Engineering Update - November 2020 by jetdigitalmedia

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November 2020 ENGINEERING UPDATE

Assembly & Screw Applications A large component of product assembly involves some threaded parts that need to be accurately screwed together in a process that is repeatable every time. This requires a form of “Intelligent Screwdriver” with position, force and torque feedback in both linear and rotary axes. It also needs to be accomplished at high-speed and act as a sensitive feedback device that can reject any faulty thread or assembly to maintain high quality control.

As a leader in the development of high performance linear motors, LinMot have in the last few years pioneered combined Linear and Rotary motors. These provide

A typical procedure involves: Finding the screw/cap

•

Finding the engagement points or

more conventional clutch and pneumatic

slot

methods combined with simpler motor

rotary motions on one shaft with great applications.

features such as torque sensing and force measurement. These can be used

step up in control and quality from using

control. •

Screwing to a position or torque

•

Checking the force and torque

programmable, the parameters can be

during assembly

changed on-the-fly so that the same

As the Linear /Rotary motor is fully

The growing PR01 and PR02 Linear Rotary family of motors now offer extra

both linear and rotary axes is a huge

•

independently controlled linear and advantages for Screwing and Assembly

This level of continuous monitoring of

•

Retracting back ready for the next cycle

assembly station can carry out different operations and provide feedback on each one. A great advantage with LinMot

in combination with linear and rotary

With closed-loop servo control and force

products is that most of the main PLC

position and velocity measurement for

and torque sensing throughout, very

networks are available on the drives

detecting all of the conditions show in

repeatable and high quality assembly

such as EtherCAT, Profinet, Ethernet/IP,

the diagram.

can be achieved. Any poor thread,

Powerlink and many others. This allows

misalignment or out of tolerance parts

this flexibility of control and information

can be detected early in the process.

feedback to be integrated into almost

It could either be attempted again for

any control system very easily.

There are many types of screw assembly such as attaching cartridge caps, checking and pre-assembly of threads and locating and tighten of screws. The process in each case are similar but with differences that need to be catered for.

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example with another screw or cap or rejected before wasting any more time on the assembly.

For more information, please contact Quin Systems, the UK LinMot distributor on 0118 977 1077 or sales@quin.co.uk. Website: www.quin.co.uk

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November 2020 ENGINEERING UPDATE

Plant-based milk products, such as oat milk, are increasing in popularity

The New HRS DSI Series uses direct steam injection to increase the speed of sterilising products such as plant milk

Appetite for plant-based milks prompts HRS to launch Direct Steam Injection Directly injecting steam as a means of sterilising and diluting liquid drink products is a well-established technique for beverages such as plant-based milk products, which are experiencing a boost in popularity. According to a report by Mintel1, sales of vegan-friendly, plant-based milks have surged 10% over the past two years, and it is now the choice for almost 25% of Britons. In response to this increased customer demand, HRS Heat Exchangers has added a new Direct Steam Injection System to its established range of pasteurisation and sterilisation systems.

the product or produce unwanted flavours. Some products, such as oat milk, also benefit from the additional dilution with water which the steam injection provides. In most cases, however the water which is added during the steam injection process needs to be removed from the end product. This is normally achieved using flash evaporation to remove excess steam and help cool the product, but there is a danger that volatile aromatic compounds can be lost, which could have a negative impact on certain products, such as fruit juices. For this reason, not all products are suitable for steam injection.

Matt Hale, International Sales & Marketing Director, HRS Heat Exchangers Matt Hale, International Sales & Marketing Director at HRS Heat Exchangers, comments: “At HRS, we are always looking to provide full system solutions for the thermal treatment processes required by our clients. As part of this we have introduced the DSI Series of steam injection modules for the pasteurisation and sterilisation of products such as increasingly popular plant milks. The first DSI Series unit has been running successfully for a number of months now and we are pleased to be able to offer another solution to our customers.”

The benefit of sterilising using direct steam injection is the speed of the process, with sterilisation For products where direct steam temperatures of 100 to 145 deg. C. injection is desirable, HRS Heat being reached in around a second; Exchangers has introduced the much quicker than the fastest heat HRS DSI Series, which injects food exchanger systems. For products grade steam into liquid products, such as plant milks, this rapid providing an instant increase in the heating prevents cooking of the thermal process. product and formation of carameltype compounds which can darken www.hrs-heatexchangers.com info@uk.hrs-he.com Tel: +44 (0)1923 232 335

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ENGINEERING PDATE November 2020

Forerunner Yesterday. Today. Tomorrow. The Sensor People have been setting technological standards in industrial automation for more than 50 years. In the field of safety at work, we convince right from the start with trend-setting inventions, such as the development of the first protective sensor ever, to our latest safety innovation, “Smart Process Gating” – the space-saving solution for access guarding on conveyor lines. This is how we ensure the success of our customers in an industry that is ever evolving.

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November 2020 ENGINEERING UPDATE

A MIXTURE OF ON-LINE AND ON-CAMPUS COURSES. PLEASE SEE WEBSITE FOR FULL DETAILS WWW.BULKSOLIDS.COM

COURSE CALENDER 2021 20-21 JANUARY

27-28 JANUARY

17-18 FEBRUARY

24-25 FEBRUARY

Measurement of the Properties and Bulk Behaviour of Particulate Materials an overview of methods for determining bulk behaviour of particulate materials

Undesired Deblending and Separation in Processes and Equipment identification of common segregation mechanisms and how to minimise the effects

Dust Control for Processes dust prevention, capture and extraction methods

Electrostatics in Powder Handling the cause and effect of electrostatic charging in bulk solids handling

8-12 MARCH

19-23 APRIL

11-13 MAY

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Port and Terminal Operations for Bulk Cargoes bulk materials handling and safety issues at ports and at sea

Storage and Discharge of Powders and Bulk Materials a basic course covering the operation, design and specifications of hoppers and silos for reliable discharge

Pneumatic Conveying of Bulk Solids, including practical components of pneumatic conveying systems, system selection and design techniques

ENGINEERING PDATE November 2020

29-30 JUNE

12-16 JULY

21-22 SEPTEMBER

23 SEPTEMBER

Caking and Lump Formation in Powders and Bulk Solids designed to look at issues relating to keeping powders and granules in a free-flowing, lumpfree condition

Powder Handling and Flow for Additive Manufacturing a guide through the critical aspects of powder management for powder-based AM processing

Pneumatic Conveying System Design in depth exploration of detailed calculations for design of pneumatic pipelines and specifying plant (Advanced course)

Rotary Valves: Design, Selection and Operational Issues an exploration of the different valves and features available

18-22 OCTOBER

9-11 NOVEMBER

8-9 DECEMBER

Overview of Particulate Handling Technology introduction to the storing and handling of bulk materials, equipment selection and design methodologies for safe and reliable plant.

Pneumatic Conveying of Bulk Solids, including practical components of pneumatic conveying systems, system selection and design techniques

Commissioning and Troubleshooting ‘Hands-on’ Pneumatic Conveying Systems a look at the practical challenges of starting up systems on site and making sure they work as the designer intended.

REGISTRATION AND ONLINE PAYMENT CAN BE MADE AT WWW.BULKSOLIDS.COM DISCOUNTED FEES ARE OFFERED FOR MULTIPLE BOOKINGS AND REPEAT REGISTRATION. CONTACT 020 8331 8646 WOLFSON-ENQUIRIES@GRE.AC.UK FOR MORE DETAILS |21

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November 2020 ENGINEERING UPDATE

Croft Filters

– Quality custom industrial filters Witches’ hat filters These filters are composed of a perforated cone supporting one or more fine wire meshes which maximise the flow area, effectively reducing resistance and ensuring reliable operation. The wellestablished, simple yet effective design makes them very popular for all kinds of industrial applications. As witches’ hat specialists, Croft Filters can manufacture them rapidly from basic sketches to final products with a pore size as small as 1 micron to suit each customer’s requirements.

specifications. Components can also be formed after the materials are made. Perforated tubes, mesh tubes and mesh discs are highly requested among Croft’s clients.

Services: Cleaning, repairing and refurbishing

weight reduction, Multi-part to single component and Expanded design capabilities, allow the customers to rethink their approach to their designs in order to improve the efficiency, utility or aesthetics of their parts.

Other custom filters

Croft can repair customers’ existing filters or replace damaged components to help them make the most out of their filtration frames. A particular customer operating within the Chemical industry has benefited from these services by having over 100 leaf filters cleaned and refurbished.

Croft Filters based in Warrington, England can manufacture filtration solutions in any shape or design, including basket strainers, duplex filters, vacuum filters, cylinder filters, screen filters, last chance filters, inline filters, pleated filters and slot tubes in perforated plate, wedge wire and woven wire mesh.

Croft also specialise in the Additive Manufacture (3D Printing) of complex metal components. Benefits of the Additive process, such as: Part

Quality of both product and service has been the key to Croft’s success; the Company takes great pride in understanding their customer’s needs, quickly supplying them with a high-quality product that exceeds customer’s expectations.

Quality perforated and mesh materials and components Additive manufacturing Croft also supply custom perforated sheet and mesh piece used in various engineering applications, they can be produced quickly and to precise

Croft Filters are a leading UK manufacturer of over 34 year experience, specialising in the manufacture of high quality custom filtration solutions. The Company supplies a variety of diverse industrial sectors, including: Chemical, Food, Beverage, Oil and Gas, Pharmaceutical and Energy amongst others. Notably, Croft’s products are widely used among engineering firms operating within different sectors.

For more information about Croft’s quality custom filters: Call 01925 766265 or Email sales@filters.co.uk

www.filters.co.uk 22|

ENGINEERING PDATE November 2020

DS-OCT12-BLACKFAST_Layout 1 20/09/2012 16:28 Page 1

Safety Guarding •

Complies with the EU Machinery Directive 2006/42/EC

•

Clamping profiles allow different materials to be installed

•

Minimal effort required in construction

•

Smooth easy to clean outer surfaces

•

Comprehensive range of accessories

•

Quick assembly time

Profile Technology Linear Technology

Connecting Technology

01296 611 660 rk@pmgb.co.uk www.pmgb.co.uk/rk

Tel: 0208 339 7370

Modular Technology

Fax: 0208 339 7371 Unit 5 Russell House, Molesey Road Email: sales@blackfast.com Walton-on-Thames, Surrey KT12 3PE www.blackfast.com

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November 2020 ENGINEERING UPDATE Aerial surveillance image of coastal erosion in the North of France.

Improving Surveillance of Coastal Erosion Resolve Optics reports on how ultra large format lenses it has developed are helping a next generation aerial surveillance camera gain data on coastal erosion faster and in more detail.

oastal erosion is a main environmental concern which requires accurate aerial data. Aerial surveillance specialists – IMAO SAS have recently undertaken a photogrammetric survey in the North of France using their extra large format camera which incorporates Resolve Optics high performance lenses. Aerial Surveillance work depends on the weather, and is challenged every day by how much data you can acquire when the sky is clear. Incorporating 3 ultra large format, low distortion custom lenses, developed by Resolve Optics, the IMAO B66 extra large format camera produces high quality aerial surveillance images two to three times larger than the standard image size generated by other large format

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cameras on the market. As a consequence not only are less images required for geographic data mapping but also these images require less processing time saving operators time and money.

