Automation Control Engineering - Issue 23 2019

ACE Automation

Control

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Engineering

Issue 23 2019

Any Time | Any Place | Any Weather

2000 Weatherproof VSD units up to 1.5MW

Quantum’s Unique Drive Rental Solution

The World’s First Wireless Valve Manifold System

Usable even in welding environments

High speed connection From power supply ON to start of communication, minimum

PLC

0.25∗s

∗ For slave

High speed response

Industrial Ethernet

Signal response time: 0.005 s

Max. 1280 inputs/1280 outputs

Communication possible in a 10 m radius

- up to 127 slave units is possible.

Master (Master station)

Wireless Slave Wireless Slave

Noise resistance

The system uses a frequency band which is not easily affected by noise generated by equipment in a factory.

Frequency hopping (changes frequency every 0.005 s) prevents interference with other wireless devices.

Interference with other wireless devices is prevented by suppressing wireless power to 1 mW or less.

kHz 10

100

MHz 1

10

GHz 100

1

10

AC welding Site noise DC welding Motor driver Electromagnetic heater, etc.

Wireless LAN Wireless RFID devices Bluetooth SMC Wireless System

For more information on SMC in the UK contact: 0845 121 5122 or check-out our website on: www.smcpneumatics.co.uk

SMC - more than just pneumatics Follow us on

www.smcpneumatics.co.uk

Contents Features Sick

22

SICK’s NAV-LOC Localisation Sets AGVs Free from Reflectors

24-26

Schunk High-performance assembly systems for the electronics industry

30-31

Festo Festo pneumatic robotics get to grips with artificial intelligence

34-35

Contrinex Contrinex Inductives ‘Beat the Heat’ on PCB Reflow Ovens

36

Lenze Lenze celebrates 50 years of automation innovation in the UK

22

38

Rainshaw Renishaw sponsors STEMworks K’NEX workshops of Engineers

24

30

34

Editor in Chief

Sales Director

Studio Designer

Antony Holter antony@aceindustrymag.co.uk 01304 806039

Alexander Arnold alexander@aceindustrymag.co.uk 01227 392585

James Sayer james@mhmagazine.co.uk 01304 806039

Editor

Sales Manager

Accounts Dept

Julie Fox editor@aceindustrymag.com 01304 806039

David Allerton david@aceindustrymag.com 01304 806039

Alison Holmes accounts@aceindustrymag.co.uk 01227 392561

Publishing Director

Business Manager

Martin Holmes martin@mhmagazine.co.uk 01304 806039

Josh Holmes josh@mhmagazine.co.uk 01304 806039

Published by: MH Media Global Ltd Office 15, Second Floor, Innovation House, Discovery Park, Ramsgate Road, Sandwich, Kent, Ct13 9FD Tel: 01304 806 039 © MH Media Global

Cover image courtesy of: Quantum Controls Every effort is made to ensure the accuracy and reliability of material published in ACE however, the publishers accept no responsibility for the claims or opinions made by advertisers, manufacturers or contributors. No part of this publication may be reproduced or transmitted in any form or by any means, mechanical, electronic (including photocopying) or stored in any information retrieval system without the prior consent of the publisher.

3

LaserMaster Ltd is a company based near Redruth in the South West of sunny Cornwall. Although we are based near the utmost southerly point of the UK, we serve our customers worldwide.

In the past 18 months we have faced a rapid growth of business increasing our staffing levels from 18 to 27. With this increase there has also been a vast amount of reinvestment back into the company with regards to more efficient and up to date machinery to ensure that our processes are as smooth and refined as possible.

At LaserMaster we have the capabilities for Laser cutting, folding/bending and fabricating sheet-metal. Although we do not have our own product, we provide a service to many different sectors from Agricultural, Automotive, Marine, Interior design, the Arts, including fine jewellery and much much more! As well as providing large orders

4

to well established companies we also provide items for customers own homes and projects from simple washers to prototypes and large batch orders. We have an online job shop, on our website, to make ordering easier for smaller components.

One customer that we have been working alongside for a number of years is Muck Truck. We have been supplying them with many sheet metal components for their Muck Truck powered wheel barrows for many years. Firstly laser cutting the flat plates, then forming the plates using one of our press brakes to put in the necessary folds and bends. After that it is welded by one of our fully qualified welders. Pins that are needed, to make the bucket tip and axles, are made on our CNC lathes.

Once fully constructed they are collected for painting and go onto the warehouse to be fully assembled and distributed.

www.mucktruck.co.uk www.lasermaster.co.uk

Quantum’s Unique Rental Drive Solution

Drive Rental Company of the Year

Any Time | Any Place | Any Weather Drive breakdown is a disastrous situation - lost production costs on average £12,000 per hour. That means you need a back up plan.

Thankfully Quantum Controls has the largest stock of Variable Speed Drives for rental in Europe - our team of engineers are available 24/7, 365 days a year to get you back up and running quickly and efficiently if you suffer a drive breakdown.

• Weatherproof Enclosures can be kept indoor or outdoor • 2000+ drives ex stock • Up to 1.5MW, 400v, 690v and High Voltage options • National Depots providing local stock & Engineer support • 24/7 Delivery, Installation and Commissioning • ABB & Schneider Rental Drives Available • Enclosure Specification c/w Door Isolator, Local Controls, EMC Compliant, Emergency Stop, Door Mounted Keypad, Ultrasonic Level Controller, Float Switch Connection, Forward/Reverse Switch, Thermistor Relay Connection, Easy Colour coded Control Connection Rail

IN THE EVENT OF A DRIVE BREAKDOWN CALL OUR 24-HOUR RENTAL DRIVE EMERGENCY HOTLINE

0330 9000 247 Scan this code with your smartphone to get your free 75 page VSD guide.

MVK FUSION …is an opportunity to standardize modular processes, opening the door to a one-module strategy

IO-Link IO-Link button button systems systems

IO-Link IO-Link inductive inductive couplers couplers

IO-Link IO-Link

03

The The PROFINET/PROFIsafe PROFINET/PROFIsafe module module unites unites three three basic basic functions functions of of installation installation technology: technology: 01 01 Standard Standard digital digital sensors sensors and and actuators actuators 02 02 Safety Safety digital digital sensors sensors and and actuators actuators 03 03 IO-Link IO-Link

Safety valves

02 Safety Safety

01

Standard Standard IO IO

MVK MVK Fusion Fusion makes makes complex complex configurations configurations easier easier because because they they can can be be done done entirely entirely by by the the engineering engineering tool tool in in the the safety safety control control system. system. Software Software developers developers and and electrical electrical engineers engineers no no longer longer need need in-depth in-depth knowledge knowledge of of other other manufacturers’ manufacturers’ tools tools and and manuals. manuals.

MVK MVK Fusion Fusion makes makes itit possible possible to to have have fewer fewer fieldbus fieldbus modules modules per per unit. unit. Some Some applications applications might might only only require require aa single single module. module. This This opens opens up up new new opportunities opportunities for for many many automation automation applications! applications!

What What makes makes the the MVK MVK Fusion Fusion fieldfieldbus bus module module unique unique is is its its variety. variety.

ItIt combines combines three three basic basic functions: functions: standard standard digital digital sensors sensors and and actuators, actuators, safety safety digital digital sensors sensors and and actuators actuators and and IO-Link.

IO-Link.

•• The The two two standard standard digital digital ports ports can can be be configconfigured ured as as inputs inputs or or outputs outputs –– they they are are customizcustomizable able for for each each application. application.

•• The The four four safety safety ports ports ensure ensure that that almost almost all all digital digital safety safety requirements requirements are are integrated integrated into into the the installation. installation.

•• The The two two IO-Link IO-Link ports ports offer offer aa wide wide range range of of functions: functions: they they integrate integrate smart smart devices devices into into the the fieldbus fieldbus system system and and they they also also enable enable the the syssystem tem to to be be expanded expanded cost-effectively cost-effectively via via IO-Link IO-Link hubs. hubs.

MVK MVK Fusion Fusion simplifies simplifies installation installation by by minimizing minimizing the the number number of of modules modules required. required.

Safety Safety door door systems systems

IO-Link hubs IO-Link IO-Link distance distance sensors sensors

IO-Link IO-Link pressure pressure sensors sensors

This This combination combination is is new new and and innovative. innovative. ItIt enables enables unique unique and and groundbreaking groundbreaking automation automation concepts concepts to to be be realized. realized. Installation Installation becomes becomes simpler simpler and and faster. faster.

One One Module Module with with Extreme Extreme Range Range

IO-Link valve islands

Flexibility Flexibility within within Safety Safety Applications Applications MVK MVK Fusion Fusion integrates integrates all all safety safety aspects aspects into into one one module: module: •• Safety Safety sensors sensors signals signals are are transmitted transmitted over over the the three three safe safe input input ports, ports, each each of of which which have have two two channels. channels. Emergency Emergency stop stop buttons, buttons, light light curcurtains, tains, two-handed two-handed units, units, safety safety doors, doors, etc. etc. can can be be qualified qualified up up to to Performance Performance Level Level e. e.

•• The The safety safety output output port port has has two two safe safe outputs outputs that that can can be be configured configured according according to to the the apapplication plication (PP, (PP, PM PM or or PPM PPM switching). switching). You You can can integrate integrate aa wide wide variety variety of of actuator actuator types types like like double double valves valves and and valve valve islands islands that that still still qualify qualify up up to to Performance Performance Level Level e. e.

