Dpa 17 04

April 2017 The Engineer’s guide to new products & design ideas

Redefining the nature of motor and drive distribution

dpaonthenet.net

18: Linear actuators

30: Simulation testing

Warner Linear steers unmanned vessel design

Tackling car sickness in autonomous vehicles

Contents Cover Story Motor & drive distribution

08: The changing face of VSD and motor distribution Linear Motion Special Report:

05: 12: Cover Story: Meeting the challenges of drives and motors!

After Colchester Zoo suffered a power cut which tripped a drive operating an ozone pump within its sea lion enclosure, Gibbons Engineering, an ABB authorised value provider, had an engineer on site within two hours to replace the faulty unit with a 22kW ABB drive, collected straight from stock. p.8 (Cover image: Colchester Zoo)

14: 16: 18:

Linear guides & actuators Guides and actuators for Adelphi’s System F filling machine

Linear system Customised drive control system for NDT equipment

Linear motion guidelines Linear transmission engineering gets straight to the point

Ball screws Inch vs. metric ball screws: are you asking the right questions?

Linear actuators Warner Linear steers unmanned vessel design

Fasteners & Adhesives Special Report: Automotive adhesives

Sales Executive: Abigail Swift abigail.swift@imlgroup.co.uk

20: 23: 26: 28:

Design: Graham Rich Design www.grahamrichdesign.co.uk

Test & Measurement

Editor: Paige West paige.west@imlgroup.co.uk Publisher: Andrew Quenault andrew.quenault@imlgroup.co.uk

Head Office: IML Group, Blair House, 184/186 High Street, Tonbridge, Kent TN9 1BQ Tel: 01732 359990 Fax: 01732 770049 E-mail: dpa@imlgroup.co.uk DPA ISSN 0965-4747 Copyright in the contents of Design Products & Applications, its websites and newsletters is the property of the publisher. The publisher and the sponsors of this magazine are not responsible for the results of any actions or omissions taken on the basis of information in this publication.

In particular, no liability can be accepted in result of any claim based on or in relation to material provided for inclusion. Design Products & Applications is a controlled circulation journal, published monthly. Completed print or online registration forms will be considered for free supply of printed issues, website access and online services. Annual subscription for nonqualifying readers is UK £121, EU £146, Airmail £212 and single copy price is £12.

10,003 Average net circulation Jan-Dec 2015

Circulation Tel: +44 (0)1732 359990 Email: subscriptions@imlgroup.co.uk

08

RTV Silicone Adhesive Sealants aid automotive electronics

Fastener specification Innovation is not restricted by size

Medical adhesive Helping ensure integrity of life-saving medical device

Locking system Protecting Smartboards with custom locking solution

Technology Focus:

30: 32: 34:

Simulation testing Tackling car sickness in autonomous vehicles

Solar Orbiter testing

32

Reliability testing for the Solar Orbiter instrumentation

CAD model test rig Creating accurate wear-test rigs using simulation

Show Preview Hannover Fair 2017

36:

Hannover Fair returns bigger and better than ever

38:

Classified section

Have confidence in Brexit!

Now Theresa May and the Government have triggered Article 50, businesses need to start thinking seriously about the future. A survey has revealed an increase in the number of manufacturing and engineering companies who believe Brexit will be good for business and industry. When asked if they think their company will have a stronger future once Britain exits the EU, 40 percent of the 269 businesses polled answered yes compared to 14 percent 11 months ago.

Interesting to see the difference in opinion but great that the UK manufacturing confidence in Brexit is on the rise.

For more information: https://goo.gl/p8wLoY

Paige West, Editor

36 April 2017 3

Move in the right direction Linear motion and actuation technology from SKF Guiding: To provide optimal solutions for all your guiding needs, the SKF range of products feature linear ball bearings, profile rail guides and precision rail guides.

Driving: For applications that require driving by transforming rotary action into linear motion, SKF provides a comprehensive range

of solutions including miniature ball screws, rolled and ground ball screws and roller screws.

Actuating: With extensive experience and knowledge of actuation systems SKF can satisfy the most demanding requirements utilising linear actuators, telescopic pillars and control units.

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Feature: Linear guides & actuators

Providing guides and actuators for

filling machine B

ased in West Sussex, Adelphi Packaging Machinery (part of The Adelphi Group of Companies) is a manufacturer of liquid filling and capping machinery for industries such as pharmaceutical, cosmetic, toiletries, food, agrochemical and lube oil.

Adelphi designed and built a new range

Hepco products on all three. The verti-

choice for Adelphi’s System F. Mike

of modern, unique machines, the Sys-

cal movement enabling nozzles to dive

McGuire, HepcoMotion Sales Engineer

tem F-1800. With the design of the new

into bottles of varying depth, is provid-

explains, SBD fits this application per-

machine focused on reducing downtime,

ed using Hepco’s SBD belt driven actu-

fectly thanks to its high capacity re-cir-

increasing productivity, and offering cus-

ators with connecting shaft, couplings

culating ball guides providing improved

tomers greater flexibility and conveni-

and motor connection kit. This incorpo-

moment load capacity and longer life in

ence, many factors were considered. For

rates a vertical counterbalance design

high duty linear applications.

the linear motion required for this appli-

supported by two Hepco SL2 stainless

cation, Adelphi turned to HepcoMotion.

steel slides.

Multi axis Nozzle Carrier movement

Hepco’s SBD actuators provide a high-

ered frequently and quickly. The weight

er level of performance in terms of load

of the nozzle apparatus, piping, and

With movement over three axis, the

capacity and life than other comparable

product being dispensed also need to

System F-1800 Nozzle Carrier uses

sized linear actuators, making it a good

be taken into consideration. The prod-

The duty is quite high for this application as the main nozzle bar is raised and low-

dpaonthenet.net 5

Feature: Linear guides & actuators is in an almost unique ‘raking’ axis. This

nance - features that Hepco’s SL2 and

Unique self-cleaning action expels debris for long system life

SBD provide.

System F has been developed as an ex-

inate the need to adjust two conveyor

tremely hygienic and versatile inline filler,

guide rails during container changeover

High performance in hostile environments

capable of accurately dosing products

routines. This feature brings savings in

with a wide range of viscosities, and

terms of reduced downtime and also in-

Catering for a number of different in-

even those with large particulates. Giv-

creased output by minimising the nega-

dustries, including food production,

en the presence of possible solid and

tive impact of container gating time.

medical, and cosmetics packaging

liquid particles such as dust and liquid

to name but a few, the environmental

droplets, Hepco’s V guide system is a

The finished F-1800 is a modern and

conditions of the System F are quite di-

good solution. V guide addresses the

unique looking machine that sets Adelphi

verse depending on the type of liquid

problem of debris entering the sliding

apart from their competitors worldwide.

that is being filled. This was another

mechanisms thanks to its self-cleaning

The number of components has been

reason why the engineers decided on

action, ensuring a smooth and accurate

reduced which has resulted in a quicker

Hepco: Hepco can operate in hostile

movement. Having invented the V guide

build time, shortened lead times and re-

conditions. Furthermore both the SL2

system nearly 50 years ago, Hepco is

duced cost for customers. With a varied

and SBD offer surfaces that can be

renowned for its V guide technology and

customer-base, F-1800 appeals to any

easily washed and wiped down during

the many benefits it offers. Hepco’s SBD

liquid filling business looking to maxim-

cleaning routines. The need to wipe

also has a stainless steel sealing band

ise their output whilst minimising their

and wash down machines, together

which prevents dirt ingress, ensuring a

energy and labour input. The high load

with high production rates is a combi-

low maintenance solution.

capacity and low maintenance solutions

ucts therefore need to be able to cope with this high duty and be low mainte-

nation that only the toughest systems

gives the ability to move nozzles between multiple parallel conveyors, and to elim-

provided by Hepco means that system

can provide.

Technically designed to offer greater versatility

Corrosion-resistance is another key re-

Built with flexibility in mind, the modu-

quirement for any liquid filling applica-

lar-designed F-1800 can be quickly spec-

Building on the success of the F-1800,

tion – particularly for customers in the

ified to meet the needs of the customer.

Adelphi have since gone on to introduce

food industry. On the nozzle adjusters,

One such example is its ability to fill vol-

another addition to its System F prod-

where mechanical components are

umes from 20ml to in excess of five litres

uct range; the F-600. After working with

close to the filling process, corrosion

on one machine, without modification.

Hepco on the F-1800, Hepco was the

resistance is essential for liquids such

In addition, three wheeled SL2 carriage

preferred partner for Adelphi, with Hep-

as oral dose pharmaceuticals and food

plates are used in conjunction with an in-

co again supplying the necessary linear

items. Here, Hepco’s SL2 stainless

novative trigger release system to enable

guides and drive components.

steel bearing wheels are sealed for life

rapid nozzle pitch adjustment down to

units, negating the need for lubrication

just 40mm. This allows very small con-

so the system can run dry, thus elimi-

tainers to be accommodated, offering

nating the opportunity for product con-

even greater flexibility of the system.

www.adelphi.uk.com/division-land-

tamination.

Another application of the SL2 and rollers

ing/packaging-machinery/

6 dpaonthenet.net

life is rarely an issue, ensuring the system is hard-wearing and durable.

www.hepcomotion.com

ELECTRONIC OVERLOAD RELAYS

Smart Devices for Smart Machines

Helping to deliver time saving methods for configuration and programming.

The E300TM Electronic Overload Relay is the next generation electronic overload from Allen-Bradley®. Its modular design, communication options, diagnostic information, simplified wiring and integration into Logix make this the ideal overload for motor control applications in an automation system. The E300 Overload Relay provides flexibility, reduces engineering time and maximises uptime for important motor starter applications.

Features include: Intelligent Motor Control

Modular Design

Easy automation system integration

For exact application needs

> Network Connectivity

> Wide Current Range

> Native I/O

> Multiple Sensing Capabilities

> DeviceLogix™ Technology Enabled

> Expansion I/O

> Integrated into Logix

> Operator Interface

> Pre-programmed Operating Modes The newly designed E300 Overload Relay has incorporated the newest technologies directly into the device to help simplify installation and configuration. The new modular design of the E300 Overload Relay allows customers to tailor the device for their application’s exact needs.

Routeco Limited, Davy Avenue, Knowlhill, Milton Keynes, MK5 8HJ T. 0370 607 1000 F. 0370 607 1001 E. sales@routeco.co.uk

routeco.com/en-gb/products rockwellautomation.com/en_UK/products

Routeco/ABE300/2017/03

Cover story

“At Brinton Carpets, we converted spinning frames from inefficient direct current (DC) control to alternating control (AC) which helped increase production capacity of spun yarn at the UK’s leading premier carpet maker, while eliminating motor spare parts, lowering maintenance costs and saving energy,” says Phil Tomkinson of Sentridge Control.

