DPA_20_08

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

3D printing in space: An astronaut’s simulation story 14: Solar race car

28: Factory simulation

Accurate power analysis boosts solar race car’s competitiveness

A no-nonsense approach to adopting new digital tools

Contents

August 2020

Check out ou r Webinar and Virtual Exhibition Sh owcase on pages 21, 23 & 27!

The Engineer’s guide to new products & design ideas

Paige’s Page: 04: Editor’s comment A simple, ‘out of the box’ temperature checking system

General Feature:

3D printing in space:

06: Electrical engineering

An astronaut’s simulation story 14: Solar race car

28: Factory simulation

Accurate power analysis boosts solar race car’s competitiveness

A no-nonsense approach to adopting new digital tools

Cover Story:

200717_9-2_Mill_DPA_UK_Snipe.indd 1

Electrical engineering at WAGO

Test & Measurement 7/16/20 10:39 AM

Sabrina Kerber, Space Architect and Analog Astronaut, EuroMoonMars, looks at 3D printing in space and what she learnt from her astronaut mission! p.30

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

Special Report: 08: Liquid dispensing systems Pressure-controlled liquid handling systems

10: Thermal imaging Specifying a thermal imaging camera for COVID-19 fever screening

12: Battery testing Testing to ensure battery integrity

14: Solar race car

Accurate power analysis boosts solar race car’s competitiveness

Linear Motion Special Report: 16: EV batteries EV battery production uses HepcoMotion’s V Guide Systems

18: Pneumatic technology Rethinking pneumatic technology for the factories of the future

20: Tubular linear motors Where tubular linear motors blow away pneumatics

22: Disc springs Fully automatic handling and testing of disc springs

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12

14

Rapid Prototyping & Simulation Technology Focus: 24: Digital twins Faster to a finished machine

26: Additive manufacturing Automotive in the Additive Manufacturing Lane

28: Factory simulation A no-nonsense approach to adopting new digital tools

30: 3D printing 3D printing in space: What I learnt from my astronaut mission 10,000 Average net circulation Jan-Dec 2018

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

32: Aerospace manufacturing

3D printing reaches new heights in aerospace manufacturing

35: Buyer’s guide

30 dpaonthenet.net 3

Paige’s Page

A simple, ‘out of the box’ temperature checking system W

elcome to the August issue of DPA!

dalone ‘out of the box’ first layer, zero

alerts, and the option for facial identifi-

contact, automatic temperature sensing

cation (subject to activation).

system at the entrance to the premises or threshold.

Large said, “I went to visit a local man-

Last month, I spoke with Tony Large,

Paige West, Group Editor

ufacturing factory (my first visit since

Technical Director at Crystal Display

Large notes, “The uptake has prob-

lockdown) because they wanted to

Systems (CDS), to learn more about

ably been the biggest we’ve had on

place a tablet on every external door

how the TAURI temperature-checking

any product launch. We’re selling quite

of the premises. The main reason this

tablet can minimise the spread of infec-

a few to existing CDS customers but

product was so attractive to them was

tion.

also many new customers, particularly

its simplicity and practicality – you don’t

in office and retail environments. Plus,

need a person to run it. Previously, this

there’s a lot of international interest.”

company was using an infrared camera

As lockdown is lifted and life slowly adapts to the new realities of social dis-

on a tripod connected to a laptop, with a

tancing and enhanced levels of hygiene

How does it work?

person standing there checking the tem-

awareness, Crystal Display Systems is

The TAURI system is designed to be

perature of each employee.

partnering with Glory Star to introduce a

simple and intuitive to operate.

new product that will give some reassurances to workplaces and public spaces.

Tony started life as an apprentice engineer at BAE SYSTEMS before entering the displays business in 2003. He became co-founder and Technical Director of Crystal Display Systems at its incorporation in 2011.

“We’ve actually had one installed at the TAURI can check a person’s body tem-

entrance to our office. As there are sim-

perature in under three seconds and

ilar products on the market, most being

The TAURI by Glory Star, a tempera-

within three feet of the monitor, using

more expensive, we wanted to conduct

ture-sensing tablet, is an adaptation of

advanced German infrared technolo-

a comparison test. So, we set them up

CDS’s existing range of distributed com-

gy. This is achieved without touching a

side by side and straight away noticed

mercial tablet devices, with the addition

screen, reducing the need for an inef-

two things; the more expensive product

of a thermal imaging camera system to

ficient and potentially infectious ther-

wasn’t calibrated properly as it didn’t

monitor the temperature of staff and vis-

mometer. A beep and red light indicate if

read the temperature accurately when

itors.

the temperature is too high and a green

taken out of the box and, when we ar-

light if the temperature is acceptable.

rived at the office the next morning, it

Coupled with a simple app and oper-

Further optional functionality includes

didn’t even work!”

ating system, the solution gives a stan-

mask detection, overt temperature email The TAURI range is future-proof with a range of additional features: • Customisable screen saver videos – free advertising!

• Dual monitor display • Face detection • Optional facial recognition • Cloud control platform to control all devices remotely.

For more information, visit: https://crystal-display.com/products/checkvue-tauri-temperature-sensing-tablet/ Do let us know what you think of the issue and if there are any specific topics you think we should be covering. Email me at paige.west@imlgroup.co.uk

Connect with us on LinkedIn. Join us on Twitter.

4 dpaonthenet.net

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The unit first thing loop control isIPCs updating, diagnosis monitoring down to the KEB DIN rail IPCs is design precisely for this type of installation. unit updating, machine diagnosis and monitoring down to the The first thing SMART All One Safety power unitEtherCAT, level with withProfinet, secure end-to-end end-to-end VPN-connection power unit level with secure secure end-to-end VPN-connection solver, Endat, Hiperface, BISS,end-to-end SSI,and Incremental TTLdown / HTLto the Real Powerlink,VPN-connection Varan and loop control isin unit updating, machine monitoring power unit level secure power level with VPN-connection you time need with chosen by customers The C6 isunit perfectly tailored todiagnosis the runtime environment and realpower unit level with secure end-to-end VPN-connection power unit level with secure end-to-end VPN-connection you need The C6value SMART isunit perfectly tailored to the runtime environment and reallevel with secure end-to-end chosen by to decide is functions STO-PLe/SIL3, SS1, SS2, SOS, SLS, SLP, power unit level with secure VPN-connection toCONTROL add and time capability with a powerful processor forend-to-end -customers Universal Motor operations – open closed loopconIntegrated VISUALISATION REMOTE -power Air and Water cooling options, built and in orVPN-connection through CAN, or simply serially. to decide is power unit level with secure VPN-connection VISUALISATION REMOTE time capability with a powerful processor forend-to-end to add value and whether you aCONTROL competitive CONTROL VISUALISATION REMOTE performing complex automation tasks.

The MAINTENANCE whether you performing complex automation tasks.

