size, whilst displays and screens are becoming thinner and flatter. As a result, connectors must also decrease in size to ensure they don’t take up too much of the limited installation space available on new, miniaturised equipment. In line with this move towards miniaturisation, HARTING has designed a range of smaller and lighter connectors which still deliver reliable results. The ix Industrial is a robust Ethernet interface built to provide the next generation of compact products with perfect high data transmission rates. A PCB jack that is 70% smaller than an RJ45 socket can be easily incorporated into smaller devices. In addition, the ix combines data transmission and power supply into a single interface, reducing the area required for connectors. Despite its small size, the ix Industrial still produces Cat. 6A performance for 1/10Gbit/s Ethernet at a control level, meaning it’s ideal for supplying passenger information screens and displays with power and data. The PushPull V4 Industrial has a resilient, one-piece housing which protects the connection from aggressive chemicals such as cutting oils. This means it can be utilised in both harsh industrial environments and outdoor applications. The V4 Industrial also comes with additional IP65/67 protection covers on both ends, meaning you’re safeguarded from total dust ingress and water. Users can also allocate colour codes to each PushPull plug and socket to help reduce cabling errors. For example, you can colour code data, signal and power lines to ensure each one is distinct and easily identifiable.
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Both the ix Industrial and PushPull V4 Industrial have been thoroughly tested to ensure they meet the required standards. The housing of the V4 has been tested according to railway standards for shock, vibration and temperature, meeting EN 45545-2, whilst the ix complies with IEC 61076-3-124 and conforms to the shock and vibration resistance levels set out in EN 50155 railway specifications. When Han-Modular was first released back in 1993, it was the first modular industrial connector to run power, signal, and data alongside each other in a single connector. The launch of the new HanModular Domino range means significant space savings of up to 50% can now be achieved. The mating face has been divided in two, resulting in an almost square surface in which even larger contacts can be accommodated. This allows users to configure customised connectors which are exactly tailored to their design requirements. Power, signal, data or compressed air can now be combined in one module, reducing the total number of interfaces required. Also, as the connection technology becomes smaller and more lightweight, users can now fit more modules and module types into one connector. As a result, assembly areas which are difficult to reach can be equipped more efficiently. With the addition of the new Domino range, there are now over 250 modules to choose from and many thousands of
potential combinations available. The new Domino modules are also compatible with standard components of the Han-Modular series, so they can be easily integrated into existing systems and machinery. If you’re seeking an even more compact connector, the Han 1A has been designed to take up less installation space. Constructed from lightweight yet durable polyamide plastic, the Han 1A can also integrate contacts for the delivery of data, signal and power. In mechanical engineering, the Han 1A provides an efficient solution for connecting tools and smaller machine modules such as heating and cooling units, fans, control terminals, lighting systems, drives and vibration conveyors. www.harting.com/UK
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ROBOTICS
Can UK manufacturing raise robotics uptake by learning from Europe? Factory automation specialist FANUC examines the potential reasons behind the UK’s reluctance to automate – and asks what we can learn from our continental cousins.
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espite punching well above our weight as a manufacturing powerhouse, the UK is in danger of slipping down the international rankings unless we increase our levels of automation. Now sitting at 25th in the global robotics league table, we are the only G7 nation outside the top 20 and have been eclipsed by most of our European counterparts in terms of the number of robots per 10,00 workers, including Italy, Belgium, Switzerland and the Czech Republic.
An improving picture The benefits to UK manufacturing of robotics and automation technology are greater than ever, helping us to meet net zero targets, boost productivity and underpin our key industries. And with an estimated 70,000 vacancies in manufacturing, robots are also alleviating the longstanding labour shortages, which have only worsened since Brexit and COVID. In regard to automation uptake, it is certainly an improving picture. Led by the automotive sector, UK robot installations were up by 3% in 2022, with operational stock growing by 7%. But at just 98 robots per 10,000 workers, we are still well behind European leader Germany at 415. Among the many potential explanations for this are a focus on short-term payback rather than the longer-term total cost of ownership (TCO), a fear of change, outdated perceptions of engineering as a career, a lack of government incentives, our reliance on cheap manual labour; and no long-term national manufacturing strategy. While some of these are beginning to change – the government recently announced a £4.5bn package of support for British manufacturing, for example – should we also be looking to our European neighbours for some automation inspiration?
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Dr Bob Struijk certainly thinks so. As the Vice President of FANUC Europe, Dr Struijk has overseen automation installations across numerous countries and believes there are a variety of reasons why certain nations are further ahead of the UK on their automation journey. “Germany is the clear European automation powerhouse and owes a large part of its success to a profound respect for engineering and manufacturing,” he explains. “The German model emphasises the meticulous craftsmanship of products, fostering a culture that places a premium on precision and innovation. Catapulted by the automotive industry, robotics and automation have been at the forefront of bringing Germany to its position today as a manufacturing leader.” In addition, bridging the gap between industry and academia has helped to boost German innovation. “In Germany, collaborative efforts between industry and academia contribute to a continuous cycle of research, development and implementation,
creating an ecosystem that thrives on technological advancement,” continued Dr Struijk. “The German apprenticeship system also provides a seamless flow of skilled labour into industry at low cost. The UK can learn from this by cultivating a similar synergy between its educational institutions and industrial sector to breed a culture of continuous improvement.” However, for a nation built on SMEs, Dr Struijk is also clear that UK government support is critical to future success: “The penetration of robotics and automation in the UK is especially low among small and medium-sized enterprises. Government tax breaks or accelerated depreciation of robots could certainly help to change this.”
Nordic nations In sixth place in the global automation league table, Sweden boasts an impressive 343 robots for every 10,000 workers. Neighbours Denmark at 274, Finland at 168 and Norway at 103 all sit higher than the UK. “With their realistic approach towards
ROBOTICS return on investment (ROI), the Nordic countries have successfully integrated automation into their industries,” outlined Dr Struijk. “By focusing on the long-term benefits, these nations have cultivated a business environment that encourages companies to invest in automation technologies.” By looking at TCO rather than just ROI – considering indirect cost savings such as reduced energy bills, less waste, higher productivity and increased production capacity – investing in automation could be a far more attractive proposition to UK manufacturers than it is today. But again, the importance of government support cannot be overlooked. “While the UK could draw inspiration from the Nordic model by fostering an environment where companies can confidently invest in automation, this must also be backed by supportive government policies and incentives,” explained Dr Struijk. “In the Nordic countries, robust government initiatives have provided financial support and created favourable conditions for the adoption of automated solutions. For
example, in the city of Odense, the government has stimulated the set-up of a ‘Robot Valley’ – a cluster of private companies, startups and academic institutions – that is helping to drive the Danish robotics market forward.”