The changing face of

and motor distribu

W

hile the face of distribution may be changing, it’s important the face of the people remain the same, as ABB’s Pete Myatt explains.

“It takes many years to graduate as a

square foot facility in order to stock a

competent technical distributor,” explains

broader range of ABB drives and provide

John Bennett of iDrives. “Our engineers

a workshop for the building of custom-

are loyal and remain with us for decades.

ised drive cabinets,” says Seamus Butler,

This is important as they are trained in

managing director.

every discipline associated with moThe business model for variable speed

tor-driven applications. As such we have

Problem solvers

drive (VSD) and electric motor distribution

the confidence to encourage customers

It is the deep technical know-how and ex-

has evolved significantly over the past 20

to give us their most difficult VSD or motor

perience that accounts for the majority of

years. While wholesalers and distributors

challenges, whether it is nuisance tripping

new business wins, as Nick Brown of EDC

still exist, the innovative technology em-

or energy reduction.”

explains: “Most of our new business starts with solving a difficult problem for a cus-

bedded within today’s VSDs and electric The importance and dependence that

tomer that often the customer and our com-

engineers, means that the know-how and

end-users place on this high level exper-

petitors have tried to solve without success.

application expertise of today’s distributor

tise is reflected in the growth being expe-

is critical. It is for this reason that ABB has

rienced by technical distributors. Recently

“For example, a renewable energy gen-

invested heavily in nurturing and training

ACS Drives & Controls Systems, the only

erating plant in Fife had a crane hoist on

the UK’s largest bespoke network of VSD

ABB authorised value provider for VSDs in

which the encoder signal was not work-

and motor partners – the ABB authorised

Ireland moved to larger premises. “We re-

ing. Despite several costly attempts over

value provider network.

cently doubled our floor space to a 12,000

many months by a competitor, the crane

motors, coupled with time-starved plant

8 dpaonthenet.net

Cover story sleep-boost,” says Kevin Brown of Quantum Controls. “Yet sometimes the installer is unaware of the potential of the asset they have purchased.”

For instance, some drives feature “energy optimisation”. This is a setting that, when activated, can add another 10 percent to the efficiency of the application. In industries like water, rather than replace the existing installation, end-users could significantly save costs by “sweating the assets”. “But to achieve this you need to know where to look. And this is one of the many roles offered by today’s technical distributors,” adds Brown.

Overcoming harmonics When installing VSDs, there are several technical challenges to consider. If overlooked, the effects can be costly and damaging. “Harmonics, for instance, can have a detrimental impact on a pump system,” says Luke Archer of MKE Engineer-

f VSD

bution

ing Group. “Electric motors may be heating up for no apparent reason; fluorescent anomalies, damaged components or un-

lighting may be flickering; or computer

usual mechanical loads are all potential

terminals could be suffering interference.

causes, sometimes in combination. We

All of these effects can be the result of

know where to look… and fast. That gives

harmonics. Yet how do you know this and

our customers a real edge.”

more importantly how do you resolve it?”

One way is to contact your local ABB au-

Sweating the assets

thorised value provider and ask for a free

Varying the speed of an electric motor

lunch and learn seminar that will show you

is straightforward but there is so much

exactly what to look out for and how to re-

more that today’s VSD can do. “VSDs

solve the effects of harmonics. The course

are packed with intelligent functions such

is free, takes place at your site and takes

as anti-ragging, multi-pump control and

about one hour.

hoist was still not operational. Our engineer arrived on site and within two hours the crane was fixed and working correctly, improving safety and control of the crane and preventing nuisance trips.”

While on site the EDC engineer spotted a 355kW ID fan running at fixed speed with a damper. While the customer wanted to fit a VSD for energy saving, space had prohibited them from doing so. However, EDC came up with solution that not only tackled the space issue but predicted savings of 846,000kWh per year.

It is this eye for detail that has secured the network much business as Pete Wilson of CovElec explains: “As you can probably imagine, there’s no single, straightforward answer for why motors fail. Power supply

An ABB synchronous reluctance motor and drive package, supplied by Inverter Drive Systems, has cut energy consumption on a twin extruder application by up to 15 percent, reduced maintenance costs and noise at Radius Systems.

dpaonthenet.net 9

Cover story Alternatively,

technical

partners

are

trained to carry out harmonic surveys

year, the drive is saving 74,250kW/hrs

pressors, for instance, the ABB author-

annually.”

ised value providers are skilled in finding

to the UK standard G5/4-1 or tele-

ways to improve productivity and also

phone-based health checks. The former

Another area of growing concern is that

keeping a plant running through reliability

are detailed site surveys whereas the

of overall electrical system efficiencies.

assessments.

latter is an initial telephone chat, where-

“It is well documented that from Janu-

by answers to a few questions posed by

ary 1st 2017 electric motors rated from

The reliability assessments consider the

the partner can give an initial assessment

0.75kW to 375kW need to conform to

maintenance requirements of the in-

as to whether your plant is suffering har-

IE3,” observes Darren Beeby of Halcyon

stalled base, whether that be ABB drives

monics.

Drives. “But do you know the impact of

or those of a third party, regardless of

the EcoDesign Directive which now intro-

industry, from oil, gas and chemicals

Electrical system efficiency

duces similar efficiency ratings for VSDs

through to food and beverage.

The immense energy savings potential of

when used with motors?”

VSDs and drives continues to dominate

The final word goes to Chris Fletcher of

sales. Most recently Magma Moulding,

There is a simple solution, says Andrew

EMR Silverthorn: “Fix it for a fair price

producers of the Trunki ride-on suitcase,

Brown of Beta Power: “Engage with the

and customers come back over and

cut its energy costs by £7,800 per year

technical distributor. They are trained to

over again. Plant engineers are busy and

by retrofitting an ABB drive to one of its

understand how the various component

stretched, so our role is to support them

moulding machines. “We conducted

parts interact with each other and can of-

by removing one less worry.”

a week-long trial with an ABB drive to

ten fine tune the system to squeeze the

see how much energy could be saved,”

maximum efficiency.”

To find out what the ABB authorised value provider can do for you, contact

says Alan Jones of APDS. “The moulding machine previously drew 40kW, but

More than just energy

your local partner on 07000 ABB AVP

since fitting the drive, this has reduced

Apart from skills in identifying the energy

(07000 222 287).

to 23.5kW. As it runs for 4,500 hours per

saving potential in pumps, fans and com-

Colchester Zoo suffered a power cut which tripped a drive operating an ozone pump within the sea lion enclosure. “We received the call from the zoo at 08:00 and had an engineer on site within two hours,” says Matthew Gibbons of Gibbons Engineering Group. “After determining that the installed drive was damaged, a replacement 22kW ABB drive was collected from our stock. Mains and control connections were set up and the pump was operational again by 13:00.”

10 dpaonthenet.net

The Engineer’s guide to new products & design ideas

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Feature: Linear system

Customised drive control system for

Non Destructive Test Equipment system

Drive and control system

N

on Destructive Test Equipment (NDT) is used extensively to analyse and measure for defect-free high precision components and fabrications in a wide range of industries where manufacturers pursue the highest degrees of component integrity and reliability.

Precision Acoustics approached LG Mo-

• The working speed of the Y axis is up to

tion to design and manufacture a very

800mm/second and the X axis 00mm/

specific drive and control system for its latest generation of ultrasonic scanning and measuring equipment for an NDT system.

second.

• Each linear axis is fitted with 0.001mm resolution magnetic encoders.

• All slides are fitted with end of travel

The requirement

limits.

The high performance scanning system developed by Precision Acoustics requires

www.lg-motion.co.uk

ultra-fast precision controlled scanning speeds which therefore calls for an extremely exacting drive system specification which LG Motion was able to meet.

Drive system specification The equipment consists of an XYZ Linear Servo & Stepper System, mounted on a frame consisting of two linear servo motors and one stepper driven vertical axis.

• Both X and Y axes are coupled to a linear bearing assembly with Duralloy coating whilst the Z axis has a standard LG series linear slide assembly.

• Each axis is fitted with a 0.001mm resolution linear encoder along its length.

• The XYZ assembly will typically meet or exceed a specification of: Positional accuracy: <0.05mm over length of travel Linear repeatability: <0.001mm, uni-directional Linear encoders: 0.001mm resolution, magnetic

12 dpaonthenet.net

Close up of gear shaft ready for NDT inspection (Credit: Shutterstock)

Advertorial

Intelligent Automation Systems inaugurates new operations in the United Kingdom London, 28 March 2017. Intelligent Automation Systems Ltd. recently officially inaugurated its new establishment at Hyde Park Hayes, a West London business centre, located less than three miles from Heathrow Airport. With this, the company reiterates its commitment to provide singlesource solutions for high-quality industrial automation and motion control products to customers across the United Kingdom.

Intelligent Automation Systems is a corporation of complementary business services that provide application engineering and design, supply, implement, test and repair industrial automation systems. This includes HMIs, motion controllers, brushless and brushed servo systems, linear systems, 2/3/5 phase stepping systems, AC induction systems, and spur and planetary gearboxes. The Hyde Park facility is part of the company’s strategy to build an integrated sales and aftermarket services channel. Driven by its endeavour to offer end-to-end solutions under one brand, this improved operations consolidates all the sales, research, and technical support activities for Intelligent Automation Systems for the UK, North Ireland and continental Europe markets.

“Intelligent Automation Systems has maintained operations within the UK since 2007. To offer seamless, comprehensive, customised solutions to our customers in diverse industries across the UK, we recently merged our activities.

Our Hyde Park facility offers cutting-edge industrial automation from global manufacturers like Trio Motion, Sanyo Denki, Fastech, Kinco Automation, RTA and SPG,” says Ajay Karavadra, Technical Director. “What gives Intelligent Automation Systems a distinct advantage is our team of engineers who draw

on more than three decades of cross-product technical know-how to provide exceptional solutions that are truly out-of-the-box, delivered within on-time schedules, and do not exceed customer budgets.”

The new operations will continue to design, source, build and implement advanced solutions ranging from one-off requirements to high-performance industrial automation systems for custom-built machines of OEMs. “Using cutting-edge technologies and high-performance products, Intelligent Automation Systems is the single-source go-to partner,” Ajay Karavadra adds. “Every solution is backed by local training and aftersales technical support. What’s more, Intelligent Automation Systems can quickly ramp up material deliveries or even ensure just-in-time lean inventory from its extensive warehouse.”

Intelligent Automation Systems Ltd. Hyde Park Hayes 3, 5th Floor, 11 Millington Road, Hayes, West London UB3 4AZ, UK Tel: +44 20 8432 2749 Fax: +44 20 8432 3051 E-Mail: sales@intelligent-automate.com Internet: www.intelligent-automate.com

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Feature: Linear motion guidelines

Linear transmission engineering gets straight to the point

T

he need for linear motion is increasingly common, especially in areas such as automated assembly packaging and robotics, but also diverse applications such as retail displays, sports equipment and many other areas. This has led to a plethora of different linear technologies, and finding your way through this can be daunting. Matt Jones, a linear motion specialist at Drive Lines Technologies Ltd, offers a quick guide through the basics. the selection

Electromechanical linear actuator

mounted within a pillow block housing.

procedure.