The MAINTENANCE a competitive trol for ASM, SM, IPM, SRM, including sensorless control SLI, SDI, SSM, SAR, SEL, SLA, SMS, SSR

powerful graphical design

powerful graphical design mount. want the brake advantage to their MAINTENANCE powerful integrated micro UPS and spacious on board powerful graphical design want the brake graphical graphical design design integrated micro UPS and spacious design on board powerful graphical design advantage to their to bepowerful applied make powerful graphical machines. memory the C6 SMART a robust, reliable powerful graphical design to be applied Dual encoder channels, selectable inputs including Re Real Time high-end layout of the operating interface with high-end layout ofathe the operating interface with with scalable scalable Concrete Canvas layout Ltd has reduced wiring installation costs and hasscalable greater memory make the C6layout SMART robust, reliable interface The powerful graphical design high-end of the operating interface with scalable high-end of operating machines. when there is nolayout system. device takes up 47mm onvariable the DINspeed high-end of the operating interface with scalable high-end layout of the operating interface with scalable More than simply rotating a motor, the drive has long been when there is noof flexibility in terms future expansion plans for machines and additional lines. high-end layout of the operating interface with scalable system.

The device takes up 47mm on the DIN high-end layout of the operating interface with scalable power, or when solver, Endat, Hiperface, BISS, SSI, Incremental TTL / HTL symbols, trends, data logger, formula management and symbols, trends, data logger, formula management and Real time with EtherCAT, Profinet, Powerlink, Varan and More than simply rotating a motor, the variable speed drive has long been rail and supports direct coupling with remote recognised as critical piece of the most modern machinery.

It with offers a gateway high-end layout of scalable symbols, trends, data logger, formula management and symbols, trends, data logger, formula and power, or2018, when What the goala of functional safety?

Tooperating minimise theinterface risksmanagement posed by technical rail andis supports direct coupling with remote In Spring due to increased demand for its products, Concrete Canvas symbols, trends, data logger, formula management and Ltd symbols, trends, data logger, formula management and power is applied. recognised as a critical piece of most modern machinery.

It offers a gateway symbols, trends, data logger, formula management and I/O modules using built in the EtherCAT. into the machine, capable of significantly increasing the performance of the power is applied. symbols, trends, data logger, formula management and equipment to humans and environment.

Machine tools, for example, can Air and Water cooling options, built in or through integrated user administration I/O modules using built in EtherCAT. integrated user administration CAN, or simply serially. purchased a new facility in Pontyclun, around six miles from the original factory in symbols, trends, data logger, formula management and In most cases integrated user administration integrated user administration into the machine, capable of significantly increasing the performance of the machine as well as offering sophisticated monitoring of the process, e.g.

In most cases integrated user administration integrated user administration endanger operators and technicians with tools that rotate at high speeds.

A C6 Monitor can be incorporated to the integrated user administration Pontypridd. new is around three times thebut sizethere of the Pontypridd facility, you want toThis hold thesite load when power is off, are applications like A C6 Monitor can be incorporated toproblems the monitoring integrated user administration machine as well as offering sophisticated of the process, e.g. mount. highlighting the onset of mechanical that could be the source you wantthe to company hold the with loadsignificant when power is off, butforthere are applications like decentralized installation using SMART’s integrated user administration Drive technology that ensures thethe required safety functions without providing opportunities continued gates and turnstiles, where the brake must disengage in the growth. case of a power decentralized using the SMART’s highlighting theinstallation onset of mechanical problems that could be theencoders source

Automation with Drive

of unscheduled downtime.

Thereviaare a variety of features offered by the integrated visualisation support a standard offers the user various advantages, Checkley of KEB. integrated visualisation viasays a standard of unscheduled downtime.

There are aMark variety features offered by the manufacturers, which issupport worth looking at moreof closely to understand which built in DVI-D interface. built in DVI-D interface. manufacturers, which is worth for looking attomore closely to understand which would be most advantageous them use.

Formore more information information visit: http://www.dpaonthenet.net/article/176233/ For visit: https://www. would be most advantageous for them to use.

For more information visit: https://www.

Click to read the full article: http://www.dpaonthenet.net/ Encoderless-safety--drive-integrated-safety-without-an-encoder.aspx keb.de/control-automation/produkte/ keb.de/control-automation/produkte/ Click to read the full article: article/123866/Closed-Loop-without-a-feedback-device-.aspx hutschienen-ipc/c6-smart/ http://www.dpaonthenet.net/ hutschienen-ipc/c6-smart/ article/123866/Closed-Loop-without-a-feedback-device-.aspx

C6 HMI -- LC WITH TOUCH 5.7“ ...

15.6“ C6 C6 HMI HMI - LC LC WITH WITH TOUCH TOUCH 5.7“ 5.7“ ... ... 15.6“ 15.6“

Automation with Drive

gates and turnstiles, where the brake must disengage in the case of a power failure. Power-to-energise brakes are also used in process control often in failure.

Power-to-energise brakes are also used in process control often in For more information visit: conjunction with a clutch to http://www.dpaonthenet.net/article/177086/ give a stop-start action. conjunction with a clutch to give a stop-start action.

Concrete-Canvas-chooses-KEB-drives--controllers-and-HMIs-for-newClick to read the full article: http://www.dpaonthenet.net/ production-line.aspx Click to read the full article: http://www.dpaonthenet.net/ article/133837/Selecting-brakes.aspx article/133837/Selecting-brakes.aspx

www.keb.co.uk

-- combines control, visualisation and remote maintenance nance nance - combines combines control, control, visualisation visualisation and and remote remote maintenance maintenance nance nance nance in one unit nance in in one one unit unit KEB (UK) Ltd. 5 Morris Close Park Farm Industrial Estate Wellingborough NN8 6XF Tel: 01933 402220 info@keb.co.uk EtherCAT-Master Automation with Drive www.keb.co.uk EtherCAT-Master Automation with Drive www.keb.co.uk brakes 0KW. Selecting Selecting brakes

EtherCAT-Master Automation with Drive www.keb.co.uk Automation with Drive www.keb.co.uk Selecting brakes Automation with Drive www.keb.co.uk standardised process control, programmable with motion nn Automation with Drive www.keb.co.uk standardised process control, programmable with motion standardised programmable with motionNN8 you need toLtd. KEB KEB (UK) 55process Morris Close Park Farm Industrial Estate Wellingborough nnn Safety IfIf you need KEB (UK) (UK) Ltd. Ltd. 55 Morris Morris Close Close Park Park Farm Farm Industrial Industrial Estate Estate Wellingborough Wellingborough NN8 NN8 6XF 6XF KEB (UK)to Ltd. I/O Morris Closecontrol, Park Farm Industrial Estate Wellingborough NN8 6XF 6XF Ifhold you need to control and handling according to IEC IEC 61131-3 KEB (UK) Ltd. 5 Morris Closeinfo@keb.co.uk Park Farm Industrial Estate Wellingborough NN8 6XF (UK) Ltd. 55 Morris Close Park Farm Industrial Estate Wellingborough NN8 6XF aaKEB load, you n and I/O handling according to 61131-3 KEB (UK) Ltd. Morris Close Park Farm Industrial Estate Wellingborough NN8 6XF Tel: 01933 402220 E-Mail: Tel: 01933 402220 E-Mail: info@keb.co.uk holdcontrol load, you KEB (UK) Ltd. 5 Morris Close Park Farm Industrial Estate Wellingborough NN8 6XF Tel: 01933 402220 E-Mail: info@keb.co.uk Tel: 01933 402220 E-Mail: info@keb.co.uk control and I/O handling according to IEC 61131-3 hold aaKEB load, you (UK) Ltd. 5 Morris Close Park Farm Industrial Estate Wellingborough NN8 6XF Tel: 01933 402220 E-Mail: info@keb.co.uk Tel: 01933 402220 E-Mail: info@keb.co.uk need brake.

