Process Engineering Control & Manufacturing - Issue 44 2020 by MH Media Global

Process

MANUFACTURING

Control &

Engineering

SEMPRE - 12

FELIXPRINTERS - 22

Mike John, managing director of industrial metrology specialist, The Sempre Group, shares a model for approaching quality in the Industry 4.0 era.

The possibilities that exist for bioprinting, and the newly introduced technology option that can provide highly reliable and cost-effective bioprinting options.

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Global Success Through Innovation Issue 44 2020 ÂŁ3.95 www.pecm.co.uk

LEGRAND - 28 Mark Williams, lead marketing manager for cable management at Legrand, talks through some simple top cable management tips.

Keeping track of temperatures

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Process

MANUFACTURING

Inside... Sections

Control &

Engineering Inside Issue 44

Editors Choice

Boiles & Maintenance

Cables

Coatings

Connectors

Control & Automation

Electrical & Electronics

Fasteners & Fixings

Fluid Handling

Gears, Drives & Motors

Health & Safety

Machining & Machinery

Measurement & Monitoring

News & Events

Process Technologies

Product News

Software & Systems

Storage, Handling & Distribution

Valves

FANUC

BURKERT

FANUC brings new IIoT data platform to UK market

the latest communication protocol, IO-Link, and the advantages it offers for industrial process control.

SPIRAX Steam systems expert ‘boas’ts prestigious training accreditation

GREYORANGE Expanding the orchestration of data and actions across the Company’s series of Ranger™ mobile robots

INMOCO Compact frameless direct drive motors newly available from INMOCO UK

BENTLEY Bentley’s in-house metrology team under the microscope

BROANMAIN PLASTICS

SCHNEIDER ELECTRIC How smart technology is transforming the industrial world

Why masterbatch is so popular and how to achieve the perfect blend to ensure consistency batch-to-batch.

ESD Investment in new ESD facility opens up £2m of new opportunities for PP Control & Automation

“The Centre of Excellence for Strainer and Filtraaon Technology”

Low Loss Basket Strainer® Cartridge Filters Y-Type Strainers Mono-in-line / Basket Strainers Duplex Strainers (Rotagate® & Firplex®) T-Type Strainers

Coalescers & Seperators Pressure Vessels Flame Arresters Sight Glasses Silencers Spools

Materials available include: Carbon Steel & LTCS Stainless Steel 304/316 Cunifer Hastelloy 6MO Duplex & Super Duplex Stainless Steel Aluminium Bronze Inconel 625 & 825 Monel Titanium All Exooc Metals Catered For ISO9001:2015 ISO3834-2:2005 ISO29001:2011 ISO14001:2015 OHAS18001:2007 SSIP Safe Contractor

Issue 44 PECM

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.

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

Research

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.

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Engineering MANUFACTURING

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Issue 44 PECM

EDITOR’S CHOICE

BIG OPPORTUNITIES FORMAPLEX

Lightweighting – a heavyweight opportunity for manufacturing By Matt Sellens, sales director, Formaplex Firmly established in the aerospace and automotive industries, the principles of lightweighting open up big opportunities for the manufacturing sector at large. And for engineers and designers looking to reduce their carbon footprint and boost the bottom line, those opportunities are just waiting to be grasped. Lightweighting is something we get asked about - a lot. It’s not a new trend but rather an evolution driven by the combination of advanced materials and processes with the drive for economy and reduction in CO2 emissions. Put simply, the principle is that if you need additional speed and efficiency, add lightness. Proof that it works is firmly established in the aerospace and automotive industries with whom we’ve been solutions providers for almost two decades. A McKinsey report, ‘Lightweight, heavy impact’, looking at how carbon fibre and

PECM Issue 44

other lightweight materials will develop across industries, forecasts significant growth. While the lightweight materials share is currently highest in aviation with almost 80 per cent, automotive is predicted to massively increase its share from 30 to 70 per cent by 2030. Carbon fibre offers huge design scope. Its cost gap to aluminium is also on track to shrink significantly over the next two decades, with forecasts based on the automotive sector making carbon fibre parts much closer in cost terms to comparable aluminium parts.

The McKinsey report backs this up, predicting that the industrialisation of carbon fibre means that costs have the potential to decrease by 70 per cent, benefiting manufacturing in its broadest sense. This all points to a continued move towards the increased use of carbon fibre as part of the drive towards greater efficiency and lower carbon emissions. The opportunities and benefits are ready and waiting for designers and engineers across all the sectors who are open to the next generation of possibilities.

LIGHTWEIGHTING – SOME SURPRISING OPPORTUNITIES We are seeing particular scope in the oil, gas, medical, space, defence and renewables sectors, where the leading players are recognising that the lightweighting revolution leads to a circle of improvements. It’s based on the simple premise that any part of any product that moves will reap the benefits of lightweighting in sometimes less than obvious areas.

For example, we worked on a customer project requiring a solution for outboard motors used on a rigid inflatable craft. The core challenge stemmed from a health and safety perspective and the need for a lighter outboard motor that could be safely and more rapidly lifted on and off the craft by two people. By using high strength forged carbon fibre to replace the traditional aluminium, we were able to meet the challenge and deliver a 12kg weight reduction.

MEDICAL LIFESAVERS In the medical sector, one of the major challenges is meeting the demand for aids that help overcome the ever growing pressures of the population demographics and the impact this has on healthcare providers. Therefore the equipment needs to provide faster, more accurate and easierto-manage ways for the care professionals to do their jobs. In surgical robotics for example, we’ve been working with a company leading the way in equipment that’s significantly lighter than traditional alternatives. It can be easily moved around operating theatres and hospitals providing surgeons with a lighter weight robotic arm that’s easier to control and is lighter and easier to handle as smaller motors are needed. It means more operations, increased value of investment, increased accuracy and more saved lives.

DRIVING ECONOMY MAKES NEWS One of our projects that attracted international headlines at the end of last year was a collaboration with the engineers of tomorrow studying at Cambridge University. We helped them create a cutting edge car weighing only 550kg by using an ultra lightweight carbon fibre chassis so it could go further and faster than would be possible using other materials. It has earned its place as one of the world’s most energy efficient solar cars able to travel at 50mph from London to the Scottish Highlands on the same power it takes to boil a kettle. It competed in the epic 3000km Bridgestone World Solar Challenge race across Australia, collecting interest from the engineering community and the international media.

THE KNOCK ON EFFECT FOR OIL AND GAS Savings of millions of pounds can be achieved by embracing the lightweighting principle in the oil and gas sectors with real long term benefits. Metal pipes can become so long and heavy that they cannot support their own weight and therefore a heavy rig is needed for support. By taking weight out of the pipe using the latest composite technologies, smaller installation ships are needed with the knock-on savings running into the millions.

Carbon fibre offers huge design scope. THERE’S LIGHT FOR THE FUTURE The opportunities for lightweighting are everywhere and the designs of the future across all manufacturing sectors can make huge all-round improvements. While the benefits for lowering the carbon footprint are well known, for those seeking to make products that are easier and safer for people to use by being smaller and lighter, it all contributes to bigger picture savings. For those ready to open up their imaginations to the possibilities it needn’t be intimidating. Choosing the right partner who already understands the concepts and possibilities across sectors can help to leapfrog the inevitable lightweighting learning curve, with endless opportunities ready to be grasped. REF: https://www.mckinsey.com/~/ media/mckinsey/dotcom/client_service/ automotive%20and%20assembly/pdfs/ lightweight_heavy_impact.ashx

For further information, please visit www.formaplex.com Issue 44 PECM

EDITOR’S CHOICE New dates announced

ESAB shapes the future The new magazine, LAUNCH, from ESAB, the world’s leading authority on all things welding, includes an inspirational message for every part of the industry, and supporting industries, and reinforces the company’s position at the top of this progressive market. Here are snippets from the first issue, but you can order your own free copy here. As fabricators and fabricators’ friends, we do some pretty epic work. And none of it would be possible without each and every one of us – the welders, the distributors, the engineers; the tools of the trade. The worldwide company is committed to, and driven by, shaping the future of the industry. It’s what the Group has always done; taking pride in combining extensive knowledge and experience, with high performing high quality products, with a hunger to innovate and improve. esab.com

ABACUS digital water measuring system

New dates for Power Electronics, Machines and Drives conference

Adding a preset quantity of water to a mix has long been carried out using pails or hosepipes. Not very accurate and certainly not consistent. Now, Hertfordshire company Aquameter has developed the ABACUS digital water measuring system for dispensing accurate preset quantities of water straight into mixing vessels, tanks, etc.

PEMD 2020 has been postponed and will now take place on 1 -3 December, still at the East Midlands Conference Centre in Nottingham. The conference will still be showcasing the latest results, applications and innovations across the breadth of power electronics, machines and drives. It’s a chance to catch up on the latest global insights, access the latest ideas and bring your organisation into a major partnership or collaboration. Technical sessions will include highfrequency converters, machine control, rail and aerospace systems, permanent magnet machines, smart grids and microgrids, thermal management, distributed generation, energy storage and fuel cells.

Easy to install and simple to use, the ABACUS delivers repeatable results day in, day out, reliably and consistently. Thousands of units have been sold worldwide to a whole variety of industries where water is added to powders or granules for mixing purposes. Just dial in the batch amount required and press the start button. The unit stops the flow of water when the required quantity has been delivered - easy. aquameter limited, 8 Woodlands Drive HODDESDON, EN11 8AZ Tel: 01 992 442 861 www.aquameter.co.uk

Find out more at theiet.org/pemd

Consistent Results Under Pressure The NEW CLC100 Leak Tester delivers the fastest and most accurate testing cycle for pressurised gas lines from -1 to 10 bar

chell.co.uk | +44 (0) 1692 500555

PECM Issue 44

Detect even the tiniest of leaks in seconds

E/M Coating Services www.emcoatingsuk.co.uk COMPANY PROFILE At the forefront of the latest designs, materials and technologies, E/M Coating Services pride themselves on offering high quality coating applications and processes to improve performance and extend the life of critical components and fabrications of all shapes and sizes for a wide range of industrial sectors. With specialised facilities we are able to design and manufacture bespoke coating systems and have in-house NACE Level 3 trained Inspectors. Quality is at the heart of our business and we operate under the highest quality control procedures including AS9100 Rev C, NADCAP, ISO9001/9008 and NACE.

New Anti-Corrosion Coating for Rare Earth Magnets Neodymium Iron Boron magnets are utilised in a wide number of industries, including the highly demanding wind turbine industry. A multitude of these magnets are bonded together to increase the overall level of magnetism. This process leads to two potential issues: Firstly, any adhesive or coating between the magnets acts as an air gap and thus reduces the level of magnetism and secondly NdFeB magnets corrode extremely aggressively. This corrosion issue is exacerbated by the environmental conditions that the wind turbines face. The corrosion mechanism for NdFeB magnets is detailed in Figure 1. This shows that when exposed to water or humid conditions, the Neodymium rich layers at the grain boundaries react to form Neodymium Hydroxide. The effect of this conversion from Nd to Nd(OH)3, is a large

volume increase along the grain boundaries, leading to cracking and degradation of magnet properties. Curtiss-Wright Surface Technologies (CWST) has been working on a solution to these issues. This involved developing a high grade anti-corrosion coating with minimal coat thickness (effective air gap). The current market leader for corrosion protection is CWSTâ&#x20AC;&#x2122;s own Everlube 6155 providing 500 hours protection in the ASTM B117 salt spray test. After extensive studies and trials, CWST is pleased to announce they have successfully developed a coating system which will provide 1,000 hours salt spray resistance for NdFeB magnets at a coating thickness of just 25um. This NEW coating system â&#x20AC;&#x201C; Everlube 1155 is environmentally friendly, easy to apply and a cost effective solution to this critical problem. Please call on +44 (0)1386 421444 for further details.

Nd rich phase

Exposure to humidity or salt spray

Nd2Fe14B

Thick Grain Boundaries

E/M Coating Services are a business unit of Surface Technologies, a Division of Curtiss-Wright, who are global specialists in surface treatments to improve the life and performance of critical components and preventing premature failures through their network of over 75 facilities worldwide. www.cwst.co.uk

Thin Grain Boundaries

Figure 1: Shows the corrosion mechanism for NdFeB rare earth magnets.

Nd(OH)3

Exposure to humidity or salt spray

E/M Coating Services Curtiss-Wright, Enterprise Way, Vale Industrial Park, Evesham, Worcestershire WR11 1GX, UK l Tel: +44 (0)1386 421444

For more information on all our services and full worldwide contact details: www.cwst.co.uk

EDITOR’S CHOICE

RRC Launch Live Online Courses Following the COVID-19 (Coronavirus) outbreak across the world, RRC have temporarily suspended classroom courses for the safety of learners and RRC staff. To help learners progress their studies in these difficult times RRC have created a new course delivery option that blends the dynamic of classroom based learning with RRC’s highly regarded Online Learning. RRC will be offering Live Online courses for a select number of courses starting with the 2019 Syllabus NEBOSH National General Certificate in Occupational Health and Safety. The NEBOSH International General Certificate in Occupational Health & Safety, NEBOSH HSE Certificate in Process Safety Management and IOSH Managing Safely courses will also be available very soon. Live Online courses will run on scheduled dates just like a classroom course. Everything required to study is accessed and launched through our easy to use Learning Centre. Contact:-RRC International www.rrc.co.uk, info@rrc.co.uk , +44(0)20 8944 3100.

Cistermiser’s new CPD presentation explains the benefits of IoT remote monitoring Intelligent washroom controls and water efficiency specialist Cistermiser has launched a new CPD learning module entitled: “Using the Internet of Things for Water Temperature Monitoring to Help Reduce Risk of Legionella”. This CPD discusses how remote monitoring systems using IoT platforms can deliver significant advantages for management of commercial buildings in the 21st century. 1 hour in duration with a closing Q&A, this CPD learning module from Cistermiser is presented in “short seminar” format and is approved by 3 third party organisations: The CPD Certification Service, RIBA and CIBSE.

www.cistermiser.co.uk

HDPE Couplings Eliminate Fusing and Joins Pipe in Seconds In response to the growth of HDPE pipe across all markets, Victaulic has developed a solution for easily joining HDPE piping systems. The Style 905 coupling installs up to 10 times faster than traditional fusing and can be properly installed using an impact gun or standard socket wrench with no heating or cooling time required. The coupling features Installation-Ready technology, comes pre-assembled and is simply pushed on to a plain pipe end, joined by a second plain pipe end, and then bolts and nuts are tightened down. There is no need to disassemble the coupling and no loose parts to lose or drop.

www.victaulic.com

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PECM Issue 44

Service & Maintenance

EDITOR’S CHOICE

Tricor PRO Plus Series

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

FISCHER FREEDOM™ SERIES EASY MATING | EASY CLEANING | EASY INTEGRATION

Sizes from ½” to 2”. Available for Litre Meter, call 01296 670200, now.

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No key code for 360° mating & optimized cable management Fully cleanable, IP68 Easy to integrate into devices OR garments

Call +44 23 9245 9600 or email Sales@ﬁscherconnectors.co.uk ﬁscherconnectors.com

Issue 44 PECM

EDITOR’S CHOICE

IHE QUALITY REVOLUTION SEMPRE

Industry 4.0: Approaching quality in the digital era

Historically, quality has been like Cinderellalast in line for an invite to the ball. But with UK industry struggling to match the productivity of its European competitors, British manufacturers can’t afford to wait for a fairy godmother. Here Mike John, managing director of industrial metrology specialist, The Sempre Group, shares a model for approaching quality in the Industry 4.0 era. British industry has a productivity problem. Compared with major competitors like the USA, Germany and France, its productivity lags. Why is this? It’s certainly not because we’re not working hard enough- studies have shown that British workers put in the longest hours in the EU. So, if we’re working longer, but are still less efficient, where are we going wrong? From my experience, UK industry has been slow to adopt technology- particularly quality control systems- and this reluctance is holding it back.

PECM Issue 44

To up its productivity game, British manufacturers require a high skill level a good knowledge base and, most importantly, a willingness to adopt the latest technologies. The British Chambers of Commerce surveyed over 6,000 manufacturing businesses with more than a million total workers and found that 81 per cent had trouble finding staff with the right qualifications and experience. As the ageing workforce retires, it will be more and more difficult to find staff with the skill level, knowledge and technological mindset needed. So, the future competitiveness of UK industry depends on improving efficiency, without expanding headcounts. It depends on technology. I have observed many manufacturers treating quality as an afterthought, reluctant to spend money on measurement equipment, testing systems or quality infrastructure. Quality has previously been more like a policing engine than a vehicle for improvement. However, Industry 4.0

brings with it a data-driven, digital approach to quality, which manufacturers can use to glean insights and for decision making. A fully digitised approach to quality removes the challenge of integrating data from fragmented sources, reduces room for error and enables manufacturers to improve their productivity.

A MODEL FOR QUALITY 4.0 The model we recommend for digitalised quality management is integrate, automate, connect, comply (IACC). The first point is to integrate all quality management into one unified electronic quality management system (EQMS). In a paper system, suppliers may be performing quality checks, only for the parts to inspected for compliance again when they arrive on the manufacturer’s site. In contrast, by taking a digital approach, where the manufacturing company could simply access the relevant data on its EQMS, the extra step is eliminated.

The next component is to automate- using programmable systems like robotics to make manufacturing and packaging processes more efficient, traceable and productive. Staff can be moved out of low value, monotonous work and into more important areas of the business, making better use of the workforce. As well as automating processes themselves, manufacturers can automate data collection. Instead of having a paper trail of data staff have written down, it is accurately recorded in the central system. Connectivity is a central part of Industry 4.0, as it is Quality 4.0. Inspection, robotics, digital inputs and outputs, software, SQL data management and enterprise reporting can be pulled together into systems greater than the sum of their parts. Wireless connectivity of equipment to the Industrial Internet of Things (IIoT) and portable tablets means manufacturers can easily implement a factory-wide data collection network. The manufacturer can connect suppliers, operations, customers and products with edge analytics and bring the data together into a common SQL database for all business processes.

be combined with a Micro Vu Optical CMM and wireless Andon status lights. The manufacturer could then connect these through Sempre Connect software to a database, to achieve pull through reporting, monitoring and trend detection.

Monitoring data collected by equipment and storing it in a central system enables manufacturers to detect trends and take proactive actions to decrease scrappage. For example, a Universal Robot UR5 could

These steps make meeting compliance obligations easy. Manufacturers can generate reports automatically, whether it is first article inspection reports (FAIRs), initial sample inspection reports (ISIRs) or

production part approval process (PPAP) documents, to comply with standard like ISO 17025, ISO 9000, 21 CFR or AS9100. The UKâ&#x20AC;&#x2122;s productivity puzzle can only be solved with a cultural shift. We need to change our mindset towards quality equipment and invest in the technology required. By working with a trusted partner, implementing a Quality 4.0 approach can be easy and deliver dramatic return on investment.

Monitoring data collected by equipment and storing it in a central system enables manufacturers to detect trends and take proactive actions to decrease scrappage.

For more information, visit www.thesempregroup.com Issue 44 PECM

EDITOR’S CHOICE

FIRM STEPS UP AT TESTING TIME SEAWARD

NORTH East manufacturing firm Seaward is part of the national effort to keep Covid-19 patients and NHS staff safe The firm is supplying vital electrical safety testing equipment to the new Nightingale Hospitals, existing hospitals across the UK, as well as internationally, and to manufacturers who are ramping up production lines of much needed ventilators and other equipment needed for patient care. Seaward builds electrical safety testing equipment for everything from ventilators to hospital beds, hoists and pumps via its medical arm, Rigel Medical. Andrew Upton MD of Seaward, said: “A limited workforce is keeping the Peterlee-based factory up and running. The greatest call at the moment is for the electrical safety checking of ventilators. “Because a lot of the equipment is either brand new or older and being brought back into use, it is vital it is safety tested to protect patients and staff. “We are supplying to the UK and the rest of the world and our team is working flat out to cope with demand. We see it as our way of being able to say ‘thank you’ to the NHS. “We have been working on behalf of the Cabinet Office commissioners to supply products to Nightingale Hospitals and through firms such as Mercedes, Ford, Rolls-Royce, Dyson and McLaren who are also part of the effort. “Although it has been hectic, and we have been producing and selling five times as much of this type of equipment, we have had to abandon everything else for the time being to concentrate of what is so urgently needed. “Our employees are more than happy to work. They understand the immediate need for this equipment, and that we have put in place the best possible measures to protect them as well, observing social distancing, the introduction of a one-way

system and converting the conference room to a canteen extension so breaks can be staggered to minimise contact. “They actually think it is great that they can play their part in supporting the NHS in some way during this national crisis and are proud to be among those people who have stepped up to help. “Our equipment is also being exported to help many international communities who are also suffering greatly due to Coronavirus both in Europe and China.” Seaward manufacture and supply a large range of electrical test equipment including hipot testers, digital ohmmeters, PAT testers and more. Visit their website seaward.com to see their full product range. Email: sales@seaward.com Tel: 0191 586 3511

For further information, please visit www.seaward.com

PECM Issue 44

EDITORâ&#x20AC;&#x2122;S CHOICE

QUALITY HINGES TALK TO THE EXPERTS.