Drawing upon approaching 30 years experience – Resolve Optics Ltd. has built a strong reputation for specialist lens design and manufacture of production quantities of low distortion, large format lenses on time to strict quality and target price guidelines. The company has the proven and rare capability to produce OEM quantities of specialist lenses with the look, feel and quality equivalent to the best professional photographic lenses.

www.resolveoptics.com

In 2017, IMAO SAS and Resolve Optics Ltd. received €1.68 million funding from a European Union Horizon 2020 programme to develop an ultra-large format aerial surveillance camera. Resolve Optics lens assembly in IMAO extra large format aerial surveillance camera

For further information on development of low distortion, large format lenses matched to your application please contact Resolve Optics Ltd. on +44-1494-777100 or sales@resolveoptics.com

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November 2020 ENGINEERING UPDATE

SAY HALO TO THE FUTURE OF DIGITAL QUALITY CONTROL While metal detectors are an integral first step in food safety, proper management with regular testing are vital to ensure optimum protection is achieved. To provide food manufacturers with a reliable, accurate and auditable testing procedure, Fortress Technology has unveiled the latest version of its Halo digital testing. Available on Fortress’ full range of digital metal detectors, the self check software is a failsafe and cost effective solution to ensure your system is meeting quality control standards.

o successfully comply with the Global Food Safety Initiative (GFSI) and Hazard Analysis and Critical Control Point (HACCP) production standards, it is important for food manufacturers to have an appropriate and effective testing system established for the audit process of industrial metal detectors. Depending on the criteria set out by each retailer Code of Practice (COP), tests are typically scheduled throughout the day at hourly intervals to confirm the inspection system is working as it should be. However, regular checks that are carried out manually can be a drain on resources. This is particularly true when testing metal detectors is made difficult due to access, machine position, product flow and environmental conditions. This is where Fortress’ Halo digital testing comes in. Guaranteed to save food manufacturers time and money, Halo automatically and independently checks for all metal materials - ferrous, non-ferrous and stainless steel. The system also checks the performance of the reject system, forming an important part of manufacturing due diligence. Traditionally installed on throat, pipeline and gravity metal detectors

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that inspect loose or freefalling products on bagging lines, including rice, sauces, cereals, powders, corn, sugar and snack foods, the latest Halo software release from Fortress is also beneficial when inspecting bulk bags and boxes on a conveyor style metal detector. In addition to reducing operational costs, digital testing also reduces waste and product rework. TIME IS MONEY Up until now, metal detectors had to be manually checked every hour for QC compliance. However, the cost of running these tests by hand on such a regular basis can be high. Rather than relying on operatives to schedule, perform, document and submit inspection checks, Halo digital testing software automates the timely aspects of the process, allowing food manufacturers to tackle this drain on resources and save thousands of pounds each month. Additionally, reducing the frequency of manual testing helps to eliminate the risk of human error and workplace injury at critical control points on a manufacturing line. Fortress Technology’s European Managing Director Phil Brown explains: “Manual tests on metal detectors handling free-falling products, those fitted above bagging lines or ones processing bulk

Image 1: Regular, manual checks on metal detectors can be a drain on resources. Particularly throat, pipeline and gravity metal detectors that inspect loose or free-falling products on bagging lines.

Image 2: The centre of the aperture, being the least sensitive, is where testing should be carried out. Halo overcomes challenges to this, particularly in vertical systems, by generating signals to disturb the magnetic field in the centre of the metal detector’s aperture.

products are challenging. They can be difficult to reach, need two people to complete the test and incur production loss while each test is completed.” 100% QC CONFIDENCE Additionally, the recommended test point on a detector is the very centre of the aperture where the signal is least sensitive. However, it’s impossible on a vertical line, for example, to manually drop a test sample into the centre

of the detector, which can result in data records showing inconsistent signal variations. When specifying Halo on a Fortress metal detector, the QC test is completed with 100 percent accuracy by generating signals to disturb the magnetic field in the centre of the metal detector’s... Continue reading on Engineering Update...

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November 2020 ENGINEERING UPDATE

It Starts With A Blank Sheet Of Paper Over the years, Georg UK have designed Rigs to test all sorts of products from the very small (eg human tissue to be bombarded with radiation) to the very large (eg full scale four carriage high speed Train). These projects spark the interest of our engineers who relish a challenge.

The process of designing a test rig Martin Summers, Test Rigs Manager at Georg UK, explains the process of designing a Test Rig when you don’t have a detailed specification. Normally design requests come with an outline specification – a basis from which to work with. But what if there isn’t a specification, just an idea? What if the idea needs turning into reality and into a business proposition? Who takes on the commercial burden of the process? Three main elements have to work as algorithms to each other and without that successful formula, three large grey areas become apparent: 1. is the specification (or wish list) achievable or unachievable? 2. do the expected costs align with the specification? 3. does the project plan align with expected time scales?

Creating a technical engineering specification Our engineers delve into the minute detail of requirements, working with the customer’s team to create a technical engineering specification. We offer blue sky thinking, which for us means generating creative ideas and designing from a blank sheet of paper, regardless of the practical constraints. This has its own challenges in all aspects of the project; engineering, academia and commerce. Using 3D design tools and analysis we can generate impressive models; but once that process commences, it’s like a can being kicked down the road

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in that the tweaking of that model can take on many iterations before a final solution is arrived at. We return to the question – what was in the original specification and how would that change through the process based on performance, reliability and life expectancy of product which have major influences on design? In conjunction with the project engineers and buyers, we need to establish realistic product, lead times and costs. Analysis of design has taken on a new dimension. Depending on design specifics, we can now zoom in to the smallest of components to understand its load and life capacity. A design is only as good as its weakest link; but by understanding these elements we can work out life expectancy based on load duties and then introduce systems to monitor those components for wear well before a potential failure could occur. There’s then the commercial hurdle to overcome. This involves extensive time and upfront costs to establish the viability of the project and high scrutiny of T&Cs is undertaken before agreements are concluded.

It can be a long process, but with the ultimate outcome of: 1. A clear specification, with an agreed matrix 2. A workable design 3. Accurate costs 4. A realistic project time line 5. A best in class engineered product supplied within costs 6. A satisfied customer At Georg UK we are proud to have achieved a number of world class Test Rigs for aerospace, rail and defence clients. Together with recent and ongoing highly sophisticated projects from Universities, Georg UK is one of the leading designers and builders of Test Rigs in the UK.

ENGINEERING PDATE November 2020

customers to view various machine statistics remotely and to receive messages if a fault occurs. A web page, accessed via a PC or mobile phone, is configured specifically for the machine with a quick view page for important data, which is linked securely through a customer’s account. The system also incorporates six “Key Performance Indicators” which the user can access when they log in.

Make Your Machines Work Smarter Industry 4.0 has led to new ways of working, changing how machines are monitored and maintained.

he COVID-19 pandemic has forced companies to rethink how they work, with office staff working remotely and engineers offering online support. It’s highlighted how remote access can keep a company in business and, in some circumstances, can be more productive and cost-effective. Historically, when a fault occurred on a machine, companies would have to wait for an engineer to drive to the site. This is both time inefficient and potentially expensive as machinery downtime causes production delays.

At Georg UK we have been highlighting to our customers the benefits of implementing an Industry 4.0 Control System to machines to utilise detailed maintenance and fault detection systems as part of their overall planning strategy. A machine fitted with a remote dial-in box with an internet connection allows an engineer to remotely connect to the machine’s computer control system via the programmable logic controller (PLC) to make any program changes to the machine. The PLC also allows

Historic and real-time data is logged within the system for later recall, allowing for easier tracking over time of downtime/production on the machine. The data can also be displayed in graphical format. New machines are fitted with vibration sensors (which can also be retrofitted) to motors and critical bearing structures which lets the system detect bearing failures before they happen, with Georg UK engineers working with customers and planning ahead for spares and replacement parts. Should a problem occur on the machine, an automatically generated alarm can be configured to email both the customer’s maintenance department and Georg UK engineers, resulting in quicker response times. Often, we’ve contacted the customer before the operator has chance to pass the information up the chain! The Control System also allows for maintenance warning messages to be sent to engineers supporting the planning of routine maintenance, such as lubrication after 1000 hours. The customer can either plan to undertake the maintenance inhouse, or arrange through Georg UK engineers. In the long term, this reduces the overall downtime and increases the productivity of the machine. To find out more about Georg UK control systems and how they can benefit your business, call: 01902 715110

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November 2020 ENGINEERING UPDATE

The “Head in the Sand” approach to engineering, O-rings, seals and testing by Chris Roberts, Director, Versaperm, e.mail: info@versaperm.com Tel: +44 (01628) 777668

Understanding how O-rings and seals leak is crucial to the safety and reliability of almost every engineering process and product. There are two approaches – the head in the sand approach or actually testing this critically important factor. There is a fundamental problem with many seals – they don’t work as well as they could or should! Just because a seal keeps out water, grease or other liquids, people think it is working properly. But they forget about vapours, which can pass straight through materials such as seals and sealants, sometimes in great volumes - before condensing on the wrong side and causing problems. As an example, gaskets, seals and O-rings made from silicone, cellulose, EVOH or PVOH are great at keeping liquid water out, but are virtually useless where water vapour is concerned. Numerous products have failed and been recalled for this reason. Modern solutions to sealing problems are often based on multilayer, laminated coatings. Each layer provides a different characteristic, such as permeability to a specific gas, tear- or rust-resistance. Even some O-rings are upgraded by coatings that improve permeability, strength etc.. Over recent years the ability to understand the physical mechanisms behind vapour permeability has lead to real improvements. Key to this understanding is the dramatic improvement in permeability testing – measurements that once took weeks, now take hours and are very precise. Versaperm is a leader in this technology and offers both the equipment to measure it and the expertise to understand it. We also offer a laboratory service that does the testing for you. The right coatings can dramatically improve the properties of many products and systems.

