Process Engineering Control & Manufacturing - Issue 47 2020

Process

MANUFACTURING

METLASSE - 22

MetLase launches ‘smart’ products to connect and increase speed of manufacturing processes

Control &

Engineering

TRIPLING PRODUCTIVITY- 36 Apple producer picks Brillopak to automate packing facility

PECM

Global Success Through Innovation Issue 47 2020 £3.95 www.pecm.co.uk

PAILTON ENGINEERING - 58 Exploring the benefits and drawbacks of greater standardisation in electric vehicle (EV) batteries

Process

MANUFACTURING

Inside...

Sections

Control &

Engineering Inside Issue 47

Editors Choice

4

Boiles & Maintenance

31

Connectors & Fittings Control & Automation

ROTAMEC

COPA DATA

32

Rotamec raises repair capabilities with new 10-tonne capacity crane

34

CBM

PAILTON ENGINEERING

METLASSE

TFC

New Covid-19 support measures will save thousands of jobs in the metalforming sector

Drives, Motors & Gears

42

Electrical & Electronics

50

Fasteners & Fixings

62

Facilities Management

66

Fluid Handling

68

Health & Safety

70

Hydraulics & Pneumatics

74

Machining & Machinery

76

Measurement & Monitoring

84

Extending small steam turbine performance and reliability to minimize costs

News & Events

90

Packaging

92

WEG

Process Technologies

96

Product News

102

Software & Systems

108

Valves

113

MetLase launches ‘smart’ products to connect and increase speed of manufacturing processes

SULZER

Motor and drive manufacturer, WEG has published its second gearbox guidebook, helping buyers to ask the right questions in the geared motor buying process for their specific application and market

Battery storage for zero emission cities Exploring the benefits and drawbacks of greater standardisation in electric vehicle (EV) batteries Common fastener problems, and how to avoid them

OMNIFLEX

How plant managers are playing with fire

ALUCAST

Alucast looks to build on £1m of electrification wins by joining new cluster

SEMPRE GROUP

Making your manufacturing systems cohesive

Issue 47 PECM

3

W

Precise process monitoring

NTTYY AN RRA AARR

oonn

ct s

years uu iiffm m pprroodd

Hygienic pressure transmitter with IO-Link Interface Whether Whether food food or or beverage beverage industry, industry, milk milk production production or or meat meat processing: processing: The The ifm ifm pressure pressure transmitter, transmitter, PM, PM, reliably reliably monitors monitors your your process, process, with with aa high high accuracy accuracy of of 0.2 0.2 percent! percent! The The excellent excellent temperature temperature compensation compensation allows allows for for rapid rapid temperature temperature changes changes in in the the process, process, eg. eg. In In CIP CIP // SIP SIP up up to to 150° 150° C. C. This This makes makes the the pressure pressure transmitter transmitter ideal ideal for for demanding demanding applications applications in in the the food food industry. industry.

A A free free factory factory calibration calibration certificate certificate for for each each sensor sensor is is available available as as aa download. download.

Interested?

Interested? ifm ifm -- close close to to you! you!

Go Go ifmonline ifmonline ifm.com ifm.com//uk/pm uk/pm

Process

The leading source for innovators in Technology, Manufacturing and Maintenance within the Engineering & Processing industry worldwide.

Published bimonthly, a subscription to PECM magazine is essential for Process Engineers, Chemical Engineers, Instrumentation Engineers, Mechanical Engineers, Plant Engineers, Precision Engineers, Environmental Engineers & General Engineers, Companies and Organizations in the Food, Dairy, Beverage, Brewing, Semiconductor, Pharmaceutical, Biotechnology, Chemical, Oil & Gas, as well as all UK's major manufacturing units.

Every issue of the magazine contains the latest news, in-depth features, together with product innovations and case studies showing how process engineers are implementing new technologies to reduce costs and impact on the environment.

With over 140,000 readers worldwide the publication is widely read, recognized, and well respected within the Process, Engineering & maintenance industries.

A subscription to PECM magazine is the industry's 'must have' publication.

Hardcopy Edition SUBSCRIBE TO 6 BIMONTHLY ISSUES OF PECM FOR JUST £27 •

The magazine gets delivered directly to your door once every issue is published

•

The quality of the hard copy enhances the reading experience

Engineering MANUFACTURING

Control &

Suscribe

The Team EDITOR IN CHIEF Antony Holter editor@mhmagazine.co.uk

EDITOR Elizabeth Hutton elizabeth@pecm.co.uk

BUSINESS MANAGER Josh Holmes josh@mhmagazine.co.uk

STUDIO DESIGNER Richard Bland richard@mhmagazine.co.uk

SALES DIRECTOR Alexander Arnold alexander@pecm.co.uk Tel: 01227 936975

ACCOUNTS DEPT Alison Holmes accounts@pecm.co.uk Tel: 01227 936976

SALES MANAGER Lee Martin lee@pecm.co.uk Tel: 01227 936974

PUBLISHING DIRECTOR Martin Holmes martin@mhmagazine.co.uk Tel: 01304 806039

DIGITAL MANAGER Jamie Bullock jamie@mhmagazine.co.uk Tel: 01227 936971

EDITORIAL ASSISTANT Chris Nicholls chris@pecm.co.uk Tel: 020 3907 9161

To Subscribe please call 01304 806039

Digital Edition SUBSCRIBE TO OUR DIGITAL EDITION COMPLETELY FREE OF CHARGE Designed for the digital age, the magazine has been created for easy viewing on all electronic devices.

All our issues stored in one place: get unlimited access to our previous and future issues.

To Subscribe please visit www.pecm.co.uk/subscribe

Please mention Process Engineering Control & Manufacturing when responding to items in this issue.

MH Media Global Ltd.

Office 15, Innovation House, Discovery Park, Ramsgate Road, Sandwich, Kent, CT13 9FD

Tel 01304 806039 l Fax: 08721 152240 l www.pecm.co.uk

Every effort is made to ensure the accuracy and reliability of material published in Process Engineering, Control & Manufacturing however, the publishers accept no responsibility for the claims or opinions made by the contributors, manufacturers or advertisers.

No part of the publication may be reproduced or transmitted in any form or by any means, mechanical, electronic (including printing), recording or stored in any information retrieval system without the prior written consent of the publisher.

Issue 47 PECM

5

EDITOR’S CHOICE

LATEST NEWS FROM MGP MGP

Report shows that weaker supply chains are hitting SMEs looking to recover from Covid-19

SME manufacturers already hit hard by Covid-19 are being squeezed between a huge drop in demand and weaker supply chains according to a new report out today.

64% of the 289 respondents, who are engaged with the Manufacturing Growth Programme (MGP), said orders had dropped due to the pandemic, with furniture, software and general engineering the worst affected.

There was a similar number (59%) experiencing issues with their suppliers.

Nearly two thirds had seen delivery times lengthen, whilst 40% had seen an increase in costs including products, materials and services.

This, along with managing production levels with depleted workforces, has led to more than half of SME manufacturers

6

PECM Issue 47

taking additional loans since March to help them navigate their way through Covid-19 disruption.

Worryingly, only 11% of respondents felt that Brexit would offer a positive outcome for their businesses.

“The results raise important questions about resilience, both up and downstream for small manufacturers, particularly given the uncertainties in the economy,” explained Martin Coats, Managing Director at the Manufacturing Growth Programme (MGP).

“Everyone was aware of the drop in orders due to the national lockdown and global issues, but what hasn’t been so well documented is the production problems some companies are facing and how disruption is causing major issues with pricing, costs and delivery performance.”

He continued: “What this tells us is that the Government urgently needs to look at more targeted support for the supply chain if we are going to see a sustained recovery in manufacturing.

“Brexit is also adding to the uncertainty, with nearly a quarter feeling it will have a negative impact on their operations.

35% were not sure one way or another, reflecting a general malaise when it comes to discussing negotiations on the UK leaving.

“Only 10% of total sales amongst our 289 respondents was exported to the EU, posing the question of whether it is as big a market for SMEs as we first thought.”

a BEIS paper in 2018 that found only 20% of all UK SMEs export, it proves that manufacturers are a lot more receptive to pursing overseas orders.

However, going global still remains a big challenge for micro businesses, with half of them not currently generating sales overseas.

Martin went on to add: “There were some positives in the findings about the resilience of our manufacturers. 21% of them have actually increased their order books during the pandemic and, of those, 62% had diversified into new markets and just over half had introduced new products.

“This shows the strength of our supply chain and the ability to innovate and this is what we need to encourage through specialist help, access to new technology and grant support to help them reach their potential.”

He concluded: “We will be encouraging policymakers to use these findings to inform the development of effective measures that will support the recovery and growth of UK manufacturing.”

For further information or to download the report, please visit www.manufacturinggrowthprogramme.co.uk or follow @mfggrowthp on twitter.

MGP, which is ERDF funded and delivered

by Oxford Innovation Services, is the UK’s leading and largest business support programme aimed specifically at manufacturing SMEs. The programme has been tracking the impact of Covid-19 through its Manufacturing Barometer and this highlighted a number of supply chain issues that it wanted to explore in more depth. It responded by joining forces with leading policy experts SQW to produce a detailed report featuring nearly 300 companies.

The survey revealed some interesting statistics around international trade, with 57% of respondents undertaking some form of exporting. When compared with For further information, please visit www.manufacturinggrowthprogramme.co.uk Issue 47 PECM

7

EDITOR’S CHOICE

NEW HOUSING CONCEPT RITTAL

Smart Enclosures That Combine Great Performance & Attractive Design

By Emma Ryde, Rittal’s Product Manager for Industrial & Outdoor Enclosures Machine enclosures are never one-size-fitsall solutions; they are as distinctive as the equipment they protect. In fact, they are often custom-designed and made-to-measure - a time-intensive and expensive option.

However, there is an alternative, as illustrated

by PVA TePla, a vacuum specialist company for high-temperature and plasma process technology. It employs standardised housing to protect its systems and not just for reasons of efficiency. Let’s be honest, enclosures are not generally front and centre in people’s minds.

They are typically in the background, placed behind production machines or on remote steel platforms in factory buildings. Even the largest enclosures are not usually offered star billing; they are workhorses, providing basic support services. They need to perform, but not grab the limelight. Nothing more is expected of them. Their mission is to ensure reliable control and switching functions for industrial plant and machinery.

They protect people and technology, create an ideal environment for electrical and electronic components, and help deliver stable manufacturing processes.

In the engineering industry, however, enclosures have a more prominent, highprofile role to play. They appear not just behind machines, but alongside them - or even as an integral part of them – and they play a rather different role. With the help of control displays on doors and side panels, or by means of connected control and support arm systems, they act as assistants to the (human) machine operator. That is certainly the case for PVA TePla, a maker of specialist machinery.

At the company’s large and light-filled factory in Wettenberg near the city of Giessen, its enclosures almost overshadow the equipment they serve. They are positioned at the very front and dominate the overall appearance of the machines.

The vacuum technology specialist has employed Rittal enclosures for many years (including as a way of fully encapsulating its MOV 743 heat-treatment furnace) and since 2019 it has deployed the new VX25 system portfolio.

“The Rittal enclosure system allows us to build manufacturing equipment that boasts an attractive product design; it does not have the appearance of industry or mass production. They are products that would not look out of place in your living room,”

explains Martin Kaiser, Managing Director of PVA Control.

A BETTER LOOK WITH LOWER COSTS

“The idea to employ enclosures to house our equipment came to us when we discovered, by accident, that a long-established customer had asked a metal-working expert to create a ‘package’ for our machines that would make them suitable for presentation in a showroom,” states Kaiser.

For Kaiser, this was an opportunity to develop an entirely new housing concept.

The proposal was to take the design of an enclosure that had always been an integral part of the plant and apply it to the entire plant and all its housing.

“We were and remain convinced that housing a machine with a series of adjacent enclosures creates a highly attractive, consistent look-and-feel that also aligns visually with other switchgear units,” emphasises Kaiser.

QUICKER ASSEMBLY & INSTALLATION Faster assembly and installation translate directly into cost savings for the company.

“We generally have the housing complete in two days,” reports Kaiser.

Enclosure Climate Control Whatever the scale...... ......we have the solution ENCLOSURES ENCLOSURES

POWER POWER DISTRIBUTION DISTRIBUTION

CLIMATE CLIMATE CONTROL CONTROL

For PVA Control, conventional housing solutions are usually custom-built by an external specialist, a slow and expensive process. It includes the positioning of posts, the attachment of panels chosen in line with the specific use case, and the application of a powder coating. The company can now reap the rewards of its new modular enclosure system, which not only improves the installation speed, it also delivers greater flexibility. Once the mechanical design of the plant is complete, the next step is to define the appearance of the system as a whole – specifically, the outer dimensions and therefore the size of the housing.

To this end, PVA Control uses suitable standard components with Rittal pitch patterns for enclosures 1000mm and 800mm wide. The aim is to create a continuous housing with side panels and doors wherever access is needed, for example for maintenance.

The housing for the MOV 743 plant comprises a total of 12 individual enclosures and the benefits of this new approach are considerable. Ordering enclosures and accessories from Rittal’s catalogue or online shop is quick and easy. Plus, using attractively priced standard products cuts costs and the enclosures offer multiple assembly and installation options.

“The VX25 accessories and frame profiles mean we can install components virtually anywhere, allowing us to easily attach, for instance, pipe brackets or cable clamps.

We are pleased to have any opportunity to flexibly add something,” explains Kaiser.

Moreover, the simple machining of sheet metal for flat parts such as doors and side panels – for example, when drilling holes or

creating cut-outs for fan-and-filter units – is a real accelerator.

Furthermore, the enclosure technology can be integrated into the development of the plant itself; in other words, the housing can “expand” as the amount of equipment “expands”. Once the plant has been preassembled, additional enclosures are easy to add-on, for example, when a cable duct needs to be routed along the top of the housing.

“If this takes too much time, it is a disaster, because the team cannot make progress with their work tasks,” Kaiser explains.

ASSEMBLY AND INSTALLATION MADE SIMPLE

The enclosures also streamline the installation and removal of doors and side panels.

Once the equipment is placed within the enclosure frames, the doors and side panels can be quickly and easily added during

the customer acceptance process. VX25 enclosures are designed so that this can be done just one person without any tools; the door is simply placed on its hinges.

“The installation of doors and side panels for this system is typically complete within an hour,” Kaiser advises.

Without this modularity, assembling and dismantling the entire plant would be considerably more difficult for PVA TePla. Standardisation gives the engineering company a great deal of freedom, and the global availability of VX25 components is an added bonus if any repairs are needed.

As for the VX25 features he finds most impressive, Martin Kaiser summarises: “It’s the 130-degree hinges, the robust base gland plates, the many possibilities created by the new plinth system, and the fact that the enclosure system as a whole requires fewer accessories and less storage space – and therefore has associated cost benefits.”

Further information at www.rittal.co.uk and www.friedhelm-loh-group.com or on twitter @rittal_ltd.

IT IT INFRASTRUCTURE INFRASTRUCTURE

SOFTWARE SOFTWARE & & SERVICES SERVICES

www.rittal.co.uk

EDITOR’S CHOICE

Exalto Bearings UK Limited

MTM Products

Exalto Bearings UK Limited are manufacturers of water lubricated bearings for the Pump and Marine Industries in a variety of materials and sizes. As an ISO 9001:2015 accredited company we adhere to strict quality procedures and continually strive to improve our products and level of service to our customers throughout the world.

MTM Products have been established for over 40 years and are a leading manufacturer and supplier of industrial graphics products including self-adhesive labels, metal nameplates, graphic overlays, engraved labels and vinyl cut decals.

While standard bearings are stocked in a range of sizes for rapid despatch, Exalto also manufactures special non-standard sizes upon request. A modular tooling system means that Exalto can respond speedily to urgent requests for standard and custom-made bearings that are required for the highest standards passing even the rigorous requirements of the nuclear industry.

Exalto Sales Department Exalto Bearings UK Limited +44 (0) 1332 340501 sales@exalto.co.uk www.exaltouk.com

We have the knowledge and experience to advise you on the optimum graphics solution for your application, taking account of operating environment. We supply to many sectors including industrial machinery, electrical, automotive, rail, construction, medical and audio equipment. We offer excellent quality and service at competitive prices. MTM are certificated to ISO9001 and ISO14001. Our products comply with the current RoHS and REACH requirements MTM – the industrial graphics specialists Let us share our expertise to make your life easier

Flanged or threaded from 15mm through to 40mm orifice and 100 bar rated the design in the electronic circuitry within the box allows: Different opening / closing speeds at the flick of a switch which helps to eliminate

10

PECM Issue 47

TMG has a strong team, including a full-time inspection department, and is ISO 9001:2015 accredited with state of the art CMM equipment offering extensive measuring capability.

Get in Touch – our team can support you whatever stage your project is at…

GRAPHALLOY® Bearings...

We Go to Extremes

Muller Coax have developed a patented energy saving valve which can offer up to 80% power saving on similar sized valves.

The valve has an optical position indicator as standard on the terminal box for the open / closed position, the position indicator as also available as an electrical signal.

The Troy Manufacturing Group (TMG) sets the standards in bespoke precision engineering.

With more than 40 years experience it offers a vast range of high quality products, using the best in class materials, manufactured right - first time & on time.

It is proud to work in partnership with its customers providing a complete, fully tracked and traced, end-to-end precision engineering service including: • Bespoke In-house Design • Quality Manufacturing • Specialist Tooling & Design • Project Management

Contact us at sales@mtmproducts.co.uk or Email: enquiries@troymanufacturinggroup.com Graphalloy_Extremes_88mmx132mm.qxp_Layout 1 10/21/20 1:06 PM Page Website: www.troymanufacturinggroup.com www.mtmproducts.co.uk

60 Years of innovation brings you the green line valve

The new green line series has been specially developed as an energy efficient series of solenoid valves. For this reason directly controlled standard valves from Muller coax has been paired with completely new patented control electronics within the terminal box.

Engineering visions brought to life…

vibration and water hammer in the pipework.

Holding voltage as low as 7.5 watts for the smaller 15mm valve reduces the power consumption when energised for long periods and the solenoid remains cold.

For over 60 years muller coax ag has been an innovative leader in the unique design and manufacture of coaxial valves for many varied and arduous applications where many other valves fail.

For further details of this range of valves and the many diverse valving solutions we can offer see our website at www.co-ax.com or contact myself John Osborn on john.osborn@coaxvalves.co.uk Tel 01908 067583.

Handle High Temperatures and Harsh Operating Conditions with Ease.

• Survives when others fail • Run hot, cold, wet or dry • Corrosion resistant • Self-lubricating • Low maintenance • -400˚F to 1000˚F (-240˚C to 535˚C) Yonkers, NY USA • Ovens, furnaces, conveyors, mixers, dampers

Yonkers, NY USA

H1

+1.914.968.8400

•

www.GRAPHALLOY.com

EDITOR’S CHOICE

What is ‘The Motor Warehouse’?

It specialises in supplying LV Electric Motors 24 hours a day, 365 days a year. Making the process of sourcing a motor as simple as it can be by issuing customers a unique password and price list that allows direct ordering online, via telephone or email and even better, no order numbers are needed.

We ‘guarantee’ to have the motor you need in transit within 30 minutes of your request. Our aim is to change the UK Motors market by offering the unique service that todays 24/7 process industry requires.

Quantum Controls has invested in a solution that will deliver the following for UK industry: • 24/7 access to the UK’s largest stock of ABB & WEG Motors • Available ex stock, held centrally by UK logistics company • 2 and 4 pole motors available foot mounted, flange mounted and up to 250kW • All motor stock held is suitable for use with all forms of motor starters, including Variable Speed Drives • 24/7 direct telephone access to expert motor engineers to discuss application and seek help with motor selection if needed • Order placed direct to logistics company, no need to wait until our offices are open

• Motor will be in transit within 30 minutes of receiving your call, ‘guaranteed’ • Delivery time advised • Instant access without the need for Official Order Numbers This new service provides instant access to

WIMES Specification Motors any time, day or night, for the first time in the UK without the need for official order numbers, out of hours.

Register for your unique login details today and receive you own access pack, email us at motors@quantum-controls.co.uk.

www.quantum-controls.co.uk

24/7 MOTOR STOCK ACCESS 24/7 access to the UK’s largest stock of WEG & ABB Motors. 2 and 4 pole motors available foot mounted, flange mounted and up to 250kW. You can get a motor any time, day or night, in transit to your site within 30 minutes of your enquiry, without the need for official order numbers out of hours!

Register today to get instant access to our Motor Stock online, email us at motors@quantum-controls.co.uk.

The Motor Warehouse from Quantum Controls 0330 9000 247 | motors@quantum-controls.co.uk

Issue 47 PECM

11

EDITOR’S CHOICE

MARKET LEADING MAINTENANCE ROTAMEC

Rotamec raises repair capabilities with new 10-tonne capacity crane

Rotamec has added a new AG Crane that can span and traverse its entire Cheddar Branch workshop.

The addition of a new crane with a 10-tonne lifting capacity has greatly boosted repair capabilities at Rotamec’s Cheddar Branch workshop. Part of an ongoing reinvestment in its repair facilities for motors, generators, pumps, gearboxes and power transmission equipment - Rotamec now has the capacity to lift and service larger units typically utilised in water, recycling and power generation applications.

A 24/7 electromechanical service provider for rotating equipment, Rotamec’s capabilities are supported by its repair facilities located throughout the UK. These allow the business to deliver high quality rewinds, machined components, remanufactured units and refurbishments on reduced lead times. To bolster this existing capability, Rotamec has added a new AG Crane that can span and traverse its entire Cheddar Branch workshop.

This new crane essentially doubles our on-site lifting capacity.

Simon Brooks, Managing Director at Rotamec, commented on the new crane: “We are always looking to expand our service capabilities, of which our in-house repair facilities are a vitally important part. Our customers include key players in the water sector and utilities, so we wanted to expand our workshop capacity to allow for the repair of larger motors, generators, gearboxes and pumps that are common in these critical applications. This new crane essentially doubles our on-site lifting capacity.”

The new 10-tonne capacity crane joins a 3-tonne rated crane located in the winding shop and a 1.5-tonne crane installed in the pump test facility at the Cheddar Branch.

This combined lifting capacity constitutes one of the largest in the South West allocated for electromechanical repair work. Furthermore, Rotamec operates branches in Exeter and South Wales – totalling over 28,000 sq. ft of floorspace – which also provide additional repair support.

“With the new crane now operational, we are able to deliver our market-leading maintenance services for larger projects,” Simon enthuses. “We can combine fast reactions with an increased workshop capability to further reduce downtime for our customers requiring scheduled or emergency repairs of critical equipment.”

For further information, please visit www.rotamec.com

12

PECM Issue 47

EDITOR’S CHOICE

Coriolis Mass Flow Meters The new Tricor PRO Plus Series of Coriolis Mass Flow Meters is an accurate and highly repeatable meter with the smallest installation length on the market for installation into systems where space is limited. The TCD transmitter offers greater robustness, performance, diagnostics, and connectivity options. With a modern HMI interface and excellent logging functionality, the DSP transmitters provide users with an efficient configuration and analysis tool.

PRO Plus Series Features: • High dosing accuracy due to short response time (max. 10 ms)

• 100 Hz refresh rate makes this series suitable for pump monitoring and fast response control • Extremely short installation length makes for an easy fit in most configurations • Excellent zero stability for drift-free accuracy and longterm reading assurance • Extensive diagnostics and self-monitoring, including empty pipe detection Sizes from ½” to 2”. Available for Litre Meter, call 01296 670200, now.

www.litremeter.com

we GEMÜ SUMONDO

Single Use Putting you in control GEMÜ SUMONDO - World’s first Single-Use diaphragm valve • Panel mount actuator & mini positioner • Gamma-sterilizable valve body material • Quick clamp body (Flowpath ready)

www.gemu.co.uk

Issue 47 PECM

13

EDITOR’S CHOICE

SUPERIOR QUALITY DONGHUA

High precision EXL chain to hit UK

Pre-lubricated as standard, using high performance synthetic lubricant ensures high workload performance in arduous and abrasive conditions.

EXL Chain is a new high precision Roller Chain with superior quality and durability being launched in the UK by Donghua Limited.

Donghua EXL Roller Chain is a premium chain positioned within our Solution range. Utilising different materials, material treatments and layer technologies, our EXL Roller Chain offers the best possible quality/ price ratio for all applications.

Aimed specifically for the after-market, EXL Chain is designed, manufactured and tested for unbeatable accuracy and performance in arduous conditions, offering enhanced wear and fatigue resistance and greater precision than our Standard Roller Chain range.

New hardened, shot-peened wide waist plates deliver increased fatigue strength and a seamless cold forged solid bush and roller give full contact between the pin, bushing and roller for higher durability.

Optimised cylindrical parts improve sliding contacts which help increase service life.

EXL Chain is designed, manufactured and tested for unbeatable accuracy and performance in arduous conditions. incorporate Donghua’s unique Easy Break Technology. This unique feature enables EXL Chain to be cut in the field using Donghua Plate Extractor tools.”

Donghua EXL Roller Chains will be available in standard pack sizes of five metres, reels available on request, and bespoke cut-tolength sizes. Available in British standard 06B to 32B, American standard ANSI 35 to ANSI 160 in simplex and duplex exstock. All Donghua Chains are marked with production batch codes for full traceability.

With increased precision, higher wear resistance and greater fatigue resistance, EXL Chain is the Roller Chain solution of choice for UK stockists.

He added: “I’m thrilled to introduce this new Solution chain to the UK and hope our Stockists will be keen to see a new design of chain which offers significant benefits over standard Roller Chain” Donghua EXL Roller Chain is supplied Pre-loaded with 40-50% of the breaking load. Roller Chains can be matched in pairs to close tolerances in our UK workshop.

For chain lengths over 5 metres, the chain can be supplied matched & tagged for fitting in sequence.

Bob Wellsbury, managing director of Donghua Limited, says: “The new EXL Chain has been specifically developed to

For more information about EXL Chain email: sales@donghua.co.uk or call 01902 866 200.

14

PECM Issue 47

SOLUTION CHAIN Solid Roller Wide waist plate design

Solid Bush

Easy Break Technology High performance lubrication

EXL®® Specification: •

Chains according to ISO 606 (DIN 8187/8188) in size range from 06B to 32B and ANSI 35 to 160 inch pitch. Avaliable from stock in 5 mtr packaging incl. connecting link

•

Solid Bush and Solid Roller design, seamless cold forged bushing and roller provide full contact between pin, bushing and roller. Optimal cylindrical for ideal sliding contacts will improve chain service life.

•

Wide waist plate geometry for higher fatigue strength

•

EXL®® chains are easy to dis-assemble through built-in Donghua Easy Break Technology.

•

High length accuracy

•

Excellent press fit between pin, bush and plates. Controlling plate hole quality by ball drifting.

•

Hardened and shot-peened plates are standardized for extra strength.

•

Pre-loaded with 40-50% from breaking load

•

Pre-lubricated with high performance synthetic lubricant to meet high workload requirements.

•

Batch code number for track and tracing

*Up *Up to to 55 metre metre lengths. lengths. Longer Longer lengths lengths can can be be supplied supplied matched matched and and tagged. tagged.

Donghua EXL®® chains are designed, manufactured and tested to meet the highest specifications for unbeatable accuracy and performance.

EDITOR’S CHOICE

MJF INVESTMENT 3DPRINTUK

£1 Million strategic expansion plan extends service portfolio at 3DPRINTUK 3DPRINTUK, a leading service provider of polymer powder bed fusion (PBF) 3D printing processes for manufacturing and batch production applications, has now fully executed an impressive £1 million strategic expansion plan. This followed considerable investment in equipment that allows the company to offer an ever-expanding range of services and materials for its customers.

The final piece of the jigsaw was the introduction of the MultiJet Fusion (MJF) 3D printing process, with the acquisition and installation of the most advanced polymer MJF system available — the 5210. This machine is the first of its kind to be installed in a UK 3D printing service bureau.

Explaining the reasoning behind this machine acquisition, Nick Allen, 3DPRINTUK’s CEO said: “We’ve been watching MJF mature since 2015 and have been waiting for the right moment to add it to our offerings. We believe the time is right to invest in MJF as it now meets the demands of our customers and their applications with the 5200 series. It is important to distinguish the investment in the 5210 system over previous systems in the original 4200 series of machines because it marks a considerable step forward with the MJF process. This is based on our extensive in-house testing of parts from both series and there are big improvements with the 5210 in key areas such as part quality, repeatability, Z-axis scaling, heating control and accuracy.”

Adding the MJF process to the company’s repertoire follows a series of recent

announcements throughout 2020 that expand on the expert services 3DPRINTUK have provided for almost a decade with the Selective Laser Sintering (SLS) process. This includes the addition of a new SLS Flexible material, new colour dyeing options and two new large-scale EOS P396 machines that allow for the production of larger parts while also significantly increasing overall capacity. Furthermore, 3DPRINTUK has also invested in new post-processing equipment from DyeMansion, which enables them to offer a shot peening service for low, medium, and high volumes of SLS or MJF parts that greatly enhances the surface finish.

On the expansion plan, Allen continued: “During the height of the Covid pandemic, we made a pragmatic decision that we would use this time to augment our 3D printing services in order to offer broader and more

flexible manufacturing options for our customers. By adding a new process — one a significant number of clients have asked for —increasing our capacity and being able to produce larger parts, we are now in a position to meet all of our clients demands for their batch production applications with polymer materials. The additional finishing options only strengthen our service offering and means that we can offer a comprehensive service from a single supplier. Throughout the whole of lockdown, when many supply chains were stalling, we were able to continue to provide a reliable service without compromising on quality for a range of projects, including those supporting the pandemic response.”

For further information, please visit www.3dprint-uk.com

16

PECM Issue 47

3D 3D PRINTING PRINTING SERVICE SERVICE SPECIALIZING SPECIALIZING IN IN LOW LOW VOLUME VOLUME MANUFACTURE MANUFACTURE AND AND PROTOTYPES PROTOTYPES T. T. 0208 0208 692 692 5208 5208 hello@3dprint-uk.co.uk hello@3dprint-uk.co.uk www.3dprint-uk.co.uk www.3dprint-uk.co.uk Upload Upload your your .stl .stl file file on on our our website website for for an an immediate immediate quote. quote.

Price Price breaks breaks for for higher higher volume volume orders. orders.

SLS AND MJF PA12

POLYMER 3D printing service NEW SERVICES AND MATERIALS AVAILABLE 3DPRINTUK 3DPRINTUK are are aa leading leading service service provider provider of of polymer polymer powder powder bed bed fusion fusion (PBF) (PBF) 3D 3D printing printing processes processes for for manufacturing manufacturing and and batch batch production production applications. applications. We We have have now now fully fully executed an impressive £1 £1 million million strategic strategic expansion expansion plan. plan.