•• AA special special Class Class BB IO-Link IO-Link port port ensures ensures that that IOIOLink Link devices devices like like valve valve islands islands and and hubs hubs can can be be easily easily and and safely safely switched-off switched-off complying complying with with safety safety standards standards up up to to Performance Performance Level Level d. d.

MVK MVK Fusion Fusion lets lets you you achieve achieve high high safety safety standards, standards, protecting protecting both both man man and and machine. machine.

Electromechanical Electromechanical safety safety switches switches IO-Link IO-Link transponder transponder systems systems Two-handed Two-handed devices devices

Safety Safety Configuration Configuration within within aa Mouse Mouse Click Click MVK MVK Fusion Fusion makes makes configuring configuring safety safety sensors sensors and and actuators actuators exextremely tremely easy: easy: select select the the safety safety function function in in the the safety safety control control system system engineering engineering tool, tool, and and within within aa few few mouse mouse clicks clicks configuration configuration is is done. done.

The The users users –– usually usually the the software software developer developer or or the the electrical electrical engineer engineer –– do do not not require require any any special special know knowledge ledge to to configure configure the the module. module. The The MVK MVK Fusion Fusion module module eliminates eliminates the the extra extra verification verification work work step step (CRC (CRC calculation) calculation) and and doesn’t doesn’t require require additional additional manufacturer-specific manufacturer-specific software. software. This This speeds speeds up up the the process process because because itit prevents prevents entry entry of of incorrect incorrect data. data.

High High Performance Performance MVK MVK Fusion Fusion is is excellent excellent for for high high power power applications applications when when reliability reliability cannot cannot be be compromised. compromised. The The module module is is one one hundred hundred percent percent compatible compatible with with PROFINET PROFINET solutions. solutions. MVK MVK Fusion Fusion is is suitable suitable for for Conformance Conformance Class Class CC (IRT), (IRT), Shared Shared Device Device and and Netload Netload Class Class III III applications. applications.

Emergency stops

Smart IO-Link sensors

Double Double safety safety valves valves Key Key and and selector selector switches switches Foot Foot switches switches

IO-Link IO-Link analog analog converters converters

DC DC motors motors Solenoid Solenoid interlocks interlocks

Door switch IO-Link IO-Link inductive inductive sensors sensors

Valves Safety Safety command command devices devices

Only One Module per Mechatronic Component With our fieldbus module MVK Fusion, we’re advancing the standardization of modular processes for the users. This makes it possible to realize new and groundbreaking concepts for the automation industry. Installations will become easier and quicker. Hopefully, only one module per component will be needed.

IO-Link IO-Link temperature temperature sensors sensors Enabling Enabling switches switches

Michael Michael Greiner, Greiner, Senior Senior Product Product Manager Manager

IO-Link IO-Link grippers grippers

Laser Laser scanners scanners

Digital sensors

Light curtains Control Control solenoid solenoid for for guard guard locking locking

A Wide Range of Uses and Comprehensive Diagnostics Rugged, Rugged, fully-molded fully-molded metal metal housing housing made made for for aa wide wide range range of of uses uses –– like like extreme extreme welding welding applications. applications.

The The safety safety address address is is set set directly directly on on the the module module via via rotary rotary switch switch –– MVK MVK Fusion Fusion can can also also be be restorestored red to to its its default default setting setting via via the the address address 000.

000.

MVK Fusion Fusion saves saves error error information information with with aa time time MVK stamp on on an an integrated integrated web web server, server, even even in in the the stamp event of of power power failure, failure, helping helping you you identify identify event errors and and reduce reduce downtimes. downtimes. errors

Unique to to the the market, market, the the module module can can be be used used Unique in at at very very high high altitudes: altitudes: up up to to 3,000 3,000 meters meters in (10,000 feet). feet).

(10,000

The module module functions functions at at high high outdoor outdoor temperatemperaThe tures (up (up to to 60° 60° C) C) in in combination combination with with high high curcurtures rents (up (up to to 16 16 A).

A). We We offer offer an an optional optional heat heat sink sink rents is for for these these extreme extreme conditions, conditions, which which extends extends is the life life of of the the module. module. the

Every single single channel channel is is monitored monitored for for problems problems Every like overloads, overloads, sensor sensor shorts shorts or or short short circuits circuits like the comprehensive comprehensive diagnostics diagnostics detect detect errors errors –– the quickly, so so they they can can be be analyzed analyzed and and fixed. fixed. quickly,

THAT’S COOL! When it’s hot outside (temperatures up to 60° C) or if the module is under high current (up to 16 A), it’s possible to mount the MVK Fusion module onto a heat sink so that the module will continue running under extreme conditions.

CAPM347 high speed 24VDC embedded printer for retail, vending and kiosk applications

B

VM, official distributor for Seiko Instruments’ printer mechanisms and portable printers for the UK and Ireland, has announced the CAPM347, a 24VDC highspeed rugged thermal print and cut unit optimised for use in ticketing and vending machines, receipt printing, lottery terminals, ATMs or other industrial, retail or medical applications. Two versions are available: for Point-of-Sale receipt printers and similar uses, the “Easy Load” version with a removable thermal head that enables simple drop-in roll replacement.

The “Auto Load” model has a hinged thermal head assembly for embedded designs such as kiosk and ticketing machines and an optical sensor that automatically initiates replacement paper loading. Both versions offer print speeds of 300mm/s on standard 58, 60, 80 and 83mm wide paper up to 90 micron thickness; the thick paper model prints at 280mm/s on paper up to 150 micron thick.

The integral cutter has a hardened V-shaped blade specified to two million operations of either complete or partial cuts that leave a small centre point attached between receipts.

The units feature an all-metal body, powerful motors and wide gears throughout to ensure reliability. They are designed to output more than 1.3 million x 150mm receipts with up to 640 dots/line. 16 x 8, 16 x 16, 24 x 12 and 24 x 24 characters are supported, resolution is 8 dots/mm.

The communication interface with the host machine is via parallel, serial or USB with Seiko’s interface boards or control chips; Windows and Linux drivers are available.

Web: www.bvm.co.uk/CAPM347.html Email: info@bvmltd.co.uk

IP66/IP69K-rated Stainless Steel Panel PC for Food, Chemical, Pharmaceutical and Outdoor Applications

B

VM announces the latest addition to the GOT800 family of stainless steel touch panel computers. With the addition of this 17” unit there are five models in the range covering sizes from 10” to 17”. The GOT817-511 is a 17” unit and has a full IP66/IP69Krated water, dust and corrosion-proof enclosure which guarantees this all-in-one industrial panel PC can be deployed in harsh operating conditions. It supports a wide operating temperature range from -20°C to +50°C and can withstand vibration up to 1G. The GOT817L-511 is an ideal HMI for use in food and chemical factories, pharmaceutical industry and other applications where hose down cleaning is required.

It is equally at home in heavy-duty outdoor applications.

The GOT817L-511 supports the Intel® Core™ i5-7300U KabyLake CPU. This industrial panel PC has a 17-inch SXGA TFT flat bezel LCD display with LED backlight. It comes with the choice of a projected capacitive touchscreen or 5-wire resistive touchscreen. The 316 stainless steel enclosure enables it to be used in critical environments that require a high level of resistance to corrosion. In addition, the 17-inch rugged panel computer comes with IP66 and IP69K rated enclosures, five IP66-rated M12-type I/O connectors and wide range power input of 9 to 36V DC, ensuring reliable operation.

www.bvm.co.uk/GOT.html

|

info@bvmltd.co.uk

Rack-mount PCs for long term reliability

B

VM offers a range of industrial 19” Rack Mount PC systems designed and tested for applications in harsh and challenging environments.

The carefully selected components that make up our Rack Mount PCs utilise industrial grade components that are designed to run 24/7 in a wide range of temperatures and environments and offer long-term supply availability of up to 7 years avoiding expensive re-design mid project. Available in 1,2 or 4U our industrial systems are built to perform and offer the latest CPU and storage options.

A comprehensive design and customisation service is available including operating system support. All units are CE certified, tested and ready to run.

bvm.co.uk/rack-mount.html info@bvmltd.co.uk

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OEM Design and Manufacturing Service

Embedded Computer Design, Integration and Manufacturing Services

"A successful product not only requires a competent functional design...... ....it also needs to be designed for manufacture."

BVM have many years of experience in providing off the shelf and bespoke industrial PC systems. Whatever your application, talking your ideas through with our experienced engineering team might just provide that different angle you’ve been searching for to see your project over the line.

Concept multiple cameras

Design Ethernet and 4g wireless on ti connec

Manufacture

Why not call us today....

Call: 01489 780144 Web: www.bvm.co.uk Email: info@bvmltd.co.uk

f

Weatherproo chassis

Polygonal clamping delivers results in turning applications

LaserMaster Ltd is a company based near Redruth in the South West of sunny Cornwall. Although we are based near the utmost southerly point of the UK, we serve our customers worldwide.

In the past 18 months we have faced a rapid growth of business increasing our staffing levels from 18 to 27. With this increase there has also been a vast amount of reinvestment back into the company with regards to more efficient and up to date machinery to ensure that our processes are as smooth and refined as possible.