Eastern Europe Finally, Eastern European countries such as Slovakia, Hungary and the Czech Republic have embraced automation as a means of prioritising worker welfare. “By automating dull, dirty and dangerous tasks, these nations have not only increased their manufacturing efficiency but have also enhanced the overall well-being of their workforce,” continued Dr Struijk. “They have benefitted from their close proximity to the German automotive market and used a combination of skilled labour and investment in robots to take a large share of the tier 1 market, as well as a host of greenfield investments by major European and Asian automakers. The UK could benefit by adopting a similar mindset,
using automation to alleviate workers from monotonous and hazardous tasks, thereby improving job satisfaction and increasing overall productivity.” There is no doubt that manufacturing is already one of the UK’s greatest success stories. By investing in automation and robotics, UK manufacturers can help to futureproof their business and ensure we continue to compete on the international stage in the years to come. www.fanuc.eu/uk/en
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ROBOTICS
The imperative of automation In today’s dynamic global manufacturing landscape, the integration of automation and robotics has become a cornerstone for maintaining competitiveness. But UK Manufacturers need to act now, or risk being left behind as KUKA explains.
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ow, more than ever, as technology advances at an unprecedented pace, the decision to automate is not just strategic but one of commercial survival. The absence of automation, coupled with the attitudes of UK manufacturers towards robotics and automation, poses a significant challenge to the UK’s ability to compete with low-cost alternatives, especially from the Middle East, where the widespread adoption of robots has been heavily publicised. Understanding why UK manufacturers are hesitant to adopt automation is crucial if they are to succeed in today’s market.
The rise of automation in manufacturing Automation in manufacturing involves the use of technology to perform tasks with minimal human intervention. Robotics, artificial intelligence, and advanced machinery have become integral components in modern factories, contributing to increased efficiency, precision, and productivity. In the context of global manufacturing, countries that embrace automation are better positioned to meet the demands of a rapidly changing market.
The Middle East One notable example of a region making significant strides in automation is the Middle East and Asia. Many Eastern countries have recognised the need to diversify and have turned to automation as a means of achieving economic transformation. As a whole, the continent of Asia led the way in robotics installations in 2022. The new World Robotics report recorded 553,052 industrial robot installations in factories
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around the world in 2022. By region, 73% of all newly deployed robots were installed in Asia. The continued adoption of robotics and automation is enabling Middle Eastern manufacturers to produce goods more efficiently and at a lower cost. By comparison, the UK is falling woefully behind, not even featuring in the top 15 largest markets and unable to compete. The embrace of automation by Eastern manufacturers is giving them a competitive edge over counterparts that lag in automation adoption. With streamlined production processes, reduced labour costs, and improved product quality, these manufacturers are better equipped to offer products at more competitive prices on the global market. As a result, they are gaining ground and challenging the dominance of traditional manufacturing.
UK manufacturers In contrast, some UK manufacturers are hesitant to fully embrace automation due to
various factors, including concerns about job displacement, initial investment costs, and a lack of awareness about the transformative benefits of automation. However, failure to adapt to the changing landscape may result in diminished competitiveness and market share, ultimately failure. But there are multiple benefits to adopting robotics, not just for the commercial gains, but also to future proof operations to sustain operational longevity. Consider the appeal to the next generation, who may not be overly enamoured at the prospect of becoming a welder, but may be drawn to the opportunity of becoming a robot programmer. Adopting automation also sends a very definitive message to your customers – you are looking to the future, you are innovative, you are investing.
Job displacement myth One common misconception surrounding automation is the fear of job displacement. While it is true that certain routine tasks may become automated, the overall impact of
ROBOTICS automation on employment is nuanced. Automation often leads to the creation of new, higher-skilled jobs in areas such as robotics maintenance, programming, and system management. Moreover, by enhancing efficiency and competitiveness, automation helps secure the long-term viability of the manufacturing sector, safeguarding and creating jobs along the supply chain, such as administration staff, drivers and warehouse/inventory staff.
collaborate to create policies that incentivise and support the adoption of automation technologies by providing financial assistance and educational programs. To remain competitive in the global manufacturing arena, UK manufacturers have to recognise the urgency of embracing automation. By investing in advanced
Investment in the future While the initial costs of implementing automation systems can be significant, it is crucial to view them as strategic investments in the future. The long-term benefits, including increased production capacity, improved product quality, and enhanced competitiveness, far outweigh the initial expenses. Governments and industry stakeholders should
technologies, optimising production processes, and upskilling the workforce, they can position themselves as able players in the international market. The lessons from the East serve as a stark reminder that failing to adapt to the era of automation may lead to a gradual erosion of competitiveness. Automation is not merely a technological luxury; it is a strategic necessity for manufacturers aiming to thrive in the current global landscape. The adoption of automation by Middle Eastern countries is pushing them further and further ahead in the race for global competitiveness. UK manufacturers must act to overcome their reservations and invest in technology that will define the future of manufacturing. Embracing automation is not just about staying ahead ¬¬– it is about securing a place at the global manufacturing table. www.kuka-robotics.com
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ROBOTICS
Compact palletising solution gives brewery the edge MEPCA discovered how a German brewery is benefitting from robotic palletising, thanks to a solution from Kawasaki Robotics.