FLEXIBLE PARTS

3DPRINTUK 3DPRINTUK is is now now offering offering the the production production of of flflexible, exible, rubberrubberlike like parts parts using using our our new new material material ‘SLS ‘SLS Flexible’ Flexible’ (PEBA (PEBA 2301).

2301).

SHOT PEENED

AA shot shot peening peening service service for for all all SLS SLS and and MJF MJF nylon nylon PA12 PA12 printed printed parts parts that that greatly greatly improves improves the the surface surface fifinish. nish.

COLOUR SLS PARTS

Colour Colour SLS SLS parts parts available available in in Black, Black, White, White, Green, Green, Blue, Blue, Red Red and and Yellow Yellow with with more more colours colours to to follow follow soon. soon.

HP 5210 MULTI JET FUSION

After After the the acquisition acquisition and and installation installation of of the the most most advanced advanced polymer polymer MJF MJF system system available available — — the the 5210, 5210, we we now now offer offer the the Multi Multi Jet Jet Fusion Fusion (MJF) (MJF) 3D 3D printing printing process. process.

Upload your .stl file now for an instant quote!

ORDER PARTS ON DEMAND 1 -10,000 UNITS, EXPRESS TURNAROUND FANTASTIC CUSTOMER SERVICE PARTS SHIPPED WORLDWIDE

3DPRINTUK

ADDITIVE FOR MANUFACTURE

EDITOR’S CHOICE

LATEST NEWS FROM CBM CBM

New Covid-19 support measures will save thousands of jobs in the metalforming sector Thousands of jobs in the metalforming sector will be saved thanks to the latest measures of Coronavirus support announced by the Chancellor yesterday according to the trade body for the sector.

The Confederation of British Metalforming (CBM), who represent over 200 companies involved in the manufacture of fasteners, forgings, pressings, cold-rolled and sheet metal products, has welcomed Rishi Sunak’s mixture of Job Support Scheme (JSS), extension of Business Support Loans and VAT deferrals as industry battles with falling volumes due to the pandemic.

According to its latest survey, 90% of its members had accessed the furlough scheme and, more importantly, 65% would

18

PECM Issue 47

change their mind on future redundancies if further assistance was in place.

the worst affected industries due to factory closures and the air travel falling off a cliff.

The report painted a stark picture of current performance, with 88% of firms admitting that volumes had been hit by the pandemic and four fifths predicting their future sales forecast will be below average.

“The furlough scheme has been a great success, but the October deadline is fast approaching and our members are starting to plan for future staffing levels against the reality of sales they are expecting.”

An overwhelming 90% of companies believe a stimulus package for certain sectors is needed, in order for the economy to recover to pre-Covid19 levels.

She continued: “The Job Support Scheme will give them more time to look at new revenue streams, whilst providing flexibility to get people back into work at reduced hours.

Geraldine Bolton, Chief Executive Office of Confederation of British Metalforming, commented: “A lot of our members are heavily involved in the automotive and aerospace sectors and these are two of

“We have spent so long addressing skills shortages in our sector, the last thing firms need is to lose skilled people as it will hamper them in their longer-term recovery.”

CBM has been lobbying Government for the last four months about a reverse Job Retention Scheme that incentivises businesses to bring back staff in some capacity.

It had also been asking for a raft of other support measures to help the cashflow of viable companies hit by the pandemic and is happy that the requested VAT and Corporate Tax extensions have been put in place to give businesses a further 12 months to make payments.

that has been turned upside down by the pandemic.”

An overwhelming 90% of companies believe a stimulus package for certain sectors is needed.

CBM represents over 200 members, providing the largest collective voice for the metalforming sector.

It provides essential lobbying, training services, access to knowledge sharing events and support with Climate Change Levy administration, the latter delivering more than £4m of savings to members every year.

“Coming to terms with Covid-19 is one thing, but it is also clear that our members are very worried about the impending spectre of Brexit and the increasingly likely reality of a ‘no deal,” added Steve Morley, President of the Confederation of British Metalforming.

“58% of companies in our sector feel leaving the EU will have a detrimental effect on their business and, importantly, more than half would like to see an extension to negotiations.”

He concluded: “The message is clear… leaving without a deal should not be an option. It would have been a testing time for business in a normal world, let alone one For further information, please visit www.thecbm.co.uk or follow @cbm_uk Issue 47 PECM

19

EDITOR’S CHOICE

Highly accurate, wide bandwidth, very fast response and fully isolated current sensors from ACEINNA All in One, Easy to Integrate Current Sensors for Inverters and Motor Control, Industrial Robots and Manufacturing Systems, Telecom and Server Farm Power Supplies, Automotive EV Charging Stations, IoT Appliance, Home Automation and many other tech applications ACEINNA’s new MCx1101 family of ±5A, ±20A, and ±50A Current Sensors for industrial and power supply applications are the first high accuracy wide bandwidth AMR-based current sensors on the market. These integrated, AMR based Current Sensor family provides the best performance for the price in the industry.

The fully integrated 3.3V and 5V MCx1101 current sensors provide industry benchmark performance for accuracy, bandwidth, and output step response time. With total error as low as 0.6% (typ), 3dB bandwidth

of 1.5MHz with low phase delay, and <300ns transient response, these current sensors have 4.8kV of isolation. They are available in fixed gain output (“MCA”) and ratiometric output (“MCR”) options. These current sensors have low offset, e.g. ±30mA typical, or ±0.3% of FSR (max) at 85C for 20A parts..

For additional technical details https://www.aceinna.com/ current-sensors. 1-978-965-3200 info@aceinna.com

Order the part from Mouser at https://www.mouser. com/ACEINNA/Sensors/ Current-Sensors/_/N7gqeu?P=1y91mso

Demag delivers maximum safety for load turning Material handling specialist, Demag, has introduced a new load turning function for its universal crane product range.

The load turning capability achieves maximum safety and significant operational advantages, without the need for potentially costly additional engineering features. The Demag SafeControl safety control unit monitors the entire load turning process. Many users of indoor cranes are faced frequently with the complex task of not only lifting and horizontally moving heavy components, such as press tools, machine beds

Pentagon Plastics Group

Introducing GRAPHALLOY®

The Pentagon Plastics Group provide bespoke mould tooling solutions and plastic injection moulding production, all from one site of UK manufacture.

GRAPHALLOY® a graphite/metal alloy, is a proprietary material that has exceptional mechanical, chemical, and tribological properties. As a result, GRAPHALLOY® works where traditional bearings often fail.

It is particularly useful where petroleum lubricants cannot be used, for example, at high temperatures and in submerged applications.

Self lubricating GRAPHALLOY® withstands high temperatures, performs well under cryogenic conditions, and can survive dry running in pumps. It maintains its integrity even when submerged in hostile liquids such as acids, Alkalies, hydrocarbons, black liquor and natural gas liquids (NGL).

Unique in their offerings the group are one of the few UK based injection moulding companies with the ability to support customers throughout the life of a project.

From the early design phase right the way through to repeat production of low to medium volume, your project will be handled by their expert and experienced in-house team.

Delivering consistency and accountability through each phase of a customer project, make Pentagon your supplier of choice for UK manufacture of plastic injection moulding.

To make an enquiry, call us on 01403 264397 or email websales@pentagonplastics.co.uk For more information on all of our services please visit www.pentagonplastics.co.uk

20

PECM Issue 47

GRAPHALLOY® bushings provide lifetime cost savings over conventional bushings and bearings and are available in NSF, WRAS and FDA grades.

Contact: Dennis Rawle | +44 (0) 7810662113 dennis.rawle@graphalloy.com https://graphalloy.com/html/ featurespecmnov20.html

or special containers, but also turning these loads.

This function has been possible with Demag cranes for decades, but it required additional engineering features.

Demag has now simplified and standardised the load turning function, with universal cranes and two hoists delivering the highest levels of safety, whilst eliminating the need for the same level of supplementary engineering work previously required.

www.demagcranes.co.uk

Snickers Workwear Sustainable Merino Wool Clothing Stay warm or cool in our 100% AllNatural Merino Wool mid- and base-layer clothes that deliver optimal comfort for all kinds of working environments and leisure activities when the weather gets chilly. There are short and long sleeve T-shirts as well as leggings and topwear that combine superior wool warmth with body-mapping designs for the ultimate base- and mid-layer protection in really cold conditions. Designed by nature for excellent ventilation and insulation, Merino wool is extremely soft, and naturally odour-preventive for an all-day fresh feel. It’s also temperature-regulating, repels water, dirt particles. It’s anti-static and Snickers Workwear ensures that the wool it uses is produced in kind-to-animals, ‘Mulesing-Free’ environments. All in all, Snickers Workwear clothing for autumn and winter give you the kind of warm, dry and fresh working comfort you wouldn’t have thought possible.

That’s why Snickers Workwear is the brand of choice for working outside in cold weather. www.snickersworkwear.co.uk

EDITOR’S CHOICE

LATEST NEWS FROM METLASE METLASE

MetLase launches ‘smart’ products to connect and increase speed of manufacturing processes

One of the UK’s leading specialists in tooling, intelligent fixturing and components is launching a new range of ‘digital’ solutions that will connect manufacturing processes and enable easier, faster automation.

MetLase, a joint venture between Unipart and Roll-Royce, commissioned a dedicated team to develop ‘smart’ products, including the Digital Gauge (conducting a digital dimensional inspection process), Smart Bench (ensures no-fault forward in the assembly process as well as connecting up-front supply chains) and Smart Cell.

The latter covers multiple manufacturing processes and can enable human interaction with cobots and robots. This means tasks, including stock control and direct-to-bench supply of components, can be more easily automated.

Engineers at the Rotherham-based firm haven’t stopped there, taking a similar approach to Smart Machining by creating a smart fixture that can gather critical data

22

PECM Issue 47

This is just the start. More and more customers are switching on to the benefits of digital manufacturing in the overall process.

“This involves taking traditional manufacturing principles focusing on assembly, bonding, measuring, workholding and assembly workstations, and exploring how we could digitise them in a way that would allow them to provide their core function whilst also gathering data.

“For us, digital manufacturing is not a standalone entity. Instead, it should be a critical aspect of the process and operation, and it should revolve around data and, specifically, digestible, actionable data.”

from a component such as clamping forces, vibration, temperature, and dimensional measurement. This provides better process control and ongoing improvements.

He continued: “With these new products, we have been able to demonstrate how easily and cost effectively data can be harvested, automatically digested and analysed, and then put to use immediately, in order to get the maximum benefit from it.”

Richard Gould, Business Development Manager at MetLase, commented: “Our digital products have to deliver bottom-line benefits to our clients, who operate in the automotive, aerospace, construction and renewables sectors.

MetLase’s digital products are already having an impact on industry, with one of the most striking examples being a project with Kautex Unipart Ltd and a leading supercar manufacturer to support in-line composite pre-form measurement.

Digital gauges are being used to support the inspection of blow-moulded plastic fuel tanks in just four seconds, replacing an inspection system that would usually take 45 minutes, during which time the line would churn out parts.

If a fault was found at this stage, all the components made in that period would be destined for the scrap pile. In addition, it also allows data to be collected that is ‘actionable’ for process improvement and machine learning.

operation, providing more people with employment opportunities and a vital start in manufacturing.”

He concluded: “This goes back to the point about making the benefits of digital manufacturing easy to understand. If done correctly, it will help companies improve their operations, become more productive,

and create employment and commercial opportunities for UK manufacturers.”

MetLase is hosting a number of Manufacturing Masterclasses to help UK industry embrace new processes and technology. All of the webinars are free to attend and can be found at www.metlase. com/webinars/

Richard added: “This is just the start. More and more customers are switching on to the benefits of digital manufacturing in the overall process.

“And we’re not just talking about impact on shopfloor. One project we’re currently exploring is the introduction of a Smart Bench to support a maritime application, where a global business has won a contract that includes an element of regenerating a region’s manufacturing sector.

“The bench potentially helps in that it instructs and inspects so well that operators, who are not highly skilled engineers, can now carry out a complex For further information, please visit www.metlase.com or follow @metlase on twitter Issue 47 PECM

23

EDITOR’S CHOICE

Cambridge Numerical Control

KLEENOIL

Cambridge Numerical Control have been established for over 40 years as a software supplier to the engineering industry.

Industry 4.0 and OEE are becoming a must have; the industry needs accurate production and productivity data, along with revision and access control of their NC programs.

Cimco MDC-Max software captures live data from CNC machine tools, manual machines and assembly processes which enables our customers to react immediately and be pro-active, not reactive in their production decisions.

Is your production machine operating efficiently? Most everyday issues are simply down to dirty oil such as; • Damage of interacting components via abrasion.

• Reduced component life via erosion.

• Obstructed critical flow paths.

• Damaged servo or proportional valves.

• Increased quality problems.

• Raised costs

New Flow/Conductivity instrument The new Starflow QSD range of open channel flow instruments are used in clean and wastewater monitoring. These have an optional conductivity sensor that makes it easy to identify pollution events in final effluent discharge channels with just one device.

The QSD can be installed in pipes, culverts or natural streams without the need for weirs or flumes to calculate flow.

Cellulose depth filtration may be considered a traditional method of fine oil cleanse, but it is still the best. KLEENOIL filters use strong, specialized cellulose fibres for strength and improved filter efficiency, especially for the retention of very small particles down to 3 micron absolute / 1 micron relative and removal of 99.7% moisture.

For applications that need that next level of filtration ‘polishing’ ; cellulose filtration remains unbeatable. KLEENOIL is an affordable solution to resolving these issues.

The Starflow QSD comes either as a standalone instrument with SDI-12 or Modbus outputs, or as part of an integrated datalogger system that computes flow and connects by cellular, satellite or ethernet networks as an IOT device.

www.kleenoil.co.uk

www.streamlinemeasurement.net

Integrated solutions

Palamatic

With an extensive range of products, from small junction boxes to wall mounted enclosures up to large modular systems, Tempa Pano has strived to innovate to suit the market requirements. Aiming to provide customers with integrated solutions Tempa Pano correspondingly offers a comprehensive range of accessories to compliment the enclosures which include low voltage busbar systems, climate control products and facilities to help the client with installation. With all these options Tempa Pano can provide it’s customer with complete solutions, tested to the highest standards.

• IP65 Wall Mount Enclosures • IP55 & IP65 Junction Boxes • IP 55 Floor Standing Enclosures • 304 & 316 Grade Stainless Steel Enclosures.

• ATEX Approved (Ex e & Ex ie) Enclosures • Electronic System Cabinets • Console Systems • Power Distribution Busbars • Climate Control Products.

Palamatic design, manufacture and provide materials handling equipment and vacuum lifting technology to help operators to perform tasks safely, removing injury risks and protecting products from damage.

Anytime, Anyplace, Anywhere...

The on-Cloud solution that delivers simplicity

Since the advent of AS9100 rev D customers require proven revision control of their CNC programs and other production paperwork.

Cimco NC-Base controls access to all CNC programs and quarantines changes, it also provides audit reports for any CNC program with revision history and user control.

Tel +44 (0)1480 468639 sales@cnc.uk.com www.cnc.uk.com

www.tempapano.com

24

PECM Issue 47

Our semi or fully automatic sack opening machines significantly reduce environmental dust emissions and dramatically increase productivity and production volumes and are a proven COSHH solution.

We also specialise in the manufacture and development of cGMP sanitary hygienic handling equipment for use in controlled environments.

We are conveniently based in Chesterfield, Derbyshire and have a sales office and factory in North Carolina, USA. For a no obligation sales visit and quotation for a solution, you can contact us at sales@palamatic.com or telephone +44 (0)1246 452 054.

There is also an optional Starflow Process Display Instrument that monitors depth, velocity, flow, temperature and conductivity.

Outputs include Modbus, 4-20mA and pulse for local control.

CATIA 3D CAD On the Cloud: easy to implement (< 20 minutes to connect to your Cloud), full design suite of applications, together with collaborative framework to manage projects and design activity.

On the Cloud platform delivers flexibility and single point of access and common interface for all applications and enables all business units – design, engineering, simulation, manufacturing, sales, marketing, finance, procurement and management – to engage in collaborative innovation. Move your business to the next level and network your organisation into a social design community.

Take away the headache and risk of backups, software upgrades, infrastructure cost and complexity and spend more time designing. www.dte.co.uk/catia-3dexperience-on-thecloud/

SIRIUS ACT Control and signalling devices in a modern design from Siemens

Robust metal designs with a high protection rating of IP69K for use in all areas SIRIUS ACT offers innovative features such as ID key-operated switches and IO-Link connection Shapely, flat 30 mm construction for a modern machine design

automation24.co.uk/sirius-act-siemens

All products

IN STOCK

for example: Emergency-stop/off button complete device SIRIUS ACT 3SU1150-1HB20-1CH0

Item number: 105190

for example: Pushbutton complete device SIRIUS ACT 3SU1150-0AB40-1BA0

Item number: 105173

for example: Indicator light complete device SIRIUS ACT 3SU1152-6AA50-1AA0

£19.17

£8.82

£9.72

We are happy to advise you personally! +44 178 489 5006 00800 24 2011 24 (free)

info@automation24.co.uk

Item number: 105203

LIVECHAT www.automation24.co.uk

LIVECHAT

EDITOR’S CHOICE

PIPE REPAIR SOLUTIONS SYLMASTA

Industry-leading products developed and manufactured in the UK Pipes are everywhere. We rely on them in our factories, our businesses, our homes.

When they start leaking or suffer a burst, the consequences can be severe in terms of the potential damage water can cause and the costs incurred through loss of earnings and hiring contractors to repair or replace systems.

Which is where Sylmasta come in. Sylmasta use resin technology to develop repair and maintenance products – including Pipe Repair Kits, which enable a user to permanently fix a leaking pipe inside of 30 minutes without the need for any formal training.

Expensive shutdowns and replacements of systems are no longer necessary. Simply use the contents of a SylWrap Kit and you can carry out repairs on live leaks which are pressure resistant up to 30bar, temperature resistant up to 250°C, and WRAS approved, so safe to use on drinking water.

Repairs are made in a simple, two-stage process which begins with sealing the leak using either Superfast Epoxy Putty or Wrap & Seal Pipe Burst Tape and then overwrapping with a resin-infused, water-activated SylWrap composite repair bandage.

SylWrap Kits can repair even the most challenging of leaks. When a furniture factory was told that the only solution for a pinhole leak in their sprinkler system was a full replacement at a cost of tens of thousands of pounds, a SylWrap Pipe Repair Kit instead fixed the problem in 24 hours.

The 8bar pipe in question was high in the factory roof, making access difficult to apply a clamp and it was located perilously close to the incoming electricity supply. It was little wonder no maintenance company could find a solution – until the furniture company turned to Sylmasta.

SylWrap Pipe Repair Kits have been used for pipe repair in factories, petrochemical plants, wastewater treatment plants,

quarries, farms, nuclear power stations, freight ships, oil rigs, leisure centres, hotels, even breweries.

This versatility and ease of application means that companies worldwide turn to Sylmasta products whenever they need their pipework repaired, knowing that resin composite technology offers an alternative to costly replacements.

If you have pipework that needs repairing, strengthening, or refurbishing, then see what Sylmasta can do for you at SylWrap.com

For further information, please visit SylWrap.com

26

PECM Issue 47

EDITORâ&#x20AC;&#x2122;S CHOICE

MCS Corporate Strategies Ltd For all R&D Tax Claims / Land Remediation / Patents / General Cost Recovery

MCS Corporate Strategies Ltd For all R&D Tax Claims/Land Remediation/ Patents/General Cost Recovery

www.mcs-corporate.com

01926 512475

gjw@mcs-corporate.com

Issue 47 PECM

27

MADE I

NT

THE UK

•M

•

N

HE UK

®

ADE

I

HAZARD FREE BONDING. ZERO COMPROMISE. Bondloc UK Ltd is an ISO 9001:2015 British Manufacturer of Industrial adhesives with over 25 years’ experience in adhesive production. Our products are used in the most demanding applications within the engineering and manufacturing industry.

Bondloc’s White Label adhesive range offers exceptional bonding performance without hazardous, carcinogenic, mutagenic or toxic ingredients. Fully compliant with the latest EU health and safety regulations with no hazard symbols, no safety phrases and no costly COSHH assessments. Furthermore, they are safer for the environment and safer for you.

•

HAZARD-FREE

•

FULLY COMPLIANT

•

HIGH PERFORMANCE

•

NO COSHH ASSESSMENTS

•

NO HAZARD SYMBOLS OR SAFETY PHRASES

•

WL77 IS APPROVED TO GAS EN571-1 AND WRAS 5520 FOR POTABLE WATER USE

Number WL42 WL70 WL74 WL77

Product Nutlock threadlocker Studlock threadlocker Instant Gasket Pipeseal thread sealant

Strength Medium High Medium Medium

For more information contact sales@bondloc.co.uk or call 01299 269269 | bondloc.co.uk

EDITOR’S CHOICE

A two-part sealant for ALL your joint repairs Available in 3 viscosities

Thin | Ultra Thin | Thick mwpolymers.co.uk | 01332 835001 GAS

ELECTRICITY

WATER

OIL

we make ideas come to life

RMIG is the world’s largest manufacturer and supplier of perforated metal and its related products.

We know our customers’ requirements for price and quality and meet their demands with uncompromising service.

Not only do we offer standard and bespoke perforated metal sheets, we are able to offer you a range of secondary operations as detailed below.

Complete solutions With a continued investment in the latest equipment and a network of professional partners we are able to produce prime quality products and solutions – from a simple perforated sheet to the fully formed and coated custom made part.

Cutting We can cut and shape perforated sheet to meet the needs of your final application.

Levelling For some applications a high degree of flatness is required, we have processes in place to ensure our perforated coils and sheets meet with your most demanding requirements.

Rolling and forming We can roll, bend and form perforated sheets to match your design.

Aesthetic finishes and protective coating We can offer powder coating and hot dip galvanizing solutions to meet your specifications.

For more information please contact us tel: 01925 839610 | email: info.uk@rmig.com | www.rmig.com

Issue 47 PECM

29

EDITOR’S CHOICE

Portable Kit Moves Materials and Equipment Up to 34,000 lbs AeroGo Inc., offers a portable kit to move machinery, material, and equipment up to 34,000 lbs. and up to 40’ long.

The load is secured by placing 4 ‘modules’ under load points and using compressed air to lift and float the load on air casters.

Satisfied customers have commented that ‘Rigging and setup are streamlined’ and ‘The system greatly reduces safety exposure.’

Lightweight and compact, the kit stores easily in an included waterproof wheeled case. The kit includes four load modules and accompanying air hoses along with a flat supply hose.

For more information, call +001 (206) 575-3344 or email info@aerogo.com. Equipment can be viewed online at www.aerogo.com/products/ portable-rigging-kit/.

Panacol and Hönle develop new system solution for filament winding processes With the newly developed Vitralit® UD 1405 adhesive, Panacol has created an innovative adhesive system for fibre and filament winding used to wrap components such as hybrid rotor shafts for electric motors and high-voltage surge arresters. Fibres or filaments can first be pulled through an adhesive bath, then wound onto the rotor or respective cylinder. The adhesive-coated fibre-reinforced windings can then be quickly cured with UV or visible light.

This innovative winding process is extremely cost and time saving. Vitralit® UD 1405 is a transparent, solvent-free, one-component epoxy with low viscosity. It can be cured in seconds with UV or visible light. Depending on the fibre material and the wavelength used, layer thicknesses of several millimetres can be achieved exclusively by light curing. The epoxy can also be thermally cured after UV exposure to ensure a complete cure in shadowed areas. www.panacol.com

30

PECM Issue 47

Solar Technologies Canada Solar Technologies Canada, proudly introduces a Sun Control Film developed by their R&D team, through innovation and collaboration with commercial and academic partners, that not only protects you from heat and ultraviolet rays but has anti-viral and anti-bacterial properties.

Actively reducing viral load on glass surfaces, specifically Human Corona Virus. The permanent antiviral nano coating on the film uses invisishield™ technology to neutralize Viruses and Bacteria in a few hours. Developed

by Future Technology Innovations Inc. and certified by world recognized and respected bodies to kill 99.9 percent of Bacteria and Viruses that come in contact with it, plus to be human safe. Sold under the STC brand this anti-viral Sun Control film is ideal for use in areas where exists a risk of bacterial or viral transfer. Such as Schools, Hotels, Hospitals, Buses, Taxis to name just a few.

Contact: sales@stcfilms.com

ETI Elektroelement ETI Elektroelement is among five largest producers of fuses in the world and one of the leading producers of innovative switches and circuit breakers. ETI’s products (fuses, MCBs, MCCBs and ACBs) cover the range from 0,5A to 6300A and we can provide individual products and product lines or complete, integral solutions for control and protection of residential, commercial, industrial installations as well as those for electric power distribution, photovoltaic and battery storage systems, and other renewable energy sources.

ETI group consists of 15 subsidiaries in various European countries and we closely cooperate with selected partners all over the world. We are pioneers in the field of protection of battery storage and photovoltaic systems and cocreators of international standards in the field of fuses and switchgear.

www.etigroup.eu

Heard about the FLUKE ii900 Sonic Industrial Imager?

Locate compressed AIR / GAS / VACUUM / STEAM leaks in your facility.

Pinpoint compressed air leaks in minutes to reduce bills and maximise productivity Scan large areas quickly and efficiently.

SAVE MONEY AND TIME: • Ensure proper air pressure to your pneumatic equipment • Lower energy costs • Reduce leak detection time • Inspecting hazardous areas? Ensure your team is safe • Easy-to-use!

• You do not need to plan down-time!

Buy now from Acutest and receive another item of FLUKE Test Equipment FREE*.

Phone: 01782 563030 Email: sales@acutest-ukti.co.uk www.acutest-ukti.co.uk

BioViron International: Leading experts in 100% Compostable and Biodegradable materials since 2005 BioViron’s range of 100% plant based, compostable and biodegradable materials offer a quality replacement to single use plastics and plastic packaging, helping businesses be better for the environment, reduce carbon emissions and waste while offering their clients a quality point of difference.

It’s time to make the switch to zero-plastic packaging.

Discover 100% water soluble, compostable and biodegradable foam, 100% home and industrial compostable film and 100% compostable thermo-forming sheet.

Visit BioViron.com and be better at business. @bioviron

BOILERS & MAINTENANCE

Rotational mould specialist gains from latest Lanemark process gas burner technology Romold, manufacturers of plastic spill containment products, is now benefiting from the latest process gas heating technology from Lanemark Combustion Engineering – the rotational moulding operations now undertaken by the Livingston-based company feature a Lanemark FDGA forced draught burner system.

A Lanemark FD30GAN-3 burner, rated at 1,320 kW, and a combustion air fan inlet filter, control system and associated pipework upgrade are all now operational at the site. Replacing and older non-Lanemark burner, the improvement in efficiency was immediately evident, according to the company’s Production Planning Manager, Michael Adams –

“Our old burner would take some 45 minutes to reach the target temperature of 260°C, which has now been reduced to just five minutes,” he says. “Heat distribution is also very even throughout the chamber which has a direct operational input on the quality of the product that is at the heart of our reputation.”

The Lanemark burner fires through the wall of a Rotospeed machine where a multidirectional arm, that supports the mould, moves as part of the rotational moulding process.

The Lanemark installation at Romold has been supplied complete with the burner manufacturer’s BurnerCare support package which delivers ongoing operational confidence via a combination of factors that include service agreements, spares supply and engineer support.

“This facility is a vital part of the production process for a company that plays a major role in its industry in the UK and worldwide,” concludes Lanemark Sales Director Jeff Foster. “We are very happy to have enhanced our involvement with Romold with this new installation and believe that it will meet the customer’s process heating objectives for many years to come.”

www.lanemark.com

Gas Process Burners Lanemark gas burner systems offer users reliable, high efficiency, process heating solutions.

FD Series Packaged Oven/Dryer Burners Specifically designed for process air heating applications in convection ovens and dryers High turndown/short flame lengths providing accurate process temperature control High efficiency gas + air modulation, gas only modulation and simple high/low control options Heat Input Range: 9 kW – 1550 kW

• • • • FD-C high turndown oven/

FD-E low cost high turndown

dryer air heating burners.

oven/dryer air heating burners.

FD-GA modulating gas + air process air heating burners.

TX Series Gas Fired Process Tank Heating Systems High efficiency (80%+) heating of all types of spray and dip process tanks Compact high efficiency small diameter immersion tube heat exchangers occupying minimum tank space Accurate performance modelling using Lanemark TxCalc design software Heat Input Range: 15 kW (1½") – 1150 kW (8")

• • • •

Midco HMA Series Air Replacement or “Make-Up” Air Heating Burners Direct fired, high efficiency burner systems, for high volume air heating applications such as paint spray booths, ovens and dryers.

Supplied either as Midco burner heads for OEM system integration or as Lanemark DB or FDB complete packaged systems including modulating gas valve trains and controls Wide range of firing rates to suit alternative temperature rise and air velocity system requirements DbCalc system design software

• • •

Midco HMA high efficiency,

high turndown, air replacement or “make-up” air heating burners.

TX high efficiency small diameter immersion tube tank heating systems.

Lanemark Combustion Engineering Limited Lanemark House, Whitacre Road, Nuneaton, Warwickshire CV11 6BW United Kingdom Tel: +44 (0) 24 7635 2000 Fax: +44 (0) 24 7634 1166 E-mail: info@lanemark.com www.lanemark.com

X4620 Lanemark Ad SDAW.indd 1

•

COMBUSTION ENGINEERING

Issue 47 31/08/2016 PECM

31

09:04

CONNECTORS & FITTINGS

PUSHING PERFORMANCE HARTING

HARTING connectors deliver time and space saving benefits

and cable harnesses separately, further improving efficiency and time-savings.

HARTING has over 70 years’ experience of producing robust industrial connectors, with a focus on developing products which are easy to handle, durable and adaptable for a range of uses.

HARTING has also responded to the trend towards connector miniaturisation with the Han® 1A. As the requirement for smaller interfaces on equipment grows, space becomes a premium. Therefore, the 1A has been designed to take up less space and provide the user with all the benefits of a modern network.

Using connectors in control panels has always involved a complex and timeconsuming installation process. As a result, HARTING have developed the Han-Eco® B, a new series of hoods and housings available in a range of designs including bulkhead, surface mount and cable-tocable.

Constructed from the same material as the Han-Eco® B, the 1A employs a modular system of inserts, meaning it can integrate contacts for the delivery of data, signal and power.

