Manufacturing Update - January 2022 by jetdigitalmedia

MANUFACTURING PDATE www.manufacturing-update.co.uk

January 2022

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MANUFACTURING UPDATE At the forefront of digital marketing, Manufactuing Update strives to bring its readers the latest in industrial manufacturing, in a format that provides the best usability and ease of use for it’s readers.

January 2022

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Large order received in South Korea

Manufacturing PDATE

Interroll reports a large order for delivery to a South Korean e-commerce company.

Interroll received a large follow-up order for more than 4.8 km of its Modular Conveyor Platform (MCP) and other equipment.

Based on the customer’s specifications, Interroll will deliver a complete conveyor platform that includes Interroll MCP modules, high-performance diverters, belt conveyors and transfers as well as roller conveyors and belt curve spiral lifts. The solution covers a total length of 4.8 km of conveyor technology at one of the customer’s distribution centers in South Korea. The project is scheduled to be completed by the end of June 2022. “The installation will support the further continuous growth of this successful customer,” says Dr. Ben Xia, Interroll Executive Vice President and Head of Operations Asia. “We are proud to continue contributing to the productivity of their distribution centers with our proven material-handling solutions.”

January 2022

Leaders in temperature measurement

Hand Held Instrumentation Heading 3

A selection of hand held instruments for many applications including a large range of digital thermometers, light level meter and a range of great value handheld sensors.

IR Industrial IR Medical Infrared Thermometers Thermometers

Pressure Manometers

Digital Light Meters

Anemometers

Temperature & Wood Moisture Meter Humidity Meter

Grain Moisture Meter

www.labfacility.com Bognor Regis tel: +44 (0)1243 871280

sales@labfacility.com Shefﬁeld tel: +44 (0)1909 569446

Lipstick, Powder and Pick Cosmetics distribution operation sees efficiency boost after automated investment.

In the end it’s about how your bottom line will be impacted. As Intralogistics applications continue to be scrutinised in terms of efficiency: They must work more flexibly, stock a wider range of items within a smaller space and guarantee faster retrieval times. To cope with these demands, Kardex has developed a new generation of automated storage systems, which also offer high order picking performance and represent excellent value for money, while consuming little energy and occupying little space. With customer demand escalating faster than ever before, e-commerce retailers and distributors are turning to more effective ways to maintain/ increase intralogistics processes whilst keeping a keen eye on the bottom line.

Manufacturing PDATE

or the retail industry it’s not about the technology, it’s about rem aining competitive and driving an improved customer service whilst keeping a keen eye on the bottom line. Kardex Remstar is seeing a real requirement in enabling ‘real-time’ optimisation, which is then reflected in an increase in picking accuracy and picking speeds which are increased by 400%. Being competitive and delivering a faster more accurate service at a lower TCO is still the main motivator. Mary Kay is one of the leading companies for direct sales of makeup and skin care and Lesley Cosmetics is the authorised and exclusive distributor for Mary Kay in the Nordics. The company wanted an efficient solution that reduced delivery time and increased picking speed and accuracy. By purchasing a Megamat RS350 they increased picking speeds

January 2022

by 200-300%, reduced picking errors from 1.5% to 0.87% and created a better flow in the warehouse, with a more ergonomic workspace and rotation in staff work tasks. With Kardex Power Pick Global software they now deliver a fast storage and retrieval solution with 3,000 order lines easily picked in a one-day shift.

Kardex is a global industry partner for intralogistics solutions and a leading supplier of automated storage solutions and material handling systems. To learn more contact www.kardex.com or visit our ecommerce insights.

sales@lamonde.com

     

4 Comm ports, inc Ethernet Built-in data logging to microSD Free no-limit programming Slim stackable design Multiple i/o wiring options Starter kit available

www.lamonde.com +44 (0)20 3026 2670

Lamonde Automation Limited Quality Products: Expert Advice

Smart Factory Innovation Hub IONA Pilot Scheme at the National Composites Centre Early in 2021, Insphere launched IONA, a network of sensors for real time monitoring and control of robot processes. Insphere has established a Pilot Programme to introduce IONA to commercial customers by offering them a free trial of the technology at their own site.