Similar to ball bushings, plain linear bear-

Engineers

Perhaps the first thing to say is that it

ings and linear slides are also offered by

is necessary to differentiate between driv-

Drive Lines. A range of liners and coatings

ing and guiding. An actuator is a powered

provides solutions for difficult and harsh

component that creates linear motion,

environments where traditional ball bush-

whereas a guide is unpowered and used

ings cannot be used. Shock loads, high

always

to keep other components â&#x20AC;&#x2DC;on the straight

speeds, and demanding environments are

needed to create

and narrowâ&#x20AC;&#x2122;. Often drive and guide are

often best addressed with a plain bearing.

and control linear move-

used together and it is important not to

have

ment, and over the years technol-

forget the importance of the guide, which

ogies to support this need have de-

can come into their own if there are (ex-

veloped. As is typical, early solutions

pected or unexpected) side or other loads

were relatively simple, but they have

that could upset the system.

grown in capability and sophistication so that today there is a wide choice of

Guides

linear motion components. In fact when

Ball bushings and linear shafting are gen-

specifying a solution for a given appli-

erally used where a cost effective solution

cation some people may feel spoiled

is required in commercial and industrial

for choice and end up not identifying

applications. They can be used in hori-

the most appropriate.

zontal, vertical and inclined orientations and generally the shaft has a round cross

Drives Lines has a wide ranging portfolio

section.

of linear products, plus the knowledge to help engineers find the best solution for

Ball bushings are in effect sleeve-shaped

their requirements. There are some basic

ball bearings designed to support a shaft

rules to understand, then an assessment

over a section of its length. They can come

of the project and calculations relating to

with an end-flange or grooves for circlip

loads, speeds etc. will form the basis of

mounting, in a thin walled variant and

14 dpaonthenet.net

The accompanying linear shafts from

Feature: Linear motion guidelines Drive Lines are precision ground and hardened. They are usually made from steel or stainless steel, although soft stainless steel and hard coated aluminium shafts are also available for food and wash down applications. Flanged shaft end supports, clamping blocks, Zimmer clamps and other accessories are also available.

A form of linear guide popular for mechanical handling and heavy load appli-

MiniTec custom workstations Fast. Versatile. Simple.

cations is the combined bearing and rail. These provide a cost effective guide solution to lift systems, platforms, monorails and cantilever loads. The system combines a radial bearing to take out high moment loads and a smaller axial roller to eliminate side movement. Typically the rail is U-sectioned and combined with a flange plate to which the bearings and rollers are attached.

When it comes to automation, tooling and machine tool linear guidance, linear ball guides provide high precision, high capacity linear motion and can be extremely cost effective. Based on a design of infinitely recirculating ball bearings, they provide equal load capacity in all directions, so guarantee smooth movement and accurate positioning. They are compact and have a low centre of gravity and are available in different precision and pre-load grades to meet most types of precision applications.

Drives Ball screws enable cost effective high speed and high precision actuation for automation and industrial applications. Ball screws offer high rigidity, minimal backlash, fast speed and positional accuracy. They can be supplied preloaded and are easy to install.

Drive Lines also offer high performance linear actuators. These combine guide and ball screw or leadscrew options and can be supplied with a drive motor to provide a one-stop fit-and-forget linear drive solution.

As well as a comprehensive range of linear components, Drive Lines also represents US Automation, an OEM supplier of innovative and cost effective motion control solutions. Its range of linear positioning stages and intelligent stepper motors provide cost effective, precision solutions for high tech and miniature applications.

Matt Jones is a linear motion specialist

“Our productivity has increased by simply being able to have our very unique workstation requirements met” Laila Andrews, Laboratory Technician

at Drive Lines Technologies Ltd www.drivelines.co.uk

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01256 365 605 dpaonthenet.net 15

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Feature: Ball screws

Inch vs. metric ball screws: are you asking the right questions?

B

ecause ball screws are available in both inch and metric dimensions, designers sometimes begin the specification process by selecting a product family based on the unit of measure. This decision may prematurely exclude the ideal product for the application and lead to significant losses in time, labour and expense. This article explains how sizing and selection questions centred on performance – instead of monikers – can lead to more efficient linear motion designs.

Inch series ball nuts provide dependable accuracy and repeatability, and are ideal for assemblies designed for inexpensive, transport-grade applications.

The lead of a ball screw is the linear

lead is specified in inches or millime-

the applications they were designed to

travel that a ball nut will travel upon a

tres, both screws translate the load in

solve. Inch series assemblies were de-

single revolution of the screw. The unit

exactly the same way. Everything else

signed as the work horses for low-cost,

of measure used to define this motion

being equal, the unit of measurement is

transport-grade applications: “I need to

is then typically assigned to the ball

little more than a parameter menu op-

move a large load from Point A to Point

nut as the product series. A 1.000 inch

tion on a motion configuration screen

B efficiently and cost effectively.” Metric

lead on an inch-series ball screw means

and, therefore, does little to actually dif-

series assemblies have evolved as the

that the load, as attached to a nut, will

ferentiate the product.

precision solution: “I need to move a

travel 1.000 inch with each revolution of

large load efficiently while maintaining

the screw. Similarly, a ball screw with

Inch series ball nuts and metric series

precise location throughout the stroke.”

a 25.000mm lead would mean that

ball nuts have traditional differences

Therefore, the question shouldn’t be

one revolution of the screw translates

in performance and configuration that

“inch or metric?” but “transport or pre-

the load 25.000mm. From a functional

are much more important than the

cision?”

standpoint, regardless of whether the

lead. Both are excellent products for

16 dpaonthenet.net

Feature: Ball screws The correct answer

Besides lead accuracy, transport grade

What to specify

Positional accuracy is a much more valu-

assemblies typically use external ball

The most important question to ask your-

able metric, and there are two classifica-

return systems to recirculate the ball

self when specifying ball screw accuracy

tions (Transport or Precision) with multiple

bearings, making it easy to visually iden-

is whether you need a transport or preci-

grades (P0, P3, P5, T5 and T7 to name

tify this product. External return systems

sion grade solution. Consideration of the

a few). Applications that require simply

tend to be noisier, less smooth and con-

differences between the product series

translating a load from one point to an-

sume more space than internal recircula-

are secondary considerations only and

other use the lower accuracy classifica-

tion systems. However, they are less ex-

may then be used to sway the final prod-

tion known as “transport grade” (typically

pensive to manufacturer and enable the

uct selection.

±23µm/300mm or higher). Applications

use of more ball bearings, increasing their

requiring knowledge of the absolute po-

load-bearing capacity or life expectancy.

Both inch and metric series ball screws

sition of that load at every point in the

For those applications in which cost, load

are excellent products if used in the cor-

stroke without external feedback use the

bearing or life expectancy are critical fac-

rect application. As with any business

higher “precision grade” accuracy (typ-

tors, designers should seek out manufac-

decision, it is important to analyse the

ically ±23µm/300mm or lower). The ac-

turers who specialise in transport grade

trade-off of performance and cost when

curacy designation doesn’t just provide a

products.

making the final product selection. Select

numerical deviation but also defines the

a transport grade ball screw for applications that require a transport grade screw.

Transport grade error is cumulative and

Why select precision grade ball screws?

linear, whereas precision grade error is

When accuracy and repeatability are

plications that require a precision grade

controlled and constrained.

critical to the performance of a system,

screw. Don’t let product monikers sway

it is important to select the correct prod-

the decision when only performance

Ball screws were invented and popular-

uct to yield the desired results. Precision

parameters are important. Start the ball

ised in the US for the automotive indus-

grade assemblies tend to be quieter,

screw selection process by creating a

try. Therefore, the product series has

smoother and have a smaller installed

performance specification based on im-

maintained the key features critical to

profile than transport grade assemblies.

portant parameters such as load, speed

this application: low cost, high perfor-

Therefore, this product is ideal for accu-

and life. The correct product may then be

mance (efficiency, load capacity and life

racy critical applications or where cus-

an inch or metric series ball screw.

expectancy), and a positional accuracy

tomers demand a higher level of operat-

that is not critical. The metric series of

ing performance. High-accuracy screws

ball screws was initially developed for

with a preloaded ball nut can eliminate

machine tool applications that required

the need for a positional feedback sys-

a product that was accurate, repeatable

tem, which can reduce the overall sys-

and stiff. The positional accuracy of each

tem cost.

overall accumulation of positional error.

Select a precision grade ball screw for ap-

www.thomsonlinear.com

series is still the main defining point of day, although it is certainly possible to

How measurement scales define product lifecycles

produce a product that crosses or over over-

Another point of differentiation between

laps the value proposition (i.e. an inch

inch and metric series products is in

series assembly with precision accuracy

how each scale describes the dynam-

or a metric series assembly with transport

ic capacity – or life – of the screw. Inch

accuracy). Thomson continues to supply

series products describe life in terms of

and support both series of products as it

millions of inches of linear travel, whereas

has embraced the differences and under-

the metric series defines life in terms of

stand that each product solves a unique

millions of revolutions. An inch series ball

application.

screw having a 2000N dynamic capacity,

differentiation between the products to to-

for example, means that it would carry

Why select transport grade ball screws?

a 2000N load for 1 million inches before

When design engineers are selecting ball

Likewise, a metric product with a 2000N

screws, the performance and price gap

dynamic capacity means that it would

between a transport grade and a preci-

carry a 2000N load for one million revo-

sion grade ball screw assembly is mar-

lutions to reach the L10 life expectancy.

ginal, making the final product selection

Because the metric series has the screw

even more challenging. The transport

lead in the equation, the dynamic capaci-

grade solution can still offer some capa-

ty cannot be directly compared and used

bility advantages when selected for the

as a point of differentiation unless con-

proper application.

verted to similar units.

it reaches its estimated L10 end of life.

Metric series ball nuts provide quiet, smooth-running and efficient performance with superior precision

dpaonthenet.net 17

Feature: Linear actuators Designing fully autonomous vehicles pre presents additional challenges since they need to share operational space with hu human-operated vehicles. In an effort to ad advance the technology for marine surface vessels, a biennial competition is being held for universities to showcase their ex expertise; an endeavour that has been sup supported by Warner Linear.

The development of autonomous marine vessels and the technology required to operate them will bring significant bene benefits to applications in search and rescue, shipping security, environmental moni monitoring and marine science. Incorporating the latest technology and cutting edge software for the sensor systems with pre precise and reliable propulsion and steering arrangements will soon bring benefits to a number of applications.