They are manufactured from highperformance polyamide plastic, which offers IP65 protection and complies with standards IEC 61948 and EN 45545-2.

In addition, the hoods and housings are suitable for both indoor and outdoor applications.

A big advantage of using Han-Eco® B in control panels is the time-savings that can be achieved, thanks mainly to the ability to rear mount inserts. Engineers no longer need to install cables through the bulkhead mounted housing before assembling the contact inserts.

Instead, pre-assembled inserts can be directly snapped into the housing from the rear, simplifying cabinet assembly and saving you time and money. This development also gives you the flexibility to pre-assemble the switch cabinet units

Only two components are required to quickly assemble an IP20 solution, while additional housing elements or single wire seals can easily extend the degree of protection to IP65, making it suitable for use outdoors.

To learn more about Han-Eco® B and Han® 1A or request a FREE product sample, please email salesUK@harting.com or visit www.harting.com/UK/en-gb/solutions/ industrial-connectors-han.

For further information, please visit www.harting.com/UK/en-gb/solutions/industrial-connectors-han.

32

PECM Issue 47

Smart ideas make work more efficient and faster.

Han-Eco速 B. Rear mounting option allows for the separate pre-assembly of cable harnesses.

The new connectors of the Han-Eco速 B series provide valuable time advantages for equipment using the Han速 B industry standard. Learn how!

Han-Eco速 B. Thought differently. Done better.

www.harting.com/UK/en-gb/rear-mounting

CONTROL & AUTOMATION

FAST, RELIABLE & VERSATILE mk PROFILE SYSTEMS

Vacuum Conveyor for Non Woven Strips mk Profile Systems recently received a request for an application in the production of non-woven strips which required cut sections of non-woven fabric to be transported from one machining station to the next. The material was very thin and light with the system needing to run at a high speed of 140m/min. The strips had to be transferred from one conveyor to the next without any damage and it also had to be possible to cut them again as they passed through the system. They had to maintain their position as they passed through the system with the conveyor technology needing to be integrated into a customerprovided frame. The system was required to be able to handle strips of various formats without retooling. mk used a vacuum conveyor consisting of a belt conveyor with BC lower belt drive. The conveyor frames were made from square, stainless steel tubes, with each having a suction nozzle that allowed for maximum flow rate to establish the vacuum. Oblong holes run along the running side of the conveyor frames. A perforated belt allows the hair removal strips to be vacuum-gripped so that they can be securely transported even at high speeds. The conveyors are only 50 mm wide and are configured as eight-line conveyors. This allows the customer to switch the vacuum on or off in individual lines and configure the system for different strip widths. This ensures an optimal suction pressure in all cases. The conveyors are equipped with ø19 mm rolling knife edges on both sides to achieve short

The finished system has provided the customer with a very fast and reliable way of conveying a small, lightweight product. transfer distances. The conveyor frames are equipped with welding bolts for mounting in the customer-provided frame. The conveyors are arranged such that the hair removal strips can be transported from one conveyor to the next. The transfer conveyors are positioned upside down with the running side facing

downwards, allowing the hair removal strips to be transferred while suspended below the conveyor. They are then transferred to the top side of the next conveyor. This ensures reliable transfer. In some locations two conveyors are arranged atop one another so that stacks of hair removal strips can be clamped between the conveyors and then transported and cut without sliding.

The finished system has provided the customer with a very fast and reliable way of conveying a small, lightweight product.

It is extremely versatile in operation and optimised for maximum flow rate with extremely short transfer distances.

For further information, please visit www.mk-group.com

34

PECM Issue 47

Curved modular belt conveyor Efficiently handle any route

Wide variety of layouts with a single drive Compact overall width and a maximum usable width Lateral movement of conveyed products are possible

www.mkprofiles.co.uk

mk Profile Systems Limited a company of the mk Technology Group

CONTROL & AUTOMATION

TRIPLING PRODUCTIVITY BRILLOPAK

Apple producer picks Brillopak to automate packing facility A complete end-of-line automation project with Brillopak has seen Adrian Scripps, Tesco’s top apple supplier, triple productivity per head.

The project saw Brillopak install two PAKStations, four UniPAKer robotic crate packing systems, four Crate DESTAKers, two bale arm closers, four vertical accumulation units and three robotic palletisers. Thanks to this investment, Adrian Scripps has tripled productivity from 2.5-5 packs to 15 packs per person per min.

This has enabled the packing hall to align its capacity with increased production that has come about as a result of replanting orchards, introducing new varieties and adopting new farming methods.

“Any equipment investments in our packing house have to stack up against investments in our orchards,” says James Simpson, Managing Director of Adrian Scripps.

Adrian Scripps’ commitment to automation has earned this family business pioneering status in a sector that is heavily reliant on manual labour for picking, processing and packing.

“In our sector it has been difficult to automate; you might assume that apples flow easily because they are round, but they don’t…and pears are even more awkward, so there are considerable handling challenges to overcome. But we have invested significantly in automation so that we can pack apples more efficiently and it is paying dividends; our productivity per person has been accelerated by robotics,” says James.

From starting life in 1960 as a traditional Weald of Kent fruit, hops and livestock farm, Adrian Scripps has grown into one of the UK’s premier growers and packers of English fruit. Several varieties of apple – Braeburn, Kanzi, Jazz, Opal, Gala, Red Prince and Bramley – along with Conference pears and blackcurrants, are grown on five farms totalling 750 hectares.

As well as being the UK’s largest exporter of apples, the family owned farming business is one of Tesco’s key apple suppliers – a relationship that stretches back more than 30 years and has seen

36

PECM Issue 47

Brillopak immediately understood what we were looking for and very quickly got to grips with the challenges. much change in the way that fruit is handled at the company’s centralised packing facility on Moat Farm.

TOP OF THE TREE In a sector that has historically shied away from automation, Adrian Scripps has become something of a trailblazer whilst remaining true to its roots as a family farming business.

Whilst every single apple is still handpicked, the company’s sorting operation has been automated for over 30 years.

Here, fruit is transported through a presizing machine in water channels; letting the apples float like this protects them from bumps, bruising and damage that may result from over-handling. Imaging technology checks the colour, sugar content, internal quality, size and shape of each individual apple, identifying any blemishes and imperfections. Apples are

then graded by weight, quality etc. Same category fruit are packed into 300kg plastic crates and transferred to the packaging operation.

“This means that the packaging operation is presented with a uniform product that has already been sorted and graded,” says James.

It is the packaging process that has been the company’s focus for automation in the last eight years, initially with the aim of reducing handling through a linear automated process.

Historically, apples were sold either loose in moulded fibre trays or in plastic bags with a neck tie. Both packing operations were entirely manual, and packing staff worked at a rate of 2.5-5 packs per minute (ppm) on average.

Then, in 2013, Adrian Scripps took the decision to invest in automated flow wrapping equipment, accelerating the speed of the packaging operation.

“That left us with lots of packs coming off the flow wrapper at speed, creating a very repetitive task – that was when we engaged Brillopak, who we knew had experience in automation in FMCGs for the grocery trade,” explains James.

On visiting Adrian Scripps, Brillopak quickly got the measure of the situation.

“We looked at mechanical systems where the pack is turned to orientate it, but the flexibility of the UniPAKer won us over – it is infinitely programmable and allows you to make very small adjustments to get the pack to the exact target location,” explains James.

“Up to three people were trying to manually pack flow wrapped apples into retail crates at a rate of up to 60 per minute per line. The packing operatives couldn’t consistently keep up with the pace, which meant upstream efficiency improvements from their grading and flow-wrap investments were impacted,” recalls David Jahn, director at Brillopak.

“Brillopak immediately understood what we were looking for and very quickly got to grips with the challenges,” says James.

ERGONOMIC PAKSTATION REPLACES ROTATING TABLE Brillopak’s engineers designed a semiautomated version of the traditional ‘Lazy Susan’ style packing station, which, later branded the PAKStation, was to go on to become one of its best-selling packaging solutions. The ergonomic system, which helps manual staff load packs of fresh produce into retail crates, has significantly enhanced productivity at more than 12 UK fresh produce packhouses to date.

“The PAKStation has made the entire process easier for the person packing.

Historically, packs were presented to packing staff on a Lazy Susan rotary table, which allows a large area for crates to accumulate. We wanted a solution whereby crates were presented to the operator without accumulation, so that the pace of packing is dictated by the machine rather than people,” says Simpson.

“Our orchard productivity has increased through advancement of the trellis system and the replanting of old orchards, introducing new varieties such as Red Prince, Gala and Braeburn. As a result we have doubled our per hectare productivity in the last 15 years, from 35 tonnes per hectare to 70-80 tonnes per hectare,” says James.

He continues: “We knew we had a lot more fruit coming into production between 2018 and 2022, so we needed our packing facility to be able to accommodate this. In 2013 our facility processed approximately 30,000 boxes of apples and pears every week, each containing 10-12kg of fruit. Now typical weekly production is 80-100,000 boxes a week.”

FLEXIBLE UNIPAKER FITS THE BRIEF The company considered other packing systems, but it was the inherent flexibility of the award-winning UniPAKer robotic crate packing solution that once again convinced Adrian Scripps to partner Brillopak on this project.

Each of the four UniPAKer crate loading cells at Adrian Scripps houses two delta type robots, each performing a single pick. The benefit of a single pick is that it eliminates the need for accumulation.

To maximise packing speed, the crate is dynamically loaded as it is moving; working alongside each other, the robots take it in turn to partially fill the crate, picking individual packs off the infeed conveyor and positioning them deftly and precisely in the crate at the programmed orientation. The robots perform this task with a degree of dexterity and rotation that would not be feasible with a layerbased automated handling system.

Many robotics suppliers shy away from applications involving delicate fruit such as apples, as they bruise very easily. The speeds required to achieve target paybacks cannot be met without unacceptable levels of product damage, rendering some automation projects unfeasible.

Brillopak overcomes these challenges through innovative end-effector design, combined with in-depth knowledge of motion control and robotics.

“Apples are not an easy fruit to handle because they bruise very easily. This, combined with the need to execute a range of crate patterns, made this project a challenge that couldn’t be met by a mechanical system. Brillopak rose to the challenge,” says James.

The PAKStation gave Adrian Scripps a flexible semi-automated solution on two of its four lines. However, with the vast majority of the company’s production in one single format, and volumes increasing year on year, it wasn’t long before Adrian Scripps was ready for the next automation chapter – upgrading its other two lines to a fully automated workflow and installing two completely new packing and palletising lines.

For further information, please visit www.brillopak.co.uk Issue 47 PECM

37

Mechelec Automati CONTROL & AUTOMATION

SOLUTION UK,AN IEESSENTIAL and US Patents Granted Packing System.

MECHELEC AUTOMATION

UK, IE and US Patents Granted for Robotic Trolley Packing System Despite the rather strange year that 2020 has proven to be, Mechelec Automation have been granted UK, IE and US patents for their Robotic Trolley Packing System, as well as successfully completing the installation of their latest project in Ireland.

Their experience and open minded approach to finding automation solutions resulted in an industry first solution packing 5 tier trolleys for single and shrink-wrapped milk bottles that can be sited and run in an end of line refrigerated environment, in addition offering the advantage of savings on floor space and transport costs.

within the UK and overseas and have recently commissioned a Robotic Palletising line for Jordans Dorset Ryvita.

The TP range of Trolley Packers are designed to provide a fully automated and cost effective trolley loading solution, at speeds of up to 250bpm and packing 4-pint bottles in a 5 x 4 format in either 4 or 5 tier trolleys.

With the trying times we find ourselves in, and the need to socially distance, automation is an essential solution.

Despite the strange year that 2020 has proven to be, UK, IE and US patents for their Robotic Trolley Packi Mechelec Automation have an engineering team with a wealth of experience in the R&D and automation industry which motivated them to design, develop, prototype and successfully bring to market their Robotic Trolley Packing System.

Mechelec Automation are a unique British Automation Provider, capable of designing bespoke automation solutions or full turnkey production lines.

Mechelec Automation have an engineering team with a automation industry which motivated them to design, to market their Robotic Trolley Packing System.

Using Robotics, PLCâ&#x20AC;&#x2122;s, and motion control solutions from the major OEMâ&#x20AC;&#x2122;s such as ABB, Fanuc, Rockwell, Siemens, and B&R allows Mechelec Automation to bring their projects together as a seamless package combining Robotics and Automation as one.

In addition to developing their Trolley Packing System, Mechelec Automation engineers have utilised their experience writing and commissioning software for various industrial production lines, both

If you would like any more information on how we can automate your production requirements contact us on: sales@mechelecautomation.com www.mechelecautomation.com To see our latest Trolley Packer in action visit: https://youtu.be/hvMGV2ZtD7I

U co su an br se an

For further information, please visit www.mechelecautomation.com

38

PECM Issue 47

ion

M e c h e l e c forARobotic Trolley utomation · PLC Programing

· Electrical Engineering

· Motion Control

· Panel Design

· Robot Programing

· Site Installation

, Mechelec Automation have been granted · SCADA Systems · Panel Build ing System.

Mechanical Design a wealth of experience in· the R&D and · Bespoke Machine Design , develop, prototype and successfully bring

· Automation Solutions · Robotic Solutions

· Turnkey Projects

Using· Robotics, PLC’s, and motion Project Management ontrol solutions from the major OEM’s · System Simulation uch ·as ABB, Fanuc, Rockwell, Siemens, Robot Simulation nd B&R allows Mechelec Automation to ringTHE their projects together as a ROUTE TO IMPROVED PRODUCTIVITY AND PROFITABILITY eamless package combining Robotics nd MECHELEC Automation as one. providing automation services, bespoke machinery and AUTOMATION automated solutions for todays demanding industry. www.mechelecautomation.com sales@mechelecautomation.com

01480 404407

CONTROL & AUTOMATION

One controller does it ALL: Integration of IT and OT on one platform Red Lion’s FlexEdge™ Intelligent Edge Automation Platform now combines the scalability of Linux® with the power of Crimson® 3.2 software into one userfriendly operating system. This fusion enables a single FlexEdge controller to provide advanced networking, security, and automation. By integrating information technology and operational technology, FlexEdge helps customers reduce costs, improve data security, and increase productivity.

Powered by Crimson 3.2 software, the FlexEdge platform provides customers with maximum flexibility to easily modify controller functionality as application needs change.

From advanced networking to automation, one controller does it all. Customers can enable additional functionality through field-unlockable software upgrades that eliminate the need to purchase or add more equipment, saving both money and unnecessary downtime.

These new capabilities open doors to new product combinations, further expanding the applications to which the FlexEdge platform can be deployed. With FlexEdge’s

modular communications sleds, users can now deploy multi-cellular radio gateways for critical communications applications. And, for environments with demanding requirements,

the platform offers multiple isolated serial ports, routable Ethernet ports, optional serial, USB, Wi-Fi, and cellular communications sleds, and field-installable I/O.

To learn more about Red Lion’s FlexEdge™ Intelligent Edge Automation Platform, visit www.flexedge.net

CryptoAuthentication™

Datakey’s new CryptoAuthentication™ tokens are ideal for embedded systems that: • Require ‘cyber robust’ removable memory devices for applications that include the transfer of passwords (or other data needed for user authentication purposes).

• Need physical transfer of security keys, certificates, sensitive data or system configuration files.

At the heart of all devices in the CryptoAuthentication™ line of memory tokens is a Microchip CryptoAuthentication™ high-security hardware IC. Its features include: • A unique and non-changeable 72-bit serial number (set by Microchip) • A 512bit one-time programmable (OTP) zone • A random number generator • A SHA-256 hash algorithm for data encryption.

To understand how it could improve the security in your embedded system, we’re giving you a chance to win a CryptoAuthentication™ Development Kit! www.nexusindustrialmemory.com/land/ cryptoauthentication-devkit/

40

PECM Issue 47

Minebea Intec launch NEW OCM Weigh Price Labeller with complete field to fork traceability and 24/7 on site service support Minebea Intec have brought their expertise in checkweighing to the labelling market with a new OCM specifically designed for the meat, fish, dairy, fruit and vegetable markets. The new WPL–S is a manual weigh price labeller best suited to low volume and products not suitable for automatic labelling. It boasts an array of features including industry leading hygienic design, field to fork traceability to adhere to government guidelines, integration with other hardware and open source software, automated reporting, a 2 year warranty and 24/7 on-site service support.

Minebea Intec are showcasing their new WPL-S as part of their virtual demonstrations within their Birmingham showroom. If you’d like to find out more, you can visit https://www.minebea-intec.com/en/services/ virtual-showrooms/ or call the office on 0121 779 3131

24/7 Motor Solution 24/7 access to the UK’s largest stock of ABB & WEG Motors. 2 and 4 pole, foot and flange mounted, up to 250kW. No order numbers needed, and a motor guaranteed to be in transit within 30 minutes of your request.

Step 1. Email marketing@quantum-controls. co.uk for your unique password to access the system.

Step 2. Go to www.motors-online.co.uk and click ‘Order Online’ and input your unique password Step 3. Order your motor online, no order number needed and we guarantee that it will be in transit within 30 minutes Register for your unique login details today and receive an access pack, email us at motors@ quantum-controls.co.uk.

01661 835 566 motors@quantum-controls.co.uk www.quantum-controls.co.uk

CONTROL & AUTOMATION

Incremental and Absolute Encoder Solutions!

When you call BEPC, you talk to engineers and encoder experts who can help you find and spec the right encoder for your application. From compact to heavy-duty stainless steel, thru-bore or shaft, incremental or absolute, we’ve got the encoder you need for motion feedback.

Thru-Bore Encoders – From the compact Model 15T/H, to the low-profile Model 260 to the versatile Model 25T/H, we’ll help you find the right solution.

Stainless Steel Encoders – For those tough, dirty applications needing a durable encoder that can tolerate washdown and extreme environments.

Programmable Encoders – Not sure of the exact configuration you need? No problem.

BEPC’s highly-configurable Model 25SP Size 25 shaft encoder and new thru-bore Model 58TP Allow you to program the electrical specifications on-site.

Absolute Encoders – Mechanically and electronically versatile, BEPC’s selection of absolute encoders is your solution when you need position information after power-off scenarios. And our NEW A58E series of encoders are EtherCAT and Profinet ready!

BEPC’s standard lead time is just 4 - 5 days Call us today, and we’ll help you find your motion feedback solution.

Web: www.encoder.co.uk Tel: +44(0)1978 262100

PRESENTING THE e-Series.

World’s #1 Collaborative Robot

Fast set-up Collaborative & safe

Easy programming

Fast payback Flexible

The e-Series cobot is designed to boost your productivity regardless of your company size, industry or application. Find out how the e-Series can deliver unmatched returns for your business.

Experience the e-Series at universal-robots.com/e-series

Issue 47 PECM

41

DRIVES, MOTORS & GEARS

KEEPING POWER ONLINE SULZER

Extending small steam turbine performance and reliability to minimize costs Beyond the large units driving generators, small steam turbines are commonly used in parallel with electric motors to power important assets such as pumps. Keeping these smaller turbines properly maintained is essential for continued performance and reliability. Sulzer has a network of specialized facilities that are equipped to service these turbines as well as the rotating equipment that they drive.

Small steam turbines, typically producing less than 1â&#x20AC;&#x2122;500 hp (1â&#x20AC;&#x2122;100 kW), are often used in industrial environments, such as chemical, oil refinery, paper mills, power plants and many food industries. These may be a primary driver or a standby unit for the back-up of a motor-driven unit.

Typical service intervals for small steams turbines are six to seven years, with biennial planned maintenance. Steam conditions play a major role in increasing unit availability and downtime for repairs.

Where wet steam conditions are found, various coatings can be applied to reduce wear. A field site visit to review case, steam valve and carbon gland leak-off provisions is key to ensuring the drain or leak-off is adequate to minimize the wear on turbine parts.

It is important to understand the key points of a small steam turbine that need to be properly maintained for continued safe and efficient operation. At the top of this list is the overspeed trip mechanism. The trip safety device is designed to operate in the event of a governor failure and prevent the turbine increasing in speed to the point of destruction. It is essential that any turbine overhaul includes a check for the correct operation of the overspeed mechanism.

SIMPLIFYING MAINTENANCE Steam turbine health relies on the bearings being properly maintained. These could be a roller bearing or a white metal, Babbitt, bearing, both of which need to be monitored for wear and to highlight any signs of failure. These may include water contamination of the oil system, misalignment or incorrect oil levels.

Frequent monitoring of oil quality, oil

42

PECM Issue 47

temperatures and performing scheduled vibration measurements for analysis is key for turbine reliability.

Sulzer has a long-established expertise in steam turbine design, operation and repair.

Decades of experience of working with assets from a wide variety of manufacturers means that customers can benefit from a rich bank of knowledge and understanding.

Coupled with a network of service centers that are equipped with all the necessary machine tools, and the ability to maintain all types of rotating equipment, Sulzer offers a local one-stop-shop for a wide variety of machinery repairs. This includes small steam turbines, which can be fully tested using in-house test stands and lube oil systems that have been installed specifically for this service.

STRATEGIC SUPPORT In the USA, Sulzer has five specialist small steam turbine repair centers strategically located throughout the country. Field service teams can provide onsite services as well as remove, install and commission assets for minimal downtime, while the workshops offer a comprehensive range of services including reverse engineering of failed parts.

Sulzer operates an open door policy where customers are invited to visit the service center and witness repair and testing procedures. These include: disposition to review recommended repairs or upgrades, balancing of rotors, running clearances and the all-important overspeed test.

Sulzerâ&#x20AC;&#x2122;s expertise in pumps and other rotating equipment means that operators can take advantage of extensive knowledge of pumps and their drivers and benefit from the companyâ&#x20AC;&#x2122;s expertise and knowledge in many pieces of equipment. This offers a more encompassing service where complete drivetrains can be inspected and repaired by the same maintenance provider.

For further information, please visit www.sulzer.com Issue 47 PECM

43

DRIVES, MOTORS & GEARS

PRODUCT TERMINOLOGY REICH DRIVE SYSTEMS

When is a coupling not a coupling Engineering and technical products, by their very nature, can sometimes be complex in their configuration and specification. So too can the terminology used to describe or name the product, and a term recognised and understood by one person can mislead or confuse another.

Statistics from Fleishman-Hillard show that 89% of people begin their selection and purchasing process via online search engines. Therefore, the specific search terms used by an individual can have a significant impact on the results they see, and in turn the product they may decide to purchase.

This article from Reich Drive Systems David Edwards highlights the importance of terminology and why it is important to ensure that the supplier and customer are both speaking the same language.

For those involved within the power transmission sector, the word “Coupling” is readily identified as a unit with two hubs, or a hub and a flange, with a flexible element.

The prime function of this assembly is to transmit power from a prime mover to a driven piece of equipment. The word “Coupling” however is used within the railway industry, and of course in relation to pipe fittings, so those working within those sectors will visualise something completely different.

Confusion can also arise in certain instances where the features of a product can lead to it being defined as something else. As an example, because a Reich coupling installed between an engine flywheel and a gearbox, has the ability to absorb torsional vibrations from the engine it can sometimes be referred to as an engine damper. Although there is no doubt that a correctly specified and installed flexible coupling will “dampen” the engine vibrations, by correct definition an engine damper, also known as a harmonic damper, is a completely different product used on the crankshaft end of an engine.

There are also Flywheel “Dampers” available, often incorporated into Dual Mass

Flywheels, however they don’t share the full range of features of the Reich power transmission coupling. Reich couplings are specifically selected for each application, with a flexible element and with a specific stiffness, to optimise the torsional vibration range. These products are also specifically selected to transmit the necessary torque between the engine and gearbox / alternator etc and incorporate a plug in design to connect the driven equipment to the driver.

properties is a coupling or a torque limiter.”

David Edwards provides further examples of terminology confusion: “Speaking to colleagues in the world of industrial brakes and clutches, they are often asked to provide a clutch solution when actually a brake is required, or vice versa. Similarly, Reich provides a range of torque limiters, which are sometimes incorrectly described by others as clutches, couplings, or slip clutches. In these instances, the debate is whether a coupling with torque limiting

With a history spanning over 70 years, REICH has built up unrivalled expertise in the design and manufacture of drive couplings for use across a wide range of industries and applications. The company has earned an enviable reputation not only for the quality and performance of their product range, but also for their ability to provide application and customer specific solutions through the company’s D2C (Design to Customer) philosophy.

The solution to the terminology issue is not to expect customers to actually describe the products accurately, but for reputable suppliers to apply their expertise and question the user about what they want a product to do and why. In this way the correct product, specification and name will always be identified, and the end user will be happy with the solution, irrespective of what they decide to call it.

For further information, please visit www.reich-uk.com

44

PECM Issue 47

Reich Couplings Keeping Industry Moving

ARCUSAFLEX COUPLING

MULTI MONT ASTRA JAW COUPLING

RCT COUPLING SERIES

MULTI MONT SELLA COUPLING

ARCUSAFLEX VSK COUPLING

TOK COUPLING SERIES

Competence in power transmission whatever your industry or application

VISIT OUR NEW WEB SITE Reich Drive Systems UK Limited Unit 4 Bankside Business Park Coronation Street Stockport SK5 7PG T: + 00 44 161 714 4191 E: info@reich-uk.com

www.REiCh-UK.Com

DRIVES, MOTORS & GEARS

Leaders in high precision thermoregulation Distributed in the UK by Labtex, Huber are leaders in high precision thermoregulation solutions for research and industry. Huber products ensure precise temperature control in laboratories, pilot plants and production processes across the globe, offering temperature control solutions for applications ranging from -125C to +425C. Driving technological development Huber has been driving technological development and continuous innovation in the field of liquid temperature control since 1968. The introduction of Unistat technology, in 1989, was a revolution in temperature control, setting industry standards for thermodynamics and accuracy.

The fundamental operational advantages of the Huber Unistat system are reduced volumes of heat transfer fluid (HTF) and high flow rates. This results in improved heat transfer, resulting in quick and precise temperature control in reaction

vessels and other closed systems. The pump design, with soft start, gives the highest possible flow rates. This allows the fastest and safest possible ramp rates to protect glass-lined or glass reaction vessels.

In addition to dynamic temperature control systems, Huber’s product range includes immersion coolers, heated and/or refrigerated baths and circulators, and chillers.

For further information visit www.labtex.co.uk

NSK bearings help bakery save €9400 per annum A large bakery has replaced the type of bearings used in its cake-cutting machines after experiencing repeat failures on the integral blade saw pulleys. The switch to NSK MoldedOil bearings immediately reduced maintenance costs and increased productivity, leading to total savings of approximately €9400 a year.

NSK´s Molded-Oil bearings (stainless steel variant) are ideal for applications in food and beverage plants. Not only do they prevent the ingress

THE UK’S LABORATORY EQUIPMENT EXPERTS

of contaminants such as water and particulates, but no lubricant can escape the bearing and enter other parts of the machine, where it could conceivably contact food. Molded-Oil bearings are equipped with a proprietary oilimpregnated material that consists of lubricating oil and a polyolefin resin with an affinity for oil. This carrier material releases the lubricant continuously over a long period.

For more information, visit www.nskeurope.com

RED HOT SCALE UP EQUIPMENT FOR PROCESS R & D

CHEMICAL | PHARMACEUTICAL | DEFENCE AEROSPACE | BIOCHEMICAL MANUFACTURING PARTNERS Major Scientific Industry brands guarantee the best products at the best prices.

Fluoroplastic (eg PTFE, PFA) Labware

Metering Pump Solutions

Analytical and Precision Balances

High Precision Thermoregulation

Vacuum Pumps and Networks

Overhead and Magnetic Stirrers

MORE SPEED • MORE FLEXIBILITY • MORE EXPERTISE • MORE RELIABILITY

ALL THE MORE REASON TO CONTACT US TODAY! 01484 600200 | info@labtex.co.uk | labtex.co.uk

46

PECM Issue 47

DRIVES, MOTORS & GEARS

DEEP GROOVE BALL BEARINGS NSK

NSK bearings adapted to meet servomotor demands Available from NSK is a range of deep groove ball bearings adapted to the specific requirements of servomotors. Thanks to the development of special greases and a highly effective, low-friction seal, NSK solutions overcome the limitations of conventional electric motor bearings when used in servomotor applications.

For rolling bearings, servomotors present a challenge. With their frequent start, stop and reversing operations – as well as tiny corrective movements prompted by the sensor system – the typical motion profile of servomotors places bearings under intense stress. Furthermore, the frequent reversing and associated micro-vibration cause the lubricant film between the rolling element and running surface to be wiped away (without the opportunity for afterflow re-lubrication) to a greater extent than would be the case with continuous rotating bearings used in conventional electric motors.

NSK has developed special greases and seals for its range of servomotor-specific deep groove ball bearings

Potential consequences include the generation of local micro-friction points on the raceways. This friction is caused when the lubricant film is insufficient and metal-tometal contact occurs between the raceway and ball.

To surmount these issues, NSK has developed a special grease known as EA7.

Compared with conventional greases, EA7 offers improved lubricating properties when subject to micro-vibrations. The grease also helps to ensure that the bearings operate with low frictional torque and correspondingly minimal power loss. In practice, the use of EA7 ­lubricated bearings in servomotor applications leads to longer operating life and the doubling of service intervals.

Another factor that increases the service life of servomotors is cleanliness during operation. If the bearing grease releases particles (such as metal or sulphur) that migrate to surrounding components, the encoder may become dirty. Over time, this contamination will render the motor incapable of detecting precise position. A further consequence of escaping lubricant

Servomotors present specific challenges that can compromise conventional electric motor bearings can be slippage during braking, which again might promote inaccurate positioning.

To provide a solution to the contamination issue, NSK has developed another grease for servomotor applications, called LGU. Compared with lithium soap grease, LGU emits around 90% less sulphur and metal particles, thus contributing to the long-term cleanliness of the bearing environment. The result: service intervals are extended by a factor of 1.5.

Companies building or integrating servomotors can choose whichever grease is most suitable. EA7 extends the service life of deep groove ball bearings when subjected to the micro movements typical of servomotors, while LGU minimises the release of particles on to surrounding components, preventing imprecise positioning. These two high-performance greases are available as an option for the deep groove ball bearing series that NSK has developed for use in servomotors.

A further feature of these bearings is NSK’s DW seal, which offers a combination of exceptionally good sealing and low frictional torque. With DW seals, the company’s designers have developed an effective solution to the conflicting requirements of reliable sealing and energy-efficient bearing operation.