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There has been strong interest from companies involved in composites manufacturing, with applications including automated material deposition, robot CNC machining, and edge trimming operations. To ensure a smooth kick off to the commercial Pilot Programme, we sought to run a trial installation in a research setting before the first installation with a customer. Fortuitously, the High Value Manufacturing Catapult has recently launched the Smart Factory Innovation Hub pilot scheme, to offer companies the opportunity to reduce the risk of implementing new digital manufacturing solutions. Insphere was selected to be a participant in the SFIH scheme and

January 2022

used the opportunity to install IONA on a temporary basis in the Automated Preforming Cell at the National Composites Centre (NCC) in Bristol. We set up IONA to track a Kuka robot end effector in real time relative to a fixed cell datum. We ran the robot through a sequence of poses to verify system performance. IONA uses multiple sensors to envelop the robot cell, enabling it to track the robot accurately in real time regardless of robot pose and orientation. The results were excellent, and the install, operation and removal of the system all ran smoothly. The team gained valuable experience integrating the hardware into a complex robot cell. Directly after the SFIH Pilot, Insphere successfully

installed the first commercial pilot of IONA. We are grateful to NCC for the opportunity to access their world-class facilities. A key offering of the HVM Catapult is to accelerate adoption of new technologies and enable UK companies like Insphere to stay at the cutting edge of smart factory implementation. INSPHERE is continuing to Pilot its IONA system, and companies wishing to discuss the possibility of a free onsite trial of IONA can get more information on the product page Find out more about IONA Download the Brochure

Precision comes as standard. Photocells with Industry 4.0 built in

OGD Precision • Distinguish 1mm objects at 300mm • Measure the distance

RANTY AR

years if m pr od

OGD LongRange • Detect and measure over 1500mm range • Even dark objects against a light background Both with M18 thread in stainless steel with IO-Link

www.ifm.com //uk/ogd uk/ogd ifm Telephone (020) 8213 1111

New inductive sensors combine compatibility with configurability

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Inductive proximity sensors in the new IF60xx range from ifm electronic offer the best of both worlds: compatibility with existing installations and additional functionality that provides important benefits in new applications.

To ensure backwards compatibility, the new sensors provide both analogue and switching outputs, while for maximum versatility and to allow parameterisation, they incorporate an IO-Link interface.

In all applications, data from the sensors can be accessed via IO-Link, which ensures freedom from errors caused by conversion losses and electrical interference.

When used as standard devices, IF60xx sensors are drop-in replacements for conventional types. They can also be used for highly accurate distance sensing over a restricted operating range which can be set by the user via the IOLink interface. This advanced feature is particularly useful, for example, when monitoring machinery for early signs of wear that lead to small positional changes.

To ensure suitability for the widest possible range of applications, the new IF60xx inductive proximity sensors are available in 17 versions. These include threaded cylindrical types with diameters of M12 to M30 and rectangular units measuring 40 x 40 x 54 mm. The range includes flush and non-flush types with 4 to 20 mA and 0 to 10 V analogue outputs. All models have a programmable switching output as well as an IO-Link interface. Sensing range is

January 2022

from 0.2 mm for the smallest units to 35 mm for the largest. Featuring robust construction to ensure long life even in demanding operating environments, all IF60xx sensors have an ingress protection rating of IP65 or better, as well as extended operating temperature ranges. Available accessories include angled mounting brackets for cylindrical models and a single-port IO-Link master that allows the sensors to be parameterised via a USB connection to a standard PC. www.ifm.com/gb/en/shared/productnews/2021/hmi/inductive-sensorswith-analogue-output-and-io-link

Tel: 01296 611660 Email: rk@pmgb.co.uk www.phoenix-mecano.co.uk 26 Faraday Road, Aylesbury Buckinghamshire HP19 8RU

Powering logistics digitalisation Specialist battery manufacturer releases whitepaper exploring role of batteries in the digitalisation of logistics

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In light of the high-profile challenges faced in supply chains since March 2020, there is a growing need for digitalisation and greater automation in logistics, intralogistics and warehousing. Reliable power is critical in this, but it is something that Ultralife Corporation, a global manufacturer of batteries for many and varied industrial applications, argues is often overlooked. The company has recently produced a whitepaper exploring the digitalisation trend in logistics, which highlights the battery requirements of popular modern logistics technologies. The whitepaper is available to download from Ultralife’s website. Interest in logistics digitalisation has grown significantly following the COVID-19 pandemic, with labour shortages, elevated demand and component shortages putting strain on operations. Among the principal technologies gaining traction are intralogistics pick-and-place robotics, automated guided vehicles (AGVs) in warehouses and asset tracking tags. Batteries and uninterruptible power supplies (UPSs) are essential in modern logistics devices. However, the requirements of these components are constantly evolving, which engineers must be aware of to ensure reliable and consistent performance. Ultralife’s