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estheimer Brewery is a private brewery rooted in more than 150 years of tradition. From its factory in the Sauerland region of Germany, it produces regional beer specialities and prepares them for distribution both regionally and internationally. In order to remain competitive in an increasingly diversified market, Westheimer installed a Kawasaki robot in August 2017, one of the first to do so among their competitors. The ease, flexibility and efficiency of its automated system have inspired it to automate additional processes in the future. Finding qualified workers is a growing challenge for Westheimer Brewery and the greater manufacturing industry. The number of applicants in the region is continuously declining, which can cause lapses in production. In addition, Westheimer wanted to reduce the physical strain on employees that can be caused by end-of-line work. The brewery’s previous, older palletising machinery would frequently break down, making it clear that it was time for modernisation. The Westheimer Brewery’s production volume has remained at a constant level for years, but the increasing product diversification was another factor the company had to consider when building its new system. It had to be flexible and adaptable to new products. Empty bottles are manually fed into an automatic sorting machine at the entrance of the plant, where they are cleaned and rinsed. After filling, the bottles are inspected and placed in crates. These steps are still manual, but Westheimer plans to install a pick-andplace robot in the future to handle these tasks. From there, production takes place on two interconnected levels – empty bottles and the final product are processed on the lower level, and bottles are filled on the upper level. In the
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new system, a conveyor belt transports the bottles between the two levels, which allows crates to be loaded and unloaded by the Kawasaki CP500L palletising robot. The robot sits on a concrete base with cabling laid through its interior. The brewery worked with German Kawasaki integrator Schröder Engineering Team to design the ideal system for its process. Together with Kawasaki Robotics GmbH, the integrator was involved in every step of the installation. The new palletising system is flexible and adaptable to new or different products. A tool changing station is connected to the magazine, where the right gripping tools are readily available for the robot to change based on product type. This flexibility not only saves time but also enables significantly higher and consistent product quality. The high degree of flexibility is also a great advantage when it comes to external orders. Westheimer Brewery works in a one-shift operation, and special orders – such as organic beer – are added at regular intervals. It also supports other breweries from its large network and numerous craft beer labels and start-ups that have shaped the beer market in recent years. Having a flexible automated system allows Westheimer to keep up with beer industry trends more easily. To meet its goals, the brewery needed a workhorse with a high payload that could fit in its space. The Kawasaki CP500L robot checked all of the boxes: the compact palletising robot has a payload of 500kg and a maximum speed of 900 cycles per hour. With a reach of 3,255mm, a palletising height of 2,200mm and a net weight of only 1,650kg, it
is the most powerful robot in its class. In addition to the speed, precision and compact design of the robot, the independent loading of the machine and Kawasaki’s Cubic-S safety system were also key selling points. A new chain gripper for the same purpose would have required more programming and been more susceptible to faults. Currently, the Kawasaki robot CP500L processes more than 1,200 crates per hour – and there is even more potential. Thanks to its integrated control system, the robot enables effective crate handling, utilising a single machine in a small space. The CubicS-based safety system also functions reliably and easily: As soon as the door to the robotic cell is opened, the power is switched off, and employees can enter the system without hesitation. The brewery’s robotic palletising system simultaneously helps it combat an industrywide labour shortage while allowing it to redeploy existing employees to more humanfriendly roles better suited to their skills. The new CP500L robot is just the beginning in the Westheim Brewery. In the long term, the company plans to replace more machines with robots and automate numerous steps in its processes. kawasakirobotics.com/uk/
SENSORS & SENSING SYSTEMS
Understanding repeatability and accuracy in flowmeters Liquid flow measurement specialist, Titan Enterprises, outlines the roles of repeatability and accuracy in flow measurement devices.
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he demand for high-accuracy meters in flow measurement has indeed grown over the years, driven by various factors such as stricter government regulations and the need for more precise measurements in critical applications. Manufacturers of flow measurement devices like Titan Enterprises are continually investing in research and development (R&D) to introduce new technologies that enhance the accuracy and performance of their flow measuring instruments. This includes innovations such as improved sensor technology, advanced signal processing algorithms, and enhanced calibration methods. An important element of Titan Enterprises’ R&D is reviewing the performance of its flowmeters and delivering improvements in product design and materials that increase both the accuracy and repeatability (or reliability) of these flow measurement devices. The academic and flow measurement expert Roger Baker states: “A high-quality flowmeter, carefully produced with a design and construction to tight tolerances and with high-quality materials as well as low wear and fatigue characteristics, is a precise meter with a quantifiable value of repeatability”. Repeatability and accuracy are distinct terms used to define the performance and quality of a flowmeter.
limits, usually set at 0.1% of repeated points. Repeatability is expressed as a ± percentage. Repeatability can deteriorate at low flow rates, so manufacturers may specify this value as a percentage plus a constant uncertainty value or as a percentage of full-scale reading, rather than a percentage of the measured flow rate. Titan’s highly repeatable small turbine flow meters are successfully employed in batching processes and dispensing applications particularly within the food and beverage, chemical, medical and laboratory sectors. They have excellent repeatability (±0.1%), making them ideal for dosing systems, and can be calibrated in situ.
What is repeatability?
What is accuracy?
The standard description of repeatability in this context is the flowmeter’s ability to produce the same result on repeated runs under identical operating conditions. Repeatability is often something that the design of the instrument defines, and without excellent repeatability, a flowmeter cannot deliver reliable measurements. Titan Enterprises sets its calibration rigs to record a certain number of pulses depending on the type of meter. The flow rigs accurately interpolate the rig and meter pulses and will not accept a reading unless it is within pre-set
The accuracy of a flowmeter relates to the quality of the measurement device and how close a measured reading is to the true flow. It is generally accepted that accuracy is used as a qualitative term, whereas linearity and uncertainty measurements are the quantitative terms defining the accuracy of a flowmeter. Linearity is usually defined by stating the maximum deviation of the reading over a stated flow range (e.g. ±1% of flow rate). It is the ability of the flow meter to remain within specified limits over its entire flow range determined by its design. The standard
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way of expressing linearity is the error of reading. A frequently used alternative in some industry sectors is the percentage of full-scale deflection or FSD. Measurement uncertainty is the level of potential error in calibration, i.e. the range of values within which the true values lie with a specified probability. It is accepted that there is always a margin of error in any taken measurement, and this uncertainty is quantified as a ± percentage. Accurate flow rate measurement is influenced by an array of variables, including pressure, temperature, density and viscosity of the fluid. All of these factors are typically included in a calibration record. The very best calibration houses claim a measurement uncertainty as good as ±0.02%, though more typically ±0.1% when these factors are properly controlled. Overall, the trend towards higheraccuracy flow meters is likely to continue as industries evolve and the demand for precise measurements in critical applications grows. This evolution is driven not only by regulatory requirements but also by the ongoing pursuit of process optimisation, efficiency gains, and improved product quality across various sectors. flowmeters.co.uk
IMAGING & VISION
New leadership for IDS Imaging Dr Michael Berger has been appointed Managing Director of IDS Imaging Development Systems with effect from 1 January, 2024. Jürgen Hartmann, founder and shareholder of the industrial camera manufacturer, is stepping down from the management board after 27 years at the company’s helm.
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EPCA magazine spoke to Dr Michael Berger and Jürgen Hartmann to understand the journey the company has been on since it was founded and to hear what the future holds under the new leadership.
Q: Mr Hartmann, why are you leaving after 27 years? A: We have been preparing for the generational change for years so that we don’t end up without a succession plan one day like other SMEs. The issue has been close to my heart for a long time because continuity and reliability are important to me, not least with regard to our partners and customers. I initiated this step four years ago with the promotion of my son Jan to the management board and the appointment of Alexander Lewinsky to the management board in 2021. I founded the company in 1997 as a two-man operation and have undergone many changes since then. But everything has its time, and after more than 40 years of working life, it’s time for me to take another step back. My wife very nicely defined my future task as follows: “Be the wind beneath the wings of your successors. I want to be that wind. Support where desired and help where necessary.