Each team was provided with a 16ft Wave Adaptive Modular Vessel

Warner Linear

steers unmanned vessel design R

esearch and development into unmanned vehicles has made considerable progress in the past few years.

15 university teams from five Pacific Rim countries, Australia, Japan, South Korea, Singapore and the USA, were set the challenge to design and build a highly capable unmanned surface vessel (USV) to complete against each other in the Maritime RobotX Challenge (MRC), held in Singapore.

One group of undergraduate and postgraduate students from the University of Newcastle in Australia, was chosen to take part in the competition and needed some assistance with the steering system of their USV. The challenge led them to

Another bright i

ENCLOSURES

POWER DISTRIBUTION

CLIMATE CONTROL

Feature: Linear actuators Warner Linear, part of the Altra Industrial

for the guidance software.

Motion Group, and a manufacturer of rugged service electro-mechanical actuators.

double ball bearing motors and a mechanical torque limiter for end-of-stroke

Nicolas Weightman, student team leader -

and overload protection. High perfor-

hull mechanical and electrical - said while

mance, synthetic, lifetime lubrication is

Each team was provided with a 16ft Wave

they didn’t win the competition, the pair of

used throughout, while unique, patented

Adaptive Modular Vessel (WAM-V) that

donated Warner Linear actuators definite-

screw-end bearing guides provide smooth

needed to be equipped with propulsion,

ly gave them the advantage of being able

extension operation, high side-load capa-

guidance and sensors that would enable it

to outmanoeuvre most of the other teams.

bility and aids screw re-lubrication.

to complete a set of predetermined tasks.

They wouldn’t have been able to run such

Each challenge, which included detection

a steering system without their help.

and avoidance of obstacles, as well as an

Meanwhile, the new challenges have been set for all those taking part in the

underwater search for an acoustic source,

The high quality K2x linear actuators are

next RobotX competition, which will be

was designed to test the design and im-

from Warner’s B-track range. They have

held in Oahu, Hawaii, December 11-18,

plementation of the sensors and control

been designed for use in tough, high-load

and the designs are well under way. The

systems.

applications where they will be in frequent

next generation of innovators will be cre-

use. The ball screw actuators are designed

ating designs that will help solve many

One of the more basic elements of the

to provide years of trouble-free service in

of the problems associated with autono-

design are the propulsion and steering

harsh, marine environments. They feature

mous vehicles and develop solutions that

systems that have to be integrated with

integral o-ring seals, bi-directional holding

will bring so many benefits to marine re-

the vision and guidance systems so that

brake and Nitrotec treated end fittings for

search.

the vessel can avoid obstacles. The team

strength and corrosion resistance. www.warnerlinear.com

from Newcastle chose to design a linkage that turned the electric outboard motors

Models also feature heavy-duty, sealed

using linear actuators.

Following some initial research, the designers contacted Warner Linear to discuss the challenge and find a solution.

Based on the team’s design requirements, Warner engineers configured two identical K2x ball screw linear actuators, The high quality K2x linear actuators are from Warner’s B-track range

which operate at 24 VDC, with a 1,270kg load capacity. The 300mm stroke and 5:1 gear ratio offered the required speed and torque to provide fast and accurate steering control, while the position feedback would provide the necessary information

idea from Rittal.

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Feature: Automotive adhesives

RTV Silicone Adhesive Sealants

aid automotive electronics I

mproving component system reliability, reduction of component weight, thermal dissipation and the simplification of module assembly are all key issues affecting Tier One supplier TRW in its development of leading edge automotive products.

wanted screws to rattle around and they

had proved satisfactory, with higher

represented both additional products and

production volumes it would be impor-

assembly operations.

tant to reduce the length of time from final assembly to dispatch. Reduction

Benefiting from new plastic materials The development of a plastic housing

of the cure speed of the sealing medium was considered an important factor to reduce production times.

made from a PBT/polycarbonate material

• Analysis of production units also indi-

provided the opportunity to build the con-

cated a need for improved heat con-

nector as an integral part of the housing

duction within the unit.

and achieve cost savings through the re-

• The mating surfaces of the male and

An approach has been adopted by TRW in

moval of peripheral seal screws through

female components of the units had

its design and production of engine man-

the usage of RTV silicone adhesive sealant.

been designed based upon mechan-

agement modules that control injection

ical design considerations with the u

and peripheral functions (such as emis-

With many key component elements to

groove being designed into the alu-

sions). In these units a key requirement

the project (plastic housing, electronics,

minium cover with the plastic housing

is the prevention/ingress of moisture into

PCB, connector assembly and the sealing

clipping into the cover. From a produc-

the system. The innovative usages of RTV

cover) there was a need for multi discipli-

tion process this resulted in the hous-

silicones have provided many benefits to

nary meetings to consider materials/pro-

ing groove being filled with sealant and

TRW in its product design and production

duction and assembly issues that would

then flipped over and onto the plastic

environments.

be faced as production levels increased.

housing.

At this point, UK Company Techsil, began

In the beginning

to work closely with TRW.

Initially these modules were based around

• Issues on self-levelling characteristics of the sealing material meant that it couldn’t be used in existing ovens as slight angles would lead to the mate-

cut gaskets to provide a seal and screws

Production issues requiring consideration

as the method of final assembly. Whilst

• Initially at the lower production vol-

areas.

functional there was potential for un-

umes, speed of curing the lid sealant

die cast aluminium housings using soft

20 dpaonthenet.net

rial moving away from required sealing

Feature: Automotive adhesives tial heat within the assembly to generate

• An integrity of build that has improved

the cure with the potential detriment to

the IP ratings achieved from IP44 to

the electronic components.

IP69; • Usage of RTV gels has enabled the

Working with TRW personnel on-site,

module to withstand vibration factors

Techsil established that the modules were

of six times the original production unit;

not getting hot enough within the con-

• Utilisation of updated thermal com-

vection oven for the heat cure process

pounds has improved the thermal dissi-

to effectively work and cure the material.

pation of the unit to improve by a factor

Techsil was able to establish that incon-

of two

sistencies in performance over time were

• Large leaded components (capacitors)

down to subtle variation of changes in the

used within the assembly have been

tooling used to make the plastic mould-

protected through the usage of easily

ing; the use and poor cleaning of mould

dispensed RTV Silicone that provide an

release agent from the component parts and a slight bowing of components through amended tolerances.

elastomeric support • PCB’s have been fully protected through the innovative usage of conformal coating that allowed even the

In a module that now included an addition

tallest of electronic components on the

cure thermal transfer compound and a

board to receive complete coverage.

condensation cure gasket there were ini-

The use of UV tracer elements within

tial concerns that using the two materials

the conformal coating allowed easy

together may result in inhibition issues.

visual inspection of the board.

Techsil was able to conduct extensive

Opportunities presented by sealant changes

tests to confirm that the materials were

RTV Silicone adhesive sealants can pro-

compatible.

vide many benefits when used within electronic assemblies. As production volumes increase, opportunities for selecting

Analysis into the feasibility of moving from

Benefits of using RTV silicone within electronics assembly

an air cure to a heat cure system was con-

• Through the use of RTV silicone within

sideration as significant production and

ducted and through careful material se-

the assembly process, TRW removed

lection of heat cure products it was pos-

more than 20 screws from within the

sible to reduce the speed of cure by 70

assembly;

alternative RTV’s must be taken into contechnical benefits may be available. www.techsil.co.uk

percent. Selection of a specialist thermal compound would allow for an improvement to the thermal path to remove heat from board to the heat sink.

The importance of production validation (PV) With critical electronic units where moisture ingress is unacceptable, the units are pressure tested to validate the integrity of the seal. When conducting a PV test it was found that under pressure the units were leaking. Investigation into the problems identified the following: 1. In certain cases only limited adhesion was achieved between the RTV silicone and the plastic (i.e. not getting a hermetic seal) 2. Originally it was thought that a convection oven would provide a suitable mechanism for the heat cure, though tests indicated that this method was not performing consistently. A trial was conducted using Infra-Red heating, unfortunately the infrared required substan-

Heated steering wheel process

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For a free Lee Chek valve, email your application to Lee Chek features include: sales@leeproducts.co.uk

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Some things need protection in harsh environments.

Then there’s Hepco.

Tel: 01884 257000 www.hepcomotion.com

Feature: Fastener specification

Innovation is not restricted by size W

hen designing a new project, manufacturers in many cases will focus on the ‘high value’ components that embody their innovation as a business. However, innovation is not restricted by size, as the importance of specifying correct fasteners illustrates in a multitude of applications. Weight, cost, ease of installation and product standardisation are four key features to consider when specifying fasteners for application. However, to gain equilibrium between these factors, manufacturers need to involve a business with expertise in fasteners.

So what are the main benefits of effective fastener specification?

The most applicable for most applications across various industries is the benefit of product standardisation. Why specify a custom manufactured 11mm bolt for one fixing and a 9mm bolt for another when you could use a single 10mm solution for both that is freely available and achieves the same purpose? It might be quicker to design these components than trawl a standard parts list during design, but this saving will quickly be eliminated when production starts.

Ian Carvell, European Engineering Direc-

aided in the final performance or design

tor at Optimas, a global provider of inte-

aesthetic of the latest consumer prod-

Optimas engineers have worked with

grated supply solutions and fastener en-

uct. Very few people will walk into a car

customers to reduce part counts by as

gineering support, explores the benefits

showroom and ask if their potential new

much as 40 percent during the design

a fastener expert can deliver to OEMs

purchase will include aluminium fasten-

phase. Standardised fasteners minimise

and tier suppliers.

ers instead of steel. Even in the industrial

the bill of materials and simplify supply.

world customers are more interested in

Over an entire development process

headline figures than the gritty details.

and production run, standardisation of-

Design engineers could be forgiven

fers huge cost savings.

for overlooking the humble fastener, considering the huge number of con-

So why should designers care?

siderations that come into play when

The truth is, well optimised fastener se-

Another benefit is weight. Selecting al-

introducing an entirely new project. The

lection can offer many tangible benefits:

uminium components over steel may

competitive nature of the modern mar-

both to manufacturer and end-user.

only equate to savings of a few grams

ket place drives the engineering focus

Sticking with the example of automo-

on a single part, but in many hi-tech

towards innovative technologies; for

tive design, fastener choice is as rele-

industries such marginal gains could

example the current focus of the auto-

vant to a supercar as it is to an off-road

represent a distinct advantage over the

motive industry is on hybrid drivetrains

construction vehicle or your daily driver

competition.

or self-parking vehicles.

