Automation Update - Issue 97

AUTOMATION PDATE

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Publication & Managing Director

Jodie Little

01843 580 460

jodie@engineering-update.co.uk

Publication Assistant

Taylor Owens

01843 267 690

taylor@engineering-update.co.uk

Editorial Assistant

Leigh Little

01843 448 443

leigh@engineering-update.co.uk

There has never been a more important time for our sector to pull together and to work together, to create a shared agenda and Manufacturing and Engineering Week will do exactly that. I am delighted to be part of the Advisory Board and that MAKE UK are a partner of this groundbreaking event.”

Stephen Phipson CBE, Chief Executive, MAKE UK and M&E Advisory Council Chairman

StocExpo 2023 Exhibitors Announced

Over 120 leading companies in the global tank storage and future fuels industry have already signed up for StocExpo 2023, which takes place on the 14th – 16th March 2023.

The world-leading tank storage and future fuels event will return to the Rotterdam Ahoy for another unmissable exhibition.

TThose exhibiting include Ivens Group, which are world-leading in total liquid storage solutions for the petrochemical sector. Emerson, which is a major provider of process automation systems, instrumentation, valves and services for storage and bulk liquid terminal facilities globally, has also signed up to exhibit.

Honeywell Process Solutions will also be in attendance, which pioneered process automation control and thermal process solutions, and today, plays a critical role across the entire lifecycle of an industrial facility.

Rikki Bhachu, Head of Marketing for StocExpo says: “Unarguably the tank storage and future fuel industry’s event of the year, StocExpo 2023, is designed for those

looking to get amongst key industry innovators and their cutting-edge services and products. Visitors will be surrounded by industry professionals who are able to offer expert information and advice, and anticipate what the future looks like globally for tank storage.”

“Returning to the Rotterdam Ahoy, the event provides an unmissable opportunity for exhibitors to showcase their new innovations, launches and developments to like-minded professionals and potential business leads.”

To view the full list of exhibitors, visit https://www.stocexpo.com/exhibitor/ For more information about StocExpo, register to attend or register to exhibit at the event, visit www.stocexpo.com

SYSTEMS IMPROVE EFFICIENCY AND PROLONG EQUIPMENT LIFE

Studies have shown, the majority of engine mechanical wear, almost 90%, occurs at start-up. At first crank of the engine, all the oil is in the sump and at the first rotation of the crankshaft the bearings, turbo bearings, rods, pistons, heads and all galleys are dry causing metal-to-metal contact to occur damaging the engine over it’s lifetime.

Common arguments are that warming up your vehicle before driving, frequent oil changes, oil preheating, etc work to prevent this problem. While all these

practices are positive, none of them actually move oil to where it needs to be at start up; only prelube does that.

Other arguments that, “diesel engines run for millions of hours anyway” or, “if prelube made a difference OEM’s (original equipment manufacturers) would put them on”, have been made to negate the value of prelube. In today’s world of environmental regulations and impact as well as rising fuel costs, industrial engine operation is changing. With no idling laws there are more frequent starts and

getting enough hours is no longer enough – consumers want to get the most out of their high-dollar equipment. Some OEMs are utilising prelube in certain applications like power generation and marine because they know the value in demanding applications and the benefit it adds. Although, typical factor-installed systems employ standard hydraulic gear pumps that are inefficient for this application.

Another benefit of a prelube system is when used for engine shut down & turbo wind-down to lubricate the hot bearings for substantial reduction in wear and increase in turbo life. Prelube is also helpful in cold climates for cold starting to help circulate the cold oil, if there is no oil heater, until it is viscous enough to move through the engine.

In today’s economy and with industrial equipment prices on the rise, owners and operators are looking for practical ways to extend equipment life and increase time between top end and in-frame overhauls to maximise investment.

Railtex 2023

Railtex 2023 will gather the UK’s railway industry from 9 - 11 May 2023 at the NEC in Birmingham.

Renewed public interest in rail travel and the need for more digitalised and greener solutions are driving the attention of many key players towards more innovative and sustainable mobility. The upcoming Railtex edition is an unmissable opportunity for railway professionals to discover the latest innovations and technologies in person, learn more about topics that move the industry from decarbonisation to digitalisation and meet business partners and new suppliers from around the world.

Attendees can expect an excellent cross-section of technologies and solutions to facilitate the safe, efficient, and sustainable operation of rail transport. Exhibits cover rolling stock technology, track, and infrastructure, signalling and communications, vehicle maintenance, fare collection systems, cable technology and many other railrelated sectors.

