Process Engineering Control & Manufacturing - Issue 46 2020

Process

MANUFACTURING

Control &

Engineering

RENISHAW - 78

EURAMAX - 84

Promoting Manufacturing efficiency through the use of 3D optical metrology

Euramax looks back at its journey and how the company has changed

PECM

Global Success Through Innovation Issue 46 2020 £3.95 www.pecm.co.uk

THE SEMPRE GROUP - 96 How to reduce human error and training-time using guidance system

PLUG AND PLAY! SMART SENSOR CSS 014.

STEGO‘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

MANUFACTURING

Inside...

Sections

Control &

Engineering Inside Issue 46

Editors Choice

6

Boiles & Maintenance

24

Coatings

25

SC21 recognition for AS.G companies at virtual FIA

Control & Automation

26

OVARRO

Electrical & Electronics

38

Facilities Management

42

Fasteners & Fixings

43

Fluid Handling

47

Gears, Drives & Motors

49

Health & Safety

54

Machining & Machinery

60

Measurement & Monitoring

66

News & Events

78

Top tips for bearings maintenance when restarting your machinery

Process Technologies

88

Product News

91

TSUBAKI

Robotics

95

Storage, Handling & Distribution

98

Valves

100

ARROWSMITH

With thousands of assets in a modern industrial setting and a single failure having the potential to result in financial loss or worse, data is now king

PROTOLABS

Protolabs receives RoSPA Gold Award for keeping employees healthy and safe

SMB BEARINGS

Sweet success for Tsubaki Neptune™ chain installed on ice cream plant palletisers

VUFORIA

A network of world-leading research and innovation centres has taken one of the UK’s largest ever deployments of Augmented Reality (AR) technology.

SEWTEC

Why automation is playing a vital role in the manufacturing industry

INSPEKTO

How Autonomous Machine Vision could help ward off the looming recession

EMS LTD

Three ways they are helping save the environment

SULZER

Local manufacture of highperformance Sulzer pumps provides cost, time and service benefits

“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 46 PECM

3

DOSCH DESIGN WWW.DOSCHDESIGN.COM

Dosch 3D: Factory Accessories

Dosch 3D: People Clean Room Vol. 1

Dosch 3D: Environments - Factory

Dosch 3D: People Factory Worker Vol. 2

Dosch 3D: Industrial Objects V3

Dosch 3D: Packaging Beverage Bottles

Dosch 3D: Industrial Buildings

Dosch HDRI: City At Night

Dosch 3D: Cars 2019

Dosch Textures: Metal

Dosch HDRI: Product Environments

Dosch 3D: Food

Dosch 3D: Construction Site

Dosch 3D: Car Details Autonomous Car

Dosch HDRI: Product Lighting

3D-Design, Animation, Visualization Besides complete 3D-models and scenes >Dosch 3D, Dosch Design products contain surface materials >Dosch Textures, High Dynamic Range Images >Dosch HDRI, as well as 2-dimensional objects for architectural visualizations >Dosch Viz-Images.

Dosch 3D: Accident Cars

Dosch 3D: Airplane Details V2

Save 10% by using the order coupon: pecm2019

WWW.DOSCHDESIGN.COM We support your creativity.

Advertisement-PECM-2019

Process

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

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

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

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

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

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

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

•

The quality of the hard copy enhances the reading experience

Engineering MANUFACTURING

Control &

Suscribe

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

EDITOR Elizabeth Hutton elizabeth@pecm.co.uk

BUSINESS MANAGER Josh Holmes josh@mhmagazine.co.uk

STUDIO DESIGNER Richard Bland richard@mhmagazine.co.uk

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

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

SALES MANAGER Lee Martin Lee@pecm.co.uk Tel: 01227 936975

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

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

EDITORIAL ASSISTANT Charlotte Charlesworth charlotte@pecm.co.uk Tel: 01227 936 970

To Subscribe please call 01304 806039

100 95 75

25 5 0

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

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

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

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

MH Media Global Ltd.

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

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

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

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

Issue 46 PECM

5

NEWS & EVENTS

COMMITMENT TO QUALITY ARROWSMITH

SC21 recognition for AS.G companies at virtual FIA Two precision engineering specialists were recognised for their commitment to quality and delivery performance this week as the Farnborough International Airshow went ‘virtual’.

Arrowsmith Engineering and TGM, both part of the £43million Aero Services Global Group (AS.G), were given the SC21 Silver and SC21 Bronze awards respectively for their ongoing ability to manufacture complex components to customers supplying some of the world’s largest airplane manufacturers and primes.

These awards are a critical performance indicator for the sector and has helped the two manufacturers secure over £3.5m of new contracts during the last twelve months.

Jason Aldridge, Managing Director of precision turning, milling, thread rolling and grinding specialist Arrowsmith Engineering, commented: “This is a great moment for our business as it marks four years of us performing to SC21 Silver standards – one of the few companies in the world to achieve this.

6

PECM Issue 46

“Over the last twelve months, and despite all of the economic shocks and turmoil of Covid-19, we have still managed to record 99.5% right first time quality and 97.55% delivery on-time and these are parts for aerospace engines and braking systems for the likes of Rolls-Royce, GKN, ITP, Incora and Meggitt.”

Sarah Stephens, Managing Director of TGM in Preston, added her thoughts: “It’s great to play a small role in the first ever virtual Farnborough International Airshow and a massive lift for our staff to be recognised for our SC21 Bronze Award for the third consecutive year.

German-based Ludolph target the SC21 Operational Excellence Award.

Phoenix CNC, renowned for its Aircraft on the Ground and speed shop support, will join Arrowsmith Engineering on the SC21 Competitiveness and Growth programme, the ADS-backed intensive booster programme.

Simon Weston, Managing Director of AS.G, concluded: “We were founded in

2015 with the aim of developing a highly specialist group, which could help a global customer base to consolidate their supply chains through innovation, efficiencies and excellent value for money.

“SC21 has been a fantastic vehicle for helping us deliver on our promise and we want to ensure that all relevant companies we own are operating to the highest possible standards when it comes to quality and delivery.”

“We specialise in long-bed CNC machining and, traditionally, have supplied into tier 1 customers in aerospace and increasingly defence. Working towards these globally recognised standards helps open doors and gives us confidence to aggressively push our strategy of moving up the supply chain and actively securing work with the primes.”

The Aero Services Global Group has made a commitment that all of its companies will work towards some form of SC21 involvement and this decision will immediately see the recently acquired AMF Precision Engineering start the journey and For further information please visit www.arrowsmitheng.co.uk/www.tgmeng.co.uk Issue 46 PECM

7

EDITOR’S CHOICE

COMPACT HIGH FLOW FMX VALVE

The IET Manufacturing Technical Network is looking for committee members Calling all manufacturing experts! We’re looking for new committee members who can share their expertise and act as advocates for manufacturing engineering. It’s a great way to raise your standing in the profession and connect with engineers all over the world.

What’s involved? Our committee helps build the community by contributing ideas for networking

activities and raising awareness of the Manufacturing Technical Network as a place for the profession to meet online.

So if you are passionate about manufacturing and have professional expertise to share, we’d love to hear from you. Find out more at

https://communities.theiet. org/communities/home/59

Coax valves UK are proud to introduce the new FMX range of compact, high flow, stainless steel externally controlled valves.

With a new unique seat arrangement gives greater flow than comparable valves: • Features of the valve include: • All wetted parts 304 stainless steel • Port sizes 3/8” bsp through to 11/4” bsp Normally closed and normally open functions available Pressure range 0-16 bar in either direction New design of endcap allows snap in mounting into manifold Reed switch sensing available FKM seals with PTFE seat as standard 3/2 pilot valve available with different electrical connections available Competitively priced Valves and accessories held in stock C

For further details contact John Osborn at john.osborn@coaxvalves.co.uk Visit website: www.fmx-valves.com

M

Y

CM

MY

CY

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

8

PECM Issue 46

Detect even the tiniest of leaks in seconds

CMY

K

W

All-round protection for your pumps with the ifm application packages.

Monitoring and Condition Based Maintenance of pumps

RANTY AR

ct

on

s

years if m pr od

u

This complete solution makes your pumps fit for Industry 4.0 • • • •

Continuous diagnostic: Full coverage of your critical assets at all times.

Early diagnostics: Monitoring of imbalance, wear and overall vibration.

Maximum efficiency: Permanent diagnostics helps keep your assets running efficiently.

Easy integration: ifm provides individual solutions suited different types of pumps.

Reducing costs, avoiding unplanned downtime and optimizing processes: The ifm Application Packages. ifm – close to you!

Go ifmonline www.ifm.com/uk/application

EDITOR’S CHOICE

EXPERTS IN THE FIELD 3DPRINTUK

3DPRINTUK Expands Material & Post Processing Capabilities Anyone familiar with 3DPRINTUK will be aware that to date the company’s 3D printing services have been dedicated to the selective laser sintering (SLS) process, specifically with the PA2200 (nylon) material.

Nick Allen, 3DPRINTUK’s CEO and founder explains how this was absolutely intentional.

“Over the past decade, as we have grown the business organically and steadily, we were committed to developing the very best in-house process/material interface that would in turn ensure the best possible outcomes for our clients’ parts in terms of quality, consistency and repeatability.”

NEW MATERIAL This approach has led to the 3DPRINTUK team becoming experts in their field, with a profound understanding of the SLS process, and is now allowing them to apply their expertise into new areas, namely through the introduction of PrimePartST — a polyether block amide (PEBA) material —designated 2301 —from the thermoplastic elastomer (TPE) family of materials .

Allen continues: “This is a big day for us.

There were limiting factors in our previous facility that prevented us from adding new materials. Now with our new factory and with our in-house developed order management system, we look to introduce a number of new offerings, with PEBA being the first of these.”

PEBA 2301 exhibits flexible, rubber-like Actual size: A. 50mm x 50mm x 16mm B. 13.5mm x 13.5mm x 41mm C. 102mm x 102mm x 40mm

characteristics similar to TPU and other TPE’s, but it is slightly harder and stronger.

PEBA 2301 also demonstrates good chemical resistance, water resistance, long term stability, with excellent detail resolution possible and rubber-like fatigue behaviour.

The material comes in matt white, but PEBA parts can easily be dyed if the natural finish is not suitable for any application. One of the key properties of PEBA 2301 is obviously its rubber-like flexibility.

PrimePartST has a higher melting point than most resin-based elastomers, and is thus ideally suited to rugged end-use applications. It is also suited for batch

production runs, and its elasticity makes it an ideal material for key functions, including anti-vibration and impact protection. Typical applications include air ducts, encapsulation components, handles, medical, seals and gaskets, and sports equipment and footwear.

Allen continues, “With everything we offer, we aim to be fully transparent. This new material is not perfect. To be fair, what material is? So understanding its limitations is as important as maximizing its strengths.”

The extensive testing carried out on the PEBA 2301 material (and the insight garnered from it), means that the 3DPRINTUK team is now able to fully support clients with applications that require the flexible properties that this material offers.

Understanding both material limitations and how to get the best from the machine / material interface is a hallmark of the highquality service standard that 3DPRINTUK offers all of its clients.

NEW FINISH In addition to the PEBA 2301 introduction, 3DPRINTUK is now also offering a shot peening service for low, medium, and high volumes of parts, following investment in more hardware from DyeMansion in the form of the PowerShot S system, which utilises the proprietary PolyShot Surfacing (PSS) process.

10

PECM Issue 46

Actual size: A. 20mm x 20mm x 50mm B. 20mm x 20mm x 30mm C. 102mm x 102mm x 40mm

The PSS process involves the plastic surfaces of parts being impacted — or shot — with a stream of particles, under considerable force using compressed air. This action results in a smoother, matt-glossy finish with improved scratch resistance. Significantly, no material is removed from the printed parts during the process, ensuring that tolerances are not affected while the surface quality of the part is greatly improved.

3D printed parts of virtually any geometry are compatible with the PowerShot S, including parts that incorporate fine features and intricate detailing. Used for standalone finished parts, the PSS process is of particular importance if additional post processing steps — such as colouring / dyeing — are required. The more homogenous surface produced by PSS ensures dyes penetrate uniformly to produce a consistent and high-quality result.

Over the past decade, we have grown the business organically and steadily to ensure the best possible outcomes for our clients’ parts.

process over many years to achieve the best possible results off our machines for a wide range of relevant applications, that continue to grow in scope. However, the post processing of parts — from cleaning through to further optimised surface finishes — has always been a necessity for many of our clients. Expanding our post processing capabilities is a vital part of the business, and the DyeMansion PowerShot S system is an important next step in our expansion, enabling us to offer our many and varied clients the benefits of shot peened 3D printed parts from a single source.”

The PowerShot S system can boost efficiency and productivity of end use parts considerably. With a cycle time of just 10 minutes for a medium sized batch of midsized 3D printed components — compared with traditional tumbling techniques that can take 6+ hours — the results can be highly cost-effective both in terms of the functionality and the life-cycle of parts themselves.

Allen comments, “At 3DPRINT UK we have honed and optimized the SLS 3D printing For further information, please visit www.3dprint-uk.com Issue 46 PECM

11

EDITOR’S CHOICE

DATA RULES OVARRO

With thousands of assets in a modern industrial setting and a single failure having the potential to result in financial loss or worse, data is now king “Collection of data from the vast array of assets, many in remote locations, can no longer be done manually,” explains Philippe Aretz, Channel Sales Director at Ovarro, the new name for Servelec Technologies.

“Technology in the form of Remote Telemetry Units (RTUs) are a practical way of doing this and it’s the reason why they are a critical part of industrial processes. In simple terms, RTU’s convert vast amounts of digital data into effective management information, whilst having an ability to act autonomously to monitor and control critical assets.”

RTU’s are effectively mini-computers that collect data locally, act upon it immediately, reporting data to the central control room and maintaining a local historical store as an additional backup. Ovarro’s TBox RTU’s are often referred to as a ‘SCADA in a box’ by the market. The RTU is the device sitting between the Control Room and the Field instruments, which provides a low latency response to changing site conditions as well as performing data filtering. They ensure that only key, critical information is passed securely via the narrow communications links, minimising data throughput but maximising useful information received.

“Digitization of industrial processes using RTUs is happening at pace. They are traditionally used on remote assets, although we are seeing them deployed widely on industrial sites,” said Philippe.

“That’s because more engineers are realizing that they currently don’t have visibility of asset conditions – usually until it fails - meaning they are forced to adopt a reactive rather than proactive approach.”

“However, collecting and leveraging data via an RTU system can deliver improved operational efficiency and better maintenance outcomes,” added Philippe.

“Specific areas of concern can be identified, and appropriate measures taken to ensure that run-to failure is avoided. RTU’s work by

allowing engineers to understand critical complex pieces of equipment – especially those off-grid in remote locations” The key features needed in an RTU are security and resilience to the site environment, an ability to operate with minimal drain on local power resources and the processing power to perform local control algorithms autonomously. It is also beneficial to have extensive diagnostics capability and a low MTTR (Mean Time To Repair) to reduce the time required for

Specific areas of concern can be identified, and appropriate measures taken to ensure that run-to failure is avoided.

technicians to spend on site, improving both efficiency and personnel safety.

Data extracted from asset can also be stored in the cloud, analysed using customized embedded algorithms and data analytics to identify anomalies – detecting problems before they occur – allowing operators to reduce waste and refine maintenance strategies. “This kind of approach means that RTUs are capable of providing high quality management information,” added Philippe.

RTUs continue to evolve and become more powerful. It’s worth bearing in mind that one thing that works in their favour is their rapid return on investment – quantifying the cost of avoiding an outage is straightforward, for example. To emphasise the point, Philippe said: “Telemetry projects have a rapid return on investment, making them self-funding in the short term. Distribution automation is another benefit, too, because it allows assets to be controlled autonomously whilst avoiding having to place personnel in hazardous industrial environments.”

For further information, please visit www.ovarro.com

12

PECM Issue 46

EDITOR’S CHOICE

Specialist funding support to businesses 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 criterion 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.

GEMÜ SUMONDO

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

We work on a success fee basis only so there’s no initial cost – you’ve nothing to lose.

Telephone: 01926 512475 e-mail: charlotte@mcs-corporate.com

www.gemu.co.uk

www.www.mcs-corporate.com Issue 46 PECM

13

EDITOR’S CHOICE

GLOBAL ACCOLADE PROTOLABS

Protolabs receives RoSPA Gold Award for keeping employees healthy and safe

World-leading digital manufacturer Protolabs has secured an global accolade for demonstrating excellence in health and safety.

The company received a RoSPA Gold Health & Safety Award for ensuring its staff, customers, contractors and any visitors to its state-of-the-art manufacturing facility in Shropshire remain safe.

“We are delighted to have won a RoSPA Gold Health & Safety Award and it is testament to the magnificent work of the whole team here. Great pride is taken in achieving excellence in the workplace, whether that is being at the forefront of innovation or creating the safest possible working environment for our employees,” explained Lee Ball, General Manager of Protolabs’ Telford facility.

“As a business we help thousands of companies across Europe to bring exciting new products to market in record-breaking time. And this Award demonstrates that we do it safely.”

organisation we always seek to do the right thing by our employees and all visitors to our facilities, so this makes the award even more special. It reinforces our commitment to excellent standards.”

The RoSPA Awards scheme is the longest running of its kind in the UK and receives entries from organisations around the world, making it one of the most soughtafter global accolades in health and safety.

Protolabs was founded in 1999 and now has bases across Europe and around the world, with a number of key European export markets including Germany, France, Italy, Sweden and Spain.

The majority are non-competitive and mark achievement at merit, bronze, silver and gold levels. Currently, around 7 million people are directly impacted, but the scheme’s influence is even wider.

Employing more than 440 people at its facility in Telford, the company uses advanced 3D printing, CNC machining and injection moulding technologies to produce custom-designed parts and prototypes in days.

Andrew Green, Facilities Manager at Protolabs, added his support: “As an

Protolabs will be formally presented with the RoSPA Award later this year.

For more information visit protolabs.co.uk or follow @protolabs_emea on twitter.

14

PECM Issue 46

EDITOR’S CHOICE

we

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

www.litremeter.com

Leaders in bespoke calibration & test systems With over 40 years experience designing and building high integrity test and calibration systems, Chell’s engineers are ready to design complete solutions for your production calibration needs.

Pressure, Vacuum & Gas Flow Automated Product Calibration All Cal. Standards to ISO17025 All Design & Build to ISO9001 Ask your engineers to call our engineers, they almost certainly speak the same language.

Chell Instruments Ltd www.chell.co.uk . info@chell.co.uk +44 (0) 1692 500555

36 Channel Smart Gas Meter Calibration System

Issue 46 PECM

15

EDITOR’S CHOICE

PRESTIGIOUS PROJECT WDS

Durable components demanded for Bombardier train assembly line KM Tools Ltd has selected WDS Component Parts Ltd to supply the carbody manufacturing facility for its prestigious project for the UK’s leading train manufacturer, Bombardier Transportation.

WDS has provided component parts for the jigs and fixtures deployed in Bombardier’s carbody manufacturing facility by KM Tools.

KM Tools made the selection based on product durability, ease of selection and service.

product volumes can be required for delivery within 24 hours.

“WDS carries a broad stock range and invariably supplies the component we need. Delivery time is very important for us, especially where we may order 100 units of a particular item, and WDS has a stock level which can fulfil our needs,” Adrian notes.

In order to select the right component, KM Tools’ engineers have a complete understanding of their required specification. Therefore, what they need is fast, clear access to component specification in order to make their choice.

Adrian explains that all the information required to make a rapid selection is available on WDS’ website, including 3D drawings which can be integrated into KM Tools’ equipment design.