01933 402220 E-Mail: need aTel: brake.

01933 402220 STO-PLe/SIL3, E-Mail: info@keb.co.uk info@keb.co.uk Integrated functions SS1, SS2, SOS, SLS, SLP, need aTel: brake.

The is Tel: info@keb.co.uk The question question is402220 KEB01933 (UK) Ltd. 5E-Mail: Morris Close Park Farm Industrial Estate Wellingborough NN8 6XF Tel: 01933 402220 info@keb.co.uk The question is which type of

availability online SLI, SDI, SSM, SAR, SEL, SLA, SMS, SSR which type of availability online 90KW. which type of

Automation with Drive

www.keb.co.uk

General feature: Electrical engineering

Electrical engineering at WAGO

W

AGO Kontakttechnik GmbH is a well-known supplier in the automation world. The WAGO product range has been developed to meet the growing demand for electrical connection and automation technology in switchgear construction and building automation. In addition to terminal blocks, the company’s product catalogue includes transmitters, power supplies, controls and I/O systems. WAGO also provides 3D and electrotechnical data for all its components.

Eliminate routine tasks to improve efficiency WAGO uses the various tools available within WSCAD SUITE for the electrical design needed to extend and enhance its manufacturing machines. It achieves considerable time-savings when generating

schematic

diagrams.

Using

drag and drop, the process of inserting sub-circuits and even entire layout pages into the electrical design is simplified.

With efficiency and productivity in mind,

maintain its manufacturing facilities and

Replacing a component in one schemat-

WAGO decided to use the WSCAD

to manage a wide range of customer pro-

ic diagram is immediately completed in

SUITE electrical CAD solution for the

jects. WAGO has also used the WSCAD

all other plans, saving time and improving

design and maintenance of its in-house

SUITE software for internal training and

quality.

manufacturing facilities. It was also used

the design of pneumatic and hydraulic

to manage the Minden site’s entire elec-

plans. With the additional capabilities of-

This reflects the clear strategy behind

trical installation. The decision was made

fered by the Building Automation (BA) and

the WSCAD SUITE: as the electrical

because WSCAD SUITE covers six rel-

Electrical Installation (EI) modules, WAGO

engineer is relieved of repetitive routine

evant engineering disciplines: electrical

will be able to expand further by building

tasks, they have more time for creative

engineering, control cabinet design, fluid

even more facilities in Minden.

tasks and handling engineering process-

power, piping and instrumentation, build-

es. Intelligent links between symbols

ing automation and electrical installation.

The company takes full advantage of

and components make it easy to identify

On top of this high functionality, the soft-

the common interface that links WSCAD

components in a control cabinet and dis-

ware is easy to use. This has enabled

SUITE with WAGO’s own Smart De-

play the schematics and all the relevant

WAGO to increase the skills portfolio of

signer package. Essentially, this makes

data – including the cable labelling and

its personnel who are using the WSCAD

WAGO both a WSCAD user and a part-

pin assignments or the current cabinet

software. The company uses WSCAD’s

ner, which also enables the company’s

structure. Having such comprehensive

Electrical Engineering (EE) and Cabinet

personnel to become extremely knowl-

information available reduces develop-

Engineering (CE) modules to design and

edgeable about the WSCAD system.

ment times and makes time-consuming

6 dpaonthenet.net

General feature: Electrical engineering manual design tasks or recurring routine

do not require additional licenses, unlike

work unnecessary.

other E-CAD solutions on the market.

“There is nothing difficult for the electri-

WSCAD SUITE delivers its photo-

cal engineer here, everything is straight-

realistic 3D views of control cabinet

forward thanks to the easy-to-use user

layouts based on high-quality 3D data in

interface,” explains Alexander Krahner,

standardised STEP format (available on

Administrator of CAE applications at

www.wscaduniverse.com or other CAD

WAGO.

libraries).

This simplicity is extremely important,

High-quality data

Fast and tailor-made solutions for a variety of requirements

because, very often, it isn’t the electri-

Having access to the best possible data

WSCAD SUITE users at WAGO benefit

cal engineer who works with the system

is by far the most important factor for

significantly from digitised and automat-

regularly, but rather the maintenance per-

WAGO across all its applications and

ed engineering and automation process-

sonnel. Their job is to enhance or convert

processes.

es. Being able to create error-free elec-

existing machines and systems and they

trical engineering schematics quickly and

lack the special expertise of an electrical

“Many WAGO products have a 2D and

with little effort puts WAGO ahead of the

CAD system. This is where one of the key

3D model as well as complete electri-

competition. For this reason, interfaces

strengths of the WSCAD SUITE solution

cal data and associated symbols,” says

to product lifecycle management (PLM)

comes into play.

Krahner. “Good data quality for every

and enterprise resource planning (ERP)

product and data consistency are of the

systems are incredibly important for elec-

A clear 3D overview ensures rapid control cabinet construction

greatest importance because all subse-

trical engineering, as are interfaces with

quent processes are based on this.”

applications from other suppliers of auto-

With details that drill down to a tenth of a

As an administrator for System & Project

closely with WSCAD SUITE experts from

millimetre, the 3D cabinet views on WS-

Engineering, Krahner is responsible for all

the very beginning, the data migration

CAD SUITE reveal the mounting location

in-house electrical CAD data. He designs

and importing of existing electrical sche-

of all control cabinet components. This

and implements the symbols stored with

matics has gone very smoothly.

minimises installation errors that could

a lot of additional information, takes care

occur early in the design stage. But that’s

of delivering all the commercial and tech-

“With WSCAD SUITE, we now have

not all. The WSCAD SUITE calculates

nical master data, configures routing

a powerful and efficient software that

and visualises the optimal wiring connec-

points for automatic connections and

covers the entire range of what we do,”

tion paths, the filling degree of the cable

maintains the specifications of all WA-

says Krahner. “So, now, we can manage

duct, cable lengths, wire types, bundles

GO’s products. He says, “DIN symbols

building automation, we can generate

and the associated cable colours. It also

are only available for a small number

electrical schematics, we can design

provides the correct labelling data for

of the components and current WAGO

our electrical installation plans in a uni-

printing. For the manufacturing of wires,

products sometimes require completely

form format, we can control fluid pow-

wire sets and cabinets (sheet metal), the

new symbols, which we are able to de-

er design (pneumatics and hydraulics),

WSCAD SUITE software can transfer all

sign and make available in line with the

and we have capabilities we never had

necessary data to NC machines, sup-

DIN system.” In this way, WAGO pro-

before when designing our control cab-

porting a wide range of manufacturers

vides complete and reliable data records

inets.”

and external service providers. These

which enable users to achieve their goals

functions are part of the software and

faster than was previously possible.

mated systems. Because WAGO worked

www.wscad.com

Save yourself the trouble.

