DPA_20_07 by Modiconlv

July 2020 The Engineer’s guide to new products & design ideas

Farm to fork

How igus plays a vital role

10: AGVs

28: Sensor integration

Motorising an Automated Guided Vehicle

Joining the dots with sensor integration devices

Contents

July 2020 The Engineer’s guide to new products & design ideas

Editorial Comment:

Farm to fork

How igus plays a vital role

04: Coal and COVID The road to recovery

Cover Story:

06: Farm to fork How igus takes our country from farm to fork 10: AGVs

28: Sensor integration

Motorising an Automated Guided Vehicle

Joining the dots with sensor integration devices

Cover Story:

200417_9_Mill_DPA_UK_Snipe.indd 1

General Feature: 4/16/20 3:45 PM

Robert Dumayne, dry-tech Director at igus, provides an overview of how igus bearings playing a vital role in removing the risk of lubricant contamination. p.6 (Cover image: igus)

Group Editor: Paige West paige.west@imlgroup.co.uk Assistant Editor: Sophia Bell sophia.bell@imlgroup.co.uk Publisher: Andrew Quenault andrew.quenault@imlgroup.co.uk Production: Holly Reed holly.reed@imlgroup.co.uk Design: Graham Rich Design www.grahamrichdesign.co.uk Head Office: IML Group, Blair House, 184/186 High Street, Tonbridge, Kent TN9 1BQ Tel: 01732 359990 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 non-qualifying readers is UK £121, EU £215.25, Airmail £315 and single copy price is £18.60 monthly.

08: Residual stress systems

Stress relief pre-heat treatment vs. straighten/flatten post-heat treatment

Drives & Motion Control

Special Report: 10: AGVs

Motorising an Automated Guided Vehicle

12: Motion control Top five commercial challenges for machine designers

16: Drives & controllers

KEB drives and controllers used for stone and slate cutting machines

Aerospace

Supplement: 18: Rocket science ABB robot helps test extreme high-temperature systems

20: Actuators Electric aircraft close to take-off

22: Drones Drones take to the skies as aerospace sector targets diversification

Sensors & Transducers Technology Focus:

24: Conductivity sensors Fast and precise conductivity sensors save water and cut costs

26: Laser triangulation sensors Laser triangulation sensors measure lateral position of rail bogie wheels

28: Sensor integration

Joining the dots with sensor integration devices

Bearings & Chains Special Report: 30: Split bearings

Split bearing solution cuts conveyor maintenance costs and risks 10,000 Average net circulation Jan-Dec 2018

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

32: Power transmission chain You do get what you pay for…

34: Pulley bearings NSK bearings and training help woodworking machine builder make savings

35: Buyer’s guide

dpaonthenet.net 3

Editorial comment

Coal and COVID: The road to recovery W

elcome to the July issue of DPA!

At midnight on Wednesday 10th June,

UK businesses that called upon the

Britain passed a historic milestone: we

government to implement a COVID-19

officially achieved two months of coal-

recovery plan in line with its net-zero

free power generation!

emission targets.

know me: my name is Sophia and I’m

For the first time in history, renewables

“We’ve estimated that the energy sector

the new Assistant Editor of DPA! I joined

have accounted for more electricity

alone will need hundreds of thousands

the team at the beginning of March and

generated than all fossil fuels put to-

of new recruits as we work towards net

am very much enjoying delving into the

gether. According to the BBC, in 2020

zero and believe that an economic re-

engineering world.

so far, renewables have been respon-

covery with climate action at its heart

sible “for 37 percent of electricity sup-

will be key to unlocking these opportu-

For my first editorial column, I thought

plied to the network, versus 35 percent

nities,” stated National Grid CEO John

I’d investigate the impact of the pan-

for fossil fuels.”

Pettigrew.

This is a huge achievement, especial-

This suggests that combating the cli-

ly considering that just ten years ago,

mate crisis and ensuring economic

wind and solar accounted for only three

recovery may go hand in hand. If oth-

percent of the country’s electricity. A

er sectors similarly strive towards sus-

significant part of this latest break-

tainability, more jobs could be created

through can be attributed to COVID-19.

– which would ultimately help to rebuild

Since the enforcement of lockdown on

the economy in the long term.

First of all, I’d like to take the time to introduce myself to those who don’t

Sophia Bell, Assistant Editor

demic on the environment.

23rd March, Britain has seen a sharp decline in demand for energy, resulting

However, I feel that there is still a long

in the National Grid shutting down the

way to go. The government will need to

four remaining coal-fired power plants.

put in place a clear and practicable plan if we are to meet our net-zero targets.

With the ongoing devastation of the pandemic, the climate crisis may have

Nonetheless, the move towards coal-

taken a backseat in public conscious-

free generation is certainly a step in

ness, but the lockdown has paved the

the right direction in achieving a bright

way for a greener future – demonstrat-

future that will aid the much-needed

ing the feasibility of committing to a

recovery of both the economy and the

more environmentally friendly way of

planet. The question is, will the UK con-

life.

tinue to lead the renewable revolution, now that lockdown restrictions are be-

But I wonder, how will the UK’s ap-

ing lifted?

proach to tackling climate change evolve now that we are entering an eco-

Do let us know what you think of the is-

nomic recession?

sue and if there are any specific topics you think we should be covering. Email

On 1st June 2020, the National Grid

me at sophia.bell@imlgroup.co.uk.

was among more than 200 leading

Connect with us on LinkedIn. Join us on Twitter.

4 dpaonthenet.net

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Cover story: Farm to fork

How igus takes our country from farm to fork

The Farm to Fork Strategy aims to accelerate the transition to a more sustainable food system that should have a neutral or positive environmental impact. It is one of the reasons why lubrication-free tribopolymer bearings are quickly displacing their traditional metallic counterparts in farming equipment, through to food processing and packaging machines. Robert Dumayne, drytech Director at igus, provides an overview of how igus bearings play a vital role in removing the risk of lubricant contamination. 6 dpaonthenet.net

Automating manual tasks to increase productivity and throughput is a given in high-volume manufacturing, such as the automotive industry. Today, modular, low-cost automation is enabling other industries to automate manual tasks with a good return on investment – this is particularly so in the food production sector with vertical farming as well as traditional agriculture. This is driven by environmental

Cover story: Farm to fork considerations, such as the requirement for the elimination of external lubricant and the necessity of low energy production. iglidur bearings and liners are based on thermoplastic polymers that ensure good basic resistance to wear. Fibres and filling materials increase the bearing’s mechanical load-carrying capacity. Most importantly, they do not require any external lubrication as solid lubricants form part of the homogenous structure made up of millions of microscopic particles. The plain bearings release tiny amounts of solid lubricants during movement to lubricate the immediate surrounding area sufficiently. iglidur A160 and iglidur A181 are blue materials that are visually detectable to comply with EU regulation 10/2011 and the requirements of the FDA. Both materials have high wear-resistance, low moisture absorption and resistance to chemicals. iglidur A160 has good chemical resistance, which also makes it resistant to aggressive cleaning agents. iglidur A181, on the other hand, is suitable for use on stainless steel shafts and in applications involving pivoting and rotating movements. Developed specifically for food contact, iglidur FC 180 and igumid FC materials are also visually detectable by their blue colour, as well as by metal detectors. In case of damage, broken pieces can be quickly detected and removed. Even the smallest fragments of 0.0139g (iglidur FC180) or 0.015g (igumid FC) can still be identified on a conveyor belt when passing through a metal detector.

The isense bearing range comprises a number of materials, including iglidur A180, as well as the heavy-duty bearing iglidur Q2E for use in agricultural engineering, the all-rounder iglidur G, the endurance runner iglidur J and iglidur P210 for pivoting and rolling applications. In the field, where there is always a lot of dust, igus linear gantries (which feature iglidur bearings) are used in automated planting, picking, weeding and sowing. The fact that the bearings are resistant to media and require no maintenance ensures maximum uptime all year round. On food assembly lines, igus linear robots are used for the automated application of metered products, such as mayonnaise or tomato sauce. This not only maintains product consistency, but it also minimises product cost. In food production machines, bottling lines, packaging systems and knifeedge conveyors iglidur materials are used as the roller bearing. On conveyor tables, xiros bearings made from iglidur B180 are used in the ball transfer units. Stainless steel balls inside allow smooth running and absorb loads of up to 500N. Aside from bearings, the TH3 series of hygienic design energy chains are deployed on food processing and packaging machines. They feature rounded corners and simple, threadless connections to prevent dead spaces where debris and germs can build-up.

Its design avoids surfaces lying on top of each other, which prevents plastic on plastic abrasion and material wear. The blue material is also highly resistant to aggressive cleaning agents and chemicals. Every year, igus also carries out not only 1,000 customer-specific tests in its test laboratory but also more than 4,000 tests of its energy chains and over 12,000 tests of its plain bearing products. The results of all tests are fed into a database and, as a result, igus provides its customers with around 40 different web tools, such as the online product finder and the service life calculator. Therefore, users are always able to find the most suitable solution that improves the technical performance of their equipment while reducing costs. They can rely on tested and safe components in their machines and systems. www.igus.co.uk/food

About the author: Rob Dumayne is dry-tech Director at igus, responsible for the development and management of the drytech technology roadmap in the UK. Disciplined in Mechanical Engineering, responsibilities during his 21-year career with igus started in internal technical sales, which developed into project engineering and systems, and then design work, including new product development and testing.