January 2022

whitepaper aims to demystify the requirements of batteries for logistics applications, outlining the most beneficial technical specifications and chemistries for each. “New and advancing technologies are proving invaluable in helping the global logistics industry to overcome demand pressures,” explained Robert Brown, marketing executive at Ultralife Corporation. “These technologies are designed to improve efficiency and effectiveness, but this can only be achieved with a reliable source of power. Unfortunately, the evolving state of technology means that the battery requirements continue to change, so many design engineers may not be aware of the best characteristics. “In the whitepaper, Ultralife explores the context behind logistics digitalisation — why it is happening, what challenges are being encountered and how that is affecting robot and device design. This background ties directly into the performance requirements of applications, such as RFID asset tagging, and in turn the battery properties that are best suited.” The whitepaper also references the commercial off-the-shelf (COTS) battery ranges that have been developed by Ultralife Corporation to exceed

the standard requirements of many robotics and devices. The ranges of primary and secondary batteries have been developed with the ideal energy densities, discharge profiles and mechanical properties to provide reliable power in challenging logistics environments. “Our whitepaper highlights some of the COTS ranges of batteries that Ultralife has developed to give design engineers a strong basis to work from,” continued Brown. “However, complex applications will require batteries that are tailored to offer more unique characteristics. For example, an application may need a battery with an irregular footprint, or one that can operate at extremes of temperature. “Ultralife has worked with engineers globally to develop bespoke battery packs and chargers that meet requirements that might not be achievable with a COTS product. This whitepaper highlights examples of applications where bespoke or off-theshelf power might be selected.” Design, automation and maintenance engineers that are involved in the logistics, intralogistics or warehousing sectors can download the whitepaper from the Ultralife Corporation website.

The new Interroll Split-Tray Sorter Fast, flexible sortation for everyone Interroll introduces the new Split-Tray Sorter: the perfect solution for small and mid-sized items. Efficiency and low maintenance make this new sorter attractive for those looking for lower operating costs and quicker return on investment. It is an ideal solution for the 3PL , E-Commerce, Fashion and CEP industries. Easy to install and reliable with its proven mechanical components & integrated control solution Lightweight and energy-efficient - with a single motor every 40 meters Compact but dense footprint with plenty of destinations Extremely quiet with only <70 dB(A) noise levels

Interroll Limited Unit 1a Orion Way Kettering, Northants NN15 6NL Tel. +44 / 15 36 31 27 70 Email: gb.sales@interroll.com

interroll.com

Engaging employees in sustainable manufacturing Turn off the aircon, limit printing, separate waste — these are all good tips for office workers, but what about the factory floor? Resources on how to engage employees in green initiatives tend to focus on white collar jobs, but engaging the production departments is just as important. Here Neil Ballinger, head of EMEA at automation parts supplier EU Automation, shares some tips.

he world’s eyes are turned to COP26, the 26th UN Climate Change Conference, which this year was hosted in Glasgow. Aim of the conference is to accelerate the implementation of strategies that will help the world reach the ambitious goals of the Paris Agreement, including the achievement of net-zero by 2050. While the majority of consumers are already adopting a more sustainable lifestyle, manufacturers must do their

part to ensure that productivity targets are met without worsening the already concerning climate emergency. To do that, green initiatives must be implemented company-wide, without silos and divisions between teams and departments. It is paramount that everyone is board and fully committed to a sustainable agenda, regardless of their job title or level of seniority. So, what can manufacturers do to engage employees on the factory floor in their green initiatives?

A clear plan It’s hard to be motivated if we don’t understand the value of what we’re doing. That’s why, to get employees on board, manufacturers must ensure that they are aware of the sustainability targets that the company is striving to achieve. For example, if managers decide to fit all the factory’s motors with variable speed drives (VSDs) and soft starters to reduce energy consumption, the implementation and maintenance of these devices can create extra work for employees. However, if employees know that the company is aiming to reduce its energy consumption by 20 per cent and that VSDs and soft starters heavily contribute to this target, they will understand the bigger picture and feel part of the collective effort to improve the factory’s carbon footprint. Sharing sustainability targets is also important in terms of retaining and attracting employees. Millennials and Gen-Z candidates are becoming increasingly aware of the climate emergency and want to work for companies that have their futures at heart. Data training

Manufacturing PDATE

Training your employees to understand the value of big data — and why the company is gathering them — is a great contribution to your sustainability agenda. By uncovering patterns and extracting valuable information from raw data, employees on the factory floor can contribute to making decisions that reduce the factory’s carbon footprint. Read more click here