Ask Hammond to modify any of our 5000+ standard enclosures ures for your next project.

Visit hammfg.com/mods, call 01256 812812 or mail sales@hammond-electronics.co.uk tronics.co.uk

Feature: Pressure-controlled liquid dispensing systems

Pressure-controlled liquid handling systems: A simple & cost-effective solution I

nfectious diseases are an ever-present threat to our society – as evidenced by the current coronavirus outbreak. Today’s laboratories are increasingly reliant on automated liquid handling systems rapidly to develop and produce new vaccines. These systems are also critical in the life sciences industry where advancements in genomics research are owed, in part, to automated liquid handling systems which are accelerating the discovery of safe and effective drugs.

and other small vessels is no easy feat be-

Factors that affect dose volume or mass

cause fluid properties and compositions

It is important to consider the following

vary widely. For example, viscosities can

factors when designing a pressure-based

be as thin as alcohol or as thick as honey.

system:

Fluids can be highly corrosive, acidic or

1. Flow resistance

Delivering liquid samples into microplates

basic. To complicate things further, these

The system’s flow rate is defined by the

fluid properties can change depending on

pressure, as well as the overall resist-

temperature, dispensing speed, and ap-

ance of the fluid path. This resistance

plied pressure. Additionally, dosing these

depends on the tube’s inner diameter

The advantages of automated liquid han-

costly – and sometimes highly reactive –

(ID), length, dispense valve geometry

dling systems are well known. They in-

liquids often requires elaborate cleaning

and fittings. The most important var-

crease throughput, drive efficiencies and

procedures between batches to minimise

iable affecting flow is the size of the

improve standards of accuracy in phar-

contamination, which further drives up

dispense tip, which directly affects the

maceutical and biotechnology processes.

costs and downtime.

velocity of liquids. Unlike pressure and

Figure 1: The components in a pressure-operated liquid dispensing system

However, these systems are a significant

time, which can be modified via soft-

investment for a laboratory. Furthermore,

Pressure-controlled liquid dispensing

ware, the right tip should be selected

they often come with a host of features

systems have unique design flexibility to

from the outset.

that are surplus the requirements of many

overcome these challenges. Mechanically

applications – and features that are not

simple, they require a minimum number

Smaller tips typically achieve the best

beneficial can only be a cost.

of components, as shown in Figure 1. A

velocity. For example, needle tips with

pressure regulator, paired with a safety

standard IDs ranging between 0.3 and

There is a more cost-effective alternative

valve, pressurises the reservoir containing

1mm work well for most aqueous flu-

in these situations: pressure-controlled

the liquid. This pressure then drives the

ids and dispense volumes from under

liquid dispensing systems. They provide a

liquid through the tubing and solenoid dis-

1 to 1,000µl or more. Special tips can

simple and quick way to dose nanolitre- to

pense valve. Finally, the nozzle dispenses

also be developed based on individual

millilitre-scale volumes of fluid with preci-

the liquid into the vessel via a needle tip

applications.

sion, reliability and scalability.

with a calibrated orifice.

8 dpaonthenet.net

Feature: Pressure-controlled liquid dispensing systems VAEM valve control module utilises user-friendly software to reduce the tip-totip variability to less than one percent in most cases.

Conclusion Improvements in the scale, speed and quality of pharmaceutical and biotechnology processes enabled by automat-

About the author:

ed liquid handling have helped to reduce

Paul Kendall, Industry Sector Manager – Lifetech

timescales and deliver faster results, while also making drug discovery more efficient.

Pressurised liquid dispensing systems can help optimise throughput in lab automation applications at a fraction of the cost of complex robotics.

Figure 2: The gravimetric results of a VTOE dosing head with a 0.6-mm ID dispense tip

For further reading, download the free To better control dosing speeds and

It’s best to avoid unnecessary heat

Festo whitepaper: http://www.festo.

pressure at the tip, the system’s up-

generation and very short open times,

co.uk/controlunderpressurewp

stream components must achieve

which affect dispense performance.

higher flows. Here, 2mm ID tubing and

Unfortunately, these two objectives can

For more information about Festo’s

valve and manifold internal passages

work against each other: smaller valves

range of automated solutions for labora-

over 1.5mm are recommended be-

generate less power but must remain

tory and medical applications, visit www.

cause these sizes work well with stand-

open for longer to pass the same vol-

festo.co.uk/liquidhandling

ard ranges of needles and disposable

ume as larger valves – and vice versa.

pipette tips.

However, using electronics, a larger

2. Pressure

Paul is an industrial engineer by trade and has been involved in business development within industrial automation for nearly 25 years. Today, he leads a strategic team to develop the GB market and is focused on delivering high-quality solutions into the market as well as helping customers develop a competitive advantage.

valve with a short, high-current pulse

Pressure has a significant effect on

can be opened, with the current re-

dosing volumes and helps control the

duced before the valve passes heat into

velocity of the fluid as it passes through

the system.

the dispense tip. It can be generated as nitrogen, or a compressor to pump

Scaling up: multi-head dispense systems

air into the closed liquid reservoir. Al-

One of the biggest benefits of pres-

though pressurised systems can cre-

sure-based dispense systems is their

ate safety issues, the pressure ranges

scalability. Individual dispense heads

found in automated dispense systems

can be combined easily to create mul-

are generally low – only 100-250 milli-

ti-channel dispense heads that handle

bars. Nevertheless, it is important to

different aliquot volumes, fluids and

have safety measures in place that can

pressures. Fluids with different classes

relieve the pressure in case of a leak or

can even be dispensed by mounting

other technical failure.

multi-channel dispense heads on an

by using an external gas source, such

3. Dispense time

electric axis – creating a gantry system.

The dispense quantities are controlled by solenoid valve controls, with the vol-

When it comes to multi-channel sys-

ume of fluid dispensed primarily influ-

tems, however, small differences among

enced by the valve’s cycle time. Valves

the inlets, valves and nozzles can cause

with short, highly repeatable response

some channels to dispense higher

times offer much better dispense pre-

volumes than others. At resolutions

cision at higher speeds. Note that sole-

of 1ms or higher, it is difficult to com-

noids generate energy when open, and

pensate for these small variations using

their performance often changes as

the processor controlling the solenoid

they warm up. Operating a higher-flow

dose time. It’s better to calibrate the

valve for shorter durations reduces this

separate channels by varying the pull-

heat but requires a valve with excellent

in and hold-in solenoid current so that

repeatability.

all channels dispense the same quantity using the same dispense times. Festo’s

Festo VTOE pre-assembled dispense heads consist of a manifold, 2/2 valve, dispenser nozzle and tubing connector.