• Discover the latest technology in person and experience products and services from numerous exhibitors in more than 180 different categories.

• Connect with industry experts and make impactful business relationships

• Gain valuable insider knowledge and find out about the current trends and topics

On-Track Display: an established and successful feature

Placed in the hall, one length of track will be used by exhibitors to display and demonstrate tools and equipment in an authentic rail setting. There is no better way to experience a product than to see how it sits and operates on track as it would in the field.

Meet the experts and learn about rail industry trends

Railtex provides an excellent opportunity to rekindle contacts and will bring prominent industry experts, stakeholders, and decision-makers in attendance, along with the exhibitor presentations and an extensive conference programme. The programme will accentuate not only the opportunities but also the challenges that the industry has been going through, and it creates a chance to expand in-depth discussions about the latest developments in the rail industry.

Interested in attending Railtex 2023? Tickets are now available and can be ordered online free-of-charge before the show or purchased online and on-site during the exhibition.

Register now!

https://www.railtex.co.uk/en-gb/visit.html

How can my business reduce its carbon emissions?

As businesses step up on meeting ESG targets and cutting carbon emissions, we’re seeing an increase in clients asking for help to meet their sustainability goals. When scrutinising the entire supply chain, many manufacturers are finding that changing the chemicals in their cleaning processes can significantly reduce carbon footprint.

Historically, cleaning solvents were notorious for having very high global warming potential (GWP) and had seriously detrimental effects on the atmosphere but the new generation of solvents have been developed specifically with the environment in mind, and are far less harmful than comparable solutions.

Fraser Technologies, who have been supplying precision cleaning solutions for over 50 years, are committed to minimising negative impact on the environment and ensuring we offer the most advanced and sustainable products on the market. One such product is Opteon™ SF80 from Chemours. SF80 has an ultralow GWP of less than 2.5 and is just as effective as competitor products that have a GWP of up to 11,000, so changing can have a huge impact on helping to lower carbon emissions, and it can improve the cleaning process and save money in the process.

One of our customers, a leading aerospace manufacturer, was looking for an alternative to the high-GWP solvent they were using. They switched to SF80, reducing their overall usage of solvent by 28%. This saved them around £30,000 per year, and dramatically reduced their carbon emissions. Previously, their GWP of their previous product was 990 – so the CO2 emissions being created were equivalent to driving around the world 143 times. After switching to SF80, the new emissions were around the same as driving from Edinburgh to Moscow.

To know more about whether your organisation can reduce the carbon impact of its cleaning process, please contact one of our team. We can look at your existing set up and suggest efficiencies, and if superior solvents can be used. It could be one of the easiest ways to help meet your company’s sustainability targets.

For more information click here

sales@frasertech.co.uk

It will take place on March 28th & 29th at the NEC Birmingham. This step up in venue will produce a similar step up in scale – the larger venue provides room to grow. Also, the event will be co-located with IntraLogisteX, a show focused on technologies for warehouses and distribution centres.

As this year, there will be a wide range of factory and warehouse automation on

show, and it will be an ideal opportunity to make sure your business can survive and thrive.

Visitors to Robotics & Automation 2023 will discover how the latest technology can be applied to their operations to provide massive improvements in productivity and accuracy. Products include Robots & Robotic Systems, Automated Assembly Machines & Systems, Parts Handling

Equipment, Conveyors and materials, Industrial Automation Control and more. There are also live demonstrations of the latest solutions taking place throughout the exhibition, so visitors can get first-hand insight into how they work in practice.

Once again, a comprehensive conference programme which will allow attendees to hear directly from people implementing projects using the latest technology. Experts from manufacturing businesses and more will share their insights and give real world examples of how they have automated their own, and their customers’, operations.

Invest a day or two in your future, and visit the show, which is free to attend for qualifying professionals. To register, visit www.roboticsandautomation.co.uk.

Robotics & Automation

2023 is moving, both in terms of the venue and the time of year.

There has never been a more important time for our sector to pull together and to work together, to create a shared agenda and Manufacturing and Engineering Week will do exactly that. I am delighted to be part of the Advisory Board and that MAKE UK are a partner of this groundbreaking event.”

Stephen Phipson CBE, Chief Executive, MAKE UK and M&E Advisory Council Chairman

Innovative brushless DC motor technology for KNF diaphragm pumps

With the new DCB-I drive, KNF is introducing an in-house developed BLDC motor generation for the first time in its history.