The range of deep groove ball bearings for servomotors is described in a new catalogue entitled ‘Bearings for Electric Motors’, which is available in print or as a PDF download at: www.nsk-literature.com/ en/industrial-motor-bearings

www.nskeurope.com Issue 47 PECM

47

DRIVES, MOTORS & GEARS

GEAR PURCHASING GUIDES WEG

WEG releases second gearbox guide in a four-part series

Motor and drive manufacturer, WEG has published its second gearbox guidebook, helping buyers to ask the right questions in the geared motor buying process for their specific application and market. The guide titled, What mechanical engineers and plant operators need to know when buying geared motors, can be downloaded for free at www.weg-wg20.com.

Choosing the right gear type is essential.

With the wrong gear type, premature wear and damage could arise, causing the gears to interconnect improperly. This leads to costly replacements that could have been prevented in the early buying stages.

To prevent instances like these, the purchasing guide has been written to help engineers analyse the key technical criteria and areas of application before making a gearbox purchase. It addresses key questions such as, ‘what are the exact power requirements for the gear unit?’ and

‘which efficiency guidelines and standards must be observed?’.

Buyers must ensure that the purchased technology guarantees high plant availability and an optimum cost-benefit ratio. Therefore, this guide explains how to assess the cost-effectiveness of a geared motor adequately. Whether the gearbox in question is going into legacy or brand new system, the purchasing guide answers the following questions: • Which gear unit best suits my application?

• How can I identify a good gear unit?

• What do I have to pay attention to when purchasing besides the cost-benefit ratio?

“This second guide will help engineers and potential buyers to make informed decisions surrounding gearboxes,

especially as the industry has diversified over the last decade,” explained Marek Lukaszczyk, European marketing manager at WEG. “This guidebook is designed to give technical buyers a critical eye in the buying process, to prevent problems later down the line. The informative book can be downloaded for free to help buyers and engineers gain a wealth of knowledge and experience about the buying process involving gearboxes. Also, keep an eye out for two more gearbox-focussed guides, which will be added to the series in the foreseeable future.”

Further information on WEG’s products can be found on the company website. The gear purchasing guide, What mechanical engineers and plant operators need to know when buying geared motors, can also be requested via this link here.

For further information, please visit www.weg.net

48

PECM Issue 47

control.qxp_Layout 1 17/09/2020 13:24 Page 3

DRIVES, MOTORS & GEARS

MANGLE DRIVE

CONTROL AND AUTOMATION

variable centre rollers VARIABLE CENTRES

FIXED CENTRES

Short lead times for UK-made NSK NH/ NS linear guides

VARIABLE CENTRES

FIXED CENTRES

coupling solution

TM

an MTI company

GEARS - GEARBOXES - POWER TRANSMISSION

tel: 0170 728 3131 email: dsg@davall.co.uk

NSK leverages the competencies of its worldwide manufacturing facilities to bring products closer to the company’s local customer base and reduce lead times.

A case in point is NH/NS series linear guides, which are produced at NSK’s UK plant in Newark. As well as stocking standard units, the Newark factory has extensive manufacturing capabilities to ensure that requests for specific lengths, coatings, seals and grease – for example – can be fulfilled in short lead times.

NH/NS series linear guides

offer double the lifespan of conventional products due to the inclusion of features like specially developed ball groove geometry. Further benefits include high dynamic load rating, high productivity, long maintenance intervals, low noise output, ease of installation and standard accuracy that exceeds conventional alternatives.

A virtual tour of the linear guide manufacturing facility at Newark can be viewed at

www.nskeurope.com/en/ media/videos/virtual-videotours.html

Cross+Morse Power Transmission Manufacturing Specialists

Since 1984

◊ Manufacturing up to 1450mm diameter ◊ Turning - CNC lathes, Vertical Machining Centre ◊ Gear Cutting - Hobbing, Planing, Shaping Gears ◊ Bevel Gears, Helical, External & Internal cut Gears ◊ Rack Shaping, Broaching, Keywaying ◊ Vertical Boring, Centreless & Rotary Grinding ◊ Bore Honing ◊ Induction Hardening

◊ Drilling & Tapping ◊ Large stocks of Transmission Drive components ◊ CAD - CAM Design & Development ◊ ISO 9001 : 2015

Yes we can make it.

Cross + Morse. Shady Lane, Great Barr. Birmingham. B44 9EU sales@crossmorse.com Tel: +44 (0)121 360 0155 Fax: +44 (0)121 325 1079 www.CrossMorse.com

32 Food & Drink International

Issue 47www.fdiforum.net PECM 49

ELECTRICAL & ELECTRONICS

CABLE INNOVATION HEATSENSE CABLES

Specialist High-Performance thermocouple and signal cable manufacturer continues to expand manufacturing capabilities CAPABILITIES Heatsense Cables is the UK’s leading specialist high-performance thermocouple and signal cable manufacturer.

The company is a technology leader in fluoropolymer extrusion, high-performance taping and cable wrapping. Related processes include cover sintering, colouring, etching and the application of various specialist coatings. The range covers cables that are resistant to flame, oils and chemicals and which operate in ultra-high vacuum, cryogenic and high radiation environments.

INSULATION & BRAIDING EXPERTS Insulation materials include PFA, FEP, PTFE, ETFE, EFGLAS, SILICONE, PE, PU, PVC, Taped & Sintered PTFE, Polyimide, Aramid, PTFE impregnated yarns and Mica.

Braiding materials include glass, quartz & ceramic fibres, other specialist yarns and various metals.

The company manufactures thermocouple cables, extension wires, equipment, wires, coaxial cables, multicore cables, microcables and fine wire from is manufacturing plant in Rochdale, Greater Manchester.

Markets include, aerospace, nuclear, automotive, medical, R&D, oil & gas and general industry. The company offers a range of approvals which meet internationally recognised specifications.

Highly customer focussed, Heatsense offers a bespoke technical design and manufacturing service, rapid response times, short lead times, low MOQ’s and competitive pricing.

EXPANSION Over the course of the last twelve months Heatsense has acquired a specialist thermocouple calibration laboratory. This has enabled the company to test thermocouple and resistance wires used in production and also ensure that all cables are calibration and resistance tested before dispatch.

The company continues to upgrade and

purchase additional specialist plant & equipment to further broaden capabilities and efficiencies.

Despite the economic impact of COVID-19 Heatsense has added a further 5000sq.ft of manufacturing space taking the total to almost 20,000sq.ft.

During this period the company has also continued to purchase specialist plant & equipment, expanded its manufacturing capabilities and taken on additional highly skilled staff.

The company continues to develop its digital strategy encompassing shop floor data capture, ERP, CRM and machine automation.

Heatsense is ISO9001:2015 and ISO14001:2015 Accredited and has been awarded F4N Status by the Nuclear Advanced Manufacturing Research Centre.

T: +44 (0) 1706 767070 W: www.heatsensecables.co.uk

For further information, please visit www.heatsensecables.co.uk

50

PECM Issue 47

The UK’s leading specialist high-performance thermocouple and signal cable manufacturer The company is a technology leader in fluoropolymer extrusion, high-performance taping and cable wrapping. Related processes include cover sintering, colouring, etching and the application of various specialist coatings. The range covers cables that are resistant to flame, oils and chemicals and which operate in ultra-high vacuum, cryogenic and high radiation environments.

INSULATION & BRAIDING EXPERTS PFA, FEP, PTFE, ETFE, EFGLAS, SILICONE, PE, PU, PVC, Taped & Sintered PTFE, Polyimide & Aramid Yarns, PTFE impregnated yarns and Mica.

Braiding materials include glass & ceramic fibres, other specialist yarns and various metals.

MARKET SPECIALISTS

Automotive

Aerospace

Nuclear

Medical

Industrial

PARTNERSHIP BUILDERS Advanced technical design & bespoke manufacturing service • Rapid response times

• Service international partners

• Short lead times

• Competitive pricing

• Based in the UK

• Low MOQ’s

*Registered owner of the world-renowned INTEMP trademark

Find us online: heatsensecables.co.uk or call: (+44) 01706 767070

Research

ELECTRICAL & ELECTRONICS

SMART TRANSPORT COPA DATA

Battery storage for zero emission cities ‘Range anxiety’ is a term coined to describe the worry of getting ‘stranded due to power loss’ when driving an electric vehicle (EV).

The low power range of EVs is infamous and a reason the market has been slow to pick up speed. But, with the UK Government vowing to reduce emissions in cities, how can battery storage make EVs feasible for public transport? Here, Alan Binning, Regional Sales Manager at COPADATA UK, explains.

Achieving zero-emission public transport is a vital element of a smart city, and there are several initiatives in place to encourage these efforts. The All Electric Bus Town scheme, published in February 2020 by the UK Government, includes a host of funding opportunities for local authorities, including an investment of up to £50 million to deliver Britain’s first all-electric bus town or city.

Unfortunately, electric buses are notoriously power hungry. In fact, most have a range lower than that of electric cars, averaging just 120 miles per charge compared to 680 miles for diesel buses.. Now, that’s what we call ‘range anxiety’. With most buses travelling upwards of 150 miles a day, maintaining power is not possible without numerous charging interludes or increased battery-based storage.

UPGRADING SUPPLY AND STORAGE

Bus depots have traditionally managed with low power requirements, meaning high power infrastructure has never been built. To change this, installing a small-scale substation to increase power supply for a bus depot is a possible option. However, this physical solution can be complex and costly.

Many city centres do not have spare real estate to house a new substation and those that do will price this land at a premium. That’s not to mention the logistical nightmare of planning permission, laying cables and building new infrastructure in a bustling city. Out of town alternatives, like park and ride spaces, are an alternative. But again, they have very limited infrastructure.

Another option is installing a fixed battery storage system to deal with peak demands of energy beyond what the site supply is able to handle. This would allow the depot access to energy whenever it is needed, allowing fleet managers to effectively manage and charge electric bus fleets.

DATA FOR DECISIONS

For electric or hybrid bus fleets, the role of a fleet manager expands beyond timetable scheduling and vehicle maintenance. Overseeing an electric bus fleet requires a closer analysis of the energy balance on site — monitoring vehicle emissions, battery charge and identifying opportunities to improve operations. zenon Energy Edition from COPA-DATA is a platform to visualize, evaluate and report on real-time energy data. As an independent software platform, zenon can be integrated with multiple assets connecting charging points, battery storage and the wider energy grid.

In an electric bus depot setting, zenon can be used to monitor the status of charging points in the depot and the energy levels of batteries. The system can also integrate traditional enterprise files, such as the bus timetable, employee rota and maintenance schedule.

This data can then be relayed to the fleet operator using a bespoke interface to allow them to make better decisions. For instance, zenon can be integrated with energy trading networks via the zenon Service Grid. Access to this data could allow operators to strategically charge batteries when energy prices are most favourable and — should contracts allow — sell energy back to the grid when prices are high.

SOFTWARE FOR ZERO-EMISSIONS

Electric buses using battery storage are just one example of how to use zenon for smart cities. However, with the Government setting ambitions for all UK buses to be fully electric by 2025, fleet managers must prioritise their transition to EV fleets over other smart city initiatives.

According to the Government, a town with 200 electric buses can save around 7,400 tonnes of CO2 in a year — that is the equivalent of taking 3,700 diesel cars off the road. ‘Range anxiety’ may still be EVs biggest turn off, but with technology to better manage the charge and energy demand of electric buses, All Electric-Bus Towns suddenly sound much more feasible.

For more information about COPA-DATA for energy applications, contact the UK team directly at +44 (0) 2920 10 88 77 or visit the COPA-DATA website: www.copadata.com.

For further information, please visit www.copadata.com

52

PECM Issue 47

ELECTRICAL & ELECTRONICS

Stud terminal blocks from Switchtec offer secure connections for energy & power distribution applications Switchtec has introduced the SCL range of Stud Terminal blocks. These high-power stud terminals are used to terminate incoming power cables within panels, providing a reliable, safe, and secure connection and keeping cable usage to a minimum.

Aimed at OEMs, panel builders, equipment manufacturers and gen-set manufacturers these Stud terminals offer a secure cable termination in applications of high vibration or where large cable termination is needed.

The Stud terminals can be fitted to standard 35mm Top Hat DIN rail or bolted down to a flat surface or a panel back plate.

Provided as single pole units, the ST series stud terminal blocks are available in 100, 125, 150, 192, 232, 269, 309, 353 & 415 Amp with a rated voltage up to 1000V and accommodate cable sizes 25, 35, 50, 70, 95, 120, 150, 185 & 240mm2.

The versatile stud terminal blocks offer many benefits and design advantages. First and foremost they can be used to establish an electromechanical connection between large cross-section, high current carrying cables with one or more wires having smaller cross-sections, with the facility to fit 2 lugs per side (back to back), making it possible to manage multiple load connections and a wide range of cable and wire sizes. They also provide the facility to interlock multiple blocks side by side, forming a compact design layout that saves space within control panels; they make it possible to distribute power in a compact space.

Removeable barriers make it easy to bridge stud terminals together.

The Stud terminals blocks are manufactured to a high standard and utilise high-grade components including Solid copper busbar with Steel nuts & bolts making them highly resistant to thread stripping and providing excellent cable retention & electrical properties.

A market leading design feature of the ST series Stud terminal is the facility to fit coloured terminal covers. The hinged clip on phase covers, suitable for all sizes of Stud Terminal are available in Grey, Blue, Brown, Green and Black, making them ideal for phase identification within a

The SCL Stud terminal blocks available from Switchtec are CE approved, RoHS 2 compliant and manufactured in accordance with EN6947-7-1. All products are available from stock and Switchtec field sales engineers are available to provide product selection and general design assistance.

panel. The covers provide IP20 protection and have the facility to insert a test probe without having to open the cover.

www.switchtec.com

Issue 47 PECM

53

ELECTRICAL & ELECTRONICS

YOUR CONCEPT, OUR CREATIVITY CLARK CABLE LTD

Bespoke cable solution provider and a single source manufacturer of cables and connectors

Above, Hospital Products.

Below, Floorcare.

Clarke Cable has been manufacturing cable solutions for over 45 years at their Congleton, Cheshire factory, having been the UK’s largest manufacturer of kettle assembly leads for a fair proportion of that time.

Manufacturing has now developed considerably, and we have evolved to become a bespoke cable solution provider for many various industries as well as being a single source manufacturer of cable assemblies and connectors.

We are proud to be suppliers to the NHS and defence industries but also to many other vital industries such as water sterilisation, medical, catering, cleaning, automotive, construction, tunnelling, and the worldwide Events industry to name just a few. We are proud to have supplied lighting, power and video cable assemblies for many touring bands and venues such as Glastonbury. We have experience in many different industries

54

PECM Issue 47

Clarke Cable are able to supply assemblies using a variety of different types of cable and specialise in PVC, LS0H, rubber, polyurethane, arctic and anti-microbial curly cable in addition to the regular types of cable used. We can supply specialist “oneoffs” where required or in large volume.

Clarke Cable supply electric plugs for many overseas territories with full approvals.

Our company motto is “Your Concept, Our Creativity” which is due to constantly offering assemblies which do not currently exist, but our development team is able to come up with solutions to meet your needs. We say the next requirement is in the customer’s head and we can bring this to life.

Our products are manufactured in the UK using top quality European components and these sell on the basis of quality, fast delivery and innovation. Clarke Cable have specialised in splitting power cables allowing fast plug and play where there are requirements for all sorts of applications such as DMX extensions.

Socapex, Cat5e, Ethercon using couplers such as Neutrik and Socapex.

During the lockdown Clarke Cable continued to proudly operate as a Tier 1 supplier for several industries, especially the medical. The anti-microbial curly cords used on crash carts in A&E showcased the durability of our assembly – specially devised by Clarke Cable for the customer.

20A Powercon True 1 Tri Splitter

Power distribution

Power/co-axial/cat 5 for projection systems

During the lockdown Clarke Cable continued to proudly operate as a Tier 1 supplier for several industries, especially the medical.

We donâ&#x20AC;&#x2122;t just cater for specialised industries. Wherever there is a need for cables then we are the company to contact for best service and top quality plus we may well be able to recommend a better way to make your product. If you need a simple cable with a plug Clarke Cable can supply.

Covid-19 has made companies rethink their supply strategies and there is nothing better than having uninterrupted supplies from a local manufacturer with top quality, competitively priced products, offering fast turnaround and with innovative, creative cabling solutions.

Coloured Anodised Locking Rings For further information, please visit www.clarkecable.co.uk Issue 47 PECM

55

ELECTRICAL & ELECTRONICS

IMPROVING SUSTAINABILITY TR FASTENINGS

EV batteries are the future but we must drive improvements now As the new 70-plate cars roll off garage forecourts across the UK, 2020 is predicted to be another record-breaking year for electric vehicles in this country.

A report by Statista published in May forecast that electric vehicles will make up more than 10% of new UK vehicle registrations this year – up from just 3.2% of vehicles in 2016.

It is vital now that all of us involved in the EV industry work collaboratively to help the sector grow in a sustainable way.

As electric vehicles become more popular, the number of EV batteries coming to the end of their usefulness on the road will soar. But whereas traditional lead-based car batteries are commonly recycled in the UK – so much so that the majority of a new lead-based battery is recycled material – that is not the case for EV batteries.

Last year a joint study published by researchers from the University of Birmingham, the University of Newcastle and the University of Leicester concluded that the rise in popularity of EVs had not been matched by a solution to the problem of recycling the end of life waste of their components.

The researchers argued that there was an opportunity for the UK to be at the forefront of a new sector in the recycling industry to meet that challenge – potentially not only handling UK EV waste but also profiting by importing and recycling EV waste from abroad.

In Japan, Nissan opened a factory for the refurbishment of used EV batteries for repurposing in electric cars as well as vehicles requiring less power, such as forklifts and golf buggies, and in street lights. Likewise, Toyota has linked units to solar panels to provide power to shops in Japan.

The Faraday Institution - the UK’s independent institute for electrochemical energy storage research - has suggested that recycled material could be a key input

for the eight Gigafactories it forecasts the UK will need by 2040 to meet domestic demand for lithium ion batteries.

Securing the raw materials these factories will need, could be a mammoth task in the face of a global rise in demand, and the fact the mines producing the minerals needed aren’t exactly on our doorstep. Lithium and manganese production is dominated by Chile, Australia and China, but the majority of cobalt comes from less stable countries, in particular the Democratic Republic of Congo. Concerns have already been raised by some experts that mining output of some of these minerals will not be able to keep pace with the growth in demand for electric vehicles.

While the Financial Times reported recently (6/9/20) that a number of companies are investing in Cornish mines in the hope of sourcing low-cost lithium domestically, a secure supply from recycled sources of the minerals needed for EV battery production in the UK would provide assurance that output could continue no matter the political situation in other countries.

Work is already underway on joint projects organised by the Faraday Institute and involving scientists and industry to increase the efficiency of batteries and make them more environmentally friendly.

The aim of the ReLiB project (Reuse & Recycling of Lithium Ion Batteries run by The Faraday Institution) is to secure the recycling of close to 100% of the materials in lithium ion batteries in the automotive sector, by identifying and removing the technological, economic and legal obstacles to it. It includes developing new methods of isolating the minerals used so they can be recycled, identifying second life uses for the components, reviewing the regulations on battery recycling to ensure they are fit for purpose - and of course encouraging the development of new businesses to actually carry out the recycling process.

All of us involved in the EV industry have a role to play in improving the sustainability

of the market. Some parts of a lithium ion battery are already reusable as are the fasteners and components within EV battery housings, busbar assemblies and electrical connectors within the battery, as well as in the charging sockets and facilities. The fasteners and components include silver plated copper or brass connector pins, brass inserts, stainless steel bolts, steel self-drilling screws, aluminium connections and compression limiters. At the end of the battery’s functional life, these should be easily removable for separation and recycled for use in other products, whilst allowing easy recovery of the spent battery cells.

But if we are to move to batteries that are near 100% recyclable, we need to do more.

Those designing the next generation of EV batteries must consider at the start of the process - rather than as an afterthought, or not at all - how units will be disposed of.

How can we make the product as efficient and effective as possible, but still ensure its constituent parts can be quickly and easily separated for recycling when it runs out of juice?

Putting Design for Manufacture at the heart of the system is key. Designers working with suppliers from the outset can reduce the number of components in their product and increase their efficiency. At TR Fastenings, for example, our specialist teams work closely with our customers from the very early stage of the design process, with our engineers able to develop, test and put into production innovative solutions to problems.

If we are to keep the cost of replacing and recycling units down, we need to develop greater standardisation of batteries so that a one size fits all system can be created for end of life disposal of all of the constituent parts.

In addition, unless there is a sustained focus on tackling the end of life situation for the current generation of batteries, the green benefits of the technology are at risk of being undermined.

For further information, please visit www.trfastenings.com

56

PECM Issue 47

Hardware Solutions for the Electric Vehicle Industry TR TR is is actively actively working working with with aa number number of of organisations organisations involved involved in in the the design, design, manufacture manufacture and and development development of of Electric Electric Vehicles Vehicles (EV), (EV), Battery Battery Pack Pack Modules Modules (EVB) (EVB) and and Electric Electric Vehicle Vehicle Charging Charging Units Units for for both both commercial commercial and and residential residential use. use.

As As this this sector sector continues continues to to emerge emerge and and develop, develop, TR TR is is able able to to supply supply an an extensive extensive product product range range and and has has the the necessary necessary technical technical knowledge, knowledge, expertise expertise and and experience experience to to support support this this industry. industry.

TRâ&#x20AC;&#x2122;s TRâ&#x20AC;&#x2122;s qualified qualified engineers engineers and and sales sales staff staff are are on on hand hand to to advise advise designers, designers, production production and and purchasing purchasing teams teams on on aa number number of of matters, matters, from from Design Design for for Manufacture Manufacture (DFM) (DFM) to to new new fastener fastener technology, technology, sourcing sourcing insight insight and and cost cost reduction. reduction.

Full Service Provider

Design & Engineering

Supplier

Distributor

Manufacturing

Quality

Logistics

Global specialist in the design, engineering, manufacture and distribution of industrial fastenings Screws, Nuts, Bolts, Washers, Sheet Metal Fasteners, Screws & Inserts for Plastic, Plastic Hardware, Spacers & Pillars, Enclosure Hardware, Locking Nuts, Blind Rivets & Nuts, Security Fasteners, Circlips, Micro-Diameter.

Contact us: +44 (0) 8454 811 800 | sales@trfastenings.com | www.trfastenings.com

ELECTRICAL & ELECTRONICS

EV BATTERY STANDARDISATION PAILTON ENGINEERING

Exploring the benefits and drawbacks of greater standardisation in electric vehicle (EV) batteries It is estimated that by 2050, 74 percent of Europeâ&#x20AC;&#x2122;s vehicle stock will be battery powered. What role will the standardisation of these batteries play in this story? Roger Brereton, heads of sales at steering system manufacturer Pailton Engineering, assesses the arguments for and against greater standardisation.

Over the next half-century, the internal combustion engine will be gradually displaced by the rise of the battery powered electric vehicle. The current generation of these vehicles rely on lithium ion (Li-ion) batteries for their power with this battery type predicted to dominate this realm for the foreseeable future. The debate over whether governments should introduce greater standardisation of batteries is not a new one. But it is more complicated than is often assumed.

The strongest argument in favour of greater standardisation is a green one.

Although vehicle electrification is touted as a solution to cutting emissions, disposing of all these batteries creates another set of environmental problems. A recent study found that in 2017, the amount of electric cars sold would produce 250,000 metric tons of battery waste. And that estimate excludes other electric vehicles, such as electric buses for example. The dangerous business of processing this waste is complicated by the fact that different manufacturers use different battery chemistries and their packs come in a range of different shapes and sizes.

Standardisation is clearly part of the solution here. If there was less variation in the size and shape, then the removal of the packs would be cheaper and less dangerous. It could also pave the way for more automation in the disposal process. At the very least, better standards around the labelling of batteries would be of benefit.

This would allow the batteries to be more easily recycled or repurposed.

The green argument feeds into an argument about costs. Firstly, the mass production of

Li-ion batteries will lower costs for vehicle original equipment manufacturers (OEMs).

Furthermore, vehicle manufacturers are often both legally and financially responsible for removing and recycling these batteries. Standardisation will reduce these costs too.

Secondly, second life applications for these batteries will emerge as a lucrative market in the coming years. It is estimated that OEMs will gain on average $67 for each battery unit that is repurposed rather than recycled. Standardisation makes the repurposing process safer and easier, which can produce financial benefits for both manufacturers and consumers.

Despite the above benefits, too much standardisation across the entire EV market is both impractical and unwelcome.

Those who design and manufacture the vehicles and their batteries guard their intellectual property closely. The likes of Tesla are not going to quickly hand over the secrets to their latest battery

chemistries for example.

Too much standardisation would in any case stifle innovation. This is not yet a mature technology and progress is being driven by competition. For example, the location of batteries in electric buses is an entirely separate debate but does highlight the opportunity to break conventions in electric vehicle design. Yes, we need strong safety and environmental standards, but we also want to encourage as much design flexibility as possible.

Standardisation is one half of the story of how we will achieve widespread vehicle electrification by mid-century. This will allow us to exploit this technology in a greener and cheaper way. The other half of the story will be the role of design flexibility and innovation. If the 2050 projections are correct, the industry will need to meet half way to provide enough flexibility and innovation to keep vehicles competitive, and the right level of standardisation to keep costs feasible.

To find out more about Pailton Engineeringâ&#x20AC;&#x2122;s bespoke steering system parts, visit pailton.com.

58

PECM Issue 47

ELECTRICAL & ELECTRONICS

Lightning Warning System The BTD-200 is a complete detection and warning system which has been developed from the Biral range of professional aviation grade lightning detection systems. Its proven detection technology reliably detects the presence of all forms of lightning out to a rage of 35km (22 miles) from the sensor.

It is a modular system which is designed to operate out-of-the-box, but is also expandable as requirements grow or change. The essential system comprises a lightning detector which is placed outside, either on its tripod mount or permanently installed, whilst a PC located indoors runs the supplied Lightning Works software.

The system includes a power supply and (optionally) the cabling to connect to the power and the host PC. Biral Unit 8 Harbour Road Trading Estate, Portishead Bristol BS20 7BL United Kingdom +44 (0)1275 847 787 info@lightningearlywarning.com

www.lightningearlywarning.com

Current measurement on an industrial scale…

The Isabellenhütte IVT-S series, brought to you by Rhopoint Components, the solution you never knew you needed!

This intelligent current and voltage measurement module has the potential to revolutionise a range of industries, such as: • Hybrid and Full electric drives • UPS systems • Stationary energy storage systems • Fuel cells and all battery management applications.

This is achieved by combining the highest quality current measurement shunt resistors with digital processing, built into a compact package, resulting in a reliable plug-and-play module.

Key features include: • Instant communication via CAN bus 2.0 interface • Accurate measurement options of current, voltage, temperature and power available • Dielectric strength of 1000V (DC) • Designed for high and continuous DC currents of up to 2500 A • Options of Daisy-chaining or on-board CAN termination • Up to 3 voltage output channels per module

For more information please contact our sales team at: sales@rhopointcomponents.com

Issue 47 PECM

59

ELECTRICAL & ELECTRONICS

TEMPERATURE CONNECTORS PEI-GENESIS

How picking the right connector first time can make the difference avoid the build-up of dangerous fumes or explosive atmospheres created by burning or outgassing plastics.

When designing industrial equipment, the operating temperature of the product is often at the top of the list for design engineers. This makes sense, after all, you don’t want to keep replacing failed equipment. However, while engineers give a lot of thought to heat in the equipment itself, the performance of the connectors and cables that join different devices is often overlooked. Here, Jonathan Parry, Senior Vice President of Global Operations and European Managing Director at cables and connectors specialist PEI-Genesis, explains how to choose an extreme temperature connector.

For the average member of the public, choosing a connector is often as simple as deciding between a one or two metre USB cable, and we still get very annoyed when the connection starts to become unreliable.

For the engineer the choice is far more complex, and the consequences far more serious than having to wiggle the connector until it works. A dropped connection could mean losing control of heavy autonomous equipment, a stopped machine and jammed-up production line, or many other detrimental effects that are best avoided.

While the working equipment in industrial settings is often well monitored by governing software and vigilant engineers, it’s often the case that the connectors are overlooked, despite them being just as crucial as any piece of line equipment.

HOT STUFF

Heat, particularly in the extreme, is a factor that engineers constantly tackle.

Heat is a natural consequence of many industrial processes, and many more still involve heat directly in the process, such as smelting and other metalworks.

Most equipment uses active cooling to control this heat, such as ventilating fans, cooling lubricant sprays and water-cooling.

For the connectors this is often not possible, which makes the choice of connector in the first instance very important.

An example of this style of connector is the PEI-Genesis supplied VEAM CIR from ITT, which has been specifically designed for extreme temperatures. This connector uses specialised LSZH plastic inserts and a variety of enclosure materials, which gives it the capability to meet ISO 834-1 fire standards, where the connectors are exposed to temperatures as high as 800 degrees Celsius.

LEAVING CONNECTORS OUT IN THE COLD

When dealing with hot environments it’s tempting to simply pick a connector with a metallic housing, such as steel or aluminium, because these metals typically don’t melt before a few-hundred degrees Celsius.

Doing this overlooks major problems, however. For instance, the connector enclosure might easily withstand the high temperatures in question, but inside the enclosure can act as a heatsink because heat isn’t actively wicked away.

Many connectors, such as common USB and serial ports, rely on plastic inserts to house the contacts, while other connectors may also enclose electronic components such as resistors, ballasts and rectifying circuits, which may be susceptible to temperatures lower than the enclosure material.

Even if temperatures don’t actually melt or scorch these plastic components, procedural stress caused by the high temperatures, as well as the effects of thermal expansion and contraction can cause connectors to fail well before their expected lifecycle.

Particular attention must be paid to connectors in hot and enclosed environments, such as on trains and boat engine rooms, where low-smoke-zerohalogen (LSZH) plastics are often used to

Sliding back down the scale, we reach the arena of cold-temperature connectors. This initially seems far easier to solve than heat, primarily because most industrial processes are exothermic.

Therefore, the cold temperatures that connectors are exposed to are often natural, with connectors being continually exposed to the elements. These cold environments often preclude the use of many plastic and rubber enclosed connectors because they can freeze and crack, creating openings for moisture to wreak havoc. Metal is also a tricky proposition, as it’s often prohibitively complex to design a metal enclosure with tolerances tight enough to protect from the weather.

With the correct choice of connector configuration and materials, however, this style is perfectly possible. The PEI-Genesis supplied Sure-Seal Connectors range is one such low-temperature capable connector.

Boasting IP67 and DIN 400 50 ratings, these connectors are enclosed in a PVC nitrile plastic which remains flexible, supple and resistant to cracking down to temperatures as low as -40 degrees Celsius.