Up to 12 dispense heads can be mounted on a single rail

dpaonthenet.net 9

Feature: Thermal imaging

Factors to consider when specifying a thermal imaging camera for COVID-19 fever screening C

OVID-19 has created a worldwide demand for infrared cameras that can screen humans for a fever condition. Glenn Wedgbrow, Business Development Manager at MicroEpsilon UK, asks: but how can you be sure the camera you choose does the job it’s supposed to do?

A key part of any automated fever screen-

are coming from healthy individuals, the

ing system is an infrared (thermal imaging)

exceptions with an elevated body tem-

camera. This should be easy to integrate

perature can be detected.

into a fever screening system, which can then be used in real time at point-of-en-

In individual fever screenings, which are

try into establishments such as factories,

primarily used at security gates and con-

offices and public buildings to prevent

trolled entrances, the IR camera is used to

people with elevated body temperatures

measure people one at a time. The medial

from entering.

canthus (tear duct) provides the strongest correlation between outside skin temper-

The basis for the effectiveness of thermal

ature and core body temperature and is

imaging cameras as fever screening tools

measured more precisely from a close

Many businesses are considering appro-

lies in the correlation between outside

distance. The tear duct is a “hot spot” that

priate fever screening systems to protect

skin surface temperature and the inter-

is ideally suited as a measurement point.

their most important assets – their people.

nal or core body temperature. There are

This measuring range has a diameter of

Now that staff and employees are increas-

two main approaches to fever screening:

approx. 3-4mm.

ingly returning to work, companies must

crowd-based and individual. In crowd-

ensure the health of returning workers is

based fever screening, the IR camera

not put at risk by workers who may have

monitors a crowd of people at once or

Absolute temperature measurement accuracy

become infected outside the company.

sequentially. If the majority of the meas-

With numerous IR camera suppliers out

ured maximum head temperature values

there, it is important to select a camera

10 dpaonthenet.net

Feature: Thermal imaging that is fit for purpose, reliable and accu-

portant. For differential thermography

4. Vascular dilatation can occur after al-

rate for your specific application.

methods, measure tear duct temper-

cohol consumption, increasing skin

atures of test subjects and set alarms

temperatures.

Most IR cameras with a spectral re-

for 1-2°C above the average temper-

5. High blood pressure, pregnancy and

sponse of 8-14µm are specified with

ature, ensuring you adjust if ambient

other physical conditions can also re-

an accuracy of ± 2°C or two percent of

temperature changes.

sult in increased skin temperature.

the measurement reading, whichever is

7. Camera software should have a visual

6. Influences from extremes in ambient

greater based on deployments in indus-

or audible alarm when the tempera-

temperature, such as a long walk through

trial environments with a wide variety of

ture inside the area tool exceeds a set

a cold car park, will impact measure-

ambient conditions, from 0°C to +50°C.

threshold. You should set your alarm

ments – possibly masking a fever and

threshold based on the degree of sen-

reporting a false negative reading.

Many IR cameras are being promoted

sitivity to false negatives and positives.

today with accuracies of ± 0.5°C or bet-

8. Eyewear and sunglasses are opaque in

ter. However, these accuracies cannot be

the 8-14µm infrared spectral range so

Most IR camera technology systems

achieved without the use of a black body

should be removed before the individ-

were designed for versatile fields of appli-

reference source. The source needs to

ual screening.

cation and can be used effectively in EBT

have high emissivity, be stable and po-

Limitations of IR cameras

(Elevated Body Temperature) screening applications. However, it is vital to know

By doing this, camera uncertainties re-

Influences of external skin temperature

sulting from device adjustment, ambient

Temperatures on the outside of the body

IR cameras available on the market can

temperature drift and short-term stability

– even at the tear duct – will not match

reliably detect the coronavirus but they

can be reduced and a system accuracy

the core body temperatures taken by a

can provide a reliable indication of ele-

of ± 0.5°C (with a confidence interval of

traditional oral thermometer. During fever

vated body temperature and possible

95 percent or better) can be achieved.

screening, several factors can influence

illness. Subsequently, a doctor can de-

the external temperature of the skin:

termine whether a person with elevated

An IR camera-based screening system

1. Medications will reduce the human

body temperature is infected. Therefore,

can detect humans with a fever by dis-

core and skin temperature and make

this technology is a great support tool

cerning which external face tempera-

it impossible for screening a fever con-

during this crisis to interrupt infection

tures are significantly higher than those

dition.

chains in advance.

sitioned near the person to be scanned.

in a given population exposed to similar ambient temperature conditions.

To achieve the best possible results, the following factors should be con-

Glenn has over 25 years’ experience in the engineering industry. Specialising in precision sensor measurement technologies, he delivers measurement solutions, including position, movement, temperature and colour inspection throughout the UK & Ireland. He liaises with design engineers and UK manufacturers in almost all industries from metal, rubber and plastics to automotive and aerospace.

2. The evaporative cooling effect from perspiration will decrease outside skin

For more information on the use of ther-

temperatures, particularly when a per-

mal imaging cameras for COVID-19

son is positioned below airflow vents.

screening, please call the Micro-Epsilon

3. Humans visibly perspiring will not de-

sidered:

liver temperature measurements that

1. Use a camera with a spatial resolution

are useful for fever screening with an IR

of 382 x 288 pixels or better and with a

the technology’s limitations. None of the

About the author:

camera or any remote infrared device.

sales department on 0151 355 6070 or email info@micro-epsilon.co.uk. www.micro-epsilon.co.uk

NETD of at least 80 mK. 2. Combine the camera with an external black body reference source. The accuracy of the measurement can be increased to ± 0.5°C. 3. Select the right optics. Check the Field of View (FOV) and Measurement Field of View (MFOV) which defines the smallest spot size that can be measured accurately.

4. Set the emissivity for temperature measurement on human tissue to 0.98.

5. Set the temperature span for maximum contrast on face temperatures (typically from 23°C to 40°C) and apply colour isotherms to highlight the hottest temperature on the human face.

6. The span and isotherm settings depend on ambient temperature variations, so the optimal setting is im-

dpaonthenet.net 11

Feature: Battery testing

Testing to ensure battery integrity L

ithium-ion (Li-ion) batteries are a reliable and cost-effective power source, helping to revolutionise technology development. Consumer and IoT (Internet of Things) electronic devices are becoming more compact with many power-hungry features – resulting in the battery pack also becoming smaller, but at the same time, requiring greater capacity.