January 2022

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

Manufacturing Company METAL LS – Turns to Delta for Machine Vision Robotic Solution Manufacturing Company METAL LS – Turns to Delta for Machine Vision Robotic Solution

Manufacturing PDATE

METAL LS, the Bulgarian manufacturer of door locking systems, door and window handles and building hardware, started planning the new automated assembly of door locks in 2019. The robotic systems that the company already used for other applications were too large for the planned production site, so the new solutions needed to be as compact and precise as possible, in addition to being state of the art. Door and security locks are precision parts with standard dimensions and components stipulated in DIN standards. Therefore, quality and precision were especially important deciding factors for METAL LS. In addition, the robots needed to achieve high productivity, assembling between 10 and 14 locks per minute. The company also needed a high level of flexibility from the solution and the possibility of retooling so that they could reuse the same system to produce different types of lock in the future. Following a comparison of various manufacturers and products, METAL LS opted for a robot system from Delta. It was the only manufacturer to offer a complete solution including programmable logic controllers (PLC), a human-machine interface (HMI), servo systems and robotic arms with Machine Vision. For implementation of this project, METAL LS and Delta collaborated to develop a custom workstation for assembly of the mechanical door lock components. The main part of the system comprises a rotation table,

January 2022

on which seven six-axis DRV90L7 articulated robots are installed. The robots are capable of extremely precise, quick movements and feature a hollow wrist that allows them to be easily combined with the correct tool for each production step. The DOP-115MX HMI is used to visualise all processes and enables the user to select various receipts for different locks via a touch screen. It also displays system information and alerts or alarms. The AS300-series (AS324MT-A) PLC monitors the assembly line, controls the ASDA B2 servo drive and communicates with the servo drive on the rotating platform. Two DMV2000 Machine Vision image processing systems equipped with cameras are installed to localise components on the conveyor and send accurate signals to the robot allowing it to pick up and assemble the parts. The AC servo system comprising ASDA-A2 and ASDA-B2 drives as well as ECMA motors ensure that the robot arms are positioned precisely and that high productivity can be maintained. A few adjustments to the parameter settings were sufficient to quickly overcome initial communication problems between the PLC, robot and the Machine Vision system. The careful preparation and system configuration carried out by the Delta team also ensured that all of the Delta industrial automation (IA) products were soon integrated into the production processes. All stakeholders are extremely happy with the progress made in the project.

Alongside the quality of the compact robotic system, METAL LS is particularly happy with the sound advice and customer service it has received from Delta. With many different production sites and teams throughout Europe, Delta is able to provide all of its customers with the support they need, when they need it. The project was kicked off when the Field Application Engineering (FAE) team arrived on site to support construction of the assembly system together with Mechatronics, Delta’s Bulgarian partner. The assembly system is still undergoing tests, but initial results are already showing improved productivity and performance. Jason Wu, Field Application Engineer at Industrial Automation Business Group, Delta Electronics EMEA region, is very happy with the successful collaboration: “With our broad portfolio of IA products, we are able to offer our customers powerful full-range solutions from a single source. Our teams of experts will support clients in implementing the specific project requirements, no matter whether the clients are in the food, drinks, packaging, electronics or automotive industry.”

Fakuma robot release pulls in the crowds Sumitomo (SHI) Demag’s launch of SAM-C robots instantly attracts positive customer feedback and sales After the world premiere of the new SAM-C robots at Fakuma, interest in the first in-house automation solution from Sumitomo (SHI) Demag Plastics Machinery GmbH, Schwaig (SDG), continues unabated. The two handle & place systems were the real crowd pleasers on the company’s Fakuma booth, attracting a great deal of attention affirms Jürgen Schulze, Director Automation SDG. He explains: “We continue to receive extremely positive feedback and sales, with customers assured about the technical and aligned processing benefits.”

Manufacturing PDATE

As part of the inaugural unveiling, two of the new scalable robots from the SAM series were showcased at the trade fair in Friedrichshafen. The SAM-C10 integrated on an IntElect2 130/520-450 demonstrated the value and flexibility of deploying robotics on an LSR application. In another groundbreaking automotive IMD showcase featuring an IntElect2 220/660-1100, height optimisation was accomplished using a compact telescopic axis. “The SAM-C series focuses on addressing standard injection moulding applications with moderate complexity, yet offers the option to adapt our handle&place solutions to market requirements as required,” reports Schulze. “Designed specifically to optimise production on a Sumitomo (SHI) Demag machine, our proprietary SAM-C robots can significantly reduce the overall footprint of a self-contained cell, while simultaneously improving user-friendliness of the machine controls.” Redefining the SDG automation platform, SAM stands for “Sumitomo (SHI) Demag. Automation. Machine.”