With the use of intelligent technology called isense – a monitoring system which accurately measures wear and reports back to a master controller – igus can offer predictive maintenance. Having a system that can predict any required maintenance before failure helps reduce unscheduled maintenance and downtime. This capability is especially useful in areas with minimal direct human operation. It also creates more efficient production and maximises productivity by minimising downtime, allowing companies to remain competitive and keep costs down.

dpaonthenet.net 7

General feature: Residual stress systems

Stress relief pre-heat treatment vs. straighten/ flatten post-heat treatment M

ost engineering components have a residual stress system. Such systems are inherent in bar stock, plates, and, to some extent, in forgings and castings. While the residual stress system can be modified by removal of material, further forming of the raw material, and heat treatment processes, modification invariably leads to distortion or cracking. “Distortion may be rectified by straightening or flattening operations. However, there is always a risk of breakage or cracking with such operations,” cautions Roger Haw, Managing Director of Flame Hardeners Ltd. Problems associated with changes of residual stress systems are often found in the heat treatment of rollers, shafts,

Problems arising from distortion during

es the risk of cracking. It is necessary to

and pins – together with items such as

treatment can be minimised by stress-

heat the component to a temperature in

gear rings, bearing rings, guide bars,

relieving at intermediate machining stag-

the range of 180-250°C and to keep it at

machine tool beds and press brake

es, and correct jigging during heat treat-

such a temperature for as long as possi-

tools.

ment. This can eliminate the requirement

ble. Larger objects may require several re-

for straightening after heat treatment.

heats during the straightening operation.

Modern machining techniques have

It’s a relatively low-cost heat treatment

led to increased rates of metal removal

operation, undertaken under controlled

“Over many years of processing compo-

and, in many cases, use of bar stock to

parameters and often giving a predicta-

nents that may distort, we have reached

produce complex machined parts from

ble response, whereas straightening and

the conclusion that it is far more econom-

which 50 percent or more of the original

flattening are risky operations due to the

ical to stress-relieve at an intermediate

material volume has been removed.

high risk of cracking or breakage.

machining stage prior to heat treatment

“Cases have been seen where, for the

“Economically, the cost of stress-reliev-

it is to straighten or flatten following heat

benefit of expedient delivery of cylin-

ing can be easily estimated and includ-

treatment. A component that cannot be

drical items, such as rollers and piston

ed in the overall estimate of cost for the

straightened or flattened is just a piece of

rods, available bar stock has been used

component,” continues Haw. “The cost

scrap – and often a very expensive piece

which can be 20 percent greater than the

of straightening is not easily estimated

of scrap,” Haw concludes.

diameter required. Gear shafts, which

as the degree of any distortion to be cor-

may have been made from forgings

rected cannot be easily assessed.”

to minimise or eliminate distortion than

some years ago, are now manufactured

Your specialist heat treatment contractor can often assist you at the design stage

from bar stock and diameters of the

For larger diameters of rollers, piston rods,

by recommending suitable treatment

length of a shaft can vary by as much as

guide bars etc., warm straightening is the

routes.

200 percent,” Haw elaborates.

most desirable process, as this makes actual straightening easier and minimis-

8 dpaonthenet.net

www.flamehardeners.co.uk

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Feature: Automated Guided Vehicles

Motorising an Automated Guided Vehicle A

utomated Guided Vehicles (AGVs) are most often used in industrial applications to transport heavy materials around warehouses or factories. It is critical AGVs don’t fail. The choice of motorisation is key. If you’re thinking about motorising an AGV, maxon has five fundamental points to bear in mind:

1. Choose compact motorisation Being compact is an important factor in warehouses – in the machinery used and the storage solutions themselves. Customer demands have increased, and 24-hour delivery is becoming the norm. As things stand, warehouses can no longer afford to be far from major

2. Focus on true plug-andplay solutions

program everything online in just a few clicks. That way, the motor is config-

delivery areas. The price per m2 on the

Essentially, robots were designed to

ured to suit you and is delivered ready

outskirts of a town is not the same as it

help humans, and motorising an AGV

to use.

is in the middle of the countryside, so

is no exception. maxon’s IDX compact

logistics firms are opting for high-rack

drives have multiple connectivity op-

Motors with integrated electronics can

storage solutions. This means they

tions and are adjustable to suit individ-

be managed remotely because they are

need ergonomic robots that can move

ual needs. When you plug in the IDX

connected. The communication buses

vertically and reach required heights.

drive it works immediately, because

used can communicate with the Eth-

However, it is difficult, if not impossi-

they are delivered pre-programmed – a

erCAT and CANopen systems and, in

ble, to have a compact AGV if the mo-

true plug-and-play solution.

the future, with IoT networks too. Ro-

tor is bulky. Therefore, it is essential to

bots can, therefore, be programmed

choose compact motorisation. Drives

When you place an order for an IDX

by computer and controlled remotely,

must also be able to fit into restricted

motor, you define all the parameters

which makes maintenance much sim-

spaces, as they are sometimes inte-

you need through an online configura-

pler. This means you can work at one

grated into existing trucks. A small foot-

tor – how the product communicates,

time on your entire fleet of AGVs, to run

print is a major issue for applications in

what cables are needed, the electronics

diagnostics or carry out an update, for

logistics.

you choose, the motor power, whether

example.

or not you want a brake, etc. You can

10 dpaonthenet.net

Feature: Automated Guided Vehicles 3. Prioritise safety AGVs operate in close proximity to operators, staff and other AGVs. It is necessary to maintain safe human/machine interaction, encompassing all of the safety measures. Robots have movement and optical sensors, allowing them to detect the presence of humans and avoid any risk of

IN THE DRIVE SENSORLESS SAFETY

collision. This safety-oriented approach also applies to motorisation. To avoid any danger from overheating, for instance, IDX drives have two integrated temperature sensors, one inside the motor and the other within the electronics. If there is a problem, the motor is secured immediately, without waiting until the whole envelope has overheated. Most motors on the market lack this responsiveness because they have sensors only for the electronics. The motorisation of AGVs can be a technical challenge. To meet customer needs, maxon has designed a compact motor, with performance 25 percent better than its competi-

tors, while keeping pricing competitive. t

4. Base the design on modularity

STO

SLS

Not all AGVs do the same job. Some will carry loads of one tonne or more, while others will lift loads of around 100kg; some will travel in a straight line, while others will have an integrated steering function.

SLA

er or not a brake or an encoder is required.

SSM

SDLC

choose the type of motor and communication, as well as the power rating, electronics, connectivity, protection rating of the motor, and wheth-

SAFETY INSIDE

SMS

1 0

Motorisation requirements vary with each application, and that is why it’s essential to have a modular solution as a base. It’s imperative to

STO

SS1

Brake active

SBC

Safety over

All these parameters can be easily configured online. maxon’s configuration tool allows customers to benefit from highly organised production that can develop a drive solution to match requirements in just 19 days.

5. Opt for fast delivery Today, responsiveness is fundamental and expected as standard. max-

KEB COMBIVERT S6 AND F6 VERSION PRO

on is well aware of the challenges in the AGV sector and guarantees delivery of IDX solutions in 19 days. Irrespective of how you use your AGV, with maxon’s capabilities and tooling, you can be sure you will have the right motorisation. https://idx.maxongroup.com/idx/index

SAFETY FEATURES without Position feedback - highly flexible 0.75 to 400 kW FOR ALL MOTORS – ONE DEVICE Inc. ASM, PM, IPM & SRM, with speeds up to 45,000 rpm SAFETY IO ON BOARD 3 x 2 channel input 2 x 2 channel output SAFETY RELAY with positively driven contact

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KEB (UK) Ltd. 5 Morris Close Park Farm Industrial Estate Wellingborough NN8 6XF Tel: 01933 402220 E-Mail: info@keb.co.uk

dpaonthenet.net 11

Feature: Motion control Design engineers are now looking for smaller components that are convenient to store and more efficient. (Image courtesy of Thomson Industries, Inc.)

Top five commercial challenges for machine designers F

rom benchtop laboratory automation to plant floor material handling to heavy-duty construction vehicles, motion control system users are under constant pressure to differentiate in an increasingly commoditised marketplace.

technology has enabled miniature linear motion components to be produced more efficiently to meet the needs of these machines. Those designing factory systems want to

Profile rails are one of the components in high demand for prototyping use by design engineers. (Image courtesy of Thomson Industries, Inc.)

Many are looking to their control com-

help customers make better use of limit-

ponent vendors for help. They are say-

ed floor space or present a cleaner, more

ing they need more functionality in less

open workspace. Even makers of larger

space. They need to deliver prototypes

equipment may want more efficient use

and products faster than ever. They want

of space so they can incorporate tech-

maximum control and flexibility over

nology that improves operating efficien-

price points and need everything to work

cy or safety, or offer other benefits that

together seamlessly. The motion control

might differentiate them in their markets.

industry has evolved in response to such requests and is committed to delivering

In the interest of meeting these space

new capabilities to help them add value

requirements, manufacturing technology

continuously.

improvements have allowed for smaller products to be produced more efficiently,

Here are five current commercial chal-

enabling design engineers to incorpo-

lenges in which motion control innovation

rate more functionality into smaller form

can make a difference.

factors. Miniature ball screws, motorised linear actuators, motorised lead screws

1. Meeting the demand for smaller products

and linear bearings are increasingly be-

Small system designers want to go even

plications. In addition, electromechanical

smaller. They strive for systems that are

actuators have become more capable

more compact, and easier to carry and

of replacing the pumps, compressors,

store. Many of their customers want to

delivery systems, and other space-con-

move analytical or monitoring instru-

suming technology essential for hydrau-

ments closer to the point of use. This is a

lic and pneumatic actuation.

perfect example of where manufacturing

12 dpaonthenet.net

ing chosen for use in smaller-scale ap-

Feature: Motion control Embedding electronics into motion control products, such as smart linear actuators, makes for an even more space-friendly solution by supporting network communications, position monitoring and other functionalities that previously required external devices. Internal electronics also eliminate complex wiring, which is prone to forming bulky, unsightly clusters. These

SMART AND DIGITAL AUTOMATION

latest actuators now connect to power sources and communications networks with just a few wires.