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Testing is more important than most people realise as manufacturing processes, such as thermoforming, extruding, moulding, heating or pressure, can easily quadruple the amount of vapour that passes through a formed component. Versaperm can measure vapour permeability not just for material samples but also for seals, O-rings, components and even assemblies. What’s more they can be measured not only for water vapour but also for hydrocarbons, oxygen, carbon dioxide and any other non-proscribed gas – all at the same time. Results are accurate in the parts per million to parts per billion ranges depending on the material and vapour. Where desired Versaperm can also control environmental conditions such as temperature and pressure, even across diurnal and seasonal cycles. Versaperm develops and manufactures its own ranges of vapour testing equipment, they are used by companies, universities, and National Standards laboratories around the world. e.mail: info@versaperm.com Web: www.versaperm.com UK Tel: +44 (01628) 777668

FOR MORE THAN

60 Y E A R S

BÜLTE Plastics (UK) LTD 8 Basepoint Centre, Harts Farm Way Havant - Hampshire PO9 1HS United Kingdom Tel. : (+44) 023 9244 9606 sales@bulteplastics.co.uk / www.bulte.com

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November 2020 ENGINEERING UPDATE

Better Cut Quality Through Improved Connectivity Kollmorgen Provides Advances in Plasma Cutting Machine Capabilities for Emerging Turkish Company Challenge A Turkish-based company was looking to improve the cost, cut quality and machine serviceability of their flagship plasma cutting machine. A change from their existing supplier’s design to a higher-quality, more-robust solution was needed to gain market share. The company partnered with Kollmorgen to address their improvement requirements. The existing machine design incorporated a servo drive with limited connectivity solutions, making it difficult to interface with popular CNC controls. Having only basic tuning capabilities resulted in lower bandwidth and poor cut quality. The goal was to improve cut quality to reduce waste, improve connectivity to industry standard CNCs and to minimize the overall system costs.

Solution Kollmorgen engineers implemented an AKM/AKD system solution to provide faster indexing and settle times. By implementing advanced tuning, the machine dramatically improved cut quality. Connectivity with the CNC was achieved using the AKD servo drive’s EtherCAT network capability. To address costs and simplify machine assembly, Kollmorgen supplied a single cable option that provides both power and feedback. Removing cables have resulted in important cost savings since each plasma cutting machine cable can exceed 10m. The Kollmorgen

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single cable option and associated SFD feedback have performed exceptionally well even in the significant EMI/ RFI noise environment associated with the machine’s cutting head. Kollmorgen’s systematic approach to identifying and addressing the customer’s critical needs led to significant improvements in machine cut quality, reduced waste, and required interconnectivity to communicate with the CNC.

Results Kollmorgen increased the company’s ability to gain market share by dramatically improving its plasma cutting machine performance. •

Bandwidth improvements led to a productivity increase of over 25%

•

AKM servo motor single cable option provided a 50% reduction in cabling costs

•

Improved cut quality reduced material waste by 11%

•

EtherCAT communications improved ease of serviceability

Learn More Ready to design and build a more ambitious machine? Click here to find out more.

SAFETY LIGHT CURTAINS WITH BLUETOOTH INTERFACE

SAFETY LIGHT CURTAIN APP MAKES COMMISSIONING AND SERVICE EASY The ﬁrst safety light curtain from Schmersal with a built-in Bluetooth interface. The SLC440/COM with Bluetooth BLE is an active optoelectronic protective device that makes all status and diagnostic data on the operating status of the device available on smartphones or tablets via a Bluetooth interface on a real-time basis. In combination with the Schmersal App "SLC Assist" the operator uses this diagnosis tool for a safe operation, setup and documentation of a Schmersal AOPD by using a smartphone or tablet. THE "SLC ASSIST" APP

INNOVATIVE TECHNOLOGY

The “SLC Assist” App gives information about:

The light curtain with Bluetooth interface and the Schmersal App gives optimal support for:

• • • • • • •

Operating mode Beam signal level OSSD status Status of the protective ﬁeld Number of OSSD switches Supply voltage Operating time

• • • •

Condition monitoring Optimal alignment Preventive maintenance Documentation according to industrial safety regulations

The App "SLC Assist" is available for Android and iOS devices. Scan the QR code below for info, videos and App downloads.

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November 2020 ENGINEERING UPDATE

New modular system leads the way for modern installation solutions Here’s the dilemma, you consistently hit the same cable and wiring issue, the only solution you have uses existing products and you know the end result is far from ideal. But it’s all you have! This is a frustrating issue faced by many electrical engineers. Surely, there’s a better way, a better solution.

ata Panel GmbH, a company in the Murrelektronik Group, has risen to the challenge and now offers an electronic installation solution for mobile machinery that is modular, highly flexible and future-proof. Mobile machinery defines a wide range of machinery designed to perform specific operations in off-road environments. Including agricultural machinery, forestry equipment and construction machinery - lifting and handling equipment, earthmoving machinery, cranes and industrial trucks.

The market segment of mobile machines is still in its infancy when it comes to “rational installation technology”. Although cable harnesses and terminal boxes are the dominant technology, in recent years more and more electronic technologies have found their way into machines – and this has had a knock -on effects in terms of wiring effort for machine builders. In addition, manufacturers nowadays have more options in their product range to better cover market requirements. All this has meant that the cable harness and the terminal box solution are increasingly reaching their limits.

Depending on the type of machine, some manufacturers say that due to the weight, the cable harness can only be installed with several helping hands and in some cases, the support of an indoor crane is required. Another critical situation is as follows: when connecting many individual strands, it is difficult to ensure that each individual strand is tightened and leakproof. If even a single seal fails, moisture or an operating medium can penetrate right into the housing of the controller, sensor or actuator causing the machine to fail completely.

Simple, fast and error-free assembly In March 2020, the Murrelektronik Group founded Data Panel GmbH with the aim of solving or eliminating the problems and weaknesses outlined above. Its portfolio includes highquality, decentralized, electrotechnical installation solutions for mobile machinery. This modular system comprising of fieldbus modules, passive distributors and pre-assembled cables offers a highly coordinated, modular and pluggable system. Specifically manufactured for the mobile machines market, the new system has revolutionised wiring and cabling and makes it possible to economically realize smaller batch sizes. The fully encapsulated CANopen fieldbus modules from the xtremeDB product family offer eight slots for inputs or outputs. The signal types - digital, analog, ratiometric, frequency/counter and encoder signals can be individually configured for inputs. DO (4A/10A), PWM/PWM(I) and PVG valve controls on the output side round off the signal range.

Unique modular system construction kit consisting of active and passive IO modules and other system components

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Thanks to the end-to-end DT-compatible connection technology, the module, which is made of a reinforced plastic housing material, can be used in machines in which the designer can use pre-assembled sheathed cables or, alternatively, use single wires for connection.

ENGINEERING PDATE November 2020

The use of passive distributors creates the intermediate step from parallel wiring harness or terminal box wiring to the plugged fieldbus technology and also offers the possibility of bringing “on-board” inputs and outputs on the controller into the field simply and cost-effectively. In contrast to the cable harness, the plug-in system allows subsequent expansions or adaptations of the machine electronics without any problems. With the complete xtremeDB product family, machine setup and commissioning can be carried out without expert knowledge using Murrelektronik’s pre-assembled and tested connection cables based on DT plug-in technology. When these connecting cables are used, the active and passive modules meet the requirements of IP68, IP66K, and IP69K. Alternatively, the cable can be assembled with DT or compatible connectors. The modular system of pre-assembled and tested components and the extensive range of accessories ensure a high degree of independence when wiring sensors and actuators. Another advantage of xtremeDB is the independence from cable manufacturers. Due to the easy handling of the components of the new installation system modular system, machine builders are not dependent on their capacity resources. In the terminal box, the change of technology results in a significant space saving, since additional input and output modules and the potential terminal level are replaced in addition to the mobile control. This means that signals are no longer wired individually and laboriously “in the box”, but simply and efficiently installed decentrally in the machine - the terminal box can thus be smaller or, in the ideal case,

The xtremeDB active CANopen fieldbus module creates the conditions for the step away from the cable harness to a decentralized, robust and pluggable installation solution

even completely omitted. Cable glands and thus potential weak points are no longer required. The installation time is thus reduced to a minimum.

Contact Murrelektronik ltd Tel: 0161 728 3133 Email: sales@murrelektronik.co.uk

In the event of service, the connecting cables can be quickly and easily replaced on site or repaired with selfattachable plugs.

The connecting lines are cast or high-pressure overmoulded and thus permanently resistant to media and high-pressure cleaning agents

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November 2020 ENGINEERING UPDATE

TR launches new security fastener to protect medical equipment from criminals A new range of security fasteners has been launched to prevent offenders from stealing or tampering with equipment in hospitals and other medical centres.

Meanwhile, in March this year it was revealed that staff had to take urgent action after vandals were able to damage the main oxygen supply for Rotherham Hospital [source: Rotherham Advertiser 10/3/20]. TR Fastenings components are used in medical equipment, ventilators, defibrillators, furniture including hospital beds, lighting and electrical points and signage. Fastenings for medical equipment are made with corrosion-resistant A470 stainless steel. The durability of the high grade material means that components need to be replaced less often and that equipment is easier to clean and maintain. Paul Standing, Products Manager at TR Fastenings, said: “It’s vital that medical staff have the confidence that when they need a piece of equipment it is where it should be.

he innovative 5-Lobe pin from TR Fastenings is the first complete range of security fasteners made from corrosion-resistant A4-70 stainless steel - the preferred material for all applications across the health and medical sector because of its non-reactive qualities. The fastener’s five-sectioned screw head means that it can only be undone by someone with specialist tools, preventing its removal by an opportunist criminal. A report by the think tank Parliament Street [page 4] last year revealed that suspected thefts of electrical equipment from NHS sites had increased by 33% over a three-year period. Among the items taken were cameras, computers, laptops and monitors. The losses caused not only disruption to care and extra cost to the NHS but also concerns that patient data security could be compromised.

“Our new 5-lobe pin fasteners provide a strong line of defence to prevent opportunist thieves and vandals from stealing or interfering with equipment that could be the difference between life and death for patients.” The 5-Lobe pin is rated as a level 2 enhanced security product and can be supplied with button or countersunk heads in either machine screws or self tapping screws. A4-70 stainless steel is a high tensile strength stainless steel with excellent corrosion resistance making it perfect for both internal and external applications. It is used in the manufacture of medical surgical instruments and in the pharmaceutical industry where cleanliness is absolutely key - the addition of molybdenum to its composition provides the A4 grade with a greater level of corrosion resistance making it suitable for use in salt water environments, or certain chemical solutions. For more information about the 5-Lobe pin security fastener visit https:// www.trfastenings.com/products/ Catalogue/Security-Fasteners For TR’s medical industry animation and further information, visit https:// www.trfastenings.com/industries/ medical

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JOC_1098 KRUK Automation Half H-A.pdf 1 24/09/2015 18:09:43 November 2020 ENGINEERING PDATE

Setting the benchmark... Faster, compact, energy saving and affordable...