01827 63391 sales@goldwassallhinges.co.uk Whatever your hinge requirements, we offer a solution. Bespoke/Stock - UK maunfactured - Expert advice

Issue 44 PECM

EDITOR’S CHOICE

THE HUCK C6L - HUCKBOLT ®

STAR FASTENERS

A classic 6-Groove locking fastener built with staying power Various C6L pins and Collars

Where a strong vibration resistant joint is critical you cannot go wrong with a Huck C6L, the original HuckBolt manufactured by Huck over half a century ago. The C6L’s exclusive locking six groove design ensures a secure permanent fit that resists loosening. Once the collar swage is complete, the pin tail breaks off and the fastener is completely installed. There is no rework required and you can count on consistent, highly uniform clamp force with every C6L installation. A quick visual inspection along with an occasional dimension check is all that’s needed to make sure it has been fully installed. The C6L is a high strength pin and collar (two piece) fastener. It easy to install and is more durable than welding, adhesives, or conventional threaded fastening systems. As well as offering superior fastening performance, the C6L system reduces labour and installation costs, along with rework and warranty expenses. Using the C6L eliminates the need for certified welders or specially trained employees, workers can be shown how to easily install these fasteners in a matter of minutes.

WHICH INDUSTRIES IS THE C6L FASTENER USED IN? C6L is one of the industry’s most popular fastening systems. It is a versatile fastener that is available in a variety of sizes, materials, finishes and head styles. It is used is in so many applications; these are just a few…

PECM Issue 44

The C6L is a high strength pin and collar (two piece) fastener. It easy to install and is more durable than welding, adhesives, or conventional threaded fastening systems. General manufacturing, heating, ventilation and air conditioning (HVAC), heavy goods vehicle chassis production, commercial vehicle trailers and rigid bodywork, container assembly, railroad and rail vehicles, agricultural, rotary and

rotating equipment, conveyors’, fencing, shopping trolleys and platform trucks, and so many other applications, its uses are far and wide. It can be used wherever a strong, high-uniform clamp force, secure, permanent fit and vibration-resistant fastener is required.

WHAT DIAMETERS, MATERIALS AND HEAD STYLES ARE C6L HUCKBOLTS AVAILABLE IN? Available Sizes: 3/16” (4.8mm), 1/4” (6.4mm), 5/16” (7.9mm), 3/8” (9.5mm) There is also a larger diameter variety available known as the Huck C50L range. Materials: Grade 5, (also available in grade 8 as C120L), Aluminium, Stainless Steel Head styles: Round, Truss, Flush (Countersunk), 98T (Rivet Head)

C6L Installation Sequence

HOW IS THE C6L HUCK LOCKBOLT INSTALLED? 1. The pin is inserted into the prepared hole and the smooth bore, free fitting collar is placed on the pin. 2. The installation tool is applied to the pintail. When the tool is activated, the jaws in the nose assembly pull on the pintail and the nose anvil pushes on the collar to remove any gap.

C6L cross section

reduce labour cost due to their easy and quick installation (no skilled labour required).

3. The nose anvil starts to swage the collar into the lock grooves on the pin. Continued swaging causes the collar to lengthen and develop clamp.

6. HuckBolts have an ability to accommodate flexing in a structure without working loose. If a pin is used with a wide flanged collar it helps to spread the load ensuring structural integrity.

4. When swaging of the collar into the lock grooves is complete, the pintail breaks off, the tool is ejected off the fastener and completes the installation sequence.

7. Huck Lockbolts have the benefit of consistent installation which eliminates future maintenance requirements and ultimately provides cost reductions. The high-fatigue, annular lock groove form extends the life of the structure

WHY USE A C6L PIN AND COLLAR LOCKBOLT OPPOSED TO A TRADITIONAL NUT AND BOLT? 1. HuckBolts (Lockbolts) have been designed to provide vibration resistant joining solutions for industrial applications – they do not rely on pre-installed nylon patches, lock wires, washers or any other additional methods that might affect their integrity. 2. Even in the most vibration-intensive environments, Huck fasteners maintain their structural integrity for the life of the joint. Traditional fasteners loosen under vibration. No matter how hard they are tightened, nuts and bolts will loosen with time if they are subjected to regular mechanical vibrations. 3. HuckBolts are installed using direct tension and swaging. This installation method helps ensure there are no gaps as there are between nut and bolt threads – a common potential source of loosening. HuckBolts feature full metal-to-metal contact

between the swaged collar and the pin. This unique swaged connection provides unwavering vibration resistance, even in the harshest vibration filled applications. 4. Because HuckBolts are not subjected to torsion during installation, they can safely be taken to higher preload values than conventional bolts. This results in higher clamp, higher strength and ultimately the highest level of vibration resistance you can find. 5. Huck Lockbolts are often preferred over traditional bolts because they offer a more efficient fastening method. They help to

8. Initial long length of fastener (pin) enables pull-out of large gaps and high retained clamp. Specialists in the supply and distribution of Huck Fasteners, Star Fasteners are proud to be the UK’s largest Huck stockists. Working globally with a diverse range of end users and distributors from across a number of industries, offering technical application knowledge, customer support, and tooling sales, service and repair. For more information about Huck fasteners and Star Fasteners unique value-added services have a look on starfasteners.co.uk or contact us on the following: - Tel: +44 (0)115 9324939 email: sales@starfasteners. co.uk www.starfasteners.co.uk

For further information, please visit www.starfasteners.co.uk Issue 44 PECM

EDITOR’S CHOICE

FIELD OF DREAMS FANUC

FANUC brings new IIoT data platform to UK market With a view to helping UK manufacturers improve the efficiency and output of their production operations, FANUC has unveiled its new Industrial Internet of Things (IIoT) platform, FIELD (FANUC Intelligent Edge Link and Drive) system. Suitable for industrial applications ranging from subcontract machine shops through to major production facilities alike, FIELD system is an open source platform which connects a broad range of FANUC and third-party production technology – including both new and legacy models dating back to 2000. Its ultimate aim is to provide fast, centralised access to all production data within a factory and help end-users take a decisive step towards Smart Factory status. Unlike other IIoT solutions, FIELD system is ‘edge-heavy’ and collects, keeps and processes a wide range of production data at source, on the shop floor, rather than in the cloud. As such, it gives operators access to much more accurate realtime data and analytics. For larger sites, FIELD system is also fully scalable across multiple cells within a factory, and allows manufacturers to make informed and intelligent decisions that can drive tangible improvements in productivity. “FIELD system operates primarily ‘on premises’. It ensures a fast response to edge devices without the need for a cloud connection,” says Craig Taylor, European Technical Support Manager, at FANUC. “This allows for better real-time processing and autonomy to move without the internet, as well as reduced cloud communications costs and better data leak prevention. However, if customers want to store data for future analysis or make a combined data analysis from different factory locations, they can do so via a cloud solution.” Craig continues: “With FIELD system, we are aiming to empower the engineer, not de-skill them. Manufacturing is becoming increasingly digitised and we see FIELD system as a tool that can amplify the knowledge of those running production, by

taking a few key inputs and using them to improve the efficiency and output of their operations.” FIELD system is compatible with a number of different applications available from the newly-launched FANUC App store, which end-users can browse and download from directly. Apps include both those offered by FANUC as well as those designed by thirdparties such as software houses, systems integrators and even end-users. Two of the most important applications available to end-users are FIELD system PMA and FIELD system ZDT. PMA (Production Monitoring and Analytics) software is used to monitor the production and performance of all machines connected to FIELD system, including flagging any which are not operating at intended capacity, as well as facilitating waveform failure analysis.

ZDT (Zero Down Time) continuously monitors the health of machines and can identify trends – such as torque changes or disturbances – with a view to informing operators when preventative maintenance action needs to be taken. Among the first third party apps to be added to the FANUC App store, and also displayed at the 2019 Hannover Fair, is one from Open Data which captures the OEE (Overall Efficiency of Equipment) of the entire production system in real-time and visualises the data on a dashboard. Craig continues: “Ultimately, the open nature of the platform is intended to improve the efficiency and quality of a production process, while also optimising maintenance. We want FIELD system to be able to keep production running, regardless of whether the equipment is exclusively FANUC or a combination of multiple different manufacturers.”

For more information on FIELD system, please visit: www.fanuc.eu/uk/en/field-system

PECM Issue 44

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Issue 44 PECM

EDITOR’S CHOICE

BOILER HOUSE KNOWLEDGE SPIRAX

Steam systems expert ‘boas’ts prestigious training accreditation Steam systems expert and trainer at Spirax Sarco’s UK Steam Technology Centre (UKSTC) Mike Maslanka is only one of 20 people in the UK to be awarded the highly regarded Boiler Operation Accreditation Scheme (BOAS) Trainer Certification by the Combustion Engineering Association (CEA). The BOAS is a nationally recognised certification for boiler operators and helps employers demonstrate that they have provided suitable and appropriate training to boiler operators and boiler house managers in line with BG01 (Guidance on Safe Operation of Steam Boilers). Spirax Sarco is one of the few organisations in the UK to have been delivering the BOAS courses since the scheme’s inception in 2005. Training employees to operate boilers and work in the boilerhouse safely and efficiently to BOAS standards can save companies thousands of pounds through lower fuel costs and a reduced need for both repair work and water treatment chemicals. The accreditation process for the BOAS Trainer Certification is highly robust due to the critical nature of boiler operations and therefore involves a number of intensive interview processes. With 4750 professionals BOAS-accredited in the UK, and a requirement to be renewed every five years, there is a consistently high demand for BOAS-certified trainers to carry out the scheme’s courses. This latest BOAS Trainer Certification, awarded to Mike Maslanka, means Spirax Sarco now has further in-house capacity and expertise to continue delivering and innovating its market-leading training programme, allowing the training centre to provide an even wider variety of engaging course content. Mike has excelled in his capacity as a trainer at Spirax Sarco’s state-of-the-art training facility in Cheltenham, providing high-quality instruction to customers, designers, installers and users and maintainers of steam and condensate systems. Prior to joining the steam solutions provider in 2017, he spent 30 years in the

There is a consistently high demand for BOAScertified trainers to carry out the scheme’s courses. Royal Air Force with his final 10 years spent working on delivering highly technical content to leadership teams. The CEA’s Director David Kilpatrick offers congratulations on Mike becoming an

accredited CEA BOAS Trainer, using his engaging skills and high-quality training materials. “Through the formal accreditation process, Mike demonstrated the level of boiler house knowledge that will ensure high standards of best practice across the industry, true to the standards of the CEA and its accredited schemes.” Mike adds: “I’d be lying if I didn’t say it was tough but I took the training really seriously and made sure I knew the systems inside out. I suppose I’ve always had a natural willingness to learn which has also meant I’ve also really enjoyed the process. Working at the Spirax Sarco Steam Technology Centre is really rewarding so I look forward to getting my teeth stuck into the upcoming BOAS courses.”

To find out more about the programme, visit: www.spiraxsarco.com/global/en-GB/training/boas

PECM Issue 44

EDITOR’S CHOICE

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

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Issue 44 PECM

EDITOR’S CHOICE

3D BIOPRINTING FELIXprinters

Meeting the challenges of bioprinting By Nadia du Plooy, Marketing Manager, FELIXprinters 3D bioprinting offers opportunities such as testing treatment for diseases using artificially affected tissues, and through using bioink, it’s much easier to solve problems on a patient-specific level, promoting simpler operations. Within this context this article assesses the possibilities that exist for bioprinting, and looks at a newly introduced technology option that can provide highly reliable and costeffective bioprinting options. With the growing demand for customized medical devices and pharmaceutical, 3D printing/additive manufacturing (AM) has begun to iron out a niche for itself in the medical and life sciences sectors. Throughout industry — but in the life sciences sector in particular — 3D printing has been truly disruptive, and some would say revolutionary, and it has promoted the manufacture of personalized implants and prosthetics, personalized and adjustable dosage forms for drug delivery, tissue engineering, and disease modeling. But the use of AM in life science applications is not necessarily straightforward. For example, the physiochemical and biopharmaceutical characteristics of active pharmaceutical ingredients (APIs) in drug formulations are extremely varied, and need to be considered alongside any proposed AM drug delivery solution. However, the over-riding demand for patient-centric drug and medical product development means that AM’s future is secured in the life sciences sector. AM is now an established technology in the manufacture of models (phantoms) for surgical planning and training, implants and prostheses, patient specific anti-microbial wound dressings, and some novel forms of drug delivery, but a relatively less advanced area, and one in which FELIXprinters is working actively is in the field of bioprinting and so called “organs-on-chip”.

THE BIOPRINTING MARKET The global 3D bioprinting market — currently valued at $965 million — is

PECM Issue 44

expected to grow at a CAGR of nearly 20% up to the mid 2020s, driven by increased healthcare demands, but also to overcome the supply bottlenecks and ethical issues associated with organ donation and tissue repair. Bioprinting also caters for the increased demand for customized patientspecific healthcare solutions, a trend that is only likely to accelerate moving forward. The key stimulus behind AM driven bioprinting is to find a solution for organ / tissue rejection, and the requirement for lifelong immunosuppressant-based therapies. The area of regenerative medicine is constantly on the look out for mechanisms that allow for the fabrication of multi-layer soft biological materials such as living cells, and in this extremely exacting area of research, AM is finding a foothold. Wilgo Feliksdal, Co-Founder of FELIXprinters explains, “To date, AM has been mainly used for the preparation of tissue construct such as blood vessels, liver, kidneys, heart tissue, cartilage, and bone. But all developments in this area of the use of AM requires a focus on the long-term viability of the “printed” cells,

the control of cell proliferation so as to provide sufficient amount of functional and supporting cells and tissue homeostasis, and the requirement for tissues used in 3D printing to be able to survive pressure and shear stress during the 3D printing process, as well as contact with potentially harmful compounds.”

A NEW BIOPRINTING OPTION With this in mind, FELIXprinters has recently launched its BIOprinter which has been developed on the chassis of the established FELIXprinters’ product line which includes the Pro and Tec series and the Pro L & XL machines. This means that at its heart is the tried and tested technology that has already been serving industry successfully for years. The BIOprinter is characterized by key features that are specifically designed for medical, scientific, and research applications, including syringe cooling, print bed cooling and heating, a dual head system, easy syringe positioning (ergonomic access to the machine supports researchers in their work), and automatic bed levelling.

Guillaume Feliksdal, Co-Founder says, “The BIOprinter has been designed to be the ultimate bio research instrument but in a cost-effective package. It has been developed alongside the brightest minds in the bioprinting sector, and we partnered with training4crm and the Technical University of Denmark (DTU), and received funding from the European Union Horizon 2020 Programme to develop the BIOprinter. Uniquely, the BIOprinter combines dual sterilizable printheads which have a modular design for easy changeovers, and separate heads are available to print different bioinks at the same time. This integrates different material properties into a single scaffold structure.” FELIXprinters has worked closely with the Technical University of Denmark (DTU) on bioprinting applications of 3D printing. Heading the research was Hakan Gürbüz, who explains the foundation of the work he is undertaking. “The aim of the BIOprinter that we have developed with FELIXprinters is to allow the printing of scalable and perfusable hybrid scaffold structures, incorporating in the same structure at least two different material properties. For this purpose, we developed a hybrid 3D printing platform that enables the printing of 3D scaffolds with dual material properties (e.g. mechanical [soft/medium/hard], conductive or biological) and perfusable microchannel networks, enabling the continuous supply of oxygen, nutrients, and necessary factors to cells growing and differentiating throughout the scaffold.” 3D printing has many advantages over conventional approaches to building scaffolds, not least its ability to position the cells precisely. Currently, there are three different classes of bioprinters that are used for deposition and patterning of biological materials including inkjet, micro-extrusion, and laser-assisted printing options. Each of these bioprinters has unique methods of depositing 3D cell structures with good resolution and viability. The FELIX BIOprinter is a microextrusion bioprinter, which makes it very simple to use.

The FELIX BIOprinter is appropriate for all types of bioprinting research, and is equipped with strong motors that can extrude a range of different viscosity of materials. many droplets of bioink by applying pressure — either pneumatically or mechanically — to force the bioink from a syringe.” “These strings are deposited in 2-dimensional layers (as directed by the CAD-CAM software), and served as the base for the subsequent layers while the stage is moved up the z-axis, resulting in the formation of a 3D structure. Microextrusion bioprinters are compatible with a wider selection of bioink including high viscosity materials such as hydrogels, biocompatible copolymers, and cell spheroids.” Effectively, the BIOprinter consists of an adaptable and flexible ecosystem to ensure that it can meet a wide range of researchers’ needs without generating unnecessary costs. One major advantage is the source control system which enables the user to use standard slicing software and make changes themselves if needed. Also, syringes are not restricted to expensive brand-specific or in-house produced products that essentially drive up operating costs. The machine instead

has been designed to use a standard 5ml syringe, and standardized petri dishes and culture plates, so there are no limitations on auxiliary parts and materials. The FELIX BIOprinter is appropriate for all types of bioprinting research, and is equipped with strong motors that can extrude a range of different viscosity of materials. In addition, the BIOprinter has been designed to be easily upgradeable, which means that the lifecycle of the machine can be extended without compromising quality, reliability, and productivity. The platform has automatic bed levelling through the use of a unique probing system which results in a completely accurate first layer, which means a high quality end result. It also retracts with a highly precise motor for better dosage or materials and more accurate material flow versus alternative air pressure systems.

SUMMARY Given its interdisciplinary nature, 3D bioprinting is accelerating at an everincreasing rate. It’s exciting times, but we need to be careful to temper our expectations of this technology with the realities. The human body is incredibly complex, and trying to replicate the many things that it does is difficult. Those working in the field are making advances every day, in both the technology and in their understanding of how it can be used and improved. There is no doubt that the future of medicine will be very different with bioprinting involved, and the FELIX BIOprinter is perfectly positioned to cater for the spike in demand in the coming years as research in this area continues to expand.

Wilgo Feliksdal explains how microextrusion printers work. “Microextrusion bioprinters usually consist of a temperature-controlled biomaterial dispensing system, a stage capable of moving in the x, y, and z directions, light illuminated deposition area for photoinitiator activation, and a video camera for x-y-z command. Unlike other bioprinters, the micro-extrusion bioprinter generates a continuous string of bioink rather than For further information, please visit www.felixprinters.com Issue 44 PECM

EDITOR’S CHOICE

FASTER TOOLING & ASSEMBLY 3DPRINTUK

The extremes of additive manufacturing When Norway based Kongsberg Maritime, a specialist in technology for use in extreme conditions, was designing a chassis for a subsea measurement instrument, it turned to 3DPRINTUK to help with the manufacture of key components. MEPCA found out more. Kongsberg Maritime is an international technology group working in the maritime, defence, aerospace and digital sectors. Kongsberg is at the forefront of pushing technology in extreme conditions, so it comes as no surprise that additive manufacturing has a role in their design process. As additive manufacturing grows and becomes a viable, recognised option for producing custom parts with a finish close to injection moulded parts, more and more design engineers are exploring and adopting selective laser sintering (SLS) technology to produce innovative products. As a result of this growth, the more engineers demand from the technology, the more investment is made to advance the capabilities of the method. Kongsberg Maritime delivers products and systems to merchant vessels and offshore installations for positioning, navigation, automation and handling systems, as well as products and systems for seabed surveying and monitoring, and fishing vessels and fisheries research. 3DPRINTUK specialise in low-volume production through additive manufacturing and in particular SLS. By 3D printing parts in SLS Nylon P12, and with very few restrictions in design, manufacturers can create components with reduced weight while maintaining strength. Users of the innovative method save on manufacturing costs thanks to material savings and assembly time reduction. In addition, clever design means that the number of components gets reduced and prototyping that used to take weeks can be done in days, in multiple variations, all branded with unique part numbers. Robert Kovacs, Senior Subsea Design Engineer at Kongsberg Maritime approached 3DPRINTUK when they started a new project to design a chassis for a scientific subsea instrument used in underwater positioning

and mapping. “The part is a multi-functional product chassis, not just a simple bracket to join two things together. It has clever features and functionality that we would not get from a similar metal or injection moulded part,” explained Robert. “The chassis flexes extensively to allow a heat shrink sleeve to be placed around battery cells and a PCB, which simplifies assembly tremendously. To secure the product during transport and handling, a tiny slide-bolt arrangement allows for a zip-tie to be inserted, again greatly saving handling time and reducing risk.” Small printed extrusions act as standoffs, screw guides and screw anchors which make the whole assembly extremely rigid. Features such as these cost nothing during printing but save greatly on handling, assembly and repair. “Right from the start, deciding to 3D print this pivotal part in a new design meant that we were able to shrink the size of the product while integrating features and functionality that are simply not available

through other manufacturing methods,” continued Robert. Robert was also able to save money on the cost of other products by nesting parts. As well as price breaks for higher quantities, 3DPRINTUK allow users to nest parts around one another to take advantage of any unused space. The smaller the space users take up within the printer, the less they are charged. Summing up his experience of additive manufacturing, Robert concluded: “I believe that the biggest advantages when 3D printing parts are the time savings thanks to faster tooling and assembly, along with the ability to make far more intelligent parts. We would, of course, have these features and advantages if this part was injection moulded. But it is not possible to make an injection mould tool with all these features in one part, as it has too many details and undercuts in too many different directions.”