At LaserMaster we have the capabilities for Laser cutting, folding/bending and fabricating sheet-metal. Although we do not have our own product, we provide a service to many different sectors from Agricultural, Automotive, Marine, Interior design, the Arts, including fine jewellery and much much more! As well as providing large orders

10

to well established companies we also provide items for customers own homes and projects from simple washers to prototypes and large batch orders. We have an online job shop, on our website, to make ordering easier for smaller components.

F

lathes are constantly growing. At or years, customers have the same time, customers are facing been using TRIBOS polygonal One customer that we have been considerable pressure to lower prices, clamping technology to achieve working alongside for a number of particularly for high-volume parts. excellent results in applications such years is Muck have been For Zisterer Präzisionsteile GmbH in as micro cuttingTruck. and toWe lower tool supplying them with sheet Villingen-Schwenningen, SCHUNK's costs.

With TRIBOS ER, many SCHUNK is metal components for their Muck decision to standardise the TRIBOS ER now bringing the patented technology Truck powered barrows for came just in time. The manufacturer of polygonal toolwheel clamping to sliding and fixed headstock and rotary many years.

Firstly lathes laser cutting the of complex hydraulic components was regularly experiencing process transfer machines.

Pilot users, as flat plates, then forming thesuch plates Zisterer Präzisionsdrehteile GmbH in using one of our press brakes to put in disruptions due to tool breakages Villingen-Schwenningen, are as tools with a long overhang and the necessary folds andGermany, bends. After cutting diameters of 2mm could not impressed. The company has reduced that it is welded by one of our fully withstand the vibrations that occur. machining time in demanding milling qualified welders. Pins that are applications by one third while signifi- Halving the speed was the only way to needed, to make the bucket tip and ensure the process stability required cantly improving surface quality. axles, are made on our CNC lathes. for high-volume production. Instead of Once are fullygood constructed theySCHUNK are There reasons why 12,000 to 15,000 RPM, the company collected for painting and go of onto the had to accept speeds of 6,000 RPM is now unlocking the potential www.mucktruck.co.uk warehouse to be fully assembled polygonal clamping technology for and and the resulting reduction in cycle www.lasermaster.co.uk lathe chuck technology. For one, the time. distributed. requirements for sliding headstock

Laser Cut. Fold. Fabricate.

CHOOSE LASERMASTER FOR YOUR LASER CUTTING NEEDS We also have capabilities to: · Use state of the art scanner for reverse engineering · Laser cut on one of our Fibre Optic Bystronic Lasers. · · · ·

Fold/bend on one of our Press Brakes Weld/fabricate CNC milling and machining Linish/deburr

· Use our Sharmic rumbler to give a smoother finish We stock most commonly used Stainless Steel, Mild Steel, Aluminium, Copper and Brass in varying thicknesses. Please contact us with your requirements.

sales@lasermaster.co.uk 01209 821902 11

Industry 4.0 Will Have the Impact of the First Industrial Revolution, Squared

I

f you're wondering how Industry 4.0 will impact your organisation and other manufacturers across the globe, you're not alone. This new operational shift is changing things faster than most people realise, and if some futurists and experts are right, Industry 4.0 will lead to a sort of brave new world in manufacturing, unlike anything we've ever seen before.

The first Industrial Revolution remarkably changed the manufacturing industry in the first half of the 19th century. With steamships, railroads, and the mechanisation of processes in the agricultural and textile industries, the first Industrial Revolution didn't just help manufacturing businesses become more efficient. It created a social, cultural, and economic shift across the globe.

In the early 1900s, a second Industrial Revolution was born as manufacturers began using electricity to streamline

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production even further and mass production pushed back the boundaries of possibility. The start of the third Industrial Revolution could be dated back to the 1950s with the use of semiconductors and mainframe computing, but it really took hold in the 80s and 90s with the rise of the digital age and the Internet. While the world is still reeling from the digital revolution today, Industry 4.0 has already begun.

Smart data and the Internet of Things have already changed manufacturing processes in many organisations. Experts predict that technology will disrupt the industry in remarkable ways. “Industry 4.0 is set to redefine the manufacturing industry, creating highly adaptable workspaces which are able to respond to customer requirements almost instantly”, says Martin Thomas, European Marketing Manager at Radwell International Ltd.

Industry 4.0 is a new era where manufacturers use Big Data, the IoT and interconnected computers to automate processes while minimising the need for human operators.

Many smaller manufacturers are in denial about the radical shift taking place as a result of advances in Industry 4.0 technology. If you work in the manufacturing industry, you can’t afford to make that mistake. Large manufacturers are investing heavily in new technology to carve out a stronger competitive edge. Your company will lose ground if you don’t adapt with smart data and automated manufacturing technology.

The global value of all Industry 4.0 components is expected to exceed £4 trillion by 2020. You should be aware of the growing trend toward the utilisation of Industry 4.0 technology if you work in the manufacturing sector.

A number of technologies are used to make smart manufacturing a reality, including the following:

If you are still sceptical, you should look at the growing number of Industry 4.0 patents that have been awarded over the last few years. In 2016 alone, over 5,000 Industry 4.0 patent applications were submitted to the European Patent Office.

Samsung, LG, Sony, Intel, Amazon, Nokia and Blackberry are some of the biggest adopters of Industry 4.0 technology.

How much of a role will Industry 4.0 play in the manufacturing industry in the future?

Manufacturers are becoming very reliant on smart data and automated manufacturing technology.

Amazon spurred the discussion by using warehouse robots to help automate many of their fulfilment processes.

The online retailing giant currently has over 100,000 warehouse robots.

Brad Porter, the Vice President of Robotics for Amazon, says that warehouse automation and machine learning are going to have a profound impact on companies in numerous other industries.

•

The (IoT)

•

Advanced robotics and automation

•

Machine learning (artificial intelligence)

•

Smart and real-time data sensors

•

Cloud computing

•

3D printing for digital fabricators

•

Software analytics and data capture

•

Mobile device technologies and platforms

•

Smart vehicle and transportation

•

Real-time data processing and communications

Porter states that robots won’t entirely replace human employees in the immediate future, because they lack the ability to understand nuance and improvise.

However, they are helping to reduce human error in many types of jobs.

Numerous robots use highly advanced route planning algorithms to help associates fill customer orders. Other robots are designed to lift heavy products up to 24 feet.

Amazon is one of the companies that has received the most publicity for its utilisation of Industry 4.0 technology.

However, this technology has been even more important for smaller companies operating on lower economies of scale, because it allows them to cut their long-term operating costs and boost production enough to compete with competitors that have been slow to adapt.

One African gold mining company used similar technology to improve its profit margin by 3.7% and reduce annual costs by £20 million.

What are some of the benefits of using Industry 4.0 technology?

You need to consider the long-term benefits of using industry 4.0 technology in your manufacturing business.

Long-term cost-effectiveness You might be hesitant to adopt Industry 4.0 technology because the initial infrastructure costs can be high.

However, the ROI can be substantial after you amortise the cost over time.

You will also reduce the cost of human labour, waste and fines for compliance failures.

You may also realise a massive increase in productivity.

If you purchase the right manufacturing automation systems, it can pay for itself quickly.

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Smart manufacturing technology uses this information to improve the production process to create higher quality products.

How quality Industry 4.0 technology supports manufacturing

Faster production time tables and better scalability

Minimising the risk of human injury and the cost of liability claims

Industry 4.0 technology also significantly improves the agility of manufacturing processes. Organisations can reduce the time it takes to deliver products by:

Employee injuries in the manufacturing industry are noticeably higher than most other sectors. The cost of injuries can be substantial because they consist of:

•

Keeping production running 24 hours a day, seven days a week

•

The risk of employee lawsuits

•

•

Not needing to slow production to compensate for employee sickness

Having to pay higher UI premiums due to past accidents

•

•

Using technology that does not slow due to human fatigue

Paying steep fines for regulatory violations after an accident triggers a compliance audit

Industry 4.0 is already proving to be much more efficient. This will lead to faster product deliveries and better customer satisfaction in industries with high wait times.

•

•

Experiencing lower employee morale if employees are concerned about being injured along with their colleagues

•

Needing to pay to replace or repair damaged equipment caused by human error

Exceptional customer responsiveness Companies using Industry 4.0 technology can improve customer satisfaction by producing goods more rapidly. However, there are other reasons why it is invaluable for companies trying to offer better customer service.

Many customers need to refine their specifications and service models over time.

Manufacturers have difficulty meeting their evolving expectations with older technology.

Fortunately, smart data and automated manufacturing technology improve responsiveness.

Manufacturers can alter the software they use to oversee production.

A few slight modifications can have a profound impact on their manufacturing models, which makes it much easier for them to respond to new customer requests.

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Facing the costs of disruptions in production due to reduced manpower after one or more employees are injured

Automated manufacturing equipment enables companies to depend on smart technology to handle more dangerous tasks. This drastically reduces the risk of human injuries, which can have crippling costs on their bottom line.

Better innovation Most Industry 4.0 advocates emphasise the scalability side of the equation.

However, the technology can be equally beneficial when it comes to improving the quality of production.

Manufacturers that use smart technology depend on deep learning. Over time, this technology develops a better understanding of the products it develops. Users can test the material specifications and technological properties of goods.

Manufacturing companies are more dependent on smart technology than ever before. They need to depend on companies that produce high-quality sensors, deep learning algorithms and IoT devices to help them meet their expectations, Radwell International Ltd has helped numerous clients improve their Industry 4.0 processes.