Kawasaki’s latest robots increase one of the largest robot ranges available today. They are more compact, provide smooth control and give increased all round performance. For assembly the new collaborative duAro; for palletising the CP Series; the general purpose CX Series and the high-speed spot welding BX Series. Check out the new robots and see just how affordable they can be....

info@kawasakirobotuk.com kawasakirobot.co.uk +44 (0)1925 713000

Kawasaki Robotics (UK) Ltd

> Corrosion resistant for up to 1000 hours in salt spray > Manufactured from a premium alloy with less than 0.1% copper content for corrosion resistance > IP tessng performed aaer impact tessng to verify the seal is maintained when the enclosure is treated roughly > Impact resistant up to 7 Joules > Reusable seals (Up to 200 compressions)

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November 2020 ENGINEERING UPDATE

mk Conveyor Quick Designer with Additional Functions mk is expanding its service range and enhancing its QuickDesigner conveyor configurator. The available options now also include adjustable side rails and new stand systems. The wide range of conveyor system variants is almost endless so mk offer conveyor technology online for fast and easy configuration of an individual belt conveyor. The configurator can be found online at www.quickdesigner.com and generates a 3D model and quotation. There is an automatic plausibility check, detailed help and live preview. Customers can view all configurations in ‘My Account’ which can be then be saved, retrieved and edited at a later date. Three top selling models for different weight and requirement classes are available as a basis for the configuration. These can be adapted intuitively and with ease to meet individual requirements And now mk is setting the benchmark again. Two new options have been added to the QuickDesigner. Therefore mk can now respond to the customers' requirements in even greater detail and provide an even larger variety of variants. One new addition is the adjustable side rails SF01 & SF03, which is now available alongside the range of fixed side rails. This side rail is a particularly effective solution for positioning products on the conveyor belt. The usable width is quick and easy to change and the height can also be adjusted. The large selection of different side guide rails ensures the optimum adjustment to the contour of the product being conveyed. In addition, the heavy-duty stand 31 based on the profiles mk 2031 and mk 2000 has been added to the range of stands. This stand is a more robust version of the height-adjustable, medium weight stand 53.2 based on the mk 2001 profile. This H-design system can be used in practically every conveyor system and is available in standard heights of 325 mm to 2000 mm with adjustable ranges of +/-25 to +/-200 mm. “We are constantly improving our QuickDesigner range to ensure that we meet the needs of our customers” states Darren Whiteside, Director at mk Profile Systems. Configure your individual belt conveyor quickly and easily, now! www.quickdesigner.com To find out more visit www.mkprofiles.co.uk, call (01949) 823751 or email info@mkprofiles.co.uk

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Small Belt Conveyor GUF-P MINI for small products with low volume and weight

Low installation height for easy integration into complex systems Belt recirculation integrated into the conveyor frame Small tail diameters keep gaps at product transfer points narrow

www.mkprofiles.co.uk

mk Profile Systems Limited a company of the mk Technology Group

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November 2020 ENGINEERING UPDATE

WJA celebrates 40th birthday with invite to join the party The Water Jetting Association is marking its 40th anniversary by inviting more contractors and service users to join its drive to promote water jetting excellence across all industrial sectors. pressures can now reach 60,000psi (4,138bar). The WJA is also the biggest provider of water jetting training across all industrial sectors. John Jones, WJA Vice-President and Chairman of its Training and Safety Committee, said: "WJA water jetting courses give contractors a benchmark upon which they can develop their in-house training and skills development, and give operatives a recognised qualification, accredited by City & Guilds.” Two new courses have been added in 2020: a competent water jetting qualification that provides additional assurance of an operative's capability; and a management and leadership course for people overseeing water jetting.

he WJA, the UK's trade association for the water jetting industry, was founded by a group of 21 contractors during a meeting held in the Metropole Hotel at Birmingham Airport on 9th October 1980. Since then, it has gone on to build an international reputation for promoting water best practice across all industries, including petrochemicals, drainage, marine maintenance, highway maintenance, industrial cleaning and manufacturing. WJA President Ron Heward said: "The WJA was founded specifically to promote safety and that purpose

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In 2019, the WJA also issued new Water Jetting Injury Management Guidelines, based on groundbreaking research it commissioned from a team of eminent NHS trauma physicians. is still central to our mission today. Our codes of practice are recognised internationally for setting the highest standards. "Our members - contractors, equipment suppliers and trainers, plus many others - have played vital roles in promoting change for the better in the water jetting industry, and we'd like to invite others to join us in this valuable work." The WJA has two codes of practice - the ‘Blue Code' for industrial high pressure and ultra high pressure water jetting, and the ‘Red Code' for sewer jetting – which the Health and Safety Executive use as a reference for water jetting practice. This is vital as operational water jetting

For the first time, the guidelines include an algorithm for effective injury response, from giving first aid to hospital treatment, which promises to save lives and reduce the long-term impact of injury. The research findings have been published in the European Journal of Trauma and Emergency Surgery, so the good practice can be shared with medical specialists throughout the world. Contact the Water Jetting Association: tel: 020 8320 1090, email: info@waterjetting.org.uk, web: www.waterjetting.org.uk.

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November 2020 ENGINEERING UPDATE

Frer series of TYPE B earth Leakage Relays – AC & DC Network protection The Type B earth leakage relay is an essential part for earth fault protection equipment on an installation where several switch mode power supplies are fed from the AC supply. The nature of a switch mode power supply is such that it may lead to high frequency, Harmonic interference and DC leakage currents elements on the AC network which will not be detected by an AC Type A or Type F earth leakage relay. This may leave to a risk of fire, damage to the installation or harm to operators. Frer’s X...DB3 series earth leakage relays Type B are designed to measure the DC, AC and high frequency leakage current. The continuous display of the system parameters, leakage current, alarm status, frequency and harmonic level on the LCD display makes it is possible to continuously monitor the insulation state and to program the preventive maintenance in order to help avoid unexpected power breaks.

Main functions: • Continuous digital indication of the leakage current: total RMS, AC fundamental, AC high frequency • Double threshold: total RMS and DC component • Storing of the TRIP current values • Internal clock and storage of the last 10 events • RS485 Modbus RTU, measurements, event archive, scope • Selectable anti Fibrillation filter with fire protection 300mA • AC measurements up to 10kHz • Automatic retry • Logic Selectivity • Selectable 3rd harmonic filter The FRER type B earth leakage relays (series X ... DB3), designed to intuitively and automatically detect leakage currents, allow the isolation status to be displayed continuously through the multi-color display. Just one sensor (TDB series ...) connected on the network is required to measure AC and DC networks, with a DC-10kHz band, and a resolution up to 1mA. They have an integrated "demagnetisation" function with zero offset of the DC, which is automatically activated each time the sensor is switched on or when the relay is

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commanded which effectively clears the measurement error due to factors such as: • presence of magnetic fields in DC (terrestrial magnetic field, permanent magnets, DC coils, ...); • temperature drifts; • mechanical shocks or vibrations. The measurement error of the RMS current (AC + DC) is proportional to the line current and depends on the arrangement of the cables passing through the sensor and on the distance of the adjacent cables. The settings of low threshold currents will be possible only by centering the cables and controlled climatic conditions (temperature, vibrations, EMI).

MEASURE: In MEASURING mode, the backlight of the display is GREEN. The first line shows the total True RMS value of the Differential Current and the annunciators related to the current settings. On the second line it is possible to scroll the measurements relating to the continuous components of the measured values such as the network frequency and to the high frequency.

ALARM In ALARM mode the backlight of the display is ORANGE and the alarm annunciator flashes. If the differential current drops below the alarm threshold for the set release delay time, the device automatically returns to the measurement mode; if instead the Memory function is set, it is necessary to press the RESET key, the possible Test / Reset Remote input or the specific RESET Modbus RTU command. The pages and views are identical to the Measure mode.

TRIP In the TRIP mode the display backlight is RED. In the case of TRIP FOR DIFFERENTIAL CURRENT the TRMS value of the Differential Current which caused the trip is displayed on the first line while on the second line it is possible to scroll the measures related to the trip instant. The graphic bar is fixed at 100% and the Trip annunciator is on.

In the case of TEST OR TOROID INTERFACE FAILURE, the trip cause is displayed on the first line. The graphic bar is fixed at 0% and only the Trip annunciator is on. In trip mode the Differential Current should be canceled due to the opening of the System Release. If the relay continues to measure a non-zero differential current, the display backlighting becomes RED BLINKING to highlight the possible event.

Relay main functions: • Continuous digital indication of leakage current: RMS total, DC, fundamental AC, high frequency AC. • Double threshold, total RMS and DC component only • Measurements in AC up to 10kHz. • Internal clock with storage of the last 10 events • Current TRIP level storage • RS485 Modbus RTU, Measurements, event archive, oscilloscope • 3rd harmonic filter and antifibrillation frequency filter with selectable 300mA fire

Anti-fibrillation The anti-fibrillation is found in Type F and Type B earth leakage relays. It is a requirement of several norms, IEC 62423, VDE 0664-T-100, to which the Frer Type B and F relays are compliant. When a leakage current above the trip level, say greater than 30mA or 300mA is operating at a High frequency the conventional Type A earth leakage relay will not see the leakage current, so there is a threat of fire. The Anti Fibrillation filter sees the high Frequency and the current and will trip the Type B relay to reduce the risk of fire, damage to pant and machniery and the risk to life. For further information, please contact sales@tvri.co.uk Tel: 01206 575755 or http://tvri.co.uk/frer-xdb3-type%20 B-earth-leakage-relays.html

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November 2020 ENGINEERING UPDATE

Advanced burst signalling system for the chemical sector

Stop unnecessary downtime with non-invasive signalling systems Over the past few years significant advances have been made in the performance and capability of pressure relief technology - essential safety components found within chemical processing plants. With non-invasive signalling devices, which make it impossible for the process medium to escape, processes with critical pressures and demanding media can also be reliably monitored. For customers for whom compatibility with harsh operating conditions is of paramount concern the NIMU (Non-invasive monitoring unit) is a reusable rupture disc signalling system designed for rapid notification of rupture disc activation even in the harshest chemical environments. The REMBE NIMU sensor is not in contact with the process meaning it is not affected by challenging process conditions or corrosive media.

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The intrinsically safe NIMU is installed into a tapping within the outlet of the rupture disc holder, completely isolated from the process so it does not create any leak paths and is not damaged following disc activation - critical for chemical customers where leak paths cannot be tolerated. With the traditional membrane type signalling devices, false alarms were unfortunately common place, as the harsh operating conditions could cause the device to activate even if the disc itself had not opened. This false signalling would cause unnecessary and costly process downtime. Unlike these traditional devices, the NIMU is not negatively affected by the process.

ENGINEERING PDATE November 2020 T +49 2961 7405-0 T +1 704 716 7022 T +39 02 62033057

Your Specialist for

PRESSURE RELIEF SOLUTIONS Consulting. Engineering. Products. Service.

www.rembe.de

Additionally, membrane detection systems are single use, meaning additional replacement costs. With the NIMU this additional cost is eradicated – the NIMU enhances overall dependability of rupture disc installations while reducing long-term expenditure. Not only is the signalling device fully reusable following disc functioning it is also reusable after routine maintenance checks. Easy to inspect during such maintenance routines, its closed circuit design allows it to be refitted into the holder by the same operator inspecting the disc, simplifying and quickening the maintenance process, a must to meet the demanding productivity requirements within the chemical processing sector. When used in combination with the REMBE iQ Safety Cockpit the operator can be instructed in the event of a system disruption and can implement the relevant emergency management protocols. The affected employees can be individually informed of a process shutdown and co-ordinated response to identify the cause and get the plant back up and running as quickly as possible.

Inc.

www.rembe.us

www.rembe.it

S.r.l.