Many industries treat connectors as a quick, one-time decision taken during integration, despite the consequences of failure perpetually bringing the problem back onto the agenda. With some more consideration, though, it’s possible for that decision to be truly long-lasting.

For further information, please visit www.peigenesis.com

60

PECM Issue 47

ELECTRICAL & ELECTRONICS

New Electrical Cable Terminals quality and speed from Essentra Components A new range of high quality, low cost terminals is now available from Essentra Components as part of their new Electrical Catalogue listing.

High conductivity and long life crimp joints are quickly formed using a crimping tool on both uninsulated or polyamide insulated options listed.

Available styles include spade terminals and cord end terminals in sizes from 1.3mm to 8.5mm core dia. Applications include electrical installation, domestic appliances, heating industry, automotive industry, cabinet and panel building where ensuring a complete and secure connection is essential.

Essentra Components cable terminals for manufacturers and contractors are part of their one-stop-shop, fast delivery from stock service â&#x20AC;&#x201C; and may be evaluated for production/ installation with free samples on request.

The new Essentra Components

Electrical catalogue is available to request and more information on the cable terminal range may be found at www.essentracomponents. com/en-gb/fibre-wire-cablemanagement.

Further information on Essentra Components products can be found on the Essentra Components website â&#x20AC;&#x201C; www.essentracomponents. com or contact sales@ essentracomponents. com. Follow them on social media: https://facebook.com/ essentracomponents/, www. linkedin.com/company/essentra

www.youtube. com/channel/UCD2g7tiLiKxsDptdC79BNQ

Introducing the New and Improved Range of AS Modular Floor Standing Cabinets with more sizes and accessories to suit your needs...

+44 (0)1925 811 290 sales@tempapano.co.uk www.tempapano.com

Issue 47 PECM

61

FASTENERS FASTENERS & & FIXINGS FIXINGS

PRODUCT SPOTLIGHT STAR STARFASTENERS FASTENERS

Blind Blind Rivets Rivets and and Structural Structural Fasteners Fasteners Star Fasteners product range includes Star StarFasteners Fastenersproduct productrange rangeincludes includes aaa wide selection of rivets, including standard, wide selection of rivets, including wide selection of rivets, includingstandard, standard, sealed, multi-grip, peel, grooved, load sealed, sealed,multi-grip, multi-grip,peel, peel,grooved, grooved,load load spread and structural blind fasteners.

They spread spreadand andstructural structuralblind blindfasteners. fasteners. They They are predominantly used to permanently are arepredominantly predominantlyused usedto topermanently permanently fasten sheet metals together; however, they fasten fastensheet sheetmetals metalstogether; together;however, however, they they are also suitable for composites, plastics are also suitable for composites, plastics are also suitable for composites, plastics and laminate materials. and andlaminate laminatematerials. materials.

WHAT KINDS OF MATERIAL DO WHAT WHAT KINDS KINDS OF OF MATERIAL MATERIAL DO DO THEY COME IN? THEY COME IN? THEY COME IN?

Depending on the fastener type, they are Depending Dependingon onthe thefastener fastenertype, type,they they are are available in variety of materials such as available availablein inaaavariety varietyof ofmaterials materialssuch such as as aluminium, steel, stainless steel (A2 & A4), aluminium, aluminium,steel, steel,stainless stainlesssteel steel(A2 (A2 & & A4), A4), copper and plastic. plastic. copper and and copper.

Huck® Structural Blind Fasteners Huck® Huck®Structural StructuralBlind BlindFasteners Fasteners

When only one side ofofthe the joint material isisaccessible, accessible, performance-engineered Huck fasteners When oneside sideof thejoint jointmaterial materialis accessible,performance-engineered performance-engineeredHuck Huckfasteners fasteners Whenonly onlyone are a smart choice.

Each Huck blind fastener has its own unique set of features.

Their strength, are a smart choice.

Each Huck blind fastener has its own unique set of features.

Their strength, are a smart choice. Each Hick blind fastener has its own unique set of features. Their strength, consistency, easy installation and visual inspection ensures that there isisaaafastener fastener for almost consistency, consistency,easy easyinstallation installationand andvisual visualinspection inspectionensures ensuresthat thatthere thereis fastenerfor foralmost almost every application. every application. every application.

Magna-Lok® Magna-Lok® Magna-Lok®

HuckLok® HuckLok® HuckLok®

Magna-Tite® Magna-Tite® Magna-Tite®

FloorTight® FloorTight® FloorTight®

Magna-Bulb® Magna-Bulb® Magna-Bulb®

Auto-Bulb® Auto-Bulb® Auto-Bulb®

Hole-filling fastener with excellent gap pull-out Hole-filling Hole-fillingfastener fastenerwith withexcellent excellentgap gappull-out pull-out and moisture resistance.

Solid circle lock creates and andmoisture moistureresistance. resistance.Solid Solidcircle circlelock lockcreates creates internal lock that virtually eliminates pin push-out internal lock that virtually eliminates pin push-out internal lock that virtually eliminates pin push-out Material Aluminium, Stainelss Steel (inc 316) Material Material-- Steel, -Steel, Steel,Aluminium, Aluminium,Stainelss StainelssSteel Steel(inc (inc316) 316) Sizes 3/16”, 1/4”, 1/4”, 3/8”, 3/8”, 1/2” 1/2”| /Heads / Heads Heads Protruding, Sizes -- Protruding, Sizes-- 3/16”, 3/16”,1/4”,3/8”,1/2” Protruding, Truss, Truss, 100°Flush Truss, 100°Flush 100°Flush

Wide grip range, double-locking actionaction clamps Wide double-locking action clamps Widegrip 1/4”range, grip range, double-locking clamps assembly from both sides for maximum joint assembly assemblyfrom fromboth bothsides sidesfor formaximum maximumjoint joint integrity. integrity. integrity.

Material Sizes 3/16”, 1/4” 1/4”Heads Protruding, Material 3/16”, Material-- Steel -Steel Steel// |Sizes Sizes-- 3/16”,1/4” Heads Protruding, Truss, Truss, 100°Oval 100°Oval Countersunk Countersunk Heads Protruding, Truss, --Countersunk

HOW TO CHOOSE A RIVET? HOW HOW TO TO CHOOSE CHOOSE A A RIVET? RIVET?

The blind fastener that you choose The Theblind blindfastener fastenerthat thatyou youchoose choose depends upon the environment in which depends upon the environment depends upon the environmentin in which which ititit is being used and the type and thickness is isbeing beingused usedand andthe thetype typeand andthickness thickness of material that is fastening together. of ofmaterial materialthat thatitititis isfastening fasteningtogether. together.

Depending on the product, the diameter of Depending on the product, the Depending on the product, thediameter diameter of of the rivet can range from 2.4mm to 19.1mm the therivet rivetcan canrange rangefrom from2.4mm 2.4mmto to 19.1mm 12.7mm for the more structural projects.

Head types for forthe themore morestructural structuralprojects. projects.Head Head types types include dome / raised head, countersunk, include dome / raised head, countersunk, include dome head, countersunk flanged flanged and large Star flanged.

Star Fasteners Fasteners flanged and large flanged.

Star and large flange.

Fasteners can can guide you to find find fastener that suits can guide to aa fastener guide youyou to find a fastener thatthat suitssuits your your application. your application. application.

WHAT TYPE OF INDUSTRIES ARE WHAT WHATTYPE TYPE OF OF INDUSTRIES INDUSTRIES ARE ARE THEY USED IN? THEY THEYUSED USED IN? IN?

Riveting is widely used in projects where Riveting where Rivetingis iswidely widelyused usedin inprojects applications where blind application requires high strength aalight blind application requires high strength weight and high strength are critical, and speedy installation; they is are used to and speedy they are theyaaare usedinstallation; wherever there a used need wherever there is istogether. need to to fasten materials wherever there aa need fasten materials fasten materials These are just a together.

Theseindustries are just just aathat fewthey examples together.

These are few examples few examples can be industries that they they can can be be found found in: in: -industries found in: -that Automotive, bodyworks (commercial Automotive, Automotive,bodyworks bodyworks(commercial (commercial vehicle), cabinets, construction, electrical vehicle), vehicle),cabinets, cabinets,construction, construction,electrical electrical appliances, exhaust systems, guttering, appliances, appliances,exhaust exhaustsystems, systems,guttering, guttering, HVAC (heating, ventilation and air HVAC HVAC(heating, (heating,ventilation ventilationand andair air conditioning) ladder manufacturing, metal conditioning) conditioning)ladder laddermanufacturing, manufacturing,metal metal industry and even sculptures and art industry industryand andeven evensculptures sculpturesand andart art installations! installations! installations!

The riveting process is environmentally The Theriveting rivetingprocess processis isenvironmentally environmentally friendly when compared to welding and friendly friendlywhen whencompared comparedto towelding weldingand and bonding as is chemical, smoke and fume bonding bondingas asitititis ischemical, chemical,smoke smokeand andfume fume free. free. free.

Star Fasteners offer wide range of quality Star StarFasteners Fastenersoffer offeraaawide widerange rangeof ofquality quality hand, hydraulic, airair and battery tools that can hand, air and battery that hand,hydraulic, battery and tools that tools we know we know can stand up to to the rigours we know stand up rigours stand up can to the rigours ofthe a busy workshop of busy workshop workshop environment.

We of aa busy environment.

We environment.

We recognise that choosing recognise that choosing rivet tool tool can can recognise aa rivet a rivet toolthat canchoosing be fairly complicated; our

62

PECM Issue 47

Has water-resistant sealant for oversize holes and Has Haswater-resistant water-resistantsealant sealantfor foroversize oversizeholes holesand and repairs.

Large blind-side footprint for use ininthin thin oror repairs. repairs.Large Largeblind-side blind-sidefootprint footprintfor foruse usein thinor low-strength materials. low-strength low-strengthmaterials. materials.

Material Sizes3/16”,1/4” 3/16”, 1/4” 1/4” Material Sizes -- 3/16”, Material-- Aluminium -Aluminium Aluminium//Sizes Heads Protruding, Shaveable, Shaveable, Low Low Profile, Profile, 100°Oval Heads Heads-- Protruding, Protruding, Shaveable, Low Profile, 100°Oval, Countersunk 100°Oval, Countersunk Countersunk

Unique bulbing fastener with high shear strength Unique Uniquebulbing bulbingfastener fastenerwith withhigh highshear shearstrength strength offers broader bearing surface for high pull-out offers o.ersaaabroader broaderbearing bearingsurface surfacefor forhigh highpull-out pull-out strength ininthin thin materials and or oversized oversized holes. holes. strength // or strengthin thinmaterials materialsand and/or oversized holes.

Material Sizes 3/16”, 1/4”, 1/4”, 5/16” 5/16” Material Material-- Steel -Steel Steel// |Sizes Sizes-- 3/16”, 3/16”,1/4”,5/16” Heads Protruding, Truss, Truss, Countersunk Countersunk Heads Heads-- Protruding, Protruding, Truss, Countersunk

BOM® BOM® BOM® For ultimate locking locking strength strength from from blind-side blind-side install, install, For ultimate

Features tapered lead-in Blind, Mechanically) Oversize, choose theaBOM BOM (Blind, Oversize, Mechanically) choose the (Blind, Oversize, Mechanically fasteners.

Unique pushwith andlocked fastener.locked features tapered lead-in with locked fastener.

ItIt features aa tapered lead-in design ultimate locking strength 10.9installation grade mandrel. mandrel.

It’sfor unique push and-pull aapull 10.9 grade It’s unique push and-pull from blind-side install. installation design results in in aa high high strength strength installation design results Material solution.

-solution.

Steel | Sizes 3/16” - 3/4” fastening fastening

Material -- Steel Steel // Sizes Sizes -- 3/16” 3/16” ,, 3/4” 3/4” Material

be fairly includes complicated; our service servicethe includes be fairly complicated; our includes service demonstrating latest demonstrating the latest latest models and best demonstrating the and models and advising on models tool options advising on tooling options best best suited to advising tooling options suited suited toon both the application and the to both the application application and and the the environment. environment. both the environment.

Every production production environment, environment, workshop workshop Every and tool tool benefits benefits from from aa regular regular and

Self-countersinking design for consistent installations Self-countersinking Self-countersinkingdesign designfor forconsistent consistentinstallations installations ininhardwood, hardwood, plywood andvehicle plymetal vehicle floor in plywood and plymetal vehicle floor plywood and plymetal floor applications applications. applications.

Material - Steel | Sizes 1/4”, 5/16” Material Steel // Sizes Sizes 1/4”, 5/16” 5/16” Material -- Steel 1/4”, Heads Standard, Wide --Flange, Plymetal, 90° Heads Standard, Wide Wide Flange, Flange, Plymetal, Plymetal, 90° 90° Heads -- Standard, Countersunk Countersunk Countersunk

Features tapered lead-in point for automated, Features Featuresaaatapered taperedlead-in lead-inpoint pointfor forautomated, automated, high-speed assemblies.

Forms bulb directly on the high-speed high-speedassemblies. assemblies.Forms Formsaaabulb bulbdirectly directlyon onthe sheet line, preventing preventing pull-through. sheet line, pull-through. the sheet line, preventing pull-through. Available in Material Steel, Stainless Steel Steel Material -- Steel, stainless steel. Stainless Sizes 3/16”, 1/4” Stainless Heads -Steel - Protruding, Protruding, Countersunk Countersunk Sizes -- 3/16”, 1/4” // Heads Material - Steel, Sizes 3/16”,1/4” | Heads Protruding, Countersunk

Penta-Lok® Penta-Lok® Penta-Lok®

Specifically designed for joining lightweight panels Specifically Specificallydesigned designedfor forjoining joininglightweight lightweightpanels panels totosteel, steel, stainless steel and aluminium extrusion. to steel,stainless stainlesssteel steeland andaluminium aluminiumextrusion. extrusion.

No through hole required ininlightweight lightweight panel.

No Nothrough throughhole holerequired requiredin lightweightpanel. panel.ItItIt has high pull out strength as unfurls inside the has hasaaahigh highpull pullout outstrength strengthas asitititunfurls unfurlsinside insidethe the composite panel. composite compositepanel. panel.

Material Size 1/4” Material Material-- Steel -Steel Steel// |Size 1/4” -- 1/4”

maintenance program and Star Star Fasteners Fasteners maintenance maintenance program program and and Star Fasteners can help help out out with with that that too. tool can too. Our Our in-house in-house tool maintenance and and repair repair workshop workshop ensures ensures maintenance that there’s there’s minimal minimal down quick that down time time and and aa quick turnaround for for every every job We also also turnaround job we we do. do. We have aa large large selection selection of of short short or or long-term long-term have hire tools. tools. hire

Standard Rivets

Multigrip Rivets

Sealed Rivets

Where structural strength is not required, standard rivets are a fast and simple way of joining all kinds of material.

The body of the rivet forms when the fastener is installed.

The mandrel head remains at the bottom of the rivet forcing the body to bulb.

Because the rivet forms a larger bulb at the back (‘blind’) side, it is also suitable for softer materials. It has excellent hole filling capabilities and is also termed as anti vibration and weather proof.

The head of the mandrel is retained inside of the rivet body and the deform is lateral. During installation the rivet body expands to fill the hole, enabling the rivet to withstand pressures up to 35 Bar (3500 kPa). If used correctly it will be gas and water tight.

Triform Rivets

Grooved Rivets

The triform rivet is constructed in a special way; during installation, the rivet body splits into 3 parts, preventing the material from being damaged. Ideal for assembling plastic and soft materials.

The grooved body enables the rivet to expand into the interior surfaces of the assembled pieces. They provide a strong connection into dense materials such as wood and plastics.

Hammerdrive Peel Rivets Rivets The mandrel passes through the body of the rivet as the pin is hammered in place. The body splits in o four pieces. Different material combinations, for example, wood, plastic, concrete, and metal etc. can be joined together.

The mandrel of peel rivet is constructed in such a way that it splits the end of the rivet body into four ‘petals’ which clamp the material and spread the load over a wide area. Is ideal for soft, thin and hollow core materials.

Rivet Head Styles

Domed Head

rivet is the most common rivet type.

Large Flange

reinforces the hole and allows assemblies of soft materials such as plastic and wood onto metal. It helps to spread the load.

Countersunk Head

offers a perfect flush finish.

For more information, visit starfasteners.co.uk | Email: sales@starfasteners.co.uk | Tel: Tel: +44(0)1159 +44(0)1159 324939 324939 Issue 47 PECM

63

FASTENERS & FIXINGS

FASTENER QUALITY ASSURANCE TFC

How to minimise your quality issues Fasteners play a crucial role in an assembly — yet quality standards are often overlooked by many businesses.

If a fastener is not made to specification, manufacturers may be unable to assemble their products, facing long lead times before the right parts arrive. In a worstcase scenario, manufacturers risk sending poor-quality products out to the market, risking loosening or component failure.

This would result in product recall, an expensive, extensive and embarrassing process, which can significantly damage a company’s reputation. Here Brian Vince, group quality manager at fastener specialist TFC shares insight on common fastener problems, and how to avoid them.

The most common problem with fasteners is that they don’t match the drawing — the dimensions, thread, head or length is incorrect. This is a relatively easy issue to pick up, taking a measurement using a vernier or a micrometer will identify around 90 per cent of problems. If needed, the next step would be to measure the component using a shadowgraph, which illuminates a shadow of the component that can be zoomed in on to identify any non-uniformities. Quality teams can also use thread gauges or a shadowgraph to check a fastener’s thread.

There are numerous reasons a fastener may not meet the required specifications.

Perhaps there was a mix up during picking or labelling, and the fasteners have been delivered in an unmarked or incorrectly labelled bag. Maybe the wrong ISO standard of part has been delivered, or the material is not tempered when it should have been. Many common errors are almost impossible to detect with the human eye, so what can we do to be sure our fasteners are the right ones for the job?

Many fasteners are coated to improve their resistance to corrosion, temperature or friction. For example, powertrain fasteners in a vehicle are commonly coated with zinc to enable them to resist corrosion, heat and oil. Polytetrafluoroethylene (PTFE) coating is common in the aerospace and oil and gas industries as it is lightweight and provides high-corrosion resistance. Quality professionals should assess whether the coating thickness is uniform across the fastener and within stated tolerances — if it is not, the part could cause problems later on.

CHECK YOUR MEASUREMENTS

FINISHING

Good communication and full traceability between distributor and supplier is crucial.

Hardness testing can also detect quality issues. Quality specialists can assess tensile strength and perform flexure or compression tests to check the material has the desired properties. This will prevent a fastener from going into an application where it is too hard and will snap, or too soft and will bend.

Dependent on the component at hand, other tests can be performed, such as load testing for springs, checking the hardness of rubber parts with a durometer, or testing the smoothness of bolt. If all testing is coming up fine, but a manufacturer experiences problems with quality during assembly, inspecting the part under a microscope means you can interrogate the problem at a very granular level to identify what is wrong.

MATERIAL

To check that the fastener is made using the required material, quality professionals can use positive material identification (PMI) testing. This technology analyses the full chemical composition and grade of a metal or alloy, which means that the manufacturer can be confident that the material’s properties match specification. Material identification is particularly important in the oil and gas sector, where a material mix up could lead to catastrophic failure.

For example, a stainless-steel retaining ring in a subsea drive shaft, instead of specified Inconel X-750 could mean drilling operations are forced to halt months before schedule.

If all testing confirms that the part is to specification, it may be a design issue that is causing quality problems. In this case, your supplier may be able to suggest an alternative option that will be more suitable for the application.

64

PECM Issue 47

RE-ENGINEERING

There is another benefit to having access to all this kit. As well as checking the quality of a fastener from a supplier, testing methods can be used to help re-engineer a component. For example, if you are not sure what material your fastener is made of, PMI testing could identify the material. Combining this with measurement techniques that provide the physical characteristics of the fastener could enable you to work backwards to identify an alternative part that would work in the same application.

well as OEM approvals and lot traceability certification you can check for. Certain industries have more rigorous certifications, such as Aerospace AS9100:2016/9120:2016 standards (AS 9100D and AS 9120).

TFC does all quality testing in-house to make sure that customers are receiving the correct parts, to specification.. We proactively check parts, so our customers don’t have to.

Good communication and full traceability between distributor and supplier is crucial.

Consolidating your suppliers into one vendor managed inventory partner, or reducing the number of vendors, will make managing quality more straightforward.

Anything we forgot? If you need a supply of fasteners checked in a way that we didn’t mention, let us know. TFC is always happy to add equipment to its test lab to meet customer needs.

While the majority of fastener manufacturers have the equipment to fully interrogate fastener quality, not all distributors possess the same advantage. If there is a noncompliance report, it pays to work with a distributor that tests in-house, rather than outsources, as external quality testing can take four to six weeks compared with next day.

COMMUNICATE AND COLLABORATE

To make sure they have the best possible chance of fastener success, manufacturers should be rigorous with their suppliers — ask to see their certifications and establish what quality measures they have in place.

A good starting point is ISO 9001, but there are other ISO and AS standards, as For further information, please visit www.tfc.eu.com Issue 47 PECM

65

FACILITIES MANAGEMENT

Extending the lifespan of your pipework Prevention is better than a cure, and that is certainly the case when it comes to the maintenance and repair of pipework When pipes begin to suffer from corrosion, chemical exposure or just general wear and tear, then the consequences can be devastating – as anyone who has ever found themselves dealing with an emergency repair or replacement of a crucial leaking pipe can attest to, especially if the flow cannot be isolated.

Sylmasta maintenance composites and resins are designed to protect and strengthen pipes and other structures. The Sylmasta range of composite pipe repair wraps and epoxy putties, pastes and coatings are used in facilities worldwide to reinforce and protect assets against corrosion, chemicals, extreme temperatures, and to restore pressure resistance.

The SylWrap Pipe Repair Kit takes the Sylmasta’s resin technology and puts it into an easy-to-use product which enables any user to permanently repair a leaking pipe in under 30 minutes. Gone are the days of hiring a contractor to carry out a costly repair or replacement. With a SylWrap kit, systems can be repaired instantly, even when pressure cannot be turned off.

The SylWrap kits are so effective that they are now used by the likes of Southern Water, Anglian Water and Affinity Water to make permanent repairs to the UK’s water networks and are used around the world in chemical plants, power stations and other processing facilities.

Whether are you looking to extend the lifespan of your pipework, protect it from external factors, or want to find out more about composite pipe repairs, Sylmasta can help.

Discover more at www.sylwrap.com.

www.sylwrap.com

Smart ergonomic solutions for every workplace

Viper Wire Rope Lubricator (Viper WRL)

bio-cleanseal® Sealing System for Clean Rooms

AJ Products is a full-service supplier of furniture and interior solutions for warehouses, manufacturing facilities and offices. A combination of over 20,000 quality products, expert knowledge, in-house design and manufacturing, and high service levels provides smart and unique solutions for every workplace. Everything AJ offers is designed to put employee health and wellbeing front and centre whether efficient pallet racking, ergonomic materials handling equipment, sit-stand workbenches or anti-fatigue mats. AJ Products can provide everything from design suggestions and planning to quick delivery and installation. Finance leasing is also available to make it easier to spread out the cost of projects from £1000 to £1,000,000 with taxdeductible, fixed monthly payments.

Viper WRL, an Australian owned company, manufactures & supplies wire rope lubrication equipment to the marine, petrochemical, mining and manufacturing industries. The use of the Viper WRL system increases the life of wire ropes by up to 300% compared to traditional lubrication methods. When used in place of manual lubrication the Viper can reduce relubrication time of ropes by up to 90% from several days to several hours whilst also providing a safer work environment.

As the Viper delivers grease into the wire rope there is also an environmental benefit with less lubricant used and significantly less waste generated. Recently the company has expanded operations with global distribution in over 70 countries & sales have grown by 32%.

UK based A&S International has successfully represented the Viper WRL for more than a decade.

The new bio-cleanseal® product line from liquitec ensures the sealing of pipe systems in controlled clean room environments. The system is based on a smooth stainless steel sealing element with an elastomer mono seal for the penetration of pipes between controlled environments. The system is designed for use under various conditions and can also withstand problematic environmental conditions. For example, it is chemical-resistant and Atex-compliant. The installation of the sealing element for pipe penetrations and the orientation of the penetration is very flexible.

The sealing element can be attached to ceilings, walls or floors and compensates a slope of the pipe segment of up to 5 °.

The sealing system is designed to completely dampen vibrations and also acts as a noise reducer. It also has smooth surfaces, a hygienic design and is manufactured in accordance with regulations and GMP guidelines.

T: 01252 359760 E: info@ajproducts.co.uk W: www.ajproducts.co.uk

66

PECM Issue 47

www.aands.international/our-brands/viperwire-rope-lubricators/

www.liquitec.ch

FACILITIES MANAGEMENT

INNOVATIVE SOLUTIONS VORTEC

­ ortec products deliver increased equipment efficiency, V spot and enclosure cooling, and amplification of air flow for conveying and blow off ENCLOSURE COOLERS

When looking to keep electrical and electronic enclosures cool, clean and protected, Vortec Enclosure Coolers are a low-cost alternative to expensive, highmaintenance air conditioners; and avoid contamination associated with dirty, humid air caused by fans.

Vortec offers multiple types of enclosure cooling systems to meet your enclosure cooling needs, all available in a variety of cooling capacities and hazardous locations; including ATEX and UL certified models.

“With Vortec’s Enclosure Cooler, our control panels don’t shut down anymore, meaning we don’t lose production time.”

SPOT COOLING

Vortec Cold Air Guns and Vortex tubes deliver ultra-cold air where and when you need it for machining and process cooling. Capable of delivering cold air down to -40C, without refrigerants, without refrigerants and using only compressed air, Vortec spot cooling products provide flexibility, longevity, and precision.

AIR AMPLIFIERS

Whether conveying, drying, or ventilating, Vortec Air Flow Amplifiers magnify compressed air flow up to 20-fold in ducted and 60-fold in unducted applications.

No moving parts provides immediate on/ off while eliminating all shock risks and meeting OSHA’s required noise levels.

AIR KNIVES

Vortec Air Knives deliver a powerful, high velocity, laminar sheet of air to discharge static and remove dust, shavings and other debris from surfaces more effectively. Air knives amplify compressed air volumes up to 25 times over compressed air input and use considerably less air than other blowoff methods.

OUR COMPANY

As the first company to develop technology

Vortec offers multiple types of cooling systems to meet your facility’s cooling needs. for converting the vortex tube phenomenon into practical, effective industrial cooling solutions, Vortec prides itself on providing innovative compressed air solutions and processes. Since 1961 we have continued to refine and expand vortex tube applications, as well as develop air amplification products. Vortec’s products are designed and built to last: with no moving parts, it eliminates the normal wear and tear that you get from most equipment.

We stand behind all of our products and offer the industry’s best 10-year warranty on most products.

sales@vortec.com | 800-441-7475 | www.vortec.com Issue 47 PECM

67

FLUID HANDLING

Process Equipment – Making the Right Connection The demands on modern manufacturing mean that processing equipment in all industries is required to tackle more and more challenging conditions in moving fluids and materials efficiently; when it comes to transferring and handling fluids via hoses and piping, the ability to ensure optimised flow and prevent any accidental release of the product is an increasingly important consideration.

It is particularly significant when, with frequent connections and disconnections, fittings become damaged which could lead to uncontrolled spills, the loss of valuable media, or contamination of the media which can prove costly in production downtime and possibly cause risk to health and the environment. .

Finding the most effective fluid transfer solutions can have many benefits for maximising return on investment by improving best practice thus increasing production efficiencies, reducing man-hour maintenance costs, preventing accidents, and avoiding downtime.

Dixon Group, a manufacturer and supplier of material transfer products across a wide range of markets has valuable experience and built a credible reputation for over 100 years, demonstrating that it is a responsible manufacturer producing and supplying safe, reliable, and long-lasting products. An ethos of open communication with customers and partners enables Dixon to develop innovative solutions to the daily challenges industry faces.

A vast portfolio of hoses, fittings and accessories is available including many innovative designs and industry leading developments. Examples include; • Breakaway check valves to prevent product loss in driveaway situations.

• Specialist Cam and Groove fittings for venting pressure before disconnect, or armless versions for use where space is a factor.

• Connect under pressure Quick release fittings.

• Specialist hose configurations such as internal swaged, bespoke ball joint armour, heat traced and duplex hose assemblies.

• These unique products are further enhanced by Dixon’s in-house custom-built fabrication and design capabilities.

Dixon’s technical team can offer site surveys or remote consultations to discuss any requirements; from specifying correct hose assembly and piping configurations to providing new methods of providing ‘the right connection’.

europe.dixonvalve.com

Fluid Carrying

Flexibility

Rotaflow and the Silver Screen Most of the work Rotaflow design engineers do involves thinking up solutions to pressure, heat and fluid related problems, so when the special effects department of a major Hollywood film production house gets in touch, it sparks a bit of excitement in the office!

Rotaflow swivels have helped production of some major blockbuster films… one that is set in a galaxy far, far away!

Another film Rotaflow swivels have been used in investigated the framing of a famous cartoon rabbit…

These two aren’t the only examples of Rotaflow swivels being used in film production.

68

PECM Issue 47

In July this year two Rotaflow multiports were delivered to a film set. They’re designed to not only allow the rotation of hydraulic control lines but also incorporated electrical wires to pass through the centre of the unit, which facilitates the full rotation of a green screen rig. It means the action can spin from a central axis point smoothly, capturing footage more easily.

The Rotaflow design and manufacture standards are what has led to repeated work between the studios and the Derbyshire-based swivel joint specialists.

www.rotaflow.com

Articulated Torsion Pipework In Hoses Rotating Cylinders

Swivel Joints Swivel joints allow pipework to pressure 1/4” to 40” and beyond.

Vacuum to over 20,000psi.

Stock and bespoke production.

Unique bearing/seal design for longer life.

ISO 9001 CE marked where applicable.

Tel:

Bingswood Trading Estate Whaley Bridge | High Peak | SK23 7LY | UK

+44(0)1663 735003

E-mail:

FLUID HANDLING

A PERFECT SOLUTION SEEPEX UK LTD

Accurate dispensing of AB Mauri bakery ingredients A significant factor in baked goods manufacturing is the need to reduce the cost of raw material delivery into dough mixes. Modern research and process techniques have been used by AB Mauri, a major manufacturer and supplier of bakery ingredients, to produce a range of Enzymes, Bread Improvers and Enhancers in a highly concentrated form. These ingredients are highly effective, requiring very small amounts to be added to each batch.

To maximise the benefit of these concentrated products accurate dispensing of the ingredients is critical, both to ensure optimal ingredient performance, and to minimise overdosing (which can add to material usage and cost). Traditional weighing and Diaphragm Pump dispensing, even with the best of metering control, can lead to significant variations in the actual additive level to each batch of dough.