They supply a large range of photoelectric sensors, pushbuttons, timers, circuit breakers and other electronic control devices. These smart devices are integrated into the IoT, which enables companies to streamline their production capabilities.

Companies like Radwell International understand that while smart technology is highly beneficial to manufacturers, it comes at a cost.

They offer solutions to reduce the price point for their customers, including offering surplus parts and used components.

They also repair smart technology, which is often more cost-effective than replacing it.

These approaches are helping minimise the costs of adopting Industry 4.0 technology, which is making it more accessible to companies around the world.

Visit www.info.radwell.co.uk/ace for more information or call 01782 576811

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Capturing the First Image is Always the Hardest Part

S

mart fridges, agricultural drones, or industrial robots - the working prototype and the first image present special challenges for developers embedding bare sensors into their devices. In this case, small sensor modules can both simplify and accelerate the process to a working prototype, providing the first image to smart devices in only 30 minutes.

The manufacturer of a fridge must have experience in refrigeration. For smart home appliances, it is no longer that simple. A modern fridge with integrated cameras can analyze the food; update the online shopping list; or, display suitable recipes. Developers of these smart devices need basic knowledge about imaging, sensor technology and the integration of camera technology into the refrigerator.

Initial integration of vision technology into smart devices often poses new challenges to development teams. They must realize a prototype; the basic functionality and the interaction of all

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components must work flawlessly. In the vision subsystem, a wide variety of components must be connected and verified. Electronic design, layout, and PCB production take time and resources.

In particular, high-speed signaling and sensor connection require in-depth specialist experience. A lack of knowhow can prolong the timeline extensively.

“We want to enable developers to qualify image sensors directly in their application, integrate them quickly and not have to worry about the basic vision technology,” says André Brela from FRAMOS. The company’s product line of interchangeable sensor modules and adapters facilitates the development of embedded vision products. According to Brela, developers that work with vision for the first time can implement initial prototypes with standard components, without a great deal of specialist knowledge. The product manager says that “it takes less than 30 minutes from unpacking the pre-soldered sensor modules to capturing the first image”.

Sensors and processors with a flexible adapter concept can be exchanged during testing to identify the best combination without affecting the interfaces. The software developers can operate independently of the hardware team. “With our sensor modules, OEMs and device manufacturers do not necessarily have to become sensor experts themselves,” says Brela.

“We believe our customers are most successful when they concentrate on their core application, like producing really good refrigerators.” For the smart additional functions, the FRAMOS Embedded Vision product line offers immediately accessible hardware and drivers that combine a wide variety of image sensors with open processing platforms. It presents image processing to newcomers the chance to have the first prototype of a smart refrigerator up and running in a short time, and at low cost. www.framos.com +44 1276 4041 - 40 info@framos.com

www.framos.com

+44 1276 4041 - 40

info@framos.com

FRAMOS enables machines to see.

Imaging and embedded vision technologies are our passion, we play a key role in automation, robotics and the IoT-connected factory and are key drivers in cognitive systems, the smart home, intelligent mobiles and autonomous vehicles.

Since 1981, FRAMOS is a leading global supplier of imaging products, embedded vision technologies, custom solutions and OEM services and supports customers as a technical consultant, development partner and external supplier.

We offer a powerful portfolio of imaging components and services to develop cutting-edge imaging and embedded vision systems.

With a team of more than 100 employees working worldwide, we aim to find the fastest and most efficient imaging solutions for our customers.

FRAMOS is your global partner for vision solutions.

New Inductive Safety Sensor Portfolio from Pepperl+Fuchs

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he new family of safety sensors from Pepperl+Fuchs - the inventor of the inductive proximity sensor includes four cylindrical and rectangular series with cable and plug connection.

The sensors are TÜV-certified in accordance with the Machinery Directive (EN 13849) Performance Level PLd, Category 2, and SIL 2.

They are used to safeguard machines and plant components as well as for reliable position detection within this environment.

Inductive sensors with an increased temperature range, as well as increased EMC resistance and E1 approval for the use of mobile machinery and vehicles in safety-critical areas, round off this new portfolio.

These safety proximity sensors do not require a special coded target and can therefore be used with standard metal actuators. The sensors from Pepperl+Fuchs have no blind zone and can therefore be mounted easily and without any additional adjustment.

The sensors are equipped with standardized OSSD outputs (Output Signal Switching Device) for signals and diagnostics that can be connected to a safety module or a corresponding control panel.

The inductive safety sensors from Pepperl+Fuchs have very high characteristic safety values due to the electronics used.

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As a result, the regular functional inspections are required significantly less often, and integration into the safety loop is notably more straightforward.

Pepperl+Fuchs is one of the world’s leading providers of industrial sensors and explosion protection. Based on an intense dialogue with our customers for more than 70 years we continue to develop new components and solutions, which support their applications the best way possible. For the landmark topic Industrie 4.0 (Industrial Internet of Things) we develop innovative technologies that pave the way to the digital networked production and to data transfer across all hierarchy levels – even beyond companies’ boundaries.

Industrial sensors: focus on the market Market-specific solutions dominate an extensive portfolio of industrial sensors that covers all applications the market requires from today’s automation technology. From the inductive and capacitive to the photoelectrical and highly precise ultrasonic sensors, identification systems and many more Pepperl+Fuchs offers all current operating principles in a broad variety.

Sensorik4.0® provides sensor technology for Industrie 4.0. Our technologies enable sensors without difficulty to communicate horizontally within the production process and to exchange data vertically – even into higher-level information systems such as MES or ERP.

Process interfaces: secure applications Components and technologies for use in hazardous areas are designed to fit the most specific requirements in the industries we serve.

They guarantee maximum availability at maximum safety. Isolated barriers, signal isolators, remote I/O or fieldbus systems, HMIs and many other technologies offer solutions for a wide range of applications including certified packaged solutions and all types of explosion protection.

Ex-Protection4.0 brings digital networked Industrie 4.0-production structures to process industries.

With concept studies like Ethernet for Process Automation integrated communication throughout all levels of an automation system via Ethernet becomes feasible – for the first time ever even down to the filed level. www.pepperl-fuchs.com

Practical Aspects of PROFINET, PROFIBUS and IO-Link Presented by PROFIBUS and PROFINET International and hosted

by Endress+Hauser, this event addresses the key practical issues arising from the use of digital communications technologies in automated manufacturing and process industry applications, with particular attention to Industry 4.0 and the Industrial Internet of Things (IIoT).

Covering key application areas such as control systems and energy management, pulp & paper, chemical, utilities, pharmaceutical, mechanical handling and logistics, robotics, automotive engineering, electrical and electronics assembly, packaging and printing, it focuses on the practical aspects of using PROFINET, PROFIBUS and IO-Link, from system design and safety considerations through to fault-

finding and maintenance.

Supported by an exhibition with demonstrations of actual tools used in configuration and maintenance, the seminar will be of great value to Designers, Production/System Engineers, Instrument Technicians/ Engineers and C&I Engineers involved in the design, operation and maintenance of modern automated factories and process plant.

With nearly 80 million nodes installed worldwide, PROFINET, PROFIBUS and IO-Link are truly market leaders, providing state of the art digital communications addressing all the needs of manufacturing and process industries, significantly lowering capital expenditure on installation, commissioning and maintenance.

This seminar is ably presented by specialists from PI UK member companies.

More information and online Registration In case of difficulty contact Ann on tel: 00 44 207 193 8018 or email admin@profibus.org.uk

HMI Industry 4.0.

The new generation for the factory automation

Connected CR1000 and CR3000 HMIs The CR1000 and CR3000 automation HMIs from Red Lion combine an ever expanding list of over 300 industrial drivers with the intuitive Crimson 3.1 development platform to create an operator experience designed to easily adapt as needs change and operations grow.

CR3000 HMIs also offer data logging, secure web server and SQL query capabilities, enabling you to easily transform your equipment into a connected solution for improving manufacturing efficiency.

Visit www.redlion.net/HMI to learn more.

020-3868 0909 I europe@redlion.net I www.redlion.net Š 2018 Red Lion Controls, Inc. All Rights Reserved.

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New DIN Rail AC inrush current limiters for capacitive & inductive loads

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owersolve’s new PSICL series is a low-cost range of peak inrush current limiters designed for capacitive and inductive loads in a variety of applications.

These include installations across complex automation systems and machinery as well as isolation transformers or LED lighting applications where they are particularly useful because you can have a large number of LED driver power supplies operating in parallel and all taking high peak currents together on switch on which can cause circuit breaker to trip.

The PSICL series is a true current limiter and cuts off all peak currents when starting loads under practically every AC condition.

Extreme conditions can occur on AC lines in the event of a break in the supply and when power returns, high current peaks can often cause havoc and will trip circuit breakers.

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In decentralised areas, this will often lead to increased maintenance costs as the breakers require re-setting.

Both items are DIN Rail mounted and internal circuitry is identical for both versions.

The PSICL current limiter prevents this happening and can result in reduced cable cross section used and smaller and faster circuit breakers.

We also have the existing full ESB101 range of inrush current limiters available which are suitable for applications from 16A to 30A single phase input, in either 115VAC or 230VAC voltage input versions. These are suitable for capacitive loads such as LED lighting etc.