Bombardier’s site in Derby is the UK’s only train manufacturing facility, designing and building AVENTRA electric multiple unit trains for UK operators. Their carbody facility manufactures key components; the underframe, roof and body sides. Within the welding facility, jigs and fixtures are used to hold the sections of train sub-assemblies in place during the welding process. KM Tools selected WDS to provide a variety of component parts used within the assembly jigs and fixtures based on high product reliability and service efficiency.

“Bombardier is very important for KM Tools because of the scale of the project,” says Adrian Degg, Engineering Director at KM Tools Ltd. “Manufacturing equipment for specialist production lines such as Derby means that we need high confidence in the components we use in our assembly jigs.

Supplying OEM customers like Bombardier, where time to market is key, also means that we need efficient suppliers. We’ve worked with WDS for eight years and they were our natural choice to provide component parts for this high-profile project.”

WDS provided a variety of components for the jigs and fixtures including locating pins, latches, swing clamps, toggle clamps, indexing plungers, hinges, knobs and handles. It’s crucial that product quality is high, especially where many of the components are used in demanding conditions on a daily basis, such as indexing plungers. Where extra durability is required, some of the components selected are constructed from hardened materials.

Depending on where the component will be used, resistance to corrosion is

“When you’re designing an item such as a jig, downloading and inserting the 3D model of the component makes the process far easier and saves valuable time.”

KM Tools selected WDS to provide a variety of component parts used within the assembly jigs and fixtures based on high product reliability and service efficiency.

also important, for example if the area is frequently lubricated and where soap is used to clean lubrication away. For this reason, KM Tools selected stainless or mild steel as the material of choice, chemically blackened where required to increase resistance to corrosion.

“We’ve always found that WDS component perform impeccably in terms of reliability,” says Adrian. “This is especially important to us and a reason for working with them. Any component failure would risk the uptime of our customers, so it’s key for the reputation of KM Tools’ as a manufacturer of high quality equipment.”

Stock availability and delivery time is an important consideration for KM Tools, especially when projects involve large OEMs such as Bombardier where higher

A crucial aspect of procurement, Adrian also explains that a reason for choosing WDS is their approach to clear pricing, which makes calculating project costs a faster process, especially where multiple units of a component are required.

“Pricing on the website is clear and easy to calculate at outset, which means you don’t have to spend time phoning the supplier to find out the best price. Not all suppliers present their costs online and it can save a lot of time, particularly if you need clarity on the cost of 100 units, rather than a single unit or 10.”

KM Tools’ assembly line installation for Bombardier came in ahead of deadline and the company will continue to partner with WDS for its ongoing maintenance work for Bombardier’s Litchurch Lane plant.

“WDS are a very good company to work with,” concludes Adrian. “The right products, easy to select, good price and fast availability.”

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

16

PECM Issue 46

EDITOR’S CHOICE

Ahead of the Pack: Professional Advice for Candidates BOOK RECOMMENDATION “Ahead of the Pack”

By Michael L. Cooper, Amazon Press

This book was written for those who want to advance their careers with some level of no-nonsense input on important parts of the process from the perspective of someone who has “been there and done that.” There are professionals who lead a wide range of companies that need top talent – our clients. There are professional recruiters who help client companies find the best talent that match their needs. And there are the professionals, I call “Candidates”, actively managing their career trajectory, evaluating opportunities that might fit their targeted career path while always sharpening their skills, experience and gaining comfort with their personal characteristics and leadership style. This book is for Candidates. There is no fluff, no dancing around issues, or gamesmanship - it is direct, and it is my opinion from deep professional experience in the capacity of all three noted above - a professional at the top levels running billion dollar corporations, a professional as an owner and recruiter for a Forbes 100 recruiting company, and as a Candidate who actively managed a career over several decades with

success. “Ahead of the Pack” is not just for those who aspire to the C-Suite but is a guide for those who want one day to work toward such a goal. It is designed to provide a greater capacity to assume leadership roles, from the shop floor to the C-Suite.

This book addresses only what you need to know to be more effective in understanding the recruiting process and advancing your career with that knowledge as a result of questions and issues raised by Candidates during the process of helping them over the

years. Some subjects you will find are not unique - because they are basic to the search process. A key difference - I provide frequent “My Advice to Candidates” throughout the book that is my judgment on various relevant subjects, less politically correct, more direct, often what is thought, not spoken. It is not a short story written to entertain. It represents what has worked for me. This practical experience across a wide range of relevant professional assignments, as a Candidate, a Retained Recruiter and a Company Executive provides a perspective that I believe is unique.

www.myadvicetocandidates.com

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

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

Issue 46 PECM

17

EDITOR’S CHOICE

CARING FOR YOUR BEARINGS SMB BEARINGS

Top tips for bearings maintenance when restarting your machinery Across the Western world, factories are restarting or stepping up their operations as lockdown measures are cautiously eased.

Owners of machinery and their operatives will be eager to know what to look out for when restarting machinery after a temporary shutdown. Here, Chris Johnson, managing director at specialist bearings supplier, SMB Bearings, provides us with his tips for how to care for the bearings in your machinery as you look to get your factory running to capacity again.

Your factory equipment may have been idle for a few weeks and now you are getting ready to restart things or step up the level of operations. You might be wondering if there are any additional checks you should make when caring for the rotational elements in your machinery. Here are some things you should bear in mind.

Corrosion is always something to watch out for when maintaining your bearings.

Prior to lockdown, when machinery was operational, it is likely that the factory was well heated and ventilated. If the factory has been shut down for a few weeks, perhaps the environmental conditions are not as ideal as they might have been previously.

In these cases, there is a slight increase in the risk of condensation, which is a cause of corrosion.

rotational torque for your bearings. This is unlikely to happen after just a few weeks of lockdown however.

Contamination is another risk to stay aware of. Particulate contaminants like dust can negatively impact a bearing’s performance and shorten its life span. For this reason, it is good to keep the factory environment clean and dust free to maximise the performance and longevity of the rotational elements in your machinery. However, there is a greater risk of contamination following a shutdown, compared with normal factory usage where cleaning schedules are adhered to.

So, what checks should engineers and operators be making as they restart their machinery? Well, if you have the benefit of digital technology like predictive maintenance and vibration analysis, you will be alerted to risks before they emerge.

In most instances though, and particularly for smaller and medium-sized operations, it is unlikely that you will have access to expensive technology like this. If the machinery is not yet smart, that doesn’t mean you can’t be instead. Routine manual checks to inspect bearing condition will suffice.

Similarly, in machinery that is idle for a sustained period there is the risk of the grease stiffening. Remember, grease is simply oil with a thickener added. If the oil begins to leach out of the grease, then the grease will stiffen, resulting in greater

You can inspect the rotational elements visually, looking out for signs of corrosion or other damage. You should also listen carefully. If your bearings are getting louder, that is usually a pretty reliable

indicator that something is amiss. Noise could suggest a range of problems from rough or damaged balls or raceways to contamination or inadequate lubrication.

In summary, if you have adequately cared for the bearings in your rotational elements until now, you should have little to fear when restarting your machinery after a brief period of idleness. As always, look out and listen out for possible signs of wear or contamination. Pay particular attention if you are noticing condensation in or around the factory as this will increase the risk of corrosion. And if ever you are facing any doubt, just ask an expert – we are happy to help!

At SMB Bearings we don’t just sell bearings, we help solve your problems.

If you are having problems with your bearings, you can visit our website or get in touch with one of our experts today by calling +44 (0)1993 842 555.

For further information, please visit www.smbbearings.com

18

PECM Issue 46

EDITOR’S CHOICE

QUALITY HINGES TALK TO THE EXPERTS.

GEMÜ Developed the World’s First Single-Use Diaphragm Valves

01827 63391 sales@goldwassallhinges.co.uk Whatever your hinge requirements, we offer a solution.

Bespoke/Stock - UK maunfactured - Expert advice

Pre-prepared Single-Use sterile production equipment that can be quickly installed and used enables Pharmaceutical manufacturers to produce fast, safe and flexible batch production. Pinch valves are used manually but not easily automated and can damage tubing. A need for aseptic valves to use in Single-Use processes prompted GEMÜ to develop the world’s first single-use diaphragm valve (GEMÜ SUMONDO). Valve body and actuator are easily connected and disconnected

from the actuator yet cannot be connected again and re-used in error. GEMÜ SUMONDO has a panel mount actuator that remains in the plant ready for the next batch. The body materials are sterilized through gamma irradiation, double bagged and with a replaceable single-use body, the valve is flowpath ready.

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

we make ideas come to life

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

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

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

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

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

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

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

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

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

Issue 46 PECM

19

EDITOR’S CHOICE

CHANGING OF THE SEASONS TSUBAKI

Sweet success for Tsubaki Neptune™ chain installed on ice cream plant palletisers Ice cream is a food that inspires universal joy like no other. People worldwide will always need ice cream to complete the perfect day out or take the edge off a hard week. However, one factor that does affect ice cream demand is the season.

Obviously, more ice cream is sold during summer than winter, which means ice cream producers have to increase production to capitalise. These duty demands can cause the premature failure of power transmission components such as chains, especially when production is taking place in sub-zero temperatures.

An ice cream plant in Germany realised that an increase in production was causing chains on its pallet lifters to fail prematurely, resulting in operational delays. To maximise chain service life, engineers at the plant contacted Tsubaki to supply a more reliable option.

FROM LUXURY TO INDULGENCE Historically, frozen desserts such as ice cream have been a luxury item. In ancient China, Greece and Rome, records attest to high profile members of society consuming them. In Italy during the 17th century, ice cream became popular, radiating out to courts across Europe. Modern ice cream production didn’t take off until the advent of industrial refrigerators in the 19th century1.

Since then, a rise in average incomes and our penchant for sweet foods has grown the market2. From being the preserve of the privileged throughout history, the global ice cream market had expanded to $57 billion U.S. by 20173.

THE CHALLENGES OF MODERN ICE CREAM PRODUCTION Propping up the majority of this large sector of the food and beverage industry are ice cream plants. Designed to operate with high efficiency to maximise profits per unit, these facilities rely on equipment that can operate in an application environment that, in many places, is well below freezing and laden with moisture. For example, ice cream is cooled

affected. The pallet lifters were operating in a sub-zero ice cream storage area, moving heavy loads across the facility.

Specifically honed for hard operation in a low temperature environment, the Neptune chain allowed the German ice cream plant to effectively capitalise on summer demand. to a holding temperature of around -25°C for storage4. This presents increased corrosion and fatigue risks to engineered equipment.

These conditions can be exacerbated by the seasonal demand for ice cream.

During the winter months, with December a notable exception, demand for ice cream falls. To reduce surplus, some facilities will scale back operations during this period.

However, in summer, demand rises, which will cause facility operators to maximise available production capacity to capitalise.

The inherent challenges of the application environment and the yoyoing of production intensity can cause equipment to fail prematurely. This risks facility uptime and profitability. Standard chains installed at ice cream plants are especially susceptible, so a specialised solution is needed.

CAPITALISING WITH SPECIALISED CHAINS As a German ice cream plant increased its production schedule from five to seven days a week to meet summer demand, engineers on-site noticed the service life of the chains installed on the pallet lifters was adversely

The nickel-plated, 16B-1 roller chains were designed to lift loads of up to 800kg. The lifter itself was driven by a 1.5 KW motor at 32 rpm. Over a five-day production schedule, the lifetime of each chain averaged to around 2 years before replacement was required. However, as production was moved to a seven-day schedule, the average service life of the installed chains fell to only six months. The inner links of the chains were breaking due to increased fatigue, a result of the combination of intense duty requirements and the cold application environment. This resulted in palletisers requiring increased maintenance work, which was reducing efficiency and increasing repair costs.

To solve the issue, engineers contacted Tsubaki, a global designer and leading manufacturer of premium quality drive & conveyor chain for most industries ranging from food & beverage to the steel industry.

After an initial inspection, Tsubaki engineers worked closely with the engineers at the plant to specify a new roller chain that would maximise reliability and reduce maintenance. The RS16B-1 Neptune chain was selected, which offered a 20% maximum allowable load (MAL) compared to the original chain. Another key aspect was the Neptune’s inherent resistance to corrosion.

A specialised coating provides exceptional protection against the debilitating effects of condensation in the low temperature storage area.

The Neptune chain was able to greatly improve chain service life during the high intensity production period, eliminating premature link breakages. Maintenance requirements for the palletisers were consequently reduced, minimising repair costs and maximising uptime. Specifically honed for hard operation in a low temperature environment, the Neptune chain allowed the German ice cream plant to effectively capitalise on summer demand.

For further information, please visit www.tsubaki.eu

20

PECM Issue 46

25,000+ Catalogue Springs Plus!

Custom Springs

To Meet Your Specifications.

ISO ISO 9001:2015 9001:2015 Registered Registered Company Company

Request a FREE Catalogue

More than 280 pages of parts, pricing and specifications.

Call: +44 118 978 1800 Visit: leespring.co.uk Fax: +44 118 977 4832 Email: sales@leespring.co.uk

INDUSTRY NEWS

AUGMENTED REALITY VUFORIA

AMRC signs landmark deal with PTC A network of world-leading research and innovation centres has taken one of the UK’s largest ever deployments of Augmented Reality (AR) technology.

The University of Sheffield Advanced Manufacturing Research Centre (AMRC), which works with more than 120 industrial partners including Boeing, Rolls-Royce, McLaren Automotive, BAE Systems and Airbus, has signed an agreement with PTC to implement Vuforia® Expert Capture (VEC) software across its three sites in the UK. This product allows tasks to be recorded using a wearable device and this content can then be turned into a step-by-step video guide with instructions for workers to implement at multiple sites and companies.

The agreement builds on a long-term relationship between the two organisations and comes after VEC played an integral role in remotely transferring manufacturing expertise safely to a number of new production lines supporting the build of over 13,000 ventilators for the VentilatorChallengeUK Consortium (VCUK).

“Vuforia Expert Capture will be used primarily by our Factory 2050 teams to deliver upskilling and reskilling solutions for our aerospace partners, with the potential for much wider application into other sectors,” explained Professor Rab Scott, Head of Digital at the University of Sheffield AMRC. “Our involvement in VCUK gave us firsthand experience of the power of AR in helping to quickly set up new manufacturing lines safely by rapidly transferring production knowledge to different facilities.”

He continued: “It has the potential to transform future supply chains and this is something we wanted to explore in more detail by giving researchers, our existing manufacturing partners and SMEs easy access to VEC and other PTC technologies.

“We already have a number of projects where we think it will accelerate

Airbus employees using VEC technology as part of the VentilatorChallengeUK consortium project the deployment of solutions into manufacturing.”

PTC, one of the world’s leading providers of industrial innovation technology, became a Tier One Partner of the AMRC in 2017, with its ThingWorx® IoT platform helping connect machinery and devices at its Factory 2050 facility.

This latest deal is one of the largest ever signed for Vuforia Expert Capture in the UK and will see the AMRC become a lighthouse demonstrator for its growing range of digital technologies and Augmented Reality solutions for industry.

In addition to VEC, experts at the research and innovation centres will also be able to maximise the capability of Vuforia Chalk, a remote assistance product that leverages AR to help employees collaborate in operational, maintenance and repair situations.

The technology is like Facetime, with augmented reality superpowers for industrial settings, with the emphasis on being easy to set up and use.

David Grammer, UK Country Manager at

PTC, went on to add: “The high-profile nature of the VentilatorChallengeUK has really thrust Augmented Reality into the spotlight and proved that it is a technology that manufacturers can easily adopt and successfully implement now and not in five, ten or even twenty years’ time.

“Using Vuforia Expert Capture and Vuforia Chalk allowed us to parachute a virtual Smiths Medical manufacturing expert into new production lines, giving engineers who had never worked on ventilators before access to all the guidance and advice they required to complete the build.

“AR reduced the time taken to create the new supply chain by a number of weeks and also protected all the workers involved in the project by ensuring staff were not moving from site to site, reducing the risk of Covid-19 spreading.”

He concluded: “We now want to increase the adoption of Augmented Reality and remote assistance in other manufacturing environments and the AMRC will provide a perfect gateway to engaging with research projects, new supply chains and in the development of new products.”

For further information, please visit www.ptc.com/www.amrc.co.uk or follow @ptc on twitter.

Issue 46 PECM

23

BOILERS & MAINTENANCE

Reciprocal agreement with Turkish distributor enhances Lanemark Combustion Engineering capability Process gas burner specialist, Lanemark Combustion Engineering Ltd., is announcing a major agreement with a new distributor in Turkey. The link with YETEN Combustion and Energy Technologies Ltd., based in Istanbul, will create opportunities for both organisations to add each other’s burner equipment to its range – with each enhancing its services to its customer base.

“YETEN is very well established in the field of high temperature burners which are used

extensively in areas such as metal processing,” says Adrian Cadman, Sales Manager at Nuneaton-based Lanemark. “Now, by being able to make selected burners from their range available to our own market, we will be able to develop our involvement in areas such as steel and aluminium manufacturing.”

With an ongoing focus on research, development and design – including use of state of the art Fluent Computational Fluid Dynamics – and on providing eco-friendlysolutions, YETEN’s reputation reflects the philosophy that has underpinned Lanemark’s own worldwide success for some four decades.

“The organisation also offers extensive test facilities which, again, mirrors our own growing capability in this area,” adds Adrian Cadman.

The agreement with YETEN is also set to strengthen Lanemark’s own burner sales in the new distributor’s markets. The company’s (FD) forced-draught oven burners, (TX) tank heating burners and its (DB) duct burners – each used extensively in processing and manufacturing operations from aluminium anodising to food processing – will, in turn, all enhance YETEN’s own market strength.

“We are committed to building on the close relationships that we have with distributors around the world and we are, therefore, delighted to be able to add YETEN to this list,” concludes Jeff Foster, Sales Director at Lanemark. “The area within which both companies have developed globally leading reputations is highly specialist so we are confident that the link between us will offer major gains to our respective customers.”

www.lanemark.com

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

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

• • • • FD-C high turndown oven/

FD-E low cost high turndown

dryer air heating burners.

oven/dryer air heating burners.

FD-GA modulating gas + air

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

• • • •

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

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

•

process air heating burners.

• •

Midco HMA high efficiency,

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

TX high efficiency small diameter immersion tube tank heating systems.

Lanemark Combustion Engineering Limited Lanemark House, Whitacre Road, Nuneaton, Warwickshire CV11 6BW United Kingdom Tel: +44 (0) 24 7635 2000 Fax: +44 (0) 24 7634 1166 E-mail: info@lanemark.com www.lanemark.com X4620 Lanemark Ad SDAW.indd 1 24 PECM Issue 46

•

COMBUSTION ENGINEERING

31/08/2016 09:04

COATINGS

Chemically Resistant Filter Housings for API Manufacturing Highly corrosive chemicals such as concentrated acids are often used in API manufacturing which places great demands on both filter media and filter housings.

Where highly corrosive chemicals are being processed, specialised filter housings such as those manufactured with an internal coating or made from exotic nickel alloys may be considered. However, neither of these

options is ideal. Coatings are prone to mechanical damage and nickel alloys have limited resistance to corrosion by certain acids and some other chemicals. Traditionally, the preferred construction materials for filter housings used in API manufacturing have been Hastelloy Steel or Titanium - unfortunately both can be very costly with long lead times for delivery.

For further information on corrosion resistant filter housings for API manufacturing processes visit www.amazonfilters.com/products/filterhousings/corrosion-resistant-housings/ or contact Amazon Filters on +44-(0)1276-670600 /Â sales@amazonfilters.co.uk.

www.amazonfilters.com/products/filter-housings/corrosion-resistant-housings

Issue 46 PECM

25

CONTROL & AUTOMATION

THE BENEFITS OF AUTOMATION SEWTEC

Why automation is playing a vital role in the manufacturing industry As automation continues to transform the workplace, manufacturing is perhaps the sector which benefits the most from automating its processes. Paul Johnson, sales director at Sewtec Automation, offers insights into the benefits of automation in manufacturing.