2. Faster prototyping As competitive pressures mount, demand for faster delivery of more personalised equipment heightens. Effective prototyping is important to many solutions, as designers typically must try various component options before settling on the one that best suits their application. Advanced modelling technology, such as 3D metal-based printers and simulation software, gives designers more flexibility and greater speed, but this enhanced modelling capability also puts the motion control components on the critical path. Whilst designers in the past may have been comfortable waiting six to eight weeks for a component, today they might need it in days. This need for speed is driving changes at the component manufacturing level. Some manufacturers reengineered processes to be able to offer nextday turnaround on one-off items for prototyping use. Some are increasing their inventory of the components most often in demand in prototyping initiatives. The distribution channels are also getting involved, increasing their stocking of inventory for components commonly used in prototyping.

3. Holistic component selection and integration Critical to increasing time to market is selecting the right components and integrating them optimally for maximum accuracy, precision, straightness,

SPECIALISED IN SOLUTIONS

noise level and other performance characteristics. The challenge is that motion control optimisation is complex. Although there are many system designers with the expertise necessary for selecting motion control products, many of them are closer to retirement than college. Replacing them will not be easy – partially because there are limited schools that train mo-

OUR SYSTEM SOLUTION FOR YOUR MACHINE: FROM AUTOMATION THROUGH THE DRIVES TO THE DRIVE SHAFT

tion control engineers. Recruits are typically from either electrical or mechanical engineering disciplines. Their motion control expertise must be nurtured on the job. Less experienced design engineers might know what kind of speed or straightness they need but may not be familiar with the capability of their motion control components to meet their requirements. Someone design-

   

AUTOMATION SAFETY POWER TRANSMISSION CONNECTIVITY

ing a patient table, for example, may know the decibel level they must achieve for compliance with industry standards or regulations but may not know how their choice of ball screw would affect the noise level or even the “quality” of noise. The electrical engineer may come at it from the electrical

To avoid under-designing or system problems, engineers will need to collect appropriate data that separate quality motion control components from inferior products. (Image courtesy of Thomson Industries, Inc.)

Packaging Machinery

Theatre Systems

Metall Processing

Textile Machinery

Process Engineering

Lift & Escalators

Intralogistics

Wood Working

Wind Power

Plastics Machinery

e-mobility

Automotive

Automation with Drive

www.keb.co.uk

KEB (UK) Ltd. 5 Morris Close Park Farm Industrial Estate Wellingborough NN8 6XF Tel: 01933 402220 E-Mail: info@keb.co.uk

dpaonthenet.net 13

Feature: Motion control a deciding factor. An equipment manufac-

neer from a more physical perspective,

4. Balancing component cost with the total cost of ownership

but neither may have enough experience

Although machine designers want to have

market, for example, may have more ap-

to appreciate the subtle interactions of all

the highest quality components for their

preciation of the value of the total cost of

components. To compensate for such,

systems, they don’t necessarily want parts

ownership over the long term. If purchase

designers may over-design, specifying

that will outlive the machine. Putting a mo-

price were the sole factor, they might opt

more capability than may be required

tion control component that is designed

for a pneumatic or hydraulic actuator solu-

and then optimising on the bench. How-

to last 20 years into a system that may

tion over an intelligent electromechanical

About the author:

ever, this can unnecessarily increase

be obsolete in five years does not make

solution. However, when other factors such

Markus Brändle is the Product Line Specialist, EMEA & ASIA Region, Screws and Linear Bearings & Guides at Thomson Industries, Inc. He has worked to run and push the ball screw and linear bearings & guides business within Europe and Asia since 2017. He aids in assisting sales and customer support with technical product training. His role also involves on-site training with engineering groups, such as OEMs and distribution customers.

time to market and production costs.

good business or engineering sense. As

as reliability, uptime, footprint and mainte-

perspective and the mechanical engi-

turer that sells many products to the rental

the component market matures, designers

nance are figured in, the electromechanical

The increasing importance of holistic

who take the time to shop can find a prod-

solution has much greater benefit.

system design, combined with the short-

uct that suits their needs and their budget

age of motion control experts, is all the

but using proper judgement requires a

more reason to involve motion control

greater understanding of motion control

5. Continuously adding product value

vendors early in the process. They have

systems – not less.

Probably the greatest commercial chal-

more experience with the impact of in-

lenge OEMs face is one they share with

tegration in multiple applications and, if

A designer driven only by economics is

the component manufacturer: understand-

consulted upfront, can save significant

more likely to under-design rather than

ing what the market will buy and how to

time and money. For engineers who pre-

over-design. Although testing will tell them

differentiate in delivering it. Many motion

fer to go it on their own, however, some

whether their design will meet the required

control users are looking to the increased

vendors are now helping via online con-

specifications in the near term, they typi-

capabilities offered by connected products

figuration tools. Thomson Industries, for

cally cannot test for the full life of all com-

that share data in the cloud as a promising

example, offers an online tool that can

ponents and will implement a shortened

opportunity for strategic differentiation.

help reduce optimal product selection

test procedure. This will not always provide

from hours to minutes. This can be found

enough data to differentiate a higher quali-

One major medical device manufacturer,

at www.linearmotioneering.com. Design

ty motion control component from a lower

for example, has put the Industrial Internet

engineers can now select the most suit-

cost/inferior designed product, which no

of Things (IIoT) at the centre of its busi-

able product for their application from

one discovers until they encounter prob-

ness strategy. The system records data

Thomson’s collection of online tools,

lems down the road.

on machine performance, and the status

which contains different product families

of its components and system errors is

from linear actuators to ball/lead screws

There are, however, many applications in

detected. In conventional systems, us-

and gearheads.

which the total cost of ownership can be

ing this data required a trained technician to tap into the machine, read the log files

Selecting the right components is very crucial for a design engineer. For example, there are various types/ sizes of ball screws and each one can affect the noise level in a different way. (Image courtesy of Thomson Industries, Inc.)

and manually schedule maintenance repair based on parts that need to be ordered. With their connected machines, those log files are securely uploaded for analysis and planning from just about any location. The motion control industry is going down this avenue as well, gearing up to help such companies integrate motion technology into their connected solutions. Toward this end, motion control vendors have added – and are continuously improving – the onboard intelligence of components, giving them the computational capability and communications necessary to participate in connected strategies. Whether it is connected systems or something else, the motion control industry stands poised to support OEM innovation with the right motion control performance at the right price. www.thomsonlinear.com

14 dpaonthenet.net

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Streamlining power design N

ew and emerging devices are integrating USB-C interfaces for versatile, fast and efficient charging. Power specialist Relec responds to the demand with the addition of two compact, efficient and rugged power supplies.

The drive to design more compact products

models operate at ambient temperatures of 0

is causing developers to rethink power

to +40°C. The rugged power supplies have a

management and integration. The USB-C

MTBF greater than 100, 000 hours.

connector has been eagerly adopted by a multitude of product designers because of its

The EA1045 measures just 100mm x 45mm

small form factor and versatility. Not only is data

and dimensions for the EA1062 Series power

transfer faster than earlier USB formats, but it is

supplies are 113mm x 47.4mm. Both are just

versatile. The interface allows a single cable to

31mm high. All models are CE and FCC-

deliver data, audio, video and power, to meet the multiple end uses consumers expect in the space constrained designs they demand.

certified and qualified to UL/cUL 62368-1 TUV USB-C PD streamlines power charging for portable devices, from laptops to phones, using a single cable.

EN62368-1 and CB IEC 62368-1. The compact, rugged power supplies are

USB-C Power Delivery (PD) is the emerging

One of the principal ideas behind USB-C PD is

available now from Relec Electronics, the

protocol for power which is gaining popularity

to offer commonality of the power supply across

specialist in power conversion and display

because it offers fast, flexible charging of USB-C-

different products. One size fits all if you like!

products based in Wareham, Dorset.

enabled devices.

Historically the choice of power supply meant there were literally thousands of different options

The EA1045 and EA1062 ranges of USB-C PD

The Power Delivery (PD) specification

for different equipment. Some products ran from

power supplies are produced by Edac Power,

‘communicates’ between two devices to establish

ac, whilst others from dc. You then had to select

a pioneer in the design and manufacture of

the amount of power that is needed from the

an operating voltage, which might be anywhere

ac-dc and dc-dc plugtop and desktop power

charger. This is configurable and ranges from

from 5V to 48V, and power rating. Then what

supplies range from 30W to 200W.

5V to 20V for laptops, notebooks and mobile

connector to use, where you could stipulate,

phones.

barrel size, length, locking mechanism and finally

As a UK franchised distributor for Edac, Relec

polarity. USB-C PD has been developed to bring

Electronics can guide customers and designers

all of that to an end.

in the selection of an external power supply to

The history of USB Following USB-A, micro, mini and USB-B and

ensure they end up with a reliable, cost effective

Apple’s Lightning connector types, USB-C has

and fit for purpose solution.

been used in a variety of products, including Android devices as well as some of the latest

A legacy of design support

MacBook models. The reversible USB-C

Relec Electronics has been supplying plugtop

connector is easy to use; because it is not

and desktop power supplies for over 40 years.

polarised, it can connect whichever way up it is

The specialist prides itself on offering the best

used. It is small enough for use with handheld

EA1045 and EA1062 power supplies

devices while supporting high data transfer rates

Edac’s EA1045 Series and the EA1062 Series

and sufficient power to run larger devices.

both cover the 100-240Vac input range and

Relec Electronics is a specialist in power

provides USB-C PD compliant outputs of

conversion and display products, representing

5-20Vdc.

leading brand names including Mornsun in

One of the key features of USB-C is that it supports the new power standard, Power

solution for each application.

power conversion alongside Bel Power, Chinfa,

Delivery or PD. PD is a universal standard

Both USB-C PD-compliant power supplies have

Cotek and Premium with key display partners,

whereby a conversation is established between

a reversible 24-pin USB-C connector system

Digiwise and RockTouch.

two connected devices to establish the voltage

which can deliver 5V, 9V, 15V or 20V from the

and power requirements needed by the device

same power source. Both series also have an

Relec’s team of specialist advisers can refine

from the power supply.

LED indicator and both incorporate short circuit,

an initial specification for a given application to

over-voltage, over-current and over-temperature

include bespoke features to meet the needs of

(optional) protection.

a particular design or project.