The PSICL Series is available in three 230VAC single phase models with continuous operating current rating of 12A, 16A and 25A. Current limiting time is 100-500mS with repeat intervals of 1000mS. They have an operating temperature range of --40ºC to +70ºC and conform to EN60950-1 and EN61000-6-2,3 standards and are CE and RoHS. MTBF figures are 300,000 hours. The PSICL is a housed in a low profile V0 flammability rated plastic case measuring 91H x 71W x 57Dmm. The same design designated PSESB Series is also available in a very slim width enclosure with measurements of 100H x 22.5W x 112Dmm.

Also available are 3 phase AC input versions of 16A and 32A continuous rating. The ESB00163 (16A) and ESB00323 (32A) three phase input series operate with input voltages of 200, 400 & 500VAC and are for inductive and capacitive loads.

Full data sheets on all models are available on the website at the following link. https://powersolve.co.uk/productcategory/inrush-current-limiters

www.powersolve.co.uk

Industrial Quality Power Supplies

TMDC Series DC-DC Converter 20, 40 & 60 Watts output power 9-36V or 18-75V DC input range 5V,12V, 24V or 48V DC output versions Fully encapsulated, chassis or DIN rail mounting

TCL-DC Series DC-DC Converter 12, 24 & 60 Watts output power 9.5-18V or 18-75V DC input range 5V,12V or 24V DC output versions DIN rail mounting

TIS Series AC-DC Converter 50 to 600 Watts output power Selectable 115/230VAC input range 12V, 24V, 48V or 72V DC output versions Optional redundancy module, signals module or DC UPS. Full safety approvals

TSPC Series AC-DC Converter 48 to 480 Watts output power Selectable 115/230VAC input range 12V, 24V or 48V DC output versions Full safety approvals and ATEX approval for hazardous locations

TSP Series AC-DC Converters 70 to 600 Watts output power Universal (up to 90W) or auto select AC input 12V, 24V or 48V DC output versions Optional external redundancy modules.

Full safety approvals and ATEX certification for hazardous locations.

TSP Series Function Modules Redundancy Module enables two units to operate in parallel mode.

Buffer Module allows hold up time up to 4 seconds depending on load.

Battery Controller Module enables TSP to be used as AC-DC UPS.

TEX120 Series AC-DC Converter 96 & 120 Watts output power 85-264VAC (85-375VDC) input range 12V or 24V DC output versions IP67 & NEMA 4X rated for harsh outdoor environments. ATEX approved

TSPC-UPS Battery Backed AC-DC 240 Watts output power Selectable 115/230VAC input range 24V DC 12A battery backed output 12V external lead acid battery outdoor environments. ATEX approved Full safety approvals and ATEX approval for hazardous locations

TIB EX Series AC-DC Converters 80 to 480 Watts output power Universal 85-264 VAC input with Power Factor Correction.

12V, 24V or 48V DC output versions.

Full safety approvals and ATEX & UL Hazloc certification.

www.powersolve.co.uk

Tel: 44-(0)1635-521858 Email: sales@powersolve.co.uk

SICK’s NAV-LOC Localisation Sets AGVs Free from Reflectors

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ICK has set Automated Guided Vehicles free from the need for reflectors or other physical markers with the all-in-one NAV-LOC localisation solution, enabling them to navigate more reliably and efficiently around shop floor and warehouse environments.

The SICK NAV-LOC (Localisation On Contour) is an easy-to-set up solution based on a SICK NAV 360o LiDAR scanner that can be integrated into new or existing AGVs. By recognising the pre-mapped contours of a factory or warehouse interior, the system eliminates the need for time-consuming and costly installation of reflectors, special paints, tracks, magnetic strips or coloured tapes.

“The introduction of the SICK NAV-LOC is an important step forward in the availability of contour-based localisation systems from SICK that promise more flexibility, lower cost of installation and maintenance for automated transport, stacking, and loading processes using AGVs,” says Neil Sandhu, SICK’s UK Product Manager for Imaging, Measurement and Ranging.

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“Especially suited to medium and large AGVs, automated forklifts, shuttle systems and mobile robots, the beauty of the SICK NAV-LOC system is that it is straightforward to set up, and it is easy to adapt the navigation path when the surroundings are altered, or the AGV needs to be redeployed to another area.”

The SICK NAV-LOC system uses precise 2D data from the SICK NAV310 LiDAR scanner to match its position to a reference map stored on a SICK SIM2000 Sensor Integration Machine, which is also mounted on the AGV. As the data is processed, a SICK algorithm continually compares the distances retrieved from the scan data with the reference map to provide position and orientation information to the AGV controller.

Setting up the NAV-LOC system begins by simply ‘teaching’ the on-board SICK LiDAR scanner prominent contour features, such as walls, large static machinery, racking or bays, as the AGV is driven manually around its working environment. Then, this data is used

by SICK Service to create a precise reference map on behalf of the customer

or machine builder, before being uploaded on the SIM2000, and easily commissioned on-site using SICK’s SOPAS engineering tool.

Unlike conventional systems, the SICK NAV-LOC does not require numerous reflectors to be positioned in groups of threes along a route, to enable a laser scanner to triangulate its position. Tracks or magnetic strips installed in the floor or adhered to fittings, or special coloured or reflective lines, are also redundant.

There is no risk of reflectors or paint being dirtied or obscured and there is no routine maintenance or route inspection needed to minimise possible AGV disruption.

Designed for robust operation in tough industrial conditions, the SICK NAV-LOC scans its contours 8 times a second. With a working range of up to 250m, it does not need special lighting and can even operate reliably with surfaces down to 10% remission at up to 35m distance.

For more information on the SICK NAVLOC Scanner, please contact Andrea Hornby on 01727 831121 or email andrea.hornby@sick.co.uk.

Precise and gentle pacemakers High-performance assembly systems for the electronics industry are considered trend indicators for assembly applications.

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n addition to traditional Pick & Place applications, they cover an evergrowing range of parts, ensure zero defect strategies, and in some cases even flexibly adapt to changes in demand without the need for user intervention.

A high-speed application of the LEM for the production of electronic components highlights the potentials wherever they are hidden, and shows how the path to pneumatic-free applications can be paved.

"Our previous systems for producing these sensors achieve cycle times of around nine seconds.

With the new system, we already achieve six seconds. For future generations, it will be as few as five", reports Frédéric Cattaneo, Team Leader for Systems Construction at LEM in Geneva.

That's 44% more output – with seamless component monitoring and significantly higher flexibility compared to today.

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Instead of one variant, the system can produce two different component variants without the need for manual intervention. Around 3 million components are expected to leave the automated system per year in the future in 24/7 operation. The market leader for solutions for measuring electrical parameters is systematically using the full potentials of assembly automation.

In this connection process stability has top priority. New technologies are always used if they can be reliably controlled.

As is the case with all high-performance assembly systems, the considerations are focused on three key issues: the costs of procurement and operation, cycle time, and process stability. All three of these factors must be optimised simultaneously to ensure an effective and competitive assembly process. There are good reasons for the fact that LEM has recourse to the system program for the modular high-performance assembly from SCHUNK.

The system program covers all conceivable requirements: gripping, rotating or translatory movements, pneumatic or electrical, modular or compact – over 10,000 application variants are possible, whereby a highly precise reproducibility is ensured at all times.

It also includes the necessary peripherals, including standardized pillar assembly systems, adapter plates, and planning tools. Highly efficient Pick & Place units, cross slides, rotary gripping modules, gantry systems or complete functional modules can be built with a minimum of engineering and assembly effort.

Force control for bending and pressing in The team at LEM painstakingly analyzes the offered advantages of the various components. While at a time-critical bending station and for grippers pneumatic components have been used until today, LEM has converted the force-

controlled press-in operation onto the mechatronic SCHUNK PPU-E 15 Pick & Place unit. For the freely programmable pacemakers, position and speed can be flexibly varied.

The unit gently moves into the appropriate tool, then bends and presses the elements with a precisely adjusted force, before the axis returns to its original position at maximum speed and places the part onto the pallet of the linear transport system.

The PPU-E, which is linearly directly driven and thus transmissionless, is currently the fastest Pick & Place unit on the market, whereby the size is specially tailored for use in electronics and small parts assembly. Due to a width of only 60 mm and a complete media feed via the back panel, it enables a particularly compact system design.

For a complete cycle with a 145 mm horizontal and 45 mm vertical stroke, the productivity booster only needs 0.6 s for 1 kg additional mass and 2 x 50 ms gripping time. At its peak, the PPU-E 15 delivers a whopping 100 picks per minute. Such high numbers of cycles are not required at LEM.

It much more depends on the smooth motion profile and the repeat accuracy of the axis, which is 0.01 mm.

The smoother the movements of the individual handling systems, the lower the vibrations of the entire system. That's what LEM is all about.

The smoother the movement curves, the more reliably the high quality of the electronic components is achieved.

For example, the tolerance in the flatness of four bent contacts is just 0.015 mm.

This is exactly why LEM uses the strengths of the SCHUNK PPU-E for.

Instead of using a tolerance and wearprone transmission of movement, the unit is moved by a wear-free direct drive.

This minimizes the maintenance effort, increases the permanent repeat accuracy, and simplifies the individual programming.

To increase process stability, both horizontal and vertical motions can be monitored with an absolute path measuring system.

Air-sprung test station LEM goes a step further with two test stations for optical inspection of the components: "Here we need speed combined with a particularly gentle movement," FrĂŠdĂŠric Cattaneo explains. 2D and 3D cameras capture the components highly accurately on all sides, measure the contacts and check the evenness of the previously bent elements.