Automation has enabled a new way working, but one sector which can benefit the most from automating processes is manufacturing.

From food to pharmaceuticals, personal care to pet care, introducing factory automation offers huge potential to increase throughput, improve quality and reduce costs.

So, how will automated production in manufacturing transform the industry’s future?

ADDRESSING THE SKILL GAP Manufacturing is currently in the midst of a skills crisis, with businesses facing the biggest shortage of skilled workers in 30 years. If four out of five manufacturers struggle to find skilled staff, something needs to be done – and the answer is automation.

It is estimated that the potential to automate processes in the sector is around 60 per cent, meaning manufacturers can ease the burden of unavailable resource by automating ‘predictable physical’ processes such as product creation, analysis and sorting.

This benefit to businesses would have a direct positive impact on the wider economy, with a 30 per cent global increase in robot installations predicted to create £3.9 trillion in additional GDP. It is also good for workers, as the creation and maintenance of automation systems demands higher skilled roles, such as precision engineering. This reduces the prevalence of what McKinsey’s automation report calls “dirty, dull, or dangerous jobs” from the workplace.

HIGH-SPEED PRECISION A key benefit of automation in manufacturing is that it improves product quality by

26

PECM Issue 46

removing human error and variance in the production process. When you consider all this can be achieved often with higher throughput and quality, it becomes a compelling proposition for any manufacturer.

As an example, Tata Global Beverages installed a bespoke automated tea-bag packaging machine which packs 2,000 tea bags every minute. The high-tech system builds 120 flip-top cartons per minute, filling each with a flow-wrapped bag containing 20 tea bags, before conducting quality control and collating multiple cartons into shelfready trays.

In many instances, machines are so advanced that businesses could find themselves close to operating ‘lights out’ production in future – where manufacturing activities or whole facilities are entirely automated without the need for human intervention.

THE INTRODUCTION OF AI With such a focus on physical manufacturing processes, like packaging and palletising products, it is important to remember the

Manufacturing is currently in the midst of a skills crisis, with businesses facing the biggest shortage of skilled workers in 30 years. software behind them. Factory robots have increasing levels of capability and come in a wide variety, from simple pick and place units to collaborative robots (cobots).

Artificial intelligence (AI) relates to advanced computerised processes that perform tasks usually requiring human intelligence. But machines do not need the most advanced technologies to be smart – many have sensors of some kind that can perform an important sorting or checking function and make a ‘decision’ based on that.

So, while many smart machines do not incorporate AI technology, there is little in a modern manufacturing facility that can be classed as ‘dumb’ machinery.

DESIGNING WITH AUTOMATION IN MIND By now, the benefits of automation are a given for most manufacturers. The

real question is, how do they automate effectively and efficiently?

designed will give better longevity and return on investment.

For those manufacturers reaching a high level of automation maturity, or with niche and complex products going through the factory floor, commissioning a bespoke automation system often offers the most effective solution. Off-the-shelf installations may be faster to procure and install, but bespoke applications which are purpose

Manufacturers must avoid automating for automation’s sake. If their automation approach is closely aligned with the business strategy and the commissioning process has a laser-sharp focus on solving a production problem, then they will achieve a clear result.

For more information, visit www.sewtec.co.uk Issue 46 PECM

27

CONTROL & AUTOMATION

Benefit from our experience to increase your success!

The valve technology by Schubert & Salzer Control Systems offers you the perfect solution for your individual control applications.

Schubert & Salzer - Your Partner in the process industries!

www.schubert-salzer.com

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

PRESENTING THE e-Series.

World’s #1 Collaborative Robot

Fast set-up Collaborative & safe

Easy programming

Fast payback Flexible

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

28

PECM Issue 46

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

CONTROL & AUTOMATION

THE 3DV/600 VISION SENSOR FANUC

Fanuc launches new 3d vision sensor with extended field of vision FANUC has expanded its range of integrated image processing solutions with the introduction of the 3DV/600 Vision Sensor.

The new sensor benefits from an extended field of vision in comparison to other models in the range, and is designed for use in multiple applications, including bin picking, feeding an assembly line, or stacking pallets. Complete with the 2D Camera Package, 3D Laser Sensor and 3D Area Sensor, the 3DV/600 forms part of a highlyintegrated, high-performance portfolio for industrial image processing.

Andy Armstrong, Sales and Marketing Manager at FANUC UK, comments: “The 3DV/600 is a practical and user-friendly addition to the range, capable of being fitted permanently into a system, or temporarily on the last axis of a robot. The other models in the 3DV series have proved hugely popular, and by expanding its field of vision, we’ve ensured the 3DV/600 can deliver the high levels of performance demanded by ambitious manufacturers.”

Its high level of integration and very short image processing ensures that the 3DV/600 can be combined with the iRPickTool for use on a conveyor belt, able to pick up items even if they are irregular-shaped or have no clearly defined pick-up point.

The 3DV/600 is pre-calibrated, which makes installation as straightforward as possible. After the sensor is installed, the robot simply has to identify the position of its ‘eyes’, and a setup-wizard supports and guides you through the necessary settings.

Furthermore, no interface development is needed, as the FANUC 3D Sensor support is fully integrated into the robot software.

Andy continues: “By fully integrating the 3DV/600 Vision Sensor, a huge amount of time is saved at both the installation and image capturing stage. The 3D-Snap-inMotion function allows the robot to trigger the snapping of an image while in motion, which saves a lot of time and is something a non-integrated vision system would be unable to do.”

The 3DV/600 has been designed with the user in mind, designed to ensure it is as intuitive as possible.

As with other sensors in the range, the 3DV/600 is equipped with blue LED lighting as standard and connected with a single cable – which reduces clutter and makes maintenance much easier for the end-user.

Andy concludes: “The 3DV/600 has been designed with the user in mind, designed to ensure it is as intuitive as possible. It’s integration and expanded field of vision make it an ideal addition to a range of FANUC robots.”

For further information FANUC UK’s range of robots and automation solutions, please visit www.fanuc.eu/uk/en Issue 46 PECM

29

CONTROL & AUTOMATION

FOAMplus® perfect protective packaging solution from Storopack As a leading global protective packaging supplier Storopack recognizes the importance of ensuring goods are protected during transit and arrive in perfect condition.

Damaged goods not only incur costs for replacement orders but also affect businesses’ reputations. So while costs need to be kept to a minimum it is vital to choose the correct protective packaging type.

Usually a void fill packaging medium will suffice. However when the product is more sensitive to shock and vibration, such as engineering, electronics, aeronautical, and many other expensive products then more consideration has to be given to using the right type of in-the-box protective packaging.

Storopack’s FOAMplus® range is a perfect solution for companies that manufacture or ship products that require this highest degree of protection eliminating transit and handling damage.

The success of FOAMplus® polyurethane foam is based upon its huge versatility as a packaging medium. The foam can either be dispensed directly into the carton where the expanding foam will mould itself to the contours of the product shape or can be made into pre-moulded cushions to enhance presentation. The product will satisfy the most rigorous cushioning demands for high value, fragile and awkward shaped products. The light weight foam packaging also ensures that shipping costs are kept to a minimum whilst providing customers with total product protection.

As a space saving solution FOAMplus®, polyurethane foam packaging is ‘on demand’ and mixes two components together which then expands up to 200 times its liquid volume negating the necessity for large storage areas required for pre-fabricated packaging.

The benefits for customers are numerous. As well as an ideal solution for protecting awkward and valuable products, customers with product

design changes and new product line additions are able to quickly adapt the packaging without the need to carry a large range of bespoke cartons or fabricated packaging.

There are two dispensing methods available for the insitu protective packaging solution. Either FOAMplus® Hand Packer, a manually operated system, with a fully electronic microprocessor control to maintain consistent quality that delivers the foam direct into polythene lined carton via a foam dispensing gun.

Alternatively the Bag Packer² Foam-in-Bag dispensing system is fast, easy to use, efficient and economical. The machine can produce up to 23 foam-filled bags per minute at the touch of a button. Polyol B 5504R, foam B component is made from 30 percent recycled polyurethane.

www.storopack.co.uk

FOAMplus® Your products deserve the best protection.

Expanding polyurethane foam pads mould around any product shape within seconds. Exceptional protection for fragile or awkwardly shaped products.

Contact us for a FREE* trial

T: +44(0)114 249 2004 E: packaging.uk@storopack.com *subject to qualification

30

PECM Issue 46

www.storopack.co.uk

SUPERIOR INDUSTRIAL PACKAGING PROTECTION PAPERplus® - Paper pads provide maximum performance, high density, and strength.

Ideal in-the-box protection for heavy products.

100% recycled content and 100% recyclable

Issue 46 PECM

31

CONTROL & AUTOMATION

A WEALTH OF EXPERIENCE FOREMOST ELECTRONICS

Key components for automation and machine builders from Foremost Electronics Foremost Electronics, the engineeringled Essex based importer and specialist distributor of electromechanical components, has a wealth of experience supplying components to designers and manufacturers of automation systems and machine builders. Key components in this market include rugged and reliable HMI solutions including emergency-stop switches and status indicators, secure rugged and flexible cable entry systems and connectors.

The IDEC CW switch range offers designers stylish, compact and spacesaving switches and pilot devices.

The innovative two-step locking lever integrated with a guard provides a higher level of safety, and the low projection hight from the panel surface reduces the possibility of unexpected activation or operator damage. The CW series add a sleek and stylish image to any panel with black or metallic bezels. The shortest depth behind the panel in its class contributes to reducing machine and control panel size. Up to 6 direct opening NC (normally closed) contacts rated at 10A are available per switch with the choice of black and metallic bezels. Options include illuminated push buttons, push buttons, pilot lights, selector switches and key selector switches.

To ensure operator safety and prevent damage to equipment the IDEC E-Stop Switch XW Series includes revolutionary new technology that has changed the way E-Stop switches are designed. This “safe break action” concept provides greater levels of human safety and is the first of its kind in the world. The “safe break action” design, found only in the IDEC products, reverses the energy direction and uses the spring-pressure to assure that the NC contacts will open if the emergency switch is damaged or the contact blocks separate due to excessive force. The NC contacts will reliably open, even if they are welded, and stop the machine. Combined with IDEC quality, this is the go-to E-Stop switch for any life-threatening situation.

The IDEC CW switch range offers designers stylish, compact and space-saving switches and pilot devices.

For clear indication of the status of a machine, factory automation or industrial system the IDC LD6A SignaLight Towers offer new concept and innovative, ergonomically designed system for instant visual and audible status recognition.

LD6A SignaLights combine the latest LED technology with IDEC safety technology. The stylish design includes an LED lens shape providing visibility in all directions. 5 different mounting styles, custom arrangement of LED units and a powerful alarm which can easily be heard in noisy areas.

Secure, rugged and flexible cable and pipeline entry system are key for installing, upgrading and maintaining industrial systems and Foremost can supply a wide range of entry systems from market leader icotek. The IMAS CONNECT is a modular designed grommet system for mounting circular connectors, keystone jacks, pushpull connectors, hose fittings, pressure compensation elements and much more.

By utilising a modular adapter system, the split icotek cable entry frame becomes a hybrid system allowing pre-terminated and standard cables or hoses to be routed.

The icotek EMC KEL U 24 is a split cable entry system for routing cables with connectors and provides an IP54 / UL type 12 rating. The cable entry system is easy

to install and provides routing, sealing and strain relief for cable diameters from 1 to 35 mm. The KEL-U 24 frame has the same cutout dimensions as standard 24-pin industrial connectors, is fast and easy assembly, offers high cable density, and strain relief according to EN 62444 For secure power connection to machines and industrial equipment Foremost offers the Neutrik powerCON TRUE 1 TOP. Suitable for heavy-duty and harsh environment applications This lockable, ruggedised and sealed power connector features IP65 protection and UV resistance according to UL50E. It is made from high impact UVresistant materials, rated to 16A and it also features a unique cable retention system.

Emma Kempster, Key Account Manager, of Foremost Electronics, comments; ”Industrial automation systems and machine building require high quality and rugged components to ensure reliable operation over long periods of time. Safety of operators and protection of machines from damage are also critical design considerations. Foremost have been working with machine and automation system designers for many years and have an unsurpassed range of HMI, cable access and safety components which greatly simplifies our customer’s sourcing process.

For further information, please visit www.4most.co.uk

32

PECM Issue 46

Reduce Reduce unscheduled unscheduled shut shut downs, downs, reduce reduce maintenance maintenance costs costs and and improve improve plant plant safety safety with with our our Valvescan Valvescan Diagnostic Diagnostic Monitoring Monitoring System.

System.

Our Our revolutionary revolutionary system system is is an an end-to-end end-to-end solution solution that that captures captures data data from from every every valve valve operation, operation, analyses analyses itit and and provides provides targeted targeted alerts alerts on on the the valve valve health health without without any any requirement requirement for for involvement involvement from from plant plant personnel personnel or or any any potential potential impact impact on on the the asset asset real-time real-time control control integrity. integrity.

It It is is aa true true IIoT IIoT solution solution for for automated automated valves. valves.

This This system system is is not not only only aa pioneering pioneering development development in in valve valve monitoring, monitoring, itit is is also; also; ●● Cost Cost effective effective and and easy easy to to install install ●● Works Works with with all all existing existing valve valve systems systems ●● Enables Enables data data retrieval retrieval and and transmission transmission to to the the cloud cloud ●● Provides Provides aa ‘real ‘real time time health’ health’ check check on on the the valve valve and and alerts alerts when when performance performance drop drop off off is is detected detected

Contact Contact us us to to find find out out more: more:

08700 08700 340 340 002 002 www.imtex-controls.com www.imtex-controls.com

CONTROL & AUTOMATION

AFFORDABLE FLEXIBILITY INSPEKTO

How Autonomous Machine Vision could help ward off the looming recession Today, we are facing a risk of a major global recession as the result of the COVID-19 pandemic. As manufacturers are planning the resumption of work after the shutdown period, experts predict that a major global recession might be inevitable.

To ward off its negative impact, ‘affordable flexibility’ is key, and manufacturers need the ability to adapt, adjust and modify their production lines, cost effectively, to meet changing needs in a dynamic and competitive environment. Most importantly, plant managers need ready-to-use, outof-the-box technology that delivers added value right away, and that they can manage on their own without any help from external experts. For industrial inspection, a key element to deliver high quality products, Autonomous Machine Vision (AMV), a new category in machine vision for visual quality assurance (QA), offers this and much more.

IT’S FUN TO BE AUTONOMOUS (IT’S CHEAPER, TOO) The INSPEKTO S70, the first Autonomous Machine Vision product, is autonomous in every way, releasing plant managers from lengthy and expensive contracts with external third parties, such as systems integrators. It is highly versatile in that it can be used to inspect any product, in any industry, produced with every manufacturing techniques.

The installation is easy and fun. Thanks to Inspekto’s Plug & Inspect™ technology, the plant’s own personnel can install an AMV system in just 30 to 45 minutes, with no external intervention. The user simply presents an average of 20 to 30 good samples to the system, which will automatically learn what a gold-standard product should look like.

Much like a human being, the S70 knows when it has enough information about the product to start inspecting it. After inspection begins, the system will alert the user to every deviation from the defined standards.

plant managers can position a QA station at every junction on the production line, instead of just at the end, realising what Inspekto calls Total QA. This minimises scrap, because resources will not be wasted on items that are destined to be defective from the very beginning.

MINIMAL INVESTMENT, MAXIMAL RESULT In times of financial instability, the first thing plant managers do is keep their budgets under control. The INSPEKTO S70 requires minimal initial investment, because it can be purchased for less than one tenth of the cost of traditional QA solutions. In addition, it can be installed while the production line is running, causing zero downtime.

This out-of-the-box, ready-to-go system comes with everything QA managers need to perform accurate and effective visual QA right away. Also, with the S70 there’s no need to invest in training. Thanks to its self-adapting and self-learning capabilities, the system operates in complete autonomy, communicating directly with the programmable logic controller (PLC) without any intervention from the plant’s personnel.

LESS SCRAP EQUALS MORE PROFIT If the country hits a phase of economic recession, cutting costs is not enough.

Manufacturers should also enhance profitability by reducing scrap and waste, identifying defective items as soon as possible and optimising their production lines so that the same defect doesn’t keep happening.

Because AMV systems are cost-effective and extremely quick and easy to set up,

Over time, Total QA allows manufacturers to see where defects are more likely to occur, so that they intervene in the most appropriate way. In times of financial instability, it is paramount that plant managers identify every opportunity to improve their production processes, working at full potential to outrun the competition.

INVESTING IN YOUR PEOPLE AMV allows manufacturers to free personnel from tedious QA procedures, whether these are manual inspection tasks, or maintenance of complex machine vision solutions.

Manual visual inspection carries an error rate of up to 25 per cent and keeps employees busy on a task that does not add value to the business. Consider this example from the automotive engineering sector. In the UK, the average value added by each employee in this sector is £100,000 a year, so manufacturers lose millions by assigning several shifts of employees to tedious inspection tasks.

By investing in an Autonomous Machine Vision system, manufacturers can move those employees into productive roles that create value for the business. A small investment in an INSPEKTO S70 can therefore save a plant hundreds of thousands per year.

It’s clear that automotive manufacturers in particular, but also industry overall could save millions by reducing the number of detectable faults in their products.

The New Deal that AMV provides could certainly be the boost that the economy requires.

To find out more about Autonomous Machine Vision, visit inspekto.com

34

PECM Issue 46

DESIGN | ENGINEER | MANUFACTURE | DESIGN | ENGINEER | MANUFACTURE

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

AWARD-WINNING PLATFORM BRILLOPAK

UniPAKer variations make Robotic crate packing as easy as 123 Brillopak has developed its award-winning UniPAKer robotic crate packing platform with the introduction of single and triplehead versions of the system, following the success of its dual robot cells in fresh produce applications. The ability to incorporate one, two or three parallel arm delta robots into a single crate packing cell enables the design of flexible systems that strike the optimum balance between speed and gentle handling.

“Whilst delta robot heads might boast mechanical speeds in excess of 120 picks per minute, such high speeds can only be achieved in real life on very straightforward crate/case packing applications such as packs of biscuits. It is very unlikely that any packaging automation supplier who is handling delicate or awkward products like flow-wrapped apples, bags of carrots or tray-sealed meat would be able to achieve anything close to those kinds of speeds without damaging the product in the process, it simply isn’t possible,” says Peter Newman, Technical Director at Brillopak.

He continues: “That is precisely the reason why we have developed single, dual and triple robot configurations for our UniPAKer packing system – to help our customers meet their performance and payback objectives without making false promises.”

Working on the premise that most fresh produce packs – whether punnets of soft fruit, bags of sprouts or flow-wrapped packs of peppers – can be packed into crates using a single robot head at speeds of 30-40 packs per minute, the UniPAKer can double or triple those speeds to achieve a customer’s target by adding a second or third robot. Each robot takes it in turn to take a pack off the infeed conveyor and position it precisely in the crate, so the desired crate presentation is achieved twice or three times more quickly than with a single robot. To maintain a compact footprint, simplify operation and minimise capital outlay, the entire system is centrally controlled and the robots share a vision system, infeed and outfeed, regardless of whether it is a dual or triple configuration.

Brillopak has added single and triple robot configurations to its popular UniPAKer packing system

The 70-80 ppm speed capabilities of the dual-head UniPAKer are the perfect match for flow wrapping lines handling fruit and veg such as apples, sprouts, tomatoes, peppers and pears, with or without a supporting tray.