About REMBE - the REMBE Alliance introduces itself REMBE is mostly associated with REMBE GmbH Safety and Control - the specialists for explosion safety and pressure relief worldwide. The company offers customers cross-industry safety concepts for systems and equipment. All products are manufactured in Germany and meet the demands of national and international regulations. The customers who purchase REMBE products are among the market leaders of various industries, including the food, chemical, pharmaceutical oil and gas as well as wood industries. The technical engineering expertise is based on more than 45 years of application and project experience. As an independent, owner-managed family company, REMBE combines expertise with highest degree of quality, and is also actively engaged in various professional bodies worldwide. Short alignment routes enable the achievement of quick responses and customer-specific solutions for any kind of application: from standard products, all the way up to high-tech special designs. In addition to REMBE GmbH Safety + Control (www.rembe. de) with approx. 250 employees worldwide, headquarter in Brilon (Germany) and numerous subsidiaries worldwide (Italy, Finland, Brazil, USA, China, Dubai, Singapore, South Africa, Japan), four other companies are also engaged under the REMBE family brand: REMBE Research & Technology Center GmbH REMBE Advanced Services + Solutions GmbH REMBE Kersting GmbH REMBE FibreForce GmbH

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November 2020 ENGINEERING UPDATE

Titan Enterprises is a leading supplier of precision flow measurement devices for the food and beverage sector. Flow measurement is widely recognised as a critical tool for food and beverage manufacturers looking to control operations including filling of vessels, measurement of liquid ingredients and controlling cleaning processes.

Precise Flow Measurement for the Food & Beverage Sector

Beverage meters ensure consistent drink quality (courtesy: Titan Enterprises) 800-Series flow meter (courtesy: Titan Enterprises)

or these and other flow measurement operations, Titan offers a range of flow meters incorporating NSF certification for use within food and beverage production facilities. Titan Enterprises maintains certification under NSF169 as equipment for food products for their 800 Series turbine flowmeters and Beverage meters. This certification is especially important for manufacturers of food production and handling machinery who can now install these flow meters secure in the knowledge that they meet NSF-standards for food production.

installations around the world. At the heart of each beverage flowmeter is a precision Pelton wheel turbine that rotates freely on robust sapphire bearings and contains over-moulded magnets that are detected through the chamber wall by a Hall effect detector. The output from Titan's 800-series and beverage flow meters is a stream of NPN pulses that are directly interfaced with either PLCs or an electronic display. This combination of materials and technology ensures a long-life product with reliable operation throughout.

Carrying NSF certification, Titan Enterprises competitively priced, 800 series turbine flow meter is designed to give reliable, high performance over 6 flow ranges from 0.05 to 15 L/min. Incorporating only non-metallic wetted components makes the 800-seies flowmeter the ideal choice for the metering of food and beverage materials. Titan Enterprises beverage flow meter is designed specifically for precise metering of lower viscosity beverages including coffee, wine, beers, spirits and soft drinks.

For further information on flow meters that carry NSF certification for food and beverage applications please visit https://www.flowmeters.co.uk/ beverage-flow-meters-drinks-dispensing-flowmeter-for-beer-wines-and-spirits/.

Based upon a unique Pelton wheel design, Titan Enterprises 800-series and beverage dispensing flow meters are inherently reliable and proven in tens of thousands of

To review a beverage industry case study please visit https://www.flowmeters.co.uk/beer-flow-sensors-titansupply-600000-flow-sensors-beer-industry/

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In addition to its NSF certified flow meters, Titan Enterprises is also experienced in supplying optimised flow meters for monitoring the flow of more viscous food grade fluids such as chocolate, cream and syrups.

* NSF (www.nsf.org) are an independent, accredited organisation, that test, audit and certify products to develop public health standards and certifications that help protect food, water, consumer products and the environment.

ENGINEERING PDATE November 2020

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November 2020 ENGINEERING UPDATE

ACCURATE DISPENSING OF AB MAURI BAKERY INGREDIENTS Concept Controls Ltd and SEEPEX UK Ltd provide a perfect solution A significant factor in baked goods manufacturing is the need to reduce the cost of raw material delivery into dough mixes. Modern research and process techniques have been used by AB Mauri, a major manufacturer and supplier of bakery ingredients, to produce a range of Enzymes, Bread Improvers and Enhancers in a highly concentrated form. These ingredients are highly effective, requiring very small amounts to be added to each batch. To maximise the benefit of these concentrated products accurate dispensing of the ingredients is critical, both to ensure optimal ingredient performance, and to minimise overdosing (which can add to material usage and cost). Traditional weighing and Diaphragm Pump dispensing, even with the best of metering control, can lead to significant variations in the actual additive level to each batch of dough.

Solution Although AB Mauri has considerable in house experience at developing the products, the related processes, and even the engineering of equipment, they wished to use an external engineering company with experience in Bakery and other process equipment to develop a solution that met demands for accurate dispensing. Concept Controls Ltd (Waltham on the Wolds) were approached, and shown some of the original systems, a number of which had performance limitations with the latest developments in ingredients. After technical analysis of peristaltic, lobe and double diaphragm pumps a higher performance pump was sought to ensure accurate repeatable dispensing of concentrated ingredients from bulk containers. During the research process the SEEPEX Progressive Cavity (PC) Pump, became a clear leader. The main benefit of the PC pump is that there is a sooth pulsation free delivery of material delivering repeatable accuracy of +/-1%. The

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flow rate is linear, proportional to motor speed and regulated by a simple speed controller over a very wide range. This was specifically useful as there is a limited time (Less than 25 Secs) for dosing of the A.B. Mauri products when operating on a standard Bread Mixer, hence a high rate of delivery is needed for rapid dispense, but a low rate of delivery for accuracy of dispense. The pressure capability of these pumps is also very wide, and the Concept Controls Ltd system uses this to deliver a high pressure and high accuracy phase at the end of the dosing cycle. The pumps can also accurately dispense products with a wide range of viscosities. By coupling this high performance PC pump, orifice plates, and a very high accuracy Endress and Hauser Coriolis Flow meter, Concept Controls Ltd, in conjunction with their partner company PVSL Ltd. (Brierley Hill), are able to meet the challenging specification requirements for A.B. Mauri. The detailed design phase started with 3D Models of the proposed equipment generated by PVSL Ltd. The result is an easy to apply Dosing System, that includes bulk frame storage for IBC containers (normally in

Stores area), with buffer tanks to allow a practical regime for maintaining product stock. The SEEPEX PC pumps are more than capable of delivering the various products to a dosing frame mounted close to the Mixers, and hence through the associated mixer lids and into each batch of Dough. The Dosing Frame is a small matrix of fast acting Ball Valves which allow the product to be fed either directly to the Mixer, or via the flow limiting orifice plate. The net result is a system that can deliver as low as 50g into a batch of product, and also extend to several kilogrammes, all within the 25 second window, and every batch can be metered to the nearest gram. The overall benefit to the end customer, is that they can rely on a very consistent product, with the advantages of the most modern process innovations, without the potential of overdosing (i.e. wasted product), overall enhanced quality and reduced overall scrap. sales.uk@seepex.com www.seepex.com

TO THE EXACT DROP DOSING PUMPS

CONVEYING CAPACITY

0.06 – 2,000 L/H PRESSURE

UP TO 48 BAR

SEEPEX progressive cavity pumps offer continuous and batch dosing with high precision and repeatable accuracy. Whether thin to highly viscous, shear-sensitive and corrosive media, with or without solids – our pumps convey products gently and with minimal pulsation.

BENEFITS

y Minimal pulsation y High metering accuracy (±1%) y Easy integration into modular systems y Multiple drive combinations possible

SEEPEX UK Ltd. sales.uk@seepex.com www.seepex.com

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November 2020 ENGINEERING UPDATE

An Optimised Design for Valve Actuators The Camtorc series actuator is a mathematically derived cam system first manufactured in 1975. It has been in continuous production since, gaining a base in industries all over the world. Imtex Controls acquired all rights to the design in 2006 and integrated it into a modular assembly that is particularly suited to space-sensitive or remote/inaccessible locations. The unique Camtorc design has many advantages over other actuator systems, and it is important for end users and buyers to be aware of these differences. This case study will explain the advantages of Camtorc, outline the modular components, compare Camtorc to other actuator systems, and also demonstrate how fail-safe valves, or applications where Maximum Allowable Stem Torque (MAST) is a concern, will benefit from improved torque-efficiency and a reduced risk of valve failure. The Camtorc actuator is a linear to rotary motion convertor primarily used for the pneumatic or hydraulic actuation of quarter-turn pipeline valves and dampers. Consequently, the design has seen a big uptake in the oil/gas, marine and power generation industries. What really sets this design apart is the mathematical profile of the cam which ensures a constant output torque during the piston stroke. This eliminates backlash. The combination of zero backlash and constant output torque means there are fewer moving parts – reducing possible causes to fail, which contributes to a longer service life and lower maintenance costs. Additionally, this optimised system also avoids two more, related problems. Firstly, the constant torque negates large side-forces which require additional infrastructure within the housing. This in turn avoids the problem of side-loads, which require more complex assemblies. As a result, Camtorc actuators are more compact and generally have lower installation costs. Compared to other actuator systems, such as the scotch yoke design, Camtorc offers substantial advantages. The scotch yoke actuator employs a piston that moves a yoke via a sliding pin. It is easiest to think of Camtorc as an optimised version of this design, clamping the yoke apparatus (attached to the pistons) around the cam so they remain in contact along a frictionless surface. On safety critical valves (i.e. ESDVs) it is increasingly common to carry out some form of valve assembly testing, such as Partial Stroke Testing (PST). The advantages for plants and rigs are that critical valves are tested for integrity without the cost burden of shutting off the valve.

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There are two distinct advantages to the Camtorc design when it comes to PST: In the dual piston-design of the Spring Module less air needs to leave the actuator to start the piston moving, and a much larger pressure drop is required to complete the stroke. This significantly decreases the risk of over-travel (spurious trips). To prevent over-travel a maximum pressure drop is often set, but on a scotch valve actuator this is usually very close to the pressure required to start moving the valve. Therefore, if the valve sticks a little (which often happens when a valve has been inactive) the test might fail erroneously: since a slightly lower pressure would cause the valve to move. With Camtorc, the larger pressure differential on the spring stroke allows for much more control of the PST system, and the maximum permissible pressure drop is far less likely to abort the test. False fails and spurious trips are costly and risky on a plant or oil rig where they might lead to a partial or complete shutdown of operations. For the buyer, all of the design benefits of the Camtorc actuator system result in a significantly reduced Whole Life Cost (Whole Life Cost is the projected cost of an asset over its entire life). The Camtorc series is available for pneumatic and hydraulic applications in either double acting or spring return configurations with a full range of modular control accessories. Please contact Imtex Controls on +44 (0)8700 340 002 or email sales@imtex-controls.com for more information.