If the vibrations are too great, the quality check with the vision sensor fails. "In order to prevent vibrations, we opted for SCHUNK linear axes with servoelectric direct drives, which move both dynamically and very gently," emphasizes the experienced plant engineer. " In addition, the entire unit can be decoupled from the micro-vibrations of the environment by means of an air spring element at the moment of the measurement, so that a highly precise 3D measurement is possible." In addition to the optical test, the insulation is tested at other stations and the components are calibrated.

Linear motor axes allow gentle movement The LDx series is regarded as a benchmark in the field of highspeed assembly. High-performance servomotors achieve particularly high outputs in a compact space. Almost all modules of the LDx series are already available as standard with absolutevalue transducers, which ensure a repeat accuracy of 0.01 mm per axis.

They eliminate the need for expensive reference runs when the system boots up and after emergency stops.

In addition, the modules need neither end nor reference sensors, reducing the investment costs, programming effort, and the number of cables in the cable set. Since several freely programmable slides can be placed on one guiding

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profile if required, particularly compact and cost-efficient concepts can be implemented.

The driving force is transmitted directly onto the slide by high-precision drive elements, free from play, without mechanical transmission elements. This results in short cycle times, maximum precision, and permanently high process reliability. Since the modules have almost no wearing parts, unplanned downtime and maintenance costs are reduced to almost zero.

LEM uses two module variants for its application: The SCHUNK LDN is equipped with an X profile and achieves a maximum drive force of 250 N, and a maximum nominal force of 120 N in the basic version. The SCHUNK LDH, on the other hand, is a compact Z-axis, which is designed especially for precise movements or controlled press-in operations in high-speed assembly as well as in measurement and testing technology.

It is impressive due to the fast response characteristics and high positioning accuracy. The maximum driving force is 125 N, the nominal force is 52 N. Optionally, the axis can be supplied with a pneumatically operated holding brake, by which the position of the axis is reliably maintained even in the event of an emergency stop. The axes are controlled with Bosch Rexroth IndraDrive controllers as standard. The modules are available with either an incremental

path measuring system (1Vpp interface) or with an absolute path measuring system (optionally with the Hiperface, SSI or DRIVE-CliQ interfaces). Due to these combination possibilities, the modules are compatible with different controllers and can thus can be quickly and easily integrated into higher-level controllers.

Pneumatic-free systems as a goal From the point of view of FrĂŠdĂŠric Cattaneo, the trend at LEM is clearly towards pneumatic systems. "In the future, we will mainly build electrical systems with electric grippers, electric linear modules, and electric rotary modules. The current system is an intermediate step from pneumatics to fully electric machines.

"The main reasons are the elimination of valves and hoses, reduced energy costs, cleanliness within the assembly process, and the significantly reduced vibrations, especially at high speeds. Instead of radically eliminating pneumatic modules, LEM prefers a gentle way to avoid overworking of the user, and to ensure maximum process reliability at all times: Step by step, individual modules are being replaced by mechatronic alternatives from the SCHUNK range. In the next step, the mechatronic SCHUNK EGP gripper for small components will take over the tasks of the tried-andtested pneumatic SCHUNK MPG-plus. www.gb.SCHUNK.com

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ed the TA1004 for n Stick” product sold

This innovative T flexible throughp The system’s rob collation unit can orrect amount, length two trolleys simu e on to a plastic the packing spee d into place and then systems with a c achine utilises a of robotics elimin system which is PLC variable height p movement throu the compatibility designs or dama The simplicity an Mechelec Automation a unique British robotic system a Automation Provider ng to minimise downtime for wash down and routine maintenan From Trolley Packing Milk bottles to Applying Tile Adhesive onto Plastic Sheets! flexibility of the system has allowed the expansion of the range des an add-on unit functionality A top sheet is thenfor fed intoshrink-wrap place and The use provides of robotics eliminates the echelec Automation have an which then both sheets are cut to size. The problems relating to variable height engineering team with a wealth ys. The ofsystem the ability toutilises palletise shrin machine a bespoke dosing,the film packing, offering free movement experience in the also automation possesses

M

industry, having worked for many years with robots, servo systems, pneumatics and PLC control. This experience, along with their open minded approached, has resulted in them producing their own Trolley Packing solution for milk bottles as well as designing a bespoke system for applying Tile Adhesive onto plastic sheets.

through multiple axis and avoiding the compatibility issues arising from differing designs or damaged trolleys.

simultaneously, offering double the packing speed of conventional automated systems with a comparable footprint.

Tileution Limited. The TA1004 precisely doses the correct amount, length and diameter beads of tile adhesive on to a plastic base sheet.

feed and cut system which is PLC and Servo control.

Mechelec engineers helec Automation have developed the TA1004 for have vast experience in using Robotics, PLC’s, and The simplicity and open construction motion control solutions from the major of the robotic system also allows easier manufacturing of the “Peel then Stick” product sold OEM’s such as ABB, Fanuc, Rockwell, access, helping to minimise downtime Siemens and B&R. for wash down and routine maintenance. leution Limited.

This allows Mechelec Automation to The flexibility of the system has allowed TA1004 precisely doses the correct amount, length bring the PLC, HMI, Motion and Safety the expansion of the range of the The patented TP1002 Trolley Packer is aspects of their projects together, as a TP1002 which now includes an add-on designed to provide fully automated, cost seamless package. unit which provides functionality for effective trolley loading, at speeds of up adhesive on to a plastic diameter beads of tile shrink-wrapped bundles to be loaded to to 250bpm and packing 4-pint bottles would like any more information trolleys. fed into placeIf you in a 5 xA 4 format in either 4 or 5 tier is then sheet. top sheet and then on our TP1002 or any of our other trolleys. This innovative Trolley Packing products and services, please contact: The system also possesses the ability to system are offers flexible throughput at sheets cut to size.

The machine utilises a sales@mechelecautomation.com or visit: palletise the shrink-wrapped product. faster operating speeds. www.mechelecautomation.com oke dosing, film feed and system is PLC Mecheleccut Automation have developedwhich www.peelthenstick.com The system’s robotic arm and servo the TA1004 for the manufacturing of collation unit can quickly Servodriven the “Peel then Stick” product sold by and control. efficiently load two trolleys

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Trolley Packing system offers put at faster operating speeds. botic arm and servo driven n quickly and efficiently load ultaneously, offering double ed of •conventional PLC Programing automated • Electrical Engineering comparable footprint. The use • Motion Control • Panel Design nates• the problems relating to SCADA Systems • Panel Build packing, offering free • Robot Programing • Site Installation ugh multiple axis and avoiding y issues arising from differing • Bespoke Machine Design aged trolleys. nd open construction of the • Automation Solutions also allows easier access, • Robotic Solutions nce. e of the TP1002 which now pped bundles to be loaded to nk-wrapped • Turnkeyproduct.

Projects

Mechelec Automation

• Project Management • System Simulation

THE ROUTE TO IMPROVED PRODUCTIVITY AND PROFITABILITY MECHELEC AUTOMATION providing automation services, bespoke machinery and automated solutions for todays demanding industry. www.mechelecautomation.com sales@mechelecautomation.com 01480 404407

Festo pneumatic robotics get to grips with artificial intelligence

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hether it’s grabbing, holding or turning, touching, typing or pressing - we use our hands for the most diverse tasks. The human hand, with its unique combination of power, dexterity and fine motor skills, is a true miracle tool of nature.

So, what could be more natural than equipping robots in collaborative workspaces with a gripper that is modelled on the human hand, and which solves various tasks by learning through artificial intelligence?

Festo showed its pneumatic BionicSoftHand at Hanover Fair 2019.

Combined with the BionicSoftArm, a pneumatic lightweight robot, the Future Concepts are suitable for human-robot collaboration.

The BionicSoftHand is pneumatically operated, so that it can interact safely and directly with people. Unlike the human hand, the BionicSoftHand has no bones. Its fingers consist of flexible bellows structures with air chambers.

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The bellows are enclosed in the fingers by a special 3D textile coat knitted from elastic, high-strength threads. With the help of the textile, it is possible to determine exactly where the structure expands and generates power, and where it is prevented from expanding. This makes it light, flexible, adaptable and sensitive, yet capable of exerting strong forces.

Specifically, the BionicSoftHand is required to rotate a 12-sided cube so that a previously defined side points upwards at the end. The necessary movement strategy is taught in a virtual environment with the aid of a digital twin, which is created with the help of data from a depth-sensing camera via computer vision and the algorithms of artificial intelligence.

Artificial Intelligence

Proportional piezo valves for precise control

The learning methods of machines are comparable to those of humans: they require a positive or negative feedback following their actions in order to classify and learn from them.

BionicSoftHand uses the method of reinforcement learning.

This meansthat instead of imitating a specific action, the hand is merely given a goal. It uses trial and error to achieve its goal. Based on received feedback, it gradually optimises its actions until the task is finally solved successfully.

In order to keep the effort of tubing the BionicSoftHand as low as possible, the developers have specially designed a small, digitally controlled valve terminal, which is mounted directly on the hand.

This means that the tubes for controlling the gripper fingers do not have to be pulled through the entire robot arm.

Thus, the BionicSoftHand can be quickly and easily connected and operated with only one tube each for supply air and exhaust air. With the proportional piezo valves used, the movements of the fingers can be precisely controlled.