Q: Mr Berger, which IDS areas will you be responsible for in the future, and which areas will your other colleagues from the management team be responsible for? A: I will be responsible for the Sales, Marketing, Product Management and
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IDS founder and shareholder Jürgen Hartman (left) with Managing Director Dr Michael Berger
System Consulting divisions. Jan Hartmann will be in charge of Finance, HR, IT and Business Innovation & Ecosystem with immediate effect; Alexander Lewinsky will take over Development in addition to his previous area of responsibility, Operations.
Q: Mr Berger: What are your goals for the next few years, and will industrial cameras continue to be the focus? A: ‘Growing together, inspiring worldwide’ is my motto. We want to anticipate customer requirements with innovative, high-quality industrial camera solutions. That is our core competence, and that is how I have come to know IDS: innovative and customerorientated. The fact that our development department is based right here at our headquarters in Obersulm is, of course, an absolute advantage for us. And, of course, the fact that Jürgen will remain with us as
a consultant for the development of these solutions. These are the best prerequisites for initiating further scaling and the next innovation steps at IDS. For me, a clear market orientation takes centre stage. We will continue to focus on industrial cameras. However, the demand for complete solutions is increasing, which is why innovative image processing components, for example, will play an increasingly important role for us. We want to offer our customers hardware and software that is optimised for their application - the latest technology plus particularly simple workflows that they can’t get anywhere else.
Q: Mr Hartmann, are you withdrawing completely from the company? A: No. Although I am consciously withdrawing from the operational business, I will continue to take care of innovations and new technologies. My desk is now in
IMAGING & VISION Development, but my role in future will be an advisory one.
Q: Mr Berger, what new IDS products can we expect in the first half of the year? A: Numerous model additions to our USB3 and GigE uEye+ camera families. Integration of many new sensors from Sony, onsemi, etc. In other words, there are even more choices for our customers, from the entry-level range right up to the 10GigE camera series. At the same time, we will continuously improve our IDS peak SDK. There will be several free software updates over the course of 2024. We will also be extending our IDS NXT platform, including with additional cameras. In addition, the streaming capabilities of the IDS NXT malibu models will be expanded. Furthermore, new 3D cameras are planned in the Ensenso series. Exciting developments can also be expected for DENKnet, the VISION solution for customised PC-based image analysis.
Q: Mr Hartmann, what have been the highlights for you in the history of IDS? My motivation has always been to recognise the potential of innovative technologies at an early stage and to adapt them for our products, especially through the industrialisation of consumer technologies. In 1997, the first product ‘Made by IDS’ was launched on the market - the FALCON colour and monochrome frame grabber. The PC plug-in card for converting analogue to digital images on the basis of a chip from the consumer market is still in use today in applications such as medical technology. I had the idea of developing my own digital cameras and not just analogue frame grabbers in 2003 when I realised that customers no longer wanted to digitise analogue signals in the PC but preferred digital signals. In 2004, IDS launched the first ever industrial camera with a USB interface. The latter was not considered suitable for industrial use at the time, but IDS used this technology in a visionary way for its high-performance digital industrial cameras - with resounding success. In 2007, we launched the first IDS camera with a GigE interface onto the market. This technological advancement opened up great potential for applications that require high bandwidth and cable length. Whenever a technology reaches its limits, we develop new products - sometimes in small steps, sometimes in quantum leaps. One such small step was the market launch of our first USB 3 camera in 2011, while our entry into the 3D segment with the Ensenso N10 stereo 3D camera in 2013 was certainly a quantum leap. We achieved something completely different in 2017 with the new IDS device generation IDS NXT with vision app-based image processing. The topic of artificial intelligence has not just been on our minds since today. Our entry into the AI segment began in 2018, and we also want to make it as easy as possible for users by adapting consumer technology. Our IDS NXT malibu, with on-camera AI and streaming, was developed in cooperation with Ambarella. This makes us the first provider to offer an Ambarella chip familiar in action cameras for use in industrial applications. www.ids-imaging.de
0161 710 3346 info@pemac.com www.PEMAC.com
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CONDITION MONITORING
Why your business needs thermal condition monitoring Product quality is high on the priority list of any reputable manufacturer. Whether your business manufactures finished articles or components for other businesses to incorporate into their products, the risks are the same: If your production equipment fails, your business quickly transitions from a profitable organisation to a loss-making company.
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any businesses used to keep a healthy level of reserve stock in the warehouse to ensure their customers were never let down in the event of an unplanned break in production. But as competition increases and margins erode, most businesses choose to tie up as little cash in stockholding as possible, making reserve stock a less efficient way to operate in today’s highly competitive environment. As businesses hold less stock, the effect of a disruption to production is quickly compounded, deliveries are more likely to be missed, and customers let down. This not only impacts revenue from lost business, but it also damages the reputation of a business. But can these issues be avoided in the first place? We believe the answer is yes: carefully monitoring the condition of your production equipment on a regular basis has shown that many supply chain problems can be eliminated. For example, if your business uses an electric motor at any stage during the production process, when was it last checked for cleanliness? Electric motors can overheat due to a build-up of dirt and debris blocking airflow holes that are designed to help cool the motor. The motor may not be old or have any obvious issues – in fact, it may appear to be working perfectly well until it suddenly fails. Other examples might be electrical connections, fuse boxes, contactor
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plates, or other components found in electrical cabinets. Over time, tiny vibrations and heat cycles can cause crimped connections to loosen, along with nuts and bolts on connective wiring, which give rise to elevated temperature as the electrical resistance increases. This type of common fault With thermal imaging, you can quickly tell the motor on the has no visual clues left is running hot and know to move in for further inspection. and can happen at any time during the production process, yet in most cases it build-up of dust and dirt, the fix may take can be prevented using predictive condition five minutes to clean it thoroughly when monitoring techniques. the motor has been turned off. If the issue If regular thermal inspections are isn’t identified early, the motor may fail or undertaken, thermal signatures can be deteriorate and require a replacement motor identified for every electrical connection, to be installed – potentially resulting in a electric motor, other electric component shutdown over several days whilst waiting or moving equipment in a facility. While for a new motor to be delivered. equipment operates as intended, Thermal cameras require little training to temperatures will remain reasonably use in the hands of an operator, and the consistent, and the insights gained will be investment in a camera, operator training, no more than regular reassurance. However, and associated reporting software may if a temperature reading suddenly begins cost less than you think. The one certainty to increase unusually, then this may be is that the overall cost will be less than an indicative of a developing fault. unplanned production shutdown. In the example of an electric motor exhibiting higher temperatures due to a bit.ly/flirWCM
HEALTH & SAFETY
Ensure your fume extraction compliance Against a backdrop of ever more stringent scrutiny being placed on the effectiveness of workplace fume extraction systems, Extractability explains how Environmental Detection Instruments can support not only the monitoring of a system’s performance but also the longterm reporting of the data captured, a vital imperative in today’s workplaces.