This new generation of brushless motors further increases the advantages of KNF diaphragm pumps to the next level in terms of performance, robustness, and durability in combination with the ability to digitally customise the motor parameters. By integrating the motor directly into the pump housing, it was thus possible to implement these features in a more compact size.

The development of our own BLDC motor allowed KNF to specify the individual components so that they are perfectly matched for their use in diaphragm pumps.

Compared to what is usual for other motors, the DCB-I features much larger ball bearings. This significantly improves the robustness and durability, which is reflected in a life expectancy of >20’000h. Furthermore, the unique design creates not only a visually appealing look, but also technical advantages. The cooling fins on the aluminium motor cover also improves heat management, especially when the motor is permanently under heavy load.

The development and manufacture of this new generation of motors is the outcome of a cooperation between KNF and a leading motor manufacturer.

As a result, not only is the motor more powerful (in relation to its size), but the development of its electronics makes it possible to use additional functionalities. As a result, this allows total control over the motor to fully exploit the potential of KNF pumps.

KNF offers the DCB-I for the following pump types:

Gas Pumps

• NMP830

• NMP830 HP

• NMP850

• NMP830 HP

Liquid Pumps

• NF30

• NF60

• FP70

KNF develops, produces and distributes high-quality diaphragm pumps and systems for neutral and aggressive gases and liquids.

For more information please click here

A Recipe for Success: Titan Enterprises discusses the process and challenges of research and development

By investing in research and development and continually pushing the boundaries of technology – and running down a few rabbit holes along the way – Titan maintains its competitive edge in the flowmeter market.

Titans’ focus for R&D is achieving a solution for our OEM customers, driven by flow technology. This can take the form of:

1. Product portfolio development: such as identifying where products can be improved as Titan has recently achieved with the launch of the new Pulsite® Link pulse & analog converter.

2. Breakout R&D: Exploring a new market focus or application such as developing a low-cost ultrasonic flow measuring device utilising our technology.

Titan Enterprises is a leading international manufacturer and supplier of small-bore liquid flowmeters, building their reputation designing and producing cost-effective reliable flow sensor products. New product development is the lifeblood of any manufacturing company.

Customer / OEM bespoke product development to be incorporated into a customer’s specific application.

Where do ideas come from?

The R&D creative process is generally sparked by a customer who presents a problem that the development team can progress and investigate workable solutions. Development routes can also derive from a ‘Eureka’ moment, a mistake (3Ms post-it notes come to mind) or where we feel the market is going – driven by emerging technology.

Neil Hannay, Senior Development Engineer with Titan Enterprises, explains: “OEM customers come to us with a problem or need and we scope out a bespoke design concept that has the potential to solve this.”

Concept Designs

In forming the initial concept designs, close working with the customer to develop specific design parameters and overcoming fundamental difficulties that

may be encountered is key from the outset. Understanding what the priority is for the customer is also essential at this early stage as it will influence the development route and technology used within the concept design process. In the simplest terms, is the customer prioritising accuracy over product costs, or looking for a lowcost solution with reliable performance?

Design Specification

Defining a more comprehensive design specification will enable concept models of designs to be composed that meet both Titan’s performance specifications and the customer’s process or system.

Working with a drinks dispenser OEM, the design brief needed to consider:

• Dimensions to fit within the limited physical space available

• Dual fluids – a single unit being able to measure both non-viscous and viscous liquids side by side

• Specific connections to fit existing equipment

• Use of approved (NSF/FDA) food grade materials

• Cost and production window

Prototypes and Testing

Once the concept designs are agreed, the next phase is to agree pricing of the tooling and final meter, based on expected production quantities. For Titan, typically our OEM customers invest in the injection moulded tooling which is bespoke for them and they ultimately own this; the design remains within Titan’s intellectual property.

Machined prototypes are put through a rigorous in-house testing process for design and performance before being issued to the OEM to test in-situ. “This allows us to uncover any unexpected issues - or indeed cause unexpected issues!” says Neil. “We often find ourselves doing lots of ‘head scratching’ in the testing phase and it’s where the team’s problem-solving skills come into their own,” Neil continues.

For example, a recent machined prototype unit in test was below its expected performance. Several rounds of rebuilding followed, from gears to body parts, but the performance of the meter was still erratic. Two crucial aspects were discovered:

1. The surface finish of the machined body was not good enough for the oval gears to freely rotate so friction lowered performance.

2. The softer material of the unit was fractionally distorted when clamped in the calibration rig, causing a minor impedance of the gear rotation which constricted the flow.

The prototype here was reworked using a harder material and polishing the internal surface, resolving the performance issues identified.