The 30-45W EA1045 and 60W EA1062 Series

http://www.relec.co.uk

PD power devices can typically deliver any one of four output voltages: 5, 9, 15 or 20V, depending on the requirements of the connected load.

dpaonthenet.net 15

Feature: Drives & controllers

KEB drives and controllers used for special-purpose stone and slate cutting machines

EB Automation has supplied a variety of drives and control equipment to Machines & Controls Ltd for use on specialpurpose cutting machines for stone tiles and roof slates. KEB provided a complete solution from a single source and gave engineering support throughout the machine design and building process.

KEB Automation, as they were able to provide all the drives, controllers, gear motors and HMIs from a single source and were willing to provide engineering support through the machine design and build phases, which you don’t always get from other suppliers,” says Wilson.

Based in Shropshire, Machines & Con-

5-axis CNC sawing machine that cuts

The stone façade cutting machine

trols Ltd is a small, privately-owned

stone tiles and cladding for buildings.

For the 5-axis stone façade cutting ma-

business. Established in 2018, it spe-

Around the same time, we also received

chine, KEB supplied four COMBIVERT

cialises in the design and build of spe-

an order from another customer for two

S6 drives, four servo motors, two gear

cial-purpose machines, including robot-

special-purpose cutting machines for

motors and a COMBIVERT F5 inverter.

ics and associated controls.

roof slates.”

All the control equipment is housed in a

Alex Wilson, Managing Director at Ma-

Both types of machine required a range

chines & Controls Ltd, states, “In 2018,

of drives and control equipment, so Alex

we received an order for a stone façade

Wilson conducted a thorough supplier

With dimensions of approximately 3m

cutting machine. The machine is a

evaluation process. “In the end, I chose

square by 2m in height, the machine

control cabinet which has an integrated

16 dpaonthenet.net

HMI touchscreen display from KEB.

Feature: Drives & controllers build stages of the project, which was

Drives, controllers and gear motors

crucial for us. We delivered the machine

Compact, flexible and powerful, the COM-

to the customer in February 2019, who

BIVERT S6 range of servo drives is suitable

is extremely happy with it. Since install-

for a wide range of highly dynamic servo

ing the machine, the customer has re-

applications, including highly automated,

ported no issues at all.”

safety-oriented machines. The drives pro-

KEB’s support through the design and

vide optimal motor control in real time and

The two slate cutting machines

integrated safety functionality. They are

The two identical slate cutting machines,

book-style format for easier mounting in

which have dimensions of around 2m x

control cabinets where space can be limit-

1m square, are inclined at 30 degrees

ed. The COMBIVERT S6 range is 100 per-

and comprise a pair of conveyors, each

cent in-house designed and built by KEB.

driven by a KEB servo gear motor. The

The drives are available in two different

conveyors pass over two cutter blades,

enclosure sizes across motor power siz-

which cut (‘hammer’) the slate to size.

es from 0.75kW up to 5.5kW or electrical

KEB COMBIVERT S6 drives control the

currents from 2.6A to 12.0A, with overload

position of the upper cutting blades, with

to 250 percent. The drives can be custom-

two KEB servo motors driving the cutter

ised with a variety of design options to suit

heads. All controls for the two machines

the specific application. Safety functional-

are housed in a single control cabinet

ity can be selected from three modules to

with operator control joysticks.

suit the requirements of the machine.

“On both machine projects, I was par-

In combination with its control systems

ticularly impressed with KEB in terms of

and drive controllers, KEB also offers a

their technical capabilities and engineer-

range of servo motors and geared motors,

ing support. They have been very helpful

including three-phase motors, servo mo-

and have always responded promptly

tors, helical geared motors, shaft mounted

when I’ve needed support on resolving

helical geared motors, helical worm geared

any issues. I look forward to working

motors and helical bevel geared motors.

also designed in a compact, space-saving

with KEB on future machine projects,” Wilson concludes.

www.keb.co.uk

comprises two conveyor bands with a bridge over them and two 4kW powered saw blades in the X-Y axis. As the stone is moved down the conveyor, the saw blades can be programmed to add chamfers and slots in the stone. Each saw blade has two axes of motion (up and down/in and out). The machine is fairly low speed (up to 1.5 metres per minute) but is precise and accurate. Two KEB gear motors drive the conveyor bands. Four KEB servo motors (two per head) move the cutting heads. A KEB COMBIVERT F5 inverter controls the two geared motors for the conveyors. The machine is totally enclosed by protective guarding. As Wilson explains, “All the control programs were written by KEB using its COMBIVIS software. This meant we had

dpaonthenet.net 17

Supplement: Aerospace

It is rocket science:

ABB robot helps test extreme hightemperature systems A

testing system designed to help with the development of components for jet engines and other hightemperature systems is 30 percent faster, thanks to a nimble ABB IRB 1200 robot. The developers predict that the new system could reduce the testing and development cycle from weeks to days.

London-based start-up Sensor Coating Systems (SCS) successfully completed the Automated Robotic REadout SysTem (ARREST) project. During this project, an automated readout system for SCS’s thermal mapping technology was developed. In this way, the company’s novel technique

Hygienic Design Extra cleanliness guaranteed

ENCLOSURES

POWER DISTRIBUTION

CLIMATE CONTROL

Supplement: Aerospace allows engineers to access temperature

and irregular surfaces. SCS offers this

test data in a faster and more accurate way

technology as a service and manufacturers

than previously possible.

send their components to the company for testing.

SCS’s technology measures the maximum surface temperatures experienced

According to Dr Jörg Feist, Managing Di-

by components in harsh high-temperature

rector at SCS, the key features that make

environments, such as aircraft engines,

the IRB 1200 ideal for this unusual appli-

gas turbines or automotive engines. The

cation include its combination of compact

unique SCS approach uses a coating that

components, which the robot then uses to

size and good reach, as well as the relative

luminesces when excited by a laser, with

calculate the optimum pattern of measure-

ease with which it can be programmed to

the luminescent light emitted relating di-

ment points across the surface.

work through non-standard patterns of

rectly to the peak exposure temperature

motion, rather than carrying out the kind

experienced by the coating. In effect, the

This approach is almost one-third faster

of repetitious movements typically called

coatings can ‘remember’ any temperature

than the previous, gantry-based test pro-

for on a production line. ARREST required

within the range of 150 and 1500°C. The

cedure. The increased agility of the robotic

SCS to develop a sophisticated algorithm

digitised temperature data is plotted on a

system makes it easier to access the com-

to compute the different moves that the

3D CAD model of the analysed compo-

plete surface of complex components,

robotic arm must make to reach all the

nent, generating a thermal map.

where the laser and optical probe might

measurement points efficiently – without

have previously struggled to reach.

any collisions or unnecessary moves.

Understanding exactly how heat is distributed across components working under

During the test process, SCS uses the ABB

“We are very pleased with the outcome of

extreme conditions helps engineers to de-

robot to guide the laser around the test

this project,” Dr Feist states. “The robotic

sign more environmentally friendly engines

subject and record the coating’s response

system adds more cutting-edge technolo-

with improved combustion efficiency and

with an optical probe. It systematically

gy to our sensing portfolio. Furthermore, it

reduced emissions. It will also help spot

builds up a detailed map of the surface –

will enhance our capabilities in future pro-

potential problems, thus improving engine

complete with the historical temperature

jects to provide temperature data more ef-

efficiency and safety, as well as prolonging

profile – from a series of points. SCS then

ficiently on highly complex components.”

the life of critical systems.

feeds the data into a 3D CAD model of the component to generate a thermal map.

“We are excited that ABB Robotics

Before adopting the robot, SCS used a

has been chosen to be part of such a

gantry system to move the test subject

The project was co-funded by Innovate

ground-breaking project and we hope to

around in the path of the laser. Now, the

UK, part of UK Research and Innova-

work again with SCS as their business

test subject remains stationary while the

tion, through the Government’s Industrial

continues to grow in future,” says Ian

robotic arm rapidly moves the laser in a

Strategy Challenge Fund (ISCF). After 18

Schofield, Account Manager of ABB.

carefully calculated pattern to build up the

months of R&D, the complete system was

map. SCS typically primes the system by

successfully tested and demonstrated us-

https://new.abb.com/

feeding in 3D CAD drawings of the test

ing real engine components with complex

https://www.sensorcoatings.com/

NEW: Hygienic Design

air/water heat exchanger

Ian Schofield trained as an Electrical/ Electronics engineer and spent his formative years designing and commissioning industrial control systems for highspeed packaging lines in the Food & Beverage industry. From various project and business development roles in engineering companies, Ian has over 25 years of experience in the sales and execution of bespoke automation and robotic solutions to a diverse range of industries. Ian is committed to helping UK manufacturing become more competitive and effective through robotic automation.

The Rittal hygiene standards for maximum productivity

IT INFRASTRUCTURE

About the author:

Significant savings on detergents and disinfectants More productivity, thanks to reduced cleaning times Comprehensive system solution, comprised of an enclosure plus climate control, up to a protection category of IP 54 and IP 69K Greater reliability, thanks to DGUV testing

SOFTWARE & SERVICES

www.rittal.co.uk

Supplement: Aerospace Rolls-Royce, Airbus and Siemens are working on the E-Fan X programme

Electric aircr close to take-o T

echnology is being developed that could see electric aircraft in our skies within just 10 years. David Latimer, Chief Executive Officer of Magnomatics, explores how pressure to reduce noise and carbon dioxide emissions is driving the innovations that will make this possible. It is fast becoming a matter of when,

As in the automotive sector, the aviation

the sub-systems and components re-

industry is turning to electric and hybrid

quired. The firm says it should provide

technology to reduce environmental

fuel savings of at least 30 percent. It

impact, as a future without jet fuel be-

should fly in 2022 and is forecast to be

comes a real possibility.

ready for regional airliners by the mid2020s.