Another potential application for the triplehead UniPAKer is for placing products such as peppers into the pocket of the flow wrapper. Using three robots operating at 60 picks per minute, the UniPAKer would be able to match typical flow wrapper speeds.

WHEN THREE HEADS ARE BETTER THAN TWO

MULTI-PICK SPEEDS UP SINGLE ROBOT SYSTEM

The triple-head system has been conceived with difficult-to-handle or bulky products in mind.

However, adding another robot is not always the best approach for increasing packing speeds. In applications where the product is fairly straightforward to pick, a single robot with a multi-pick head might be a more cost-effective and space-efficient option. In this configuration, the robot performs two picks, then places the packs in the crate, two at a time. This design works well for tray-sealed meat packs, which are uniform packs with flat surfaces, but cannot be handled at very high speeds as the film lid may tear. Speeds of 60-70 ppm can comfortably be achieved on this application.

Brillopak is currently building its first triplehead UniPAKer cell for a supermarket customer with the goal of packing bags of carrots into plastic retailer crates at speeds of 100 ppm.

Carrots are a difficult product to handle as each bag of the same weight is a different shape and size, therefore the robot has to slow down to perform the pick and position the pack in the crate; too much speed will result in the bag falling out of the gripper or an untidy crate presentation. Using a single robot head in conjunction with a flexible finger gripper, the UniPAKer can handle carrots at speeds of 37 ppm per head. A triple-head system can achieve over 100 ppm, which should enable the customer to meet its two-year payback target.

Brillopak’s UniPAKer robotic pick and place cell was originally engineered for packing bags of potatoes and apples into crates.

Designed to handle VFFS, tray-sealed or flow-wrapped packs up to 1kg, the UniPAKer has been proven over-and-over again to improve productivity and improve pack presentation on shelf.

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

36

PECM Issue 46

SAFETY FIELDBOX UNIVERSAL. SAFE. COST EFFECTIVE. The SFB safety fieldbox for PROFINET/PROFIsafe systems is suitable for simple plug and play installation of up to eight safety devices.

Thanks to its universal device interface with an 8-pole M12 connector, it can be used to connect a wide variety of safety devices: electronic and electro-mechanical safety interlocks, switches, sensors, light curtains and operation panels.

The SFB is a simple, inexpensive installation solution which provides highly flexible, individually configurable safety solutions for complex machines and systems.

•

8 universal 8-pin M12 device ports

•

Connection of electronic and

•

4 control panels connectable

electromechanical switchgear devices (with EMERGENCY STOP) •

1-channel and 2-channel control of the

•

Automatic resettable fuse integrated

•

Robust industrial design

interlocking function

ELECTRICAL & ELECTRONICS

YOUR CONCEPT, OUR CREATIVITY CLARK CABLE LTD

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

Above, Hospital Products.

Below, Floorcare.

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

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

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

38

PECM Issue 46

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

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

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

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

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

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

20A Powercon True 1 Tri Splitter

Power distribution

Power/co-axial/cat 5 for projection systems

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

We don’t just cater for specialised industries. Wherever there is a need for cables then we are the company to contact for best service and top quality plus we may well be able to recommend a better way to make your product. If you need a simple cable with a plug Clarke Cable can supply.

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

Coloured Anodised Locking Rings For further information, please visit www.clarkecable.co.uk Issue 46 PECM

39

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

40

PECM Issue 46

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

ST2XM

EXTREME Multi-Channel Flow Computer •

FIVE METER CHANNELS WITH ONE VIRTUAL CHANNEL

•

I/O EXPANSION CARDS FOR MULTIPLE INPUT & OUTPUT COMBINATIONS

•

7" GRAPHIC TOUCHSCREEN

•

RS-232, RS-485, ETHERNET & WIFI

•

SUPPORTS BACnet™ MS/TP, MODBUS MS/TP, HART®, DNP3

•

STEAM, HOT/CHILLED WATER, OIL & GAS

•

FISCAL METERING / CUSTODY TRANSFER

KEP has been a world leader in flow metering for decades. Our years of flow measurement experience and our knowledge of applications for custody transfer/fiscal metering, fuel loading, district energy and many more make our flow computers the right choice. The new ST2xm flow computer expands on our popular ST2 series with a new design for advanced functionality and features. It offers multiple inputs and outputs via an expansion card rack, enhanced metering capabilities, improved security and auditing with a high capacity data logger.

Website: kep.com • Phone: 732-649-7100

WilSon Energy Limited are the exclusive UK distributor for the full range of KEP Flow Product Instrumentation.

Website: wilsonenergy.co.uk Email: Enquiries@wilsonenergy.co.uk Phone: 01636 857240

FASTENERS & FIXINGS

PRODUCT SPOTLIGHT STAR FASTENERS

Lockbolt Fastening System Key Benefits There is a Huck® Lockbolt for every application – Bobtail®, Magna-Grip®, C50L®, C6L® C120L®, Hucktainer® Compared to conventional nut and bolt installations, which can loosen in high-vibration environments, Huck Lockbolts have proven to be resistant to the effect of vibration in a number of very demanding applications. They are widely used in rail, automotive, agricultural vehicles and machinery, commercial vehicle trailer and chassis applications and also wind power industries.

The secret to this performance can be found in the unique Huckbolt design in which the collar is fully swaged into the locking grooves of the pin. Huckbolts are precision engineered two-piece fasteners that once installed, no matter how vibration intensive the environment, do not come loose. Huckbolts provide direct metal-to-metal contact when installed which eliminates the transverse vibration often found in conventional nuts and bolts.

Engineered for a wide range of applications, Huckbolts deliver superior joining, shear, and tensile strength for an unmatched fastening solution.

Key Benefits: -

• Lower lifetime total cost of joint - high shear and tensile strengths for increased fatigue life of the joint

• High speed, easy to install systems reduce production time

• Wide grip ranges minimise fastener inventory • Improves health and safety - replaces welded joints • Tamperproof – once installed cannot be removed without specialist tooling

• Maintenance free joints – no need to torque or re-torque

• Do not loosen even under extreme vibration

Huck Lokbolts

Huckbolts can be effectively used with virtually any metal, and metals with dissimilar coefficients of thermal expansion present no problems. Varying material thicknesses in a joint are readily accommodated, and surface finishes are not damaged. Most importantly, Huckbolts are proven to hold up over years of service in demanding high stress, high vibration environments.

Star Fasteners are the UK’s largest Huck fastener and tooling distributor. Together with a hire tool fleet and an approved in-house tool maintenance repair department, an all-encompassing service can be relied upon.

Star Fasteners have a wealth of application and fastener knowledge that can make the impossible, possible. A standard fastener in the Huck range may provide your answer. If not, help with a cost-effective tailor-made solution is made available to all. sales@starfasteners.co.uk Tel: +44 (0) 115 9324 939

For more information, visit www.starfasteners.co.uk Issue 46 PECM

43

FASTENERS & FIXINGS

SURGE IN GLOBAL DEMAND TR FASTENINGS

TR responds to unprecedented global sheet metal fastener demand The outbreak of the Covid-19 pandemic created a surge in global demand for medical equipment, with the subsequent knock-on effect of a huge demand for sheet metal fasteners, specifically for those companies producing essential equipment, including ventilators.

International specialist TR Fastenings focused on being as responsive as possible to meet this demand and is now further investing in its sheet metal range to accelerate growth of this product portfolio.

TR has been leading the sheet metal fastening industry for over 45 years, providing products to more than 5,000 global customers from 32 business locations in 18 countries. TR’s ability to move with the times and adopting a fast track approach has firmly positioned the company as a market leader; an internationally respected manufacturer who is flexible enough to continually adapt its range and stay ahead of the competition.

This latest investment sees expansion of its own highly regarded Hank® Self Clinch Fasteners and the launch of a new range of K-Series® Thin Nuts. TR’s own facility in the UK can manufacture as small as M2 and as large as M36 which are used across a wide range of industry sectors.

TR has a robust business model for large OEM’s and SME’s and competitive advantage is achieved through flexible pricing, volumes and short lead times with the capability to source raw materials locally, allowing faster production times to meet demand.

There are many application challenges within the sheet metal industries and TR can offer fastener testing capabilities across mechanical, dimensional, installation, and plating and finishes.

TR supplies sheet metal products for pressing, riveting or welding during manufacturing or assembly processes.

TR’S WEBSITE LEADS THE WAY IN SHOWCASING SHEET METAL FASTENING SOLUTIONS TR’s industry leading website now further enriches the customer journey by showcasing the very latest information on sheet metal fasteners with technical, explanatory animations and visualisation tools showing how products can be installed. The videos and enhanced online resources provide key insights including detailed product specifications such as dimensions, materials and performance guides, FAQs, spotlight pieces and customer feedback supported by global sales and marketing activity.

Steve Wallis, Sales Office Manager at TR Fastenings, said: “The recent pace of change across the industry has been unprecedented and TR has been able to utilise years of experience to adapt to this.

Customers are looking for higher quality and smarter application-based sheet metal fasteners, and selecting and installing the right fastener, within tight timeframes, is a challenge.

“This is where TR’s global teams can add real value, from our knowledgeable customer services assisting with product suitability through to our expert quality and application engineers providing guidance from early design through to specification and manufacturing.”

For further information, please visit www.trfastenings.com/industries/sheet-metal

44

PECM Issue 46

TR Fastenings has been at the forefront of sheet metal fastening solutions for over 45 years, supplying fastening components to more than 5,000 companies worldwide.

Stocking over 100,000 sheet metal products, TR’s product offering includes our own branded Hank® Self Clinch fasteners and Hank® Rivet Bushes, which are highly regarded throughout the sheet metal industries.

Sheet Metal Product Range

Hank® Self Clinch

Hank® Rivet Bushes

K-Series® Products

Blind Rivets

Blind Rivet Nuts

Weld Products

Spring Steel Fasteners

Masking Caps & Plugs

Enclosure Hardware

DIN/ISO Bolts & Screws

Full Service Provider (FSP)

Design & Engineering

Supplier

Distributor

Manufacturing

Quality

Logistics

Contact the team today for more information T: +44 (0) 8454 811 800 I sales@trfastenings.com I www.trfastenings.com Issue 46 PECM

45

FASTENERS & FIXINGS

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

46

PECM Issue 46

• 01623 551 800

FLUID HANDLING

New couplings & accessories catalogue now available Dixon Europe are driven to provide ‘the right connection’ in meeting specific hose and coupling requirements across all industries.

Their strength in service, technical support, training and advice ensure the correct specification of bespoke hose assemblies and couplings.

Our latest couplings & accessories catalogue is now available to download from www. dixoneurope.co.uk or in hard copy.

Dixon has been building a credible reputation for over 100 years, demonstrating that it’s a responsible manufacturer producing and supplying safe, reliable and long lasting products. Open communication with customers and following through with solutions strengthens trust as a supplier of both current and future products.

Dixon products can be relied upon, as quality control starts at the innovative design stage,

and is further supported with technologically advanced engineering and manufacturing processes. Dixon will not compromise on high quality control, utilising assurance standards and inspection procedures at each critical step of the production process To find out more about how Dixon can help you make the right connection and the Dixon range head to dixoneurope.co.uk or contact our customer sales department on 01772 323529

www.dixoneurope.co.uk

Dixon Petrochemical Products

Fluid transfer products for upstream, downstream and refining Products:

• Hoses and hose assemblies • Hose & pipe fittings • No-spill couplings • Safety breakaway fittings • Blow-Out prevention couplings

• Hydraulic Fracturing: Low Pressure Systems • Loading arms • Liquid level sensing • Zero emission valves

Services:

• Global inventory and locations • Sales and technical support worldwide • In-house engineering & design • ISO 9001 accredited • Pressure Equipment Directive (2014/68/EU)

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

©2019 Dixon Group Europe Limited

• TECHNICAL EXPERTISE • UNCOMMON EXCELLENCE • DESIGN • CUSTOMER SERVICE • INNOVATION • MANUFACTURING • QUALITY • TECHNICAL EXPERTISE

Issue 46 PECM

47

FLUID HANDLING

Fluid Carrying

Flexibility Articulated Torsion Pipework In Hoses Rotating Cylinders

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

Vacuum to over 20,000psi.

Stock and bespoke production.

Unique bearing/seal design for longer life.

ISO 9001 CE marked where applicable.

Tel:

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

+44(0)1663 735003

E-mail:

New Titanium Swivel Produced

by Rotaflow Rotaflow are specialists in producing swivel joints that operate in extreme environments.

For over 40 years Rotaflow have produced thousands of swivel joints that are designed to cope with high water pressure in hoses, deep sea oil wells, subzero climates, strong winds, long term sun exposure and a variety of corrosive chemicals.

The latest in a long line of swivel joints designed to operate in difficult conditions is a heavy duty swivel made from Titanium, forming part of a fire suppression system on a North Sea oil rig.

The swivel is a bespoke heavy duty, high temperature design with 3 inch nominal bore size and additional bearing races to handle the high loads required by the end user. The swivel also has integral flanges for easy installation and to allow the swivel to carry the high pressure and flow rate.

Rotaflow also supplied a smaller version of the swivel joint manufactured in 316L stainless steel as requested for a smaller system on the rig.

www.rotaflow.com

Flotronic introduces ‘ONE NUT’ barrel unloading Flotronic has introduced a new barrel and drum unloading system, combining the unique ‘ONE NUT’ pump with their barrel unloading skid. The new system enables you to pump highly viscous materials out of your barrel at significantly increased flow rates. This system is built around our ‘ONE-NUT’ sanitary style pump which is based on our 3A and EHEDG design. This style of pump has already proven itself in the hygienic / sanitary industries and is a match for any environment or process where avoidance of product contamination is paramount. The system can be Cleaned in Place using the pump itself or an external CIP rig or, because of the ‘ONE NUT’ design of the pump, it can be easily stripped down for cleaning.

“Using an inflatable seal, the system ensures minimal wastage is achieved and the minimum of product remains in the barrel.”

Says Leighton Jones, Sales Director, Flotronic Pumps. “As the seal inflates it creates an excellent seal while moving down the barrel and at the end of the process it deflates for easy removal. There is less hold up compared to other systems, which means you can empty challenging viscous fluids from full size drums in a matter of minutes, improving productivity with increased profit potential.”

This hygienic hands-free control of the

unloading is efficient and reliable using proven technology, with application across the food, beverage and pharmaceutical industries.

Flotronic provide bespoke systems to customer requirements and can cater for any fibre, metal or plastic 200 litre/55 gallon drum or similar. The barrel unloading skid can be fully mobile or fixed in place, with the system designed to suit your needs, including roller systems if required.

www.flotronicpumps.co.uk

48

PECM Issue 46

DRIVES, GEARS & MOTORS

MICROMOTORS EMS LTD

Three ways they are helping save the environment You’d never leave your refrigerator door open at home. Not only would this mistake spoil your dinner plans, but it would also be a massive waste of energy. So why do we often find doorless fridges in supermarkets?

Refrigeration in these stores hasn’t always been particularly energy efficient, but micromotors are helping to make an important switch. Here Dave Walsha, commercial development officer at precision drive system supplier EMS Ltd, explains how micromotors are helping three other industries become more environmentally friendly.

A study carried out with the support of the Department for Environment, Food and Rural Affairs found that “retail food outlets are responsible for around three per cent of total electrical energy consumption”, adding that “refrigeration systems account for between 30 per cent and 60 per cent of energy used.”

To help fix this, brushless dc motors are replacing the inefficient AC drives traditionally found in supermarket fridges to reduce their energy consumption. The fast moving consumer goods sector isn’t alone. There are many applications across industry that can benefit from energy-saving technologies, where small motors can make a significant impact.

SAVING FUEL The main way to improve an automotive vehicle’s impact on the environment is to reduce its fuel consumption. This can be achieved in two main ways, either by improving the efficiency of the engine or by lightweighting the vehicle to reduce the amount of energy that is needed to power it.

Micromotors are key for the growing number of actuated components in car interiors including windows, powered displays and reclining seats. In place of traditional iron core dc motors, many modern vehicles feature ironless rotor motors that help to automate these components.

Automakers are not only switching to ironless rotor micromotors because they

are lighter, but they are also more energyefficient and power-dense. Since the motor’s source of energy comes from the vehicle’s engine, the less power it consume the less environmental impact the car will have.

EVERY GRAM COUNTS Fuel is a major cost variable that can be the difference between the success and failure of an airline, making the aviation industry incredibly fuel-conscious.

Due to this cost sensitivity, reducing aeroplane fuel consumption is not only an environmental factor, but is central to business operations.

Cabin equipment inside planes is more electrically actuated than ever before.

Customers have adjusted to a level of luxury, especially those travelling in first class, with powered seats, screens and window shutters all commonplace features onboard an international flight. Powering these devices requires motors and having the most power-dense motors available for the task is the most effective choice.

In fact, the window shutter in the business class section of the Airbus A 319 is powered by a brushless motor that weighs just 192 grams — the 3242 BX4 model from FAULHABER, which is available to purchase from EMS. The reduction in weight may be small compared to the overall size of the

aircraft, but the number of flights a plane makes per year means that these savings quickly mount.

CURATING CROPS Fighting weeds is a challenge, especially since many of them are becoming immune to pesticides and stronger formulations need to be deployed. However, agricultural robots could alleviate our reliance on environmentally damaging pest control chemicals.

Using a vision system, agricultural robots can be trained to seek out weeds in fields and use their actuated robotic appendages to remove them without the need for any pesticides. To achieve this, the robots need to have quality precision actuation with high levels of power density, meaning that a reliable choice of servo motors is crucial for the success of the application.

Overall, micromotors are a strong contender to reduce the environmental impact of many electrical applications.

From refrigeration to cars, planes and agricultural robots, micromotors can help reduce operational costs while also making applications greener.

For more information on how micromotors can benefit your application contact EMS today.

For further information, please visit www.ems-limited.co.uk Issue 46 PECM

49

GEARS, DRIVES & MOTORS

A COMPLETE SERVICE LDA TRANSMISSION ENGINEERING LTD

Firm now boasts a strong customer base in the distributor market as well as supplying a number of OEM customers Established in 1980, LDA Transmission Engineering Ltd has grown from a local distributor of chains, sprockets and related products into a manufacturer of bespoke industrial chains and sprockets.

Originally supplying local end user business, over the years they have developed and changed their approach and now have a strong customer base in the distributor market as well as supplying a number of OEM customers. From a small beginning in a two roomed office they now occupy a modern site, on a busy industrial estate, which houses their offices and manufacturing facility.

The chain manufacturing workshop is equipped with a range of assembly presses,

including a new 50 ton hydraulic press, spin riveting machines and large steel benches for assembly and inspection. This allows them to manufacture special attachment chains for the full range of transmission and conveyor chains in steel, plated (nickel & zinc) and stainless steel all under one roof. They also manufacture special pitch chains from scratch with precision laser cut plates and machined round parts, all done with the help of their own ‘in house’ CAD design, these are truly UK manufactured chains.

Around seven years ago they added a machining department to the business, this allows them to offer a sprocket manufacturing programme to existing and new customers which perfectly

complimented the chain side of their business, bringing their costs and prices to customers down in the process. They now have a range of lathes, milling machines and keyway presses to enable them to offer a complete service.

In addition to all of the above they also stock a full range of steel and stainless steel double pitch chains and hollow pin chains which are imported from factories in Europe (Spain & Italy), also they have a full complement of agricultural chains and attachments so they can provide a speedy service for these chains when needed.

For more information about how LDA can help with your chain and sprocket requirements please get in touch.