In-Situ Testing and Final Design

The prototype is sent to the customer to test in situ and verify both the meter’s physical and mechanical performance meets their requirements in all operational situations. Any modifications to dimensions for example, or adjustments to fittings within the system are worked into the final design. This iterative process of finalising design requires close working with OEM customers, including re-evaluating costings and agreeing production volumes.

Titan’s flow meters are typically incorporated into much larger industrial systems where accurate, reliable recording or control are required. Neil concludes: “Investing in R&D is paramount to us staying ahead of the game and taking advantage of the latest technologies, and our R&D spend is more than three times the industry average.” A team that combines suitable training and commercial experience, market awareness, problem solving skills and a creative spark enables Titan to deliver solutions for their customers or inventions for breakthrough markets.

For further information on Titan’s range of liquid flowmeters visit https://flowmeters.co.uk/. To discuss a flow measurement solution for your specific OEM application, contact Titan Enterprises on +44 (0)1935 812790 or sales@flowmeters.co.uk

C.K TOOLS LIGHTS THE WAY WITH NEW HEAD TORCH

C.K Tools, the trusted choice for trade professionals, has launched a brand-new Wide Field Head Light (T9630) to ensure greater visibility and safety when accessing wires or cables in dark and confined spaces.

The COB LED head light comes with an RRP of £39.00 and four modes of operation – spotlight, wide field, full beam, and dipped beam –providing the versatility needed to suit all manner of environments electricians find themselves in.

More importantly, the head light performs at a high CRI (Colour Rendering Index) rating of 80, which when optimised with a combination of 400 lumens of brightness (equivalent to a 40w LED bulb) and 5,700 kelvins of colour temperature (similar to natural light) means it can more closely project the true colour of the object it is shining on –critical when working with coloured electrical wires in dark spaces.

For extra portability, the head light is charged via USB, with six hours of runtime, three hours of charge

time, and a charging indicator. To withstand the variety of environments and spaces it will be used in, the head light also comes with an IK-07 impact rating and IP54 ingress protection from limited dust and water spray, for extra durability.

Paul Pugh, Head of Marketing at C.K Tools, said: “Accessing wires in dark and confined spaces is a necessity for every electrical engineer, and it becomes that little bit harder in the winter months when brighter, natural light is less abundant.

“What many don’t consider is that the source of light is just as important as the tools being used on the wires – if not more so; it can make the difference in cutting or connecting the right wires. This is where electrical engineers should be looking beyond just practical elements, such as the portability and price, and placing more important on the CRI and Kelvin capabilities of their light choices.” www.ck-tools.com

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Flow Sensing Challenges in Food & Beverage Production

Titan Enterprises offers a range of highperformance flowmeters in food grade materials where both food hygiene and precision flow measurement are required.

Flow measurement is a critical tool for food and beverage manufacturers, the industry having a diverse range of processes that require the precise control of liquid flow rates. Production processes including filling of vessels or bottles, measuring liquid ingredients, and controlling cleaning processes, require varying degrees of complexity and accuracy to ensure consistent product yield and minimise wastage. Although there are a wide variety of general flowmeters on the market, only a few high-performance measuring devices will ensure the high levels of hygiene and precision are maintained for applications in the food and drinks sector.

“The physical properties of the liquids themselves lend additional complexities to the choice of flow measuring equipment,” says Neil Hannay, Senior Development Engineer at Titan Enterprises. “Consideration of whether the liquid is viscous, volatile, corrosive, flammable, or contaminated with particles, for example, or

needs to be maintained at a high temperature, are key factors in deciding a suitable flow meter.”

Monitoring Flow of High and Low Viscosity Fluids

Flow monitoring of high viscosity liquids, such as cooking oils, sauces and syrups (e.g. syrup injections in beverage lines) require devices such as Titan’s oval gear flowmeters, which provide highly accurate flow measurement. Unlike other flowmeters, measurement accuracy of oval gear flowmeters improves as the liquid viscosity increases, from a nominal 1% to around 0.1% of flow rate at higher viscosities.

Whereas for low viscosity liquids such as water, beer, wine and spirits, Titan’s NSF-approved 800-series and beverage flowmeters provide a low-cost drink dispensing solution. Designed to give high performance over 6 flow ranges from 0.05 to 15 l/min, these devices have totally non-metallic NSF-approved wetted components making them ideally suited for applications where both food hygiene and precision flow measurement are required.