For example, Rolls-Royce, Airbus and Siemens are working on the E-Fan X

Moving to electric aircraft would help

programme, which will have a two-meg-

the aviation sector meet EU targets of a

awatt (2MW) electric motor mounted on

60 percent reduction in CO2 emissions,

a BAE 146 jet. It is set to fly in 2021.

90 percent less NOx and 75 percent

rather than if, a short-haul electric aircraft

less noise by 2050. The technology

will take to our skies. The pace of inno-

United Technologies, which includes

would see batteries put inside a plane’s

vation is accelerating as more organisa-

engine-maker Pratt & Whitney in its

wings instead of being slung under-

tions bring their research and develop-

portfolio, is working on its Project 804,

neath them, making the aircraft more

ment resources to the goal of creating

a hybrid electric demonstrator de-

aerodynamic.

the all-electric aircraft.

signed to test a 1MW motor as well as

20 dpaonthenet.net

Supplement: Aerospace Most large aircraft currently use hydraulics, but these systems are inefficient and carry the risk of leaking potentially harmful fluids. Magnomatics has been working with collaborators Triumph Aerospace, Romax and the University of Sheffield to develop a highly reliable and compact flight aircraft control surface actuator. For the more-electric aircraft, existing electromechanical actuator systems – both rotary and linear – are prone to

cations on unstable aircraft where a high

mechanical jamming events caused by

bandwidth is required.

failures in the mechanical drivetrain. For example, the mechanical gearbox in the

The low inertia and inherent torque fuse

rotary topology and the screw/gearbox in

also protect the actuator system from

the linear topologies.

jams or impacts. Rather than failing, the magnetic gear in the PDD simply slips

raft off

These failures can be caused by a combi-

until the problem is removed. This takes

nation of shock loads, such as wind gusts

place without damaging the system com-

or object strikes, and the kinetic energy in

ponents, which means other actuator

the rotor of the high-speed motor driving

components, such as end stops, can be

the actuator. The large mechanical gear

light-weighted, bringing further benefits

ratio employed between the motor and

for this type of actuation system.

the control surface has the benefit of reducing the volume/mass of the actuator

This slipping function has already shown

motor but increases the kinetic energy

to be of great benefit in difficult applica-

stored in the output rotor of the electrical

tions in other sectors. In the oil and gas

machine.

sector, a pump driven by a Magnomatics magnetic gear has been installed in a par-

Magnomatics has designed, built and

ticularly difficult oil well in California, by

tested a number of prototype electric

artificial lift specialist ZiLift, which is based

motors as part of the Electro-Mechanical

in Aberdeen. This pump ran continuously

Magnetic Actuator Systems (EMMAS)

for over two years whilst previous installa-

project. The electric motors use Magno-

tions were failing after just 30 days.

matics’ proprietary Pseudo Direct Drive (PDD) technology.

All these features suggest that a PDD based actuator for flight control surfaces

The PDD integrates a permanent magnet-

will be as reliable as the traditional hy-

All of these initiatives are supported by

ic motor and a magnetic gear, resulting

draulic systems used today. This is a key

the relevant governments. In the UK,

in a very compact electric motor. When

step on the way to the all-electric aircraft.

the Aerospace Technology Institute (ATI)

compared with current benchmark tech-

A number of aircraft manufacturers and

has been established to stimulate and

nology, the results look very promising.

leading suppliers are showing interest in

steer the technical innovation required

this exciting new technology.

to maintain the UK as the number one in

Two variants of the PDD have been de-

the European aerospace sector. It is set

signed, a basic machine and a second

to allocate £150m per annum of funds to

one using a fault-tolerant (FT) stator wind-

innovative projects and has secured a to-

ing and a fault-tolerant control system

tal of £3.9 billion research and technology

developed by the University of Sheffield.

funding.

Even with the fault-tolerant winding, the PDD is around half the mass of current

Highly reliable flight actuator

technology with a conventional winding.

Whether pure electric or hybrid, industry experts agree that there will also be the

The PDD has a further benefit – low iner-

need for reliable all-electric actuators for

tia. This results in a very good response

control surfaces and other systems.

rate, making it suitable for military appli-

www.magnomatics.com

About the author: David joined Magnomatics in February 2013 in a business development role and became CEO in December 2015. Before Magnomatics, David was Chief Executive Officer of EVO Electric, a spin-out company from Imperial College. Under David’s leadership, EVO gained a strong position in the electric and hybrid vehicle sector and it formed a joint venture with GKN Driveline in June 2011.

dpaonthenet.net 21

Supplement: Aerospace

Drones take to the skies as aerospace sector targets diversification A

recent Protolabs Aerospace report shows more than half of people believe commercial drone deliveries will be commonplace by 2023, as governments and firms find new ways to guarantee services.

78 percent of companies questioned from the UK felt convinced that disruption, in the form of drones, represents aerospace’s best opportunity for growth in the future. This figure from the UK outperformed its peers in Italy (75 percent),

COVID-19 has left an undeniable im-

According to a new European aerospace

France (64 percent) and Germany (57

pression on the manufacturing world,

study, challenges posed by the pandem-

percent).

as companies struggle to come to terms

ic are even accelerating the willingness to

with what a ‘new normal’ will mean for

embrace drone technology and, encour-

“COVID-19 has brought huge disruption

people who make things.

agingly, the UK is leading the way.

to the global economy, with the aerospace sector being among the hardest

With the uncertainty of Brexit still shroud-

The first findings of Protolabs’ Horizon

hit,” explained Bjoern Klaas, Vice Presi-

ing industry, the last thing firms needed

Shift report, which involved 325 aero-

dent and Managing Director of Protolabs

was a global pandemic that ripped up the

space business leaders, highlighted an

Europe.

rule book when it came to supply chains

increased appetite for ‘low space’ inno-

and imposed previously unheard-of re-

vation and more investment into the fast-

“However, a crisis can act as a catalyst

strictions on how we trade.

track testing of robots and drones.

for further innovation, forcing organisa-

It has also seen the very best of UK man-

More than half of the companies ques-

rapidly changing times. Our report shows

ufacturing. Businesses, who saw sales

tioned (53 percent) believe commercial

that right now within aerospace, the ‘low

fall off a cliff overnight, have pivoted to

drone deliveries will be commonplace

space’ sector is demonstrating agility in

transfer their expertise into supplying

by 2023, as both the public and private

its approach to innovation and there is a

critical parts for ventilators and other

sector seek safe ways to guarantee ser-

real appetite to see it work in the UK.

frontline efforts, whilst others have ex-

vices whilst containing the spread of any

plored new solutions to help satisfy the

viruses.

tions to seek alternative ways to survive in

need to do things at a distance.

22 dpaonthenet.net

“In fact, the UKSA (the government agency responsible for the UK’s civil space

Supplement: Aerospace programme) recently announced a new drive to fund space-enabled technology to strengthen the NHS response to coronavirus. Drone technology can help meet challenges, such as delivering test kits, masks, gowns and goggles, in the management of infectious disease outbreaks. “Commercial drone deliveries are the most likely disruptor, and this was reinforced across the duration of our study, which was carried out as the COVID-19 pandemic started to take grip. In just a few weeks, the appetite for this technology increased by 11 to 53 percent.” Despite the positive outlook, there are a number of obstacles standing in the way of companies operating in low space. Cost of initial investment over return on investment (ROI) is seen as the biggest

Respondents work across senior man-

“There are real opportunities for suppli-

challenge by a third of respondents and

agement, R&D, engineering design,

ers to look at ways they can deliver parts

this is closely followed by technology in-

technology and supply chain manage-

that can be used in this transition, whilst

tegrations and issues caused by inflexi-

ment, providing a comprehensive over-

exploring material applications that de-

ble supply chains.

view of the sector.

liver the lightweight savings and opti-

Detailed testing programmes and prod-

Disruption was a core theme throughout

uct development cycles are the main

the survey, with 62 percent saying that

For further information and to down-

barriers to innovation, whilst risk man-

disruptive technologies are making their

load the initial findings, please visit

agement and an inability to learn from

companies more competitive.

www.protolabs.co.uk

mum performance required.”

failures could also stifle progress. Advances in technology will also unlock More than a third of companies want in-

the value migration to new business

vestment in STEM education, improved

models, including faster charging of

international regulation/collaboration and

lithium-ion batteries (59 percent), artifi-

increased government support.

cial intelligence (59 percent) and battery storage (58 percent).

Disruptive times The Protolabs ‘Horizon Shift’ report was

Bjoern Klaas concluded: “We are oper-

completed during March and April and

ating at a time when the unimaginable is

involved 325 leading aerospace profes-

fast becoming reality and the aerospace

sionals from France, Germany, Italy and

sector and supply chain has to keep

the UK.

pace with this change in attitude.

Further information Protolabs helps aerospace customers to accelerate product development, reduce costs and optimise supply chains with technology-enabled 3D printing, CNC machining and injection moulding. Clients upload their 3D CAD drawings to www.protolabs.co.uk, where customised software reviews files and emails an interactive quote with pricing and design analysis. The company typically produces one to 50+ 3D printed parts in one to seven days, one to 200+ CNC machined parts in one to three days and 25 to 10,000+ injection moulded parts in one to 15 days.

Electronic enclosures. Plastic, extruded & die-cast. In-house mod services: • machining • printing • drilling • custom colours

01256 812812 • sales@hammond-electronics.co.uk • hammondmfg.com

Feature: Conductivity sensors

Fast and precise conductivity sensors save water and cut costs T

he need for effective wash-down and cleaning whilst meeting increasing demands to save resources and cut costs has always been a tricky challenge – especially as optimum hygiene is essential in food and beverage manufacturing.