For further information, please visit 0161 477 5252 | sales@LDAchains.com

50

PECM Issue 46

Industrial Chain & Sprocket Specialists

0161 477 5252

sales@LDAchains.com

PUMPS

PUMPS FOR CHINESE REFINERY SULZER

Local manufacture of high-performance Sulzer pumps provides cost, time and service benefits Close collaboration between Sulzer specialists in Asia, Europe and the US was key to a complex project that allowed twelve sophisticated pumps from three individual designs to be manufactured at Sulzer’s China plant for the first time. Sulzer’s ability to bring the new models into production quickly allowed its customer to meet tight project timelines, as well as demanding technical and commercial goals.

Market demand for fuel and products derived from oil and gas is being met by expanded exploration and the use of new technologies to maximize the potential of existing wells.

The introduction of new technology is improving efficiency for the petrochemical sector, which in turn helps to reduce the cost of everyday items, from recycling bins to toothbrushes and the tires on your car.

China’s hydrocarbon processing industry is the largest, and fastest growing, in the world. To meet demand and maintain competitiveness, companies across the sector are continually investing in new capacity and advanced technologies. For one refinery, that included a major project to upgrade and optimize its facilities.

CHALLENGING START In 2016, the refinery took the decision to introduce new equipment across its plant, including a new ebullated bed hydroprocessing system using H-OilRC technology from a French process licensor.

This system is designed to add value in the refining process by extracting valuable hydrocarbon products from heavy feedstock residues, which may contain high levels of solids and other contaminants.

When it came to the selection of pumps for the new system, the refinery was aware that the nature of the various feedstocks created demanding operating conditions.

The internal components can be exposed to high levels of wear and there is a significant potential for flow to be disrupted by large solid particles.

The refinery knew that it was possible to obtain pumps designed specifically to

52

PECM Issue 46

CP feed pump for the ebullated bed residue hydrocracking application perform well in these conditions, but it was unable to find a local source of supply.

Using equipment manufactured in China wherever possible is an important part of the refinery’s procurement strategy, as it seeks to localize supply chain and ensure ease of maintenance and support.

GLOBAL EXPERTISE, LOCAL PRESENCE That’s where Sulzer was able to help. As a global pump specialist, Sulzer already had a significant presence in China, producing pumps in the Dalian factory since 1999, and at a second plant in Suzhou since 2010.

Sulzer also has a long-standing relationship with the parent company of the refinery, supplying and supporting pumps at many of its facilities in the country. After discussing the requirements, oil and gas industry

experts at Sulzer recommended two proven technologies from the company’s extensive portfolio. Just as importantly, they also agreed to manufacture the critical pumps in China.

Like any major facility upgrade project, the ebullated bed system was planned to a tight schedule. So once the agreement was in place, Sulzer moved quickly to bring the new products to life in its China plants.

MAXIMUM PERFORMANCE, MAXIMUM DURABILITY The first of those products was the CP multistage barrel pump designed to API 610 type BB5 specifications. The Sulzer CP design incorporates an axial-split volute casing, which is less susceptible to wear than alternative designs when a high level of abrasive solids are present.

The refinery knew that it was possible to obtain pumps designed specifically to perform well in these conditions, but it was unable to find a local source of supply.

Sulzer’s design and manufacturing specialists in China worked closely with their colleagues from the USA, who hold the design responsibility for the CP, to allow for some important design modifications. This particular application required a low flow, high head, high speed solution, so Sulzer had to pay special attention to the surface characteristics of the fluid channels within the pump in order to minimize losses and achieve the target performance.

PROBLEMS CRUSHED The second key technology was a solution to the problem of pump performance impairment by large solid particles. For applications like these, Sulzer has developed a range of pumps with a special “coke crusher” unit at the pump inlet stage. This technology uses a rugged, bladed rotor that will break up solids to ensure they pass smoothly through the rest of the pump.

Sulzer in China worked with colleagues in Germany and the US to integrate the coke crusher technology into two pump types for the project: the BBT, an API 610 type BB2 centrifugal pump, and the ZF, an API 610 type OH2 centrifugal pump.

ZF pump with the coke crusher for the large solids abrasive service

DELIVERING UNDER PRESSURE In addition to building up the necessary in-house manufacturing processes, Sulzer in China also had to qualify suitable local suppliers for key components of the new pumps. The company’s expert sourcing teams conducted detailed supplier audits to

ensure that each one met Sulzer’s exacting global quality standards, especially when it came to critical parts such as the inner casing of the CP pump and the coke crusher components for the BBT and ZF units.

During the development and manufacturing process, representatives from the refinery made regular visits to Sulzer’s plants, giving them the confidence that work was proceeding on schedule and to the highest quality level. They were also present to see all the new pumps successfully meet their performance specifications in testing. In total, 12 of the newly localized pump models were delivered to the customer: three CP units, six BBT units with the coke crusher installed, and three coke crusher-equipped ZF units.

“This project was an important next step for our partnership with the refinery and for our support of China’s petrochemical sector as a whole,” says Zhang Jianfeng, Managing Director of Sulzer’s Suzhou manufacturing facility. “We have demonstrated that we can provide our customers with all the benefits of local manufacturing combined with Sulzer’s excellence in technology, quality and reliability.”

ZF pump with the coke crusher for the large solids abrasive service For further information, please visit www.sulzer.com.

Issue 46 PECM

53

HEALTH & SAFETY

NEW WEBINAR EXTRACTABILITY

How to choose your own fume extraction equipment In their latest webinar series, Extractability teach you how to go through the process of choosing the right extraction system, from start to finish.

cleanable filters to save you a significant amount of money.

• What are my ongoing costs? There will always be an on-going cost with LEV units, eg, filters, maintenance, and your annual LEV testing.

You’ve probably heard by now that welding fume was recently reclassified as carcinogenic in February of last year.

There’s now a legal requirement for all fume and dust (not just from welding) considered to be a contaminate to be extracted before it goes into the breathing zone of your employees.

• Requirement for annual TExT? A Thorough Examination and Test report is a legal requirement that needs to be carried out every 14 months, though most people choose to get it done annually.

What are the risks not acting or choosing the wrong products?

You’re liable to get fines from the HSE. If they find you haven’t got extraction or that your extraction isn’t suitable, they’ll issue you a breech notice, which can mean a partial or full closure of your business, especially if they find a large number of breeches or an immediate danger to your workers. By way of longer-term risks, if any of your workers develop health complications, in 10-30 years’ time, and they can directly attribute their condition to one of your work processes and prove that you didn’t have suitable LEV at the time for them then you would be liable for a lawsuit. On the smaller end of the spectrum, you may buy the wrong product, wasting your time and money. If you have any concerns or are due an HSE visit, you can always call Extractability, who will be happy to walk through the whole process with you. They can also tell you what kind of things they will be looking out for and what they might pick you up on.

In order to protect against lawsuits, Extractability offer ProtectoScan EDI that provides constant, year-long air monitoring so that you can both keep on top of your fume extraction and produce solid, datadriven, proof that your workplace has been compliant with Government advice.

To begin the process of choosing you fume extraction you need to consider: • What are the processes in your workplace that produce contaminant?

• Training? Your welders need to be trained on their LEV systems. The HSE inspectors may ask workers using LEV equipment if they have been trained, if they haven’t, the HSE will pick you up on it.

A few of your work processes might require extraction under HSE guidelines that you haven’t previously considered.

• What are my constraints? Consider your workshop size, for example if you have a low ceiling you may not be able to fit fixed extraction or if you struggle for floor space it might not be suitable to have mobile units wheeled around. You will also need to take into consideration your workers’ physical ability, are they able to push/pull a mobile unit into position? At times, your location can dictate certain environmental laws meaning that you may not be allowed to use a vent to atmosphere system • How much of it do I do? You may not need to go all out on a fitted extraction system if you only use a welder occasionally for maintenance. If you are welding for less than 200 hours a year, you may be able to use a small, cost-effective, disposable filter unit that would grant your LEV conformity without having to spend much money.

If you are doing more than 200 hours a year of welding you will need a unit with

Extractability is more than happy to cover these points with you, including the training of your staff and will issue you with a certificate as proof.

What type of system would suit your needs?

If you’re doing off site work and need a mobile system or something to extract from an on-torch set-up like the SifGun Evolution, then you would look at vacuum systems. If you needed a mobile or a several mobile units to position in different spots in your workshop, particularly if you are working on a large project, you might look at a large mobile unit like the ProtectoXtra or ProtectoXtract.

Alternatively, for multiple welders working in booths, a fixed system will be the most efficient form of protection.

It is important to also consider what materials you are looking to extract. If you need to extract flammable or explosive dusts you will need to look at systems designed to reduce the risk of fire.

If you are unsure or unable to find a system to suit you, Extractability can advise or even build a bespoke system to suit your needs.

Find Extractability’s full webinar series at Youtube.com/c/WeldabilitySif

54

PECM Issue 46

Does welding take your breath away?

The HSE are currently visiting all fabrication companies to ensure adequate, working, certified fume extraction is in use.

They have the power to issue an improvement notice, enforcement order, fine or even a prohibition notice!

The solution is simple. Extractability, a division of Weldability Sif, can evaluate your company to determine if you are compliant, advise what fume extraction solutions are available to you and install or provide the necessary equipment.

Contact us today to discuss.

0845 862 2620 • sales@extractability.eu www.extractability.co.uk

ÂŽ

www.weldability-sif.com

WELD www.learn-to-weld.com

HEALTH & SAFETY

PROCESS SAFETY REMBE

Protecting compressors under challenging circumstances

The use of dry gas seals on large operating equipment such as turbo compressors has increased significantly over a number of decades particularly in harsh working environments such as oil & gas, petrochemical and gas processing industries. A dry gas seal uses a clean gas under pressure on the external side of the seal, so that any leakage through the seal is the buffer gas into the compressor. Not only does this protect the environment from being contaminated with process gas, but it keeps dirty gas from getting inside the seal and causing damage.

An important component of a dry gas seal is the vent system. For the primary vent system, a rupture disc is typically installed in parallel with the vent line to rupture at a set pressure and prevent excessive pressure to instruments on a primary seal failure. A signalling system, on the primary vent system is recommended to enable

Used extensively in downstream projects, the IKB is the only reverse acting rupture disc to be manufactured using REMBE’s unique Contour Precision Lasering (CPL) technology. integrity checks while the seal system is still online.

Customer’s using dry gas seals require rupture discs to be installed to vent excess

pressure in the event a catastrophic failure of the primary seal occurs. In the event the pressure increases beyond its predetermined limit a higher gas flow or back pressure in the piping system is present and needs to be safely vented. A signalling device is also required to detect a change in the rupture discs status in order to initiate a shutdown of the process in the event of an overpressure situation.

REMBE’s reverse acting rupture disc with an integrated polyamide signalling device (SGKIKB) is a cost-effective rupture disc which is suitable for the demanding conditions found in dry gas seal applications.

Used extensively in downstream projects, the IKB is the only reverse acting rupture disc to be manufactured using REMBE’s unique Contour Precision Lasering (CPL) technology ensuring high quality, accurate, burst control even in the harshest of environments.

For further information, please visit www.rembe.de

56

PECM Issue 46

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

Made in Germany

Your Specialist for

PRESSURE RELIEF and

EXPLOSION SAFETY

© REMBE® | All rights reserved

Consulting. Engineering. Products. Service.

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

covid

ssentials E Helping you stay safe at work

The social distancing segregation screen and our freestanding sanitiser gel dispenser

Segregation Screens Freestanding, lightweight & portable Tough, non-shatter & recyclable

Sanitiser Gel Dispensers Touch-free, automatic infra-red operation Portable, easy to move unit

View our full Covid essentials range on our website

For more information get in touch today

W: teknomek.co.uk T: +44 (0) 1603 788 833

HYDRAULICS & PNEUMATICS

Efficient compressed air distribution

Customers no longer have to choose between performance and safety Safety has been CEJN’s top priority for many years, constantly striving to develop safe and high performing products. This led them to develop the eSafe: an ergonomic one hand operated, compact, high flow coupling that vents before disconnection, eliminating the risk of hose whip. eSafe is an innovative and patented safety coupling offering the highest flow combined with a low pressure drop. A low connecting force and easy to grip design makes eSafe the natural choice when choosing a safety product with top of the line features.

The eSafe range features real craftsmanship. It is the only coupling on the market that allows operators to get maximum capacity out of their tools. Jobs are completed faster, use less energy and the result is higher productivity, cheaper energy bills and lower environmental impact.

Strong and durable with a long service life, the eSafe range complies with ISO Standard 4414 and EN 983. eSafe is a new generation of premium couplings for premium performance available from Tom Parker Ltd. For more information, contact the Tom Parker Ltd Business Development Manager: John Pomeroy. Tel: 01772 255113.

Alternatively email Business Development: business.development@ tom-parker.co.uk

BENEFITS Easy and quick to install Reduced pressure drop n Corrosion, fire and UV resistance n No welding n n

SicoAIR is the practical and useful solution for compressed air distribution, from small distribution systems to large industrial plants. SicoAIR features a range of calibrated aluminium pipes with nylon junctions, offering good resistance to shock and pressure. For more information contact Tom Parker Ltd.

APPLICATIONS Compressed air Vacuum Water Nitrogen

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

www.tom-parker.co.uk

Request a catalogue: marketing@tom-parker.co.uk Issue 46 PECM

59

MACHINING & MACHINERY

BOOSTING WELD CAPACITY KM TOOLS

KM Tools welding gantry supplied to Bombardier Transportation KM Tools Ltd has demonstrated its machine building capabilities by supplying a new welding gantry to Bombardier, the UK’s leading rail engineering and manufacturing company. Now installed at the iconic Litchurch Lane facility in Derby, the new gantry is supporting the production of carbody structures manufactured at the site.

Bombardier is the only company in the UK with the capability to design, develop, manufacture, test and service trains.

Producing multiple unit rail vehicles for a host of UK train operators, the business has to ensure adequate manufacturing capacity to support these extensive operations.

Litchurch Lane has been producing railway rolling stock since the late 19th century, and now KM Tools Ltd is a part of the site’s modern era.

The welding gantry provided by KM Tools is a key machine in the production of train underframes and roofs. Sections of underframe/roof are held in jigs next to one another, ready for welding. With the expert help of operatives in protective gear, the welding gantry passes over, its two heads carrying out high-quality welds across the length of each seam. Once one side of the underframe/roof section is welded, the jig is rotated 180 degrees and the process repeated for the opposite side.

Adrian Degg, Group Engineering Director at KM Tools Ltd, was instrumental in the project: “We are primarily a machine builder, working with our customers to

The welding gantry provided by KM Tools is a key machine in the production of train underframes and roofs.

Above left, KM Tools made sure the software and user interface were almost identical to other machines to ensure operator familiarity. Above right, Bombardier required a new welding gantry that closely matched those already operational on-site.

provide specialist equipment to support OEM production lines. We had previously supplied a wide range of jigs and fixtures to support Bombardier’s production activities, so when the time came to add a new welding gantry at the facility, we were ready to offer a solution.”

to side depending on its current position relative to the seam. Allen-Bradley controls were installed on the machine, with programmable safety features. KM Tools made sure the software and user interface were almost identical to other machines to ensure operator familiarity.

Bombardier required a new welding gantry that closely matched those already operational on-site. KM Tools offered to reverse engineer a new machine to the required specification, offering a reduced lead time and increased value compared to its competitors. The welding gantry would need to be installed and operational by mid-February, 2020.

The machine was finished within seven weeks, with installation completed before the deadline. The machine is now operational, boosting welding capacity at the site.

KM Tools managed the entire build process. After inspecting an existing machine, engineers replicated the frame and installed two welding heads with seam tracking. Seam tracking is controlled via an articulated mechanical contact (See Photo 5) mounted on the head, which moves the welder up and down or side

Adrian concludes: “We enjoyed working on this machine, and it has operated without issue since it was commissioned. We have KM Tools engineers on-site to quickly react to any issues, so there is extra assurance there. We’re used to meeting the needs of leading OEMs across multiple industries, which has greatly aided our work at Bombardier. By utilising this experience and offering a turnkey solution – we were able to deliver an ideal, value-added machine quickly.”

For further information, please visit www.kmt.tools

60

PECM Issue 46

MACHINING & MACHINERY

Manes Controls Ltd Manes Controls Ltd have a long-established reputation and expertise in control system design and manufacture, we now bring all this experience to our range of standard inverter drive products.

Please have a look at our full range of motor speed control panels now available to purchase online with 3-5-day delivery times.

machines and many more………….

Manes Controls Ltd, Unit 504, Phoenix Park Ind Estate, Phoenix Close, Heywood, Lancashire, OL10 2JG

Tel: +44 (0)1706625500 Fax: +44 (0)1706625588 mail@manesindustries.co.uk

These panels can be used for various applications such as conveyor belts, fans, centrifugal pumps, hoists, mixers, grinding

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

CNC ROUTERS & LASER CUTTERS Introducing the NEW Fibre Laser Marker

Features • High-speed galvanometer • Compact and light weight • Low power consumption, less than 500W • Air-cooled • The machine can increase production and reduce costs Typical Applications Industry: Gold and silver jewellery, sanitary ware, food and beverage packaging, pharmaceutical packaging, medical devices, eyeglasses, clocks, automotive parts and electronic hardware.

Materials: Gold, silver, stainless steel, ceramic, plastic, glass, stone, leather, fabric, wood etc.

Introducing the NEW CNC Laser Cutters The NEW ATACAM range of Laser Cutters includes models for both metalic and non-metalic materials. They are equiped with co2 laser tubes, which can be used for cutting metalsheet such as carbon steel, stainless steel and non-metalic materials such as acrylic, MDF, plywood, etc.

Model AL1390 (pictured) for Non Metalic cutting and Model ALM1390 for Metalic and Non Metalic cutting.

Tel: 0208 339 7370 462 Ewell Road, Surbiton, Surrey KT6 7EL, England

Fax: 0208 339 7371

Email: sales@blackfast.com Web:

www.blackfast.com

Call for more information or a demonstration, or visit www.atacam.co.uk ATA Engineering Processes Ltd ATA House, Unit B, Boundary Way, Hemel Hempstead, Herts, HP2 7SS t: 01442 264411 e: sales@ataeng.com www.ataeng.com

Issue 46 PECM

61

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

62

PECM Issue 46

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

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!

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 Issue 46 PECM

63

MEASUREMENT & MONITORING

THE WG20 MOTOR SERIES WEG

Energy saving motors to exhibit at MACH 2020 Leading mechanical equipment manufacturer, WEG, will exhibit its extensive range of motors, drives and soft starters at MACH 2020 in Hall 7, booth 727. As the UK’s largest manufacturing show, MACH is held at the National Exhibition Centre (NEC) in Birmingham from Monday April 20 to Saturday April 25, 2020.

At the show, WEG will exhibit the WG20 motor series, the first geared motor range to be entirely developed in-house at WEG. Comprising helical, parallel shaft and helical bevel gear units, the model boast torques between 50 and 18,000 Nm. Manufactured with a light aluminium housing, the WG20 motor delivers high efficiency performance, without compromising on its sophisticated design.

In fact, the cleverly designed aluminium housing of the WG20 motor enhances its energy efficiency. By improving heat conductivity, the housing encourages heat dissipation from the motors internal parts and prolongs its lifespan.

WEG will also exhibit the W22 3 phase motor. This motor range has been developed to provide high levels of performance while also delivering maximum energy efficiency. The motor includes a newly developed cooling system, which has been redesigned to provide improved air flow through the motors frame to maintain a low operational temperature.

A range of W22 motors for standard use, as well as the W22Xd for use in explosive atmospheres will be showcased at the stand. For customers seeking motors for aggressive applications, WEG representatives will be available to explain how the intelligent design features of the W22Xd, such as the exclusive bearing sealing system, makes it an ideal product for these environments.