Flow Monitoring at High Temperatures

In processes where ingredients need to be maintained at high temperatures – chocolate for example – a flowmeter designed for applications requiring precise flow measurement at elevated temperatures would be needed. Capable of operating up to 110°C, Titan’s inline non-invasive Atrato® ultrasonic flowmeter is largely immune from viscosity and offers excellent turndown and repeatability.

Titan Enterprises offers a range of oval gear flowmeters in food grade materials for viscous products such as sauces, oils and syrups, as well as NSF-approved miniturbine flowmeters for drink dispensing. As an experienced OEM supplier, Titan develop customised flow meters for specific customer applications within the food and beverage industry.

To discuss an optimised flow measurement device for your OEM application please contact Titan Enterprises on +44 (0)1935 812790 or email sales@flowmeters.co.uk. Or visit our website for further information.

Is the photographer’s knowledge of your industry important?

“Carter Manufacturing is a global supplier of precision bearings and tooling to aerospace, medical, nuclear and defence. We require exceptional images to support our business and make it stand out across all the markets in which we are active. Having used various photographers in the past, we have a good idea of what we need in a photographer to achieve our desired images. Experience in all the sectors in which we are involved is not realistic but having knowledge of some plus the ability to adapt those to others is the

Turning Heads in a Rotating Industry

Industrial photographer, Adrian Waine, is no stranger to the pages of Manufacturing Update. His imagery ranks amongst the best we feature. In this article we get a new perspective on what it takes to create stunning images in challenging environments – Mel Meader, Chief Operating Officer, of Carter Manufacturing, explains in this interview with editor Taylor Owens how Adrian provides the creative spark for their pictures.

What references do you seek before hiring a photographer?

“We discovered Adrian Waine through his images being credited in an associates website. For us, the work speaks for itself and having found these images we started to dig a little deeper. Once satisfied with the imagery, we set about talking with Adrian informally to get a feel for him and how he approaches each commission. His wider industry expertise and experience quickly shone through and gave us the confidence we were seeking.”

Does the photographer’s equipment or lack of it have any consequences?

“The right equipment is necessary, especially lighting. We strive to create original images to capture the imagination of our target audience. Ambient light alone is very limiting in this respect. With the equipment must come knowledge in how to use it for maximum creative effect. We discuss a shot list in advance which defines who needs to obtain what. Adrian supplies all photography and lighting equipment required to capture a shot. He also brings a time-served assistant with him and suggests must-haves in terms of relevant props. This makes the photography process much easier on the day as everything is to hand when needed.”

When the photographs are completed do you feel that the investment in time and money are worthy of the results?

“Without a doubt. We have had several uses from the imagery and expect more. They are being used in our website and have been used in exhibition stands, within our social media and marketing campaigns. The key to getting the most out of the time hinges on the advance preparation. The magical creative flair, if you like, is left to Adrian.”

Is organising a photographic shoot in a working factory disruptive?

“I know it sounds repetitive, but again preparation is key when commissioning a professional photographer like Adrian. Disruption is often minimal when you append time building a shot list, prop portfolio and select the people involved in advance. Adrian adapts where he can and will always adjust or generate an additional shot outside of the plan if he can and so maximise the useable shots taken on the day.”

Modern cameras and high-end phone cameras, pack a lot of punch these days, are you not tempted to try taking your own pictures?

“You cannot capture the images of this quality using a phone or personal camera. Attention to detail comes from experience and Adrian’s speaks for itself. Lighting, camera angles and feel cannot be re-created without using a time served photographer. Owning an oil painting set doesn’t make you an artist! Working at the forefront of emerging technologies you need to create the right feel when drawing in customers. Adrian achieves this well and we believe that it is well received by our customers, ‘a homemade shot’ will not do.”

Is building a long-term relationship with a photography important?

We began working with Adrian in 2020, and have already completed three shoots with him, with more in the pipeline. Adrian seems to keep well on top of trends. We see our future relationship with Adrian being a constant to keep our imagery fresh, current and eye-catching in an ever changing world.

Does photography help the business attract new talent?

Carter Manufacturing is a pioneering company and to inspire and attract a new generation of engineers to propel our industry forward we need to show

our workplaces for the centres of technological excellence that they are. Adrian’s images come together to tell that story.

www.carterbearings.co.uk

Mel Meader, Chief Operating Officer, Carter Manufacturing Limited

+44 1865 821 720

Mob 07859 879040

mel@carterbearings.co.uk

www.photographyforindustry.com

Photography : Adrian Waine

Tel 0151 356 3855

adrian@photographyforindustry.com

Adrian was formerly staff photographer with Saudi ARAMCO and was regularly commissioned within the oil processing facilities of Saudi Arabia.