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s the demand for effective fume extraction systems continues to rise, so does the scrutiny from regulatory bodies, especially the Health and Safety Executive (HSE). In recent times, the HSE has intensified its efforts to identify potential lapses in fume extraction practices, urging businesses to provide tangible proof that their systems are not just in place but are consistently effective. This renewed focus prompts companies to re-evaluate their strategies and consider whether they can truly substantiate the reliability of their Local Exhaust Ventilation (LEV) systems. A critical aspect under the HSE’s magnifying glass is the ability of businesses to demonstrate that their LEV systems offer constant and reliable protection to employees. Many enterprises have invested time and resources into researching and acquiring fume extraction equipment to safeguard their workforce against current and future health risks. However, the HSE is now demanding more than periodic LEV testing; it is urging businesses to prove that fume levels within their workshops have consistently remained within safe limits. The first challenge is providing evidence of a clean air return. In the absence of a comprehensive method to validate the effectiveness of fume extraction, some insurers are reluctant to endorse systems that cannot affirm a consistent supply of clean air. It is no longer sufficient to rely solely on routine LEV testing; companies must now explore additional measures to verify the continuous efficiency of their fume extraction systems. One innovative solution gaining traction is the use of Environmental Detection Instruments (EDIs). Unlike traditional three-day air monitoring services, EDIs
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offer a real-time, constant stream of data, providing a comprehensive overview of fume levels within a workshop. Companies such as Extractability offer the Protectoscan EDI, a reliable tool that not only monitors air quality but also produces annual records. This wealth of data can serve as irrefutable evidence during HSE inspections, demonstrating the effectiveness of fume extraction systems over an extended period. Moreover, the Protectoscan EDI goes beyond mere monitoring; it actively engages with fume extraction units. In the event of breached fume levels, this intelligent system triggers extraction units to mitigate potential risks promptly. This automated response not only ensures the safety of employees but also adds an extra layer of reliability to fume extraction systems, addressing concerns
about human error or forgetfulness. Extractability understands the challenges companies face in staying compliant with evolving HSE regulations. The Protectoscan EDI is positioned not just as a monitoring tool but as a strategic asset in establishing and maintaining compliance. In conclusion, the HSE’s intensified scrutiny of fume extraction systems necessitates a proactive approach from businesses. Companies must move beyond routine LEV testing and embrace technologies like the Protectoscan EDI to not only prove compliance but also to enhance workplace safety, protect employees, and fortify their position against potential regulatory challenges. www.extractability.co.uk
PUMPS & PUMPING SYSTEMS
Efficient food waste disposal SEEPEX, a specialist in progressive cavity pumps for food and beverage applications, offers a sophisticated solution for chopping, pumping, and moving food waste. This simplifies the handling of challenging by-products, ranging from fish, whole chickens, and vegetables to peelings and fruit stones. The BTM progressive cavity pumps not only reduce food producers’ costs, but also improve their standards of hygiene and health & safety.
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ruit, vegetable, meat, poultry and fish processing facilities inevitably produce waste. This includes not just trimmings, wash residue and byproducts, but also off-specification batches, overproduction, and expired goods. Strict sanitary guidelines dictate the handling and quick removal of this waste from production areas. Clearing this food waste not only frees up capacity for primary processing operations but also provides an opportunity. This involves turning waste and by-products into additional revenue streams by using them for animal feed, compost, or even to generate renewable energy. However, some waste products are notoriously difficult to handle – large, highly viscous, or non-flowable foodstuffs can be a challenge. These include whole chickens, chicken frames, heads, feet, and necks, as well as other animal bi-products. Whole vegetables and fruit, along with fruit stones, seeds, and peelings, also fall into this category. As a result, some operators still rely on traditional methods to remove them from the production area. Conveyor belts are often used in large food production factories. Compressed air systems, vacuums and water flumes are also common. Operators use waste containers, like tote bins or dolavs, for manual handling. These methods can be inefficient, unsanitary and expensive.
Automated, all-in-one alternative Fortunately, there are sophisticated, hygienic and cost-effective alternatives on the market. The SEEPEX open hopper BTM pump range is one such option. Many fruit, vegetable, meat, poultry and fish processing factories across the UK and Europe have adopted this pumping technology for the disposal of food waste. The BTM progressive cavity
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SEEPEX integrated system hygienically removes waste, including whole fruit and vegetables, peelings and fruit stones.
pump with a feed auger and macerating knives, chops and pumps food waste in a single operation. This process effectively reduces solids waste volume by up to 60% and provides a pumpable consistency without requiring additional water. Changing from traditional waste removal methods to an enclosed food waste removal solution like the SEEPEX BTM pump has several advantages for food manufacturers: Hygienic waste removal: Firstly, it is more hygienic. Transferring food waste products through a closed pipe system eliminates the need for dedicated cleaning of tote bins. This is especially beneficial before re-entering high-care areas, as it helps prevent potential cross-contamination.
Improved health & safety: Secondly, it is safer. Manual handling or conveyor systems can cause waste products to fall on the floor. This creates an immediate health and safety risk for workers and increases the risk of slipping accidents. In contrast, SEEPEX automated solutions streamline the process, needing only one staff member to load products into the hopper or even fully automating the feeding process. This improves efficiency and safety on the factory floor by minimising traffic and hazards in high-risk areas. Reducing the number of forklift trucks, operatives, and tote bins significantly improves overall safety. Cost-saving solution: Finally, the BTM pump range is more efficient, generating significant cost savings. By chopping and
SEEPEX BTM pumps with patented cutting unit chop and pump in a single operation, and enable hygienic waste removal.
PUMPS & PUMPING SYSTEMS pumping all-in-one, the BTM pump is able to create a pumpable consistency without requiring any additional water, resulting in savings from water usage. It can also reduce food waste volume by up to 60%, making it easier to transport and cutting transport costs. The operating and energy costs of the BTM are considerably lower than vacuum or compressed air systems, generating savings. Automating the process and eliminating manual labour also allows food producers to cut down on labour costs, freeing up employees for more profitable primary production roles. In chilled, high-care production areas,
using a simple pipeline to remove waste instead of manual transport through doorways will help reduce energy costs and minimise potential contamination from external sources.