Redesigned end shields have also been introduced to reduce bearing operating temperatures and therefore decrease the frequency of re-lubrication.

The W22Xd version has evolved specifically for deployment in explosive atmospheres. Building on the same design concepts as the successful W22, the W22Xd encompasses a new frame design, which ensures higher mechanical stiffness.

“Manufacturers are increasingly looking for ways to improve the energy efficiency of their facilities — and many machine builders will be seeking products to achieve this during their visit to MACH 2020,” explained Marek Lukaszczyk, European marketing manager at WEG. “WEG’s range of industrial motors ensures factories can achieve their ambitious efficiency goals, without compromising on the performance of their equipment or dramatically increasing costs.

“In fact, the WG20 geared motor provides an optimal programme for lowering operational costs. Due to the standard mounting dimensions, users benefit from easy interchangeability without the need for system conversion. Moreover, the WG20 can be switched to different voltages around the world and meets many certifications for international markets.”

Alongside the WG20 and W22 motor series, WEG will also exhibit products from its extensive range of drives and soft starters. Please visit Hall 7, booth 727 at MACH 2020 for a demonstration, or arrange a meeting in advance by contacting info-uk@weg.net.

For further information, please visit www.weg.net

64

PECM Issue 46

WG20 Geared motor range available up to 18,000Nm with either IE3 or IE4 efficient motors Designed with standard mounting dimensions, the geared motor is easy to install and perfect for replacing existing units.

WG20 is compact, efficient and robust.

Visit WEG at MACH 2020 Hall 7 Stand 727

Isn’t it time you considered changing gear?

Issue 46 PECM

65

MEASUREMENT & MONITORING

On-site Flow Calibration Production facilities looking to reduce plant downtime during routine calibration, then the extended on-site calibration services from Young Calibration is here to help.

Current calibration services for medical and pharmaceutical sectors is now extended to cover food and drink plants, with an all stainless steel reference flow calibration rig for fluid flow to 600 l/min using a bank of 3 micromotion coriolis meters with a measurement uncertainty of 0.15%. Soon be added to the UKAS accredited onsite schedule, will include relative humidity, dew point, temperature, pressure, and electrical capabilities. The company holds ISO 17025:2017 for laboratory and onsite based calibration services, helping companies to comply with regulatory compliance, due diligence, quality and measurement uncertainties.

Contact: ay@youngcalibration.co.uk Tel: 01273 455572 www.youngcalibration.co.uk

T860 EN 180x132.indd 1

66

PECM Issue 46

L300 TC 8 Zone Temperature Alarm / Controller

New PhoenixTM ATEX Certified Finishing System

The Labfacility L300-TC (Thermocouple) temperature alarm / on-off controller can be used in conjunction with a PC to provide accurate monitoring and alarm or on-off control of up to 8- zones simultaneously. It can also be used as a stand-alone instrument without the need for a PC.

PhoenixTM has complemented its range of ‘Thru-process’ Finishing temperature profiling systems with the new FIS04 ATEX system.

Developed for automotive paint plants, where paint engineers face demanding challenges of ATEX classification requirements, for safe operation of monitoring systems.

The in-built, self-calibration facility for the thermocouple version is a rapid and convenient method for on-site calibration and does not require any additional equipment other than a special, external link. The L300TC has 8 thermocouple (type J, K, T, E, N, R, S & B) inputs and a resolution of 0.1°C on display, 0.01°C in software. This unit is RoHS compliant and CE marked.

At the heart of the PhoenixTM FIS04 ATEX system, the Intrinsically Safe PTM1410 Epsilon-x data logger certified to Group II Category 3G allowing safe operation in Zone 2 ATEX classified areas (eg: paint booth, flash off zone and cure oven). Providing up to 10 points of measurement, paint processes can be monitored accurately and effectively. Thermal View Finishing software provides graphical cure analysis tools for verifying process compliance with ease.

www.labfacility.com/temperatureinstrumentation/bench-top-instrumentation/ l300-pt-8-zone-temperature-alarmcontroller.html

Tel: 01353 223100 sales@phoenixtm.com www.phoenixtm.com

29/04/2020 15:19

SEN - 8

SEN - 3

01623 427701 info.uk@kobold.com

www.kobold.com

For our extended pressure instrument range and all other Kobold instrumentation products visit:

SEN Series Pressure Sensors with AUF-1000S Plug-on Display

SEN - 9

Special Offers NOW for Combined SEN/AUF-1000S Sets

Quality Engineered Instruments

MEASUREMENT & MONITORING

MEETING INDUSTRY DEMAND VEGA

Visible efficiency for process automation: VEGA extends its level and pressure device portfolio New compact VEGABAR pressure sensors and VEGAPOINT level switches mean VEGA is now a full-range process automation level and pressure supplier.

These new lower-priced instruments are designed for standard applications – in line with the latest industry demands.

NEW STANDARD SENSORS WITH A FOCUS ON HYGIENE In many basic process areas, simple, cost-effective automation sensors for efficiency improvements are often the key requirement. To meet this, VEGA has introduced a new compact level and pressure instrument series, designed to be simple and highly efficient - without sacrificing dependability, hygiene or accuracy.

STANDARDISATION GIVES BIRTH TO EFFICIENCY A hygienic universal adapter system can be flexibly selected and adapted according to individual needs and, if necessary, quickly exchanged between devices. It is fully compatible across these new pressure and level switches. They can also withstand intense CIP processes, and along with hygienic designs and surface finishes comply to industry approvals and standards.

VEGABAR units have optional switch points and indication built in as well as Bluetooth for set up

VISIBLE ALL AROUND: ILLUMINATED 360° SWITCHING STATUS DISPLAY The sensor development focused on simple use, and this includes fast and easy indication. A 360° status display means switching states can be quickly seen on the plant, an ultra-bright LED ring, has 256 freely selectable colours and the remains clearly visible, even in daylight. This immediately and efficiently shows operators both the switch and process status.

FIT FOR THE FUTURE WITH IO-LINK

FP11 VEGAPOINT Capacitive Inductive switches for liquids and powders. Above right, VEGAPOINT 21 Bluetooth enables precise set up and selection of status colours

The devices all feature IO-Link options, this enables sensor parameters to be stored and re-written to devices by the master or the controller if a sensor replacement is made, reducing set-up mistakes and reducing down time. This ensures higher product quality, more optimal utilisation of the machines and increased process speed – delivering noticeable savings.

BLUETOOTH FOR FASTER SET-UP AND ADJUSTMENT All these devices, like many others in the VEGA instrument range, can be set up and monitored using Bluetooth and VEGA Tools App for Android and iOS. In environments where access is difficult, distancing is in place or the environment is inhospitable, the remote communication - even in ATEX areas – enables safer, faster and easier device operation.

CONCLUSION: FUTURE-ORIENTED AUTOMATION FROM A SINGLE SOURCE Hygienic design, modularisation, high availability and easy operation means greater process efficiency. Backed by decades of experience, VEGA offers ground-breaking level and pressure measurement technology for the automation and monitoring of production systems.

For further information, please visit www.vega.com

68

PECM Issue 46

We bring colour into view!

Compact pressure sensors and switches with 360° custom-colour status display

256 colours Individually Individually selectable: selectable: Measurement Measurement in in progress progress Sensor Sensor switching switching Process Process malfunction malfunction

15 cm

Compact Compact design design

Hygienic Hygienic adapter adapter system system

Adjustment Adjustment via via smartphone smartphone

£262 VEGABAR VEGABAR 39 39 G½" G½"

www.vega.com/vegabar

MEASUREMENT & MONITORING

PRESSURE DECAY LEAK TESTING FURNESS CONTROLS

Ultra low-range differential pressure sensors

Furness Controls are UK manufacturers of ultra-low-range differential pressure sensors and leak testing equipment. Founded in 1963, the company has become worldrenowned for its range of multifunction leak testers, flow testers and differential pressure transmitters, and for their UKASaccredited calibration laboratory.

For leak testing, Furness Controls has developed a range of automated instruments capable of detecting very fine air leaks through the differential pressure decay method. With this approach, products are pressurised, isolated from the pressure source and monitored for very small changes in pressure over time.

By using a differential sensor, comparing the pressure in the item against a reference, very low pressure drops can be measured, equating to a mere 0.01 ml/min in some applications. For manufacturers, the key realisation is that air decay testing is applicable across a range of leak test problems; there is a well-defined relationship between the flow of air through a leak, and the flow of more viscous liquids

such as water or oil. In fact, if the rate of airleak is low enough, a water-carrying device such as a tap can safely be regarded as leak tight. This is why most standard test parameters for such devices are given in air leak rates such as cc/min at a given pressure in bar.

Not only are Furness Controls’ leak testers sensitive, due to their differential pressure sensors, over time they have developed many other features such as automated test cycles, industrial communications, programmable electrical I/O and pneumatic outputs. The latest line of instruments can happily run an entire test station or be controlled through a PLC. They have large colourful touch screens for ease-of-use, and support multiple ancillary test types such as blockage tests, ramp tests, sealed-part tests, and bell tests. The applications for pressure decay leak detection are too numerous to list, and cover most industries, but a sample of the latest solutions the company has provided include: Airconditioning pumps, automotive fuel lines, EV batteries, surgical robotics and military radio enclosures.

www.furness-controls.com | +44 1424 819 980

70

PECM Issue 46

Flow testers are also a major product line for Furness, with a range of touch screen instruments recently released in parallel with the leak testers. These instruments use laminar flow elements to accurately measure flows in products such as heat exchangers, gas burners and exhaust systems.

With a range of high accuracy pressure transmitters, laminar flow elements, Pitot tubes and calibrators, Furness Controls aims to provide the complete solution for the testing and measurement in the arena of low flow and pressure, and have been innovating in the field for over 50 years.

v

Innovating in the field of testing, measurement and control for 50 years

Leak Testers

Leak Testing instruments for production testing of components and assemblies Touchscreen interface • Multi-step tests Industrial Comms • Programmable I/O Leak • Flow • Sealed-part testing

Low Range Pressure Transmitters

A range of differential pressure transducers suited to the measurement and control of air/gas flow and pressure, with an accuracy better than 0.25% even in the ±50 Pa range

Pitot Tubes and Laminar Flow Elements Classic Prandtl style Pitots, averaging Pitots and laminar flow elements in a variety of sizes

Furness Controls Ltd., Bexhill, England E: sales@furness-controls.com T: +44 1424 819 980

Calibration

Our portable calibrator has a pressure range of 0.01 Pascals to 20 kPa, and flow range from 1 ml/min to 2000 l/min

www.furness-controls.com Issue 46 PECM

71

MEASUREMENT & MONITORING

100 UP

RHEINTACHO UK

Rheintacho UK celebrating 100 years of existence in Leeds In 1919 Rheintacho UK was founded in Leeds. Is was founded as Foundrometers Ltd and after a turbulent century of takeovers, sales, mergers, spin-offs, management buy-outs and name changes, Rheintacho UK Ltd, as it is now called is more successful than ever in an everchanging market.

Rheintacho UK is not only the specialist in the Rheintacho Group for all mechanical and electrical instruments and many devices, but also is the competence center for intrinsically safe applications and devices (ATEX certification). Since 2015, Rheintacho has had a handheld mechanical tachometer called HTM which is ATEX certified. Last year, we added the complete family of eddycurrent tachometers and corresponding gearboxes and we are now working on a device which presently is not available anywhere in the world, something printers and paper/pulp manufacturers have been waiting for.

In addition to its own manufacturing unit in Micklefield, Leeds, Rheintacho UK also trades the products of the Rheintacho group. This includes a huge portfolio of speed sensors, second to none in the world of rotational speed monitoring, measuring and control. And the newest generation does even more than measure speed. They also detect direction and position, opening a new world of possible applications to customers. The newest addition to the sensor family also integrates temperature measurement into a very small sensor offering not only a space saving solution but also offers less intrusion into a gearbox, for example.

GROWTH CONTINUES INTO 2020 After 2 strong years in 2017 and even double-digit growth in 2018, 2019 was a difficult year with all the Brexit uncertainty and we were able to keep our sales stable. So far, 2020 has started with a bang despite the uncertainty in connection with a possible “no-trade-deal� scenario.

Rheintacho UK is confident that this growth will continue in the future.

HIGH RELIABILITY Did you know...

The British Bulldog is one of the most dependable types of dog in the UK. Their reliability is unsurpassed and they will serve you well for years. Our tacho generators and eddy current tachometers have been around for years and require no maintenance.

www.rheintacho.com

SPARES AND REPAIRS Our Spares and Repairs Division is another strength of Rheintacho UK. We supplies spares, do repairs and maintenance and can reengineer nearly any instrument

or indicator, regardless of whether it is our own brand or not. Many old manufacturers no longer are in business, but our specialists and stock of exotic parts enables us to support you with your maintenance challenges.

For further information, please contact RHEINTACHO at sales@rheintacho.co.uk or call us at +44 (0)113 287 4411

72

PECM Issue 46

MANUFACTURERS OF HIGH QUALITY HIGH PERFORMANCE INDUSTRIAL INSTRUMENTS

Exhibitors at CHEM UK, WWEM & HANNOVER MESSE Rearranged exhibition dates will be advised, when confirmed.

Calibration and On-site Commissioning

Light instrument system panel builds, including: Data Loggers & HMI’s

For your FREE Product Summary Brochure

01623 427701 www.kobold.com info.uk@kobold.com

Precise - multifunctional - reliable - proven

FLOW – LEVEL – PRESSURE – TEMPERATURE – ANALYTICAL - CALIBRATION

MEASUREMENT & MONITORING

THE RTR-500 SERIES T&D CORPORATION EUROPE

Precise data monitoring in tough conditions With the RTR-500 series, T&D Corporation presents a wireless data logging system adaptable to individual needs. The versatile wireless devices are perfectly suited to the requirements of the food and pharmaceutical sectors, cold storage, construction sites and public buildings.

They enable the supervision of difficult to access places, both indoors and out. T&D also provides accompanying software applications for reliable results, and the continuous availability of measurement results.

Networked data logger systems simplify procedures and allow error-free access to measured data at any time, and from any location. T&D’s RTR-500 series is ideally suited to large areas, storage facilities for chilled and frozen food, and temperature management during the transportation of pharmaceuticals, food and precision equipment. The data loggers of the RTR-500 family support users who need a wireless logging option with maximum flexibility. They monitor temperature, humidity, mA, voltage, pulse, UV, illuminance and CO2 via WLAN, LAN, GSM or USB. The RTR-507S captures temperatures from -25 to 70° C and humidity from 0 to 99% RH. The recording interval is selectable for up to 15 choices, in time spans from 1 second to 60 minutes. The compact data logger is also splashproof (IP64 standard). With its wireless radio communication capabilities, it is perfect for applications where temperature and

humidity at various measurement points have to be managed simultaneously, such as in temperature-controlled storage facilities like libraries and warehouses.

Another logger from the RTR-500 series is the RTR-501. It has a rugged design and internal sensors that can be used in environments with temperatures of -40°C to +80°C, and has an IP67 waterproof rating.

The RTR-501 also provides a wireless radio communication range with compatible base units of up to 150 metres, which can be expanded further with repeaters. Monitored data can be transmitted via a base unit, and automatically uploaded to T&D’s free cloud storage. The RTR-501 is EN12830compliant and therefore suitable for use in the transport, storage and distribution of temperature-sensitive products. The large battery L model has an even longer battery

life and can be used for up to four years.

The RTR-500 series allows the user to mix and match an array of loggers with various base units or data collectors, in order to meet individual needs.

With the free Cloud T&D WebStorage Service, the RTR-500 series find its perfect companion. It enables unlimited access to data view as current readings, recorded data, battery levels and radio signal strength, alert view as alert log, watchdog log, in easy-to-read graphs or tables. The ID and password as read only access is also available and, to avoid an overload, oldest records will be automatically zipped before the storage capacity is reached. Several complementary and free apps and software applications also contribute to easy, allround supervision and monitoring.

For further information, please visit www.tandd.com Issue 46 PECM

75

MEASUREMENT & MONITORING

WE’VE BEEN LISTENING! CAPTION DATA

Introducing the NanoULTRA range!

What we’ve heard from our customers is they want better product information, easily accessible, easy to understand and order from. They also told us they value our way of doing things, our agility and our cutting-edge technology and they wanted the products and the company to look the part of the world class partner we are.

Our purpose is to harness the Industrial Internet of Things to help you power your business. In order to give our customers this clarity we have re-branded to create a new identity and a true product family. Our company logo now represents the wireless solutions for IIoT that sit at the heart of all we do.

Our standard hardware products service a wide range of applications and offer you the chance to immediately access the Industrial Internet of Things to power your business. They all seamlessly link to the CDLSmartHub™ where you can configure and manage assets, set alarms, view audit trails, integrate and export data, view trends and visualise data. Investing in the NanoULTRA and CDLSmartHub™ gives you access to a fully integrated end-to-end IoT solution to effectively manage your assets.

The products within our range all have their own unique attributes that deliver solutions within specific application areas. But what they all do is log data and transfer it securely to our IoT asset management platform, the CDLSmartHub™, where the raw data can be turned into actionable insights, delivering you a quick return on investment Our unique position of having application specialists, hardware, software and firmware engineers in house allows us to go a step further and custom build our standard range to ensure our customers get exactly what they need. This ability to adapt and remain agile can allow customers to engage us on these special projects and ensure that their Industrial IoT needs are met!

NANOULTRA – EDGE

Managing a network of field assets has never been easier with the NanoULTRA – Edge. It has the flexibility of up to 16 I/Os,

integrated SD card and communication via mobile phone networks. Its highresolution data transfer happens seamlessly and securely from multiple assets to our secure cloud platform, the CDLSmartHub™.

PECM Issue 46

NANOULTRA – SHOCK

NANOULTRA – MATRIX

The NanoULTRA – Matrix allows you to connect multiple wireless sensors to a single base station allowing measurement of temperature, humidity, CO2, WME and more.

The analogue input wireless sensor option allows not only connectivity to our sensors but opens up the ability to connect with 1000s of available ‘off the shelf’ sensors, which creates infinite options for accessing the Internet of Things within your sensor networks.

Our internally made, battery-powered wireless sensors incorporate state-of-the-art sensing technology to accurately measure and monitor data, before transmitting to the NanoULTRA – Matrix base station.

The data is then transmitted via mobile phone networks to our secure cloud platform, the CDLSmartHub™, where raw data can be turned into actionable insights.

Previously known as the RDL//1000 and the Nano//1000, we plan to build on this product’s capability.

NANOULTRA – VIBE

Monitoring the levels of vibration in a static environment has never been easier with the event based NanoULTRA – Vibe.

It has been carefully

info@captiondata.com | +44 (0) 1905 754078

76

designed to be robust for use in harsh environments such as construction sites, yet simple to use and sensitive enough to capture low frequency vibrations providing you with valuable data on events as they happen. Formerly known ad the RDL// Vibe, this unit will continue to be a leader in event-based monitoring for the construction industry.

Managing the tracking and condition of assets on the move has never been easier.

NanoULTRA – Shock is a battery powered, web based, real time monitoring system that tells you where your shipment is whilst in transit, and what shock loadings and environmental conditions your goods are subjected to. Previously known as the Shocktrail, this product is designed to meet our customers’ logistical tracking needs.

NANOULTRA – ATOM

Deploying remote environmental sensors has never been quicker and easier. The NanoULTRA - Atom is a self-contained, battery powered temperature and humidity data logger that seamlessly communicates its values to the CDLSmartHub™, recording temperature and relative humidity (RH). Formerly known as the NanoATOM, this compact unit quickly addresses your environmental needs.

Investing in hardware from the NanoULTRA range and CDLSmartHub™, gives you access to a fully integrated end-to-end IoT solution to effectively manage your IIoT needs.