Such devices are often carried in peo-

gers of transporting lithium batteries.

usage. The sample must not leak, vent,

ple’s pockets, increasing the potential

Manufacturers of lithium batteries (cells

disassemble, rupture or ignite. The eight

safety hazard and risk of personal injury.

and packs) have to meet stringent re-

tests evaluate samples for risks from

Batteries must, therefore, be tested at all

quirements.

electrical, mechanical and environmental

levels, including electrical, chemical, cor-

conditions, and are as follows:

rosion, mechanical, and abuse. These

The United Nations (UN) Manual of Tests

1. Altitude Simulation – simulates low-

include:

and Criteria contains test methods and

pressure air transport conditions. A

• Life cycle testing – verifies how long

procedures for the classification of dan-

sample is stored at a specified pres-

a battery lasts and demonstrates the

gerous goods, according to the provi-

sure and ambient temperature for at

quality of the battery. These tests in-

sions of the UN’s Recommendations on

clude life cycle testing, environmental

the Transport of Dangerous Goods, with

2. Thermal Test – tests battery and seal

least six hours.

cycle testing and calendar life testing.

Section 38.3 addressing the require-

integrities and electrical connections

• Abuse testing – simulates extreme en-

ments that apply to lithium cells and

at temperature extremes with quick

vironmental conditions and scenarios

batteries. The provisions are used as the

transitions. A sample is cycled 10

to test batteries beyond limits.

basis for transportation companies to

times through extended periods of ex-

• Performance testing – demonstrates

accept batteries and customs officials

posure to extreme hot and cold con-

the efficiency of batteries, such as

will check that the battery manufactur-

ditions, after which it is stored for 24

performance testing under various cli-

er’s self-declaration meets the require-

matic conditions.

ment of UN38.3.

• Environmental and durability testing

hours at ambient temperature.

3. Vibration Test – simulates vibration during transport, a sample is subject-

– shows the quality and reliability of

UN38.3 requires that lithium cells and bat-

ed to vibrations of varying amplitudes

a battery through testing vibration,

teries are subject to as many as eight sep-

over three hours in each of three mu-

shock, EMC, thermal cycling, corro-

arate tests. Five tests are mandatory and

tually perpendicular mounting posi-

sion, dust, salt and humidity.

apply to all cells and batteries, with three being dependent on whether a cell, battery

tions.

4. Shock Test – simulates cell and bat-

Testing to minimise air transport hazards

or a rechargeable battery is being tested.

There are also safety concerns when

Tests must be completed in a defined

testing device and subjected to three

battery inventories are transported, with

order, as this creates a method for age-

calibrated shocks of varying intensity

increased attention to the potential dan-

ing the battery to replicate its real lifetime

in both a positive and negative direc-

12 dpaonthenet.net

tery to impacts that may occur during transport. A sample is secured to a

Feature: Battery testing tion. The sample is placed in all three mounting positions for a total of 18

or over-charging. The vent allows the

rent. This is combined with two Field

safe release of gas.

Effect Transistor (FET) devices to control

• Positive Temperature Coefficient (PTC):

the charge and discharging. Also present

5. External Short Circuit – low imped-

PTCs act as both a current fuse and a

is a temperature-sensing device (ther-

ance short circuit at elevated temper-

thermal fuse so that, when excessive

mistor) designed to invoke protective

ature. A sample that has been heated

current is drawn, the resistance of

action via the control IC in the event of

to a specified temperature is subject-

the PTC grows, resulting in increased

an over-temperature scenario.

ed to a specified short circuit condi-

heat generation. The resistance of the

tion for at least one hour.

PTC is selected so that it trips at the

Technology evolution

pre-determined current.

The development of Li-ion technology

separate shocks.

6. Impact/Crush Test – applies to cells

About the author:

• Separator: When the separator reach-

has played a significant role in the pace

es its defined temperature (typically

of technology evolution, as today’s users

7. Overcharge Test – a sample is subject-

130ºC), the pores are blocked by the

demand that technology give them in-

ed to a charge current equal to twice

melting of the material, preventing

creased functionality with portability.

that of the manufacturer’s maximum

electric current to flow between the

recommended

only, the cell format determines crush or impact.

charge

electrodes. The separator is also

However, while the overall failure rate

current at ambient temperature for 24

continuous

sometimes known as a ‘shut-down

of lithium batteries in use is low, safety

hours.

separator’.

concerns still exist – particularly in con-

8. Forced Discharge Test - a sample is

• Thermal Fuse: Some prismatic batter-

nection with their transport in aircraft.

forced discharged at ambient temper-

ies have an additional feature, a ther-

UN38.3 details testing requirements that

ature at an initial current equal to the

mal fuse which limits the current under

are now applicable to all lithium cells and

maximum discharge current specified

fault conditions.

batteries. Manufacturers using lithium

by the manufacturer and for a calculated time interval.

Richard Poate is Senior Manager at TÜV SÜD, a global product testing and certification organisation.

batteries must account for these testing A protection circuit (PCM) is usually fit-

requirements in the design, manufacture

ted within the battery pack, consisting

and distribution of their products.

Unlike most other standards and reg-

of a custom-designed integrated circuit

ulations that relate to product testing,

that monitors the cell and prevents over-

UN38.3 requires that the test sequence

charge, over-discharge, and over-cur-

www.tuv-sud.co.uk

must be repeated from the start if any of the five mandatory test phases are non-compliant. Not only does the product need to be aged correctly, if you fix one problem, there is no assurance how that adaption will affect the results of the other tests within the test sequence.

So, the entire test process needs to go back to square one if a product fails any of the five mandatory test stages and the manufacturer will have to provide new samples, as well as pay for tests to be re-conducted. This not only costs extra, but it will also delay time to market for new products and could seriously impact a manufacturer’s profitability.

Design safety features Manufacturers of Li-ion and Li-ion polymer batteries include internal protection devices, as well as the protection circuits within the overall battery pack, to guard against excessive heat and pressure.

Typical protection devices include: • Vent Plate/Vent Tear Away Tab: Excessive build-up of pressure within battery cells is caused primarily by excessive abnormal heat generation

dpaonthenet.net 13

Feature: Solar race car

Accurate power analysis boosts solar race car’s range, speed and competitiveness T

he Yokogawa WT5000 Precision Power Analyser is being used

by Solar Team Twente, to maximise their chances of winning the ultimate challenge for solar-powered race cars, the biennial Bridgestone World Solar Challenge.

voltage or current. That means you need a really accurate and sensitive power measurement system.”