Reduce unscheduled shut downs, reduce maintenance costs and improve plant safety with our Valvescan Diagnostic Monitoring System. Our revolutionary system is an end-to-end solution that captures data from every valve operation, analyses it and provides targeted alerts on the valve health without any requirement for involvement from plant personnel or any potential impact on the asset real-time control integrity. It is a true IIoT solution for automated valves. This system is not only a pioneering development in valve monitoring, it is also; ● Cost effective and easy to install ● Works with all existing valve systems ● Enables data retrieval and transmission to the cloud ● Provides a ‘real time health’ check on the valve and alerts when performance drop off is detected

08700 340 002 www.imtex-controls.com



November 2020 ENGINEERING UPDATE

Sophisticated End of Arm Tooling Enhances Automated Manufacturing When the term “Gripper” is used, many will visualise a simple set of pneumatically or mechanically operated jaws, or perhaps even vacuum cups. Whilst this is technically still a valid perception for some applications, the truth is that Gripping technology, or to use the alternative term - End of Arm Tooling, has come a long way as it has evolved to keep pace with, and in many cases enhance, the operation of robot systems and special purpose machines. This article from Zimmer Group UK’s Ian Sinclair explores some of the advances in End of Arm Tooling technology which demonstrates that in many cases, what was once termed a gripper is now a sophisticated automation module in its own right. Grippers have changed dramatically over the years from the once basic unit that would simply hold a component during transfer, to become in many cases, technology based modules capable of performing sensing, measurement, re-orientation or process operations. Key contributors to this ongoing process of evolution have been the readily available electronic, pneumatic and mechanical components which themselves have become both more compact, sophisticated and cost effective. This, together with innovative design concepts, has led to the development of a whole series of sophisticated and often intelligent gripper / end of arm tooling modules.

What were once just termed grippers have in many cases now evolved into sophisticated end of arm tooling modules

This concept of intelligent, multi-function end of arm tooling modules mounted to robots is growing across a number of diverse sectors including automotive, aerospace, medical device, white goods and more recently into areas related to household products and modular building construction. The operations which they perform are equally diverse, ranging from simple product handling, to glueing, sealing, drilling, dispensing and assembly. Where large parts are being manufactured, it is often the case that the robots being used will also be large to provide the required working envelope. Robots such as this will usually have a reasonably high payload, so they are capable of carrying and manipulating sophisticated end of arm tooling systems.

Zimmer Group’s Ian Sinclair explains: “Where in the past, the technology used to hold or manipulate components was usually relatively simple, today it is often the opposite. For example, it is not uncommon now to find our latest E-Gripper technology being used for small parts handling, where users can take advantage of adjustable gripping forces and variable jaw strokes. This provides much greater levels of flexibility without the need for manual intervention, where different part variants may need to be processed either at random or in sequence.” Another growing trend with end of arm tooling is the use of bespoke designed multi-function modules. These can incorporate not just the gripping mechanisms needed to pick and manipulate products, but also incorporate one or more production processes. Ian Sinclair continues: ”Incorporating one or more technologies within the end of arm tooling on a robot system increases efficiency in manufacturing processes. For example, where parts may be large or cumbersome to handle, it can sometimes be easier to take the process to the part than try to move what might be a large and heavy object. This also saves cycle time by eliminating the need to move the part between different workstations.”

This multi-function end of arm tooling system from Zimmer incorporates horizontal and vertical drilling systems plus gripping systems to handle cabinet flooring and hinge plates

Ian Sinclair concludes: "Of course, we continue to see growth across our standard product range, which itself includes a number of innovative and digital concepts, but there is no doubt that automation system integrators and machine builders are seeking to incorporate more technology into the end of arm tooling elements of a project wherever possible. Our expertise in this area means that we also continue to see growth in the number of sophisticated end of arm tooling systems that we design and build.”

Tel: +44 1283 542103 | Web: https://www.zimmer-group.de/en | Email: info@zimmer-group.co.uk

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F R E S H A I R

ENERGY EFFICIENT

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Book your free site visit. www.ecocooling.co.uk sales@ecocooling.co.uk

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SAVE UP TO 90% COMPARED TO AC

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November 2020 ENGINEERING UPDATE

Are your enclosure features suitable for a F&B environment? Author: Emma Ryde

After 12 years of visiting end user sites to assist with specification of enclosures and the relevant cooling and power distribution products, it became all to apparent that most enclosures (despite the application) are selected mainly based on an IP rating. But should this be the only factor when selecting enclosures for Food and Beverage production? It’s a general misconception that an IP rating is fundamentally the most important design point of an enclosure. Whilst it is a very important feature the overall design of the enclosure must be considered. When working in an environment such as Food and Beverage, an IP rating that matches the harsh washdown procedures is a must but, there are other considerations just as important. Over the years I have seen enclosures filled with water and foodstuff (despite the IP rating), enclosures with metal lock parts missing, enclosures specified by material only (Stainless) and worst of all enclosures selected on a cost factor only. Whilst one of the greatest fears in the Food and Beverage sector is the potential for bacteria and cross contamination, it amazes me that in this day and age more end users don’t address these issues and continue to use products that don’t meet hygiene standards and are substandard for the application. However, whose responsibility is it to select the right products initially? The Electrical Engineer, the Production Manager, the Hygiene Officer, the Maintenance engineer? As a supplier we also have a responsibility to inform and educate people to ensure that when they select a product they do so having made an informed decision. A standard enclosure is typically built to prevent dust and ingress entering into it and to protect the installed equipment, and this is still the case with the Hygienic Design enclosure except it

Hygienic Design

Extra cleanliness guaranteed 54|

ENCLOSURES

POWER DISTRIBUTION

CLIMATE CONTROL

ENGINEERING PDATE November 2020 needs to consider much more than just those few factors. This when the Design of the enclosure means everything.

The design of the enclosure is everything In a Food Manufacturing environment specific Zones such as Zone 1 are where Hygiene means the most. These are areas where open process of the food manufacture takes place, because of this these areas are cleaned in the harshest of ways. High power hot jets of water typically cover the production lines and any equipment in or around it. Chemicals can also be used to ensure the elimination of bacteria however, if the equipment in that area isn’t designed for those sorts of conditions then the resulting factor is, degradation of equipment, down time and worst case foodstuff and bacteria still being present.

The 3 zones with a Food and Beverage factory.

The seals on standard enclosures are design to keep out wind driven rain not high-pressure hot water. Standard seals in this type of environment will only withstand so much before they breakdown and start to allow water into the enclosure. This then jeopardises the components within it and the risk of stopping production increases. I’ve seen many enclosures where the seals have broken down over time and due

Important features of a Rittal HD Enclosure for maximum hygiene.

to cleaning, foodstuff is then forced within them during the washdown process. This then becomes a breeding ground for bacteria. Because standard enclosures are usually design to sit within a factory without the presence of water then the design of the door and housing also isn’t suitable. It makes the cleaning of it near impossible. It may look clean in some instances but because of the design constraints product will be in the areas you cannot see, not to mention bacteria which isn’t visable to the naked eye. Enclosures for such complex applications need to be well thought out and consider all of the manufacturer’s risks. Creating an enclosure which does not have the usual crevices, where food stuff can sit means less risk to the consumers of products they purchase. Typically hinges, door locks, cable glands and plinths on an enclosure aren’t design for the application so they have areas where foodstuff can congregate, a specifically designed enclosure for this application addresses these issues. Features on an enclosure such as wall brackets that are round and smooth, a door designed to prevent water sitting on it allowing it to erode the seal, cable glands with interior threads so the outer surface is smooth. These are features that have been design with the end user in mind.

NEW: Hygienic Design air/water heat exchanger

Electrical enclosures are a fundamental part of the production line but are usually overlooked as just a ‘metal box’. This ’metal box’ houses the heart of the production line, its what keeps thousands of pounds worthof equipment protected and ensures production keeps running preventing downtime, it keeps the users around this equipment safe, and in specific applications it should by sympathetic to its environment. One size doesn’t fit all as they say, the wrong enclosure could do more harm than good and ultimately create more problems. Selecting the right product for the right application means time and attention can be focused elsewhere, giving the manufacturer greater peace of mind. To show the true effect of the features of a Rittal HD enclosure, Rittal put a HD enclosure to the test against the best selling Rittal AE enclosure. The results of the experiment may just shock you, and even be happening in your factory right now! CLICK HERE to download the free infographic for more info

The Rittal hygiene standards for maximum productivity

IT INFRASTRUCTURE

Enclosures are more than just a ‘metal box’

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SOFTWARE & SERVICES

www.rittal.co.uk

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November 2020 ENGINEERING UPDATE

Electrostatically Recovering Copper Wire A combination of an ElectroStatic Separator and a Metal Separation Module is enabling the recovery of fine copper and other metals from a waste product at a UK metal recycling company. regulates and presents an even, monolayer of material onto the belt of the Rare Earth Roll Separator.

Inside the ElectroStatic Separator

Bunting is one of the world’s leading designers and manufacturers of metal separators for the recycling and waste industries with European manufacturing and product testing facilities just outside Birmingham in the United Kingdom. The Bunting ElectroStatic Separator significantly enhances the ability to recover fine metals such as copper wire. In this project, the fine feed material is from air-extraction post-shredding; a mix normally classified as waste despite the valuable metal content. Prior to ordering the equipment, controlled tests conducted at Bunting’s Customer Experience Centre determined that a three-stage separation process would enable high levels of metal recovery and purity. On site, between one and two tonnes per hour of the metal mix initially passes through the Metal Separation Module before the final stage of ElectroStatic Separation. The Metal Separation Module consists of a Ferrite Drum Magnet, Vibratory Feeder and high-intensity Rare Earth Roll Separator. The Ferrite Drum Magnet removes strong magnetic metal with the remaining mix passing onto the Drum Magnet-Rare Earth Roll Magnetic Vibratory Feeder. This Separator Module

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The Rare Earth Roll Separator has a belt feeding material onto a head pulley constructed from high-strength neodymium rare earth magnets. As material passes over the head roll, weakly magnetic metals are attracted to the radial high-intensity field and held on the belt before being deposited underneath. A strategically placed splitter enables the separation of the attracted metals (including fragmented stainless-steel) from other non-magnetic materials (e.g. fine copper wire and aluminium). This non-magnetic metal mix passes onto the third separation stage to recover fine copper wire at a feed rate of approximately one tonne per hour. The ElectroStatic Separator produces a separation by exploiting the difference in electrical conductivity between various materials. This enables the recovery of metals such as fine copper wire. In this project, the recovered copper wire has a purity of +95%. Additional information on metal recovery and separation using the ElectroStatic Separator, magnetic separators, and eddy current separators is available on the Bunting website. Bunting-Redditch website www.mastermagnets.com Tel: +44(0)1527 65858 All photographs were taken by Paul Fears Photography

15th International Exhibition of Railway Equipment, Systems & Services

F 1 WS

O H S AT

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IL A R IC

T N E EV

CONNECTING THE INDUSTRY 13TH INTERNATIONAL RAILWAY INFRASTRUCTURE EXHIBITION

In 2021, Railtex will play host to Infrarail at the NEC, Birmingham from 11-13 May. The UK’s most important events in the rail calendar will come together to form the ultimate show for the rail industry. To be part of the most comprehensive rail exhibition of 2021 contact the team on +44 (0)1727 814 400 or via email railtex@mackbrooks.co.uk

T H R E E S H O W S | T W O D AY S

B R O U G H T TO YO U B Y D ATAT E A M B U S I N E S S M E D I A

Sensors & Instrumentation live

WHEN

29-30 JUNE 2021

WHERE

NEC, BIRMINGHAM

CO-LOCATED

In June 2021, the NEC Birmingham will host an industry event like never before as three leading exhibitions Sensors & Instrumentation Live, Electronics Industry Live (formerly known as What’s New In Electronics Live) and Future Robotics Live - join forces for the first time. This exciting new partnership will also offer a one ticket policy with co-located events, Interplas, Med-Tech Innovation Expo and TCT 3Sixty opening the doors to thousands of visitors and potential clients for your business. Get in touch to find out how your business could benefit from exhibiting and secure your bespoke package today!