BionicSoftArm: One robot arm, many possible variations The strict separation between the manual work of the factory worker and the automated actions of the robot is being increasingly set aside.

Their work ranges are overlapping and merging into a collaborative working space.

In this way, human and machine will be able to simultaneously work together on the same workpiece or component in the future – without having to be shielded from each other for safety reasons.

The BionicSoftArm is a compact further development of Festo's BionicMotionRobot, whose range of applications has been significantly expanded. This is made possible by its modular design: it can be combined with up to seven pneumatic bellows segments and rotary drives. This guarantees maximum flexibility in terms of reach and mobility, enabling it to work around obstacles even in the tightest of spaces if necessary. At the same time, it is completely flexible and can work safely with people. Direct human-robot collaboration is possible with the BionicSoftArm, as well as its use in classic SCARA applications, such as pick-and-place tasks.

Flexible application possibilities The modular robot arm can be used for a wide variety of applications, depending on the design and mounted gripper.

Thanks to its flexible kinematics, the BionicSoftArm can interact directly and safely with humans.

At the same time, the kinematics make it easier for it to adapt to different tasks at various locations in production environments. Elimination of costly safety devices such as cages and light barriers shortens conversion times and thus enables flexible use – completely in accordance with adaptive and economical production. www.festo.com

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"Designed to meet industrial requirements, with built in high Ingress Protection (IP) for harsh environments, the Powerbox’s three-phase ENI250A is not only a robust and efficient power solution but a mechanically reconfigurable platform able to fit different form factors or even direct integration into DC motors"

Patrick Le Fevre C.M.C.O

Powerbox power solution for high speed e-commerce hub conveyers

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he Powerbox three-phase ENI250A series is housed in an IP54 case, delivers a constant 250W and up to 480W peak power with an efficiency up to 94%. The ENI250A includes a microcontroller that offers many possibilities to adjust protection behavior to meet specific customer requirements.

Factory automation is already well established in many industries, but with the progress in Artificial Intelligence (AI), remote communication and the growing demand for shorter customer lead times, it is predicted to explode in coming years. Similarly, the growth of automated parcel-hubs is expected to rise spectacularly. The rapid development of e-commerce has contributed to the creation of highly automated hubs with conveyers, sorting switches and many other equipment requiring efficient and intelligent power solutions able to work in demanding environments.

Parcel hub-designers and hub-operators are facing multiple challenges in having to deal with a large variety and types of equipment. This not only requires high quality, high performances power supplies, but the ability to operate in

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harsh environments with a complex mix of mechanical, thermal and electrical constraints.

Addressing 24VDC motors, the 250W ENI250A24 can deliver 480W peak power for one second, sustain high capacitive loads and manage energy recycling when a DC motor is decelerating or stopping. This function is very important for energy saving and to increase equipment life-time. For higher power or redundancy, the ENI250A24 can simply be paralleled. The unit has an operating temperature range from -25 to +70 degree Centigrade.

Other output voltages are available on demand to power 36V, 48V DC motors, as well customized voltages.

The ENI250A24 includes soft-start, over current, voltage and temperature protection. An LED indicator informs the status of the power supply and a DC-OK signal and remote reset provide for easy integration within the conveyer operation management system. It is designed using Powerbox’s reliable power platform concept and uses an active power factor correction (PFC) in combination with a high efficiency and compact LLC topology.

Exhibiting versatility, the ENI250A24 accepts input voltages from 323VAC to 560VAC three phase, and is designed to meet safety specifications 60950-1 and 62368-1. EMC is in accordance with EN61000-6-3 and EN61000-6-2.

Housed in an IP54 case, the ENI250A24 has dimensions of 250x160x55mm, weighs 1.5Kg and mounting brackets are available for easy installation. Designed for easy integration within customers’ equipment, the ENI250A platform can be factory re-configured to fit specific form-factors.

Contact information: PRBX (Powerbox) Ltd. Suite 57 & 58, Lynx House, Basepoint Business Centre Caxton Close, Andover, Hampshire, SP10 3FG Phone: +44 (0) 1264 326 457 Email: info.uk@prbx.com

POWERBOX Mastering Power

A Cosel Group Company

From module to full custom we support your transition towards Industry 4.0!

The combination of our extensive standard product range, our custom design capability, and our service offering, is truly unique. 40+ years of designing power supplies for demanding applications has built a rock solid experience. Our “Making the complex simple� business idea runs throughout our operation, from our customer interface and cooperation to how we design our products.

Board Mount

Internal

External

Systems

Integrated AC/DC power module with PFC built in.

Single output AC/DC high efficiency switch mode power supply.

Rugged power solution designed for safe operation in high electrical field applications.

DC UPS system with dual out out and embedded control.

150W to 750W DC/DC converters for industrial high input voltage 180VDC to 425VDC.

DIN Rail and baseplate ruggedized power solution for rough environment.

3-phase power solution for high speed e-commerce hub conveyers .

Battery backup with digital monitoring and enhanced communication system.

8W to 20W Extra wide input range 13:1 reduces inventory.

Large range of AC/DC and DC/DC cassettes for industrial application.

Discharge protection with CAN BUS and microcontroller.

Supercapacitor energy storage for surge energy demand and emergency backup.

PRBX (Powerbox) Ltd Phone: +44 1264 326 457 info.uk@prbx.com www.prbx.com

Contrinex Inductives ‘Beat the Heat’ on PCB Reflow Ovens

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ontrinex’s Inductives ‘beat the heat’ on PCB Reflow Solder ovens by providing exceptional reliability detection of the emerging PCB, overcoming the high-temperature environment and offering a longer sensing distance.

The Process Control system on a Reflow Soldering oven needed to improve the detection reliability of PCBs to trigger a subsequent operation. The longdistance inductive sensor is mounted above the exit conveyor of the reflow oven and detects each board as it passes out of the oven, triggering a transfer mechanism to move the board automatically to the next process stage.

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KEY ADVANTAGES include:

CUSTOMER ADVANTAGES include:

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Outstanding temperature stability - Sensor performance unaffected by elevated temperatures

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Improved production OEE as the sensor reliable signals operations after the reflow oven

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Patented Condist® technology of Extra Distance sensing gives best-in-class operating distances Extended sensing range ≤ 10mm

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Minimal replacement sensor costs, due to the sensor’s long service life

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Low risk of thermal or mechanical damage because of extended operating distance

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Rugged inductive sensor with metal housing

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High-quality ASIC sensors with IOLink interface

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High performance and high switching frequencies

Click to download product brochure to find out more, or Click to download product catalogue page 16.

CUSTOMER APPLICATION: Product Quality Control Test Line During manufacture of PC motherboards, reflow soldering is used to secure components in place on printed circuit boards. Following assembly, boards are conveyed into a reflow oven, where the temperature increases progressively to achieve a predetermined thermal profile, melting the solder paste on the boards.

As each board leaves the oven, a sensor must trigger the customer’s control system and activate a transfer mechanism, moving the board automatically to the next process stage.

The ambient temperature immediately adjacent to the oven may reach 80°C (176°F), which has caused unacceptable rates of failure of other manufacturers sensor in the past, whereas sensors must operate continuously in this environment with ultra-high reliability to achieve the required OEE and throughput.

Extended sensing distances are highly desirable for this application as several types of motherboard, each with different component heights, pass through the oven. The longer-distance sensing enables the sensor to be positioned further away from the hot boards.

CUSTOMER SOLUTION: Contrinex inductive sensors from the Extra Distance family (500 series) are ideal for this application, with their vacuum-encapsulated electronics

ensuring excellent resistance to thermal shock and vibration. Condist® technology delivers best-in-class operating distances and sensors have a continuous rating to 70°C (158°F). Trials confirmed highly stable performance even in the elevated ambient temperatures around the reflow oven, without the need to use hightemperature sensors.

Extra Distance sensors are mounted vertically on steel brackets attached to the exterior of the reflow ovens and sense the presence of each motherboard as it passes beneath the sensing face.

The operating distance is set at 10mm, eliminating the risk of collision with components on the board, and an M12threaded metal housing allows easy positional adjustment when necessary.

Extra Distance sensors with an industry-standard NPN normallyopen configuration connect with the customer’s control system via a flexible PVC sheathed cable. No additional electrical or mechanical protection is required in spite of the adverse operating conditions.

Previously, sensors from other manufacturers did not detect boards reliably and had unacceptably short service lives, causing frequent interruptions to production. Sensor replacement costs were excessive.

Contrinex inductive sensors have been reliable and long-lived, providing a professional sensing solution with an attractive total cost of ownership.

To find out more, or to discuss how I can help reduce price and cost on sensors please email me Mark.Weymouth@Contrinex.com www.contrinex.com

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Lenze celebrates 50 years of automation innovation in the UK

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019 marks a special milestone for Lenze: the global specialist in Motion Centric Automation is celebrating the 50th anniversary of the launch of its business operations on British soil.

Founded as Simplatroll Ltd in 1969 and based in Bedford, the business quickly established itself as a leading drives and power transmission specialist.

At this time, inverters were a new technology and designers that required variable speed mostly used DC drives or mechanical variators. Demonstrating a flair for innovation even in its infancy, the business offered market leading solutions to its growing customer base, along with a portfolio of supporting products such as clutches, brakes and couplings.

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Over the five decades that followed, the UK operation adopted the Lenze brand from its parent company and flourished. An emphasis on recruiting and developing talented young engineers contributed to this growth and established Lenze as a pioneer of automation and control technology.