Bespoke Options Customised solutions are available for transporting more challenging by-products. To ensure continuous pumping, the BTM pump range incorporates an auger with a large pitch, feeding the product into the cutting elements. Horizontal and vertical grinders can also be integrated, as can solids traps to prevent
pump damage. Dewatering devices can help reduce waste volume even further. Additionally, all BTM pump systems can be fitted with Smart Conveying Technology (SCT), a pump maintenance solution from SEEPEX that enables rapid dismantling and cleaning, reducing maintenance time by up to 85%. With SCT, the adjustable stator can also increase pump stator life by up to 200%. Pumps fitted with this maintenance solution can be fully maintained in place without removing any pipework and are also suitable for Clean-In-Place (CIP). www.seepex.com
Severn Trent boosts sewage plant reliability
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inworth is the largest sewage plant within Severn Trent’s region, and the fifth largest in Europe. The plant operates 24-7, serving a population of around 2.5 million people in the Birmingham and Black Country areas. The plant covers an area equivalent to 300 football pitches.
Maintain-in-Place Technology After seeing SEEPEX’s success at Severn Trent’s Stoke Bardolph and Finham THP plants, the Minworth site decided to explore SEEPEX’s Maintain-in-Place (MIP) capabilities and digital solutions that included pump monitoring. SEEPEX provided an open hopper progressive cavity pump with MIP technology to replace original progressive cavity pumps without altering the physical footprint or the installed power. SEEPEX MIP technology
includes Rotor Joint Access (RJA) and Drive Joint Access (DJA). RJA enables the pump’s compression zone to be moved over the stator, allowing access to the rotor universal joint and giving the ability to remove debris without extensive maintenance work, for example, removing pipework and the pump’s stator. With DJA, the pump baseplate is split into three sections (rotor/stator, pump hopper and drive end), enabling maintenance tasks such as replacing a worn auger or a mechanical seal to be completed safely without needing to dismantle the whole pump. SEEPEX’s Digital Solutions provide a comprehensive platform for pump performance monitoring, detecting potential issues with early warning notifications, and scheduling maintenance tasks. With the ability to track and analyse data on pump operation, tasks such as topping up mechanical seal quench pots are transformed from regular, time-consuming inspections into quick, planned interventions. Additionally, the monthly report provides a high-level overview of pump performance, including a simple RAG status to quickly identify any areas requiring further investigation.
SEEPEX PC pumps with maintain-in-place Drive Joint Access technology.
Optimised performance at Minworth’s THP process with SEEPEX feed pumps.
Improved pump performance
reliably and consistently, maintaining optimal performance levels as confirmed by advanced analytics. Thanks to SEEPEX’s innovative MIP technology, maintenance staff can easily access and dismantle the pump, streamlining maintenance and reducing downtime. Integrated SEEPEX Digital Solutions provide a comprehensive platform for tracking pump performance and scheduling maintenance tasks in a preventative capacity, avoiding costly reactive maintenance and maximising process throughput and biogas production. The benefits delivered by the introduction of the SEEPEX solution include one year of uninterrupted pump operation for improved process resilience and peace of mind. Quicker maintenance with maintain-in-place technology has reduced downtime and costs, while the verification of pump performance has been possible through SEEPEX advanced analytics. Improved process resilience through continuous monitoring and maintenance planning has also been realised, giving peace of mind from knowing the pump is operating at optimal levels.
Over the course of over a year, the SEEPEX pump has performed
www.seepex.com
www.mepca-engineering.com
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EVENT PREVIEW
Machine Vision Conference opens 2024 visitor registration The UK Industrial Vision Association (UKIVA), organisers of the prestigious Machine Vision Conference, has announced that visitor registration for the much-anticipated show opens in February. This fantastic two-day show will take place on 18-19 June at the CBS Arena in Coventry.
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he Machine Vision Conference (MVC) is renowned for bringing together the whole machine vision industry, from well-known industry brands showcasing their cutting-edge solutions to leading industry experts sharing their vast knowledge. Whether you are a seasoned industry professional, or new to the world of machine vision, MVC is the place to immerse yourself in the latest innovative industrial vision and imaging technologies. Adopting machine vision solutions is recognised for bringing significant benefits to a vast array of businesses due to their ability to streamline processes which, in many cases, delivers financial benefits to businesses. The flexibility and adaptability of this innovative technology is demonstrated by the diversity of the industries where it is applied, such as food and beverage, pharmaceutical, healthcare and medical devices, automotive, aerospace, packaging, solar energy, electronics, semiconductor, sport, traffic and transport. Food manufacturing is one of the industries where vision technology can provide a significant competitive edge for manufacturers. It offers numerous opportunities to improve quality assurance that was previously unattainable, such as examining the food product itself, verifying the integrity of food packaging to prevent premature spoilage and scrutinising food labelling for accuracy. The introduction of newer technologies, such as hyperspectral imaging, is expected to have a profound impact on the industry in the future. Whatever the industry, it is likely that vision technology is incorporated in some shape or form. MVC attracts a range of machine vision providers, all of whom are
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trying to capture the imagination, through the showcasing of their latest products and services, and of those seeking business improvement solutions as well as those just starting their research into the far-reaching potential of this industry. To further enhance your experience, exhibitors will be carrying out demonstrations and product launches at their stands so you can see with your own eyes what’s possible, as well as seek advice and recommendations. MVC’s comprehensive seminar programme is a great place to hear from the industry’s most knowledgeable experts about future developments, and to keep on top of current industry trends. In between visiting numerous exhibitors and educating yourself at seminars, MVC will offer fantastic networking opportunities with industry colleagues and experts, as well as an abundance of chances to build new business relationships that have the potential to develop into lucrative business opportunities. One of the exhibitors at the 2023 event,
Nathaniel Hoffman, Market Product Manager for Machine Vision and Measurement at SICK UK, said: “The Machine Vision Conference is the one place to go to meet all the suppliers in the machine vision industry; to talk openly about your requirements and understand what is possible with machine vision. It is fully supported by SICK.” MVC visitor registration opened in February. To plan your visit to the Machine Vision Conference and book your free ticket, visit the event’s website. www.machinevisionconference.co.uk
EVENT PREVIEW
Strong exhibitor bookings for Automation UK The two-day Automation UK show will return to the CBS Arena in Coventry on 18-19 June. This event provides an unparalleled opportunity for businesses to exhibit their cutting-edge automation and robotics solutions. With the attraction of a vast number of visitors and buyers expected to fill the hall, it’s understandable that the response to the exhibitor space offering has been fantastic.