For further information, please visit 3dprint-uk.co.uk

PECM Issue 44

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BOILERS & MAINTENANCE

Lanemark brings proven process heating to small brewery sector The specialist processing needs that are central to the growing number of mini- and micro-breweries in the UK all have a number of production methods and objectives in common – with accurate, controllable vessel heating always high on the list. Lanemark Combustion Engineering Ltd. has been at the heart of this scenario for many years with its range of gas fired process tank heating (TX) small diameter immersion tube burner systems – which can operate using either natural or propane gas. The designs are used in particular with vertical cylindrical

coppers and hot liquor tanks in, typically, 5 to 80 UK barrels (80 to 130 hectolitres) brewing enterprises. “Gas offers clear-cut economies of use compared to alternatives such as electricity or steam,” says Lanemark Sales Director Jeff Foster. “In all cases, our designs comprise a burner firing through the wall into a submerged, small bore tubular heat exchanger to achieve heating that is both evenly distributed and, typically, in excess of 80% efficient.” Because brewing vessels are often cylindrical,

Lanemark has also developed a helical coil tube design which sits on the base of the tank and follows the curved wall in a circular layout. Accuracy of control is optimised via Lanemark’s optional modulating temperature/gas input controls which allow the brewer to maintain the ideal rolling boil brewing temperature. Importantly, all Lanemark burner designs can be supplied complete with Lanemark’s BurnerCare support service. Ranging from installation, commissioning and service and maintenance scheduling to a rapid response call out facility, it translates into genuine peace of mind for all users across the sector.

For more information visit 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

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•

COMBUSTION ENGINEERING

31/08/2016 09:04

EDITOR’S CHOICE

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 & 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. In November 2019 the company was awarded F4N (fit for Nuclear Status) by the Nuclear Advanced Manufacturing Research Centre. The company continues to develop its digital strategy encompassing shop floor data capture, ERP, CRM and machine automation.

In March this year the company added a further 5000sq.ft of manufacturing space taking the total to over 17,000sq.ft. It also added to its capabilities by purchasing plant & equipment which manufactures PTFE impregnated yarn which is primarily used in the aerospace industry. 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 Issue 44 PECM

CABLES

MEETING YOUR CABLE NEEDS LEGRAND

Top Tips to Cable Management Specification

Cable management is an integral part of the specification process. When it comes to specifying cable management systems, there are a number of key areas to consider in addition to cost per unit and installation time. Mark Williams, lead marketing manager for cable management at Legrand, talks through some simple top tips during specification.

1. LOCATION Consider what elements the cable management system will be exposed to. If the system is to be located in a corrosive environment or a marine location for example, the requirements will be very different to that of an internal commercial building installation. Legrand’s industry experts and cable management technical product guides can offer in-depth advice on what to consider when selecting your material.

PECM Issue 44

2. CONSIDER THE CABLE USED It’s important to consider what type of cable will be used throughout the installation and if support or protection is needed. • Single insulated (non-sheathed) cables require additional mechanical protection (as per BS 7671), as well as support, and therefore an IP4X or IPXXD distribution trunking system is generally the solution of choice as it fully encases the cables. • If using armoured cables, an open cable management system, such as steel wire cable tray, perforated tray or cable ladder, is considered more suitable.

3. WEIGHT Calculate the total weight to be supported by the cable management system, taking into consideration current requirements and potential needs in the future.

Remember that the total loading should be calculated based on not only the weight of the cables, but also any ancillary items that are subsequently fitted to the cable management system, such as light fittings, as well as external forces such as weather and the surrounding environment.

4. REGULATIONS AND STANDARDS Wiring regulations can differ depending on the installation or location of the project you’re working on, so it’s imperative to monitor and review the guidelines, prior to an installation. Amendments to the wiring regulations BS 7671, for example, have to be monitored and respected. This can influence the selection of cable management systems as you may need to opt for a solution that ensures avoidance of premature collapse of the cabling system. In this instance, metallic solutions may be the preferred option.

5. SCALABILITY It can be tempting to build in redundant capacity during the design and specification stages of a project rather than designing a system that can be easily adapted in the future. Planning ahead has the potential to save businesses time and money in the longer term, so it’s worth considering in the design stages.

cable management system that excels in each of these areas, you will not only have a system that reduces installation time, and therefore total installed cost, but you will also have a system that can meet your needs today and tomorrow. For more information on Legrand’s range of cable management solutions please visit www.legrand.co.uk or call 0345 605 4333.

Planning ahead has the potential to save businesses time and money in the longer term, so it’s worth considering in the design stages.

Remember, when considering scalability, retrofitting can be expensive and not all systems can be easily integrated with one another. Consider this at the design stage by specifying a system that can easily interface with others.

6. FULL RANGE OF ACCESSORIES Take the time to specify a system that offers a full range of accessories including brackets, fixings and couplers, from one source. Work with your supplier to ensure you specify the correct amount of fittings, brackets and fixings in order to prevent delays on site. Effective cable management can help to enhance cable performance, longevity and future flexibility in terms of business growth if implemented effectively. There isn’t a “one solution fits all”, so it is vitally important that the correct system is chosen from the outset. By selecting a For further information, please visit www.legrand.co.uk Issue 44 PECM

CABLES

INSTALL WITH CONFIDENCE ELAND

Cables – Think of them as a Service not just a Product Cables are more than just the sum of their construction. More than just a metallic conductor wrapped in insulation and sheathing materials that meet a set of standards. They are compliance legislation, they are technical specifications to meet an installation environment or specific application, and they are compatible with accessories and terminations. Yet cables are still more than this, and it’s these additional elements that can make a project run smoothly and provide the information needed to specify and install with confidence. Here’s a few of the things to look out for: Independent QA testing – Have cables been rigorously tested in an accredited laboratory (ISO/IEC 17025) to confirm that the standards and compliance legislation have been achieved? A good laboratory will also look at key practical aspects such as the ease of stripping for termination and whether they meet the strict tolerance levels needed to fit seamlessly with glands and other terminations. Third-party accreditations – Quality marks such as the BSI Cable Testing Kitemark demonstrate that cables meet the performance and safety standards demanded of them. They are a globallyrecognised and trusted symbol and show an additional level of due diligence in the choice of product. Ready access to technical expertise – Having experts on hand to provide detailed and in-depth knowledge of cables and their electrical characteristics can help you navigate the inevitable questions that arise. Utilising this asset from specification

through to installation can prevent unnecessary delays to project timelines. It’s even more valuable when it’s the commercial team who provide this support, in conjunction with a true technical team – it makes asking questions even easier and integrates your cable supplier into an extension of your own project team. Ability to tap into industry knowledge – Whether best practice guidance or practice solutions to onsite challenges, you want to be dealing with people who not only know cables but understand how they work as part of the bigger picture. Industry specialists with decades of project management experience, and wiring qualifications themselves, can help give you the edge you need. A tailored delivery solution – More than simply getting the cables delivered where and when you need them, it’s about whether they’ve clearly been stored in optimal condition, they’re delivered securely and properly packaged, with drums in good condition so as to not impede installation. The accompanying paperwork should be complete and have

Utilising this asset from specification through to installation can prevent unnecessary delays to project timelines. all the required legislative and compliance information clearly displayed. Quality cables are delivered looking like they’re in great shape – trust your eyes and expect the best. For more information on how Eland Cables can support your project or application with high quality cables AND the value-added service that makes a difference, please get in touch. sales@elandcables.com 020 7241 8787

For further information, please visit www.elandcables.com

PECM Issue 44

COATINGS

Applying Premier Premcote Tape System

Aluminising capabilities extended As the leading global supplier of coatings protective against metal dusting, coking, oxidation and sulfidation we have listened to what our customers have told us they need and over the last 5 years extended our furnace capability for long and large components and expanded our capabilities for measurement and control. Aluminising, correctly processed, remains the most effective long term protection mechanism against metal dusting and we have built

our reputation for detailed consideration of all processing requirements up over 30 years. As the preferred supplier for an increasing number of customerâ&#x20AC;&#x2122;s and their steam reforming technology, we intend to continue working alongside, whether for ammonia, methanol or hydrogen production, with the next generation of technology developments.

www.diffusion-alloys.com E: enquries@diffusionalloys.com

Premier Coatings Gains Environmental Premier Coatings Gains Standard ISO 14001:2015 Environmental Standard ISO By gaining this award, Premier Coatings Ltd, leaders 14001:2015 Premier Coatings Ltd have in corrosion prevention and

demonstrated their commitment sealing technology, announce Premier Coatings Ltd, leaders insustainably corrosion to working and that they have achieved the have implemented procedures prevention and sealing technology, internationally recognised all areas of the business environmental ISO haveacross announcestandard that they achieved the to ensure their environmental 14001:2015. internationally recognised environmental obligations are successfully fulfilled. The certification recognises standard ISO 14001:2015. an organisationâ&#x20AC;&#x2122;s commitment to reducing the environmental The certification recognises an organisationâ&#x20AC;&#x2122;s Tel: 01233 770663 impact of their operations, commitment to reducing the environmental Fax: 01233 770633 hereby positively enhancing e-mail: enquiries@ their environmental impact of their operations, hereby positively performance. premiercoatings.com

enhancing their environmental performance. By gaining this award, Premier Coatings Ltd have demonstrated their commitment to working sustainably and have implemented procedures across all areas of the business to ensure their environmental obligations are successfully fulfilled. Tel: 01233 770663 Fax: 01233 770633 e-mail: enquiries@premiercoatings.com

Issue 44 PECM

CONNECTORS

myHARTING HARTING LTD

HARTING launches new digital services to help customers HARTING has always been at the forefront of new technologies and innovative ideas. However, it’s not just in the area of new products where we are evolving our offerings. During the current difficulties, developing close working relationships with customers and simplifying processes are key to working together efficiently. In light of this, HARTING have recently launched myHARTING, a digital project and partnership platform with a range of tools designed to help you manage your day-to-day tasks. All you need to do is login with your current details or register for a free account to access a wide range of benefits, which include: myHARTING Cockpit: An easy to use home page which displays all your relevant data and information. Wishlist: Store all your favourite products and solutions in one place for quick access. Download History: Easily store and access premium content that’s relevant for you, including CAD files, technical data and whitepapers.

All you need to do is login with your current details or register for a free account to access a wide range of benefits.

Upgrade to eShop: Apply for an upgrade to an eShop account, where you can check pricing and stock, place and track orders and manage delivery details. Newsletter Subscription: Manage your account so you only receive information that matters to you. In addition, if your role involves sourcing and designing interfaces for industrial connectors, the new and improved Han® Configurator is the perfect solution. It’s an online 3D tool which allows you to design and build a connector that meets your exact requirements. You start by selecting three inputs (contacts, voltage and current) to generate the first possible solution. At each stage of the process you can receive suggestions for alternative interfaces and the smart assistant feature will only allow you to apply valid configurations, avoiding numerous

combination options and saving valuable design time. You’ll benefit from an onscreen 3D visualisation of the current configuration, meaning you can view your creation from

a range of angles. It’s also extremely easy to download all documentation (including STP files) with a single click and quickly save, load and share your configuration within a team; an ideal solution if you’re working remotely or in a different location from your colleagues. So if you’d like to benefit from a fast, efficient configuration process with a host of additional functions, visit our website to try the new Han® Configurator.

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

PECM Issue 44

CONTROL & AUTOMATION

RK Height Adjustable Monitor Floor Stand With the new height adjustable monitor floor stand, RK Rose+Krieger is expanding its monitor mounting product range to include a robust ergonomic standing workstation for industry which can be set up quickly and is much more economical than complex workstations. The work surface and monitor mounting are supported by a stable triple column system on a black powder coated base frame. The position can be easily adjusted by hand and has an adjustment stroke of 400mm. The standard version of the stand has feet (steering rollers optional) and a rotary flange connecting plate. Pre-assembled modules are supplied for quick and easy set-up. The stand can also be combined with all available RK monitor holding components.

www.pmgb.co.uk/rk

Issue 44 PECM

CONTROL & AUTOMATION

MOBILE ROBOTS GREYORANGE

Expanding the orchestration of data and actions across the Company’s series of Ranger™ mobile robots In December 2019, GreyOrange, a global software and mobile robotics provider that leverages artificial intelligence and machine learning to optimise fulfilment operations, announced the release of its latest Fulfilment Operating System, which integrates GreyMatter software with the company’s series of mobile robots. This release embodies capabilities that optimise fulfilment for companies with omnichannel and e-commerce needs and increases store efficiency by packing replenishment orders according to individual store layouts and preferences.

PECM Issue 44

It also expands the orchestration of data and actions across the Company’s series of Ranger™ mobile robots. Ranger robots are developed in conjunction with GreyMatter software and use machine learning to adjust decisions and behaviour based on real-time observations. Additionally, maximumlife engineering ensures every Ranger robot delivers ‘last and learn’ value. Communication among the robots and the GreyMatter central system incorporates that learning, enabling the entire system to continue to get smarter.

GreyMatter intelligence is incorporated as a learning layer in the Ranger robots so that as they operate, they can adapt to what is happening within the distribution centre and externally, as order patterns and fulfilment expectations fluctuate. The robots communicate with each other and with the GreyMatter central system so it can continuously recalculate order fulfilment priorities and inventory movement patterns based on realtime factors such as order fulfilment commitments, actual fulfilment speeds, available resources and time remaining in dispatch windows.

Ranger robots are developed in conjunction with GreyMatter software and use machine learning to adjust decisions and behaviour based on realtime observations. “Synthesizing GreyMatter with a family of individually purposed robots that are built to be collaborative with each other and with the GreyMatter hub makes GreyOrange unique in the industry; it represents the culmination of many years of intensive research and development by the Company,” said Akash Gupta, Chief Technology Officer for GreyOrange. “We’ve seen the performance benefits of designing artificial intelligence-driven software and mobile robotics together, so that each enhances the learning

and adaptation of the other, rather than alternative approaches that simply interface software and robots,” he added. By adding numerous adaptive-learning, self-learning, collaborative decisionmaking and analytics enhancements to GreyMatter and the Ranger robot series, GreyOrange can more intelligently connect people, processes and technology to modernise fulfilment for throughput speed, scale, accuracy and yield.

The company’s next era Fulfilment Operating System, driven by alwayssolving GreyMatter software, considers predictive and real-time data regarding orders, promises, inventory, shipping windows, and resources to orchestrate how workers and robots work as a team to fulfil the right orders at the right time. GreyOrange experts help organisations master fulfilment in the Age of Immediacy so they keep promises, capture more revenue, and improve the work experience for warehouse employees.

For further information, please visit www.greyorange.com Issue 44 PECM

CONTROL & AUTOMATION

EDGE AUTOMATION SOLUTIONS RED LION CONTROLS

Anything IN. Anything OUT. And that’s just the beginning. The Edge Automation Platform FlexEdge™ enables users to design and integrate flexible Edge automation solutions for their applications. The platform offers devices with router features up to modular gateways and scalable edge controllers for data acquisition and data digitization. The interchangeable connection options of each individual device offer great flexibility and make the platform future-proof in the event of changing conditions. Engineered for industrial customers with diverse needs who want to effortlessly connect systems and process data at the edge, FlexEdge’s modular architecture boasts a wide variety of wireless and wired communication options. This breadth of options makes it an easily configured communication gateway that connects with any industrial communication requirement, regardless of protocol or manufacturer. And unlike fixed-function devices that require customers to learn many products — or systems with fixed chassis that take up unnecessary space — FlexEdge™ offers a form factor and platform that adapts as quickly as application needs change. It’s available with advanced networking functionality or advanced automation features, including protocol conversion; virtual HMIs; an advanced web server with Bootstrap, JavaScript and CSS; data, security and event logging; and cloud connectivity.

ONE PLATFORM. LIMITLESS POTENTIAL

FlexEdge offers a form factor and platform that adapts as quickly as application needs change.

Avoid costly and complex rip-andreplace scenarios by leveraging the FlexEdge™ sled architecture, designed to enable organizations to leverage new communications technologies as they become available.

the new equipment working with the existing infrastructure means capital budgets are kept in check.

BACKWARD COMPATIBLE. FORWARD THINKING

The FlexEdge™ form factor adapts as applications needs change; effortlessly scale by adding up to ten hot-swappable I/O or PID modules. On-device wiring diagrams and removable wire clamp screw terminal blocks ease installation, while the at-a-glance module status indicator and individual channel LEDs improve troubleshooting and system testing.

PLUG AND PLAY. AND PLUG. AND PLAY

Regardless of the brand of PLC or other equipment specified, the FlexEdge™ platform, powered by the software automation platform Crimson®, enables connectivity to virtually anything in your system with point-and-click simplicity. And

RUGGED OUTSIDE. RELIABLE INSIDE Rugged construction, a wide operating temperature range, industrial certifications and Red Lion’s Crimson® software provide a dependable solution for control, networking and data visualization in even the harshest environments. Scan and Design your own ideal FlexEdge™ Solution model with the FlexEdge™ Builder:

For further information, please visit www.flexedge.net

PECM Issue 44

CONTROL & AUTOMATION

GET EVERY LAST DROP FROM YOUR EXISTING EQUIPMENT. Powered by Red Lion’s automation software Crimson®, the new Edge Automation Platform FlexEdge™ enables companies to get the most out of their existing equipment, regardless of the manufacturer. • • • •

Protocol conversion > 300 protocols Digitalization of legacy equipment Easy Edge-programming with Crimson® Modular network connection: cloud or on-premises, 5G ready

Scan and design your own model by using the FlexEdge™ Builder

EMAIL FLEXEDGE@REDLION.NET TO REQUEST A DEMONSTRATION WWW,FLEDEDGE.NET

ENGINEERING CONNECTIONS

5 STAR CUSTOMER SERVICE

Issue 44 PECM

CONTROL & AUTOMATION

THE FUTURE OF AUTOMATION CAMBRIDGE CONSULTANTS

Hank:The smart flexible gripper

The Covid-19 outbreak has brought into sharp focus how much we depend on seamless logistics for much of our daily lives – just think about toilet paper for example! And those supply chains that are under increasing strain are a perfect storm of heightened demand coinciding with a reduced workforce due to self-isolation and general social distancing measures. Against this backdrop, the need for collaborative automation to augment the human labour force is greater than ever. Even before the onset of Covid19, things were starting to change in the world of robotics in warehouse automation, and when the current crisis is dealt with, I expect that trend to continue. Most of the easily automated tasks have already been automated, the remaining ones need more intelligence and flexibility to be integrated into the robotics before they’ll succeed. One of the secrets of robotics – most robots are actually pretty dumb. It’s only in the last few years, as they’ve been combined with tech like machine vision and artificial intelligence, that they’ve been able to access a whole new set of semi-structured tasks, where the objects they’re handling, or the effects they need to achieve, vary from time to time. One particularly hot area is reverse logistics – handling goods that have been returned to the shop or manufacturer. This is tricky

Hank uses soft robotic fingers controlled by airflows that can flex the finger and apply force. because the items are all slightly different, so really hard to automate. But with the right sensors and algorithms, this is the sort of thing that can be done now. We’ve been working on a smart flexible gripper called Hank. Hank uses a pioneering sensory system embedded in its pneumatic fingers, providing a sophisticated sense of touch and slip, meaning it can emulate the human ability to hold and grip delicate objects using just the right amount of pressure, minimising any damage to the object. While warehouse automation has taken great strides over the last decade, today’s robots cannot emulate human dexterity at the point of picking diverse individual items from larger containers. By giving a robot additional human-like senses it can feel and orient its grip around an object, applying

just enough force, while being able to adjust or abandon if the object slips. This allows you to address the challenge of handling individual items, however much they vary in size and shape. Hank uses soft robotic fingers controlled by airflows that can flex the finger and apply force. The fingers are controlled individually in response to the touch sensors. This means that the end effector does not require millimeter-accurate positioning to grasp an object. Like human fingers, they close until they ‘feel’ the object. With the ability to locate an object, adjust its position and then grasp that object, Hank can apply increased force if a slip is detected and generate instant awareness of a mishandled pick if the object is dropped. It’s an exciting time in automation and, contrary to what you might hear, most companies developing automation solutions are doing so because they can’t recruit enough people to do the work, not because they want to eliminate human workers. Robots work best as a force multiplier – allowing you to do more with your existing workforce – giving the repetitive, dangerous or dirty jobs to the robots, and leaving the tasks which require the most flexibility and intelligence to people. Think of the goal as making an Ironman suit, not a Terminator.