SOLUTION Although AB Mauri has considerable in house experience at developing the products, the related processes, and even the engineering of equipment, they wished to use an external engineering company with experience in Bakery and other process equipment to develop a solution that met demands for accurate dispensing.

Concept Controls Ltd (Waltham on the Wolds) were approached, and shown some of the original systems, a number of which had performance limitations with the latest developments in ingredients. After technical analysis of peristaltic, lobe and double diaphragm pumps a higher performance pump was sought to ensure accurate repeatable dispensing of concentrated ingredients from bulk containers.

During the research process the SEEPEX Progressive Cavity (PC) Pump, became a clear leader. The main benefit of the PC pump is that there is a sooth pulsation free delivery of material delivering repeatable accuracy of +/-1%. The flow rate is linear, proportional to motor speed and regulated by a simple speed controller over a very wide range. This was specifically useful as there is a limited time (Less than 25 Secs) for dosing of the A.B. Mauri products when operating on a standard Bread Mixer, hence a high rate of delivery is needed for rapid dispense, but a low rate of delivery for accuracy of dispense.

The pressure capability of these pumps is also very wide, and the Concept Controls Ltd system uses this to deliver a high pressure and high accuracy phase at the end of the dosing cycle. The pumps can also accurately dispense products with a wide range of viscosities.

By coupling this high performance PC pump, orifice plates, and a very high accuracy Endress and Hauser Coriolis Flow meter, Concept Controls Ltd, in conjunction with their partner company PVSL Ltd. (Brierley Hill), are able to meet the challenging specification requirements for A.B. Mauri.

The detailed design phase started with 3D Models of the proposed equipment generated by PVSL Ltd. The result is an easy to apply Dosing System, that includes bulk frame storage for

IBC containers (normally in Stores area), with buffer tanks to allow a practical regime for maintaining product stock. The SEEPEX PC pumps are more than capable of delivering the various products to a dosing frame mounted close to the Mixers, and hence through the associated mixer lids and into each batch of Dough.

The Dosing Frame is a small matrix of fast acting Ball Valves which allow the product to be fed either directly to the Mixer, or via the flow limiting orifice plate.

The net result is a system that can deliver as low as 50g into a batch of product, and also extend to several kilogrammes, all within the 25 second window, and every batch can be metered to the nearest gram.

The overall benefit to the end customer, is that they can rely on a very consistent product, with the advantages of the most modern process innovations, without the potential of overdosing (i.e. wasted product), overall enhanced quality and reduced overall scrap.

Companies involved: Concept Controls Ltd. www.concept-controls.co.uk PVSL Ltd. www.pvsl.uk.com SEEPEX UK Ltd. www.seepex.com

For further information, please visit www.seepex.com Issue 47 PECM

69

HEALTH & SAFETY

EXPLOSION SAFETY REMBE

Explosion isolation system Q-Bic wins the Red Dot Design Award When it comes to the winners of design awards, most people think of futuristic automobiles, furnishings or everyday objects. However, for the first time, protective systems have now also received an award. Two in-house developments from the German safety manufacturer REMBE, known as the world market leader in the explosion safety scene, have received the Red Dot Design Award: the Q-Bic extinguishing barrier and the design study for a new generation of the EXKOP quench valve, both products for explosion isolation. The REMBE engineers have thus demonstrated that, besides the highest standards of safety and reliability, they also have an eye for the visual.

However, not only does the new Q-Bic isolation system look good but the design has been developed with functional and hygienic aspects in mind. The Q-Bic

extinguishing barrier offers a variety of visible and invisible highlights: the firmly attached transport handles, which allow safe installation and transport of the extinguishing barriers, are obvious.

They are very helpful, especially when the Q-Bic is installed in hard-to-reach places or at high altitudes. Thanks to the convex dirt protection cap, neither water nor dust deposits can accumulate on the Q-Bic. The â&#x20AC;&#x153;inner valuesâ&#x20AC;? of the Q-Bic are also remarkable: the blue-green extinguishing powder QXP prevents cross-contamination and the patented SJX nozzle ensures an optimum application of the extinguishing powder. Thanks to the specially developed release mechanism without explosives, the Q-Bic can be easily imported worldwide. The Q-Bic is particularly suitable for large pipes attached to dryers and filters or complex shaft geometries such as conveyors and elevators.

Fig. 1: Winner of the Red Dot Design Award: REMBE Q-Bic

Fig. 2: Q-Bic explosion isolation system

Q-BIC AS CHEMICAL BARRIER The Q-Bic explosion isolation system registers the beginning of an explosion and extinguishes the explosion flames

within milliseconds by introducing the extinguishing powder QXP. The special nozzle system SJX ensures optimum distribution of the extinguishing powder in the pipe. This guarantees a secured

isolation. The explosion isolation system Q-Bic is specifically suitable for large pipes or complex shafts geometrics for example in conveyors or bucket elevators.

For further information, please visit www.rembe.de

70

PECM Issue 47

T +49 2961 7405-0 info@rembe.de

Made in Germany

Your Specialist for

PRESSURE RELIEF and

EXPLOSION SAFETY

© REMBE® | All rights reserved

Consulting. Engineering. Products. Service.

Gallbergweg 21 | 59929 Brilon, Germany F +49 2961 50714 | www.rembe.de

HEALTH & SAFETY

THE SILENCE OF THE ALARMS OMNIFLEX

How plant managers are playing with fire When flames took hold at the Kader Toy factory in Thailand in May 1993, it heralded the start of the world’s worst industrial fire, killing 188 workers and seriously injuring 500 more. The investigation into the tragedy found the failure of the fire alarm as the principle cause. Despite disasters like this, an alarming number of obsolete systems remain in situ — putting industrial sites and employees at risk. Here Gary Bradshaw, director of industrial remote monitoring specialist Omniflex, warns plant managers against delaying the replacement of redundant alarm systems and playing with fire.

Every industrial or manufacturing plant should have an up-to-date alarm monitoring system because even the slightest changes in temperature, flow or environment can damage the production process and lead to costly downtime. Chemical processing, for example, requires critically controlled temperature and humidity levels, so the slightest variation can result in defective products or outputs, damage to equipment and can crucially halt production all together. Having a fully functional, operational alarm monitoring system is therefore essential, no matter the industry.

Despite the importance of fire prevention, between 80 and 90 per cent of alarm systems fitted in industrial facilities in the UK today are obsolete — a worrying

There is often a reluctance to prioritise alarm replacement, with operators ignoring the warning signs. status, as well as monitoring specific conditions from different points across a site. Any condition changes were relayed back to the central control panel, triggering a warning light to alert the plant operator of any issues requiring immediate action. statistic given that malfunction can cost millions. With the stakes so high it’s hard to comprehend why plant owners take the risk and continue production with alarm systems that aren’t fit for purpose.

CLEAR AND SIMPLE The late 1960s and 70s saw a huge increase in the installation of hard-wired, panel based, annunciator systems. The panels featured a series of colour-coded warning lights showing the system’s overall

At the end of the 80s and early 90s industrial plant managers began moving away from hard-wired alarms in favour of PC based SCADA systems. In contrast to traditional annunciators that were considered old fashioned and took up too much room, computer-based systems offered a contemporary, compact alternative. Manufacturers could now connect multiple communication points without having to install miles of cabling and it essentially didn’t require huge capital investment. It was during this time that many alarm manufacturers, including Babcock, Century and Highland Electronics either went out of business or were taken over.

OPERATION OVERLOAD Digitisation undoubtedly improved the efficiency of alarm systems to monitor, analyse and report across a wider range of communication points. However, the increase in capabilities led many operators to overload the systems. Sites increasingly became reliant on control systems with complex displays, making it difficult for operators to distinguish critical alarms. This approach was widely publicised as the reason for several high-profile incidents, including the fire at the Buncefield oil storage depot in Milford Haven and the Texaco oil refinery plant explosion in Pembroke.

72

PECM Issue 47

Despite incidents like these, thousands of industrial plants remain at risk across the UK. There is often a reluctance to prioritise alarm replacement, with operators ignoring the warning signs. Convincing senior level plant management that investment in a replacement system is worthwhile can be difficult, especially because the financial return isn’t immediately apparent. Ironically, the return is generally only realised once the system has helped a company to avoid a production loss by alerting operators about an issue.

Yet, replacing an alarm system doesn’t have to be a timely, costly or disruptive exercise and can safeguard facilities when a system fails with minimum disruption.

Omniflex is the leading monitoring specialist in the UK with the capabilities to configure a replacement for any redundant alarm system, whoever the original manufacturer and whatever the specification. We engineer all solutions off-site and design them specifically to fit into an existing alarm structure. This drastically reduces installation time and associated production downtime.

Alarm failure has cost industrial plants millions of pounds, and in the case of the Kader Toy factory, over 150 lives.

With such a lot to lose it’s incredible that so many take the risk, especially when retrofitting a replacement to an existing system doesn’t cost the earth.

To find out more about updating your alarm annunciators and safety-critical alarms, contact Omniflex on 0161 491 4144 or visit the website to book your free site survey today.

For further information, please visit www.omniflex.com Issue 47 PECM

73

HYDRAULICS & PNEUMATICS

FLAWLESS DESIGN PARO SOFTWARE B.V.

Saving Time From Hydraulic Schematic to Hydraulic Manifold Production with Paro Software Exclusively focusing on hydraulics, Paro Software has been supplying a complete suite of hydraulic software, helping hydraulic professionals to design flawless hydraulic systems to deliver faster to their customers, save time and eliminate repetitive work and human error.

HYDROSYM FOR DESIGN OF HYDRAULIC SYSTEMS

In HydroSym, hydraulic engineers design hydraulic systems of any complexity. With the connected Paro Library of over 40,000 hydraulic parts, it is easy to click and add any part to the worksheet. Whatâ&#x20AC;&#x2122;s more, is that each part comes with a datasheet for automatic Bill of Material creation once the design is ready. No extensive knowledge of CAD-type software is necessary to use HydroSym. Smart Tools in our software will help guide to a flawless design, such as smart connecting lines with information flows, automatic jumpers, easy positioning of items between connecting lines, and straightforward changing of solenoid properties.

HYDROMAN FOR DESIGN OF HYDRAULIC MANIFOLDS

HydroMan is a complete 3D hydraulic manifold design software package for the rapid design of complex hydraulic manifolds, and is equally effective for simpler designs.

HydroMan is well-organized, efficient and extremely easy to use. With HydroMan, you can quickly and easily produce an error-free manifold design. Thanks to the combination of 3D and 2D, designing in HydroMan is easy and efficient. Smart Tools in our software will help to identify potential mistakes during the designing process, and prove a checklist for your circuits. Once your design is complete, HydroMan will generate the corresponding drilling list, production and assembly drawing, bill of materials and a checklist; all very efficient with just one click.

HYDROCAM FOR PRODUCTION OF HYDRAULIC MANIFOLD HydroCAM software provides the natural next step saving hydraulic engineers more than 80% of their time by digitizing the final step in production of hydraulic manifolds:

automating the programming of the CNC machine.

HydroCAM software makes it possible to automate the programming of CNC machines for hydraulic manifold production. This is a breakthrough in achieving complete optimization of the entire process of hydraulic manifold creation from the initial design to the final production. Before, it would take hours (if not days) to program the CNC machine for manifold production; HydroCam automatically generates the program for the CNC machine based on HydroMan designs.

Thanks to the combination of 3D and 2D, designing in HydroMan is easy and efficient.

For further information, please visit https://paro-nl.com/

74

PECM Issue 47

HYDRAULICS & PNEUMATICS

Explore an ecological future Electric vehicles are gaining momentum around the world, with more and more major cities increasingly switching to electric buses for public transport. The global Dürr Technik Group devotes itself to all aspects of “e-mobility” and has developed oil-free compressors that are powered by their own electric motor(s). These compressors offer energy savings with fewer pollutants in the “Automotive” sector.

Maximise output with high flow and low pressure drop safety hose reels from CEJN

For vehicles over 3.5 tons, a reliable and robust compressed air supply is essential - for applications ranging from brake release air to door opening to air suspension. Instead of mechanically connecting the existing compressors with the vehicle engine in a conventional manner, the newly developed and efficient Dürr Technik compressors have their own electric motor(s).

These are extremely environmentally friendly, run independently of the vehicle engine and only draw power when needed, meaning the a very low energy consumption.

The compressors that we manufacture are oil-free meaning oil control or oil changes are a thing of the past. Coupled with their compact and robust design, very low noise / vibration, low whole life costs, ease of installation and the fact that they are almost completely maintenance free, they can be installed into many positions within the vehicles that would have been impossible in the past. Depending on the product selected our compressors can achieve temperature ranges of between -40 and +40OC and can be operated with a duty cycle of 100 percent.

The compressor B-304 WR from Dürr Technik is especially suitable for vehicles with a total mass of up to 13.5 tonnes.

With a centralised air intake system, this allows flexibility of installation to suit the manufacturers requirements.

For vehicles over 13.5 Tonnes, the E-Bull-300 from Dürr Technik is the ideal choice. At 400 V and 50 Hz, the compressor delivers 280 l / min at 10 bar - at a sound pressure level of 72 dB (A), similar to a vacuum cleaner. With the E-Bull-300 weighing in at only 45 kg, with dimensions of 474 x 286 x 496mm and an IP67 rating it is suitable for all types of vehicle. In addition, Dürr Technik can make individual adjustments to suit specific customer requirements. Durr Technik pride themselves by offering complete solutions with dryers, after coolers, ambient cooling fans, support brackets and enclosures as required.

Further information can be found at www.duerr-technik.com

Compressed air

Water

FEATURES n n n n n

Lowest pressure drop on the market Slow retract Hose guide Quicker hose change New hose stopper

An emphasis on quality, safety and performance make CEJN the ideal choice for safety hose reels.

Premium materials have been selected to withstand outdoor use, UV radiation, chemicals and resistance to wear. With CEJN’s additional products: hoses, couplings and blowguns, it is the most optimised system on the market. For more information contact Tom Parker Ltd.

Sales: 01772 255109 | Online: tom-parker.co.uk

Request a catalogue: catalogue@tom-parker.co.uk Issue 47 PECM

75

MACHINING & MACHINERY

LATEST NEWS FROM MAN ALUCAST

Alucast looks to build on £1m of electrification wins by joining new cluster A recent £2.5m investment in its new CNC machining shop is paying off for Alucast, with the new technology paying a pivotal role in helping it secure new contracts in the electrification sector.

The UK’s leading independent aluminium foundry is using its increased 5-axis capability and Magmasoft® casting simulation to develop and produce a range of complex casings and housings for high profile car makers across Europe.

Some of these products are liquid cooled and feature complex core designs, requiring high integrity castings that must be leak proof and finished with the latest machining techniques.

Whilst it is early days, the management team at the Black Country manufacturer

is expecting volumes destined for electric powertrain/vehicles to account for 25% of its turnover going forward and this is one of the reasons why it has decided to join a new UK cluster featuring Balluff, Brandauer, C-MAC SMT and PP Control & Automation.

This group, which collectively employs over 400 people and boasts sales in 35 countries, will offer a single-source supply chain solution for electric motors, drivetrain components, battery cells, casings and housings, transfer laminations, PCB assemblies and wider infrastructure services.

“Our engineers have been working with the car makers and tier 1s on a range of new development parts that can be used in electrification,” explained Tony Sartorius, Chairman at Alucast.

From left, Lord Carrington, Tony Sartorius (Alucast), Lord Whitby and John Swift (Alucast)

76

PECM Issue 47

“Casting is a great way of giving a component strength, whilst helping to reduce weight by using aluminium. We also have all the technologies you need in-house, including the four main casting processes, prototyping, finishing, 5-axis CNC and design input through industryleading software.”

He continued: “Over £1million of orders have already been secured in this field and we believe we can at least treble this through our involvement with the electrification cluster that has been born out of the Manufacturing Assembly Network (MAN).

“It gives us expertise across a range of ‘in-demand’ manufacturing disciplines and the capacity to take on significant projects, not only in automotive but in other sectors where electric power could be key.”

MAN’s ‘Electrification Cluster’ was launched in August with a major digital marketing campaign and dedicated E-brochure that details the group’s capabilities and supply offering.

This is being reinforced by a number of educational videos and potential seminars where they will aim to unpick some of the common challenges facing companies involved in this industry.

to its new machining shop, access to 20 CNC machines providing bed sizes ranging from 400mm to 630mm.

It gives us expertise across a range of ‘indemand’ manufacturing disciplines.

The company’s single source approach has seen it work with some of the world’s leading tier 1 suppliers and car makers, as well as specialists in vacuum products, hydraulics, rail, bus and commercial heating systems.

“We are delighted to welcome Alucast to the cluster and are already working with it on a number of exciting new development projects where its knowledge of housings and casings is coming to the fore,” added Richard Halton, Business Development Manager at C-MAC SMT, a leading independent provider of complex, high reliability electronics and system assemblies.

“It’s a natural fit to have a world leader in castings joining global specialists in strategic manufacturing outsourcing, sensors, inspection systems, wiring looms, high volume pressings and laminations and electronic assembly.”

Alucast offers gravity, high pressure, low pressure and sand casting and, thanks For further information, please visit www.alucast.co.uk or www.man-group.co.uk Issue 47 PECM

77

MACHINING & MACHINERY

SPECIALISTS IN TOOLS & GAUGES WISEMAN THREADING TOOLS LTD

WISEMAN THREADING TOOLS LTD Specialists in Tools & Gauges for Screw Threads We have been supplying threading tools and gauges since 1987.

Together with supplying plain plug and ring gauges this is all that we do, we therefore consider ourselves to be specialists in this field.

We supply worldwide.

We hold extensive ready stocks that include all of the standard stuff that others offer, but also includes taps, dies, die nuts, die head chasers, thread rolls and gauging for threads not normally available 'off the shelf '.

Our real time stocks can be checked and purchased online at www.threadtools. com Just enter the thread details into the search box on the home page.

You will be directed to the item, if stocked, or to our specials, (custom manufacture), sales team. who will quote to supply at competitive rates, in good time.

As an account holder you can also order online from our listed in stock items, at your normal terms. We realise that you need the right item at the right price and quality, and in a reasonable time frame.

We are geared to provide that.

We can ship stocked items same day.

Our experienced sales staff can assist and advise you on any technical issues.

We welcome enquiries from resellers and can offer terms to suit.

WISEMAN THREADING TOOLS LTD 11 Padgets Lane South Moons Moat Redditch B98 0RA UK 0044(1527)520580 sales@threadtools.com www.threadtools.com

For further information, please visit www.threadtools.com

78

PECM Issue 47

Threading Tool Specialists

HSS DIES & DIE NUTS Large shelf stocks for all Standard and many Special Threads. Check our stocks online.

THREAD CUTTING AND ROLLING HEADS and parts and repair service

THREAD ROLLS FOR ALCO & FETTE HEADS. READY STOCKS CUSTOM MANUFACTURURE

HSS TAPS Huge Stocks for all Standard threads CUSTOM MADE taps our SPECIALITY! We stock taps for many non standard (SPECIAL) threads All types; Spiral flute and point, Fluteless, Left Hand, etc, etc.

Wiseman Threading Tools Ltd 11 Padgets Lane, South Moons Moat. Redditch B98 0RA Worcs UK 004(0)1527520580 sales@threadtools.com www.threadtools.com

THREAD GAUGES all types. Large stocks for standard and SPECIAL threads. Any non stocked can be quoted for custom manufacture.

CHASERS FOR COVENTRY & LANDIS TYPE DIE HEADS Ready stocks for most size heads most standard and some special threads Geometry available for most materials.

Custom manufacture our speciality!

MACHINING & MACHINERY

ROTOR STACKING SOLUTION RPI

Rotary system reduces the rate of teardowns by 95% RPI, the world leader in high-accuracy rotary positioning and inspection devices, has developed a system for the measurement and assembly of gas turbine rotors that reduces the rate of teardowns by 95%.

The assembly of a gas turbine rotor is an extremely complicated and time-consuming process. It can take a week or more to assemble the rotor, and the geometric tolerances of the assembly must be very closely controlled to ensure efficient performance and safe operation.

If the rotor doesn’t meet final assembly criteria, it’s subject to a ‘teardown’, where it must be completely disassembled and reassembled. This additional work interrupts the entire manufacturing process and can cost tens or even hundreds of thousands of dollars in damaged parts, labour and delivery penalties.

These costly teardowns can be avoided if individual rotor component geometries are fully characterised and if the rotor assembly is simulated prior to its actual assembly.

This virtual assembly process is commonly known as “rotor stacking.”

RPI’s Integrated Measurement and Assembly Platform (iMAP) is a complete rotor stacking solution featuring a highprecision, motorised air-bearing rotary table, an AccuScanTM circular geometry inspection system and IntelliStackTM rotor stacking software. iMAP systems can handle components as large as 35 tonnes and over 20 m3 with sub-micron mechanical accuracies , and a measuring resolution of less than 250 nm. Traditional dial indicator measurement methods are still employed by some global OEMs, where data is manually collected and recorded from perhaps 8 to 12 data points per part surface, one surface at a time.

It sometimes takes a full shift just to measure a single part. With an iMAP system, this time-consuming and error-prone process is replaced by the automated collection of up to 4,000 data points per surface from as many as 8 surfaces in one 30-second

rotation of the part, resulting in tremendous annual labour savings. iMAP systems deliver new levels of accuracy, flexibility and quality to the assembly process and have been installed in power generation, industrial turbine and aircraft engine manufacturing plants worldwide. They offer measurements an order of magnitude better than even the most precise traditional inspection methods, and they have proven to significantly reduce the rate of teardowns.

Jim Palmer, Sales Manager at RPI, said: “Teardowns are costly not only in the typical sense, but also in terms of time and labour.

The margins for assembly of gas turbine and aircraft engines rotors are microscopic, smaller than an eighth of a strand of human hair. With AccuScan, our customers can reliably measure the tolerances to prevent teardowns or operational problems later on.”

“The systems allow customers to have confidence in their turbine rotor assembly process. The significantly more reliable measurement data collected by iMAP enables the rotor stacking software to accurately model component parts, resulting in the design of precisely aligned rotor assemblies before you’ve got anywhere near the assembly line. iMAP has been independently verified and proven to

offer our customers significant operational improvements over their traditional assembly methods.”

According to Greg Valente, software architect for the system, “Without iMAP, rotor assembly is a shot in the dark, where you’re using look, feel and bit of good luck to try to meet extremely tight assembly tolerances. “iMap allows you to quantify the inspection and assembly processes, giving you predictability, and it allows you to spot anomalies and see details of part quality that would otherwise go unnoticed.

Opportunities for defects are significantly reduced by eliminating manual calculations and human recording errors. “iMap systems enable a level of accuracy not achievable any other way. It’s a failsafe way to assemble an efficient turbine, maximising energy output and reducing maintenance.” iMAP solutions can be supplied in a variety of configurations with probes to suit each specific application.

Jim Palmer continued: “The dial indicator measurement system often results in more guess work and many more teardowns, with around a 50% failure rate. RPI’s technology has reduced this to less than a 5% failure rate.”

For further information, please visit www.rpiuk.com

80

PECM Issue 47

)

3

9

"

5

"

"

4

#

6

V

info@rondean.co.uk

*

7

4

;

!

www.rondean.co.uk

2

8

;

R

8

9

%

$

!

7

8

&

4

<

!

:

S

+

>

?

(

=

<

'

!

;

3

(

@

4

5

>

,

=

(

-

W

=

A

)

@

T

>

5

?

8

.

B

C

S

)

D

Q

=

/

0

"

=

7

&

E

S

<

1

=

W

F

T

G

5

H

X

F

;

I

8

A

S

@

J

R

F

8

Y

@

R

K

>

6

4

L

7

M

8

9

K

:

K

P

7

N

Q

M

R

8

K

S

A

5

:

O

8

@

>

;

?

;

P

Q

7

3

Q

S

R

<

8

9

S

3

;

S

3

4

S

T

T

8

5

U

We Know Our Machines!

h

Edwards Treadle Shears Various sizes available

v

c

w

]

\

c

i

n

l

r

b

]

\

b

c

x

]

u

c

y g y

m

b

\

]

[

b

c

a

b

u

c

^

u

_

i

c v

Hand Folders, Box Pan and Straight available

g

z

w

]

\

c

i

j

\

k

b

k

[

{

{

|

w

b

h Z

`

b

]

\

n

}

p

l

~

}

n

p

l

\

h

l

]

f

m

]

^

[

Â&#x20AC;

H

f

Needs Analysis: We Only Offer the Right Machine

g Â&#x192;

k

h

]

[

b

\

i

Â

^ Â&#x2021;

Â&#x201E;

]

~

Â&#x2026;

Â&#x201A;

Â&#x2020;

[

`

l

^

[

`

z

b

u

Â&#x201A;

g Z

n

Â&#x2030;

] Â&#x2C6;

b

\

n v

g s

j

z

]

c

^

]

g n

Â&#x201A;

q

z

]

c

^

g

]

Â&#x201A;

g \ Â&#x201E;

g \ Â&#x201E;

h a

b

g

u

`

g c

\

]

u

c

|

g

^

]

Â&#x160;

]

{

\

l

{

\

z

]

c

^

]

g

^

g

g

^

\ Â&#x201E;

l

{

\

g

^

g

^

]

g i

l

Â&#x2020;

\

g

^

]

Â&#x2039;

b

Rigorous Multi-Point Pre-Dispatch Inspection Jones & Shipman 540P Surface Grinder Superb CondiÂ&#x2014;on

XYZ CNC Mill KR-V2000 h z

k

i

`

x

a

Z

n

t

o

n

a

]

u

c

Z

]

o

q

Â

n

Â&#x201A;

q

^Ć&#x161;Ä&#x201A;Ć&#x152;Ć&#x161;Ć&#x152;Ĺ?Ć&#x161;Ä&#x17E; sÄ&#x17E;Ć&#x152;Ć&#x;Ä?Ä&#x201A;ĹŻ Ä&#x201A;ĹśÄ&#x161; ^Ä&#x201A;Ç w

W e b : w w w. r o n d e a n . c o . u k E m a i l : i n f o @ r o n d e a n . c o . u k

x

r

]

]

m

\

\

a

^

i

b

u

c

s

f

b

u

o

[

\

o

b

Â&#x201A;

d

o

]

ŽůÄ?Ĺ&#x161;Ä&#x17E;Ć?Ć&#x161;Ä&#x17E;Ć&#x152; dĆ&#x152;Ĺ?ƾžĆ&#x2030;Ĺ&#x161; ĎŽĎŹĎŹĎŹ ĎŻĎŹŕ´ź q

[

`

b Z

[

\

]

^

_

`

[

a

b

c

d

]

[

`

b

g

h

g `

e

f

b

i

[

r

b

\

]

j

m

\

a

^

k

b

l

c

m

d

`

]

n

[

`

o

b

o

o

p

o

h

q

h `

e

r

f

]

m

b

a

i

b

[

b

\

c

e

s

b

]

u

[

i

\

[

b

f

d

]

t

[

o

`

q

b

e

C O N TA C T U S N O W !

0191 410 5886

uyyw151-(108)-83

MACHINING & MACHINERY

THE FINAL PROCESS FRONTIER ZEEKO

Automated Precision Polishing on your CNC machine â&#x20AC;&#x201C; the Zeeko Zephyr Programme Zeeko may not be the most famous name in manufacturing engineering â&#x20AC;&#x201C; but in the optics industry it is a byword for excellence in precision polishing. A 7 axis machine from the UK engineering company Zeeko Ltd., that is based in the East Midlands, is the machine of choice in the optics industry for polishing the most challenging of complex surfaces.

Zeeko has been developing its processes and control software for polishing ultraprecision freeform surfaces for satellite mirrors for almost 20 years. High end applications where tolerances are measured in nanometers and surfaces are prepared to sub-micron precision before polishing. As all engineers know, polishing is difficult and automated polishing is particularly difficult.

So the news that Zeeko has developed a high removal rate polishing process, which is effective on regular engineering materials, and removes microns of material at unprecedented speed, has caught the attention of production engineers everywhere.

This new process is more akin to grinding than to traditional polishing techniques, but still achieves a highly reflective polished surface. It can impressively be demonstrated on materials like mould and tool steels, tungsten carbide, titanium, Inconel, molybdenum, aluminium and other often difficult materials.

That Zeeko has also released a version of its new polishing software and announced that by writing a simple post processor it can be integrated to any regular 3 axis, 4 axis and 5 axis CNC machine as an automated process is even more exciting. For automated processes this is the final frontier!

Just a few months after its launch, it is already being adopted by the mobile phone industry for moulds, the aerospace industry for turbine blades, mould makers, hip joint makers and by the additive manufacturing / 3-D printing industry which is testimony to its versatility.

Zeeko Ltd, 4 Vulcan Court, Vulcan Way, Coalville, Leicestershire, LE67 3FW, UK For further information please contact info@zeeko.co.uk or call to +44 1530 815 832

82

PECM Issue 47

MACHINING & MACHINERY

High speed glass handling specialists How do you turn sheets of glass through 90o at the rate of up to 12 per minute without touching the delicate coated upper glass surface, with scratch-free zero contact between lower glass surface and conveyors? Glass handling professionals Ashton Industrial shows you how with a neat, compact high performance engineering solution in a straight line layout employs lifting arms that pass like the teeth of a comb between transport belts and transport rollers.

station arrive on transport rollers and are instantly lifted clear as arms extend through from below so the next lite in line can already start its approach while those arms are pivoting away.

At the end of the turn the arms duck back underneath, passing between transport belts as they set the glass down to drive away to the next station. Return is at high speed underneath both conveyors.

Click the blue VIDEO LIBRARY button on www.ashton-industrial.com Glass from a first edge grinding Magazine AdvertNEW.pdf 1 29/06/2018

09:07

Boasting the largest rental fleet of Rockwheels in the UK we are proud to offer our own designed rotary cutters in a range of sizes to fit excavators up to 125 tonnes.

Powerful , robust and accurate , Rockwheels are effective in a wide range of applications including Trenching, Profiling, demolition and lots more. Excavated material can be recycled offering even more value. Low vibration and low noise operation means Rockwheels are an ideal choice for working in urban areas and wherever there are environmental constraints.

WHY A HAMMER? WHEN A ROCKWHEEL IS MORE EFFECTIVE! Protected Motor // Valve Technology protects the hydraulic motor.

Only Two Hydraulic Lines // No Drain Line Required - Works on hammer circuit.

Transmission Ratio // Gearbox Units for Maximum Torque.

Heavy-Duty Design // For The Toughest Job Sites.