To achieve the accuracy and precision required, the team chose the Yokogawa

This young team comprised aerodynam-

sible but not so fast that the car’s battery

WT5000 for two crucial tasks. First, to

ic, electrical, mechanical and structural

runs out of power when it is not in bright

validate the accuracy of the ‘fuel gauge’,

engineers from the University of Twente

sunlight.

the car’s on-board sensor measuring the

and the Saxion University of Applied

battery’s state of charge. This system

Sciences in the Netherlands. Having first

There are four important electrical sys-

measures current flowing into the battery

taken part in 2005 and finishing ninth,

tems in a solar race car: the array of solar

(from the solar panels) and flowing out of

they were determined to win the 1864-

panels, the battery and its management

the battery (to the motor). By subtracting

mile (3000km) race from Darwin in the

system, the inverter (motor drive) which

output from input, it can calculate the re-

north of Australia to Adelaide in 2019.

converts the solar panels’ direct current

sidual charge in the battery. This required

output to a three-phase alternating cur-

extremely accurate, continuous meas-

To win the World Solar Challenge, a race

rent supplied to the motor, and the motor

urement of current flows. Secondly, to

car must generate as much solar energy

itself. The team was aiming for the electri-

measure the power output of the motor

as possible. It must then efficiently con-

cal power conversion circuits to surpass

system – including the inverter and the

vert the electricity it generates and deliv-

99 percent efficiency.

motor itself, at a range of power input

er it to the wheels. At the same time, it

values – to enable the team to refine the

must keep energy losses to a minimum:

“We were looking for that extra one per-

design and incrementally improve its ef-

race teams pay minute attention to aero-

cent efficiency to give us an edge over

ficiency. This called for extremely accu-

dynamic design to keep wind resistance

other race cars,” says Rob Kräwinkel,

rate power analysis at a high sampling

to a minimum. In the case of RED E, the

Team Electrical Engineer. “When you are

frequency.

name given to Solar Team Twente’s race

already at better than 95 percent efficien-

car, total wind resistance is the equiva-

cy, eliminating any remaining losses is

“With the WT5000, we also discovered

lent of a conventional car’s wing mirror.

hard to do. You have to be able to look

that the current sensors in the fuel-gauge

The driver must then race as fast as pos-

at a detailed level at tiny deviations in

circuit had an offset, which [was] making

Solar Team Twente (Image by Martina Ketelaar)

14 dpaonthenet.net

Feature: Solar race car the car’s state-of-charge measurements

demonstrated that our new inverter de-

aged when a very strong crosswind gust

inherently inaccurate,” Kräwinkel con-

sign outperformed the equivalent off-the-

forced the car off the road and down a

fesses. “By compensating for the offset,

shelf model by a significant margin.”

slope, where it rolled over. The winners’

we could confidently provide the driver

trophy, therefore, had to be handed to the

with a vital extra 1 or 2km of range from

Alas, the team must now wait until 2021

Belgian team, Agoria, who achieved an

the battery at a given speed.”

to see the culmination of their dream.

average (and slower) speed of 53.8mph.

With over half the race completed in The modular and extensible WT5000 is

2019, RED E was in the lead and on

It should be quite a race in 2021! To

an accurate precision power analyser

course to win, with an average speed

download the full case study click here.

with a specified measurement accuracy

of 55.7mph, when mother nature inter-

of ±0.03 percent. Measurement band-

vened. The car was irreparably dam-

width is 10MHz for voltage and 5MHz for current, and the maximum sampling rate of 10Msamples/s exceeds the data refresh rate required to validate RED E’s fuel gauge system. With the very best isolation, noise immunity and advanced filtering capabilities, WT5000 users can make simultaneous measurements on up to seven inputs and view them on its high-resolution 10.1” touchscreen.

“The WT5000 is a very nice instrument to use, it’s intuitive, and it’s easy to find your way around the controls,” states Rob. “It’s also easy to tweak the display so that it shows the measurement outputs you are interested in, like when it clearly

Yokogawa WT5000

https://www.yokogawa.com/uk/

Feature: EV batteries

Cutting-edge electric vehicle battery production using HepcoMotion’s V Guide Systems G

lobal concern for the environment continues to drive developments in green technology. This is particularly notable in the increase in demand for electric vehicles. As the uptake of electric vehicles (EVs) increased, the EV battery industry has needed to grow in tandem. The specific benefits of HepcoMotion’s V guide system have proved invaluable in satisfying the requirement for new production facilities and processes.

Vertical closed-loop track system

lel, with one above the other. A small

The compositions of EV batteries vary

an actuator, connects the lower and

depending on the type of electric vehi-

upper tracks. Not only is this system

cle, but generally, they are composed

space-saving but it also maintains the

of individual battery cells and modules

product in a single orientation.

length of track, vertically moved by

which come together to form a pack.

The battery for a BMW i3, for example,

With a vertical closed-loop track layout,

comprises 96 battery cells. Twelve cells

there is a small gap between the main

are combined into one module and

production line and the short length

eight modules come together to form

of track that connects the upper and

one pack. Therefore, the manufacture

lower tracks. It can be challenging for

of EV batteries requires many elements

many linear guidance systems to cope

to be combined, making it particularly

with gaps and provide the seamless

suited to long line manufacturing.

guidance required for the carriage to traverse. Hepco’s V guide systems can

HepcoMotion specialises in high quality

However, making a compact, space-

traverse joints or gaps, making them a

linear and circular solutions, and au-

saving system is high on the agenda.

popular choice in EVB applications.

tomation components. The top three

Production formats vary but all the

companies in Korea’s battery market –

key EV battery manufacturers use a

SK Innovation, LG Chemical and Sam-

vertical closed-loop track layout, which

Cutting-edge production by key Korean conglomerates

sung SDI – are investing heavily in the

optimises the space in a 3D capacity.

SK Innovation, South Korea’s leading

production of EV batteries worldwide

The footprint remains the same, but

oil and chemical company, has been

and HepcoMotion is supplying to all of

production can be doubled by having

mass-producing EV batteries since

them.

two production lines running in paral-

2012 and is set to increase its pro-

16 dpaonthenet.net

Feature: EV batteries duction capacity with expansions into

is simple and does not impinge too

Compliance

Europe and the US. Producing pouch

much on production time. The adjust-

A further reason why Hepco is often

type EV batteries for customers such

ment facility of the V bearings can be

favoured in this type of application is

as Volkswagen, SK Innovation is one

used to remove quickly any play that

due to its high compliance. Mounting

of the top battery suppliers for electric

has occurred. Moreover, they can be

to an uneven surface can be time-con-

vehicles. SK Innovation utilises 104

replaced individually, saving both time

suming and costly. The unique design

metres of Hepco’s core GV3 track, ar-

and money. A V guide system will not

of Hepco’s V bearing allows it to per-

ranged in a vertical closed-loop track

fail catastrophically, meaning exces-

form when mounted to un-machined

layout, 50 metres long and two me-

sive downtime and a complete system

or uneven surfaces. The GV3 twin

tres high. Well suited to long lengths,

change will be avoided.

bearing is constructed from two pieces

GV3 can be specified to any length,

and therefore allows a small amount of

supplied as butted sets to fulfil longer

Corrosion-resistant

compensation for deviation in mount-

length requirements such as this. GV3

The chemicals involved in the manu-

ing surface flatness. Ball rail systems

is a superior V-based linear motion

facture of EV batteries mean that cor-

cannot tolerate any deviation in mount-

range, designed to serve a diverse

rosion-resistant materials are often

ing flatness and require surfaces to be

range of automation and linear appli-

required. One of the key benefits of

machined before installation.

cations.