For further information, please visit www.cambridgeconsultants.com/home

PECM Issue 44

CONTROL & AUTOMATION

DIGITAL TRANSFORMATION SCHNEIDER EELECTRIC

How smart technology is transforming the industrial world By Martin Walder, VP Industrial Automation at Schneider Electric When it comes to the world of manufacturing, Industry 4.0, the Industrial Internet of Things and Smart manufacturing are all terms we hear thrown around a lot. Whilst these terms can all be used in isolation; they share one very important commonality – they are all impacted by digital transformation.

A SMARTER WORLD According to the National Institute of Standards and Technology (NIST), the smart landscape can be defined as “fully integrated, collaborative manufacturing systems that respond in real time to meet changing demands and conditions in the factory, in the supply network and in customer needs”. At present, manufacturing systems are benefitting from an array of new, innovative technologies. Technologies including; big data, robotics, machine learning, artificial intelligence, augmented reality, 3D level of control and the oversight that they bring all play a role in helping us to create a digital twin of an entire manufacturing system. The benefit of these digital twins is the increased business performance and greater real-time understanding of an object or process in play.

LIGHTHOUSES: SHEDDING SOME LIGHT ON THE FUTURE A smart factory brings with it countless benefits. Smart factories embrace planning, supply chain logistics and all aspects of product development and innovation. Those failing to adopt smart manufacturing technologies and practices are the ones who will fall behind the competition and ultimately are likely to disappear. With this in mind – for factories to become

truly smart, they first need to understand what it means to be smart. The World Economic Forum has listed nine of the world smartest factories, calling them ‘lighthouses’ that shed light on the benefits of Industry 4.0. These factories are the ones that have successfully implemented the smartest technologies, whilst keeping people and sustainability at the heart of what they do.

ENTER: LE VAUDREUIL A great example of one of these lighthouses is the Le Vaudreuil, one of Schneider Electric’s motor control manufacturing plants in Normandy. This factory draws on our EcoStruxure technology and utilises a wide range of our digital tools. This factory represents the future of manufacturing. Think about it. Inside the factory there are mini data centres storing critical site data, all USB keys pass through a decontamination terminal, and sensors monitor machinery to predict – as opposed to reacting to all factory maintenance needs. What’s more – as a result of augmented reality, the factory is benefiting from a 7 per cent increase in productivity, and energy savings of up to 30 per cent. Seems like a no brainer.

be done. Smart factories are here to stay, but they aren’t here to replace our jobs. They are here to help businesses remain competitive and successful. And – with greater success, comes more jobs. Ultimately, smarter factories will also facilitate more jobs in the long run. Another important development is the arrival of 5G. It will bring faster downloads and faster responses from applications as a result of lower latency. Sensors will become even more widespread and responsive, and businesses will be able to react to information in real time. With 5G technology having now arrived in the UK, we must assess how it can make smart factories even smarter. Among the possible applications are preventative maintenance and controlling machines remotely. To avoid falling off the bandwagon and keep pace with the competition, manufacturers need to embrace these smart technologies – and become a smart factory. Perhaps the nine lighthouses can shed a bit of light on what the future has to offer.

THE FUTURE OF SMART MANUFACTURING If we can be sure of one thing, it’s that the future is constantly changing. Right now, we’re focused on Industry 4.0. But – very soon, Industry 5.0 will be the talk of the town. Industry 5.0 will focus on the human elements. It will no longer be all about machine and system interconnectivity, but – about how machines and humans can work together – something known as cobotics. We must remember that automation has not taken over human roles in the factory. Whilst new technologies are vital for future success, so too is human input. Be it by offering a sense of direction, or gathering and analysing data, there is still a lot to

For further information, please visit www.se.com/uk/en Issue 44 PECM

CONTROL & AUTOMATION

UPGRADE & SUPPORT OPTIONS OPTIMAL INDUSTRIAL AUTOMATION

Increasing productivity in a time of crisis… Optimal Industrial Automation is offering a range of upgrade and support options to businesses facing unprecedented demand such as the food processing and pharma manufacturing sectors. Customers can benefit from services that range from the recommissioning of mothballed equipment with cutting edge control automation, right up to the application of game-changing process automation solutions, such as Process Analytical Technology (PAT) software, to massively increase production from existing equipment. Innovative automation projects and revamps of existing systems are being used to drive plant productivity and deliver the conversion of production lines in record time. “The big challenge is how to fast-forward technological development for machines, processes and production lines that may have been sitting, ticking along, for up to ten years, or longer. Control automation has transformed radically in that time, making systems far more efficient, flexible, and responsive to changes in demand,” says Martin Gadsby, Director at Optimal Industrial Automation.

manufacturers leverage factory automation to increase productivity or repurpose production and processing assets. In this way, it aims to contribute towards avoiding shortages.

“Our own advanced PAT knowledge management platform synTQ developed by our sister company Optimal Industrial Technologies, for example, is being used right now by major global companies and SMEs to increase output – nearly threefold in some cases. This is being achieved while maintaining the same physical manufacturing footprint. “Optimal Industrial Automation, together with Optimal Industrial Technologies, is in the unique position of having managed the system integration for more synTQ projects than any other supplier globally. We’ve already offered support to government-led initiatives to help fast-track projects such as testing kit production, inoculation drug development and scale-up.”

EXPERIENCE COUNTS WHEN THE PRESSURE IS ON For over 30 years Optimal has supported businesses in a wide range of industries to

optimise production costs, product quality and business sustainability by building, integrating and enhancing their factory automation systems. Customers in the most demanding and highly regulated of sectors such as pharmaceutical, life science, chemical, aerospace, green energy and food & beverage have enjoyed substantial benefits, even before the added pressure of a global pandemic. To address the continuing uncertainty about how global and local supply chains will operate in the following months, the company is providing extra support to help

Customer projects vary in scale and level of complexity from applying individual PLC control to individual processes, through to robotising production machines, applying machine vision systems and commissioning productivity improvement tools such as PAT-based software. Martin Gadsby concludes: “Many manufacturers need to quickly ramp up production to cope with the current situation – while also reducing manual input from operators to support social distancing measures. Automation is the answer to a lot of our immediate production needs. We want to do what we can to help businesses in these challenging times, and would like to invite anyone interested in an automation upgrade to contact us to discuss how we can support them.”

For further information, please visit www.optimal-ltd.co.uk

PECM Issue 44

Automation and

System Integration for Process & Productivity Improvements Complex plant PLC / DCS solutions SCADA, HMIs & panel building Batch & continuous process solutions Pharmaceutical production upgrades Process Analytical Technology Industry/Pharma 4.0 With over 30 years of experience, we are a knowledgeable and totally reliable partner for complex process automation, robotics & special purpose machine building in all process areas. We have specialist and intimate pharmaceutical manufacturing knowledge and rare PAT skills. Our aim is to optimise manufacturing automation systems for challenging and highly regulated industries, substantially increasing both productivity and quality.

Tel: 01454 333222 Email: sales@optimal-ltd.co.uk www.optimal-ltd.co.uk Upgrade existing process automation infrastructure, improve productivity and increase manufacturing capacity.

CONTROL & AUTOMATION

NEW OPPORTUNITIES ESD

Investment in new ESD facility opens up £2m of new opportunities for PP Control & Automation One of the UK’s leading providers of strategic manufacturing outsourcing services has invested over £100,000 into creating a new Electrostatic Discharge manufacturing facility.

Five people are now employed in this area and all have undergone specific training to ensure compliance

PP Control & Automation, which works with 25 of the world’s largest machinery builders, is now targeting up to £2m of new opportunities where this dedicated and controlled environment will help it take on more complex and delicate builds encompassing high-end PCB assemblies and box builds. “It is a decision that is already paying off,” explained Garry Myatt, Sales Director at PP Control & Automation.

earliest possible stage to help optimise a design that’s efficient to manufacture and have parts readily available to ensure a quicker time to market.”

“A number of our existing clients were asking us for this additional capability, so we decided that the time was right to make the investment and bring this service into our offering.” He continued: “This meant developing an environment that met the needs of our customers and legal compliance to the recognised standards and involved special flooring, benches and test equipment - all grounded to earth to ensure that life of the electronics is protected from potential electrostatic discharge. “Five people are now employed in this area and all have undergone specific training to ensure compliance. We estimate that there is £2m of new opportunities in the pipeline and, if these come to fruition, this manufacturing cell will increase in capacity and we’ll need to recruit more staff.” As a strategic outsourcer with its core competency being ‘box build and system integration’, populated printed circuit boards are handled just like another material line item by PP Control & Automation and the requirement is managed accordingly through an approved vendor process.

PP C&A’s outsourcing partnerships provides machine builders with better production flexibility, reduced lead times and greater control over their supply chain and costs. With 80% of customers on a kanban supply agreement, implementing the right processes and key partnerships from the start is key, with robust planning and lean manufacturing operations, backed by a skilled workforce of electro-mechanical technicians, ensuring that the business is currently operating >98.50% ‘on time in full (OTIF)’ service. PP Control & Automation is also ideally positioned to offer ‘Design for Manufacture and Assembly’ (DFMA) in conceptual development of ideas as well as in basic consulting. “Many companies continue to develop a product design that leads to unnecessary costs, requires an inflexible supply chain and suffers from inefficient manufacturing processes,” pointed out Garry, who has more than 25 years’ experience in sales. “This is why our Engineering, Operations and Supply Chain are integrated at the

Garry concluded: “We’ve got a lot of exciting diversification plans, some of which focus on making the most of the ESD manufacturing facility with both existing and new clients. “With 2019 being a record year, securing over £3m of new orders from the healthcare, food and drink and packaging sectors, we anticipate further growth in 2020 from this new manufacturing service. “A spin-out from Aston University is already tapping into this area where we are offering a full turnkey service, from material sourcing through to testing. Volumes are increasing monthly and the expectation is there that this will be a service that PP will take globally on behalf of the client.” Backed by Canadian investment company Ardenton Capital, PP Control & Automation is exploring the possibility of a joint venture or an acquisition in North America.

For further information, please visit www.ppcanda.com or follow @ppcanda on twitter

PECM Issue 44

Specialists in the engineering and manufacture of process automation solutions to improve efficiencies, output and support continuous improvement programs.

SPECIAL PURPOSE MACHINE MANUFACTURER SERVICES • • • •

In-house design In-house manufacture Testing & commissioning Programming

EXPERTISE • • • • •

Assembly & testing Process automation Robotics & product handling Product identification Manual workstations

FOOD & BEVERAGE

AUTOMOTIVE

AEROSPACE

PRINTING

PACKAGING

MEDICAL

TEXTILES

DEFENCE

HEATING

to discuss your next automation project, please get In touch with our design team

T: 01274 308005 E: info@tfautomation.co.uk Hillam Road, Bradford, West Yorkshire BD2 1QN

CONTROL & AUTOMATION

IO-LINK

BURKERT

Simplifying industrial process automation

Industry 4.0 continues to gather pace as more manufacturers are looking to benefit from the ever-expanding array of automation tools and products available. At the heart of every system are network and communication protocols that connect sensors and devices to controllers; sites often combine industrial ethernet with fieldbus systems such as CANopen, AS-Interface, PROFIBUS, CC-Link or DeviceNet, so where would a new I/O solution sit. Kieran Bennett, Field Segment Manager .hygienic â&#x20AC;&#x201C; Food & Beverage, looks at the latest communication protocol, IO-Link, and the advantages it offers for industrial process control. Most production sites will already have some degree of automation infrastructure - which will have an influence on how the network is extended, while others may be looking at the best place to start. One

PECM Issue 44

thing is for certain though, investment costs will be on the agenda when assessing the most appropriate solution.

be used, because this can influence the choice of products that are compatible with the automation solution.

REDUCING INSTALLATION COSTS

One of the more recent communications protocols to become established is IOLink, which has been designed to connect actuators and sensors in the field to the first tier of digital communication. One of the advantages of this technology is that it is standardised under IEC 61131-9, which means the connections, identity codes, parameters and diagnostics are all the same, regardless of the manufacturer.

Automation has the potential to reduce operational costs and improve efficiency as well as reliability. However, to achieve these improvements, the design and installation of the new equipment needs to be properly planned and implemented. Decisions about centralised or decentralised control, data recording, maintenance and reliability will all affect the cost of installation. For the food and beverage industry, automation offers many advantages that can be enhanced by the most effective choice of equipment. At this point, selecting control valves, sensors and actuators would appear to be the next logical step. However, it is important to establish the communication protocols that are going to

PLUG-AND-PLAY Using 3- or 5-wire connections between sensors or actuators and a local IO-Link master, both power and signal data can be connected easily. These cables use standard M12 connectors and can be preassembled and tested, making plug-andplay installation very simple.

Just this characteristic of IO-Link can save considerable time and expense for the installation, but it also eliminates cabling errors that can be difficult to locate, greatly reducing the commissioning time. Furthermore, the internal diagnostics in this system can identify a broken cable, which makes trouble-shooting much quicker and minimises downtime. The standardisation also includes the IO device description, which means that when a device is connected to an IO-Link master it is identified and assigned the correct description, which is passed to the PLC or other higher control device.

Automation has the potential to reduce operational costs and improve efficiency as well as reliability.

SIMPLIFIED MAINTENANCE

to any replacement sensor or actuator, reducing the time required to restart the production process.

Once an automated process control system is running, the next hurdle is maintenance, but again this is made easier by standardisation. Due to the two-way communication of IO-Link, the parameters stored in the controller can be transferred

IO-Link has progressed from its original use in production automation and is becoming increasingly important in process automation; it is now perceived as an alternative to AS-i for valve automation. As such, it is important that manufacturers,

such as BĂźrkert, integrate IO-Link technology into their products so that they can be included on the specification sheet when a company has taken the decision to implement IO-Link. To that end, BĂźrkert has already included compatibility to four of its control heads, which will cover the majority of control valve configurations. The control heads can be combined with butterfly valves, ball valves, single and double seated valves for both BĂźrkert and third-party products. The compact positioners are designed for integrated mounting on pneumatically operated process valves as well as any linear or rotary actuators. The remote setpoint adjustment can be made via IOLink and a contact-free analogue position sensor measures the position of the valve spindle. The whole product range is optimized for decentralised automation, as is the IO-Link communication infrastructure.

For further information, please visit www.burkert.co.uk Issue 44 PECM

ELECTRICAL & ELECTRONICS

HIGH-SPEED DATA TRANSFER NEW YORKER ELECTRONICS

New Exxelia Ultra-Broadband Capacitors Ensure Low Insertion over Wide Bandwidth up to 40GH New Yorker Electronics, a global franchise distributor of the Exxelia Group, is now distributing three new series of Exxelia Ultra-Broadband Dielectric Ceramic Capacitors. These new broadband capacitors show low insertion loss up to 40GHz are perfect for Optoelectronics, High-Speed Data transfers and more.

designed for optoelectronics and highspeed data, broadband test equipment and broadband applications and broadband microwave / millimeter wave amplifiers and oscillators. In circuit applications, it is ideal for DC Blocking, Coupling and Bypassing applications.

Thanks to Exxelia’s extensive MLCC manufacturing experience, New Yorker Electronics’ has well extended its RF capacitors product offerings with these new ultra-broadband series, the XBL, UBL and UBZ. Unveiled at the 2019 European Microwave Week tradeshow in Paris, the Ultra-Broadband Capacitors are available in standard EIA sizes compatible with SMT ‘pick and place’. And, its highly reliable

Exxelia is a leading global designer and manufacturer of high reliability passive components. Exxelia Technologies (formerly Eurofarad) is a designer and manufacturer of complex passive components and precision subsystems: ceramic, plastic film and mica capacitors, filters, position sensors, slip rings and precision mechanics for high technology applications: Aerospace, Defense, Medical, Space, Rail and Oil Exploration.

PECM Issue 44

ceramic material is also compatible with any soldering processes. The new series ensures an ultra-low insertion loss and excellent return loss over a wide bandwidth. The UBL, UBZ and XBL Series are primarily

FEATURES & BENEFITS: • EIA 0201 and 0402 Case sizes • Low insertion loss up to 40 GHz• RoHS Compliant

Exxelia is a leading global designer and manufacturer of high reliability passive components.

APPLICATIONS: • Optoelectronics / High-speed data • Broadband test equipment & applications • Broadband microwave / millimeter wave amplifiers and oscillators New Yorker Electronics currently has the ceramic broadband capacitors available for orders. NYE is franchise distributor of the Exxelia Group, and supplies its full line of Film, Mica, Tantalum, Aluminum Electrolytics

and Ceramic Capacitors as well as its EMI/ RFI Filters, Magnetics, Position Sensors, Slip Rings and Rotary Joints.

For further information, please visit www.newyorkerelectronics.com Issue 44 PECM

ELECTRICAL & ELECTRONICS

Whippendell Whippendell specialises in providing electrical solutions for harsh environments such as the Rail, Naval and Commercial Marine Industrial Sectors. This includes design, manufacture, in-service support and maintenance. For example, the company has been supporting the Royal Navy since the 1930s, with equipment on all current surface ships and submarines. We offer a range of electrical panels, motor starters, control systems, power conversion equipment and aircraft ground power support systems.

Many of our solutions arise from a reverse engineering task to replace obsolete systems with modern alternatives. Typical applications include high pressure air control systems, pumps, steering gear, stabilisers, lifts, winches, mechanical handling equipment and HVAC systems. Solutions can be designed around Whippendell components or to customer preferred requirements and components – use of COTS and PLC technology is standard. www.whippendell-marine.co.uk

Installations with simple solutions to stay safe and work smarter Containing more information than ever before, the new catalogue is organised into 12 comprehensive categories and includes a wealth of essential information on safe isolation and useful selection tables for a wide range of test tools, making it easy to identify the best product for the job. Featuring nearly 300 items of electrical and environmental test equipment and accessories, the latest catalogue includes 24 extra pages of over 35 brand new products offering great value and complete solutions to many applications, from safe isolation through voltage and magnetic field detection to PAT testing. New for this issue is the latest PDS and PDSX Series of proving units. Smaller, lighter and with new CALCHECK options for calibration checking test equipment, Martindale’s next generation PDSX proving units enable contractors and maintenance teams to safely

PECM Issue 44

Visit www.radics.tech for more information

RADICS - BASED I&C SOLUTIONS: ADDING VALUES FOR NPP SAFETY AND PROFITABILITY RadICS platform, approved by U.S. NRC on july 31.2019, provides state-of-the-art safety functions and possesses the following cost benefit features:

and simply prove the operation of voltage indicators, two pole testers and test lamps, plus common 18th Edition tester functions. Additional information on professional 18th Edition multifunction testers suitable for carrying out all the tests needed to certify domestic, commercial and industrial wiring installations according to the latest regulations is included. For further information or to obtain your free copy of the latest catalogue, please contact Martindale Electric on 01923 441717 or visit:

martindale-electric.co.uk

• High Reliability with Fault Tolerant Features that are based on IEC 61508 SIL 3 certification. • Simpler Maintenance and Repair due to the advanced diagnostic and monitoring features.

• Surveillance Testing Optimization due to extensive self-diagnostic testing features to reduce burdens on plant personnel. • Lower regulatory risks because it has the newest and most complete NRC-approved Topical Report. • Unique diversity strategy approved by NRC. No need for a Diverse Actuation System.