January 2022

and comprises both the robotics components as well as the company’s complementary strategic and pragmatic support. The debut Cartesian “C” kinematics are currently available in four payload sizes. The company anticipates rolling out additional robot kinematics and adapted options as early as K-2022 and further expanding the SAM platform within this short timeframe. “With our SAM-C robots, we offer our customers an attractive price to performance ratio, enabling plastic manufacturers to deploy CE conforming automation solutions into production lines faster and more intelligently to help address current labour and skills challenges”, states the Automation Director. Responding to increasing demands from customers for flexible automated solutions that requires minimal human intervention and low maintenance costs, Automation SDG has helped to fill a critical gap in standardised production. “By minimising the footprint, manufacturers are able to increase their machine estate. This in turn enables them to boost their capacity, repeatable precision, component quality and efficiency and consequently reduce defects and waste.”

Having used robot technology to automate the company’s injection moulding machines since the middle of the 1990s, Schulze regards the launch of the Automation SDG platform as a natural extension of its processing expertise. He confirms: “Applications like the standard SDR Sepro robots used since 2009 will continue to form an essential part of our new automation platform. However, the addition of our own-branded SAM robots reasserts our strategic vision and ambitions – optimised system technology engineered specifically for SDG injection moulding machines.”

ENGINEERING PDATE

DLM Load Cells for Catena’s Cleanroom Client

Manufacturing PDATE

Dynamic Load Monitoring (UK) Ltd. (DLM), of Southampton, UK has delivered two load cells to Catena Inspection & Engineering Services Ltd. for use at a nuclear cleanroom site where propulsion systems are developed for the UK’s Ministry of Defence (MOD). The load cells, of 500kg and 1,500kg capacity, were the latest products to be delivered to the undisclosed location by Catena, of Nottinghamshire, UK, which constantly provides equipment and services to the facility, principally related to proof load testing and lifting applications. Stainless steel shackles with custom engraved asset numbers were also part of this project.

Hickling said: “Using telemetry load links and compression load cells allows us to move away from using loose weights for proof load testing when used with a hydraulic set-up; we can apply smaller, incremental loads in a more controlled manner. We can also use a load link in the line to check lifts are equally distributed and not exerting excessive unknown loads.”

Tyler Hickling, lifting and fabrication sales at Catena, explained that the order initially started with a request for load monitoring technology that could, firstly, measure low weights and, secondly, do so to an extreme degree of accuracy. DLM is a renowned manufacturer of equipment that can meet such requirements, while giving the user the ability to monitor data wirelessly, which is a further requirement of such end user environments.

These Catena-branded load cells were from DLM’s TL-3.0 family, a thirdgeneration of its popular telemetry tensile link line. The lightweight wireless tension measuring unit combines a high level of performance with a robust design for harsh environments. They are made from aerospace grade aluminium and offer a range up to 800m (over 2,600 ft.) and a huge battery life of 700 hours. Hickling pointed out that the TL-3.0 can be paired with an unlimited number of displays to one load cell or 12 load cells to one handheld display.

Hickling added: “Given the nature of the facility, there wasn’t a great deal of information provided, beyond what we needed to know to source the best possible solution, which turned out to be a pair of custom telemetry tensile links. I was only privy to the maximum weight lifted and the resolution required. They will be used separately, repeatedly, for specific lifts where the weight needs to be monitored closely.” As well as utilising load cells for proof load testing contracts, Catena is increasingly providing a range of force measurement technologies for a variety of industrial applications. DLM, a specialist in the design, manufacture, repair and calibration of load cells and load monitoring equipment, is its go-to manufacturer for product and expertise.

January 2022

Martin Halford, managing director at DLM, said: “We have worked successfully with Catena for many years now, especially on MOD-type contracts where off-the-shelf solutions are not suitable and something customised is required to meet the high defence standards. In this instance, we drew on our extensive experience within the marine and offshore industry to design a stainless steel version of our popular TL-3.0 telemetry load link, suitable for the maritime defence industry. It is fantastic to be able to play a small part in supporting the UK government in keeping our waters safe, and this type of work really fits in nicely with our focus on the offshore and marine sector, which is reflective in the products and services we offer.”

ENGINEERING PDATE

January 2022

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