- but in entirely different ways. To design something from ‘the ground up’ maybe

Ease of installation of fasteners should

Manufacturers want to be able to pub-

one of the most well-worn clichés, but

also be considered as it can make a

licise something that their competitors

focusing on fasteners can be a route to

notable improvement to production line

cannot. There is very little perceived

profitability and clarity of purpose for

efficiency. The assembly teams don’t

public interest in how a fastener has

manufacturers.

want to contend with a puzzle of bins

dpaonthenet.net 23

Feature: Fastener specification and components that resembles some

ing expertise and understands which

expert from the initial design phase of

recurring nightmare. Correct specifica-

of the four benefits are of most impor-

a project, so that fastener engineers

tion of fasteners can mean a reduction in

tance to your application.

can become familiar with your appli-

bins, and also clearer definition of what

cation and its specific demands. The

should go where. When production line

For example, you have been tasked

earlier that a partner such as Optimas

personnel are installing thousands of

with specifying fasteners for a new

becomes involved, the more ingrained

these components every day on multi-

supercar from a low volume, premium

the performance benefits will be with

ple units, a clear fastener policy leads to

manufacturer. Product standardisation

your design.

speedier installation across the line and,

and production line efficiency wonâ&#x20AC;&#x2122;t be

ultimately, improves productivity.

as important as weight saving in this

Regular meetings with the design team

scenario. Buyers are willing to spend

will expedite the research and develop-

Finally it is a question of cost. Building

extra to ensure the vehicle contains ex-

ment process, while also offering the

prototypes, amending design, reaching

ceptional components exclusive to the

speed of response required to reach

industry standards and then achieving

manufacturer.

challenging deadlines. Finally, familiari-

a finished product before launch dead-

ty with a projects fastener requirements

lines is incredibly capital intensive. As a

Conversely, heavy truck and commer-

can aid experts with synergising the

manufacturer, can you afford to increase

cial vehicles will require extremely du-

supply and manufacturing process, en-

this by operating a fastener policy that

rable components. Weight is less of a

abling time and cost savings through-

isnâ&#x20AC;&#x2122;t streamlined? In most cases itâ&#x20AC;&#x2122;s a

concern when compared to strength,

out a production run.

no, so taking an integrated and involved

as drivers may be using the vehicle in

approach to what fasteners you specify

extreme circumstances. OEMs will also

As a designer or manufacturer, fasten-

can minimise the financial impact

be keen to standardise fasteners in cer-

ers can offer great benefits to all stages

tain areas and implement efficient in-

of development and manufacture if the

So how can a manufacturer implement these benefits into their design?

stallation designs to reduce the cost of

optimised approach is applied. As with

manufacture and remain competitive.

many things in life, finding the right bolt

The first step is recognising where you

So clearly reaching the nirvana of fas-

could benefit from the support of ex-

tener specification requires a tailor

Ian Carvell is European Engineering

perts. From the earliest design stages

made approach that is based on each

Director at Optimas

you should work with a supply chain

individual application. The best way

manager who is able to offer engineer-

to achieve this is to involve a fastener

24 dpaonthenet.net

hole can be a real life saver.

www.optimas.co.uk

UK manufacturing alive and well with Goss Springs The great British myth that there is nobody left manufacturing anything in the UK is firmly laid to rest with a look at what Goss Springs has to offer.

The family owned business has been manufacturing high quality springs, wire forms and pressings for more than 65 years. There are countless examples of component manufacturers having gone to the wall in recent years under severe competition from low cost manufacturing countries yet companies like Goss Springs continue to flourish by moving with the times and working hard at identifying and then delivering what the customer wants.

Design facility Goss’ facilities based in Epping Forest consist of a Design and Engineering team with the capability to produce rapid prototypes and customised tooling for a particular design. The company encourages close co-operation with the customer in order to optimise design, life and cost of the product required. Advice will be given at an early stage on material properties, methods of manufacture, heat treatment and surface finish in order to produce a suitably robust component at an acceptable cost.

Investment in new machines Goss Springs has invested over the years in the latest technology available and today this includes sting thehigh rulesspeed presses, sophisticated wire forming and spring machines which can coil, loop and load test automatically without human intervention. recision components

mple helical springs to al contacts.

Giving the customer what he wants Goss Springs offer a unique capability to design to a customer specification with the offer of very low batch quantities. At the other end of scale the company regularly supplies components to the aerospace, defence, automotive, medical and electrical industries. Backed up by certification and 8 approvals to support its position as a leading manufacturer of standard and customised products LDWIDE • Oil & Gas to a wide range of industries, Goss proves the old adage that listening to the customer and then e • Marine working with him to supply what he wants actually works.

rking in close development to bined with the most

Follow us

Goss Springs Ltd Bower Hill Industrial Estate, Bower Hill, Epping CM16 7BN

Tel: 020 8527 5599 www.goss-springs.co.uk enquiries@goss-springs.com

Our passion is bending and twisting the rules Goss Springs specialises in manufacturing high precision components and assemblies. Our components range from simple helical springs to complex multi-stage pressings with precious metal contacts.

We offer a design and technical service, often working in close consultation with our customers during product development to ensure we meet their exacting requirements combined with the most cost effective production methods.

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• Oil & Gas • Marine

www.goss-springs.com T: 0208 527 5599 E: enquiries@goss-springs.com Goss Springs Ltd., Bower Hill Industrial Estate, Epping, Essex, CM16 7BN

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Feature: Medical adhesive BPR Medical Firesafe Cannula Valve

Helping ensure integrity

of life-saving medical device I

ntertronics’ customer BPR Medical is a small British company which combines creativity and entrepreneurialism to design, develop and manufacture world-beating products for export worldwide and use in the United Kingdom. As with any manufacturing company, the success of its products depends to a considerable degree on assembly methods.

The company’s latest success story

the fire by cutting off the oxygen sup-

Technical Director Ben Johnson’s team

is the Bidirectional Firesafe Cannula

ply. It is a development of an existing,

evaluated a number of possibilities,

Valve, used for in-home medical oxy-

unidirectional design and acts as a

including premixing and dispensing

gen supplies to extinguish fires which

thermal fuse whereby the oxygen sup-

via a pinch tube valve. This yielded

can occur in the line between the con-

ply is cut off when a fusible component

inconsistent results due to changes in

centrator and the user’s mask or nasal

softens as a result of the heat from an

viscosity which begin to occur natural-

cannula. Such fires can occur if the line

approaching fire in the oxygen delivery

ly as soon as epoxy is mixed, exacer-

comes into contact with ambient flame

tube. Integrity of operation is vital and

bated by temperature fluctuations. It

– such as a candle – or more common-

could literally represent the difference

also took an unacceptable amount of

ly if the patient is a smoker.

between life and death.

set-up and clean-up time.

The UK’s Home Oxygen Service sup-

When BPR had chosen a two-part

ports some 90,000 patients. In the US,

epoxy to bond both halves of the

The accuracy of volumetric dispensing

accident & emergency units attend

valve’s body, the next task was to find

Having determined that volumetric

to in excess of 1,000 thermal burns a

a dispensing solution that would as-

technology would provide a better

year caused by ignitions associated

sure deposition of a precise, repeata-

solution, BPR contacted Intertron-

with home medical oxygen, of which

ble volume of the adhesive, metered

ics and two other vendors to arrange

smoking was by far the leading cause.

and mixed in the correct ratio, on to

equipment demonstrations. Trials us-

a cylindrical assembly. The resulting

ing the selected epoxy were conducted

Life and death integrity

bond integrity would help ensure con-

in a wide ambient temperature range,

BPR’s innovative inline Bidirectional

formance for CE marking under Euro-

and rigorous pull, flexural and other

Firesafe Cannula Valve extinguishes

pean Medical Device Directive.

testing of the assembled valve, re-

26 dpaonthenet.net

Feature: Medical adhesive vealed that the preeflow eco-DUO pre-

via a preeflow plug ‘n’ mix interface and

cision metering, mixing and dispensing

stored settings ensure consistency and

system suggested by Intertronics was

repeatability, and eliminate daily set-up

the correct solution. It offers ±1 percent

time. Thanks to preeflow’s accuracy,

dosing accuracy, >99 percent repeata-

the volume of epoxy applied has been

bility and can dispense volume flows of

reduced to 0.05g from the pinch tube

0.2 to 32ml per minute, with a minimum

valve’s 0.06g.

volume of 0.01ml. The preeflow positive displacement technology means that

Ben Johnson states that they had to go

the volume dispensed is not affected by

through a number of stringent process-

viscosity changes in the material.

es to ensure the integrity of the bonding of the two body halves. An essential

Ben Johnson and Product Develop-

part of this was how the two-part epoxy

ment Program Manager Mike Brudenell

adhesive was applied: to ensure a high-

worked with Intertronics to configure

ly accurate, repeatable dose on a rotat-

the dispenser into its bespoke manu-

ing jig, but also to maintain the correct

facturing jig, into which the two popu-

dispense volume regardless of viscosity

lated halves of the Firesafe valve body

changes caused by temperature.

are manually loaded prior to being rotated whilst the epoxy is applied. Each

Ben estimates the return on investment

of the 20,000 units per month produced

to be in the region of £2,000 a month.

at the time of writing is non-destructively tested, whilst regular samples are

www.intertronics.co.uk

subject to a three-point flexural test.

See accompanying video: https:// The system operates an automatic purge at the end of the shift, eliminating the need for cleaning down. Control is

youtu.be/_xkT2DNxCAo preeflow eco-DUO and eco-CONTROL

Feature: Locking Chain selection system

Protecting Smartboards

with custom locking solution V

estel is a global manufacturer of household and B2B appliances and devices. When responding to a national tender from the Ministry of Education to install Smartboards in schools in Turkey, Essentra supported Vestel by providing a custom locking solution to ensure the safety and security of the product and its users.

Essentra understood the reputational

Safety & security: By restricting access

significance of providing Vestel with an

to the Smartboard the lifetime of the

effective and permanent locking system

product has been significantly increased

to prevent the free movement of the slid-

alleviating any cost incurred by the

ing whiteboards. By securing the white-

school for repairs.

board in place the solution would also restrict unauthorised use of the Smart-

Reassurance: The customised locking

boards, protecting both the equipment

system reduced student misuse of the

and the students.

whiteboards and preventing damage to the Smartboards and unauthorised stu-

Essentraâ&#x20AC;&#x2122;s R&D team worked closely with

dent access to the internet.

Vestel to provide a full and in-depth deVestel was awarded the contract by the

sign and prototyping service, producing a

Quality: The robust and reliable build of

Ministry of Education to supply Smart-

range of 3D CAD and 3D printed samples.

the locking system had led to the total

boards in 350,000 classrooms in both pri-

The company was then able to test thor-

elimination of misuse of the sliding white-

mary and secondary schools across the

oughly the effectiveness of each locking

boards in schools, which in turn protect-

region. After installation, Vestel received

system prototype, the results of which

ed the Smartboards.

a number of reports that the Smartboards

enabled Essentra to further enhance the

were being damaged by sliding white-

lock by modifying the prototype to im-

Productivity: By ensuring that use of the

boards that could be moved across, con-

prove the locking pin strength and ensure

sliding whiteboards and Smartboards

cealing the Smartboard screen. As stu-

that the catch was able to rotate 180°.

was limited only to supervised activities,

dents could easily move the whiteboard

productivity, application and concen-

revealing the Smartboard behind, use of

Results

tration of students has significantly im-

it was unregulated and access to the in-

Through dedicated design, prototyping

proved as the locking system limits the

ternet was also unrestricted. The resulting

and development, Essentra were able to

improper use of the sliding whiteboards

damage to the LCD screens rendered the

provide Vestel with a robust and secure

and Smartboards.