FASTENERS & FIXINGS

TR launches the EPW, a self-extruding high strength screw for thin sheet metal TR Fastenings (TR), global specialist in the engineering, manufacture and distribution of industrial fasteners, has designed, developed and patented a new fastening solution, the EPW thread-forming screw for thin sheet metal. The EPW screw is a self-extruding, high strength thread-form fastener which creates its own female thread in punched sheet metal, thereby dramatically reducing assembly times and costs. The screw works by being aligned to the pilot hole in the sheet metal, where it then forms the extruded collar, combining the forming of the thread and the creation of a strong extruded profile, before finally tightening and clamping into the metal. The key benefits of the EPW screw include: • Removable and re-usable strong screw joint • High stripping torque • High break loose and prevailing torque • Excellent vibration resistance • Combined thread forming and creation of strong extruded profile • Very high radial compression on screw shank

automotive, electronics, technology, energy, medical, telecoms and general industry sectors. Depending on size, the minimum economical manufacturing quantity is approx. 20,000 pieces. A fully interactive animation of the EPW and how it works can be viewed on the dedicated product page on the TR website: https://trfastenings.com/products/productinnovation/epw-screw

• Standard machine screws can be used in the thread created by the EPW screw • Can be used for electrical earth connections • Suitable for both manual and automated assembly The screw is designed to function best in thin sheet materials, typically Steel (0.4-1mm thick) and Aluminium (0.4-1.5mm thick). They are available in a variety of surface coatings from standard Zinc plating to Zinc Nickel and organic Zinc flake for higher corrosion resistance. The screw is suitable for use in a variety of applications for home appliances,

Karol Gregorczyk, TR VIC Sales and Development Director, comments: “We are committed to providing the highest possible service to our customers, both in terms of the quality products we manufacture and how we deliver and distribute those products. The development and launch of the new EPW screw is a culmination of the hard work and talent of our TR VIC Italy design team, as well as the significant investment TR has made in the factory. “The EPW screw will allow our customers to make significant improvements to their manufacturing processes, reducing production times, increasing efficiency and cost-effectiveness.”

www.trfastenings.com

jetpress.com

YOUR GLOBAL SOURCE FOR

FASTENERS & COMPONENTS

Experts in metal & plastic engineered fasteners • Extensive stocks available for rapid delivery! • Vast range of proven solutions to choose from • First class technical support & customer service • Bespoke design, development & manufacturing

Find your solution at jetpress.com sales@jetpress.com • 01623 551 800 50

PECM Issue 44

FLUID HANDLING

Dixon launches new Couplings & Accessories catalogue Dixon are excited to be launching their new full colour comprehensive Couplings and Accessories catalogue which will be available from January 2020. The company’s global reach includes a wide range of products for numerous industries, including petroleum exploration, refining, transportation, chemical processing, food & beverage, steel, fire protection, construction, mining and manufacturing. The new 400 page catalogue comprises of Dixon’s traditional hose fittings and couplings including Cam & Groove couplers, quick disconnects, valves and clamps; with the addition of some new products such as the Arctic Steel range of marine water strainers and accessories, ADS outalarm liquid level measuring probes, split flange swivel joints and a brand new loading arm. The newly enriched technical section serves as an excellent information reference point to procurement, engineering and maintenance teams alike. New innovations featured within the latest catalogue include evolutions in the design of traditional Cam & Groove fittings; the Vent-

Lock safety release Cam and Groove couplings permit the release of static pressure when disconnecting hose assemblies whilst the armless EZ Link Cam & Groove couplers feature a pushto-connect positive locking system and low-profile design perfect for space is restricted. At Dixon™ we are committed to providing ‘the right connection’ for your fluid handling applications. Our world-class customer service backed by over 100 years of manufacturing expertise and BSI ISO 9001 approval ensures you will receive accurate hose coupling and assembly recommendations for your application requirements. We are proud to design and manufacture fully tested and certified customised solutions to your fluid and air handling challenges. For additional information, products and technical support Dixon’s evolving website plays host to the full product range and keeps you in touch with all of the latest product developments, technical information and literature.

To request a copy of the new catalogue in hard copy contact Dixon’s customer Service Team on: 01772 323529 or email: sales@ dixoneurope.co.uk. Alternatively download your own PDF version direct from the website www.dixoneurope.co.uk

www.dixoneurope.co.uk

Dixon Hose & Coupling Products The Right Connection for your fluid transfer application Products:

• Hose assemblies • Fittings & accessories • Clamps • Quick release fittings • Blow-Out prevention couplings

• Valves • Loading arms • Liquid level sensing • Marine Accessories • Bespoke Fabrications

New Couplings & Accessories Catalogue Now Available

+44 (0)1772 323 529 • dixoneurope.co.uk •

• T E C H N I C A L E X P E RT I S E • U N C O M M O N E X C E L L E N C E • D E S I G N • C U S TO M E R S E RV I C E • I N N O VAT I O N • M A N U FA C T U R I N G • Q U A L I T Y • T E C H N I C A L E X P E RT I S E •

Issue 44 PECM

FLUID HANDLING

LABTEX We are now distributing the advanced metering pump range developed by the highly regarded and innovative Heidelberg based company, ProMinent. This exciting new specialism will further enhance our ability to offer solutions for an increasingly wide range of scale-up processes. The foundation of ProMinent’s global success story is high-quality products based on decades of engineering expertise, an in-depth understanding of applications and continuous innovation. The modular ProMinent range, integrated into carefully designed solutions, will enable customers in a wide range of industries to achieve maximum

... always an intelligent solution

safety and efficiency in their production processes. We share Prominent’s commitment to environmentally sound, sustainable and costeffective solutions for metering technology in the pharmaceutical, chemical and manufacturing sectors. Greg Smith, Managing Director at Labtex, said “ProMinent group’s position as a global market leader means a continuous commitment to excellent products and services and an obligation to think and act responsibly. It is a real privilege to be working with such a great company, with an innovative culture and commitment to excellence, very similar to ours. I look forward to the journey ahead.” Sales & Service 01484 600 200

COMPRESSION FITTINGS ORIGINAL RANGE Sizes 15 -100mm

QUICK RANGE Sizes 15 -50mm

LEAK SEALING CLAMP Sizes 10 -100mm

Malleable

info@labtex.co.uk

DZR Brass

Fluid Carrying

Flexibility Rotating Cylinders

Malleable

DZR Brass

For detailed information contact our sales department: C. A. Baldwin & Co. Ltd., Valan House, 146-154 Wells Way, Camberwell, London SE5 7SY Telephone: 020 7703 2138 Fax: 020 7701 8436 info@cabaldwin.com www.cabaldwin.com

PECM Quarter page, CABCO.indd 1

Articulated Torsion Pipework In Hoses

TAPPING CLAMP

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.

10/03/2016 10:38

Labtex supplies leading laboratory products including HUBER liquid temperature control systems, DIEHM glass reaction systems to 100 litres, PREMEX and AMAR high pressure autoclaves, POPE wiped film or short path evaporators and distillation systems, Nutsche filter dryers, BOLA labware in PTFE and other technical plastics, Vacuubrand vacuum pumps, ASECOS storage solutions for hazardous materials to BS EN 14470-1 and SICCO desiccators. We also work with LLG Germany, the 3rd largest lab supplies distributor in Europe and have a catalogue of 20,000 items from over 200 respected brands.

Tel: +44(0)1663

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

PECM Issue 44

E-mail:

735003

FLUID HANDLING

DECADES OF EXPERIENCE ROTAFLOW

Rotaflow Show Versatility with Hygienic Swivels Manufacture Although synonymous with heavy engineering such as oil and gas, Rotaflow are able to produce high quality swivel joint across a multitude of engineering sectors including, but not limited to nuclear, subsea and food and beverage. This article highlights one such project, where Rotaflow was approached by a leading global toothpaste manufacturer to overcome a problem on one of their production lines. The solution was multiple bespoke 4” 316L Stainless Steel swivels with PTFE main seals that were designed and manufactured in a timely fashion and shipped to USA, so there’s a good chance that Rotaflow have been in some way a part of the machinery that produced your toothpaste! Since this initial supply, Rotaflow have been contacted to supply further swivels of the same design. This repeat business is one the many ways an engineering company can measure success – in a field with extensive marketplace competition, repeat orders are an indication of quality.

The standards and operations that Rotaflow have to adhere to across various industry vary significantly. This multi-sector experience, coupled with the high-quality design and manufacturing Rotaflow deliver, are just a couple of reasons why they are trusted by multinationals to produce swivel joints that are integral to the effective working of a machine. Experience building swivel joints for a wide range of machines in a multitude of environments means the design and manufacturing teams at Rotaflow produce hard-wearing and longlasting joints that perform exactly as they should.

With this in mind, manufacturing businesses have to be able to trust their engineering partners implicitly. Engineers such as Rotaflow aren’t simply building parts, they’re adding value to a business. Every day that a machine functions effectively is another day where products can be manufactured and sold.

QUALITY ENGINEERING HELPS PREVENT PR DISASTERS In the cosmetics industry, the build quality of the swivel joint has to be perfect. Any leaks or issues will adversely affect the production of (in this case) the toothpaste. Disease and infection control risks are very real, so every care has to be taken to ensure the swivel joint is not a potential source of poor hygiene or infection. The potential for a PR disaster is huge and the ramifications for the business long-lasting, so there’s absolutely no room for error. Decades of experience ensure that an effective design and manufacturing process minimises hygiene risks and means that Rotaflow can be trusted to produce swivel joints for a wide variety of food and beverage, plus cosmetic industries. The reputation comes from decades of impeccable performance in these fields.

In manufacturing a break down could cost huge amounts of time and money, not to mention the delay on production, putting pressure on supply chains further down the line.

You don’t know the cost of poor quality parts until you suffer a break down – then the cost is more than just the price of a replacement, it’s days or weeks of lost production, lost time and lost market share.

With quality of design and manufacture at the forefront of everything that Rotaflow do, they continue to be trusted by many of the worlds’ leading businesses, producing consumer products that we all use every single day.

MULTI-INDUSTRY EXPERIENCE COMES TO THE FORE

In a field with extensive marketplace competition, repeat orders are an indication of quality.

For further information, please visit www.rotaflow.com Issue 44 PECM

GEARS, DRIVES & MOTORS

LOW FOOTPRINT DESIGN INMOCO

Compact frameless direct drive motors newly available from INMOCO UK A range of low profile direct drive motors with a compact and frameless design are now available from INMOCO in the UK. Celera Motion’s Omni™ Series direct drive motor range features high torque density in a compact design, suited to high performance, reliable and compact systems. Highly utilized in medical equipment requiring low profile precision rotary axis control, the Omni Series is designed for

PECM Issue 44

use with applications such as surgical robotic arms. With features including high acceleration, zero backlash and high mechanical stiffness, as well as low inertia and reduced settling time, the Omni Series provides optimal control accuracy of highly dynamic axes. Low cogging also delivers accurate and smooth motion. Combined with its low footprint design and minimal, compact cabling, Omni

Series motors are optimal for use within robotic axis joints. Based on a frameless construction, the direct drive motors are integrated within a robot joint to drive a high ratio gear set. Characterised by an increased torque potential as a result of a direct drive motor’s higher pole count, the Omni Series is able to provide high output from compact dimensions, beneficial for medical robot applications where footprint is at a premium.

Omni Series motors are optimal for use within robotic axis joints A key advantage of the Omni Series is Celera Motion’s customisation services, where windings, stator lengths, flanges and form factors can be tailored to meet application requirements. Celera Motion’s application engineering team works directly with OEMs to develop customised projects - rotary stages, electronics, controls and encoders. This also means that Celera Motion is equipped to develop a complete mechatronic sub-system. Following specification, Celera Motion provides analysis and modelling development prior to presentation of a prototype. The design is then selected, tested and validated for supply chain manufacture, before entering serial production. INMOCO’s UK engineering team provides initial consultation and facilitates the process with Celera Motion’s US-based applications designers. The Omni Series comprises the UTH high torque motor, UTL low to medium torque, and the UTO for applications which require an outside rotating configuration. The UTH high torque motor achieves a peak torque of 47.7 Nm, a continuous duty of 15.9 Nm, and a maximum speed of 5,000 rpm, with an outside stator diameter of 533 mm. The

motor enables low stator and rotor mass in a thermally efficient package, crucial for medical robot joint applications.

The large through hole construction provides compact, efficient routing of cables and optics.

The frameless direct drive kit construction provides simple integration to machinery.

The Omni Series is compatible with a wide range of drives and controllers.

For further information, please visit www.inmoco.co.uk Issue 44 PECM

GEARS, DRIVES & MOTORS

Productiv’s rapid response brings Cyclopic centreless wheel drive system to Advanced Engineering 2019 A novel centreless wheel drive system with multiple potential applications was showcased at the Advanced Engineering event in Birmingham 30-31 October, assisted by Coventry-based venture engineering specialist Productiv. Productiv has created a working prototype of Cyclopic’s revolutionary patented Wheal system, which combines drive, steering, braking and operating height adjustment in a single unit. The ground-breaking prototype was showcased at the entrance of the National Exhibition Centre and was well received by thousands of visitors the show attracted.

Each Wheal is fitted with its own separate drive system, giving complete 360-degree manoeuvrability – allowing for easy parallel parking, and so creating a ready solution for urban zone parking. In combination with road reading technology, the Wheal also delivers a unique vehicle levelling capability with no need for additional fluid power systems for levelling. In just 13 weeks, Productiv created a complete working aluminium prototype for the show, from the Cyclopic team’s own prototype, as well as optimising the electronics and control software.

Alan Rallings, Director of Cyclopic, commented: “Uniquely combining operating vehicle height, drive, steering and braking in a single unit, the Wheal has multiple applications, not least in electric vehicles and other mobility solutions. The Productiv team did an exceptional job in creating a completely operational model with full control system, in such a short period, once we knew we were given the opportunity to showcase the Wheal at the Advanced Engineering event. We anticipate strong interest from many sectors given the flexibility and capability of the Wheal.” Matt Hardwick of Productiv added: “This was a genuine challenge which showcases the unique capabilities of Productiv in having design, prototyping and systems engineering all under one roof. The Wheal is a highly novel design which is versatile enough to be used in both on-road applications, such as delivery vehicles, and other applications such as caravans/trailers.” Cyclopic Ltd would welcome any interest from any company or individual that would like to invest / sponsor the next stage of prototyping the Wheal

For more information on Productiv, visit www.productiv.co.uk. Further details on the Wheal can be found at www.cyclopic.co.uk.

PRECISION MOTION CONTROL As an advanced motion control technology distributor and manufacturer, Mclennan supplies and fully supports a wide range of precision motion control components from its distribution partners - and also has the capability to combine these products with its own design and build service for bespoke and turn-key motion sub-systems - for applications across industry and research.

Servo motors & drives Stepper motors & drives Synchronous AC motors Feedback devices Gearboxes Motion controllers & software Mechanical components Custom engineered motion systems

sales@mclennan.co.uk

PECM Issue 44

NOVEL MOTION CONTROL TECHNOLOGY

From Allied Motion Inc., KinetiMax™ HPD series outer rotor brushless motors deliver a high torque-to-weight ratio and excellent efficiency as a compact and frameless rotor/stator partset. Available in six frame sizes, the high power density motor offers a smooth, low cogging and continuously rated torque from 0.24 to 6.7 Nm with power output up to 1170 Watts.

JVL’s HLMT series hollow shaft rotary actuators take a novel approach to decentralised precision positioning tasks where a through aperture is required for routing services or maintaining a clear line of site. The design features an offset motor mounting in five model variants with clear through-hole diameters from 20 to 30 mm and rated torque output of 5 to 142 Nm. AMP’s TSM14POE series is a Power over Ethernet (PoE) enabled integrated miniature microstepping motor package that combines a PoE linked closed-loop digital drive, feedback encoder and an Ethernet-supported motion controller as a single-cable motion control solution based on AMP’s well proven StepSERVO™ technology.

Call us or visit our website for more information

www.mclennan.co.uk

+44 (0)1252 531444

GEARS, DRIVES & MOTORS

ABSOLUTELY DRIVEN NEW RANGE OF DRIVES AND VARIABLE SPEED GEARBOXES

For further information and sales contact Greg Smith on 01484 600200 or greg@labtex.co.uk

ATEX compliant to EC Directive 94/9/EC

Distributed in the UK by:

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 Molded-Oil 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 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 oil-impregnated 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

Cost effective fail safe power off brake for e-parking SG Transmission has developed a 40 mm diameter static holding brake (12Volt DC, 0.6Nm Torque) for a German automotive customer as a parking brake with fail safe power-off braking. The approach is a fully automated production process with single part feed, including an air gap pre-set during the manufacture process with reduced part count for simpler assembly.

The electrical connection is with integrated terminals. The spring applied brake has been optimised to: - reduce complexity of parts - reduce manual handling - reduce cost - cover high quantity needs of over 100,000 pieces per year Call us on 01388 770360 or visit

www.sgtransmission.com with your requirements.

Issue 44 PECM

HEALTH & SAFETY

NEXT GENERATION EXTRACTION EXTRACTABILITY

Pulling the trigger on welding fumes

Compliance with the Health and Safety at Work Act 1974 and the Control of Substances Hazardous to Health Regulations Act 2002 has led to a shift towards fume extraction at source and coincides with the emergence of a range of new, next generation fume extraction torches recently launched by Extractability, a division of Weldability Sif. The SifGun Evolution fume-extraction MIG Torch is more robust than competing models, with a sturdy metal swan neck available in a range of angles and an ergonomic, easy to manipulate, metal trigger.

The SifGun Evolution fume-extraction MIG Torch is more robust than competing models.

The brand-new fume extraction concept includes improved airflow and greater visibility of the weld pool, so while the gun may look very similar, the internals have been totally upgraded. The extraction is close to the weld pool, so the fumes coming from the welding process are extracted immediately. As a result, the user’s exposure to welding fumes is reduced by up to 95% and the SifGun Evolution, in particular, features an optimised nozzle, which balances pressures to prevent disruption of the shielding gases. This means you can use the same shielding gas flow rates as with a standard MIG torch. The welding torch is delivered ‘ready to use’. It only needs to be connected to a welding machine and extraction unit. The SifGun Evolution fume extraction torch is available in air-cooled and water-cooled versions. The extraction torch is available in 150amp, 250amp and 350amp air-cooled hand-held versions and a 500amp water-cooled version. All with 4 metre cable lengths as standard, 5 and 6 metre length cables available upon request. Conforming to EN60974-4.

Long established manufacturer of towing and recovery equipment, Boniface Engineering, recently enlisted Extractability to bring their workplace up to date with the recent health and safety regulations surrounding welding fume. Through the installation of SifVac mobile extraction units and Extractability’s new SifGun Evolution fume extraction MIG torches, Boniface Engineering have ensured the safety of their workforce. As the welders regularly weld high tensile steel, the extraction systems must be able to keep up with the high intensity usage and volumes of thick fume. Therefore, in addition to the 26 SifVacs and SifGun Evolution torches, the forward thinking and health conscious safety officer at the company also purchased eight ProtectoXtras ensuring a completely fume free environment in their workshop. For more information, visit www.weldability-sif.com, call the Extractability team at Weldability Sif on 0345 130 7757 or email sales@weldability-sif.com

For further information, please visit www.weldability-sif.com

PECM Issue 44

Hazardous fumes to clean air with the SifGun Evolution MIG welding torch with intergrated extraction

This kind of on-torch extraction offers up to 95% reduction of fumes and the SifGun in particular features an optimised nozzle, which balances pressures to prevent disruption of the shielding gases

For more information about the SifGun Evolution call us today to discuss

0845 862 2620

sales@extractability.eu www.extractability.co.uk

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www.weldability-sif.com

HEALTH & SAFETY

GRAPHITE RUPTURE DISC GRX REMBE

The first pure graphite rupture disc with FDA conformity This rupture disc has been developed for processes with corrosive media, low pressure and temperatures of between -180 °C and +500 °C under oxidizing and reducing atmosphere, +1,500 °C under inert conditions. The GRX is applicable for highest temperatures by using a unique chemical vapour deposition method (PyC coating). By this PyC coating, the rupture disc holds significantly longer at very high temperatures, while remaining permanently leak-tight in comparison to other coatings and impregnations. For example: Rupture discs with a coating made of synthetic resin would no longer be able to offer this leak-tightness at temperatures far above 200 °C. With a maximum working pressure of 80 % of the minimum burst pressure, the GRX is usable for rupture pressures from 20 mbar g. Nominal pipe size is available from 1/2” to 24”. Optionally, a vacuum support can be integrated, which is installed without adhesive components that would meld at very high temperatures. The GRX is also available with a burst indicator, upon request. The signaling device will inform you about the rupture disc response. The installation occurs directly between the flanges.

Some facts about GRX • Highest temperature resistance (applicable from -180 °C up to +500 °C)

The GRX is applicable for highest temperatures by using a unique chemical vapour deposition method.