Today Lenze helps customers to solve complex operational issues, enhancing their performance with an extensive solutions-based offering. It is one of only a few providers that work with customers through the entire development process of a machine, from initial ideas to after sales, from the control system through to the drive shaft.

“We are proud to be celebrating our 50th anniversary in the UK and all we have achieved,” says Eric van den Broek,

business lead for Lenze Region West.

“Technology has developed rapidly in the time since our inception and our business has evolved as a result. Today we are focussed on pioneering advanced motion control solutions for customers, making it easy for them to reap the rewards from Industry 4.0 initiatives while providing the same flexible and reliable service we are known for. We’ll be celebrating this exciting milestone with several special events and activities throughout the year.”

Maintaining its UK base in Bedford, Lenze now boasts sales of approximately £20m in the UK, employing 45 people, over half of whom are skilled engineers. www.lenze.co.uk

Smart automation doesn’t always mean AI! Universal Robots outlines why collaborative automation and implementing robots simply as a tool, is the answer to many UK manufacturers’ current concerns. In most cases the automation needs of UK manufacturers are relatively simple. They must increase levels of output per worker to address labour shortages and a competitive marketplace. Plus, they must enable greater levels of product customisation to meet customer demand.

Some will argue the factory of the future requires a wholesale (and expensive!) digital transformation, with buzzwords like artificial intelligence freely bandied about. However, for those that find this overwhelming, we have a simple message. Robotics is nothing to be frightened of. In fact, you can bring automation into your business simply by viewing robots as a tool!

Our cobots are already delivering real value for manufacturers of all sizes by

carrying out straightforward tasks that were previously done by hand. They don’t need to “think” for themselves.

Instead they take on the dull, dirty or, dangerous jobs, leaving human co-workers to make more rewarding contributions.

The right application and a proper design of accessories allowed the team put together a system without a safety guard, negating the need for additional costs for the installation and factory floor re-design.

For example, the staff at Singaporebased, Clearpack has discovered firsthand the benefits of introducing cobots into its production line.

The only job of the cobots is to take on the heavily lifting. Yet this simple change has helped numerous Clearpack customers in the FMCG sector to optimise their warehouse space and enjoy a fast return on investment (ROI).

Clearpack was quickly able to design a safe, compact and easy-to-use palletising solution comprising a UR10 cobot and the LIFTKIT by SKF Motion Technologies.

To find out more, read the full case study here: www.universal-robots.com/ case-stories/clearpack/

COBOT AUTOMATION TOUR 2019

Save the date

Practical Training in

Collaborative Automation MAY 14TH BIRMINGHAM JUNE 18TH EDINBURGH JULY 16TH SOUTHAMPTON

Sign up for an event near you: urrobots.com/eventsUK19

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Renishaw sponsors STEMworks K’NEX workshops to inspire the next generation of Engineers To improve science, technology, engineering and maths (STEM) engagement in primary schools across Gloucestershire, global engineering technologies company Renishaw is sponsoring a local not-for-profit company STEMworks to deliver 100 workshops with students aged nine to eleven to inspire the next generation of engineers.

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uring these sessions, STEMworks will talk about what engineering is, what engineers do and then students have the opportunity to think like engineers as they participate in a K’NEX competition in the classroom increasing STEM-related skills such as problem solving, teamwork and following a technical brief.

At each session, a class is given a brief and one hour to build a machine using creative building toys, K’NEX. The sessions are often supported

by Renishaw STEM Ambassadors who help the students understand how they can design, build and test their ideas. This also gives the students role models from the engineering industry, which will hopefully encourage them to pursue a career in this field in the future.

“Hands-on activities, such as the K’NEX competition, are an exciting and effective way of engaging and developing future engineers,” explained Oliver Jelley, Industrial Placement Engineer at Renishaw who recently supported a workshop. “This competition gives students an insight into the skills needed to be an engineer and allows them to feel proud of their final designs.”

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“We have the opportunity to influence over 3,000 students by running 100 workshops at schools across Gloucestershire,” explained Rebecca Bound, Education Outreach Officer at Renishaw. “It can be challenging for schools to deliver engaging workshops if they are limited by the curriculum or a lack of resources. The collaboration between Renishaw and STEMworks means that we can work with more schools to deliver exciting activities that contextualise engineering and encourage students to consider studying STEM subjects at a higher level.”

Renishaw offers an extensive education outreach programme to support primary and secondary schools across Bristol, Gloucestershire and South Wales. Renishaw also partners with local initiatives such as the Bristol Music Trust, local Brownie groups and Cheltenham Science Festival to engage with more students and help them understand more about STEM subjects.

For more information about Renishaw’s education outreach programme, visit www.renishaw.com/education-outreach

Automated Production, Warehouse & Transport Monitoring Ensures Complete Cold Chain Management

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ecent years have seen an increase in legislation in the production, storage and transportation of temperature sensitive good that renders regular checks of controlled conditions essential. FilesThruTheAir explains how automated monitoring systems can save time, improve efficiency and reduce wastage by ensuring industry standards are met without the extra effort.

The safe storage and transportation of pharmaceutical products, biologicals and food is predicated on the correct management of the cold chain. According to the FDA, goods must be kept in the designated temperature range, with any excursions outside of this temperature being closely monitored and recorded to ensure the goods remain safe for distribution.

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The cold chain industry is expanding due to the rapid growth of biopharmaceuticals and food products travelling large distances that require temperature-controlled conditions.

This increase has resulted in the addition of complex distribution chains with a variety of storage and transport modes, throughout which the cold chain must be managed, maintained and recorded.

To meet these needs, a system that automatically alerts the user to temperature and humidity excursions enables staff to rectify any storage or transport issues, reducing the chance of damaging the goods.

In addition, accurate and consistent data records are needed to prove due diligence in upholding these industry standards meaning that data logging throughout the cold chain is vital to pass inspections.

The FilesThruTheAir range of WiFiconnected data loggers wirelessly records and stores data to the EasyLog Cloud platform, an online system that allows you to monitor, manage and analyse data from multiple devices across numerous locations all in one place.

When a device is triggered into alarm mode, an email is automatically sent to pre-specified recipients detailing when it was triggered and at what temperature.

Each logger has its own programmable settings including configurable high/ low alarms and logging rate (anything between every 10 seconds and 12 hours) meaning that different areas and products can be monitored to different specifications.

The different hardware options include rechargeable batteries, extended-life batteries or mains power, and product ranges that include LCD screens to display live data locally.

As well as storage, these devices can be used to monitor goods in transit to create an inclusive system of the entire cold chain, as the liability of the condition of the cargo remains with those transporting the goods.

This can be done in two ways.

It is possible to extend your wireless monitoring system by installing WiFi data loggers in each transport vehicle, which can log throughout the journey and upload to the Cloud at departure and arrival points where it will connect to WiFi, or throughout the journey with the assistance of a cellular router on board.

Alternatively, FilesThruTheAir’s range of Cold Chain data loggers are userfriendly USB devices activated with just the click of a button to produce reports of temperature and humidity recorded during transit that can be viewed when plugged into a computer.

To find out more about the various temperature and humidity monitoring options and the solution for your needs, call a member of the FilesThruTheAir team today on +44 (0) 1425 651111 or visit www.filesthrutheair.com.

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Protective Enclosure made from 40mm Aluminium Profiles A toothbrush manufacturer has used mk Profile Systems’ 40 series profile to create a protective device guard for their packaging area. The toothbrushes were already in their primary packaging, so there were no sanitary requirements but the protective guard is located in a typical cleanroom.

The guard, which was all made from the mk 40 series profile, was made entirely to the bespoke specifications of the customer. The profiles were anodised, the cut edges are blank and closed with sealing caps. The profile slots are closed with sealing strips.

An mk ZRF-P timing belt conveyor was also incorporated into the protective guard. It was crucial to ensure that the enclosure allowed easy access to the interior to allow for maintenance work to be carried out. This was done by incorporating two maintenance doors also out of the 40 series profile, with a locking mechanism for the doors being provided by the customer.

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Different panelling made from powder-coated sheets, Makrolon and powder-coated perforated sheets were used, again as per the customer’s requirements.

Finally, the enclosure was mounted on levelling feet, which can easily compensate for uneven floors.

The customer has a perfectly tailored solution to their guarding requirements with integrated conveyor technology, all from one single source. mk Profile Systems offers over 250 different profiles across their 25mm, 40mm, 50mm and 60mm ranges. Their extensive conveyor range covers over 20 standard conveyor systems for all all types of goods in nearly all factory environments. The modular nature of the mk system means that all elements of the system work in conjunction with each and can easily be adapted or added to at a later date.

To see the full mk range please visit www.mkprofiles.co.uk or call (01949) 823751.

ModuLeS and Much More

Packing machine with safety enclosure constructed from clean room profiles Load and unload removal transportation via belt conveyor, timing belt and gravity roller conveyers Transport and filling of cartons, weight measurement via integrated scales Accumulating run with separating function and cyclical operation mk Profile Systems Limited a company of the mk Technology Group Unit 2·Wolds Farm Business Park Kinoulton Lane·Kinoulton·Nottinghamshire, NG12 3EQ Phone +44 (0)1949 823751·Fax +44 (0)1949 81270 www.mkprofiles.co.uk·info@mkprofiles.co.uk