DESIGN, EMBEDDED, ENGINEERING & MANUFACTURING www.electronicsindustrylive.co.uk WANT TO GET INVOLVED? Contact Harriet Campbell on T: 0844 381 4235 or at E: hcampbell@datateam.co.uk

ROBOTICS, MOTION CONTROL, VISION & AUTOMATION www.futurerobotics.co.uk WANT TO GET INVOLVED? Contact Aamir Rashid on T: 01622 699 188 or at E: arashid@datateam.co.uk

Sensors & Instrumentation live

SENSORS, TEST, MEASUREMENT & CONTROL www.sensorsandinstrumentationlive.co.uk

WANT TO GET INVOLVED? Contact Louise Pudney on T: 01622 699 104 or at E: lpudney@datateam.co.uk

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November 2020 ENGINEERING UPDATE

In this article, Fulton’s aftercare and business development manager Jeff Byrne takes a look at technical boiler house risk assessments, from their legalities to the potential savings that can be achieved.

t is strongly advised that all companies with a steam boiler have a technical risk assessment in place for its boilers and boiler house. It is required by law under the Management of Health & Safety at Work Regulations 1999 and is necessary to comply with the requirements of SAFed document BG01, HSE INDG 436 and HSE INDG 417 Rev1, under which steam or hot water plant should be operated.

destruction and/or devastation as a bomb, potentially causing catastrophic damage, serious injury and possibly multiple fatalities. With around 100 pressure vessel failures and at least one fatality per annum in the UK (HSE RIDDOR 2014), the importance of a technical boiler house risk assessment (TBHRA) cannot be overstated.

Why do you need a Technical Boiler House Risk Assessment? Besides the legal requirement, a faulty steam boiler brings with it the risk of a steam explosion. With significant stored energy, failure of steam (or pressurised hot water boiler plant) can produce a similar level of

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So, a TBHRA is therefore essential for owners, operators and managers to ensure that staff are aware of the risks and

their responsibilities for the safe operation and management of industrial steam and hot water boiler plant. It is also likely to be the first thing a HSE inspector would ask to see in the event of an inspection. A TBHRA is also a vital link in the safety chain to identify risk and develop measures to mitigate those risks, thus ensuring the safety of all involved with the plant. We simply cannot stress the importance of the TBHRA enough, because noncompliance with the law can result in substantial fines and the likelihood of a custodial sentence in the event of serious injury or a fatality.

ENGINEERING PDATE November 2020

The Fulton approach to TBHRAs Fulton’s method with the TBHRA requirement is to take a very collaborative approach with its clients; and use only experienced steam boiler and steam system engineers with over 60 years’ knowledge of not just steam boilers, but steam, water and condensate systems. This highly-experienced team will scrutinise and photograph every area of risk and will produce a full report proposing and prioritising mitigation measures. This will give owners, operators and managers peace of mind that their plant may be operated safely and that all relevant guidance and legislation is supported once any identified hazards are rectified.

What are the typical findings of a TBHRA? Unlike a vehicle MOT, a TBHRA does not pass or fail a steam system, but instead highlights hazards and the potential risk and then proposes measures to rectify any issues. According to INDG 436 “a risk assessment does not need to include excessive detail”, but issues highlighted can include boiler specification, location, operation and condition, poor record keeping, lack of suitable/ relevant training or trained operator absence cover,

shortage of plant drawings and manuals, control system reliability, ventilation issues, poor/no suitable operational procedures, water quality issues, etc.

Beyond the TBHRA? Once its assessment is completed and delivered, there is no commitment by the customer to involve Fulton in any postassessment remedial works. But the document does highlight areas of the steam system that require attention and will prioritise the risk they pose from high priority (red) to lower priority (green). The assessment must also be made available to the boiler operator and, in the event of the sale of equipment, the new owner/operator. However, unlike a MOT, a TBHRA is a live document that should be updated on an ongoing basis when any changes or modifications affecting the operation of a boiler occurs. This can include personnel changes,

additional training, physical changes including boiler/ burner upgrades, legislation amendments, etc. Fulton can offer support to the customer once the TBHRA has been completed, or during or after the annual review. This support can be provided onsite or via telephone or video conference assistance once the review is completed. A TBHRA also offers excellent value for money because it not only highlights areas of potential risk for owners, operators and managers, but can also identify where enhancements to the steam system could lead to improved energy efficiency. For example, the cost to replace an old, inefficient or dangerous burner could easily be offset within a few years by the fuel savings achieved through the upgrade. For further information on Fulton’s technical boiler house risk assessment package, call the office on +44 (0)117 972 3322, email aftercare@fulton.co.uk. www.fulton.co.uk.

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November 2020 ENGINEERING UPDATE

IET YWE:

Young women engineers make national final and get set to inspire more girls to join the industry To celebrate Ada Lovelace Day, six young female engineers have been announced as finalists for the Institution of Engineering and Technology (IET) Young Woman Engineer of the Year Awards 2020. These prestigious engineering industry awards celebrate women working in modern engineering – and aim to help change the perception that engineering is predominantly a career for men by banishing outdated engineering stereotypes of hard hats and dirty overalls. Bethany Probert (23), Ella Podmore (25), Neera Kukadia (28), Dr Melanie Jimenez (33), Shrouk El-Attar (28) and Denize Ivy Pilarta (21) have all been shortlisted for awards. The finalists are: Bethany Probert is a Junior Software Engineer at Altran UK, working in the High Integrity Software Centre. Ella Podmore is a Materials Engineer for luxury British supercar maker McLaren Automotive. Neera Kukadia is a Project Engineer at Transport for London.

Dr Melanie Jimenez is a Royal Academy of Engineering Research Fellow at the James Watt School of Engineering, University of Glasgow. Shrouk El-Attar is an Electronic Engineer at Elvie.

Denize Ivy Pilarta is an Apprentice NonDestructive Examination Engineering Technician at BAE Systems Submarines..

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As well as highlighting female engineering talent, the IET Young Woman Engineer of the Year Awards seek to find role models who can help address the UK science and engineering skills crisis by promoting engineering careers to more girls and women. Just 12 per cent of those working in engineering occupations are women (source: Engineering UK). 2019 Young Woman Engineer of the Year, Ying Wan Loh, said: “The IET’s YWE award is the most prestigious award for early career women in engineering in the UK. Since winning, I’ve had the chance to collaborate with a BAFTA-winning celebrity, a famous sportsperson and many senior members in the engineering community. “With this platform, I’ve been able to raise awareness for STEM in wildly interesting and creative ways. The YWE award is recognised internationally and I’ve received invitations to give talks abroad and was also recognised in Forbes 2020 30 under 30 list.

“The difficulty in attracting women into engineering is down to a combination of things, including a lack of understanding around what engineering is, perceived gender norms, the image of engineers within the UK, careers advice girls are given in schools and the way that companies with engineering roles advertise their opportunities. “It’s also a result of the lack of engineering role models for girls, which is why our Young Woman Engineer of the Year Awards are all about finding role models to get girls and the next generation excited and inspired about a career in engineering. “I’d like to congratulate Bethany, Ella, Neera, Melanie, Shrouk and Denize for making the final six and in helping to demonstrate the tremendous female engineering talent in our industry today.” The winner will be announced at the IET’s Young Woman Engineer of the Year Awards ceremony on Thursday 4 March 2021. For more information, visit https:// youngwomenengineer.theiet.org/

“The IET gives female engineers a voice to be heard and I am using this platform to raise the profile of women in STEM. Representation matters, and I am so grateful to the IET for giving me this once-in-a-lifetime opportunity to inspire young people everywhere to become engineers.”

The IET will also be hosting a webinar on 3 December, giving people the chance to meet this year’s YWE finalists and find out more about them and the outstanding work they are doing, as well as ask the finalists questions in a live Q&A session. Details of the webinar will be shared across the IET’s social media channels in due course.

Jo Foster, Equality, Diversity and Inclusion Manager at the IET said: “Engineering is a fantastic career – it’s diverse and exciting with the opportunity to do something life- or even worldchanging. But the lack of women in the sector is a huge problem.

This year’s YWE Awards are being sponsored by BAE Systems, Boeing, BP, Collins Aerospace, Frazer-Nash, GCHQ, Leonardo, MBDA, Ofcom, RAF, Royal Mail, Teledyne e2v, Thales and Wiley.

“

Hygiene and safety are top priorities.

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

November 2020 ENGINEERING UPDATE

CERATIZIT CTCM120 and CTCM130 carbide grades with innovative Dragonskin coating ensure optimum turning performance with stainless steels

For turning stainless steel components – regardless of whether they be cast, forged or semi-finished parts – CERATIZIT has the optimum insert in its range. The well-established CTPM125 carbide grade has now been joined by two new cutting materials to complete our product range: these are the more wear-resistant CTCM120 and the tougher CTCM130. Thanks to the application of the latest Dragonskin coating, both grades are high performers and process-secure.

The arrival of these two new carbide grades, which are recommended for turning austenitic, stainless steels and supplement the existing all-round cutting material, coincides with the publication of the new CERATIZIT Up2Date supplementary catalogue. Development was focused on the most frequently used stainless steels V2A (e.g. 1.4301) and V4A (1.4545), with the aim to provide the user with a wider selection of inserts to seamlessly cover every application – from roughing to fine machining.

The complete range for austenitic, stainless steels is characterised not just by the precise coordination of the three grades, but also by the free selection of different chip breakers. Depending on their application, customers can choose from three geometries for negative indexable inserts or two for positive inserts – across all three cutting material grades. As a result, CERATIZIT has seamlessly covered all application ranges for machining austenitic, stainless steels.

The universal PVD-coated carbide grade CTPM125 has proved its worth over many years. It is characterised by a well-balanced ratio between toughness and elevated-temperature hardness and promises to deliver high reliability when machining all stainless steels. The new addition to the range is the CVD-coated, highly wearresistant cutting material grade CTCM120, which allows high cutting speeds with austenitic steels and boasts a smooth cut. It also impresses with its long tool life which in some cases was double that of the competition in benchmark tests. The particularly tough CTCM130 carbide grade, which CERATIZIT recommends for interrupted cuts, for example. If cutting speeds need to be kept low and conditions are unstable, the attributes of CTCM130 helps to increase process security.