• Maximum leak-tightness due to an innovative coating • Extra long service life • Highest corrosion resistance and can therefore also be used with very aggressive process media • Also available in vacuum-resistant design • Special application coped by the new coating technology: liquid sodium process at 490°C

ABOUT REMBE - THE REMBE ALLIANCE INTRODUCES ITSELF REMBE is mostly associated with REMBE GmbH Safety and Control - the specialists for explosion safety and pressure relief worldwide. The company offers customers cross-industry safety concepts for systems and equipment. All products are manufactured in Germany and meet

the demands of national and international regulations. The customers who purchase REMBE products are among the market leaders of various industries, including the food, chemical, pharmaceutical oil and gas as well as wood industries. The technical engineering expertise is based on more than 45 years of application and project experience. As an independent, owner-managed family company, REMBE combines expertise with highest degree of quality, and is also actively engaged in various professional bodies worldwide. Short alignment routes enable the achievement of quick responses and customer-specific solutions for any kind of application: from standard products, all the way up to hightech special designs. In addition to REMBE GmbH Safety + Control (www.rembe.de) with approx. 250 employees worldwide, headquarter in Brilon (Germany) and numerous subsidiaries worldwide (Italy, Finland, Brazil, USA, China, Dubai, Singapore, South Africa, Japan), four other companies are also engaged under the REMBE family brand: REMBE Research & Technology Center GmbH (http://www.rembe-rtc.de/index-en.html) REMBE Advanced Services + Solutions GmbH (www.rembe-services.com) REMBE Kersting GmbH (https://rembekersting.de/en/) REMBE FibreForce GmbH (www.argusline.de)

For further information, please visit www.rembe.de

PECM Issue 44

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

Made in Germany

Your Specialist for

PRESSURE RELIEF and

EXPLOSION SAFETY

Consulting. Engineering. Products. Service.

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

HEALTH & SAFETY

HEALTH & SAFETY AT WORK INSTITUTION OF OCCUPATIONAL SAFETY & HEALTH

Improving productivity, efficiency and reputation

Could your business benefit from greater productivity, increased efficiency, reduced costs, enhanced reputation and a safer workplace?

how safety and health can positively impact the whole business.

If so, now is the time to invest in IOSH’s Managing Safely, the market-leading safety and health course for businesses of all sizes. It has been delivered worldwide for over 25 years by a huge network of training providers. It is tried, tested and trusted.

• It’s contextualised. The content of the course and the scenarios that are explored will directly reflect your sector, workplace and even factors relating to your geography or business demographic. So, it’s easy to put everything they’ve learned into practice. • It’s world-class. IOSH is the Chartered body for safety and health professionals and the quality of the training and the content of the course reflects that.

And there’s more: • It’s thorough but flexible. With the consequences of safety and health failure potentially fatal, you cannot rush training. Our three-day course takes the right amount of time to get learners up to speed. It’s available face-to-face or via e-learning to suit your business needs.

Who should attend? This course is for anyone who manages or supervises people, in any industry sector or environment. They’ll learn to:

• It’s business focused. IOSH works with business leaders in the development of flexible courses to ensure they deliver the insights and efficiencies you need to gain a competitive edge.

• assess risks • control risks • understand responsibilities • understand hazards • investigate incidents • measure performance

• It’s unique. Managing Safely combines practical step-by-step guidance with an engaging and inspirational approach that will make your managers think afresh about

They’ll learn about the ‘why’ as well as the ‘how’. Why should we look out for our colleagues? Why should we continue to innovate? How can I make a difference?

Successful delegates are awarded an internationally-recognised IOSH Managing Safely certificate. It’s a vital achievement and demonstrates that they have the knowledge to be more efficient, productive and safe in the workplace – to the benefit of all.

Why IOSH? Here’s why: • Track record. Managing Safely from IOSH is the market leader in safety and health and we’ve trained 172,000 delegates on 23,000 training courses in 76 countries. • Vision. We can help you prepare for tomorrow. The world of work is transforming at a rapid pace and we want to ensure that you are ready to embrace those changes and profit from them rather than being left behind. • Status. We are a global organisation with 47,000 members in 130 countries, many of whom are business owners themselves, and we represent their views to governments and regulatory bodies to make sure business can continue to drive the positive change we all need and deserve.

For further information, please visit www.iosh.com

PECM Issue 44

HEALTH & SAFETY

FieldComm Group Validates United Electric Controls Vanguard WirelessHART Gas Detector

Metal and modular’s auto brake range sets the standard for materials handling safety

United Electric Controls, a leading producer of safety, alarm and shutdown technology, has announced that its Vanguard WirelessHART Gas Detector is now HART Registered. This registration ensures that all WirelessHART users will be able to add Vanguard device drivers the next time they update their device descriptor (DD) libraries. It also assures users that they can add Vanguard systems to existing WirelessHART networks, seamlessly and securely. The HART communication protocol is the largest digital communications technology deployed in the process industries with more than 40 million field instruments supporting HART technology installed worldwide. The FieldComm Group owns the HART specifications and provides specification development and training, as well as device registration.

Metal and Modular, the specialist in innovative safety, security and materials handling equipment, has achieved BS EN 1757-3:2002 for its Auto-Brake Trolley range. Weighing just 140kg, the Auto-Brake Load Trolley has a capacity of up to 2000kg, making it ideal for most transportation requirements. Meanwhile, the Auto-Brake Panel Trolley has an integral high-load ratchet strap with a load capacity of 1000kg and is suitable for transporting a wide range of materials in an upright position. All the trolleys are fitted with all-terrain wheels and castors from world leading castor manufacturer, Blickle. Metal and Modular’s Design Director, Michael Brown commented: Our Auto-Brake range was designed to improve health and safety and reduce risk and we’re delighted to have received BS EN 1757-3:2002 accreditation.”

www.ueonline.com

www.metalandmodular.co.uk

A New Benchmark In Safety & Comfort V12 Footwear creates safety footwear that is as tough as the environments they face. There footwear is designed with three simple but important principles in mind: comfort, safety and durability. Innovations In Footwear Our award winning sports range of safety trainers and hikers are super lightweight, highly comfortable and available in both men’s and women’s fit that range from UK sizes 2 – 13. The range was developed to offer a lightweight alternative, prevent slips and falls, as well as address the lack of properly fitted safety footwear for women. The range took 18 months to develop and has helped increase the current options for correctly fitted women’s PPE, which we hope will also help encourage more women pursue careers in industries that are mainly male dominated.

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Issue 44 PECM

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

PECM Issue 44

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

UNBEATABLE QUALITY COBORN

Coborn – The Diamond Grinding Partner of the Future Coborn has a unique, global position supplying specialised, individually built, high-precision equipment to the polycrystalline diamond industry, single crystal diamond and the gemstone industries. Customer care is paramount to Coborn’s company ethos and through global collaboration and partnerships, the company strives to provide its customers with unbeatable quality, reliability and economy. “Coborn is the only global company that is totally focused on grinding and polishing all types of diamonds. Coborn is a vital part of the diamond industry’s value chain,” says Steve Westlake, Managing Director of Coborn.

COBORN NAMED IN THE TOP 10 PRECISION MANUFACTURING TECH SOLUTION PROVIDERS FOR 2020 Coborn has been recognised on several occasions for its engineering excellence, most recently named in the Top 10 Precision Manufacturing Tech Solution Providers for 2020 due to be published this month, by US-based “Manufacturing Technology Insights”. The annual listing is comprised of ten companies that are at the forefront of providing Precision Manufacturing Tech solutions and transforming businesses.

PG4 ENHANCEMENTS AT GRINDTEC 2020 Coborn will be showcasing the enhancements to its PG4 CNC Planetary Grinding Machine for single crystal diamond (SCD) tool production at this

INTRODUCING THE FG1C

Coborn is the only global company that is totally focused on grinding and polishing all types of diamonds

At GrindTec, Coborn will also introduce the FG1C, which is its state-of-the-art Form Grinding Machine for SCD two-point and four-point tools. The FG1C features; • High-stability granite base. • Fast traverse motion for polishing. • Air bearings on the pivot and main spindle for smooth polishing and lowwaviness tools. • Dual position camera.

year’s GrindTec Exhibition in Augsburg, Germany from 18 to 21 March 2020. These improvements include; • Acoustic analysis of the polishing process. • High-resolution camera for improved imaging. • Closed loop nano-stop.

PECM Issue 44

Robert Bullman, Sales Manager at Coborn, is looking forward to presenting the company’s innovations at GrindTec. The Screwdriver Station for Coborn’s flagship RG9AR (Reciprocating Robot-loading Grinding machine for PCD tools) and the new Coborn Care Service Packages will also be highlighted at the exhibition.

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GRINDTEC 2020

Coborn will also be demonstrating the new RG9A Smart Machine. This new development is in partnership with relayr and the innovative, live dashboard for Predictive Maintenance, Performance Optimisation and Business Analytics will be presented.

Coborn Engineering located in Hall 3, Stand 3025

Coborn aspires to be an innovative partner for its customers by offering value through a range of bespoke products, services and financial solutions which specifically meet its customers’ needs and address the ever increasing demands of the global diamond industry

Augsburg, Germany 18 to 21 March, 2020

FINANCIAL OPTIONS At GrindTec Coborn will be introducing the different financial models that the company can now offer; CAPEX, OPEX and EaaS alongside the new Coborn Care options.

CREATING PARTNERSHIPS Coborn aspires to be an innovative partner for its customers by offering value through a range of bespoke products, services and financial solutions which specifically meet its customers’ needs and address the ever increasing demands of the global diamond industry. “By working in partnership with business leaders, Coborn strives to promote the use of diamond in any application by adding value to all involved in the global diamond industry value chain,” explains Steve Westlake.

For further information, please visit www.coborn.com Issue 44 PECM

MEASUREMENT & MONITORING

STATE-OF-THE-ART KOBOLD

The world’s smallest dual-tube Coriolis Mass Flow Meter: High precision measurements within 150 mm Due to the weight influence of sensor coils, for the measurement of very small flowrates it is common practice to use single tube Coriolis flow meters. The sensor coils of dual-tube Coriolis sensors are mounted onto one of the two measuring tubes, thus having, by very small tube diameters, a significant weight influence on the tube on which they are mounted. Therefore, the influence of the sensor coils on the measurement results increases by decreasing tube diameter. For this reason single tubes are often favoured for the measurement of very small flow‑rates, where the coils are mounted to the chassis and not on the tube. However, with the use of just one measuring tube the influence of external interferences increases dramatically. To reduce this sensitivity and at the same time delivering accurate measurements at very small flow rates, Heinrichs Messtechnik has developed the dual-tube Coriolis principle to a new level. In this new state-of-the-art technologie, the sensor coils are no longer mounted onto the tubes, but rather between them, thus freeing the measuring tubes from the influence of the coils weight allowing for extremly small tube diameters in dual-tube design. The result is the world’s smallest dualtube Coriolis Mass flow-meter: The high Performance Coriolis (HPC). With an installation length of just 150 mm it is now possible to achieve high accuracy measurements with deviations of just ± 0.1 percent. Furthermore, the sensor shows insensitivity to temperatures of up to 180 °C, to pressures of up to 600 bar as well as to strong vibrations. “Market observations have revealed an open gap in the measurement of small flow rates”, explains Frank Schramm, the managing director of Heinrichs Messtechnik GmbH. The current problem is that the state-of-the-art stipulates the use of dual-tube technology, where the magnets are mounted to one tube, the exciter and sensor coils to the other. However, for very small flow rates this principal has a decisive limit. For example, where extremely small

PECM Issue 44

Heinrichs Messtechnik GmbH developed the smallest dual-tubed-Coriolis-MassFlowmeter in the world: The High Performance Coriolis (HPC). With an installation length of just 150 mm high accuracy measurements are achieved with deviations of just ± 0.1 percent flow rates demands a tube diameter of just 1 mm, the vibrating behavior of the coils weight can influence the measurement results significantly. “Therefore it is common practice to use one tube systems for these applications, in which the coils are mounted to the chassis of the sensor. This system has the decisive disadvantage in that the second tube, which also serves as a measurement reference, is omitted, requiring that the sensor coils be mounted on to the chassis of the enclosure making the sensor more susceptible to vibrations and other disturbances. For this reason, Heinrichs Messtechnik GmbH has set as its objective, the development of a high precision, shock resistant Coriolis Mass Flow Meter.

Emerged is the High Precision Coriolis – short HPC – with its installation length of just 150 mm the smallest Coriolis mass flow meter in dual-tube design.

REDUCING DISTURBANCE INFLUENCES BY POSITIONING THE SENSOR COILS BETWEEN THE MEASURING TUBES “Due to the sensitivity single tube Coriolis sensors, a costly mechanical decoupling is often required, rendering them inappropriate for many applications. Our quest was therefore to find a means of unifying a dual tube design with very small diameter tubes”, explained Schramm. Since the fundamental problem lies in the weight of the coils, which when compared

The whole development phase took a mere 1.5 years. To achieve this short development time Heinrichs Messtechnik utilized the latest simulation technology.

Instead of mounting the coils onto the tubes, the manufacturer chose to mount them onto a PCB situated between the measuring tubes. By simultaneously doubling the number of pick-up coils from two to four, the resolution is increased significantly. with tube diameters of 1.5 mm or less present a significant weight, Heinrichs Messtechnik adopted the following solution: The conventional approach of mounting the coils onto the tubes was abandoned in favour their mounting on a printed circuit board mounted between the tubes. This method also enables the use of four sensor coils instead of two, as is usually the case with dual-tube Coriolis, providing a higher resolution. On the measuring tubes themselves only very light magnets are mounted, which, with a weight of only 0.08g, have little to no influence on the vibrating behavior of the tubes. Instead of conventional brazing, the magnet holders are mounted onto the tubes using a special laser-welding technology. Utilizing this method, Heinrichs Messtechnik aims at keeping the production costs of the sensor to an absolute minimum, it not only allows for a stress‑free connection, but also eliminates the time-consuming and elaborate process of brazing in a vacuum oven.

INSENSITIVE TO EXTERNAL INFLUENCES Using the dual-tube design, the new HPC displays extreme insensitivity towards external influences, allowing for precise measurements with a maximum deviation of ± 0.1 Percent of the mean value and a Zero-point stability between 0.001 and 0.005, making a mechanical decoupling in most cases superfluous. Owing to the

measuring tubes high working frequency of over 200 Hz, the coupling of installation vibrations or similar oscillations into the measuring system is prevented and so with avoiding fault signals. A further advantage in mounting the sensor coils on a motionless PCB is the elimination of open wiring within the sensor, as is the case of standard commercially available devices. This wiring often presents a vulnerable weak point, since the wire and its point of connection must vibration continuously with the frequency of the measuring tubes. With the exception of the laser welded measuring tubes, the HPC consists essentially of a solid drilled and tapped stainless steel block. Furthermore, the HPC has been stripped of a splitter at the inflow of the tubes, instead possessing a reservoir – in which the process pressure distributes the fluid exact into the measuring tubes, hence preventing flow disturbances generally caused by splitters. This technique has the timesaving advantage of one less component to weld as well as one less potential material stress source. The result is an extremely robust device capable of withstanding temperatures and pressures of up to 180 °C and 600 bar respectively. “In principle, the device may also be ordered with Hastelloy tubes and other alloys”, added Schramm.

VARIABLE ASSEMBLY CONCEPT For flexible installations, different constructive variations of the HPC are available: Besides the traditional Inline

Version, which can be inserted directly into the process line, there are three further models available, which are suitable for either wall mounting, by means of wall brackets, or may simply be placed on a table. “For our Table model there are two available options: either with the measuring pipes pointing downwards below the supply line or pointing upwards above the supply line. For the measurement of gas, upward pointing tubes are recommended to prevent any issues with fluid collecting in the tubes. The same also goes visa versa for the measurement of fluids”, Schramm remarks. Collectively, the devices are available in three measuring ranges: 0–20, 0–50 and 0–160 kg/h. On request other adaptations are also available, for example, customer-specific enclosures, connectors or interfaces. In particular for the chemical and semiconductor industry, fullywelded stainless steel enclosures are also available.

RAPID DEVELOPMENT SUCCESS WITH HIGH-END SIMULATION The whole development phase took a mere 1.5 years. To achieve this short development time, Heinrichs Messtechnik utilized a stateof-the-art simulation technology. “By these means the required number of prototypes was drastically reduced, reducing so with development costs significantly”, Schramm says contentedly. Furthermore, with the aid of the simulation technology customer-specific requirements can be captured and individual solutions presented in the shortest of time. The HPC was presented for the first time on the Hannover trade fair from 23rd to the 27th of April, simultaneously being the official launch of sales. Furthermore, ATEX and IECEx approvals are also planned as well as a patent registration of the technology. Parallel to the launch of sales, Heinrichs Messtechnik is also working on a new miniaturized transmitter with flexible interfaces, specially designed for compatibility with the HPC.

For further information, please visit www.kobold.com Issue 44 PECM

MEASUREMENT & MONITORING

Hydraulic Oil Flowmeter Calibration Low cost hydraulic and water flowmeter calibrations undertaken in primary standard facility. Oil and Hydraulic flowmeters covering 0.1 to 700 l/min across varying viscosities using our standard calibration procedures can cover the calibration of turbines, gear, paddle, positive displacement, helical, variable area, ultrasonic and coriolis flowmeters. A range of oils are available such as, hydraulic oil, ISO 4113, IPA, JET-A1, AVGAS and dielectric fluids. Having a complete range

T860 EN 180x132.indd 1

PECM Issue 44

of transfer standard flowmeters backed up with gravimetric primary standard the Youngs’ laboratory is one the UK’s most versatile facilities offering quick, reliable and cost-effective flow meter calibration. Water flowmeter calibrations up to 4000 l/min also available. Email: ay@youngcalibration. co.uk Tel: 01273 455572 Web: www.youngcalibration. co.uk/calibration/oil-flowcalibration

Bolt Thermocouple with 2m of Glass Fibre Stainless Steel Over Braided Cable Bolt sensors are generally screwed into the surface which normally increases the speed of response and sensitivity of the measurement. Suitable for use up to +250°C. These are available in type K or J with the following bolt thread/pitch sizes:

M8 x 1mm / M10 x 1mm / M12 x 1mm. Bolt lengths available are 13 or 25mm. All bolts have grounded junctions and are available to buy direct from www.labfacility.com

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MEASUREMENT & MONITORING

MEASUREOF PERFECTION BENTLEY

Bentley’s in-house metrology team under the microscope Deep in the heart of the Bentley factory in Crewe is a large, airy and air-conditioned workshop that visitors, even out of a government lockdown, will never see. It’s packed with the kind of precision instruments you’d expect to find in a space agency facility or university science lab. It’s here that Head of Metrology Michael Stockdale and his 25colleagues measure every part of a Bentley to the highest standards of precision. Metrology is the science of measurement, and it’s fundamental to the quality, performance and longevity of every Bentley that each component is made to consistently precise dimensions. Stockdale and his colleagues can measure every part of each model Bentley makes, from the smallest washer to body panels and interior trim, and ensure that no component strays from the close tolerances prescribed for it. “We have the tools to measure everything from the graining of leather to the surface of a cylinder bore, down to fractions of a micron” explains Stockdale. Having measured components individually, they are measured again as sub-assemblies and once more as part of the finished vehicle. Thus, the Metrology team plays a vital role in ensuring that near perfection is repeatable.

THE PRECISE CHOREOGRAPHY OF THE FLYING B Measuring and enforcing the highest standards of dimensional accuracy is especially important for a vehicle, where multiple components become subassemblies. To take just one example, the retractable Flying B mascot that adorns the bonnet of the Flying Spur, whichsmoothly deploys and retracts only because each component in its complex control assembly is made to close and consistent dimensions. It is illuminated and linked to the keyless entry system as the driver approaches the car, yet it must also retract automatically in the event of an accident. To achieve this precise choreography and to ensure that it sits perfectly centred within its plinth, elements of theFlying Bsystemhave tolerancesas low as 0.15millimetres.

PECM Issue 44

TOLERANCES FINER THAN A SINGLE RED BLOOD CELL Laymen use ‘a hair’s breadth’ as a description of the tiniest imaginable measure, but such a term would be too imprecise for Bentley’s Metrology team. As Stockdale points out, a human hair can be anything from seventeen microns toover one hundred and fifty microns thick. In contrast, there are instruments within Metrology that can measure down to 0.5microns. A micron is one millionth of a metre, and a human red blood cell is 5 microns in diameter. Not every component of a Bentley needs to be measured to tolerances of less than a micron, but there are some. As an example, Stockdale cites the crankshaft at the heart of Bentley’s 6.0-litre W12 engine, the most advanced 12-cylinder engine in the worldwhich powers the new Flying Spur. Spinning at up to 6,000 rpm, the crankshaft converts the immense downward forces generated by the pistons into rotary movement that powers the wheels. Though invisible to the naked eye, each of the twelve machined bearing journal surfacesin which the crankshaft sitsfeatures minute grooves that hold a microscopic film of oil.