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he main aim of the Automation UK event is to highlight the significance of automation and robotics for the growth of the UK economy. The show seeks to inspire more businesses to invest in these technologies by demonstrating the business benefits they can deliver. Automation and robotics solutions have already demonstrated their effectiveness in numerous industries, delivering improvements in areas such as efficiency, productivity and safety. This is a key driver to why Automation UK draws a large number of visitors from sectors like manufacturing, retail/consumer, automotive, electrical, electronics, engineering, aerospace, maritime, food, drink, logistics, transport, oil, gas and nuclear. A key benefit attracting exhibitors to participate in Automation UK is the chance to reach out to hundreds of potential customers through abundant opportunities for face-to-face meetings. The appeal for buyers to visit the show is to discover a vast array of automation and robotics solutions being showcased. They’ll be keen to see and experience innovative live demonstrations and to learn how these technologies and equipment can deliver improvements for their business. There are plenty of other compelling reasons why businesses won’t want to miss out on exhibiting their state-ofthe-art products and services at the show. Automation UK provides a unique opportunity to connect, collaborate and network with over 1,0000 visitors and industry experts, all under one roof. A further benefit is the chance to discover the latest industry trends and insights into the future of
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the automation and robotics industry. One of the visitors to the 2023 Automation UK, Tea Chalidze, Manufacturing Excellence Manager at Marks & Spencer, said: “I’m here to look at new equipment and to see what’s on the market, especially regarding robotics and automation, which is our future, so attending this show and exploring and seeing new ideas is very useful.” The presence of major brands as exhibitors in the 2023 show demonstrated that there is a demand for this type of exhibition in the UK. Some of the founding exhibitors include ABB, Fanuc UK, Piab, KUKA Robotics UK, RM Group UK, Schubert UK, Festo and RARUK Automation. In addition to the founding exhibitors, the following companies have also secured their exhibition space at the event this year: AMP Automation, Apem Components, AP Technologies, Apex Dynamics (Midlands) Ltd, Beckhoff Automation, Bowe Systec, Gudel Lineartec (UK), Heidenhain (GB), Hepcomotion, Idem
Safety Switches, Iko Nippon Thompson Europe, Lamonde Automation, Mikata Technology UK, Mitsubishi Electric, Mobile Industrial Robots, MRK Engineering Solutions, Olympus Technologies, Omron Electronics, Onrobots, Rollon UK, Safety Systems Technology UK Ltd, Schmalz UK, Schunk Intec Ltd, TM Robotics (Europe), Troax UK, Universal Robots, and Zimmer Group. These exhibiting companies specialise in products and services such as robots, robotic systems, systems integration, automation control parts and systems, sensors and machine safety. BARA (British Automation & Robot Association), who is the show organiser, is urging potential exhibitors to book their space early to avoid disappointment as it is anticipated that the rest of the floor space will sell fast. More information about how to book can be found on the event’s website. www.automation-uk.co.uk
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EVENT PREVIEW
National Manufacturing Summit returns The National Manufacturing Summit returns to the Manufacturing Technology Centre on March 14 this year. Its organisers outline what they have in store for visitors to the event.
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he UK manufacturing sector has always been supported and promoted by a wide array of events. However, many have typically been based on a legacy format that, over the last decade, has become somewhat stale and uninspiring. In 2020, MTC Events surveyed the manufacturing horizon along with industrial partners to ascertain what the manufacturing industry wanted to see in the future from industry events. Without a doubt, the resounding response was there was an overwhelming feeling that events - and the industry bodies organising events - were not fully representing the voice of industry, and that events were scripted and even politically focused too much on specific policy areas by the organisers. The call was for industry to have more involvement in both the construction of events and the content, delivering an unbiased voice for industry. Taking this feedback, it was decided that another industry conference wasn’t going to be good enough to stage that unbiased industry voice, and something bigger and more purposeful was needed. The idea of an annual summit was created jointly between the Industrial Policy Research Centre (IPRC) and the MTC Events team. An event of significance, fuelled by industry, for industry, giving UK manufacturers a stage to project an unbiased voice. In March 2021, the inaugural National Manufacturing Summit was held at the Manufacturing Technology Centre in Coventry. The first new large-scale event of its kind for some time, NMS 2021, was underpinned with government representation from all four nations, industry partners, academics, leaders, and experts from our sector. A fully virtual event, while some COVID-19 lockdown restrictions were still in place, NMS 2021 was a resounding success, with more
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than 1,500 delegates joining across the two days. NMS returned in February 2022 and marked the first major MTC-led face-to-face event to be held at the venue since the start of the pandemic. Building on the considerable virtual audience from the year before, we combined in-person conference sessions with a full live broadcast, thus creating the MTC’s first ever large-scale hybrid event. The 2022 National Manufacturing Summit was centred around three core themes – ‘fossil fuels to renewables’, ‘factory to door’, and ‘field to fork’ – providing a clear focus on the UK’s charge to achieving net zero by 2050. We welcomed over 4,500 inperson and virtual attendees over two days from across five continents, with over 540 companies represented. In 2023, building on the success of the previous year’s hybrid model, the National Manufacturing Summit was even bigger still. NMS 2023 was centred around unlocking the digital revolution and sought to address the prevalence of digital technology in UK manufacturing, both now and in the future. This year, our focus turns to technology, skills, and training, a topic that is high on the agenda within our sector, as we explore how advances in technology will affect the workplace and workforce of the future.