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In brief, when turning stainless steel, the choices are: CTCM120 – Highly wear-resistant grade for high cutting values. The high cutting speed and longer service life increases productivity; CTCM120 – Highly wear-resistant grade for high cutting values. The high cutting speed and longer service life increases productivity; and CTCM130 – Tough grade for interrupted cuts and difficult conditions; for maximum process security and reduction of the reject rate. Find out more at https://cuttingtools.ceratizit.com/gb/en.html

THE FUTURE OF DIGITAL PRESSURE MONITORING The GD4200-USB

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November 2020 ENGINEERING UPDATE

SICK’s Deep Learning Brings Simplicity to Complex AI Inspection SICK has launched a suite of Deep Learning apps and services to simplify machine vision quality inspection for challenging components, assemblies, surfaces or food produce, especially those that have previously defied automation and remained distinguishable only by human inspection. SICK Deep Learning radically reduces set-up time and cost by enabling Artificial Intelligence image classification to run directly onboard SICK smart devices. With Deep Learning, programmable SICK devices take decisions automatically using specially-optimised neural networks and run accurate and reliable inspections that would have previously been extremely challenging or simply impossible to achieve in high-speed automated processes across many different industries. Developed with user-simplicity at their core, SICK’s Deep Learning products cater for a wide range of needs and skill levels. The Deep Learning Starter App is designed for easy-set up by entry-level users, while the ready-touse Intelligent Inspection Sensor App provides quick and easy integration with a large set of configurable machine vision tools. More experienced programmers and integrators can also create and customise their own Deep Learning sensor apps using the SICK AppSpace software platform. “With SICK Deep Learning, what formerly took a team of developers half a year to create, can now be achieved for a relatively small investment in a just a few hours,” says Neil Sandhu, SICK’s UK Product Manager for Imaging, Measurement and Ranging. “Machine builders and production teams alike can revisit inspection

processes that have previously been too complex to automate, whether retrofitting systems into existing production environments or developing completely new machines. “Through a simple step-by-step user interface, the SICK neural networks are trained by being shown example images and learn in the same way that humans do to judge a good inspection and what variations can be tolerated. “There is no need for laborious development using a set of rules and algorithms to identify defects, find patterns or edges, which can be particularly time-consuming for items that are more difficult to assess such as baked goods, creases on leather car seats or the grain of timber, for example.” Released as part of the initial launch, SICK Deep Learning is available using the Inspector P 621 2D vision sensor, and the SIM 1012 programmable Sensor Integration Machine generally running with SICK’s Picocam or Midicam streaming cameras. The longer-term roll-out will see SICK Deep Learning enabled across both SICK smart 2D and 3D vision sensors, and SICK data processing gateways. With SICK Deep Learning, the image inference is carried out directly on the device in a short and predictable decision time, without the need for an additional PC, and results are output to the control as sensor values. Because system training is done in the Cloud, there is also no need for separate training hardware or software, saving on implementation time and cost. Users follow the intuitive graphic interface of the SICK dStudio online service to select and train their neural network in a few simple steps: Once

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the SICK devices are set up, users are prompted to gather images of the inspection in realistic production conditions, and then sort them into classes. Using dStudio, the pre-sorted images are uploaded to the Cloud where the image training process is completed by the neural network. The user can then apply further production images to evaluate and adjust the system. When satisfied, the neural network can be downloaded to the Deep Learning-enabled SICK device, and the automated inference process will begin with no further Cloud connection necessary. SICK is offering a free trial for users to assess whether Deep Learning is suitable their application and to ensure a simple and quick start. Once onboard, a Deep Learning support portal is also available to guide users through the process, if necessary. For more information, and to enquire about a free trial, please contact Andrea Hornby on 01727 831121 or email andrea.hornby@sick.co.uk. www.sick.co.uk

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November 2020 ENGINEERING UPDATE

Metal Additive Manufacturing for High Temperature Applications – Material Developments

By Will Dick-Cleland, Process Technology Team, Alloyed

Honeywell Aerospace assess the use of a new high temperature alloy (ABD®900AM) with its in-house laser powder bed fusion (L-PBF) metal AM technologies. The aerospace sector has long been recognised as an early adopter when it comes to cutting-edge technology inventions, and as such it is unsurprising that the use of additive manufacturing (AM) as a production tool is relatively familiar in many of the leading aerospace OEMS and their supply chains. The sector is typically not a mass production industry, but is instead characterized by complex lowvolume manufacture which plays directly to the strengths of metal AM (and specifically the Laser Powder Bed Fusion (L-PBF) process) when compared with traditional metal manufacturing processes. In an area that is highly competitive, where conventional manufacturing processes are costly — especially for metal components produced in relatively low volumes — and with supply chains constantly under pressure to conform to ever more stringent environmental performance restrictions, the aerospace sector needs to become more agile. Metal AM processes, with the ability to manufacture innovative geometrically complex parts in a timely, local, and cost-effective way, have a huge part to play.

AM IN AEROSPACE AM’s disruptive for potential for the aerospace sector is widely acknowledged, holding out the opportunity to break the typical compromise between scale and scope in manufacturing first by reducing the capital expenditure required to achieve economies of scale, and second by increasing the variety of designs that a given amount of capital expenditure can produce. One AM platform can at the same time build a number of complicated parts with variable

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designs, and this means that large centralized factories with assembly lines are not always required, and with AM complexity, production change overs, and customization are cheaper. As AM technologies continue to develop and secure a stronger foothold in production scenarios, there is simultaneous development ongoing across the sector to refine associated parts of the AM ecosystem, with a great deal of emphasis being placed on in-process monitoring for traceability and validation purposes, as well as automated post-processing technologies. A further, vital area of development is materials, particularly metal powders for AM that meet — and exceed — the functionality and performance of existing production materials as well as meeting the requirements of specific applications.

ALLOYS FOR HIGH TEMPERATURE APPLICATIONS It is fair to say that, to date, metal AM processes have not performed well with the highest temperature materials — that is to say, materials for components that operate at the top of the temperature range within jet turbines. In the aerospace sector such applications would include, but are not limited to the critical areas of a turbine engine such as the back-end of the compressor, the combustor, the high and low pressure turbine areas, and the exhaust. All parts in these areas of the engine are exposed to high temperatures and higher levels of oxidation. For such high temperature applications, the aerospace sector typically uses nickel (Ni) alloys such as IN738, IN713 and MarM247. However, these alloys are incompatible with

welding techniques due to their chemistry, as they do not respond well to rapid thermal gradient changes and it is virtually impossible to control the amount of cracking during the weld process. Therefore, these alloys have historically been processed using casting methods where the cooling rates are relatively low. This is the conundrum facing users of metal AM within the aerospace sector looking to capitalize on the

Continue reading on Engineering Update

ENGINEERING PDATE November 2020

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November 2020 ENGINEERING UPDATE

PP C&A helps EYOTO eye global expansion with new outsourcing partnership One of the UK’s leading strategic manufacturing outsourcing specialists is helping EYOTO™ bring new tele-optometry solutions to market. PP Control & Automation, which works with more than 25 of the world’s largest machinery builders, is supporting the Aston University School of Optometry spin-out to build its eMap™ product, the world’s first edge to edge, fully digitised, remotely accessible lens analysis system. The aim with this technology is to give global eye care companies and retailers the opportunity to bring lenses to life at the click of a button, with incredibly advanced surface inspection and fullcolour power maps in just 55 seconds. Volumes are already increasing rapidly with social distancing and Covid-19 and the new Midlands-born partnership will be crucial to helping meet global demand. Garry Myatt, Sales Director at PP C&A, commented: “EYOTO had been let down badly and needed a partner they could trust to pick things up and put in place a full manufacturing line that would deliver substantial quantities within the first six months. “Our ability to have the right skills available in engineering competence, cable preparation and creation, electromechanical build and assembly meant we had the majority of what we needed under one roof and then it was simply case of designing the build process. “One of the key things we did was to invest over £150,000 into a new dedicated Electrostatic Discharge (ESD) and Complex Box Build manufacturing area specifically for eMap™ and similar products going forward.” He continued: “This ensures that the customer requirements and legal compliance to the recognised standards are met and involved the installation of special flooring, benches and test equipment - all grounded to earth to ensure that life of the electronics is protected from potential electrostatic discharge.” PP Control & Automation used its proven product introduction methodology to take on the eMap™ contract in a matter of weeks.

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Learning ‘on the product’ was accelerated, with a joint ‘Design for Manufacturing’ exercise undertaken during the first few machine builds, quickly identifying a number of aesthetic improvements and functional changes behind the enclosure covers.

She continued: “This is just the start. We have a major technology roadmap in place that will involve the regular introduction of new products, especially with Covid-19 increasing the importance and need for remote ophthalmic equipment.

Despite little set-up time, all deadlines have been met on schedule and production improvements have been incorporated to make it easier to manufacture going forward – crucial when scaling up and targeting global retailers who demand product immediately.

“We are confident that PP C&A has the capacity, skills and design for manufacture expertise to play a crucial role in all of these new product introductions.”

The partnership has been built on transparency and trust, with any issues and faults quickly identified and overcome by tapping into the collaborative expertise of engineers and designers at both firms. “Engaging with PP Control & Automation removed a lot of the stress we were under, as we quickly realised it would deliver on the manufacturing side of things, leaving us free to concentrate on what we do best,” explained Claire Mchaddan, Vice President of Product Development at EYOTO. “We went from being in a very difficult position with no manufacturing partner to meeting all of our forward production targets…better still, we now have a dedicated cell to help us scale up eMap™ volumes and embed future technology launches.

EYOTO is already well on the way to launching its next tele-optometry solution, this time bringing one of the eyecare sector’s most traditional pieces of equipment into the 21st century. The first product in the tele-optometry platform will allow an Eye Care Practitioner (ECP) to conduct an eye examination from a remote location – a different room, city, or continent. It eliminates the need for an ECP to be physically present with the patient and this will be followed by a complementary pipeline of remote and mobile technology offers. There is massive interest in this new technology and the first machines will go into production by the end of 2020. For further information, please visit www.ppcanda.com or follow @ppcanda on twitter. More details on EYOTO can be found at www.eyoto.com

Renold Gears OQSx Oil Quality Sensor

The Renold Gears OQSx Oil Quality Sensor is your ideal solution for accurate real time gearbox oil condition monitoring. Easily and quickly installed the OQSx detects all wear and contamination elements to an exceptionally high level and provides an accurate statement of oil condition second by second – in any oil type and in any application, giving you a true 360 degree view of how your oil is performing.

> Accurately reports precise condition of oil in real time > Patented technology > Independently certified for accuracy, sensitivity and reliability > Robust and reliable in the harshest conditions > Easy to install > Configurable for any oil type, in any application

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