Most Experience on the Market // Invented and Engineered by Webster Technologies who have a history of design for the Mining Industry from 1960. info@webstertechnologies.co.uk // www.webstertechnologies.co.uk // 0114 2488 262

Issue 47 PECM

83

MEASUREMENT & MONITORING

SWITCH TO DIGITAL SEMPRE GROUP

Making your manufacturing systems cohesive In 1969, Margaret Hamilton, director of software engineering for Apollo 11, was famously pictured standing next to a stack of paper containing the program listing that helped take the first team to the moon.

Now, a 4GB phone has over a million times more memory than the Apollo 11 computer had in RAM. Here Russell Pursglove, software product specialist for industrial metrology provider The Sempre Group, explains the benefits of swapping reams of paper for automated quality management.

Keeping track of quality management data manually involves reams of paper, tedious filing and makes it challenging to access information when needed. Paper documents can easily be misplaced or overlooked, which could mean trouble if parts are not to specification or there are problems with quality later on. All in all, a problematic approach.

Yet, when we visit the facilities of British and Irish manufacturers, we often see huge filing cabinets of essential quality management documents like first article inspection reports (FAIRs) and product part approval process reports (PPAPs). In my experience, only around five per cent of manufacturers use automated quality management software, with the rest opting for paper or detached digital methods.

CRYING OUT FOR CHANGE

Though one step up from managing everything on paper, isolated digital documents unnecessarily complicate manufacturers’ communications with their customers. Without a digital thread connecting drawing to product to report, the process can never be fully traceable.

Customers can become confused about product quality, which can create a sense of unprofessionalism and drastically reduce the customer’s trust in the supplier.

Manually managing and auditing isolated drawings and models can waste manufacturers thousands of pounds of employee time and lead to human error — a very poor use of a valuable workforce.

Consider this example. A manufacturer

is manually creating FAIRs, loading up metrology equipment, taking notes and saving the data in an Excel spreadsheet.

Skilled staff are spending hours entering data into an isolated document that isn’t communicated properly across the business or supply chain, creating a lack of traceability. At a time when most manufacturers have an enterprise resource planning (ERP) platform available to connect digital systems, why would you use isolated documents or paper?

FINDING A SOLUTION

Quality 4.0 makes data king. The journey to achieve Quality 4.0 includes automated data collection to improve reporting, storing and handling of information regarding product quality.

By taking a Quality 4.0 approach — using automated quality management software, plant managers can easily improve efficiency, productivity and quality. For example, using High QA, inspection managers can automatically identify geometric dimensioning and tolerancing (GD&T) from models or PDFs, identify

critical dimensions and automate results and statistical process control (SPC) data to auto-populate reports.

Automated QMS tools offer manufacturers an all-in-one solution for quality management, collecting and storing data at every point, from drawing to final product. They eradicate the need for time consuming paperwork and filing, which means manufacturers can easily communicate important quality information across the supply chain and can remove the headache of compliance reporting.

Manufacturers are able to get the best out of their workforce — a real asset during the pandemic where there may be fewer employees on site. The system can check for errors in digital documents, ensuring that they are always filled out right first time.

By implementing a Quality 4.0 approach, using paper to collect data will soon become as outdated as the reams of paper that got Apollo 11 to the moon. For more information about automated quality management software solutions, visit www.thesempregroup.com.

For further information, please visit www.thesempregroup.com

84

PECM Issue 47

MEASUREMENT & MONITORING

High performance data logger systems for individual needs Japanese market leader T&D Corporation designs versatile wireless data logger systems, such as the RTR-500 series, the Bluetooth featured WiFi logger TR-7 series and the easy-to-use Bluetooth logger TR4-series, as well as appropriate software applications. The company’s efficient solutions provide error-free workflow and documentation.

The data loggers in the RTR-500 family support users who need a wireless logging option, as well as maximum flexibility. They can measure temperature, humidity, mA, voltage, pulse, UV, illuminance and CO2.

They can also monitor a wide range of temperatures and humidity levels.

The TR4 series comprises three competitively priced models, two of them waterproof.

Their high precision and wide-ranging measurement capabilities, combined with ultimate flexibility, make the TR4 data loggers ideal for use in private, industrial or public areas. They can be utilized for heating control in housing or agricultural sites. Additionally, they are ideal for monitoring the transportation of sensitive goods such as fresh or frozen food, or products for medical use.

T&D’s Bluetooth featured WiFi TR-7wb series is ideal for temperature and humidity

monitoring. No computer is needed in order to use the TR-7wb series on site, as it can be set up on mobile devices, both iOS and Android. The TR-7wb (WLAN) and TR-7nw (LAN) data loggers can measure wide-ranging temperatures and humidity.

T&D also offers constantly updated and improved software solutions, such as the free of charge and multifunctional T&D Cloud WebStorage Service, which includes the monitoring of recorded data, automatic downloads and warning notifications for the data loggers mentioned above.

www.tandd.com | www.webstorage-service.com | Facebook: T&D Corporation/Europe | europe.office@tandd.de

Why are airflow Rotameters so popular?

A rotameter is a flowmeter that measures the volumetric flow rate of a gas or fluid. It consists of a tapered tube with a moving internal float.

Sometimes known as variable area flowmeters.

The rotameter needs to be installed vertically, as the flow rate, is read from the float position in the tapered tube, determined by the balance of forces underneath the float from gravity.

With no flow, the float sits at the bottom of the tube, as the fluid flow increases the float begins to rise until an equilibrium is maintained with the viscous forces and gravity.

With good care and cleanliness, they can provide excellent results for relatively small cost.

Contact: ay@youngcalibration.co.uk Tel: 01273 455572 www.youngcalibration.co.uk

LAUDA Technology Ltd LAUDA continues to provide an expanding range of feature-rich, future proof solutions with energy efficiency and connectivity front of mind, serving a diverse range of industries including automotive, aerospace, chemical, pharmaceutical, biopharmaceutical, food & beverage, brewing, digital printing, laser and beyond.

With the capability to provide temperature control solutions in the range -100 °C up to 550 °C and supply solutions for viscometry, tensiometry, surface and interfacial tension measurement, LAUDA has the proven capability and expertise to assist across a diverse range of workplace types from Research & Design laboratories, to pilot plants and full-scale production lines.

Email: info@lauda-technology.co.uk Tel: +44 (0)1780 243118 www.lauda-technology.co.uk

L300 TC 8 Zone Temperature Alarm / Controller The Labfacility L300-TC (Thermocouple) temperature alarm / on-off controller can be used in conjunction with a PC to provide accurate monitoring and alarm or on-off control of up to 8- zones simultaneously. It can also be used as a stand-alone instrument without the need for a PC. The in-built, self-calibration facility for the thermocouple version is a rapid and convenient method for on-site calibration and does not require any additional equipment other than a special, external link. The L300TC has 8 thermocouple (type J, K, T, E, N, R, S & B) inputs and a resolution of 0.1°C on display, 0.01°C in software. This unit is RoHS compliant and CE marked.

Available to buy direct from www.labfacility.com Tel: +44 (0) 1243871280 Email: sales@labfacility.com www.labfacility.com/temperatureinstrumentation/bench-top-instrumentation/ l300-pt-8-zone-temperature-alarmcontroller.html Issue 47 PECM

85

MEASUREMENT & MONITORING

MIM

KOBOLD

New Electromagnetic Flow Meter from Kobold Leading instrument manufacturer Kobold continues to design and develop quality measuring and analytical instrument products and have just launched their latest compact flow meter to the market, the MIM. With factories within the Kobold Group experiencing well over one hundred years of trading, Kobold has an enviable and extensive wealth of technical knowledge and experience to draw upon when developing new products. At the concept stage, Kobold will often draw upon the experience of their international sales offices to establish a framework of practical features and functionality, and thus produce an instrument which is suitable and compliant for an international market place.

This indeed was the process for the new MIM instrument.

Innovative design and quality have become hallmarks of all Kobold manufactured products but refreshingly, during their concept stage Kobold are clearly applying focus to practical ease of functionality and to some extent, resisting the trend and temptation to incorporate unnecessary features and over complicated software.

From the MIM concept Kobold have produced a high quality and versatile compact flow meter for measuring conductive liquids, ensuring suitability for a wide range of industrial applications. Heavy duty construction in stainless steel provides a clean and robust instrument module.

The design of the 90° step indexable TFT display screen is clever, yet simple and robust, ensuring suitability for multi directional flow applications, programmable from the touch screen. A nice feature of the TFT display screen is that it can be used by operators wearing gloves.

Unlike some of the TFT screens on the market using inclination sensors for screen position, the MIM screen remains clear and stable in use, a reminder of Kobold’s instinctive preference for simplified practical functionality and reliable service.

in most process applications as standard.

This includes bidirectional measuring, combined flow, temperature, and volume measurement, monitoring, and transmitting.

Dual configurable outputs can be selected such as analogue, frequency, pulse, and switching, but also switched dosing and controlled start/stop for the dosing function.

Typically with an electromagnetic flow meter there are no moving parts in the measuring device and this can be a key advantage in many industrial applications.

In principle the induced voltage is picked up by two sensing electrodes which are in contact with the measuring agent and sent to the measuring amplifier. The flow rate will be calculated based on the cross sectional area of the pipe.

A key advantage of this measuring principle is that the measurement is not depending on the process liquid and its material properties such as density, viscosity and temperature, however, be mindful that the flowing media must have a minimum conductivity value.

The MIM instruments can now be ordered from Kobold Instruments (UK) Ltd and official UK distribution partners, and stockists.

From the MIM concept Kobold have produced a high quality and versatile compact flow meter for measuring conductive liquids, ensuring suitability for a wide range of industrial applications.

As you would expect, Kobold’s MIM instrument incorporates all the practical control and display features required For further information, please visit www.kobold.com

86

PECM Issue 47

The webinar will be held in English, will last about one hour and is free of charge. After the lecture part, the Optris application engineers will answer further questions of the participants via live chat.

You can register here: www.attendee.gotowebinar.com/ register/7081038910237592590?source=pecm “With this webinar we want to demonstrate numerous users from the electronics and the electrical industry the many possibilities of infrared measurement technology for their processes. For example, the Optris microscope optics enable reliable temperature measurement on tiny objects from 240 µm”, explains Dipl.-Ing. Torsten Czech, Head of Marketing at Optris GmbH.

Pyrometers. IR Cameras. Accessories.

Software.We measure temperature non-contact from –50 °C to +3000 °C. Visit: www.optris.co.uk

from £ 225

The focus of the webinar on Thursday, November 5, 2020 at 10:00 a.m. will be topics and applications around the electronics and electrical industry in connection with non-contact temperature measurement technology.

Thereʼs no two ways about it: our IR sensors of the optris CT series can be used in short and long wavelength measure areas.

Optris GmbH continues its successful webinar series for users from different industries in November

Unusual.

MEASUREMENT & MONITORING

when temperature matters www./attendee.gotowebinar.com/ register/7081038910237592590?source=pecm Issue 47 PECM

87

MEASUREMENT & MONITORING

SIMPLE INTEGRATION MITSUBISHI ELECTRIC

SICK joins Mitsubishi Electricâ&#x20AC;&#x2122;s e-F@ctory Alliance A joint solution for easy integration of vision technology is now available. Machine builders, systems integrators and end users can now quickly realise inspection, validation, position detection and quality control applications built around SICK cameras and Mitsubishi Electric Devices.

The solution has been developed for applications across a number of different industries, including automotive, food and beverage, life sciences, machine building and OEM design. It combines a SICK vision camera with ready-built and tested function blocks for the Mitsubishi Electric GX Works PLC programming environment. This makes it simple to set up vision applications on Mitsubishi Electric PLCs. Users will also have the assurance of full support from Mitsubishi Electric and SICK. Both companies believe that vision solutions provide essential information that can enhance a whole range of automation processes. But more than that, they are the eyes of Industry 4.0 and therefore a key element of the digital transformation of industry.

SICK and Mitsubishi Electric have worked together closely for a number of years. Now they are taking that collaboration to the next level, as SICK joins the e-F@ctory Alliance.

This has led to a newly developed solution, which makes it easier than ever for users to embed vision technology into applications such as product manufacturing, handling and packaging.

For further information, please visit eu3a.mitsubishielectric.com/fa/en/solutions/efactory

88

PECM Issue 47

Electromagnetic Flowmeter MIM Series All metal design

Stainless steel version

°F °C

Flow and temperature measurement

Monitoring function

∑

Total and partial quantity counter

2 configurable outputs

Display operation also with gloves

90°

Rotating colour display

Space saver

01623 427701 www.kobold.com info.uk@kobold.com

NEWS & EVENTS

Denso P2 System™ Used in Refurbishment of Old Water Pumping Station As part of United Utilities water quality improvement programme, JMC North West Ltd, on behalf of NMCN, recently completed works to bury the above ground timing loop at the Pex Hill Service Reservoir.

The challenge was to provide a durable, reliable corrosion prevention solution to protect over 90 double flanged joints prior to full encapsulation.

To provide this high level of protection, JMC North West Ltd turned to Winn & Coales (Denso) Ltd for their services.

Winn & Coales recommended their Denso P2 System™, proven to effectively protect ferrous pipes, joints and fittings from the costly effects of corrosion. Fully compliant with the P2 Civil Engineering Specifications for the Water Industry (7th Edition), this timeproven system can be easily applied on-site before the pipe

The Denso P2 System applied to double flanged joints Inset: Densoclad™ Tape is wrapped over Denso Profiling Mastic™ as part of the Denso P2 System is buried – providing long-term corrosion prevention for the project at Pex Hill. The Denso P2 System incorporates Denso Primer D™, Denso Profiling Mastic™ and Densoclad™ Tape.

Training on how to apply the system was provided, on-site, by two members of the Winn & Coales

www.denso.net

DIN11864 and DIN 11853 Aseptic Unions for Orbital Welding DIN11864 and 11853 unions were developed to meet the exacting needs of the food, chemical and pharmaceutical industries.

This range of unions has been developed from the three most common systems used in the hygienic and sanitary industries; namely the “Aseptic” screwed union to DIN11864-1; the “Aseptic” flange union to DIN11864-2 and the “Aseptic” clamp union to DIN11864-3.

Available with optional lengths to suit both orbital and manual welding, these unions have been designed to match tube

Save Up To 10p Per Litre On Diesel & Petrol With A Free Fuel Card From Your Trusted Partner

Designing bespoke packaging solutions to perfectly fulfil clients’ needs

Here at FLEETMAXX SOLUTIONS we offer a considerable number of fuel card options, all of which have been tailored to different meet different needs.

Crocodile began as a family company back in 1991 in response to a growing demand for innovative and versatile industrial packaging solutions. To this day Crocodile remains entirely family owned and run and the goal of providing high quality sophisticated packaging solutions that add genuine value to clients has not changed. Crocodile has a truly global outreach, with manufacturing partners in China, Germany and the USA. But the key to Crocodile’s success is it’s commitment to quality, which is why all aspects of the business from design to manufacturing, right through to delivery of the product is managed under the same roof in Swindon. By controlling every aspect of the business Crocodile ensures that only the best product and customer service is delivered.

We want to help you choose the right one for your business, and we would like readers to enjoy it FREE OF CHARGE. What makes us different from other fuel card companies is that we really do care about our customers, we want to be your TRUSTED PARTNER. Whichever card you choose you will receive the same great personal service, no hidden extra charges, and we never have you on an automatic price escalator like some of our competitors. www.fleetmaxxsolutions.co.uk/businessdiscount-fuel-card/

90

PECM Issue 47

CALL US ON: 01793 821 555 Email: quentin@crocodile.uk.com www.crocodile.uk.com

and pipe specifications to DIN11866 Table A (DIN11850); DIN11866 Table B (ISO 1127) & DIN11866 Table C (ASME BPE).

Size range: 10mm to 150mm and 1” to 4” Specials are available up to 304mm Materials: 316L SS 1.4404 and 1.4435 Specials available in Duplex and Alloy 22 Tel: 01269 841 324

www.alchemprocess.co.uk

What cable solution do you need?

From ladle cars in steel industry to submarines deep down in the oceans – our custom designed cables and cable systems are developed to withstand the most harsh environments you can imagine.

When a cable needs to be exposed for fire, heat, acid, radiance, pressure or withstand millions of bending cycles and twist there are multiple things to consider in the design and choice of materials.

With our long experience and expertise in development and manufacturing of wires, cables and cable assemblies, we help you to find the most suitable, yet cost efficient solution for your specific application. No matter how demanding or extreme they may be.

Contact us today, we are curious to hear about your challenges.

habia.com

NEWS & EVENTS

Specialist Funding Support to Business Is your company one of the 97% of businesses that incorrectly assume they can’t apply for funding to support their innovative work?

MCS Corporate Strategies Ltd provide specialist funding support to businesses, with a core focus on cost recovery. As an independent consultancy, we help businesses and institutions to access the government grants and incentives they’re entitled to. This includes Research & Development, RDEC and Patent Box. Research & Development Tax Credits form a key part of Government strategy to boost innovation in business. This tax relief scheme reduces the real cost of investment in improving products and processes and remains one of the largest single Government funding mechanisms available for business.

We make the whole identification and application process quick and simple.

1. We identify your eligibility and take the difficulty and stress out of making a R&D claim.

2. We work with you to gather the details and then prepare all submission documents.

3. We liaise with your accountants and HMRC to submit and process your claim.

4. We handle the entire claim process, from initial assessment to completion.

The single key criteria for qualification is that you be registered as a UK corporate entity.

Claims are retrospective (two years) and intended to be claimed year-on-year. SME’s and large companies qualify.

Manufacturing, engineering and all disciplines, activities, parts, products, prototypes; IT software and first-of-class items are examples of what is included as items for research and development. The CIRD definition of R&D is wide and inclusive of very broad activities.

We work on a success fee basis only so there’s no initial cost – you’ve nothing to lose.

Telephone: 01926 512475 e-mail: charlotte@mcs-corporate.com

www.mcs-corporate.com

When managing real pressure is your job…

MIPC® helps engineers stay on-site and on top of the latest industry developments and good practice in primary containment of hazardous substances.

MIPC® shortlisted for the Best E-learning/ Online Education Initiative memcom membership excellence awards 2020

Using a blend of live, online classes, one-to-one sessions with expert tutors, and e-learning, enhanced by a mentor’s support and guidance, EEMUA’s Mechanical Integrity Practitioner Certificate course delivers in-depth training to engineers where they work – to give professionals the flexibility to learn on-site or on-call.

The next EEMUA MIPC® training course: Induction begins in November 2020 Learning starts in January 2021 Registration open now.

For more information please contact EEMUA online-learning@eemua.org +44 (0)20 7488 0801 www.eemua.org

Issue 47 PECM

91

PACKAGING

FOAMplus® perfect protective packaging solution from Storopack As a leading global protective packaging supplier Storopack recognizes the importance of ensuring goods are protected during transit and arrive in perfect condition.

Damaged goods not only incur costs for replacement orders but also affect businesses’ reputations. So while costs need to be kept to a minimum it is vital to choose the correct protective packaging type.

Usually a void fill packaging medium will suffice. However when the product is more sensitive to shock and vibration, such as engineering, electronics, aeronautical, and many other expensive products then more consideration has to be given to using the right type of in-the-box protective packaging.

Storopack’s FOAMplus® range is a perfect solution for companies that manufacture or ship products that require this highest degree of protection eliminating transit and handling damage.

The success of FOAMplus® polyurethane foam is based upon its huge versatility as a packaging medium. The foam can either be dispensed directly into the carton where the expanding foam will mould itself to the contours of the product shape or can be made into pre-moulded cushions to enhance presentation. The product will satisfy the most rigorous cushioning demands for high value, fragile and awkward shaped products. The light weight foam packaging also ensures that shipping costs are kept to a minimum whilst providing customers with total product protection.

As a space saving solution FOAMplus®, polyurethane foam packaging is ‘on demand’ and mixes two components together which then expands up to 200 times its liquid volume negating the necessity for large storage areas required for pre-fabricated packaging.

The benefits for customers are numerous. As well as an ideal solution for protecting awkward and valuable products, customers with product

design changes and new product line additions are able to quickly adapt the packaging without the need to carry a large range of bespoke cartons or fabricated packaging.

There are two dispensing methods available for the insitu protective packaging solution. Either FOAMplus® Hand Packer, a manually operated system, with a fully electronic microprocessor control to maintain consistent quality that delivers the foam direct into polythene lined carton via a foam dispensing gun.

Alternatively the Bag Packer² Foam-in-Bag dispensing system is fast, easy to use, efficient and economical. The machine can produce up to 23 foam-filled bags per minute at the touch of a button. Polyol B 5504R, foam B component is made from 30 percent recycled polyurethane.

www.storopack.co.uk

FOAMplus® Your products deserve the best protection.

Expanding polyurethane foam pads mould around any product shape within seconds. Exceptional protection for fragile or awkwardly shaped products.

Contact us for a FREE* trial

T: +44(0)114 249 2004 E: packaging.uk@storopack.com *subject to qualification

92

PECM Issue 47

www.storopack.co.uk

SUPERIOR INDUSTRIAL PACKAGING PROTECTION PAPERplus® - Paper pads provide maximum performance, high density, and strength.

Ideal in-the-box protection for heavy products.

100% recycled content and 100% recyclable

PACKAGING

STOROPACK PAPERPLUS TRACK 速

STOROPACK

No need to change the paper, simply change the crimp setting on this fast and compact packaging system THE PERFECT FIT FOR EVERY PRODUCT The Track system is ideal for medium to large packages weighing between 5 and 50 kilograms. A perfect solution for shipping valves, controls, spare parts, electronic components, heavy duty products, and engineering parts.

HOW PAPERPLUS速 TRACK STANDS OUT FROM THE REST This one machine does it all. Fast and compact, the new on-demand paper packaging system is designed for high throughput use where secure packaging material is a must for eliminating transit and handling damage. Users only have to change the crimp setting and not the paper type, meaning the paper pads can be tailored to each parcel if needed.

Saving valuable time and improving cost efficiencies.

It is ideal for cushioning and block and bracing applications, the paper pad system produces cushioning pads in seconds directly at the packing station, delivering highly effective padding while using less material. The volume of paper pads can also be adjusted.

PAPERplus速 Track also benefits from: safe blade-free technology, the paper is perforated making it very easy to individually separate each paper pad mechanically.

The system has a small footprint, featuring a touch screen for crimp adjustment. It can also be connected to Wi-fi and controlled from an external location via smartphone or tablet. Paper replacement is fast and simple.

PAPERplus速 Track like all other Storopack padding systems, can also be be easily integrated into any existing warehouse operation, and as a result guarantees optimal packing processes and reduces operational costs.

For further information, please visit www.storopack.co.uk

94

PECM Issue 47

COMPLETE DESIGN AND PACKAGING

CARDBOARD DUST â&#x20AC;&#x201C; A THREAT TO MAN AND MACHINE

CHALLENGES Complete Design & Packaging (CDP) is the leading supplier of high-quality printing for retail packaging. The company uses state-ofthe-art technologies, including an expensive, highly sensitive high-tech digital printing press.

However, cutting and punching the packaging generates a lot of paper dust, which affects machines and the quality of the end products.

Two full-time employees alone were responsible for cleaning, as a representative appearance is also very important for a showpiece company like CDP: factory tours are regularly held here.

Keith Furr, Plant Manager at Complete Design and Packaging, says:

Zehnder came at the right time!

We were really impressed by how meticulous the team was in their assessment and how passionate they were about improving the air quality on our premises

BENEFITS

DETERMINE YOUR SAVINGS POTENTIAL WITH CLEAN AIR! Ben Simons, Country Manager UK +44 7909 533878 ben.simons@zehnder.co.uk www.zehnder-cleanairsolutions.com

A healthy working atmosphere and clean, low-particle air increase employee motivation, boost productivity and improve the overall quality of the end products. The cleaning effort could also be cut by 50 %. In addition, particle reduction makes a decisive contribution to investment protection, as the load on the high-quality digital printing press and the entire equipment is drastically reduced.

PROCESS TECHNOLOGIES

INCREASED YIELD KECOL

A sticky situation results in business benefits Caramel can be a challenging material to extract, particularly when delivered in one tonne totes. One of the ways the Burtons Biscuits came up with, was to put totes into a warm room to enable the caramel to flow easier from the tote via a pump then into a hopper. However, they found that one of the main drawbacks on this process of totes was that the caramel would stick to the inside walls of the tote as the pump sucked out the caramel. At times this would mean that between 10% to 30% of the caramel would be left in the tote, unable to be extracted. The method was to connect a pump to the bottom outlet of the tote and transfer the caramel to a hopper, which worked well until the level of caramel in the tote fell to between 10% and 30%. From this point the pump cavitated and could not draw the caramel in, resulting in between 10% and 30% of the contents of the tote being returned to the supplier, costing anything between ÂŁ50,000 and ÂŁ140,000 per annum in unused caramel.

One idea that came from the Continuous Improvement team while looking at available options to reduce this waste or increase the yield was to revert to 200L drums of caramel rather than the tote.

Kecol were asked to make proposals for transferring the caramel from the 200L drums to the line hopper and offered a

Kecol H800SN Maxiprime unit c/w 10:1 ratio piston pump.

Engineers and modified the standard Maxiprime to suit the existing drum loader.

Kecol supplied a trial unit to Burtons for a two-week trial period to enable evaluation of the proposed system. Whilst the system transferred the caramel at the required rate and reduced the waste, the drum loader used by Burtons could not place the drum into the Maxiprime in the correct position.

To resolve this, Kecol worked with Burtons

Burtons purchased 2 x H800SN Maxiprime systems and have reduced the waste caramel to less than 1%, significantly reducing expenditure and increasing yield.

A video of the systems in operation can be seen at https://www.youtube.com/ watch?v=e3rcELdSMpo&feature=youtu.be

For further information, please visit www.kecol.co.uk

See us a

t

Stand N

o. 4E 02

THE HOME OF VISCOUS PUMPING SOLUTIONS

Kecol have over 25 years of experience in handling all types of viscous products in the food, pharmaceutical and cosmetics markets, as well as general industrial applications.

A sample of products we already pump… ✓Honey ✓Petroleum Jelly ✓Mascara ✓Sauces ✓Lanolin ✓Lip Gloss ✓Essences ✓Eye Ointment ✓Meat Paste ✓Paraffin Wax

T: +44 (0)1746 764311 E: sales@kecol.co.uk W: www.kecol.co.uk

✓Face Scrub ✓Teething Gel ✓Tomato Puree ✓Medical Adhesives ✓Veterinary Creams ✓Fruit Paste ✓Toothpaste ✓Malt ✓Jam ✓Wax

PROCESS TECHNOLOGIES

COOLING TOWER FROG

®

CORTEC

Cooling System Layup Season is Here: Hop to It with Cortec’s Cooling Tower Frog®!

With fall and winter on their way in many parts of the world, maintenance engineers will soon be thinking about shutting down cooling systems for the season. Since winter often brings subzero temperatures, this means water treatment professionals often must drain the water to prevent freezing. However, standard operating procedures often call for little else to protect against the insidious corrosion that can lead to other problems and shortened equipment service life down the road. In light of these facts, now is an excellent time to stock up on Cortec’s Cooling Tower Frog® for simple, effective corrosion protection during dry layup of cooling systems this coming fall and winter.

Cooling Tower Frog® provides an added layer of corrosion protection without much extra effort required. Although specifically designed for seasonal, short-term, or longterm dry layup of cooling tower systems, Cooling Tower Frog® can also be used for protection of closed loops, as noted in Cortec’s handy updated product line guide to cooling water layup.* Cooling Tower Frog® presents an extremely efficient

method of protecting multi-metals in enclosed spaces through the use of Vapor phase Corrosion Inhibitors packaged in polyvinyl-alcohol (PVA) water-soluble bags. When these bags are slit open, the corrosion inhibitors vaporize and disperse throughout the enclosed system, forming a strong, self-replenishing protective molecular layer on all metal surfaces, including recessed areas and interior cavities.

Cooling Tower Frog® is extremely easy to apply, reduces chemical consumption and cost, and avoids direct worker

contact with chemicals. Little or no surface preparation is necessary. After the cooling tower or closed loop has been drained according to normal layup procedures, workers simply have to throw away the outer barrier bags, slit open the water-soluble bags, and place them flat inside the equipment, making sure all internal spaces are closed off from the outside atmosphere. Two bags treat over 1,000 gallons (3,800 L or 3.8 m³) of enclosed space. At the end of layup, the Cooling Tower Frog® does not have to be removed. It simply dissolves in the makeup water as the system refills.

The greatest benefit of the Cooling Tower Frog® is the opportunity to avoid corrosion problems from clogging, leakage, or system failures that could otherwise increase downtime and repair costs. The next best aspect is that this can be done with very little deviation from the normal maintenance routine. This season, “hop to it” to make sure your water treatment customers are well supplied with an excellent solution to corrosion in laid up cooling systems!

Learn more about the Cooling Tower Frog® here: https://www.cortecvci.com/Publications/PDS/Cooling_Tower_Frog.pdf

98

PECM Issue 47

PROCESS TECHNOLOGIES

SEPURA™ Achieves World-Class Stamp of Approval Filtration specialist Bowman Stor has achieved the prestigious DIBt approval status for its key range of SEPURA™ oil-water separator products.

The DIBt (the German Institute for Construction Technology) is a globally-recognised authority that ensures the technical fitness for an intended use of an innovative or nonstandardised construction product, service or process.

Ever since Bowman developed its groundbreaking separator concept in 2004, the organisation has continued to strive for new levels of excellence and SEPURA has already achieved an international reputation for quality and unparalleled performance. The innovation was enhanced by the invention of their revolutionary SILEXA™ filtration media - a fully sustainable, renewable, patented media made from recycled glass bottles.

The attainment of the new accreditation follows months of painstaking work and major investment, and covers the low to mid-range units (SEP60 through to SEP2500).

Bowman Stor’s managing director, Richard Potts says that the DIBt approval is a milestone in the ongoing evolution of the SEPURA range:

demands required by building control personnel.”

Customers who want the superior condensate filtration associated with genuine SEPURA separators and filters can ONLY obtain them through SEPURA’s designated distributors.

“Meeting the strict standards of this globallyrecognised authority demonstrates that our manufacturing and quality assurance systems are on a level with the leading names in our industry. It also affirms that, in a market where conformance is paramount, our separators are fit for purpose and reach the exacting

To place an order or for further information on SEPURA’s unique range of filtration products contact: Multi Factor Europe Ltd t: 01978 855995 e: sales@mfeuk.co.uk or visit our website: sepura-technologies.com

sepura-technologies.com Sepura DiBt Half Page Ad 132x180L.qxp_Layout 1 06/10/2020 10:09 Page 1

British Ingenuity, International Quality SEPURA™ have attained the coveted German DIBt approval for our SEP60, 120, 360, 900, 1250, 1800 & 2500 separator units.