Smartboards unusable, and led to the

custom solution to meet its specific re-

schools having to pay for costly repairs.

quirements.

www.essentracomponents.com/en-gb

Smartboard and screen

28 dpaonthenet.net

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Feature: Simulation testing

Tackling car sickness in autonomous vehicles A

utonomous driving raises the possibility of more people experiencing car sickness. Fortunately, automotive OEMs have a new tool to tackle this and it comes from an unlikely source, Phil Morse technical liaison at Ansible Motion explains.

ers have widely reported problems with dizziness, nausea and disorientation. It even has a name: Simulator Adaptation Syndrome (SAS).

The causes of SAS are thought to be

A recent study by the University of Michi-

suggests that as many as 66 percent of

essentially the same as those of conven-

gan’s Transport Research Institute set out

adults could experience mild to moderate

tional motion. In both cases, there is a

to find what people will do in cars once

motion sickness.

disconnect between the driver’s percep-

they become superfluous to the driving

tion of movement and their other senses.

experience. Researchers Michael Sivak

That’s quite an alarming statistic for car

When travelling as a passenger in a car it

and Brandon Schoettle interviewed more

manufacturers, so naturally the goal is to

tends to be due to focusing on things that

than 3,200 adults on four different conti-

find ways of mitigating those risks with-

don’t relate to the vehicle’s motion; in a

nents about what they would do.

out detracting from other aspects of the

simulator it’s more often due to a latency

in-car experience. Before that can be

between a driver’s inputs and the simu-

The figures varied considerably, but on

done, however, there needs to be a way

lator machinery’s reactions that wouldn’t

average 35.6 percent concluded they

of scientifically studying the onset of car

occur in real-life. The effect, however, is

would end up taking part in activities that

sickness. And that, in short, means mak-

very much the same.

are expected to increase the risk of mo-

ing people feel sick on demand.

tion sickness, such as reading, working or watching videos.

The prevalence of motion sickness in simFortunately, there’s already a well-prov-

ulators means that the efforts of the en-

en way of doing this. For nearly a half

gineering firms that build these machines

Overall, the report estimated that between

century, simulators have been used as a

are typically directed towards eliminating

4 and 17 percent of adults – depending

means of training aircraft pilots. In more

it. After all, it is quite difficult to conduct

on region – would experience ‘moderate

recent decades they’ve been adopted for

meaningful experiments of any duration if

or severe motion sickness at some time’

coaching racing drivers and providing vir-

the participants are experiencing discom-

as a direct result of the things they would

tual testing for road cars. Over the years,

fort due to the simulator itself. However,

do in an autonomous car. Another report

both automotive and flight simulator us-

eliminating SAS when you don’t want it, in

30 dpaonthenet.net

Feature: Simulation testing order to prevent false-positives is far from

simulator technology has generally been

licate and study the circumstances that

straight-forward. Simulator specialist An-

carried over from aircraft applications,

would trigger motion sickness in normal

sible Motion claims to have cracked this

where massive, slower-moving “hexa-

car use.

by taking a clean sheet approach to the

pod” pointing machines are perfectly ac-

design of its Delta series of Driver-in-the-

ceptable. The dynamics of road vehicles

Several OEMs are now looking into how

Loop (DIL) simulators.

are characterised by short, sharp move-

this can be applied to study the effects

ments and trajectory responses, as op-

of car sickness in autonomous cars. As

Part of this revolves around the use of

posed to the lower frequency movements

with other types of simulation-driven ex-

sophisticated hardware and software

of aircraft.

perimentation, the beauty of using a DIL

to reduce the motion, optical, and oth-

simulator for these riding comfort studies

er sensory latencies to the point where

To provide the required agility, Ansible Mo-

is that vehicle engineers are granted with

feedback delays are imperceptible even

tion has developed a unique ‘stratiform’

complete and repeatable control over the

to professional test drivers. When a driver

motion system. This simplifies the actu-

entire environment. It allows for hands-on

takes an action, the visceral experience

ation requirements by placing the driving

testing with real people to begin much

must be genuine, realistic. Achieving

cabin on top of a series of layers. The first

earlier and more often in the vehicle de-

this in terms of physics calculations and

X-Y stage provides lateral and longitudi-

velopment process, saving time and

graphics generation and so on is no mean

nal movement, while the stages above

money. Plus, perhaps most importantly,

feat, but achieving the required fidelity

generate the yaw, pitch, roll and Z-plane

it’s safe.

from a motion control system is an even

‘bounce’ motions. This layer stack results

greater challenge.

in a much lower centre of gravity than tra-

All this means that DIL simulator testing

ditional hexapod machines, which means

promises to be a powerful tool for under-

The main reason for this is that the hu-

the controls are smaller and easier to

standing and reducing the occurrences of

man vestibular system, which provides

manage and manipulate.

motion sickness in autonomous cars. And that brings us back to the original ques-

our sense of balance and spatial orientation, is deceptively complex and inher-

Ansible Motion’s level of control authority

tion: How might you choose to spend

ently non-linear in its behaviour. Simply

and fidelity means that SAS is success-

your time in a car that can drive itself?

attempting to replicate or scale down

fully eliminated for most drivers and ex-

real-world forces doesn’t work within the

periments. But it also means that motion

Phil Morse is a technical liaison at

confines of a laboratory environment. In-

sickness can actually be purposefully

Ansible Motion

stead, Ansible Motion uses a radically dif-

induced within the simulator. This coun-

ferent approach, by mathematically mod-

ter-intuitive approach can be used to rep-

www.ansiblemotion.com

elling the vestibular system’s responses as an integral part of its machine control techniques.

Again, it’s not just a software and control issue. The simulator’s motion system has been designed from the outset to align itself with all six of a vehicle’s primary movement axes. It is also designed to provide sufficiently low inertia and sufficiently high mechanical stiffness to accurately carry out the desired motions in the time required. That might sound like a given, but traditional automotive driving

Innovative Enclosure Solutions for Industrial & Electronic Applications

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Feature: Solar Orbiter testing ment, which performs extreme ultravi-

Artist impression of Solar Orbiter device, launching in 2018 (Credit: ESA)

olet imaging spectroscopy to remotely characterise plasma properties of the Sun’s on-disk corona. This may teach us more about the causes of solar flares, the structure of the heliosphere, solar wind, and how the Sun creates its magnetic field.

Test system Space is one of the harshest environments for technology to function in.

Temperatures can vary wildly. Cosmic radiation can cause problems in circuitry. Lubricants that work well on Earth can be entirely ineffective in the vacuum of space. The key to a successful space exploration mission is reliable and proven components and instruments.

NI products were chosen because

Reliability testing for

the Solar Orbiter instrumentation N

ational Instruments (NI) provided key hardware for on-board the Solar Orbiter, which is a European Space Agency (ESA) spacecraft that will find out more about our nearest star.

CompactDAQ hardware and LabVIEW software could provide a complete automated test, control, and data-logging solution for a rigorous series of validation tests spanning nine months. The versatility of NI products would cover a diverse range of uses because the variety of C Series modules can cope with many different signal types. As requirements and projects evolve, ESR Technology may also look to modify the system or the test process, which makes the flexibility of the NI platform a real advantage.

Metis Automation’s solution to the problem relies on this flexibility to acquire signals from multiple devices simultaneously. It presents the test operator

NI’s CompactDAQ hardware performed

Ten science instruments on-board the

with a simple interface that requires no

thorough and extensive testing of the

spacecraft will perform a range of meas-

knowledge of the instrumentation detail

scan-focus mechanism on the Spec-

urements and imaging of the Sun to gain

behind the scenes, making it quicker

tral Imaging of the Coronal Environment

new information about the solar wind,

and easier to run the tests.

(SPICE) instrument on-board Solar Or-

the heliospheric magnetic field, ener-

biter, and LabVIEW software was used

getic particles, transient interplanetary

Test automation

to develop an automated test framework

disturbances, the Sun’s magnetic field,

Tests of SPICE require a combination

called Metest to aid in creating a software

and its dynamic atmosphere.

of manual interaction and automated control. The solution Metis developed

solution.

Scheduled for launch in October 2018,

allows the creation of automated test

Solar Orbiter - next generation Sun explorer

the mission will provide high-latitude

scripts so one engineer can run a test

observations of the Sun from 40 million

unattended and only return occasional-

Solar Orbiter will launch from Earth to

kilometres, inside the orbit of the clos-

ly. This is a massive improvement over

hurtle hundreds of millions of kilometres

est planet Mercury and closer than any

manual testing that previously would

through space to examine how the Sun

man-made object in history.

have required a test operator to attend

creates the heliosphere, the vast bub-

to the test rig full time and make frequent

ble of charged particles blown by the

Space mechanism manufacturer ESR

manual adjustments to the system. An-

solar wind into the interstellar medium.

Technology is testing the (SPICE) instru-

other key benefit of the automated test

32 dpaonthenet.net

Feature: Solar Orbiter testing system was the repeatability of tests.

Once an automated test script is created, it can be re-run. ESR Technology can now easily repeat complex tests that give unexpected results to help identify any issues with the unit under test or determine whether environmental factors affected the result, which is extremely beneficial.

Flexible data logging ESR Technology needed high-speed data logging for high-resolution data of important events, but constant highspeed logging leaves you with the challenge of unmanageable volumes of data over long test periods. The Metis software solution includes the option to automatically schedule or trigger data logging at fast rates, meaning the operator can configure a test in advance and schedule when high-speed logging should occur. Only the relevant data is acquired at high rates, which saves ter-

LabVIEW Architects. A little known, but

abytes of disk space and simplifies data

immensely useful, LabVIEW feature was

analysis.

used - the ability to synchronise the start of timed loops - to deliver code that can

A flexible, maintainable system

synchronise measurements across sen-

CompactDAQ modules have many

sors from different vendors. The code

types of signal conditioning built in, so

can acquire synchronised data from

ESR Technology can directly wire all its

the CompactDAQ and the Micro Epsi-

sensors into its modules to simplify the

lon sensors with the flexibility to handle

wiring. It can also adapt the test hard-

errors for each device, whilst remaining

ware for new signals by simply changing

modular.