By using a high accuracy Perthometer (a tool designed to measure surface finishes) the Metrology team can verify that those minute grooves are within their definedtolerances, in turn ensuring that each W12 engine produces both the immense power and lifelong durability its owners would expect.

A FLYING SPUR CARVED FROM SOLID ALUMINIUM As well as measuring individual surfaces and components to microscopic levels ofaccuracy, the Metrology team measures entire vehicles. The department is home to what are termed ‘cubing’ reference vehicles; an entire vehicle body machined out of solid aluminium that actsas a templateagainst which panels and interior components are measured.The cubing Flying Spuris the ideal Flying Spur against which all others are measured, every millimetre of its body scanned using high accuracy digital cameras to create a complete and precise map of the car. “Imagine an issue at the prototype stage where the panel gap between grille and bonnet is a millimetre too large, “explains Stockdale. “Does the fault lie with the grille, or the bonnet? The cubing reference vehicle provides the answer, because it’s made to the precise dimensions of the CAD data.”

OPTICAL LASER SCANNING Different materials call for different measuring techniques. The unique threedimensional diamond quilted leather inserts in the doors and rear quarter panels of the Flying Spur cannot be measured by a tactile device becauseto touch the surface would distort the reading. Instead, an optical laser scanner is used to chart and check the precise contours of each diamond. The cabin of the Flying Spur posed a fresh challenge, because of the range of functionality built in for every seat. The rear seats alone offer 14-way adjustment, five massaging modes and the two outer seats are both heated and ventilated. Everything from the seamless fit of the one-piece

Measuring and enforcing the highest standards of dimensional accuracy is especially important for a vehicle, where multiple components become subassemblies.

headlining, wood trim and sumptuous leather upholstery depends upon achieving close tolerances between a variety of different materials, from wood and metal to fabric and leather.

PRECISE TEMPERATURE CONTROL Materials expand when warm and shrink when cold, so it’s essential that measurements are taken at a consistent reference temperature. Within the Metrology area, air conditioning keeps the area at a steady 20°C. But for components that demand the highest levels of precision, there’s an inner sanctum called the High Accuracy Measurement area, where a dedicated climate control system ensures that the temperature never deviates by more than half a degree Celsius. Within this area are three gigantic granite blocks to which components can be clamped for the ultimate in stability, essential for an accurate

reading. But first, the components to be measured have to soak in the atmosphere –literally. “A large component like an engine block might have to soak at a consistent temperature for up to a week, so we can be sure that it’s 20°C all the way to the core” explains Stockdale.

AN UNSEEN CONTRIBUTION Visitors to Crewe will never visit the Metrology department, nor will the owner of a Flying Spur, Continental GT or Bentayga ever be able to point to the handiwork of its team in their vehicles. Yet the way a Bentley looks, performs and lasts owes everything to the accuracy with which each of its components measures up to the ideal. And for that, the Metrology team are the hidden heroes, custodians of the continuing quest for dimensional perfection. Every Bentley that leaves the factory is a tribute to their unseen contribution.

For further information, please visit www.bentleymotors.com Issue 44 PECM

MEASUREMENT & MONITORING

FROM SIMPLE TO COMPLEX VEGA

New sensors and switches portfolio for food, beverage and automation With the launch of its new low cost high specification VEGABAR pressure switch/ sensor and VEGAPOINT level switches, it enables VEGA to help customers in even more areas in the food and beverage production processes. This brand new compact instrument series is perfectly tailored to the standard applications that still require high quality and strict hygiene. The new level and pressure devices have a universal adapter system of process fittings that provide the flexibility needed to keep installation and spares inventory costs low. A unique ultra-bright, eyecatching, 360° illuminated status display ring ensures visibility, safety and process reliability. Its status colours can be customselected easily seen from any direction – even in bright daylight. Some of the new pressure switch/sensors feature displays and keypads with dual easy-read text and VDMA menu, ensuring the right set up every time and easy understanding of pressure measurement or switch status. Another prominent feature of the instruments is their communication capabilities. They feature Bluetooth wireless, which offers another option for safe remote and easy set up or function check of devices without the need for a PC, cables or connectors. Just download the free, simple (and award-winning) VEGATOOLS App. Also available is the IOLink protocol, this ensures compatibility, intelligent data transfer and simple, fast system integration.

The new VEGABAR compact pressure switch/sensors and VEGAPOINT compact capacitive level switches. They feature a super-bright 360° status display, selected from 256 different colours, easily seen from any direction.

A unique ultra-bright, eyecatching, 360° illuminated status display ring ensures visibility, safety and process reliability. More information available at www.vega.com

PECM Issue 44

RADAR IS THE BETTER

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The new design and easier to use interface plus the option to view data from all networked TR-

7wb/nw loggers makes handling easy and effective. They are ideally suited to the supervision of climatic conditions in public buildings and warehousing, storage of sensitive products and the safeguarding of laboratories, server rooms or refrigerators. T&D Corporation

Pyrometers. IR Cameras. Accessories. Software.We measure temperature non-contact from –50 °C to +3000 °C. Visit: www.optris.co.uk

T&D’s Bluetooth featured WiFi loggers of the TR-7wb series are ideal for temperature and humidity monitoring, and designed for those who require a broad range of measurement tasks. No computer is needed in order to use the TR-7wb series on site, as it can be set up via Bluetooth and with the T&D Thermo App on mobile devices, both iOS and Android.

Thereʼs no two ways about it: our IR sensors of the optris CT series can be used in short and long wavelength measure areas.

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MEASUREMENT & MONITORING

when temperature matters

Issue 43 PECM

OPT-EN-03-Unusual-2019_88x267-ProcessEngineeringControlManufactoring_GBP.indd 109.04.20 109.04.20 10:53

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

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PROCENTEC provides critical companies with free diagnostic software for industrial networks In a time where we all need to stand together to battle the debilitating corona virus, Procentec wants to help those who work around the clock to maintain our way of living. For the duration of this corona crisis, Pieter Barendrecht CEO of Procentec, offers companies that are currently hard at work creating a vaccine or antidote, or companies that are critical to keeping everything running, our newest Diagnostic solution - Osiris as a Software - for free. For us as a company it is relatively easy to work from home. But for the people who work in the vital industries within our nation, continent or for that matter the world, it is of the utmost importance to keep all networks running with fewer people then normal and more pressure. Most likely because of colleagues that have fallen ill. Our solution will help them to get the best remote overview of their networks inside their plants. Notifying in advance if something will break down, preventing unwanted stops of the production process. Please share and forward this message to all who it may seem relevant, so that we as just a small company may contribute to beating this crisis!! For those who are interested, please send an email to Pieter Barendrecht at pieter@procentec.com. Our team will contact you as soon as possible to provide you with our solution.

www.procentec.com

PECM Issue 44

vendor managed services

With our VMS solutions, great things come in threes Time and cost savings Control of your industrial comsumables Improved stores/stock management

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NEWS & EVENTS

High quality surface treatments from Curtiss-Wright surface technologies Curtiss-Wright Surface Technologies (CWST) provides high quality surface treatments which will improve the life and performance of critical components through its global network of over 70 operating divisions and specialist onsite teams. Our surface treatments have been successfully used by OEM’s in major industries such as aerospace, automotive, oil & gas and power generation for many years. We are only too aware of the logistical challenges and costs faced by our customers and so we can offer a “One Stop Shop” solution providing a wide range of surface treatments including Controlled Shot and Laser Shock Peening, bespoke and trade Coating Applications, Thermal Spray Coatings and Parylene Coatings for metal, alloy, plastic and electronic components as well as Analytical Services. We offer our customers a single source solution and point of contact for all their surface treatments, supporting their requirements through our global network of over 70 worldwide facilities and on-site field teams, improving and reducing turnaround times and costs. We are specialists in protecting components from common failures and reducing maintenance costs for key industries such as aerospace, oil and gas, automotive, medical and general industrial markets. Building on the unique heritage of Glenn Curtiss and the Wright brothers, CurtissWright Surface Technologies has a long tradition of providing innovative solutions and building solid and trusted customer relationships. Full quality and customer approvals including NADCAP, ISO 9001:2008 and AS9100 Rev C.

To find out more please visit www.cwst.co.uk.

Denso 003 press release March 2020 Steelcoat™ System Replaces Failing Pipebridge Protection Winn & Coales (Denso) Ltd’s Steelcoat 100/400™ system was recently employed to protect a pipebridge in Stokeon-Trent where the previous bitumen-based coating was beginning to show signs of failure.

Lorien appoints David Mallinson as UK Managing Director Lorien Engineering Solutions has promoted David Mallinson to UK Managing Director. He succeeds Steve Slater, who has taken on an international group role with parent company GP Strategies, which includes responsibility for all of Lorien’s international operations including the UK, Poland and South Africa. Lorien, which specialises in capital projects for food, brewing, drinks, life sciences,

PECM Issue 44

safety compliance and sustainability, has enjoyed a successful year to date with more than 15 new client wins. Mallinson, who was previously Engineering Director, has been with Lorien for more than 11 years and has a track record of delivering successful projects and building strong client relationships. www.lorienengineering.com/ en-gb

Due to the fees involved in erecting scaffolding and covers to protect the pipebridge during its repair, a cost-effective, easy-to-apply solution was required. CPC Civils selected the Steelcoat 100/400 system for the protection of 40 metres of 680 mm diameter pipe and 16 flanged joints, with Frazer Civils of Wednesbury supplying the material for the project. The entire area to be protected was wire brushed to remove loose pieces of the old coating before the new Steelcoat system was applied. Winn & Coales provided on-site training and returned

to site twice to check on the projects progress, with three operatives completing the entire application in just one week. Winn & Coales (Denso) Ltd are leading suppliers of corrosion prevention and sealing systems. Their Steelcoat 100/400 system provides an effective, long-term solution for corrosion prevention on exposed steelwork and pipework, particularly in areas faced with damp working conditions.

www.denso.net

PROCESS TECHNOLOGIES

Surface Technologies CWST have developed a Post Additive Manufacturing process to: l Improve surface finish and surface characterisation l Improve component cleanliness l Remove support structures l Remove sintered surface l Surface compression and densification l Management of residual stresses l Improve fatigue life

www.cwst.co.uk | eurosales@cwst.com | 01635 279621 Issue 44 PECM

PROCESS TECHNOLOGIES

THE PERFECT BLEND BROANMAIN PLASTICS

Well colour me pink! That’s how Masterbatch works If you’re looking to achieve a splash of colour, texture or even anti-bacterial into your plastic components, chances are your moulder is using masterbatch in the mix. With the global masterbatch market set to increase in value to USD 15 billion by 2026i, Thomas Catinat, Operations Manager at Broanmain Plastics explains why masterbatch is so popular and how as a moulder they go about achieving the perfect blend to ensure consistency batchto-batch. Masterbatch is commonly divided into five segments - black, white, colour, additive and fillers. Each formulation offers different functions that when distributed evenly through the polymer mix give it its unique plastic fingerprint. Colour masterbatch is a highly concentrated pigment. Supplied in pellet form rather than powder or liquid, it is blended into plastics to create a range of end-use applications, for example food and beverage packaging, appliances, automotive and pharmaceutical packaging. Additive masterbatch offers improved performance of plastic products, for instance illumination, UV resistance, anti-oxidants, antimicrobials or anti-static. Filler masterbatch is used to create better properties such as stiffness or a lighter weight polymer. Chalk, for example, is used to bulk out the plastic. Specific fillers can also be added to make a component fire retardant. Black and white masterbatch are typically used in building and construction, automotive, consumer goods and domestic appliances. Achieving a special effect, such as chrome, wood grain, stone, marbling and even sparkle is also possible. These types of compounds are often used to boost consumer appeal and mimic heavier materials.

READY MIXED OR CREATE ON DEMAND? Compounded mixes might be purchased in bulk when creating larger quantities of

PECM Issue 44

Masterbatch colour is a highly concentrated pigment which moulders blend with base polymer resins and additives to achieve a special formulation (iStock.com/Irina Vodneva) components. But for many end customers, masterbatch is often the most cost effective way for moulders to create the perfect recipe time and again. Blended in-house, moulders use volumetric dosing units to automatically mix the material ready for processing. Using granular masterbatch can be a lot less messy than powders or liquid, with fewer health and safety risks from dust or spillages.

customer’s requirement for pigment colour, as well as special properties like heat stability.

JET BLACKS AND BRIGHT WHITES

The ability to maintain a low stock holding and call up a specific blend when required from an external supplier can be more economical, helping to keep production costs down on short runs.

For a number of components, such as electronics, producing the deepest blacks and the purest whites can be more challenging that some think. It requires a high pigmentation concentration, especially to make contemporary products such as mobile phones really stand out. Achieving uniform colour is critical. And although there’s usually a standard range of around 40+, there can be over 1000 different masterbatch formulations.

Universal masterbatch offers convenience, are more readily available from suppliers and work with most polymers. The downside is not all universal masterbatches are compatible with all base materials. Conversely, polymer specific masterbatches are formulated using the same base polymer that it will be blended with. These tend to be bespoke and customised to suit a specific

Typically, a white masterbatch is used to add opaqueness or whiteness into plastic products. Different grades of titanium dioxide (TiO2) are applied to reflect or scatter light. As well as outdoor applications, some whites are suitable for food contact plastics. One of the key advantages of the white masterbatch is it has a high rate of dispersion, so can easily incorporate other colourants.

Picking the perfect colour is one thing. Ensuring consistency batch-tobatch is quite a science. Everyone sees colour differently. Black masterbatch is good for electro-static conductibility, durability and exposure to extreme weather. Thatâ&#x20AC;&#x2122;s why black is used in a lot of functional outdoor plastic applications, such as construction pipes, as it is stronger and lighter than coloured equivalents. Performance enhancing additives are often added to both black and white masterbatch

COLOUR MATCHING

Out of all the product types, colour masterbatch is experiencing heavy global demand.

Picking the perfect colour is one thing. Ensuring consistency batch-to-batch is quite a science. Everyone sees colour differently. While Newton divided the spectrum into seven named base colours - red, orange, yellow, green, blue, indigo and violet, according to psychophysicists we see tens of millions of different hues and shades. Given this, the human eye cannot be relied upon to match samples accurately. Once a specific masterbatch has been created, specific formulation details, including colour pigments, raw material ratios, notes and directions are held on a recipe card. A moulder can call up these instructions at any time to ensure production consistency.

for the base polymer. The more plastic is reprocessed, the greater the molecular structure changes. This loss of chemical properties affects the composition and therefore is likely to affect the compatibility of all the ingredients within a blend. Aesthetics aside, understanding the environment in which the end component will be used is critical. For example, components exposed to direct sunlight will need to use a specific masterbatch to prevent discolouration. The chemistry of some colour pigments may be incompatible with the chemistry of some base polymers. Additionally, other agents, such as fillers, could impact the fusion.

One thing is certain, masterbatch has become integral to modern day plastic processing. Out of all the product types, colour masterbatch is experiencing heavy global demand. This robust growth can be attributed to brand differentiation trends in packaging, FMCG, furniture, construction, agriculture and aerospace. Likewise, black and white mastermatch is being extensively utilised by automotive manufacturers for lighweighting and to improve fuel efficiency. Just like a paint swatch, new innovations emerge on the market all the time. To trial a different pigment or plastic effect, contact us for advice on whatâ&#x20AC;&#x2122;s new and how a new formulation might impact processing stability.

Should a recipe card be unavailable, physical samples can also be matched using a light box or spectrophotometer. Homogenisation of a blend, including the dispersion of the masterbatch during dosing, plays a big role in minimising colour and product performance variations. Most recipes detail the percentage by weight of masterbatch to be applied. Yet, discrepancies can occur. Changing the host polymer or switching suppliers is typically when this might happen. For this reason, moulders tend to stick with the same supplier. As with all plastic processing, stability is essential. Thermal resistance and durability need to be factored in. Itâ&#x20AC;&#x2122;s precisely for this reason why most processors avoid using a high percentage of recycled plastic mixes

Thomas Catinat, operations manager at Broanmain Plastic.

For further information, please visit www.broanmainplastics.co.uk Issue 44 PECM

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 84 Issue 44 W:PECM www.kecol.co.uk

✓Face Scrub ✓Teething Gel ✓Tomato Puree ✓Medical Adhesives ✓Veterinary Creams ✓Fruit Paste ✓Toothpaste ✓Malt ✓Jam ✓Wax

Kecol Pumping Systems Kecol Pumping Systems offers solutions to many product transfer problems – read on to find out more.

ecol Pumping Systems Ltd are manufacturers of Air driven, Positive Displacement Piston Pumps and Priming Devices in polished stainless steel or carbon steel, for transferring high viscosity nonflowable products from drums and containers as used in the cosmetic, food, pharmaceutical, chemical and general industries. Products in drums or similar sized vessels that normally need to be heated in order to reduce the viscosity - can be transferred cold. Products with a viscosity up to 10,000 Poise can be transferred (cold) using the Kecol Maxiprime Pump and follower plate system and is also used to transfer pastes and products that stick to the inside of an open top drum, wiping the inside of the drum or vessel, eliminating product waste. Kecol Air Powered Drum Pumps and transfer systems are suitable for all standard size closed top or open top drums and can be adapted to suit open top containers with an internal diameter up to 1200mm. Non contact parts as well as contact parts are available in polished stainless steel, clamp - type construction is also available for hygienic applications. Typical applications in the food industry include transferring tomato

The inside of a standard 200 litre Open Top Drum is wiped clean – as the drum is emptied – with minimal product waste

puree, concentrated fruit juice, honey, fruit pastes, biscuit creams, jams, butter, margarine, sweet mince meat, sausage meat and meat pie fillings with cooked vegetables. Applications in the pharmaceutical and cosmetic industries include transferring mascara, petroleum jelly, face creams, base creams, magnesium hydroxide, aluminium hydroxide, toothpaste, lip-gloss waxes and suntan lotions.

Kecol’s articulated pump systems

The Kecol Follower plate system will also work on 200 litre Open Top Drums fitted with an aseptic bag – wiping the bag clean

Applications in the chemical and general industries include the transfer of paints, resins, adhesives, polymers, latex, high viscosity grease, mastic’s and inks – all pumped cold without pre-heating the products. As manufacturers, Kecol Pumping Systems can offer solutions to your particular product transfer problem, by offering a bespoke system designed to exceed your particular production requirements for single drum/vessel use or multi drum use.

Kecol Pumping Systems Ltd Faraday Drive Bridgnorth Shropshire WV15 5BJ T: 01746 764311 E: sales@kecol.co.uk www.kecol.co.uk Issue 44 PECM

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

Apex Dynamics bogus products warning APEX Dynamics, a leading supplier of highprecision gearboxes to the food, packaging and automation sectors, is urging customers to be on their guard against a wave of counterfeit products that have infiltrated the UK market in the last 12 months. One of the unfortunate consequences of building a successful premium brand is the appearance of fake goods and, despite determined efforts to combat this problem, APEX Dynamics has continued to see bogus products bearing its branding being sold online at knockdown prices. APEX Dynamics’ products are specially designed with patented features around the bearings and seals of the gearbox, making them ideal for use in a food or pharma environment and the company has warned of the consequences of customers purchasing counterfeit products which does not meet its quality or warranty standards. APEX Dynamics can be contacted at sales@apexdynamicsuk.com. Find out more at: www.apexdynauk.com

PECM Issue 44

Whale Engineering Spins New Web whale.engineering is the URL of the new capabilities and services website of Whale Engineering - a turnkey solutions provider of highly engineered universal and bespoke mechanical parts and assemblies, and engineering technical services. A division Whale Tankers – one of the largest manufacturers of liquid waste vacuum tankers and jetting equipment in Europe – Whale Engineering has access to a manufacturing site in the Midlands of more than 17 acres, whilst also operating from Tamil Nadu in the Indian sub-continent. Enjoying a worldwide presence and a growing reputation for the latest design, production and testing technologies deployed to create a diverse range competitively-priced components, Whale Engineering services a diverse range of customers operating in the water & waste treatment, construction, mining, industrial, automotive, aerospace, packaging, power & energy and textile machinery sectors. whalemail@whale.co.uk 0121 704 5734

Imtex Controls Celebrates its 30th Year Anniversary First established in 1990, Imtex Controls is a privately owned, British engineering & design manufacturing company. With its factory situated in Deeside and sales representatives throughout the whole of the UK, they have expanded significantly and now manufacture the largest independent range of valve position monitors; becoming a pioneer in developing automation valve communication products. Imtex delivers on products and services such as valve position monitors, IIoT valve monitoring and testing solutions and manufacturing Camtorc actuators for both on/ off and modulating valve and damper systems in virtually any environment including extremeL service applications. For any further information, please see the details below.