The event will provide a national forum for discussing key topics, which this year include: • Workforce development on the road to net zero • The future workforce and technologies • Tackling the skills crisis to build manufacturing resilience • A review of the current scene within manufacturing Event delegates will also have the benefit of seeing the latest technologies and demonstrations on display by a number of event exhibitors. Like every edition of NMS, our focus is informed by industry demand. With proven year-on-year growth, the National Manufacturing Summit affords opportunities for industry, academic partners, government, and the wider HVM Catapult network to not only be a part of the conversation but to help shape it, too. The original aim for this conference was to create an event fuelled by industry, for industry, and to give UK manufacturers a stage to project an unbiased voice. Four years on, and we truly believe that the National Manufacturing Summit continues to be just that. www.nmsummit.co.uk
February 2024 www.mepca-engineering.com
December 2023
January 2024
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Regular Sections: Food Processing Machine Building Robotics Imaging & Vision Drives Motor & Controls Sensors & Sensing Systems Test & Measurement Additive Manufacturing Pumps & Pumping Systems Packaging & Inspection Manufacturing Software Health & Safety
Overall Readership
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To advertise with MEPCA please contact: James Davies on 01795 509105 jamesd@cimltd.co.uk
Hannah Moody on 01795 509115 hannah@cimltd.co.uk
James Burke on 01795 509115 jb@cimltd.co.uk
INDUSTRY UPDATES
Carl Kammerling launches ifm cuts the cost of precision 2024 ‘Fusion’ promotion distance measurement
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arl Kammerling International (CKI), the home of C.K. Tools, has launched its popular Fusion promotion for 2024, offering more deals than ever before. Live from 1 February until 31 May 2024, the Fusion promotion will run across independent and chain wholesalers across the country, ensuring customers have access to the best tools for the job at a fantastic price. The promotion will see over 350 discounted products across the full CKI brand portfolio, including C.K. Tools, C.K. Magma, C.K. Classic, Avit and Kasp Security. With discounts of up to 65% on offer, this is CKI’s most standout Fusion promotion to date. Rhiannon Wyn Thompson, Trade Marketing Executive at CKI, said: “With more than 200 years of heritage in the trade, we understand how important it is for our customers to invest in quality, durable tools – at a great price. “It’s never been easier for savvy electrical and industrial trade customers to shop smarter by taking advantage of the fantastic savings available across the bestselling ranges CKI is known for.” For further information on the terms and conditions of Fusion 2024, visit the Carl Kammerling website. www.carlkammerling.com
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ith the new P|Prox range of inductive distance sensors from ifm electronic, reliably measuring the distance to metallic targets with micrometre precision no longer requires expensive measuring systems. P|Prox sensors are easy to install and set up, and thanks to their IO-Link communication, they are easy to interface with almost any type of control system. P|Prox sensors are factory-calibrated and ready to use out of the box. They can be relied on to deliver accurate, repeatable results, continuously outputting distance-to-target data via IO-Link, which is unaffected by the type of target metal. When the highest precision is required, simple onepoint calibration or even more accurate three-point calibration is possible. P|Prox sensors have an IP69K rating and an operating temperature range of -25 to +70ºC. They are available in flush and non-flush mounting versions with 60mm long industry standard M12, M18 and M30 threaded stainless-steel housings. All types are resistant to the effects of external magnetic fields, and all incorporate four LEDs for local status indication. www.ifm.com
Dynamic, cost-effective and reliable: the new KR FORTEC
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ith the new KR FORTEC, KUKA is launching an all-rounder on the market. The heavy-duty robot is energy-efficient and dynamic in handling applications. The KR FORTEC industrial robot delivers great versatility in a small footprint. With high dynamic performance, it achieves short cycle times – and its compact shape makes it ideal for tasks such as handling and spot welding. The speedy KR FORTEC tackles all this with low energy consumption. The new KR FORTEC is now available – with an extended arm available that handles loads of 240kg across a reach of 3700mm. Technically, this heavy-duty robot fits between the KR QUANTEC and KR FORTEC ultra. Cross-model modularisation ensures a high transmissibility of robot series components. “We developed the KR FORTEC to achieve a lower total cost of ownership (TCO) and to launch a resource-saving
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product on the market. The KR FORTEC is up to 700kg lighter than its predecessor,” explained Maximilian Pettkuhn, Portfolio Manager at KUKA. For customers, modularisation means lower costs for spare part storage. The KR FORTEC exemplifies reliability, with a long, trouble-free operating time and low maintenance requirements. Optimised accessibility makes maintenance work effortless and quick. The two in-line wrists adopted from the KR QUANTEC and KR FORTEC ultra models are waterproof and dustproof as standard equipment. Beyond that, the KR FORTEC can operate between 0° and 55°C. Several foundry variants are available for harsh and dirty environments.
The working envelope of the KR FORTEC can be expanded with the KL 4000 linear unit – which is modularly adaptable between 1.5 and 30m. A further advantage is that the KR QUANTEC also fits on the KL 4000. For cooperation with the KR FORTEC ultra on the same linear unit, the KL 5000 is simply selected. This allows customers to continue to adapt and combine products easily to meet individual requirements. www.kuka.com
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CONNECTIONS 3D Print Manufacturing
Machine Safety
Midlands 3D Printing T: 01785 594389 E: sales@midlands3d.com W: www.midlands3d.com
Anti Vibration Products, Mounts & Bushes
Schmersal UK Ltd T: 01684 571980 E: uksupport@schmersal.com W: www.schmersal.co.uk
Marking Solutions
Fibet Rubber Bonding (UK) Ltd T: 01282 878200 E: sales@fibet.co.uk W: www.fibet.co.uk
Connectors & Cabling Solutions
T-Mark T: 0870 803 1877 E: sales@t-mark.co.uk W: www.t-mark.co.uk
Pipework Systems
CEMBRE Ltd T: 01675 470 440 E: sales@cembre.co.uk W: www.cembre.com/en
Drives, Motors & Gears
Jacob UK Ltd T: 01694 722841 E: sales@jacob-uk.com W: www.jacob-group.com/uk
Pressure Measurement Specialists
Nord T: 01235 534404 E: GB-sales@nord.com W: www.nord.com
Dust & Fume Solutions
ESI Technology Ltd T: +44 (0)1978262255 E: sales@esi-tec.com W: www.esi-tec.com
Robotics & Automation KUKA Robotics UK Ltd T: 0121 505 9970 E: sales.uk@kuka.com W: www.kuka.com
Impact Technical Services T: 0116 244 8855 E: enquiries@impactts.co.uk W: www.impacttechnicalservices.co.uk
Flow Meters
Sensors Titan Enterprises Ltd T: +44 (0)1935 812790 E: sales@flowmeters.co.uk W: www.flowmeters.co.uk
High Shear Mixing Equipment Silverson Machines Ltd 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 Intoware T: 0115 977 8969 E: hello@intoware.com W: www.intoware.com
Industrial Fans Axair Fans UK Limited T: 01782 349 430 E: sales@axair-fans.co.uk W: www.axair-fans.co.uk
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IFM Electronic T: 020 8213-0000 E: enquiry.gb@ifm.com W: www.ifm.com PLUS Automation Ltd T: 0121 58 222 58 E: Sales@PLUSAutomation.co.uk W: www.PLUSAutomation.co.uk
Storage Solutions BITO Storage Systems Ltd. T: 02476 388 852 E: Info.uk@bito.com W: www.bito.com
Test & Inspection AMETEK Land (Land Instruments International) T: +44 1246 417691 E: land.enquiry@ametek.com W: www.ametek-land.com
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Kawasaki Robotics Tel:+44-1925-713-000 www.kawasakirobotics.com/uk/