Image source: Shutterstock

A high-speed CombiLyz Conductivity Sensor, supplied by BAUMER, has made an important contribution at Granarolo, Italy’s largest dairy processing operation. Effective cleaning of a hygienic dairy processing system usually requires a range of liquids – such as milk, water, lye and acids – working within a complex, clean-in-place (CIP) process, where different liquids flow alternately through pipes and tanks. All these liquids have a financial and/or envi-

value of conductivity within 15 seconds,

underneath the metal are faster. However,

ronmental cost so must be used sparingly

compared to around 50 seconds typically

frequent temperature fluctuations tend to

and, where applicable, recycled.

achieved by other sensors. This means the

wear-off the transition between plastic and

control mechanisms can react faster and

metal, causing these types of sensors to

Precision and speed were crucial to the

separate the individual phases by actuat-

fail more frequently, rendering them unsuit-

success of the CombiLyz conductivity sen-

ing values.

able for hygienic applications.

The sensor’s ability to measure precisely

Bruno Landuzzi, Maintenance Manager

The CombiLyz sensors also have a col-

the electric conductivity of liquids in the

at Granarolo explained, “Our tanks, pipe-

our-coded touch display which enables

system determines which type of medium

lines and thermal treatment systems are

easy parameterisation. The freely definable

is flowing and its concentration. The Com-

cleaned up to 30 times a day and thanks to

conductivity areas can be allocated to any

biLyz sensor provides a precise measured

the quick temperature compensation of the

display colours, such as blue for water and

CombiLyz sensors, we can save more than

red for acid. This means operators can see

100,000 litres of water per year at every

from a distance which medium is passing

measuring point.”

through the pipes at any given moment.

sor in this challenging CIP fluids handling.

Additionally, the sensor transfers its measThe fast temperature compensation re-

ured values via a 4/20mA interface with op-

sponse is primarily due to the design of the

tional HART protocol.

CombiLyz sensor which features a onepiece hygienic design measurement probe

The options available are the CombiLyz

made of PEEK plastic. This contains the

AF14 (where the entire sensor is contained

inductive sensor elements for measuring

in a single housing) and the AF15 (for appli-

electric conductivity and the temperature

cations with limited space). The AF15 has

sensor.

the sensor element and display separated and connected via a cable, to facilitate

The sensor tip has a low thermal mass

more flexible positioning. Both options

and low thermal transition, enabling the

have an IP69k rated stainless steel hous-

sensor to react very quickly, even to signif-

ing to ensure suitability for high-pressure

icant temperature fluctuations. Only sen-

steam cleaning.

sors with two-part measurement probes where the temperature sensor is located

24 dpaonthenet.net

www.baumer.com/ch/en/

Industrial robot and cobot solutions from SMC

SMC produces compact and lightweight automation components for robotics applications and End-of-Arm tooling.

We offer a wide variety of products that can be used for handling work pieces of different shapes and materials. These include: Pneumatic, Electric and Magnetic Grippers, Compact Cylinders, Vacuum components and Fieldbus Systems. If you’re looking to automate some of your manual applications with industrial robots or cobots, we have the experts that can help you!

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Feature: Laser triangulation sensors

Laser triangulation sensors measure lateral position of rail bogie wheels

The optoNCDT 1420 laser triangulation displacement sensor measures the lateral position of the bogie wheels relative to the railhead

aser triangulation sensors from Micro-Epsilon are being used to measure the lateral position of rail bogie wheels relative to the railhead in a rail traction technology project by SET Limited.

issues. What we want to do is to see this

“Actively yawing the wheels along with

technology implemented as the technolo-

active torque control manages the con-

gy of choice for rail passenger vehicles of

tact patch at the optimum point of the

the future.”

rail, practically eliminating RCF. This is because ideal [close to radial] steering

In the ActiWheel solution, the motor is inte-

reduces the energy in the contact patch

grated into the wheel, which means there

to a point where RCF does not occur

is no transmission between the two and

and wear is very small.”

ActiWheel is a traction system that uses ar-

no moving parts beyond a bearing which

tificial intelligence to guide trains along the

every wheel and axle has. In addition, there

tracks – enabling quicker, smoother and

are no friction braking systems, so there

Reliable, durable and lightweight

more economical rail travel. The solution

would be a significant reduction in the

The ActiWheel is a high-reliability, du-

could dramatically change the way that rail

amount of maintenance required.

rable system and Cooney expects his

vehicles run on the railway. As Martin Whit-

wheels to last somewhere between four

ley, Director at SET Limited, explains,“This

Neil Cooney, Technical Director at SET

to 10 times longer than a conventional

revolutionary wheel motor can be con-

Limited, comments, “One of the biggest is-

set-up. There is virtually no wear, which

trolled to produce more driving force on

sues facing the rail infrastructure is Rolling

means the rail isn’t being damaged and

one side or the other in order to steer the

Contact Fatigue [RCF], which occurs due

the wheels don’t deteriorate. The solu-

wheelset down the centreline of the track.

to the energy in the contact between the

tion is also lightweight, which means it’s

For the last 200 years, conventional rail ve-

wheel and the rail. Conditions under the

a lot easier to accelerate and decelerate

hicles have only had a solid axle and wheel

contact patch are always severe and the

the train and there is additional carrying

coning providing this capability, which

yield stress of the rail wheel is always ex-

capacity for passengers.

drives some significant compromises and

ceeded, on at least a microscale.

26 dpaonthenet.net

Feature: Laser triangulation sensors For the last nine months, ActiWheel has

provides distance information from the sen-

“The sensors have performed very well

been put through its paces in a technical

sor. All optoNCDT 1420 sensors operate

in the demonstrator project and on other

demonstrator project. An ex-London un-

using a web interface for fast sensor set

projects where we’ve tested the ActiWheel

derground train with a single carriage was

-up and configuration. Additional features

system. They are reliable even in the harsh

fitted with an ActiWheel system on each of

of the optoNCDT 1420 include video sig-

environment underneath a train, where

its eight wheels.

nal display, signal peak selection and freely

dust, dirt and moisture are present. They

adjustable signal averaging, which enables

operate reliably whether it’s a cold, wet,

For this project, each ActiWheel system

the optimisation of the measurement task. A

rainy day or a bright sunny day. In the

incorporates an optoNCDT 1420 laser

region of interest (ROI) function allows back-

demonstrator project, we didn’t even have

triangulation sensor. “A critical part of the

ground signal noise to be filtered out.

to clean the sensors after a couple of thou-

ActiWheel system is to understand the

sand miles of testing.”

lateral position of the wheel relative to the

SET engineers built a special frame that

rail. Then we can control the wheel and

lies beneath the wheel axle on the train.

avoid the flange contacting the rail head,”

The optoNCDT 1420 sensors are mounted

explains Cooney. “We’re really using the

at 400mm from the railhead, just in front

sensors to confirm that our complex con-

of the flange radius, pointing directly at

trollers are actually working correctly.”

the railhead. Measurement data from the

www.micro-epsilon.co.uk

sensors is output to the ActiWheel control The optoNCDT 1420 laser triangulation sen-

system via 4-20mA.

sor, with an integral controller, is designed displacement, distance and position meas-

Robust and reliable in harsh conditions

urement applications. The measuring rate is

“The sensor met all our technical require-

adjustable up to 4kHz. A range of different

ments in terms of its flexibility, resolution

output signals enables easy integration of

and robustness. We are measuring down

the sensor into plant or machine control

to 0.1mm accuracy and lateral movement

systems. As well as analogue voltage and

can be up to a maximum of 20mm,” states

current outputs, a digital RS422 interface

Cooney.

for high-precision, high-speed, dynamic

ActiWheel is an autonomous control system that uses AI to guide the carriages along the tracks, enabling faster, smoother and more economical rail travel

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keller-druck.com

Feature: Sensor integration

The SICK SIG200 gateway and SIG100 sensor hub

Joining the dots with sensor integration devices T

here was a time when sensors were simple switches, and their manufacturers just hardware suppliers. All that has changed. Sensors are the ‘eyes and ears’ that collect data on the front line of production and logistics operations. Equipped with ever-smaller microprocessors, they have become intelligent.

architecture, but the data generated can

data efficiently. They deal with the data at

be shared not just at the machine level,

a local level while making it visible global-

but also via cloud-based systems. First,

ly. Manufacturers like SICK have already

that data can be monitored and trended

begun to roll out a portfolio of devices to

on a PC, machine HMI or cloud-based

facilitate sensor integration into fieldbus

dashboard. It also has the potential to be

environments and higher automation hi-

used in ERP (Enterprise Resource Plan-

erarchies.

ning) and MES (Manufacturing Execution System) software; indeed, this is seen as

Sensor integration gateways

fundamental to the future of Industry 4.0

To begin with, most people are familiar

manufacturing and logistics.

with IO-Link Masters that sit on a higher-level bus system, such as PROFINET

With their own decentralised comput-

Digitisation, intelligence and networking

or EtherCAT. They act as a gateway for

ing power right on board, sensors may

will increase until, eventually, systems will

IO-Link data to be passed on to the

no longer need to rely completely on a

control and optimise themselves – all us-

PLC or higher-level systems. The SICK

higher-level or central control system to

ing the data from sensors. Data transpar-

SIG200 Sensor Integration Gateway is

process and make sense of all the data

ency enables trends to be monitored and

an IO-Link Master with the addition of an

they produce. They can also provide ad-

gives us the ability to understand more

on-board web server that collects, com-

ditional data to the control system via IO-

about a system. From Overall Equipment

bines, evaluates and transmits signals

Link. Some even process applications,

Effectiveness (OEE) to Deep Learning, it

from IO-Link devices from any manufac-

or ‘Smart Tasks’ by themselves. Soon,

is the integration of the data that allows

turer. It works as both an IO-Link Mas-

some will combine multiple functions in

a user to become more aware of what is

ter and small, distributed logical control

a single device, for example, detecting

happening within a system.

system in one. It needs only one cable

piston position, vibration and angular velocity for end-of-arm tooling.

to communicate simultaneously via the The key to all this integration lies in the

fieldbus with the machine controller

gateways and devices that act as the

and with higher-level enterprise or web-

Integration of hardware takes place at a

translators – and, sometimes, as localised

based systems.

local level within the systems and control

controllers – to aggregate and route the

28 dpaonthenet.net

Feature: Sensor integration Sensor integration flow wrapping example

Sensor hubs To expand this integration, a sensor hub can squeeze the outputs from a number of on/off sensors into one string that can be passed via an IO-Link Master to the PLC. SICK’s SIG100, for example, can be used to bundle up to twelve standard I/Os in a single IO-Link data packet, which can then be communicated to machine controllers and cloud-based systems via the SIG200. A maximum of 52 I/Os can be connected to one SIG200 by using the SICK SIG100.