Overview of the test system

Summary

C Series signal conditioning modules, which makes this test system flexible

Before using this feature, engineers re-

Developing hardware for space relies on

and extensible for future tests. The NI-

ported data samples that were out of

the ability to verify demanding perfor-

DAQmx driver set even lets users ac-

sync by hundreds of milliseconds, add-

mance characteristics under a variety of

quire from multiple different signal types

ing significant post-processing effort.

environmental extremes. ESR Technol-

within the same measurement task,

With the Metis solution, samples were

ogy and Metis Automation have devel-

making software development easy.

synchronised to within a single millisec-

oped a flexible and reliable testing solu-

ond.

tion using LabVIEW and CompactDAQ.

High speed, synchronised data acquisition

The NI platform and the expertise provided by Metis Automation has proven

measurements from some generic

Simplifying code with LabVIEW object-oriented techniques

analogue sensors with Micro Epsilon

The LabVIEW software was developed

insight into the physics of the Sun. The

capacitive sensors, which have very

using object-oriented techniques. Ob-

modularity and scalability of the system

high resolution and micron-accuracy

ject-oriented programming (OOP) sim-

will allow extension of this architecture

distance measurements. All sensor

plifies hardware dependencies and

into future test rigs.

readings had to be synchronised to be

test steps for more flexible software

useful.

development that can accommodate

ESR Technology needed to combine

the reliability of the SPICE instrument, ensuring it can deliver ground-breaking

http://sci.esa.int/solar-orbiter/

changes to the test requirements withMicro Epsilon provides LabVIEW drivers

out affecting code already written. Us-

for reading values through an Ethernet

ing OOP saved a lot of time during the

connection at high rates. Metis Auto-

extensive test and debugging phase of

mation has several experienced Certi-

the project.

fied LabVIEW Developers and Certified

www.metisautomation.co.uk www.esrtechnology.com/ www.ni.com

dpaonthenet.net 33

Feature: CAD model test rig tuator is calibrated to a predetermined boost level. When this boost level is reached, the flapper opens and allows exhaust gas to bypass the turbine. From a wear standpoint, the primary concern is wear on the shaft and bushing, which is difficult to predict because of the non-uniform contact due to force exerted by the flow stream and rotational motion of the shaft.

In the test rig, a motor drives an eccentric crank shaft connected to a crank arm that moves the shaft back and forth over the range that would be driven by the flapper. A 12.8kg mass hangs on the end of the shaft to represent the force exerted by the flow stream on the flapper. Each revolution of the motor represents one open-and-close cycle of the device. The shaft is also maintained at a temperature of around 450°C to replicate the real-life operating tempera-

Creating accurate wear-test rigs using simulation Typical BorgWarner turbocharger

B

orgWarner is a global product leader in powertrain solutions, with a focus on developing powertrain technologies to improve fuel economy, emissions and performance. When designing wastegate (WG) actuators, BorgWarner must ensure the life of the actuators over millions of cycles of operation despite non-uniform loading that contributes to the difficulty of predicting wear patterns. A new ANSYS Mechanical feature that analyses wear between sliding parts provides accurate predictions in one day - a big time saving compared to the several days that were required in the past to perform physical testing.

This capability will expedite design iterations between the designer and analysts and help to design more accurate wear test rigs.

ture. The test rig accurately predicts the wear experienced by the WG actuator during turbocharger operation, but it requires building an expensive prototype.

In addition, running the test rig through enough cycles to predict the wear on the actuator takes about a week.

Without analytically predicting the wear, BorgWarner engineers often found that their first design did not meet wear-life specifications, so the entire design, build and test process needed to be repeated, often several times. The ability to determine wear on the shaft and bushing prior to building a prototype would save time and avoid multiple prototypes. Until recently, the only method available to analytically determine wear had been to use the Archard wear equation, which describes sliding wear based on the load, sliding distance, hardness of the contacting surfaces and a dimensionless constant K. While this equation is useful in predicting wear on evenly loaded surfaces, it does not take non-uniform loading into account so it cannot be used in this case.

In a very popular style of BorgWarner

stream that seals the WG. The exhaust

ANSYS Mechanical now calculates wear

turbocharger, the WG actuator shaft

gas exerts a continual force on the flap-

Recent releases of ANSYS Mechanical

is mounted vertically inside the turbo-

per, while a spring at the opposite end

have given engineers the ability, for the

charger. One end of the shaft is connect-

of the shaft resists the force to keep the

first time, to calculate wear based on

ed to a flapper in the exhaust gas flow

WG closed. The internal spring of an ac-

non-uniform loading. In this case, Borg-

34 dpaonthenet.net

Feature: CAD model test rig Warner engineers began with a computer-aided

resulting wear pattern. The simulation also cal-

design (CAD) model of the test rig, including the

culated contact pressure as a function of crank

crankshaft, crank arm, bushing, shaft and pen-

rotation angle, an important predictor of wear.

dulum assembly (which holds the weight repre-

The contact pressure over the surface of the

senting the flow stream pressure). The boundary

shaft as predicted by ANSYS software matched

conditions for the model included a fixed support

the wear patterns on a shaft that had undergone

holding the bushing in place, a mass connect-

physical testing. The software also predicted the

ed to the end of the shaft, and rotational joints in

wear generated on each node of the shaft during

the bushing and crank arm. The material proper-

the two cycles of rotation. Engineers plotted the

ties were defined as a function of temperature.

accumulated wear over the two cycles and ex-

Material hardness was defined as a function of

trapolated this information for the full one-week

the yield stress of the underlying elements, but

test period.

temperature was not included in this simulation.

The generalised Archard wear model was used

The new simulation capability in ANSYS Me-

to predict wear based on the loads calculated

chanical can predict wear with a high level of

at each point in the contact zone by the ANSYS

accuracy. This process reduces the time needed

Mechanical simulation. The value of K was de-

to investigate a design from several days to just

termined based on an engineering handbook.

one day. This capability will save BorgWarner

A frictional contact was used between the shaft

time and money by making it possible to eval-

and the bushing.

uate different design alternatives based on their

CNC PowerEngineering

Guaranteed Results !

NUM steps up to the challenge !

wear performance prior to the prototype stage so Engineers ran the simulation over 720° of motor

that just one prototype can be built with a high

rotation, which amounts to two open and close

degree of confidence.

cycles of the actuator. The contact nodes were moved as per the wear increment at each time

Aliihsan Karamavruc is Senior Computer Aid-

step. Additional equilibrium iterations for the cor-

ed Engineering Analyst at BorgWarner Turbo

rected deformation were then performed. The

Systems, USA.

software performed rezoning whenever the mesh became distorted due to wear.

http://www.ansys.com/Products/Structures/ Durability

Accurate prediction of wear The simulation results included deflection of the

www.borgwarner.com

components as a function of crank shaft rota-

If we can't improve the performance of your machine then

tion angle, which plays an important role in the

Engineering will not be charged* Got an Idea? Lets make it happen... Together!

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ANSYS Mechanical mesh of key components of the test rig

dpaonthenet.net 35

Show preview: Hannover Fair 2017

Hannover Fair retu

bigger and better than I

ndustry 4.0 and energy efficiency will be among the key themes at this year’s event, which takes place 24-28 April 2017. This preview will give you a taste of what’s on offer at one of the world’s leading industrial technology showcases.

The Hannover Fair will see a record 500+ Industry 4.0 application exhibits, including a dedicated Industry 4.0 meets the Industrial Internet forum addressing topics on cybersecurity, smart workforce, standards and future opportunities.

The 2017 show will feature its usual array

markets and supporting innovative Polish

of industrial automation and production

companies. Around 150 of these com-

Trade show line up

technologies, with a focus on the added

panies will feature at this year’s show, in-

Seven international leading trades will be

value that comes from factories and en-

cluding the Polish division of Festo, which

taking place under one roof. Discover a

ergy systems going digital. Highlights will

looks after approximately 6,500 custom-

wide range of product innovations with the

include self-learning robots with near-hu-

ers in factory and process automation. To-

following trade show line up:

man touch sensitivity, advanced technolo-

gether, they will mount a Partner Country

gy solutions for a more sustainable energy

showcase that will centre on the themes of

Industrial Automation:

future and the importance of collaborative

energy and IT.

This section of the trade show will discuss the issues of process automation, energy/

robots.

The major Polish participation at this year’s

resource efficiency, robotics and system

Big names to look out for include Siemens,

show will also be marked by the presence

integration. It aims to provide business-

who will be demonstrating how industrial

of Polish Prime Minister Beata Szydlo,

es with advice on how to succeed in the

companies of all sizes can benefit from

who will be opening the show alongside

transition to the smart factory and will

the digital transformation, ABB who will be

German Chancellor Angela Merkel.

demonstrate the latest technologies that

presenting the concept of a digital substa-

help make the transition as efficient as

tion and Microsoft who will showcase how

possible.

Integrated Industry – Creating Value

MDA – Motion, Drive & Automation:

‘Integrated Industry – Creating Value’ is

Over the last few years, power transmis-

Poland will be stepping out on stage in

this year’s lead theme. The age of integrat-

sion and control has become an increas-

front of an international audience as the

ed industry is here with mature Industry

ingly pivotal factor in the efficiency, sus-

official Partner Country to make its case as

4.0 technologies hitting the market. Indus-

tainability and performance of industrial

an attractive partner in a large and diverse

trial subcontractors will demonstrate how

manufacturing processes. Here, you can

range of industries. Apart from domes-

digitalisation helps them offer innovative

discover technologies that will keep to-

tic reindustrialisation, the country’s main

and highly customised solutions quicker

morrow’s factories moving and visit the

economic focus is on opening up foreign

than ever before.

MDA forum to hear from representatives

its customers and partners are influencing the industry.

36 dpaonthenet.net

Show preview: Hannover Fair 2017

turns

n ever of key mechanical engineering supplier industries.

Digital Factory: In the future, suppliers, producers and clients will be integrated and networked.

At this part of the trade show, key people from business, research and politics will come together to discuss resulting business models and key areas of investment.

Energy:

to applications for using it in production

further development of an already existing

plant and machinery, through to contract-

product or system. The presentation will

ing offerings and services.

take place on 25 April at 3:30pm at the In-

The transition to renewable energy sourc-

dustrial Automation forum.

es remains one of the great challenges of

Industrial Supply:

the future. Discover new technologies that

There is a demand for industrial process-

Hermes award:

ensure the success of the energy transition

es and end products to become more

The 14th international Hermes Award ex-

and meet experts from a variety of disci-

efficient and durable. This will involve the

pedites the process of turning new ideas

plines who are working on concepts which

establishment of smart workpieces, com-

into market-ready products and process-

will allow us to generate, store, transmit and

ponents and systems that can be seam-

es. The international technology prize will

distribute electric power more cleanly and

lessly integrated into an intelligent manu-

be awarded to outstanding products and

cheaply. There will also be several forums

facturing process. Here, you can explore

innovations on display for the first time at

dedicated to digital energy management,

what existing solutions are already making

the 2017 show.

energy efficiency and fuel cells/batteries.

industrial processes and end products more lightweight, efficient and durable.