We will continue to listen to our customers to build on this change and ensure we deliver the best service we can. We hope you are excited about our re-brand and look forward to hearing your feedback!

| www captiondata.com

Meter Monitoring Made Easy Local & remote alarming Invoice & costed reporting Remote site management 24/7 Gas

Water

Pyrometers. IR Cameras. Accessories.

Software. We measure temperature non-contact from –50 °C to +3000 °C. Visit: www.optris.co.uk Our cost-effective Xi series IR cameras with their automatic spot finder function and analog/ digital outputs are ideal even for OEM applications.

www.tmethermometers.com

from 940 €

For a free quote: +44 (0)1903 700651 sales@tmethermometers.com

MEASUREMENT & MONITORING

On target.

PC-SEP16-TM ELECTRONICS.qxp_Layout 1 12/09/2016 09:23 Page 1

Electricity

Heat

Meter Monitoring System by

www.autometers.co.uk

Contact us today 0161 8619056 info@autometers.co.uk

when temperature matters

Issue 46 PECM

77

NEWS & EVENTS

REPLACING THE WHEELCHAIR RENISHAW

RLS magnetic encoders enable Marsi Bionics to build ‘life-changing’ exoskeletons BACKGROUND Marsi Bionics S.L. is a leading technology start-up based in Madrid, Spain. It designs and builds custom exoskeletons for medical applications with the aim of potentially replacing the wheelchair in everyday life for some patients.

Millions of people suffer from debilitating neurophysical conditions such as paraplegia, cerebral palsy and spinal muscular atrophy (SMA). Neurological rehabilitation with passive aids such as canes, crutches and walkers is vital in the treatment of mobility issues caused by these conditions. Recent advances in robotics have allowed treatment with powered (active) robot exoskeletons that support the patient’s body and enable greatly improved outcomes.

The exoskeletons, created by Marsi Bionics, give physically disabled people the freedom to stand, move and interact with their environment.

Data collected from the encoders is fundamental for generating the position references. RLS and Renishaw provided Marsi Bionies with the best encoder feedback solutions for its applications. RLS, a Renishaw associate company, has been chosen by Marsi Bionics to supply the latest in magnetic encoder technology for the creation of two new products: the ATLAS 2030 exoskeleton for children and the MBActive Knee (MAK) single-joint exoskeleton for adults.

CHALLENGE The ATLAS 2030 exoskeleton has up to six degrees of freedom per limb. This device enables the user to perform both unaided and self-actuated actions such as walking and sitting. Full exoskeletons consist of motorised joints, limbs, electronic control and power systems.

The designer must find a compromise between a lightweight and compact structure that facilitates easy handling by the user, who might be physically

78

PECM Issue 46

weakened, and a robotic system that implements a physiologically complete biomechanical model.

For stable walking, equilibrium control of the exoskeleton-user assembly is achieved by tracking its zero-moment point (ZMP) references, which are based on the desired Normalized Dynamic Stability Margin (NDSM). The exoskeleton’s controller can subsequently adapt reference walking gait patterns, stored in memory, to maintain stability.

Successful dynamic walking requires precise control of the legs’ joint angles in terms of position, velocity and acceleration via rotary encoder feedback. This is difficult to achieve as each mechanical joint is compliant and includes elastic elements to help mimic and support the real joints and muscles of the human user.

Alberto Plaza, R&D engineer and manager of the MAK project at Marsi Bionics, describes the stringent encoder

requirements of human exoskeletons: “The most difficult challenge when developing exoskeletons is the reliability of obtaining accurate angular position references, as they change from one structure to another, complicating standardisation and assembly of the devices.

Previously, we had used our own custommade PCB encoders that were fully linked to the kinematic structures of the MAK and ATLAS exoskeletons. But problems regularly occurred because the joint motors generate stray magnetic fields that can interfere with magnetic encoders and cause faulty readings.

“When designing the ATLAS and MAK devices, we decided that the components that make up the joints, such as the encoder, should be as compact as possible without compromising performance as there are significant space constraints. Another aspect to bear in mind is functionality: we need absolute rotary encoders to ensure that the angular position of each axis is always reliably known, even after a power failure.”

SOLUTION Marsi Bionics selected the RLS Orbis encoder for its ATLAS exoskeleton and the RLS RM08 encoder for its MAK kneejoint exoskeleton. The Orbis encoder is a component-level absolute rotary encoder designed for space constrained applications: it has a through-hole design, which enables direct mounting on the joint motor shaft. The RM08 encoder is a miniature high-speed rotary magnetic encoder: it has an 8 mm diameter and is IP68-rated for use in harsh environments.

Both encoders feature low weight and volume to minimise inertias, a non-contact and frictionless design to eliminate mechanical wear, and high angular resolution and accuracy to ensure excellent servo performance.

“We needed encoders that met our performance criteria without adding excess weight and volume, as any excess in the structure could be detrimental to the user’s mobility and might hamper the walking movement”, says Mr Plaza.

We needed encoders that met our performance criteria without adding excess weight and volume.

RESULTS RLS magnetic encoders have enabled Marsi Bionics to design and build exoskeleton orthopaedic devices that could improve the quality of life for people suffering from diseases such as SMA, multiple sclerosis and hemiplegia caused by stroke. Active exoskeletons will particularly impact the lives of young children, aged six and above, who are unable to move around by themselves.

“It is of the utmost importance to achieve a stable movement and an exact position

of each joint of the device. For that matter, the data collected from the encoders is fundamental for generating the position references. RLS and Renishaw provided us with the best encoder feedback solutions for our applications”, concludes Mr Plaza.

For further information on Renishaw, visit www.renishaw.com.

Issue 46 PECM

79

NEWS & EVENTS

GLOBAL CLIENT BASE AWI

AWI makes £1m investment in material to meet industry demand One of the UK’s leading manufacturers of round, flat and profile wire has completed a £1m investment in material to ensure it continues to meet the growing requirements of its global client base.

Alloy Wire International (AWI) continued manufacturing wire from High Performance nickel alloys throughout the Covid-19 pandemic, maintaining supply to sectors including medical, power generation and commercial transport.

The company, which offers a 60-strong range of Exotic alloys, has ensured it always has over 200 tonnes of European and DFARS compliant material at any one time, so that it can manufacture and deliver within three weeks of clients placing their orders.

This is just one element of an ongoing investment drive that has also seen the redevelopment of its offices in Brierley Hill and the introduction of the latest wet drawing machine for producing wire from 1.6mm to 0.7mm diameter, plus a take-up spooler that can handle and store larger weight rolled wire profiles.

Mark Venables, Managing Director of Alloy Wire International, commented: “We’re still averaging 160 enquiries every week, so there doesn’t appear to be a let up in demand like some parts of industry are seeing.

“With this in mind, we have remained true to our commitment to always have 200 tonnes of material in stock at any one time, meaning we can complete orders in just 3 weeks – and when an emergency arises we look to our Emergency Manufacturing Service that can see wire supplied in just three days!”

He continued: “We appreciate it’s a big investment at this current time, but we know it’s the right decision as our customers span over 55 different countries and when one territory is a little bit down you usually find another is increasing orders.”

Bob Jones inspecting raw material stock using Positive Material Identification equipment “All of the material is sourced from approved suppliers to ensure melt quality, which can be important to the successful performance of the client’s end products and this could be aircraft parts, oil rig components or medical equipment.”

Alloy Wire International is approaching 75 years of manufacturing wire in the UK and currently supplies in excess of 5000 customers involved in automotive, aerospace, defence, medical, nuclear, oil and gas and renewables.

Material, including Phynox, Inconel and Hastelloy, is available from 0.025mm (.001”) to 21mm (.827”) in small batches or medium/large volume – all within a threeweek timeframe.

Its global reach also continues to gather pace, with the appointment of Andrew

Marshall of AM Wire Pte Ltd to look after Singapore and nearby territories.

He has been supporting spring makers and other wire consumers in the region for many years and will offer immediate access to a number of key industries.

Angus Hogarth, Sales Director of AWI, concluded: “The pandemic has thrown up some massive challenges, but we’ve tried to stay true to our core philosophies and our staff have really delivered – first in supplying the NHS and, in more recent weeks, keeping up with demand from other sectors.

“Investment will continue in material and equipment, with our next purchase planned to be new cutting and straightening machines that will deliver an increased range of products for our customers.”

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

80

PECM Issue 46

NEWS & EVENTS

Fabricator completes £1.3 million investment SevenHills Fabrication, one of the Steetley Corner Group of companies, has completed an investment programme worth more than £1.3 million.

“Our plan is to continue expanding our operations following a decade of growth and having the technology, equipment and skills to run a manufacturing operation which continually adapts and improves is the future for this company. This approach should be the standard for British manufacturers.”

The Sheffield company, which has demonstrated 31 per cent year-on-year growth with a turnover of 3.5 million GBP, has completed its investment drive with the installation of a £200,000 press brake and a £150,000 robot welder.

The latest investments have been supported by the Sheffield City Region Business Investment Fund and enable SevenHills Fabrication, a specialist fabrication and laser cutting business based at the city’s Holbrook Industrial Estate, to continue its transition into Industry 4.0 operations.

Managing director of SevenHills, James Harding-Terry, said: “The company’s transition to industry 4.0 is essential for future-proofing the business.

“Over the past three years, SevenHills has installed a £550,000 Bystronic fibre laser cutting machine, a £60,000 electric tubebending machine and a £250,000 computer system for full mapping of production, accounting, purchasing and distribution.

“The new machines complete a substantial

investment programme for us that really sets this company apart from traditional fabrication businesses as we take on increasingly complex and challenging projects across a range of sectors.”

SevenHillls, which can trace its history back to 1926, has completed other investments, including £50,000 on improved extraction facilities, LED lighting throughout its operations and measures to improve the company’s energy consumption, waste material ratios, local environment and staff working conditions.

James added: “Operating in conjunction with new machines such as the tube bender, press brake and our robot welder, the computer system will help to up-skill our workforce so that they are able to adapt to Industry 4.0 methods.

SevenHills’ growth contributes to Steetley Corner Group’s £8.9 million turnover, growing at 23 per cent.

James Harding-Terry added: “Aside from the challenges and opportunities presented to industry through Brexit, the UK has to achieve manufacturing stability, growth and global excellence so that domestic businesses like ours may succeed. We must compete at the highest level, adopting the best resources available.”

SevenHills Fabrication supplies high technology solutions to aerospace, defence, hygiene, medical, oil and gas and agricultural sectors and its output covers bespoke single items through to large batch production.

Steetley Corner Group incorporates IT consultancy company, Acuma Technology, towbar specialist PCT Automotive and SevenHills Fabrication, based at Sheffield’s Holbrook Industrial Estate.

www.sevenhillsfabrication.com

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

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

www.mcs-corporate.com

01926 512475

gjw@mcs-corporate.com Issue 46 PECM

81

NEWS & EVENTS

IIOT INNOVATIONS SCHNEIDER ELECTRIC

Schneider Electric and RS Components Launch Initiative to Drive Industrial Digital Transformation

Schneider Electric, the leader of digital transformation in energy management and automation, has launched a joint initiative with RS Components (RS), the global industrial and electronic products and solutions provider.

The partnership extension sees the introduction of the latest Schneider Electric automation and IIoT (Industrial Internet of Things) innovations and technical knowledge to RS, including the Modicon M262. The leading PLC and motion controller, the M262 brings together factory control, monitoring and cloud computing, without peripheral equipment and complex programming, securely and cost-effectively.

In total, RS will be adding more than 3,000 Schneider Electric solutions to its platform as part of the ongoing initiative. Products include robotics, motor control, and safety devices from across Schneider Electric

IIoT range. Whilst the company will provide engineers with access to Schneider Electric’s broad industrial technology range, stocked in-depth and available for 24-hour delivery across the EMEA region, the partnership will also enable RS to extend its knowledge of key IIoT innovations and pass on their benefits to customers.

With the initiative, Schneider Electric is broadening its customer base, bringing its new launched IIoT innovations to a wider field. While increasing its reach, the extension also enables the company to ensure the highest level of service is provided to users. By taking a more active role with RS, Schneider is effectively upskilling the industry to improve decision making and specification.

“We want to be the first choice for every customer requiring industrial control devices, whatever their demands. That

means we have to have the ability to specify and support, as well as execute,” said Kristian Olsson, Vice President of Industrial Automation and Control at RS. “Having Schneider Electric’s expertise directly embedded into our company, effectively allows us to provide the best possible technical advice for and help customers make the best possible decisions.”

“Working together for 30 years and across 25 countries, RS is a valued and trusted industrial partner. Investing in them effectively expands industry knowledge and raises the level of its solutions,” said Martin Walder, VP of Industrial Automation at Schneider Electric. “With our suite of products and service experience, we are uniquely positioned to help the end user choose and maintain their industrial solutions. We hope the initiative will help grow the RS offering and enable us to bring our expertise to customers.”

For further information, please visit www.se.com/uk | www.rs-online.com

82

PECM Issue 46

NEWS & EVENTS

Fabricator completes £1.3 million investment SevenHills Fabrication, one of the Steetley Corner Group of companies, has completed an investment programme worth more than £1.3 million.

“Our plan is to continue expanding our operations following a decade of growth and having the technology, equipment and skills to run a manufacturing operation which continually adapts and improves is the future for this company. This approach should be the standard for British manufacturers.”

The Sheffield company, which has demonstrated 31 per cent year-on-year growth with a turnover of 3.5 million GBP, has completed its investment drive with the installation of a £200,000 press brake and a £150,000 robot welder.

The latest investments have been supported by the Sheffield City Region Business Investment Fund and enable SevenHills Fabrication, a specialist fabrication and laser cutting business based at the city’s Holbrook Industrial Estate, to continue its transition into Industry 4.0 operations.

Managing director of SevenHills, James Harding-Terry, said: “The company’s transition to industry 4.0 is essential for future-proofing the business.

“Over the past three years, SevenHills has installed a £550,000 Bystronic fibre laser cutting machine, a £60,000 electric tubebending machine and a £250,000 computer system for full mapping of production, accounting, purchasing and distribution.

“The new machines complete a substantial

SevenHills’ growth contributes to Steetley Corner Group’s £8.9 million turnover, growing at 23 per cent.

James Harding-Terry added: “Aside from the challenges and opportunities presented to industry through Brexit, the UK has to achieve manufacturing stability, growth and global excellence so that domestic businesses like ours may succeed. We must compete at the highest level, adopting the best resources available.”

investment programme for us that really sets this company apart from traditional fabrication businesses as we take on increasingly complex and challenging projects across a range of sectors.”

SevenHillls, which can trace its history back to 1926, has completed other investments, including £50,000 on improved extraction facilities, LED lighting throughout its operations and measures to improve the company’s energy consumption, waste material ratios, local environment and staff working conditions.

James added: “Operating in conjunction with new machines such as the tube bender, press brake and our robot welder, the computer system will help to up-skill our workforce so that they are able to adapt to Industry 4.0 methods.

SevenHills Fabrication supplies high technology solutions to aerospace, defence, hygiene, medical, oil and gas and agricultural sectors and its output covers bespoke single items through to large batch production.

Steetley Corner Group incorporates IT consultancy company, Acuma Technology, towbar specialist PCT Automotive and SevenHills Fabrication, based at Sheffield’s Holbrook Industrial Estate.

www.sevenhillsfabrication.com

Engineering Equipment and Materials Users Association

Many EEMUA resources are free or discounted for members, so please log in and help yourself to Guidance Notes, training, e-learning, Checklists, live Webinars and replays, engage with peers in forums, live online events, and much more. www.eemua.org

13405 01 EEMUA 159 COVER Above Ground SPINE 32mm.indd 1

A guide to inspection, maintenance and repair

Publication 159 Edition 5

Publication 159 Edition 5

Members help yourselves…

Above ground flat bottomed storage tanks

Publication 186 Edition 7

Knowhow contributed ‘for industry, by industry’ is shared as practical aids for engineers in their work – wherever they are, whatever time they have.

A Practitioner’s Handbook for potentially explosive atmospheres

EEMUA’s resources help people working in engineering as they make businesses, the environment, and everyone’s future safe and prosperous.

Above ground flat bottomed storage tanks A guide to inspection, maintenance and repair

There’s more to EEMUA…

for potentially explosive atmospheres

A Practitioner’s Handbook

Control Rooms: A guide to their specification, design, commissioning and operation

Publication 186

Publication 201 Edition 3

Edition 7

Supporting Engineering Equipment and Materials Users Association www.eemua.org

Engineering Equipment and Materials Users Association

29/08/2017 12:56

12028 Book186 Explosive atmospheres cover March 2016 17mm spine.indd 1

20010 EEMUA Pub 201 Control Rooms Ed 3 10mm spine.indd 1

05/07/2019 16:19

24/03/2016 14:07

The mechanical integrity of plant containing hazardous substances A guide to periodic examination and testing EEMUA Publication 231 SAFed Publication IMG1 Edition 2

Join in…

New Corporate Members are always welcome to share EEMUA’s knowledge and influence. If you’d like your organisation to join EEMUA, please get in touch.

Engineering Equipment and Materials Users Association

Risk Management of Legacy Systems with Potential for Excess Overpressure

Publication 236 Edition 1a

SafetyAssessment AssessmentFederation Federation Safety Unit 4, 4, First FirstFloor Floor Unit 70 South South Lambeth Lambeth Road 70 Road Vauxhall Vauxhall London London SW8 1RL SW8 1RL www.safed.co.uk www.safed.co.uk

Healthand andSafety Safety Executive Health Executive Redgrave Court Court Redgrave MertonRoad Road Merton Bootle Bootle Merseyside Merseyside L20 7HS L20 7HS www.hse.gov.uk www.hse.gov.uk

Engineering Equipment Engineering Equipment & Materials MaterialsUsers’ Users' Association Association 63 MarkFloor Lane Second London 16 Black Friars Lane EC3R 7NQ London EC4V 6EB www.eemua.org www.eemua.org

www.eemua.org

EEMUA Book 231 The Mechanical Integrity... COVER 3mm spine.indd 1 XXXXX EEMUA Publication 236 2mm spine.indd 1

WWW.EEMUA.ORG Contact membership@eemua.org or call on +44 (0)20 7488 0801

26/02/2019 12:13 04/05/2020 17:00

Helping you improve safety, efficiency and compliance

Issue 46 PECM

83

NEWS & EVENTS

CELEBRATING 70 YEARS EURAMAX

Euramax looks back at its journey and how the company has changed Yorkshire based window and door manufacturer Euramax is celebrating its 70year anniversary. Incorporated in 1950 as a family run business, Euramax now employs 150 people, operates from a 205,000 square foot facility and manufactures over 3,000 products a week. Boasting an impressive number of firsts in its 70 years, the company has also witnessed the paradigm shift from cost-effective windows and doors to luxury, double-glazed materials.

Originally founded as Ellbee, the company’s journey began in Leeds, manufacturing aluminium window frames for narrowboats and the automobile industry before partnering with a glazing company to supply pre-glazed aluminium windows.

In the 1990s, Ellbee became the first company in the UK to supply unplasticised

84

PECM Issue 46

polyvinyl-chloride (PVCu) windows to the static caravan market. It also became the first to develop an internal clamping system for efficient window installation, which is still widely used in the industry today. As the company expanded, Ellbee moved to its first of three factory sites in Leeds in 1964.

In 1996, Euramax International was formed and in 2013 the company moved to its current facility in Barnsley. After the arrival of managing director Nick Cowley in 2019, Euramax broke into the portable building and modular construction markets.

At present, Euramax manufactures and supplies PVCu windows, doors and composite doors for a number of sectors, including the holiday home and home improvement markets, as well as builders’ merchants, including Wickes, Selco and Travis Perkins.