This means that our products meet the most demanding industry standards with superior performance and quality that you can rely upon.

Complete product catalogue now available on our website.

SEPURA™ is part of the Bowman Group

www.sepura-technologies.com

t:

+44 (0)1543 379212

e: sales@sepura-technologies.com

Issue 47 PECM

99

PROCESS TECHNOLOGIES

Hygienic engineering, design, development & fabrication Genuine expertise in the application of Hygienic and Pharmaceutical Industry Standards, from design, materials, and manufacturing, to surface finish options, traceability and documentation takes years of practical experience and specialist knowledge. Axium’s highly qualified engineers have been delivering a complete in-house engineering service for decades offering, process development solutions, custom fabrications, skilled metal polishing, and super-precision machining.

Fully Integrated In-House Support • Engineering Design to ASME BPE & EHEDG standards • Product and Process Development • TIG, Spot and Orbital welding • CNC Equipped Machine Shop • Bead-blast, Mechanical and Electropolishing • Full Traceability and Certification • 100% Inspection

www.axiumprocess.com

MAGNETIC. VISIBLE. PURE. IN DETAIL: JACOB has managed to incorporate detectable particles into its sealing rings. In a case of contamination they can be sensed by a metal detector and removed out of the product stream.

Some call it a quantum leap - we call it: DETECTABLE DESIGN.

www.jacob-uk.com

100

PECM Issue 47

20017_Detectable_Design_UK_105x148_5mm.indd 1

23.06.20 // KW26 13:06

PRODUCT NEWS

THE F-TECH RANGE WILKINSON STAR

More new fume extraction systems meeting latest HSE welding requirements New from Wilkinson Star, one the of the UKâ&#x20AC;&#x2122;s largest independent distributors of Welding and Industrial Equipment, is the F-Tech Fume technology product range of high vacuum fume extraction systems and welding torches.

Welders and operatives can be exposed to welding fumes, grinding dust and oil mist in the working environment. It is therefore obligatory for employers to create safe and healthy working conditions for operatives by reducing these health risks.

The F-Tech Armur is a high vacuum dust extraction system offering a mobile solution to extract dust from manual welding and grinding processes. The Armur unit features a high performance German motor and a choice of 3 mtr suction Armoflex or Armotech

cantilever arm and a user friendly digital panel with hour meter, clogged filter alarm.

This unit offers E12 99.5% filter efficiency and comes with a 5 year warranty on both 110V and 230 V models.

The F-Tech Pocket is a portable extraction unit designed to extract and filter fumes from welding processes, micro dust, vapours and odours. At only 20kg, it is a robust unit with a practical long handle perfect for site work and those difficult to reach areas. This unit has a 2mtr hose fitted with a plastic extraction nozzle.

The Pocket also has a filter efficiency of E12 99.5% and comes with a 2 year warranty.

Additional features include a hourmeter and it is available in 110 and 230 Volt.

The F-Tech Fox is a high vacuum dust extraction system offering a portable solution to extract dust from manual welding and grinding processes.

Offering a 5 year warranty the Fox unit offers automatic cleaning of the filters which are manufactured in Europe and offer a long service life. The robust tandem motors offer pure efficiency in providing a vacuum over 20,000 Pa to extract and filter harmful welding and grinding dust. An auto start/ stop unit is also available to reduce noise levels and energy consumption when the unit is not running. The Fox will also run two welding torches simultaneously.

The F-Tech range of fume extraction MIG welding torches are of Swiss manufacture.

They offer the user more extraction efficiency at the welding source. Available in 300, 400 and 500A air/water cooled versions in 3, 4 and 5 mtr euro fittings.

Also added to the range are the Down and Draught extraction benches, the heavy duty Armur-Force for manual plasma cutting and grinding dusts. Also new is the F-TECH ICAP; a wall mounted welding fume extraction system with self supporting HD cantilevered 3 mtr arm.

The F-Tech range is available through Wilkinson Starâ&#x20AC;&#x2122;s extensive distributor network. For further details please contact Wilkinson Star on 0161 728 7900 or visit wilkinsonstar247.com.

For further information, please visit www.wilkinsonstar247.com

102

PECM Issue 47

NEW

Welding is all about harnessing the power of electric arc. When it comes to pulse welding, we understand the importance of generating consistent and precise arc for achieving optimal results. The key lies in merging inverter welding technology with advance MCU circuitry. With this in mind, we give you the JASIC MIG300P and MIG500P. The duo comes with high-precision waveform management, delivering high-quality pulse and consistent droplet formation.

With the addition of CANbus and expert synergic welding, these 2 models give you full control for your welding tasks.

0161 793 8127 wilkinsonstar247.com jasic.co.uk Find Us On

@wilkinsonstaruk

PRODUCT NEWS

Ecoseal Ecoseal is approved to Gas Industry Standard (GIS) Leakage Control (LC) 25. It is the only product on the market to have achieved the specification set out in GIS LC25. The specification sets out the requirements for flexible joint penetrating sealant repair systems for external application to ferrous distribution pipes with either lead/yarn or mechanical type joints. The maximum operating pressure must be equal to or less than 2 bar, in areas where pipe movement might be experienced.

There are three viscosities of Ecoseal, thick, thin and ultra-thin. Each variety is designed to repair a different leaking, corroded or damaged joint.

This includes mechanical, lead yarn and tightly packed joints.

Ecoseal is a two-part Polyurethane resin. This means a chemical reaction takes place when the two parts meet and combine. The process is user and environmentally friendly as no toxic fumes or chemicals are released.

Ecoseal provides an alternative to encapsulation repair systems. It is time-saving and costsaving because it eliminates the need for site assessments and measuring for encapsulation muffs. It provides an option to inject through the socket or directly through the lead joint face.

Ecoseal can be used on spigots, mechanical joints, socket joints, and valves. It can be used on a range of pipes up to 2 bar pressure.

admin@mwpolymers.co.uk | 01332 835001 | www.mwpolymers.co.uk

New Tsubaki Chain Configurator lets users build the perfect chain Anyone working with industrial chain can now design their optimum attachment chain with the new online Tsubaki Chain Configurator.

Featuring a wide range of design options and the ability to export formatted 2D and 3D CAD models -the new configurator is an indispensable resource for those looking to specify customised chains.

Try out the new Tsubaki Chain Configurator by using the QR Code or visiting https://tsubaki.eu/support/chain-configurator/ The Tsubaki Chain Configurator allows users to build BS/DIN and ANSI single strand attachment chains via a drag and drop interface. Chain type, roller type, chain size, base material, length and repeating sections can all be customised, with an array of Tsubaki attachments available to meet multiple application requirements.

Chains can be viewed from all angles during the process, including the internal components. Furthermore, the configurator provides measurements for overall length and specific parts of the chain.

When a customised chain design is complete,

users can generate a 3D model within the configurator, select and download a 2D or 3D CAD file in a wide array of formats, download and print designs as a PDF or request a quote.

Anyone can specify an optimum Tsubaki chain quickly.

tsubaki.eu

104

PECM Issue 47

The configurator is available in English, German, French, Spanish, Portuguese, Polish, Russian, Dutch and Italian.

L

MANUFACTURERS OF HIGH QUALITY HIGH PERFORMANCE INDUSTRIAL INSTRUMENTS FLOW – LEVEL – PRESSURE – TEMPERATURE – ANALYTICAL - CALIBRATION

Precise - multifunctional - reliable - proven

Exhibitors at CHEM UK, WWEM & HANNOVER MESSE Rearranged exhibition dates will be advised, when confirmed.

Calibration and On-site Commissioning

Light instrument system panel builds, including: Data Loggers & HMI’s

For your FREE Product Summary Brochure

01623 427701 www.kobold.com info.uk@kobold.com

Issue 47 PECM

105

PRODUCT NEWS

QUALITY, SAFETY, PERFORMANCE TOM PARKER

High flow and low pressure drop maximises output Fluid power specialists Tom Parker Ltd have introduced a new range of CEJN safety hose reels for compressed air, water, and electricity, in their 2020-2021 catalogue. In today’s productivity driven environment, Tom Parker Ltd’s emphasis on quality, safety and performance make the CEJN brand the ideal choice for safety reels. With their additional products: hoses, couplings and blowguns, it is the most optimised system on the market.

From a safety perspective, the team at CEJN evaluated different reels on the market, looking into injuries suffered by people and harm to the environment.

Four areas were highlighted: hose retraction, hose replacement, stopballs and locking features. The most dangerous aspect of a hose reel is the spring force during rewinding. CEJN’s new safety reel is equipped with a sturdy centrifugal brake in the drum, combined with a strong spring force, giving a slow and steady retraction, which is both safe for the people and objects nearby in the workplace. Also highlighted were the risks and difficulties of changing a hose.

When a casing is opened, severe injury to the user can be caused by the strong embedded tension of the metal spiral within. To combat this, CEJN safety reels feature an encapsulated spring cassette to protect the user if the reel needs to be dismantled. CEJN’s new design no longer requires a user to dismantle the reel to change a hose; meaning the task takes under a minute and is completely safe.

CEJN is committed to producing superior performing products. During the product development stage of the safety reel, the design team had one main ambition: to create a reel where flow limitations and pressure drop were virtually eliminated.

Today they proudly offer a solution that is almost twice as effective as the standard reel when it comes to performance.

CEJN’s focus on performance aims to create solutions that help customers save money. In addition to perfecting performance in their product design, fittings and transition are optimised

to eliminate pressure drop, leakage and system loss, to help maximise tool efficiency. As the hose can be easily changed if damaged, the reel can last much longer than most other reels on the market. By investing in a CEJN safety reel, a product is purchased that will last for years to come.

From a quality perspective, CEJN’s primary goal has been to create the best and most durable reel on the market. Reels adapted for industrial use take advantage of premium materials chosen to withstand outdoor use, UV radiation, chemicals, and

resistance to wear. To maximise durability, all materials have been tested for high and low friction, to find the combination that provides the longest life span.

Tom Parker Ltd offer CEJN safety reels that provide a high flow and low pressure drop to maximise output. The patented closed safety reels are developed and manufactured in Sweden. All designed with CEJN’s core company values: safety, performance, quality, innovation and protecting the environment. CEJN: the future of high performance hose reels, available from Tom Parker Ltd.

For further information, please visit www.tom-parker.co.uk

106

PECM Issue 47

PRODUCT NEWS

SKY-HIGH COLLABORATION FANUC

FANUC’s collaborative robots boost productivity and cut cost While aerospace has long been a major lifeblood for the UK manufacturing sector, recent years have seen a perfect storm of investment, R&D and new technologies drive the sector into new heights. One research facility at the forefront of this relentless pursuit of progression is Cranfield University’s Aerospace Integration Research Centre (AIRC), which has turned to FANUC’s collaborative robots to boost productivity and cut cost through greater human interaction.

Opened in 2017, the AIRC was co-founded by the university alongside Airbus and RollsRoyce supported by the Higher Education Funding Council for England. Its aim is to seamlessly blends academia with industry, and focuses on all aspects of integration in aerospace, including power plant, subassemblies, and airframe structure. With a firm focus on taking concepts from theory to flight demonstration, the site’s laboratories connect the University’s ‘land-side’ groundbased research with the AIRC’s ‘air-side’ flight research.

Within the AIRC’s extensive facilities lies one area dedicated to research into human-robot collaboration: the Intelligent Automation Laboratory.

“Certainly for the UK aerospace industry, there is a big drive to reduce cost and increase both production rates and efficiency,” begins Professor Phil Webb, Professor of Aero-Structure Design and Assembly at the AIRC. “Currently there is a low uptake of automation within the sector, yet with a number of emerging challenges on the horizon – such as new materials and possible aircraft geometries – the traditional way of building aircraft is going to become much more manual, and much more difficult to do both effectively and profitably.”

He continues: “The work that we do in the Intelligent Automation Laboratory is focused around using automation in new and less-common applications. The underlying principle we’re really interested in is how to get more people working closely with robotics and automation.”

was proving to be challenge for AIRC team, until they encountered FANUC’s CR-35iA: the world’s only collaborate robot with a payload of 35kg.

The aerospace sector is not the only UK industry which has been slow to respond to the advent of automation. In fact, according to the International Federation of Robots (IFR), the UK as a whole has just 71 industrial robots per 10,000 workers in the UK. That positions the UK behind 14 other European countries. In contrast, Germany – Europe’s most automated country – has 309 units per 100,000 workers.

One of the more commonly-quoted barriers to the uptake of industrial robots has been guarding, and the extra space – and cost – this can add to a cell. However, Phil and the team at the AIRC have overcome this hurdle by turning to collaborative robots, which allow humans and robots to work alongside each other in a safe and productive way, without the need for guarding.

Phil explains: “I started working with collaborative robots nearly 15 years ago. I was driven by the mission that there was only so much we were ever going to do with a conventional robot. Ultimately, you have to keep the person in the loop as they have the inherent skills that we are a long way from recreating with robots.

“The FANUC CR-35iA is the robot I’ve been looking for since I started doing this.

The opportunity to work without physical guarding, and handle workpieces up to 35kg, means you can work with some really meaningful components in this industry.

Crucially, it also gives you the capability to do so safely.”

“Normally people put a steel cage between the two and never the twain shall meet,” adds Phil. “Here, however, we’re interested in how to use the best capabilities of both humans and robots, whilst maintaining safety and making the human operator feel comfortable, which again is often neglected.”

With a maximum payload of 35kg and reach of 1,813mm, the CR-35iA is a fullyfunctioning industrial robot. However, it benefits a series of integrated sensors and highly responsive ‘touch-to-stop’ reactive functionality, meaning that if the robot’s arm comes into contact with a fixed object or person, it gently stops and retracts. A safety system ensures that the robot stops at a maximum force of 150N, however this can be reduced even further if required.

While collaborative robots are not a new phenomenon, many robots in the market have maximum payloads no greater than 15kg. Sourcing a robot that could handle the larger workpieces more commonly found throughout the aerospace supply chain

The AIRC’s FANUC collaborative robot is treated with the same approach to resource planning as the team’s human staff, with each task effectively broken down into whether it is more appropriate to be undertaken by the CR-35iA, or a human.

To find out more about FANUC’s range of collaborative robots, please visit: www.fanuc.eu/uk/ Issue 47 PECM

107

At its core Sapman v12 is a sophisticated Manufacturing, Warehousing and Stock Control solution. This modular product provides extensive facilities for Stock Control, Sales and Purchase Order Processing, Warehouse Management, Bill of Materials, Works Order Processing, Engineering Control, MRP and CRP. With the Microsoft SQL database engine at its core this product provides a leading edge business management solution.

Our highly skilled team has 20 years of experience resolving our customers’ Assembly, Manufacturing Control and ERP requirements, their Stock Control and Warehouse Management needs using our advanced, effective and efficient software solution.

Sapman v12 fully integrates with Sage’s Accounting solutions: Sage 50 and Sage 200. It also provides an upgrade path from Sage 100.

disposable BBQs our customers rely on Sapman v12 to run their businesses.

Sapman v12 is highly customisable to operate with virtually any business model. With successful installations in a huge range of industry types from manufacturers of medical products to

Sponsored development of specific functionality is possible where customers require some modification to allow the software to exactly map their business’s operational model.

SAPMAN V12 AND SAGE 50 IT ALL STARTS WITH A SALES ENQUIRY! SELL IT

BOM V12 produces the BoM : tree-view with collapsible/expandable nodes

Quotations: Quote ( including price breaks)& Drawings & Pricing : v12 can attach drawings to the Quote

SFDC Shop Floor Data Capture : using barcodes v12 manages the job though the shop floor

SoP : The Sales Order Processing gets underway

WiP With Shop Floor Data Capture SFDC v12 knows :

MAKE IT

What Material/Subcomponents have been used, Who has worked on the job and on what machine - Get Material, Labour & Machine Variances & produce management reports -

Stock : Stock Enquiry : Check material Needs : Make to Order or Ex Stock?

If not it may generate a Purchase Order for more Stock

Every stock issue is linked to an original GRN - ensuring full Serial Number and Batch Traceability

If the Sale item is Make To Order (MTO) then the Works Order Processing routine kicks in

Stock Finished item is booked into Stock

v12 is suitable for Batch Manufacturing, Make to Stock, make to Order, Kanban & service works

v12 knows where it is; it covers multiple sock locations and stock with Sub Contractors

Stock values from v12 update Sage50 Nominal Ledger

Stock values per client defined categories can be up dated to Sage50 Nominal at client defined times

PoP Purchase Order Raised Purchase Invoice received & Sage 50 updated for Nominal Codes, Purchase Ledger and VAT WoP The confirmed order has to be manufactured & v12 produces the works order

SEND IT Stock Stock records updated, Despatch note raised; Certificates of conformity produced

Sales Invoice raised & Sage 50 updated for

WHAT THEY SAY “We really like the Shop Floor Data Capture system which enables us to see the current status of any Works Order live and onscreen.”

Alan Saitch, Managing Director, Lada Engineering Services Ltd

“V12 offers us greater productivity, improved communications with third parties and the interconnectivity between the various menus and our Sage Accounting software makes operating our company infinitely easier.”

Colin Mallard, Finance Director, Lakeland Laboratories Limited

“V12 was a complete transformation for our business back in 2014, with the added bespoke service and repair package designed by the SMS team the customer input and traceability became seamless.”

Mike Perkins, Managing Director, Encoders UK Ltd

Nominal Codes, Sales Ledger & VAT

For more information on Sapman v12 please visit our website at Sapmanv12.co.uk.

Email us on info@sapmanv12.co.uk or please telephone us on: 0333 456 12 12.

108

PECM Issue 47

SOFTWARE & SYSTEMS

COMPREHENSIVE ERP SYSTEM SAPMAN V12

If you make stuff we’ll help you make it If you have a warehouse we’ll help you manage it If you hold stock we’ll help you control it Buying an ERP system used to be a major capital expense, potentially running to tens of thousands of pounds for an up and running system. The cost of the software purchase and associated consultancy made it a hugely considered financial outlay.

For manufacturers looking for a rapid Return On Investment – this was a major obstacle for many businesses : together with the desire to spend their CapEx budgets on modern machinery and increased manufacturing capacity rather than software!

For companies that want the software “out of the tin” - and do not require any bespoke programming – a system install and set-up, including training and data conversion would be around £2,950.

Our licencing is £95-£20 per month (depending on user numbers) with no minimum contract obligation. Additional users can be added as required and, indeed, reduced.

and Sage200, and we still have some clients on Sage Line 100 yet to upgrade.

A key market for us is Sage users.

Sapphire Manufacturing Systems Ltd. The developer of Sapman v12 has been an Authorised Sage Developer for over 20 years. So most of our users run on Sage50

We can demo the software remotely via Team Viewer or organise a visit to your premises or you can visit our Bristol Demo Suite: call us on 0333 456 12 12 to have a chat.

One of the great advantages of Sapman v12 for Sage users is that users can benefit from multi depot stock and full Serial Number and Batch Traceability without the need to upgrade their accounting engine from Sage50 to Sage200. This is an additional cost saving benefit

STOP PRESS Problem Sage announce Sage50 Manufacturing is End Of Life Solution Sapmanv12 More Features – Less Cost – Sage Developer Fully Supported – Continuous Development Sapmanv12.co.uk A MANUFACTURING AND STOCK CONTROL SYSTEM FOR SAGE USERS Issue 47 PECM

109

SOFTWARE & SYSTEMS

A NEW DIMENSION PROCENTEC

Procentec is proud to be a member of the HMS group!

As of October, Procentec has become a member of the HMS group. HMS Industrial Networks AB, a wholly owned subsidiary of HMS Networks AB (publ), has acquired 70% of all shares in the Dutch company Procentec B.V. “A logical step in the continuous growth of the Company” says Pieter Barendrecht CEO of Procentec.

He continued: “We are very excited to become part of HMS which opens up new doors for Procentec.” HMS’ size and international presence will be a great asset for Procentec in our continued expansion.

There will also be excellent opportunities for IP-sharing between the companies, as well as for co-creation of solutions related to industrial networking and Industry 4.0” “Procentec fills a gap in HMS’ offering within communication infrastructure. Industrial networks are vital in industrial processes, and Procentec’s products and services

improve uptime and data availability significantly in these critical networks” says Staffan Dahlström, CEO of HMS Networks, and continues: “With Procentec, HMS gets access to an aftermarket business related to the huge installed base of industrial networks globally, positioning HMS much closer to the end users of industrial networks. This is a very interesting new dimension for HMS given the fact that we today mainly supply products to device manufacturers and machine builders”.

PROCENTEC: YOUR NETWORK PARTNER Procentec supply innovative solutions, training and consultancy to the Industrial Automation Market. Our primary focus is the development and manufacturing of automation products for PROFIBUS, PROFINET, Industrial Ethernet and Ethernet/ IP. We keep challenging ourselves to find the best, easy to use solutions that help

reduce downtime and create ease of mind for our users.

HMS NETWORKS: CONNECTING DEVICES HMS stands for “Hardware Meets Software”.

HMS products make it possible for industrial machines and devices (hardware) to connect with control systems and the Internet (software). The company motto, Connecting Devices, is the foundation for realizing the Industrial Internet of Things.

Their well-known brands include Anybus, Ewon, Intesis & Ixxat.

For more information, please contact: Pieter Barendrecht, CEO Procentec +31 (0)17 46 71 800 Staffan Dahlström, CEO HMS Networks AB, +46 (0)35 17 29 01 Joakim Nideborn, CFO HMS Networks AB, +46 (0)35 710 6983

For further information, please visit procentec.com

110

PECM Issue 47

MONITOR YOUR INDUSTRIAL NETWORKS 24/7 AND REDUCE COSTLY DOWNTIME! How do you keep your plant running 24/7, maximize productivity and reduce network failure? Factories lose between 5% - 20% in productivity due to unplanned downtime, where just 1 minute of downtime can cost thousands of dollars. In addition, the current pandemic may limit access to your factory, making control, maintenance and troubleshooting a difficult job.

ComBricks

Atlas

Procentec, the leading diagnostic solutions provider for industrial automation with over 20 years of experience, enables you to fully take control over your plant with innovative solutions for permanent monitoring.

→ Remote monitoring of your PROFIBUS installation accessible via web-browser

→ Remote monitoring of your Industrial Ethenet installation

→ Customizable modular system for PA and fiber optic repeaters

→ Clear overview of your network’s health & topology

→ The only product with an integrated oscilloscope

→ Compact and robust construction, easy to install on DIN rail

For more information and advice on our solutions, please contact Global Sales Manger, Jonathan Machin

Your network partner.

Tel. Email

+44(0) 753 4307 696 jmachin@procentec.com

SOFTWARE & SYSTEMS

Smart and fast 3D analysis

The eSUPPRESSOR™

With the 3D sensor from EVT it is now possible to realize 3D analysis without PC. Simply attach the pre-calibrated sensor, select the task from the ready-to-use inspection tools and then measure an angle, distance or gap with a measuring frequency of up to 3000 measurements per second. The result can be taken directly from the sensor as a good or bad signal. Optionally, the data can be sent to the PLC via Profinet or Modbus to correct a production process immediately and automatically.

The eSUPPRESSOR™ from IEP Technologies is the most technologically advanced explosion protection suppressor in the industry today.

Effective and reliable protection is provided by the eSUPPRESSOR™ with the following features: • Monitoring of all safety functions • SIL2 compliant design and pending 3rd Party Certification • Integrated Lock out/Tag Out • No Pyrotechnic Actuator

The sensor is only connected to a computer (Windows/Linux) for a short time for configuration. The inspection is configured with the ready-to-use inspection tool and can be used immediately. The sensor can also be used for more complex tasks than the ready-to-use inspection tools allow. In this case more detailed tools can be used in the remote configuration system of the EyeVision software.

Tel: +49 721 668 004 230 | info@evt-web.com www.evt-web.com

112

PECM Issue 47

IEP Technologies is the worldwide leader in providing explosion protection systems and services. For over 60 years we have offered protection solutions that can suppress, isolate and vent combustible dust or vapor explosions in process industries.

+1-855-793-8407 • info.IEPTechnologies.com IEPTechnologies.com

Robust and reliable manual machine function switching: Herga Technology launches new multi-function industrial footswitch range Herga’s new 6256 series footswitches will suit applications where durability, reliability and long working life are key factors for plant & equipment OEMs and machine builders. Using Herga Technologies unique development gate process, the modern and aesthetic high impact injection moulded ABS/PC housing design has been extensively validated for durability, temperature, environmental conditions and is a significantly cost-effective but highly capable alternative to more expensive cast-metal footswitch solutions. Applications areas include operator enabled function switching where hand control is not feasible or safe in metal or plastics processing, laser machining, hydraulic press, welding, riveting stamping and more. sales@herga.com +44 (0)1284 701422.

VALVES & FLOW CONTROL

Oliver Twinsafe Oliver Twinsafe continues to grow through product development in the valve industry aimed at international oil and gas companies.

They have recently completed an API Annex F PR2 qualification on their metal seated 1-13/16” 10,000psi double block and bleed valve. The qualification included 200 cycles at a temperature range of -46 to +144 deg C. Oliver Twinsafe completed the qualification with third party witness and zero through seat leakage.

The potential for this development, which will probably be patented, is huge, particularly in the Far and Middle East sectors where Oliver Valves has its own sales organisations.

For more information on our company and its products please visit our website www.valves.co.uk or contact our Deputy Chairman, Mark Oliver on 01565 632636.

Process Valves & Instrumentation Ltd

PUTTING YOU IN CONTROL!

01260 277025 sales@pviltd.co.uk www.pviltd.co.uk

The application of Single-Use disposable products not only enables Pharmaceutical manufacturers to produce fast and safe batch production but also require significantly less time to replace compared to the cleaning and sterilization processes (CIP/SIP) in a conventional plant. Single-Use processes are contributing in helping to overcome global challenges, particularly in controlling the rapid spread of infectious diseases and in the case of pandemics where time lost is critical, as it can affect the number of lives saved. SingleUse plant allows new biopharmaceuticals and vaccines to be brought to the market faster. As the world’s first single use diaphragm valve, GEMÜ SUMONDO is a major step forward in Single-Use applications. The diaphragm valve body can be easily connected/ disconnected from the actuator which is a tried and tested design with both position control and position feedback options as required to ensure complete monitoring of the Single-Use system, making the SUMONDO even more versatile!

www.datastorgroup.com

For more information, please click here.

We are a global provider of an endless selection of process equipment. Established in 2010 and based in Congleton, Cheshire. PVI boast a combined industry knowledge of over 60 years with our team having varying experience with both mechanical and instrument solutions in all industrial sectors such as Chemical, Pharmaceutical, Oil & Gas & Food/ Beverage and have exclusivity with WEIR BDK for their sleeved & Lined plug valves.

We also have partnerships in place with ARI, IFM & Gestra and many more giving us unrivalled access to their many products and global support. In addition, we also work closely with other brands ensuring we are able to offer you the very best products at the most competitive price.

Issue 47 PECM

113

VALVES & FLOW CONTROL

STEAM EQUIPMENT EXPERTS VALSTEAM

A strong passion for developing equipment and for solving problems Focused on providing groundbreaking products for industrial steam and fluid systems, the Valsteam ADCA project has been in the market of steam equipment for more than 35 years.

Valsteam ADCA started as an industrial plant for pipeline and steam boiler house contractors. Already building pressure vessels and auxiliary equipment in-house, Valsteam ADCA has grown up to become steam equipment and valve manufacturers, using the knowledge acquired along the years, and can now assure the complete production cycle: design, machining, welding, assembly, tests, quality and packaging for a very wide range of products.

GIVING NEW WORLDS TO THE WORLD Right from the start, the family owned Portuguese company had a strong passion for developing equipment and for solving problems. Today, Valsteam ADCA has two production facilities with a total manufacturing area of 22 000 square meters, located in a small village in the ocean side of Portugal, and are currently growing again, expanding their main production facility. The team today consists of almost 90 people that together drive the Portuguese caravel along the five continents and more than 80 countries, with the same ambition their ancestors were driven by: to reach more and to give new worlds to the world!

A “ONE STOP SHOP” Up to now, the company consolidated a very wide range of products and solutions for steam and other industrial gases and liquids, present in the process industry. Today, the company stands as a “one stop shop”, with more than 6.000 different products and more than 15.000 product parts for all kind of industries.

From standard and non-standard series to tailor-made products, Valsteam ADCA is one of the European companies with the largest range of products, which can be divided into six sections:

• Steam traps • Pressure reducing valves • Control valves • Pipeline ancillaries • Special construction equipment • Adcapure: the hygienic/sanitary line, a complete range on its own, specially dedicated to industries with high purity standards, such as the food, chemical, cosmetic and pharmaceutical industries.

PRODUCING LOCALLY, SUPPLYING GLOBALLY Valsteam is nowadays a global company, but kept the best that a family owned business can have: agility in developing new products, flexibility in production and proximity to staff and clients. The requests of customers for different special products meet in the company the willingness and determination to accept new challenges, which is evident in the company’s vision to always look to and invest in state of the art machinery and advanced engineering

software, that allow the continuous increase of the factory’s productivity and the quality and efficiency of the products.

For more information and to check the latest news, visit www.valsteam.com

114

PECM Issue 47

Portable Confined Space Ventilators & Air Blowers Fume & Dust Extractors Where fumes, smells or dust occur, the Miniveyor Air VAF fans can move contaminated air out of a confined space or building.

They effectively exhaust fumes, ventilate confined spaces, and increase the flow of fresh air.

The Miniveyor Air range are tough! The rugged VAF ventilators easily withstand blows without denting, giving less downtime and greater productivity and come with an industry leading 10 year warranty on the body.

The vane axial fans work on positive and negative airflow and are at home either extracting dust and fumes or blowing clean air into a confined workspace. In fact whatever the industry you work in, from marine, construction, mining, telecoms, fabrication or maintenance services, our VAF series fans will take whatever is thrown at them.

VAF-200 (8”)

VAF-400 (16”)

VAF Air Ltd Tetbury Ind. Estate Tetbury, United Kingdom sales@vaf-air.com +44 (0)330 016 0002 or visit -

VAF-300 (12”) Pneumatic

www.vaf-air.com

Scan Now with your Smart phone to buy at our OnlineIssue store 47 PECM 115

How I teach machines to speak

OPTIME enables me to keep an eye on hundreds of machines in just a few hours â&#x20AC;&#x201C; which makes OPTIME a quick, easy and economical condition monitoring solution. www.schaeffler.com/optime www.schaeffler.co.uk

116

PECM Issue 47