Sensor Integration Machines Sensor Integration Machines (SIMs) are programmable devices with configurable on-board software, so they can be used to process many different tasks, including more complex machine vision applications. They also include some or all of the functionality of an IO-Link bles them to be displayed, monitored,

Easy data transparency

recorded and analysed via a server

How can you easily detect all the IO-Link

The SICK SIM1000 and SIM2000 Sen-

or cloud system. By transferring data

devices in a machine? This is simple us-

sor Integration Machines, for example,

via mobile communications protocol

ing software such as SICK’s FieldEcho.

collect and evaluate data from multiple

(MQTT), a real-time overview of selected

This closes the remaining gaps in integra-

sensors working together at the field-lev-

plant and processing parameters can be

tion and makes all IO-Link devices visi-

el via standard interfaces, including Eth-

provided, and SMS text or email alarms

ble, providing direct access to process

ernet, IO-Link, CAN and Serial. With up

can be configured.

and service data and enabling the IODD

Master.

to four Ethernet ports, they can support

device descriptions to be automatically

interfaces for cameras, lighting, LiDAR

The SICK TDC system also enhanc-

downloaded. It visualises all configured

scanners, encoders, photoelectric or

es system transparency to SICK and

IO-Link Masters and the IO-Link sensors

displacement sensors, as well as to

third-party sensors compatible with

and actuators and displays their status.

higher-level controls and the Cloud. The

Ethernet, CAN, RS232, RS485, 1-Wire

multi-sensor outputs, values and results

and UART interfaces. Output communi-

It is networked production and control

can be used to drive typical industrial

cations can be via cable, wireless signal

processes, working in complex machine

automation applications such as cam-

or GSM.

environments, that will shape our indus-

era-based inspection, measurement, or identification of objects.

trial future. The degree of digitisation in The SICK SIG200 can take sensor data

future will mean smart factories will or-

and pass it on over REST API to the

ganise themselves using huge amounts

Gateways

cloud or fieldbus to the machine control-

of up-to-date information to make inde-

The term ‘gateway’ can mean different

ler. The SICK TDC can take data directly

pendent decisions. This information will

things depending on what is using the

or via REST API and pass it to the cloud

be provided by smart sensors.

‘gate’. In the case of sensor data, it may

or a local network storage solution.

be the SICK Sensor Integration Gateways. More generally, a cloud gateway is

www.sick.co.uk

About the author: Charlie Walker is Product Specialist for Presence Detection at SICK UK. A graduate of Lancaster University, Charlie helped run a factory engineering department before specialising in the application and technical support of sensors. He has particular experience of implementing IO-Link sensor applications and knowledge of their successful integration with many well-known PLC brands. Charlie joined SICK UK in 2017.

a device that takes all sorts of data and passes it to the next level via the relevant protocol. An example of this would be SICK’s TDC (Telematic Data Collector),

Telematic data collector

used to aid real-time condition monitoring and predictive maintenance. The SICK TDC collects and processes sensor outputs and data in stationary and mobile machinery, together with GPS localisation information, and ena-

dpaonthenet.net 29

Feature: Split bearings

Split bearing solution cuts conveyor maintenance costs and risks F

or companies and employees in the mining, mineral processing and cement industries, maintenance and replacement of conveyor bearings may come at a very high price. Clive Jennings, SKF Cooper Split Bearings Product Manager at SKF, presents a way of reducing safety risks as well as material and downtime costs. Anatomy of an SKF Cooper split spherical roller bearing – including optional seals

According to some studies, 43 percent of

The conveyors typically use standard open

longevity. The range includes sealed ver-

accidents and 24 percent of fatalities in

(unsealed) pulley bearings, which are vul-

sions which give better protection against

these sectors happen while maintaining

nerable to contamination. These have a

contaminants, for even longer life and lower

conveyors. A key danger often lies in the

relatively short service life (usually less than

grease consumption. Best of all, the bear-

need to hoist heavy couplings and gear-

that of the pulley lagging) and require large

ings are designed for in-situ replacement in

boxes to access bearings. If the process of

amounts of grease to purge contaminants.

much fewer steps, with no need to remove

replacing a bearing could be made quicker

or hoist the gearbox and drive coupling.

and simpler, and if bearings were made to

Rapid wear and damage necessitate fre-

last longer, everyone would benefit. Work-

quent bearing repair and replacement, typi-

Their anatomy includes inner and outer

ers would be safer, maintenance would

cally in hard-to-reach locations. Replacing a

rings, a cage and rollers, an outer shroud

be less expensive and loss of production

standard bearing in the machine’s trapped

and two inner clamp rings. The shrouds

would be minimised.

position is especially difficult and hazard-

and clamp rings are bolted together with

ous, requiring a long sequence of proce-

screws. Two seals are added if that option

dures. It can take up to 24 hours in total.

is chosen. Rings are split using a precision wire-cut-

ing and contamination conditions faced by

Increased bearing life, performance and operational economy

rotating machinery and their bearings in

SKF Cooper split spherical roller bearings

and outer rings and means that the two

plants which handle minerals and cement.

answer all these problems with a durable

halves align more accurately, and supe-

design that brings improved reliability and

rior clamping is achieved. Outer race and

Harsh challenges The challenges SKF has overcome to make this possible are considerable. First, there are the extreme temperature, heavy load-

30 dpaonthenet.net

ting technique, rather than by fracturing. This minimises discontinuities in the inner

Feature: Split bearings shroud joints interlock to ensure close

tasks which require rental of equipment

The split outer ring dimensions match

alignment between the halves and to lower

such as cranes and alignment tools. Work-

those of standard spherical roller bearings,

the chances of damage at the splits while

ers are exposed to safety hazards through-

enabling an easy fit into split block hous-

operating. The angular inner race joints

out this long operation, in which hoisting

ings with standard locating rings where

are also wire-cut, contributing further to

of heavy components poses particular

necessary. Shaft requirements for the

the smoothness of the roller path. This

concerns.

split bearing (ISO h9 shaft diameter toler-

wire-cutting approach not only improves

ance and IT5 form) also match those of a

clamping and reduces looseness but low-

By contrast, replacement with an SKF

standard spherical bearing mounted on an

ers the chances of fretting corrosion at the

Cooper split bearing takes substantially

adapter sleeve.

shaft interface.

less time and consequently, reduces workers’ exposure to risks. Table 1 highlights

A long-awaited breakthrough

In combination, these design elements

the much smaller number of procedural

Over a hundred years since the heavy-duty

extend the bearing’s life and improve its

steps involved in using a split bearing.

belt conveyor’s introduction, many oper-

performance. Tested against comparable

ators still see maintenance as its Achilles’

competitors’ split spherical bearing prod-

Crucially, gaining access to replace a split

heel. Heavy grease consumption and pre-

ucts, its steel clamp rings increase permis-

bearing does not require movement of the

mature bearing failure – together with the

sible axial loads by around 50 to 100 per-

conveyor belt, and it involves little or no

difficulty and time demands of repair and

disturbance to the drive coupling or gear-

replacement – generate high costs, limit

box. There is certainly no need to discon-

productivity and endanger maintenance

nect and lift them from the machine. Only

teams. These are major concerns for all in-

a slight raising of the shaft is necessary. As

dustries, and nowhere more so than in the

well as removing a significant hazard, this

world of mines, minerals and cement.

SKF Cooper split spherical roller bearing

solution saves maintenance staff from having to spend time repositioning and aligning

Designed for faster and safer pulley bear-

the assembly after bearing replacement.

ing replacement in the trapped position, SKF Cooper split spherical roller bearings

Easy applicability

slash mean time to repair (MTTR) and

The SKF Cooper products are interchange-

improve worker safety. Their design and

able with competitors’ split spherical roller

manufacturing techniques also enhance

bearings. They are also compatible with

performance and extend service life, es-

any SKF metric (SNL, SNLD) or inch (SAF,

pecially when sealed variants are chosen

SAFD, SDAF) split plummer block housing.

to counteract contamination, so fewer re-

First to be launched was the 231 series,

placements and less grease are needed. In

with shaft diameters ranging from 240 to

short, they offer a safer alternative that cuts

450mm and from 9.5 to 18 inches. These

maintenance costs, increases machine

can replace standard 23152 K to 23192

availability and minimises lost production.

K spherical roller bearings mounted on cent. An additional bonus is a reduction in running noise levels.

adapter sleeves.

www.skf.co.uk

Standard, non-split bearing

By adding seals, the bearing’s service life

SKF Cooper split spherical roller bearing

Safety lockout/tagout

can be more than doubled and, in some

Block machine (pulley) from rotation

cases, multiplied by 2.9, compared with an

Block and move belt to access pulley

unsealed bearing. At the same time, this

Disconnect gearbox coupling from motor

can reduce grease consumption by 90 to

Disconnect gearbox coupling from machine

95 percent, saving on lubricant expense,

Remove coupling from machine

labour, exposure to safety risks and impact

Lift and remove gearbox

on the environment.