“Euramax has transformed into a company that adapts to support its customers’ marketplace,” said Nick Cowley, managing director at Euramax. “Following trends and analysing the requirements of our sectors has allowed us to expand our customer base to a number of home improvement customers and builders’ merchants, leisure home and modular home manufacturers across the country.

“The caravan market has changed dramatically since the 1960s. Static Caravans that were not highly regarded and were considered popular for those who couldn’t afford to travel abroad, have now been developed into impressive modern homes. As the style, size and purpose of these products developed, so did the requirements of Euramax’s products,” continued Cowley.

“Energy efficiency was not a consideration in the original development of the caravan market. But, gradually the need for warmer accommodation was in demand. We knew that the market needed energy efficient windows, which is why we moved from supplying single glazed aluminium windows, to double glazed PVCu, which has better thermal properties. In fact, our windows are rated A for their energy efficiency by The British Fenestration Ratings Council (BFRC).

“While the industry and its requirements have changed, our ability to consistently supply glazed PVCu windows to what is an ever-changing market has remained the same. Some of our longest serving customers include Willerby Holiday Homes, Atlas Leisure Homes and Carnaby Caravans.

“Turning 70 is a great milestone for

composite options can become swollen in the summer,” added Cowley.

Euramax has transformed into a company that adapts to support its customers’ marketplace.

Euramax. There aren’t many window and door manufacturers that can say they have survived a recession. We’ve gone from barges to building and construction and I’m very proud of that. Who knows what the next 70 years will bring?”

“In addition, we developed our unique hybrid PVCu and composite doors in 2019.

We wanted to provide our customers with the best of both worlds as we found that

“I don’t think our success this far would’ve been attainable without the dedicated team we have,” said Richard Banks, commercial director at Euramax. “Some of our employees have been with us nearly 40 years now.

“During my time with Euramax, I have seen many changes in personnel, products and processes. However, the one thing that has remained consistent is the dedication of our employees to fuel our passion to listen to our customers and deliver the solutions they require,” said Banks.

August 2020 marks 70 years of manufacturing for Euramax. For more information or to browse its products and the sectors it supplies, go to www. euramaxuk.com or call +44 (0) 1226 361639.

For further information, please visit www.euramaxuk.com Issue 46 PECM

85

NOW ONLINE WHERE PRODUCTIVITY MATTERS This year’s meeting place for processing equipment, packaging machinery, industrial robots and vision systems.

CONNECTING BUYERS WITH SUPPLIERS ONLINE

ppmashow.co.uk O OW WN NEED D A AN ND D O OR RG GA AN NIISSEED D B BYY

PPMA PPMA Group Group of of Associations Associations is is aa trading trading brand brand of of PPMA PPMA Limited.

Limited.

When managing real pressure is your job…

MIPC® helps engineers stay on-site and on top of the latest industry developments and good practice in primary containment of hazardous substances.

Using a blend of live, online classes, one-to-one sessions with expert tutors, and e-learning, enhanced by a mentor’s support and guidance, EEMUA’s Mechanical Integrity Practitioner Certificate course delivers in-depth training to engineers where they work – to give professionals the flexibility to learn on-site or on-call.

The next EEMUA MIPC® course: Learning starts in September.

Enrolment to suit your schedule July – September.

MIPC® shortlisted for the Best E-learning/ Online Education Initiative memcom membership excellence awards 2020

For more information please contact EEMUA online-learning@eemua.org +44 (0)20 7488 0801 www.eemua.org

PROCESS TECHNOLOGIES

ONE-STOP SHOPPING ALUMINIUM DIE CASTING SRL

Die casting is just the beginning Die casting processes can often deliver products that can be used “as cast”, i.e. no additional manufacturing activities are required, and the parts are immediately ready for use. Nonetheless, there are situations where supplementary treatments are necessary to optimise the casting’s performance and capabilities. In these instances, opting for a ‘one-stop-shop’ supplier that performs both die casting and post-cast operations is the most efficient and reliable solution.

Pierluigi Buffagnotti, Production Manager at Aluminium Die Casting, looks at the benefits of relying on full-service, die cast-to-finish suppliers.

To remain competitive in a continuously evolving market, manufacturers need to continuously push themselves to maintain short lead times. Die casting, with its ability to create near net shaped parts of any form and size with high accuracy, can support industries with a manufacturing process that is extremely fast and economical,

particularly for high-volume production.

Despite the good quality of as-cast parts, certain applications may require extended service lives, electrically conductive properties, aesthetically pleasing appearances or other characteristics.

When die castings need to exhibit any of these particular features, manufacturers can continue their efforts to keep short lead times by choosing one-stop-shop die casters that can also perform these additional operations.

As the need for subcontractors is drastically reduced, logistics and management costs are also slashed. This further streamlines industrial operations whilst reducing any risks associated with managing a process through multiple vendors.

KNOW YOUR FINISHING NEEDS When selecting a single point of contact for die casting and post-cast operations, it is important to know what the end

product surface should look like. There is a broad range of tools, techniques and machines offering very different aesthetic or functional properties to die casts.

For example, there are several smoothing and polishing methods, such as sanding, vibratory finishing or ball burnishing. While these all perform the same tasks, they greatly differ in the processes used and the end results.

In addition to surface finishing treatments, machining and mechanical processing are also extremely useful post-cast methods, as they can offer threading, turning, boring as well as special mechanical polishing and sanding treatments. Amidst the different metalworking lathes available to perform these operations, computer numerical control (CNC) machines are among the most advantageous. As they offer high repeatability and accuracy, they can maintain the high-quality levels built into die castings, ensuring superior end products.

Supplementary treatments may be necessary to optimise the casting’s performance and capabilities. Therefore opting for a ‘one-stop-shop’ supplier that performs both die casting and post-cast operations is the most efficient and reliable solution.

88

PECM Issue 46

Equipped with a broad selection of finishing machines, Aluminium Die Casting is able to offer a wide range of finishing operations, offering a comprehensive die cast-to-finish service.

Finally, the ability of die caster to apply seals or gaskets to metal parts may be particularly important for outdoor uses or in other wet and/or dusty environments.

In these cases, ensuring reliable ingress protection (IP) ratings are crucial to establish reliable operations.

While some businesses specialise in only a few specific methods, others are able to provide a more comprehensive service portfolio. The versatility of the latter group is highly advantageous to manufacturers, as they can discuss with post-cast experts specialised in different methods which ones are the most suitable to obtain the desired optical, physico-chemical and tribological features. The manufacturers can then choose between different available options or combine two or more treatments, when required, without the need to handle different post-cast subcontractors.

The capabilities of Aluminium Die Casting, a brand of Altra Industrial Motion Corp., go well beyond die casting. The company is a full-service, die cast-to-finish supplier able to offer high-precision post-castings by means of its highly accurate and advanced machines. More precisely, Aluminium Die Casting can perform finishing operations, such as sanding and tumbling, thermal and surface treatments, liquid or powder painting as well as apply IP rated seals and

gaskets that meet the needs of various industries, including food and beverage, healthcare, and automotive sectors.

Aluminium Die Casting can support its customers with 19 different CNC machines, including both horizontal and vertical milling equipment, in conjunction with 10 high-pressure die casting units. Further, it supports its customers with the extensive expertise of its engineers, who are happy to discuss the production requirements and suggest the most suitable manufacturing and finishing methods. Thanks to their advanced knowledge, Aluminium Die Casting teams can address even the most challenging applications.

CUTTING-EDGE POST-CAST TECHNOLOGIES FOR HIGHER QUALITY Customers that want to bring the quality of their aluminium parts to the next level should opt for automated post-cast solutions. This is one of the main reasons why Aluminium Die Casting implemented a number of robots on its factory floor. In particular, some of the 19 CNC machining systems feature robotic arms, responsible for loading components. Robots are also a key component of the company’s die casting units, which runs in fully automated and independent modes.

As the need for subcontractors is drastically reduced, logistics and management costs are also slashed.

Besides delivering a high-quality result, automated processes further streamline the production processes by ensuring reduced lead times and prompt supply. As a result, customers’ manufacturing lines are not held back by die casting and post-cast processes.

By offering a single point of contact for complete die casting projects, backed by extensive expertise and advanced capabilities in die casting and finishing, Aluminium Die Casting offers the ideal solution for manufacturers. These can avoid dealing with multiple suppliers and benefit from quick lead times without compromising on service and quality.

For further information, please visit www.aluminium-casting.com Issue 46 PECM

89

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 90

PECM Issue 46

Electromagnetic Flowmeter MIM Series All metal design

Stainless steel version

°F °C

Flow and temperature measurement

Monitoring function

∑

Total and partial quantity counter

2 configurable outputs

Display operation also with gloves

90°

Rotating colour display

Space saver

01623 427701 www.kobold.com info.uk@kobold.com

CONTACT US FOR ALL YOUR SPOT WELDING EQUIPMENT AND TEST/WELD INSTRUMENT NEEDS

Exclusive UK Importer & Sole Distributor of TECNA Industrial Welding Equipment Supported by a 5 Year Warranty

Wilkinson Star Ltd • Shield Drive • Wardley Industrial Estate • Worsley • Manchester • M28 2WD Telephone 0161 793 8127 wilkinsonstar.com

92

@wilkinsonstaruk PECM Issue 46

/wilkinsonstaruk

NEW

W MEETING NTEION HSE LEGISLA

F-TECH FUME EXTRACTION SYSTEMS

F-TECH FUME EXTRACTION MIG WELDING TORCHES

Exclusive Supplier for UK and Eire

FOX ARMUR POCKET

starparts.sales@wilkinsonstar.com • +44(0)161 728 7922 Wilkinson Star Limited, Shield Drive, Wardley Industrial Estate, Worsley, Manchester M28 2WD • +44(0)161 793 8127 • www.wilkinsonstar247.com

** Wheel Wheel Mounted Mounted Units Units

PRODUCT NEWS

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

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

Chain & Sprocket Engineers since 1980 Industrial Chain & Sprocket Industrial Chain & Sprocket Specialists

Specialists

Food & Beverage, Processing & Packaging, F Food & Beverage, Processing & Packaging, FMCG Waste Management, Waste Management, Materials, Paper & Construction Materials, Paper & Board, SteelConstruction Plus many more Manufacturers & Suppliers of: BS & ANSI Attachment Chains Stainless Steel & Plated Chains Double Pitch Chains Hollow Pin Chains Agricultural Chains Sprockets - Specials Manufactured ‘in house’ Sprockets - Standard Sprockets bored & keyed

Plus Many More

Manufacturers & Suppliers Of

BS & ANSI Attachment Chains Stainless Steel & Plated Chains Double Pitch Chains Hollow Pin Chains Agricultural Chains Sprockets - Specials Manufactu Sprockets - Standard Sprockets

Web: www.LDAchains.com Web: | Email: sales@LDAchains.com | Tel: 0161 477 5252 www.LDAchains.com

94PECM PECMIssue Issue 1 4046

Followsales@LDAchains.com us on Instagram Email: Tel: 0161 477 5252

ROBOTICS

INTRODUCING THE CRX-10IA FANUC

New Cobot offers solution for post-lockdown manufacturing FANUC’s new lightweight collaborative robot, the CRX-10iA, is now available to UK customers.

The 39kg cobot was launched at IREX last year, and is a compact collaborative robotic solution which can aid manufacturers looking to increase productivity while adhering to current social distancing guidelines. Available for viewing at FANUC UK’s headquarters in Coventry, the CRX10iA will be on show at its upcoming technology day to allow manufacturers the opportunity to see how collaborative robots can help their business.

Given the close contact between operator and machine, the CRX-10iA has been designed with safety front of mind.

Movement automatically stops upon light contact with humans, and if an object is struck hard, the cobot instantly backs away from it. The smooth and elegant design provides protection from pinching, making it an ideal partner for production workers, and is certified according to the ISO 10218-1 safety standard.

Andy Armstrong, Sales and Marketing Manager at FANUC UK, comments: “Excitement has been building over the

Excitement has been building over the CRX10iA ever since it was showcased at the end of last year.

CRX-10iA ever since it was showcased at the end of last year. Bringing our lightweight collaborative robot to market, at a time when manufacturers are looking at their production lines and trying to figure out how to adhere to social distancing without impacting productivity, is critical.

“As with all cobots safety is key, but we’ve also made installation and set up as straightforward as possible. An intuitive touchscreen panel allows programming to be done through a ‘drag and drop’ function, which means that those new to automation can create work programs quickly and easily. It is even possible to teach the

cobot the desired motion sequence though manually guiding it to the appropriate points, which we hope will help to make process as painless as possible for those new to the technology. For those new to collaborative technology, we’ve created a free downloadable eBook on successful cobot implementation”.

Crucially, the CRX-10iA benefits from regular software updates and the ability to add various application updates such as grippers, sensors, or camera, to ensure the cobot can adapt to the unique conditions of a production line. This is underpinned by a long service life, with FANUC expecting all mechanical components to operate maintenance-free for the first eight years of use provided the CRX-10iA is used correctly.

Andy concludes: “UK manufacturing is at a critical juncture, and it is only by introducing automation in processes that we can boost productivity to an internationally competitive level. The CRX-10iA represents an extension of our broad portfolio of industrial robots and automation solutions, ensuring that there is an option for anyone looking to increase the productivity of their business.”

FMCG & Board, Steel

s

ured 'In House' s bored & keyed etc

For more information on the CRX-10iA, please visit: https://crx.fanuc.eu/en/ Issue 46 PECM

95

ROBOTICS

ROBOT/HUMAN SIMILARITIES THE SEMPRE GROUP

How to reduce human error and training-time using guidance system AR allows you to experience an enhanced version of reality. From computer games to manufacturing, this technology can help humans gain repeatable and reliable results just as a robot would. Here, Chloe Reynolds, regional sales engineer for lean enterprise at The Sempre Group, explains how manufacturers can use AR to further bridge the gap between humans and robots in assembly and more.

The global COVID-19 pandemic has forced many operators to develop new skills as

96

PECM Issue 46

they take on a more varied role in a smaller workforce. During this transition, integrating and training new employees is a timeconsuming and costly process, and one that may initially result in high rates of human error as trainees learn new manufacturing processes.

The Office for National Statistics highlights the issue that maintaining social distance guidelines has “led to business and factory closures and supply chain disruptions,� making the training process more

complicated and costly.

Robots are commonly used to overcome issues, like training time and human error. However, integrating robots into a manufacturing process is not always possible. Aerospace or automotive assembly lines may need to carry out human quality control where a robot may not be able to differentiate between a superficial blemish on the inside of an engine and a potentially dangerous hairline crack on the external wing of a plane.

BRIDGING THE GAP BETWEEN HUMAN AND ROBOT AR operator guidance systems, like the Arkite Human Interface Mate (HIM), use AR to transform workstations into a digital and interactive environment. Operator guidance systems reduce human errors by projecting step-by-step instructions onto a surface that guide operators as they work. These systems use safety features, like light picking and visual projection, to notify the user if a step is not completed correctly. It maintains safety and consistency by not allowing the operator to move on unless the task is completed to the correct quality standard.

These guidance systems work on a rightfirst-time model and reduce the waste commonly caused by human error by up to 75 per cent, delivering a faster return on investment and further bridging the gap between humans and robots.

The global COVID-19 pandemic has forced many operators to develop new skills as they take on a more varied role in a smaller workforce.

AR also delivers training benefits.

Embedded smart sensors add validation by taking time stamps and qualitatively measuring performance to ensure that certain tasks have been completed correctly. Embedded smart sensors

reduce the need for a large amount of management support and training, without forfeiting high quality standards and control over the assembly line. These systems also digitalise the resulting data and integrate it with existing enterprise resource planning (ERP) systems, cutting down on paperwork.

Humans will never have the precision of robots during manufacturing, but the human qualities are why people are so useful. Plant managers can give their operators tools, like AR guidance systems, to make them perform with some of the benefits of a robot, getting the best of both worlds.

To find out more, visit www. thesempregroup.com today to read more about how you can benefit from integrating AR systems into your production line. Or, to speak to an expert, call +44 (0)1452 632712.

For further information, please visit www.thesempregroup.com Issue 46 PECM

97

STORAGE, HANDLING & DISTRIBUTION

MEETING MARKET REQUIREMENTS TEMPA PANO

Providing customer with complete solutions, tested to the highest standards Established in 1989 to specifically manufacture and design enclosures and cabinets for low voltage applications, Tempa Pano has since proved its market presence through affordable high quality products. With offices based in the UK, France, Romania and Bulgaria , as well as distributors in the Middle East and Asia – Tempa Pano constantly strives to be within close reach of the markets’ demand. Tempa Pano’s UK operations have been present since 2000 serving it’s UK customer base with bespoke engineering solutions and customer-oriented support. Further the company is expanding it’s presence in the UK market by moving to it’s newly acquired premises within the next year with a view to increase capacity and introduce new production capabilities.

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

Below is a breakdown of the Tempa Pano Enclosure and Busbar ranges:

• IP66 Wall Mount Enclosures • IP55 & IP65 Junction Boxes • IP 55 & IP65,66 Floor Standing Enclosures • 304 & 316L Grade Stainless Steel Enclosures.

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

Coupled with a highly experienced and qualified engineering team whose expertise is readily available Tempa Pano UK is confident in finding the best technical solutions with effective designs and take pride in being customers first choice solution partner.

For further information, please visit www.tempapano.com

98

PECM Issue 46

“your reliable solution partner„ Introducing the New and Improved Range of AS Modular Floor Standing Cabinets with more sizes and accessories to suit your needs Easy to configure with options to bay side-to-side, top to bottom or back to back Improved gutter design for better ingress protection New Gasket that provides protection for longer New range of accessories to help with installations

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

VALVES

74 Manchester Road Congleton Cheshire CW12 2HT Phone: +44 1260 277025

Process Valves & Instrumentation Ltd are proud to be the exclusive stockist and distributor for the WEIR BDK range of Plug, Lined ball & Diaphragm valves in the UK. In the past 12 months we have supplied in excess of ÂŁ300K of there sleeved plug valves delivering every order on time and showing considerable cost saving to our clients. We are doubling our stock holding in the new year providing an even better service.

WWW.PVILTD.CO.UK

100

PECM Issue 46

Portable Confined Space Ventilators & Air Blowers Fume & Dust Extractors Where fumes, smells or dust occur, the Miniveyor Air VAF fans can move contaminated air out of a confined space or building.

They effectively exhaust fumes, ventilate confined spaces, and increase the flow of fresh air.

The Miniveyor Air range are tough! The rugged VAF ventilators easily withstand blows without denting, giving less downtime and greater productivity and come with an industry leading 10 year warranty on the body.

The vane axial fans work on positive and negative airflow and are at home either extracting dust and fumes or blowing clean air into a confined workspace. In fact whatever the industry you work in, from marine, construction, mining, telecoms, fabrication or maintenance services, our VAF series fans will take whatever is thrown at them.

VAF-200 (8”)

VAF-400 (16”)

VAF Air Ltd Tetbury Ind. Estate Tetbury, United Kingdom sales@vaf-air.com +44 (0)330 016 0002 or visit -

VAF-300 (12”) Pneumatic

www.vaf-air.com

Scan Now with your Smart phone to buy at our Online store

For all your cable needs

Quality, compliant cables and accessories

Eland Cables’ complete cable solutions cover a comprehensive portfolio of power, control, data and instrumentation cables and accessories alongside expert technical support, UKAS accredited lab testing for quality and compliance, BSI KitemarkTM testing, and tailored logistics.

We perform | We connect | We deliver

FS 672069

EMS 672067

OHS 672066

www.elandcables.com | Call our sales team today on 020 7241 8787