ComVac:

Engineer Powerwoman: For the fifth time, a jury will be looking at

Compressed-air and vacuum solutions are

Research & Technology:

the innovative work of women in techni-

integral to a vast and ever-expanding array

Experts from science and industry will be

cal professions. The winner will need to

of technologies and services across multi-

coming together at the Research & Tech-

convince judges based on her technical

ple industries. ComVac is a broad-based

nology fair to discuss visionary products

prowess and commitment. The award

part of the show, spanning all aspects of

and applications. You will see the latest

hopes to promote the uptake of women in

vacuum and compressed-air technology,

developments and solutions from adap-

sectors such as science, technology, engi-

from systems for generating, treating and

tronics and bionics to nanotechnology and

neering and mathematics. The winner will

distributing compressed and vacuum air,

organic electronics.

be announced on 28 April at the WoMenPower conference.

Awards & competitions Hannover Fair encourages fresh concepts

To ensure you get a full show experience,

and innovations and the show will demon-

trained tour guides are available to lead

strate this by continuing to host three

you to the exhibition stands of selected

award ceremonies.

companies whose offering is relevant to your topical industry theme. The tour lasts

Robotics award:

approximately two hours and exhibitors

For the seventh time, the show is teaming

will provide exclusive 15 minute demon-

up with trade journal Industrieanzeiger and

strations to participants.

the Robotation Academy to sponsor the Robotics Award. Entries must be on show

For more information about the show

to the public for the first time at Hannover

visit: http://www.hannovermesse.de/

Messe or otherwise constitute a significant

home

dpaonthenet.net 37

Datafocus: NEW THOMSON WEB VIDEOS PROVIDE HOW-TO GUIDES ON BALL SCREW APPLICATIONS Thomson Industries released its latest set of educational web videos, illustrating how to efficiently handle ball screw demands.

The “Tech Tips” videos include: How to Install an XC Lead Nut Video: To demonstrate the full anti-backlash functionality of the screw assembly, this video shares essential steps around the installation of an XC nut.

This video illustrates an efficient method of installing or replacing a ball nut in order to avoid ball bearing mishaps.

How to Load Ball Bearings into a Metric Series Ball Nut Video: In case of ball nut accidents causing ball bearing loss, Thomson demonstrates how to reload and assemble a metric series ball nut back onto a screw.

To view the videos, visit http://www.thomsonlinear.com/website/com/eng/design_tools/ techtip_videos.php.

To advertise here please call Abigail Swift on 01732 359990 or email Abigail.swift@imlgroup.co.uk SMITHS INTERCONNECT LAUNCHES BRAND TRANSITION TO SIMPLIFY CUSTOMER ACCESS TO TECHNOLOGIES AND SOLUTIONS Smiths Interconnect, a division of Smiths Group plc, today announces it is unifying its technology brands of EMC Technology, Hypertac, IDI, Lorch, Millitech, RF Labs, Sabritec, TECOM, and TRAK under the single brand identity of ‘Smiths Interconnect’.

This brand transition supports a recent strategic reorganisation focused on creating a more agile structure that can better anticipate and respond to customers’ evolving needs.

Individually, the technology brands represent state-of-the-art solutions across the connectors, microwave components and microwave subsystems markets. Providing a strong umbrella brand that supports the breadth of these products and technologies will make Smiths Interconnect a more comprehensive solutions provider, improving the customer experience by streamlining access and interactions across multiple applications For more information Roberta Rebora, Marketing Communications Director, Smiths Interconnect Tel: +39 010 60361, Email: roberta.rebora@smithsinterconnect.com

HIGH PERFORMANCE SEALS EXTEND PROCESS EQUIPMENT OPERATING TIMES BY 6000% DuPont Kalrez Spectrum 6375 perfluoroelastomer O-ring seals have been chosen by a major European manufacturer in the AgroSciences marketplace to replace PTFE sealing products previously utilised in their manufacturing equipment.

As a result of adopting the 6375 product, the previously daily procedure of seal replacements for their filling line equipment has been extended to an average of a two monthly procedure. This has achieved a 6000% improvement for their filler machine equipment, while a similar replacement of FEP/FKM seals on other equipment has extended plant operating times from an average 8 hour period to a substantially higher MTBF period of between 8 – 12 months. Since switching the Kalrez Spectrum 6375 custom O-rings, the manufacturer has substantially increased their operation uptimes for filling machines, as well as achieving improved overall reliability of packing lines.

Kalrez perfluoroelastomer parts are available in the UK from the official DuPont licensee company Dichtomatik Ltd. Kalrez Spectrum 6375 components have been designed specifically for applications in the chemical processing industries. These products also combine innovative polymer and cure technologies to ensure outstanding performance with an extensive selection of chemicals and operation at excessive temperature levels. The range of aggressive fluids handled includes acids, bases, amines, steam, ethylene oxide and many other even more hazardous chemicals.

Further information is available from: Dichtomatik Ltd, Donington House, Riverside Road Pride Park, Derby, DE24 8HX Tel: 01332 524401 Fax: 01332 524425

VEROTEC SUPPLIES ANOTHER SUITE OF CUSTOM IMRAKS TO THE ICONIC BT TOWER The 191 metre tall Grade II listed BT Tower, one of London’s most recognisable modern structures, is a tourist landmark and still a major UK communications hub containing microwave infrastructure links and the TV Network Switching Centre.

Continued expansion by BT has required Verotec to supply a further 11 special IMRAKS, verotec.co.uk/racks-accessories-c-9.html, to extend an existing installation. Each rack in the bayed suite is 47U high and 600mm wide, with a special non-standard extended depth of 1200mm. The high energy levels inside each rack require special fire protection panels to segregate it from its neighbours and thermal management requirements mean that airflow through the cabinet is also a key requirement. The top covers, fitted with twin custom cable entry assemblies, are ventilated, as are the front and rear doors. Internally, the racks are configured with cable distribution trays and equipment chassis supports, positioned to BT’s specification.

Tim Armstrong, Verotec’s Commercial Director, commented, “We initially assembled the complete 6.6m long, 1.2m deep and 2.2m high suite in our facility to check that everything was positioned correctly before breaking it back down into smaller units for shipping, ingress into the building and subsequent re-assembly on site. The versatility, configurability and availability of extensive range of dedicated accessories for our IMRAK 19” racking system makes it the ideal platform for this type of demanding application where specialised requirements have to be met.”

For more information tel: + 44 (0)2380 246900 fax: + 44 (0)2380 246901 sales@verotec.co.uk www.verotec.co.uk

38 dpaonthenet.net

Buyers Guide: Batteries & Chargers

Linear Motion

To advertise here contact

Linear Motion Solutions

Abigail Swift

on

01732 359990 or email abigail.swift@imlgroup.co.uk Tel: +44 (0) 1484 601002 www.reliance.co.uk

Displays

Elmatic_FC_Qtr_Layout 1 11/09/2015 10:04 Page 1

Sensors

Heating Elements

Systems

Displays Displays Touchscreens Touchscreens Displays Industrial Pc’s Industrial Pc’s Display systems Touchscreens

LARGEST MANUFACTURERS OF INDUSTRIAL HEATING ELEMENTS IN THE UK

Unimeasure Pull Wires www.unimeasure.com

Display systems Industrial Pc’s

Review Display Systems Ltd systems Display www.review-displays.co.uk Review Display Systems Ltd 01959 563345 www.review-displays.co.uk Review Display Systems 01959 563345

Ltd

www.review-displays.co.uk 01959 563345

Fasteners & Fixings

• Tappex Thread Inserts Ltd – 54 years of UK manufacturing excellence in Threaded Inserts for Plastics, Composites & Light Metal alloys • Tappex provide an Applications technical service, prototyping and bespoke installation tooling historically across multiple industry sectors: OEM/Automotive/ Medical & Industrial Equipment manufactures • Tappex offer fastening solutions produce from Brass, Steel & Stainless Steels with both Metric, Unified and British Standard threads Contact details: Tappex Thread Inserts Ltd Tel: +44 1789 206600 Email: sales@tappex.co.uk; New Website: www.tappex.co.uk Downloadable catalogues and applications advice on the website.

• Pull-Wire Displacement sensors • Easy Installation • Compact-Low Cost from £99.00 • Where small size is required • Ranges to 2000”(50m) • Repairs to any manufactures

• Cartridge Heaters

SE Systems Ltd Tel: 01702 530174 Fax: 01702 530200

• Ceramic Knuckle Heater

sales@sesystems.co.uk www.sesystems.co.uk

• Immersion Heaters

Springs

• Ceramic Core Heaters • Square Section Heaters • Nozzle Heaters

MANUFACTURERS OF SPRINGS PRESSINGS • WIRE FORMS Unit 1, Latimer Road Industrial Estate Latimer Road, Wokingham Berkshire RG41 2YD T: 0118 978 6573 F: 0118 989 4434 E: simpson.springs@btinternet.com www.simpsonsprings.co.uk

Geared Motors – 12mm / 90mm dia

• Mica Heaters • Thermocouples • Tubular Heaters

Tel: 029 2077 8727 Fax: 029 2079 2297 Email: sales@elmatic.co.uk www.ELMATIC.co.uk

Offer Truly Economical Solutions to drive application problems with a comprehensive range of motors, geared motors and accessories.

Hybrid solutions also available at moderate cost.

Our products are widely used in industry, education and R&d markets, with some of the following as typical applications.

Robotics, laboratory equipment, surveillance cameras, slot machines, shop displays,vehicle equipment, telecoms equipment,lighting and ventilation control.

Locking mechanisims, machinery activators, shop displays etc etc.

MFA/Como Drills Felderland Lane, Worth, Deal, Kent CT14 0BT Tel: 01304 612132 Fax: 01304 614696 Web: www.mfacomodrills.com

Sensors

position and motion sensors Comus Europe Ltd Rice Bridge Industrial Estate Thorpe Le Soken Essex CO16 0HL T: 01255 862236 F: 01255 862014 Sales@comuseurope.co.uk www.comuseurope.co.uk

Transformers

Easy to use: Rely on

by Murrelektronik

LETâ&#x20AC;&#x2122;S GET TO THE POINT IODD on Board: For the fastest possible integration of IO-Link devices Automatic IO configuration: Commissioning in the shortest possible time Expert mode for maximum flexibility of installation concepts

by Murrelektronik

... with MVK Metal or Impact67

Murrelektronik Ltd 5 Albion Street, Pendlebury industrial Estate, Swinton, Manchester M27 4FG Phone: 0161 728 3133 | Fax: 0161 728 3133 sales@murrelektronik.co.uk

murrelektronik.uk