Quicker bearing replacement SKF Cooper split spherical roller bearings

Remove split block housing cap

Lift and support machine shaft

Remove and replace bearing

Replace housing cap

Reposition gearbox

are especially useful when it comes to

Connect gearbox to machine

bearing replacement in the trapped posi-

Connect gearbox to motor

tion. To replace a standard, non-split bear-

Check alignment of motor to gearbox

ing, the gearbox and drive coupling must

Remove machine blocking

be disconnected, hoisted out of the way

Remove safety lockout/tagout

and then replaced afterwards in the cor-

Table 1: Comparison of general in-situ sequence of bearing replacement procedures between standard and split bearings in the trapped position

rect alignment. These are time-consuming

About the author: Clive Jennings is the SKF Cooper Split Bearings Product Manager at SKF.

dpaonthenet.net 31

Feature: Power transmission chain

You do get what you pay for… W

hen it comes to a power transmission chain, Tsubaki proves that buying a quality product results in significant lifetime cost-savings. The climate in most industries now is focused on cost reduction to protect margins. While this is a noble pursuit – and one that can offer real benefits to a business and its customers – it is important that when it comes to procurement, the Total Cost of Ownership (TCO) is considered over initial cost savings. While some components may seem like the

Tsubakimoto proves that buying a quality product results in significant lifetime cost-savings

cheapest solution in the short term, they can quickly prove expensive if regular

Tsubakimoto believes that the key to

All too often, when we hear about a

maintenance, repair and replacement

real world cost savings lies in an extend-

business cutting its costs, we hear

work become necessary.

ed, low-maintenance operating cycle.

that the cuts have been achieved by sourcing cheaper components during procurement. However, while these savings may look appealing in the short term, the only real way to gauge success is to look at the total cost of the product throughout its life. Cost of installation, maintenance requirements, downtime caused by early failure, and replacement are all hidden costs which can add up when a budget component is specified. A power transmission chain is an area where many procurement managers may feel they can reduce costs by specifying budget chains. As the technology is apparently so simple, and there are few outward differences in appearance between brands, it would

Cost-saving comparison table showing the differences between a standard chain and a Tsubaki Lambda Lube-Free chain

32 dpaonthenet.net

be easy to assume that this is an area where budget components may be

Feature: Power transmission chain justified. However, the truth is very different; a chain which has been properly specified and well produced using high-quality materials can often earn its initial procurement cost back many times over when com-

Precision Safety Screens

pared with cheap chains. Jake Yamamoto, Sales & Marketing Director for Tsubakimoto Europe, comments: “Initial procurement is just one cost that needs to be considered when determining the TCO of [the] power transmission chain. After procurement, there is installation time, which can vary greatly between products, as well as the necessary maintenance requirements – such as lubrication or removing links due to elongation. Then, there is the cost of replacement. A chain with a shorter life will need replacing, which not only causes downtime but also introduces a further round of procure-

Protect Components from Rogue Contamination

ment into the equation. When all of these hidden costs are taken into

All Stainless Steel Insert Design

consideration, it is easy to see how budget chains can quickly become

Internal Retention System

a false economy.”

5.5, 8, 10 and 12mm Dia. Sizes 25-300 microns absolute Cost-effective design for high volume applications

The ability for a premium chain to offer significant TCO savings has been experienced first-hand by a food producer who was looking for an alternative roller chain solution for its cake production line. The basic 12B chain that it specified as standard had an average life span of nine months, despite regular maintenance. The plant’s management was concerned about the regular replacement costs and approached Tsubaki to see if an alternative solution could be provided. Having conducted a site inspection, a Tsubaki engineer specified Lambda lube-free chain. The Lambda chain does not require any external lubrication, which instantly saves maintenance costs. As the chain surface is dry, any contamination risk is avoided. The chain bearing surfaces remain lubricated, which minimises wear and offers a much longer operating life. The procurement cost for a single length of Lambda chain was almost 150 percent more than the cost for the basic 12B chain – which may have put a lot of operators off. However, once installed, the chain lasted for 40 months without the need for any maintenance. Over 40 months, the basic chain would have been replaced four times and accrued regular maintenance costs. As such, the Lambda chain was almost 45 percent cheaper to run which represented a saving (as shown in the table). If you consider lubrication and replacement maintenance time, then the TCO figure starts to look more realistic, and closer to 100 percent more expensive. This is also without adding any potential downtime costs. If the chain is replaced during a routine maintenance window, then there is no figure there, but if the plant could be up and running instead of being stopped while the roller chain is replaced, then the cost per hour of lost production can easily run into thousands. Jake Yamamoto concludes: “Tsubaki invests heavily in R&D and offers a wide range of products which have been designed for all types of industries and environments. This means that for most applications, even traditional hard-wearing ones, we can specify a solution which will last many times longer than a basic chain. We will conduct a site visit prior to specification to make sure that we understand the unique requirements of every job so that we can provide an accurate estimate for our chain’s TCO.” https://tsubaki.eu/

dpaonthenet.net 33

For more information, contact Lee Products Innovation in Miniature Tel: 01753 886664

Fax: 01753 889588 www.industrial-microhydraulics.co.uk e-mail: sales@leeproducts.co.uk Lee Products Limited, 3 High Street, Chalfont St Peter, Bucks. SL9 9QE

Feature: Pulley bearings

NSK bearings and training help woodworking machine builder make savings A

fter suffering repeated failures of its table guide rollers, an international woodworking machine manufacturer called upon the expertise of NSK and its AIP Added Value Programme to resolve the issue. The decision proved lucrative, with NSK

A proposal was made to adopt NSK pulley

the ingress of dirt and other types of con-

bearings, predominantly because of their

tamination. These bearings also serve to

higher tolerance levels. In tandem with a

reduce wear on the raceways and ball

suitable NSK training course that allowed

surface, cut noise levels, and reduce vi-

consistent table guide assembly, it was

bration and the danger of lubricant fail-

calculated that the problem would be re-

ure. A further advantage of NSK pulley

solved. Sure enough, these actions ena-

bearings, which accommodate radial and

bled the fault-free running of the machine

axial forces in both directions, is their po-

and reduced fitting times for the bearings.

tential to be re-greased through the inner

helping the company to save a total of

ring.

€13,333 per annum in reduced labour

Pulley bearings from NSK correspond in

and assembly costs.

design to a sealed double-row angular

At the woodworking machine manufac-

contact bearing. Based on their function

turer, NSK pulley bearings were subject-

Upon arriving at the customer’s facility,

as pulley bearings, the outer ring – which

ed to an initial trial, which demonstrated

NSK set about investigating the problem

can be cylindrical or crowned – is rein-

their performance, without any failures. In

with the table guides, discovering that

forced.

tandem with employee training in bearing

the existing bearings had insufficient tol-

installation and removal, it was possible

erance. This issue, in combination with

Importantly, in harsh operating conditions

to reduce assembly costs and staff de-

inconsistent bearing assembly methods,

(such as those found in woodworking

ployment.

was resulting in frequent failures.

shops), NSK pulley bearings feature contact seals that provide protection against

34 dpaonthenet.net

www.nsk.com

Buyers Guide: Springs

Geared Motors – 12mm / 90mm dia

MANUFACTURERS OF SPRINGS PRESSINGS • WIRE FORMS

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.

T: 0118 978 6573 F: 0118 989 4434 E: sales@simpsonsprings.co.uk www.simpsonsprings.co.uk

Batteries & Chargers

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

Displays

Robotics, laboratory equipment, surveillance cameras, slot machines, shop Displays Displays displays,vehicle equipment, telecoms equipment,lighting and ventilation control. Touchscreens Displays Touchscreens Industrial Pc’s Locking mechanisims, machinery activators, shop displays etc etc. Touchscreens Industrial Pc’s Display systems

Display systems Industrial Pc’s Display Review Display Systems Ltd systems

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

Review Display Systems Ltd

MFA/Como Drills Felderland Lane, Worth, Deal, Kent CT14 0BT

Tel: 01304 612132

Fax: 01304 614696

Web: www.mfacomodrills.com

01959 563345

www.review-displays.co.uk 01959 563345

Business Advice Consultants

http://www.mcs-corporate. com

R&D/Cost Recovery/Patents/ Land Remediation Research and Development Tax Credits Patent Box Land Remediation Claims www.mcs-corporate.com gjw@mcs-corporate.com 10 Station Road Kenilworth CV8 1JJ 01926 512477

To advertise here contact

Andrew Quenault

01732 359990 or email andrew.

quenault@imlgroup.co.uk

Fasteners & Fixings

• Tappex Thread Inserts Ltd – 60yrs+ 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 produced from Brass, Steel, Stainless Steels & Titanium inserts 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

Success is sealed

36: Electric actuators The electric vs pneumatic debate

200117_8-9_Mill_DPA_UK_Snipe.indd 1

contact

Andrew Quenault on

March 2020

igus plain bearings help adaptive skier find the fast lane

advertise here

Downloadable catalogues and applications advice on the website.

The Engineer’s guide to new products & design ideas

20: Plain bearings

1/13/20 12:07 PM

FREE MAGAZINE REGISTRATION

01732 359990

If you or/and a colleague would like to receive this title free of charge every month, you can register online by scanning the QR code below, this code can be used by more than one person or visiting the website: https://data.imlgroup.uk/dpa-reg-page/ or phone +44 (0)1732 359990

or email Open the QR code on your phone or launch the camera on an iPhone, scan the QR code above and complete the online form

andrew.quenault@imlgroup.co.uk

Zero Cabinet – on-machine power!

Power supply

by Murrelektronik

Move your power supply out of the cabinet and onto the machine We help our customers move components from the control cabinet onto the machine. This concept makes applications transparent, user friendly and cost-efficient. Customer advantages: Use smaller control cabinets (or no cabinet at all!). Reduce power loss, energy costs and wiring by converting the voltage from 230 V AC to 24 V DC directly next to the load. IP67 approval rating ensures the power supply can stand up to all the on-machine demands.

DPA_20_07

Articles inside

Split bearing solution cuts conveyor maintenance costs and risks

Split bearings

You do get what you pay for

Laser triangulation sensors measure lateral position of rail bogie wheels

Farm to fork

Electric aircraft close to take-off

Residual stress systems

Fast and precise conductivity sensors save water and cut costs

ABB robot helps test extreme high-temperature systems

Conductivity sensors

Coal and COVID

Rocket science