T 08700 340 002 www.imtex-controls.com

MANUFACTURERS OF HIGH QUALITY HIGH PERFORMANCE INDUSTRIAL INSTRUMENTS • CHEM UK 2020 - Booth H8 Manchester – Event City 16th to 17th September • WWEM 2020 Water, Wastewater & Environmental Monitoring - Booth P7 Telford International Centre 11th to 12th November HANNOVER MESSE – Hall 11, Booth C35 Hannover – German 20th to 24th April

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

Precise - multifunctional - reliable - proven

FLOW – LEVEL – PRESSURE – TEMPERATURE – ANALYTICAL - CALIBRATION

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 £50-£75 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

A MANUFACTURING AND STOCK CONTROL SYSTEM FOR SAGE USERS 88

PECM Issue 44

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.

Issue 44 PECM

STRENGTHEN YOUR NETWORK

Procentec's Osiris provides unique insight in your networkâ&#x20AC;&#x2122;s health and topology. Individual license dedicated for your Windows PC Monitor PROFIBUS, PROFINET and Industrial Ethernet networks Commissioning of PROFINET and Ethernet/IP Predictive maintenance Built-in assistant Delphi helps get your operations running again

info@procentec.com | www.procentec.com| Tel: +31 174 671 800

Osiris as a software package Procentec's Osiris provides unique insight in your networkâ&#x20AC;&#x2122;s health and topology. Until now this powerful software tool was only available on Procentec's portable Mercury tablet and permanent Atlas module. Both devices run on diagnostics platform Osiris to analyse the information feed from, for example, an EtherTAP. This enables our build-in assistant Delphi to come up with a solution to help you to quickly and effectively get your operations running again. PC-version of Osiris At the request of many users Procentec now offers a subscription PC-version of Osiris. The features of Osiris as a Software are identical to the ones found on our Atlas and Mercury diagnostic platforms. With our new release we enable you to install Osiris on your very own hardware devices. Osiris offers reliable and smart diagnostics to better streamline the topology of a network.

Smart diagnostics prevent downtime Implementing a new network? Providing a solid baseline for a network prevents many operational problems down the line when new devices continue to be connected to the network. With Osiris it is possible to preventively detect all kinds of downtime boosters like EMC issues caused by faulty shielding, communication and power cables positioned too close together, termination troubles, plus complications with device connections and devices. Preferably Procentecâ&#x20AC;&#x2122;s powerful diagnostic technology is used for preventive and predictive applications, but the software solution is just as effective in quickly and precisely locating and solving network issues in case of gridlock; preventing staggering downtime costs. Flexible ease of use Instead of having to analyse, interpret and formulate a way to solve your network issues yourself, by trying to make sense of all the messages, Procentec offers a virtual network engineer with the included Delphi

wizard that does all that in a fraction of the time. With Osiris you can realise 24/7 monitoring with total accuracy. You now have the flexibility to deploy Osiris on your PC, laptop, and server or to make use of our Osiris diagnostics platform on our Mercury and Atlas devices for advanced active monitoring of your network. In this setup Procentec also offers passive monitoring for any Ethernet or PROFINET network featuring another 2019 release: the Procentec EtherTAP. The advantages are multiple.

Technology to create the future No matter which option you select to put Osiris to work, Procentec always guarantees an effective set-up to monitor network load, detect CRC errors, capture PROFINET alarms, check communication cycle times, notice dropped packets and measure the jitter in the PROFINET real-time communication. In the end it all boils down to our strong commitment and focus on innovation in industrial automation to help manufacturers improve quality, efficiency, compliance, flexibility and use, so they can perform at the leading edge of their industry. Would you like to find out what Procentec can do for you company? Fill out our contact form and our sales engineers will contact you as soon as possible.

ONE-STOP IMPROVEMENT

INDUSTRIAL INNOVATORS PLATFORM

DATA VISUALISATION Drag and Drop visualisation tools including charts, sophisticated trending, scatter plots, parallel coordinate plots, multi-sparklines and contextual messaging built to support process analysis, system benchmarking and event analysis. PROCESS MODELS Empirical steady-state and dynamic models for soft sensors, monitoring, control and optimisation. Continuous and batch models, with parametric and non-parametric options. All model parameters, predictions, performance metrics are accessible via an intuitive user interface with context-driven help.

Create meaningful, intuitive user interfaces for data entry or process simulation.

Context-driven information panels provide guidance and assistance when you need it.

PROCESS MONITORING using SPC, MVSPC Design and evaluate monitoring models for improving the detection, identification and diagnosis of faults within complex processes. Each monitor can be fully evaluated by streaming historical process data into the engine, to ensure high robustness and provide effective and meaningful alarms. Configurable tools include Real Time Shewhart, EWMA and CUSUM charts with Western Electric Rules, automated Outlier detection and alarming. Full suite of templates for multivariate process monitors using Principal Component Analysis, Partial Least Squares. Multivariable Alarm Thresholds and MVSPC plots with SPE & T2 statistics. Complete Multi-Model Operating Modes, Fault Fingerprints, Fault Diagnosis tools. SIMULATED CONTROL ENGINEERING PID Controller with selectable structures. State of Art Linear and non linear Model Predictive Control, for both continuous and batch processes. Adaptive control system for challenging problems. Stiction compensator. Tools include Robustness Analysis, automatic management of lost signals, uncertainty and model switching for multi product systems. Integrated performance metrics and de-tuning functionality. OPTIMISATION Steady State and Incremental Linear, Quadratic, Sequential Quadratic Programming (LP / QP / SQP), Real-time Optimisation Engines with prioritised relaxation for industrial applications, Batch Endpoint Optimisation using unique PLS design.

Rapid side-by-side comparison of controllers for faster fine-tuning.

www.PerceptiveAPC.com â&#x20AC;˘ info@perceptiveapc.com

ALARM & EVENT MANAGEMENT Design Configurable Events and Alarms which can be transferred into an SQL database in the Real Time Platform. Alerts can trigger emails or reports to key personnel provide a real time record of an incident.

Perceptive Engineering Limited Vanguard House, Keckwick Lane Sci-Tech Daresbury Cheshire WA4 4AB UK +44 1925 607150

Perceptive Engineering Pte Limited Galaxis Work Loft #05-51 3 Fusionopolis Place Singapore 138523 t +65 6250 7565

Perceptive Engineering Ltd (Ireland) Nexus Innovation Centre, University of Limerick Republic of Ireland t +65 6250 7565

Industrial I n n o v a t or s P l a t f or m Your Process. Improved.

PERCEPTIVE

A user-friendly process optimisation tool, designed to enable rapid development and testing of real-life industrial processes in a safe, controlled environment

CAPTURE, ALIGN, CLEAN Simplified yet powerful tools for aligning historical process data with lab results and at-line instrumentation readings â&#x20AC;&#x201C; even operator comments. No data needs to be excluded, to provide the most detailed picture possible of your process. Remove outliers, fill gaps, apply filtering using a comprehensive range of intelligent tools that will prepare your data, ready to yield its secrets.

ANALYSE, VISUALISE, REALISE Parallel Coordinates tools and Unsupervised Learning techniques enable intuitive assessment of multiple variables, with just a few clicks. You will quickly understand when your process has performed well, when improvements could have been made, and which variables are having the biggest impact on quality or efficiency.

MODEL, EVALUATE, UNDERSTAND Develop a robust digital model of your process, representing its real-world behaviour and operation. You now have your plant, on your desktop, ready to be put through its paces. Batch and continuous manufacturing processes can be transformed into interactive digital equivalents, validated against real-world data to ensure their fidelity.

SIMULATE, TEST, IMPROVE The next step in digital process improvement is to simulate and test multiple scenarios, to determine how to get more from your plant â&#x20AC;&#x201C; yield, throughput, quality. Investigate, quantify and evaluate improvement scenarios. Determine, assess and prototype a model-based solution, ready for approval. All in a non-intrusive off-line environment.

INNOVATOR DATASHEET 080

Models and strategies developed offline can then be robustly deployed in the real world. Seamlessly import them into the PerceptiveAPC Real Time Suite, configure the interface, then start making immediate improvements to your operations.

29 SEPT - 1 OCT 2020 NEC, BIRMINGHAM

FREE TO ATTEND REGISTER NOW THE COMPLETE PRODUCTION LINE EVENT See the latest processing and packaging machinery, robotics and machine vision in action Network with industry peers and gain valuable insight at our must attend seminars

ppmashow.co.uk O OW WN N EE D D A AN ND D O OR RG GA AN N II SS EE D D B BYY

SOFTWARE & SYSTEMS

mvIMPACT-CS Release 2.2 – PC version of the Smart Vision software now available Intelligent Software by Manufacturing Experts

Optimise Your People, Processes, Productivity and Profitability Hosokawa Micron’s digital toolkit, Hosokawa Gen4, converts live data from sensors and controls into a ﬂexible, scalable and secure solution to optimise production processes, reduce energy bills and achieve tangible benefits that will drive business growth.

hosokawagen4.com +44 (0)1928 333139 | info@hosokawagen4.com

Hosokawa Micron’s innovative powder processing equipment is now Hosokawa Gen4-compatible.

hosokawa.co.uk

Release Version 2.2 of the “mvIMPACT Configuration Studio”, or mvIMPACT-CS for short, has been issued; it comes with a cascade of new features and is now also available for use on a PC. Until now, users of the mvBlueGEMINI smart camera could only use mvIMPACT-CS to perform the full range of inspection tasks in a visual, quick and cost-effective manner if they possessed programming expertise and knowledge of image processing. Using the PC version and with the help of wizards, inspections can now also be simply and intuitively performed using PC and GigE Vision and USB3 Visioncompatible industrial cameras as a basis. This user group can therefore now also look forward to the guarantee of a quick and trouble-free entry into the world of industrial image processing With the new “HALCON Script” tool, which is available as an option, it is now possible to

load and execute HALCON scripts in mvIMPACT-CS. Here it does not matter whether mvIMPACT-CS runs on the Smart Camera or on a PC. Last but not least, the new release includes two additional expert tools. While the “Filter image” tool makes it possible to optimize the image quality, under sub-optimal lighting conditions, for example, the “Check blobs” tool allows the user to detect objects in the image, count them and check the shape and other properties of those objects.

www.matrix-vision.de

Issue 44 PECM

STORAGE, HANDLING & DISTRIBUTION

Mitsubishi Caterpillar Forklift America Inc. installs touchpath manufacturing execution system to increase production capacity Houston, Texas-headquartered forklift manufacturer Mitsubishi Caterpillar Forklift America Inc. (‘MCFA’) has implemented international supply chain solutions provider TouchPath’s ‘TouchMES’ manufacturing execution system, integrating it with the company’s ERP system to increase production capacity and support expansion, it was announced today. From its 860,000 sq. ft., 850 employee Houston-based plant MCFA manufactures and distributes Mitsubishi forklift trucks, Cat® lift trucks and Jungheinrich® warehouse products, via a network of 450 dealers across North, Central, South America and the Caribbean. TouchPath has operations in the UK (Halifax HX1 5ER) and the USA (High Point, NC 27265). www.touchpath.com

Konecranes Demag UK partners with WES Lifting equipment manufacturer and service provider, Konecranes Demag UK Limited, has reaffirmed its commitment to providing equal employment opportunities by entering into partnership with the WES. The move is consistent with the company’s objective of promoting the engineering sector to women and recruiting female employees to establish a more diverse workforce. Konecranes Demag is taking an active role within the WES, attending the organisation’s events and adopting best

practice procedures. The company will also advertise technical vacancies on the WES website, job boards and newsletters to make job opportunities more accessible to female engineers. Konecranes UK HR Director, Karen Winfield, stated: “This is an issue about which I am passionate and I am delighted that Konecranes Demag is working with the WES to inspire and support women in engineering careers.” www.konecranes.co.uk

KASTO KASTO manufactures manual, semi-automatic and fully automated bandsaws, circular saws and hacksaws. The company also builds compact industrial warehouses for computer-controlled storage and retrieval of bar, tube, profile, sheet and other materials. Systems can be either standalone or interlinked with saws, other machine tools, and more. KASTO’s service encompasses planning, design, software development, project

PECM Issue 44

management, execution, service and support from a single source. KASTO Ltd is the subsidiary serving the UK and Ireland with offices, demonstration facilities and a showroom in Milton Keynes. We would be delighted to meet with you to explain more on our stand 610 in hall 19 at the MACH 2020 show, which runs from 20th to 24th April at the NEC in Birmingham. www.kasto.com/uk

VALVES

Bonut Engineering Ltd Bonut Engineering Ltd was established in 1966 and is a leading UK manufacturer and supplier to the fastener and general engineering industry. We specialise in the UK manufacture of engineer’s studs, shaft collars, precision turned parts and valves in stainless steel, high grade alloy and non-ferrous metals. Bonut has also acquired the Dereve Safety and Water Valve business as well as the fusible plug business which is now consolidated under the Dereve brand. Our experience of both the fastener and valve manufacturing businesses enables us to support our customers over a wide sector of Industry.

www.bonut.co.uk

3M High Flow Filter System range extended for lower process flow applications

CIP/SIP Utilities Valves

The new High Flow 10” Filter Cartridge from 3M uses the same proprietary high efficiency polypropylene microfibre filter media as the existing 40” and 60” length versions. The compound radial pleat structure and large diameter core offers the same significant advantages: high flow rates per filter cartridge in a compact design, allowing fast and easy filter change-outs.

Compact, inexpensive, yet fast acting describes the GEMÜ 550 Angle Seat Globe Valve range for CIP/SIP applications. The valve spindle is sealed by a self-adjusting gland packing providing reliable valve spindle sealing even after a long service life. A wiper ring fitted in front of the gland packing protects the seal against contamination and damage. With an all stainless-steel actuator, spindle, body and even the switchbox or positioner, it exactly suits cleanroom and utilities process lines. And using our glowing LED 1235 switchbox it lights up the whole area! For flow control we fit a GEMÜ control cone in the valve and using our 1434 digital positioner, look how compact that can be – the positioner is only 95mm high! The GEMÜ 550 is available as an on/off or control valve. Take a look at the GEMÜ 550 designs for CIP/ SIP valves.

For further details on this product range, visit 3M.co.uk/highflow or 3Mireland.ie/ highflow

Tel: 01925 824044 Email: enquiries@gemu.co.uk www.gemu.co.uk

3M, the science-based technology company, has added a 10” filter cartridge and housing (referred to collectively as a filter system) to its High Flow Filter System range, extending its capability to lower process flow applications, including modular water treatment systems and filling lines.

Issue 44 PECM

MEASUREMENT & MONITORING

SAFE ELECTRICAL SWITCHING PYROPRESS

Experts in Hazardous Area Instrumentation Established more than 60 years, Pyropress is a leading UK based designer and manufacturer of weatherproof and ATEX/ IECEx certified switches and transmitters for measuring pressure, differential pressure, vacuum, temperature, level and flow. Its quality, reliable and durable products incorporate proven design techniques and technology to provide safe and reliable electrical switching of alarm or control circuits within flameproof (Exd), Intrinsically safe (Exia), marine or industrial areas and are available with SIL2 certification to customers worldwide. All ranges are available with SIL2 approval and have a documented failure rate of 1 failure per million hours of operation. They have also been certified both IP66 and IP67 in line with the latest standards.

DEVELOPMENTS FOR ATEX AND IECEX SWITCHES Pyropress has added new features to its Perseus range of ATEX and IECEx switches for use in hazardous areas which is now available with a stainless steel housing for the first time. “We have added an adjustable differential setting capability to the Perseus range of Exd flameproof switches and Exia intrinsically safe switches. It allows fine tuning of compressor cycling in air conditioning and HVAC applications for example and has other uses where hysteresis control is required,” says Stephen Burns, Managing Director Pyropress Limited. “The same module allows two switches with separate settings. There is also the option of a second M20 electrical entry. The Perseus range has been available with only black anodised aluminium for 10 years so introducing the stainless steel housing completes the entire offering. Pyropress are able to offer custom switches and transmitters to suit different applications across all industries and we hold sufficient stock to manufacture millions of combinations to suit specific applications.

The Perseus range of switches is available in pressure, temperature, level and flow variants and is fully certified to the European ATEX 2014/34/EU and International IECEx for explosion proof (Ex d) and intrinsically safe (Ex ia). They are available for operating pressures starting at 0.4 mBar, for ultra low pressure, vacuum and differential pressure and reaching 800 Bar on the high pressure range. Pyropress offers many options and variants for applications where gas, vapour, powder and dust are present. For further

details contact us or your nearest Pyropress distributor.

NEED IT FAST? We offer an Express Manufacturing Service for our switches which can mean having a bespoke sensor delivered within 48 hours of order placement. We can also offer products that are customised to your application. We have full onsite design, machine shop, manufacturing, and calibration facilities, enabling a fast response, and all backed with our highly commended customer service.

For further information, please visit www.pyropress.com

PECM Issue 44

PERSEUS PRESSURE SWITCH Exd or Exia ATEX/IECEx certification | Stainless steel or black anodised aluminium housing to IP66 & IP67 standards | 316 Stainless steel wetted parts | M20 x 1.5 ISO electrical connection | Other threads available via adaptors | Select housing material, certification, pressure range and process connection |

ATEX / IECEx AS STANDARD

SPDT MICROSWITCH

EXD (FLAMEPROOF) OR EXIA (INTRINSICALLY SAFE) AVAILABLE

316 STAINLESS STEEL WETTED PARTS

BLACK ANODISED ALUMINIUM OR 316 STAINLESS STEEL BODY

VITON DIAPHRAGM

RANGES BETWEEN 0.1 BAR AND 800 BAR

ADJUSTABLE SETPOINT WHILST OPERATIONAL

M20 X 1.5 (F) ELECTRICAL ENTRY

STAINLESS STEEL

ULTRA LOW, LOW AND DIFFERENTIAL PRESSURE RANGES ALSO AVAILABLE

BODY OPTION PICTURED

PRESSURE RANGES & PRICING PRICE

CODE

RANGE

MAXIMUM PRESSURE

ALUM

0.1 - 1.5 bar

12 bar

£250

1.2 - 4.2 bar

12 bar

0.2 - 3.0 bar

3.0 - 9.0 bar

0.4 - 6.0 bar

PRICE

CODE

RANGE

MAXIMUM PRESSURE

ALUM

£315

30 - 180 bar

500 bar

£280

£345

£250

£315

70 - 420 bar

500 bar

£280

£345

25 bar

£250

£315

4.0 - 14 bar

700 bar

£315

£380

25 bar

£250

£315

10 - 36 bar

700 bar

£315

£380

50 bar

£250

£315

28 - 108 bar

700 bar

£315

£380

ST.ST.

6.0 - 18 bar

50 bar

£250

£315

50 - 200 bar

700 bar

£315

£380

8.0 - 34 bar

50 bar

£250

£315

115 - 455 bar

700 bar

£315

£380

15 - 90 bar

500 bar

£280

£345

200 - 800 bar

1000 bar

£315

£380

The design features a simple form of adjustment. The switch is factory set and shipped at a mid-range falling and adjusted upon receipt. The set point can even be safely adjusted whilst the switch is electrically connected and in the hazardous area.

PART NUMBER BREAKDOWN PF61

Bespoke variants are available.

Contact sales@pyropress.com

HOUSING

PROCESS CONNECTION

S = 316 STAINLESS STEEL

1 = 1/4” BSP.P FEMALE

A = BLACK ANODISED ALUMINIUM

2 = 1/4” NPT FEMALE

CERTIFICATION B = Exd ATEX / IECEx FLAMEPROOF

to discuss alternative microswitch, diaphragm, process connection, range and electrical entry options.

RANGE CODE

O = Exia ATEX / IECEx INTRINSICALLY SAFE

T: +44 (0)1752 333933 | sales@pyropress.com www.pyropress.com

PLUG AND PLAY! SMART SENSOR CSS 014.

STEGOâ&#x20AC;&#x2DC;s new Smart Sensor is a plug-in solution for Condition Monitoring. The CSS 014 detects ambient temperature and humidity in switch panels. Thus lifting climatisation in enclosures to the next level: Predictive maintenance and remote monitoring allow for immediate response to unwanted and harmful change in environment within your application. See more here.

WWW.STEGO.CO.UK

NE W SMART SENSOR CSS 014

Process Engineering Control & Manufacturing - Issue 44 2020

Articles inside

up £2m of new opportunities for PP

Control & Automation