Hepco’s V guide systems is that stainless steel is a standard choice. Hepco’s

As electric vehicles continue to move

Typically operating at 1m/s with a 20kg

SL2 stainless steel linear guide is not

towards becoming a viable choice

payload, the movers travel around the

priced as a ‘special’ and is not subject

for mainstream drivers, the long-term

system via dynamic track sections that

to long lead times. Furthermore, Hep-

outlook on the electric vehicle battery

vertically align with adjacent tracks,

coMotion provides a range of stainless

market looks positive. With end-users

providing a sizeable flow process

steel and corrosion-resistant elements

including SK Innovation, LG Chem

through various stages of production.

that can be mixed and matched so

and Samsung SDI, Hepco’s V guide

SK Innovation uses Hepco’s six bear-

that the optimum combination of hy-

systems are a key production element

ing carriages, which can traverse gaps

giene, wear and performance can be

contributing to a cleaner, environmen-

as four bearings are always in con-

achieved.

tally friendly future.

gap – keeping the carriage parallel. A

HepcoMotion’s SL2 is a core com-

www.hepcomotion.com

centrally mounted linear motor unit in-

ponent in systems for South Korean

dependently moves the carriages, pro-

electronic component maker, Sam-

viding complex sequences of move-

sung SDI – the world’s largest supplier

ment for individual carriages.

of lithium-ion batteries. Two SL2s are

tact with the rail when traversing the

supplied as joined sets to fulfil the 20m LG Chem, a Korean chemical compa-

circuit. This application requires a con-

ny, also uses Hepco’s GV3 linear guide

sistent level of precision to ensure SL2

in its automated system that produc-

carriages that carry the product are

es EV battery film. Again, a vertical

aligned correctly to production equip-

closed-loop system is employed and

ment and processes. Operating at 2m/s

the GV3 linear guides are supplied as

with an 80N payload, this is a high-duty

butted sets to fulfil the 20m circuit.

application.

With a variety of configurations ideally suited to EV battery manufacture – in-

Adaptable

cluding singe-edged slides, six bearing

Flexibility is also a key factor in the pro-

carriages, and assembled carriages

duction of EV batteries as manufactures

with added top-plate – HepcoMotion

need to produce different batteries for

has a solution to meet practically any

each model car and, as such, the sys-

requirement.

tem needs to be able to accommodate different sizes quickly and efficiently. As

Low maintenance

the movers are individually controlled

One of the biggest challenges in the

with linear motor technology, the mov-

EV industry is producing the output to

ers can easily be programmed to suit

match the demand. Low maintenance

the different requirements of the various

is core to optimising production pro-

batteries. This can all be done with-

cesses as it means less manpower and

out having to re-configure the system,

downtime, which equates to significant

saving production time and thereby in-

cost-saving. When a Hepco V sys-

creasing product throughput.

tem shows sign of wear, the process

dpaonthenet.net 17

Feature: Pneumatic technology

Rethinking pneumatic technology for the factories of the future I

ndustry 4.0 needs intelligent systems and technologies with built-in sensing and communication. This requirement is creating a new spirit of innovation in the pneumatic sector.

managers to make informed decisions

seen as one of the fastest and most suit-

that can help increase uptime and availa-

able means of providing controlled move-

bility of assets in the pursuit of improved

ment on complex automated lines, a

Overall Equipment Effectiveness (OEE).

critical requirement for digitised manufacturing. Imagine, for instance, a multi-prod-

As manufacturing continues this rapid

uct assembly system utilising pneumatic

journey to digitalisation, one must won-

actuators for the use of controlled motion

der what will become of conventional

and/or force. These precise and reliable

Times are changing in the manufactur-

technologies that have been around for

components are typically powered by

ing sector – and fast. Widespread digi-

a long time. Take pneumatics, for exam-

clean-dry air, which is why the demand

talisation has helped usher in the era of

ple, which remains based on the age-old

for pneumatic automation equipment is

Industry 4.0, where automation and data

principle of controlling compressed air

expected to increase substantially in the

exchange combine to provide real-time

through tubes. Can this technology play

era of digital manufacturing.

insight into the performance of equip-

a central role in the flexible and smart

ment.

production lines of factories of the future?

Pneumatic system capability in the new era

In this brave new world, based on con-

The answer to this question is a resound-

This presents real opportunities for the

cepts such as the Industrial Internet of

ing ‘yes’, according to the findings of a

suppliers of pneumatic systems, as they

Things (IIoT), digital networks are key.

recent research study of discrete manu-

look to adapt to the need for the real-time

They provide the ‘eyes and ears’ of re-

facturers carried out by Parker Hannifin’s

processing of data. Many suppliers have

al-time data processing, enabling factory

Pneumatic Division. Pneumatics is still

adapted their products in line with Indus-

18 dpaonthenet.net

Feature: Pneumatic technology try 4.0, developing pneumatic systems

in this area, and many manufacturers are

to 6 Cv. This provides machine design-

that are equipped with cost-efficient

already shifting their plants in this direc-

ers with a new set of tools to ‘right-size’

sensors. These enable OEMs to monitor

tion. The use of IE and IO-Link network

their valve selection to ensure optimum

intelligently the real-time status, position-

nodes make simple and cost-effective

valve/actuator performance. In addition,

ing, velocity, condition and efficiency of

the control, safety and maintenance of

the new Safety Exhaust Valve uses sens-

the various components that make up

a range of different devices, machines,

ing technology to protect workers from

the modern automation line. These in-

systems and users – regardless of loca-

harm and potential machinery damage at

clude actuators, air-preparation units,

tion. Indeed, ensuring that key automa-

start-up. In terms of performance spec-

proportional devices, and smart direc-

tion components are IIoT-enabled in this

ification, the externally monitored safety

tional control valves.

manner is an excellent way for machine

valve ensures the ultra-reliable and rapid

builders to create white space opportu-

exhaust of trapped air from a machine via

At Parker, for instance, the entire product

nities for innovation in the factories of the

a redundant two-channel design in the

development cycle has been focused on

future.

event of a fault in the safety circuit or an

making simple devices smarter by en-

emergency e-stop situation.

suring that they can communicate easily

In terms of product development, Park-

with the rest of the network on the factory

er’s IE/IO-Link-enabled connectivity and

floor. In the past, a filter could have be-

networking solutions have meant that

Celebrating a new spirit of innovation

come clogged, causing possible down-

a range of new intelligent components

These new products and technologies

time while the system was checked and

have come to market. The CPS line of

demonstrate that Industry 4.0 is bringing

the filter changed. Now, however, the fil-

analog/digital sensors, for example, can

about significant change to the pneu-

ter element can communicate its status

provide end-users with the cycle time,

matics industry. As an already well-es-

directly to the cloud, sending a message

position feedback and overall health of

tablished and well-understood technol-

via the PLC when it needs to be changed.

an actuator. The sensor continuously de-

ogy, pneumatic technology lends itself

This ability to underpin intelligent mainte-

tects the position of the magnetic piston

to the advancement of the IIoT-enabled

nance proves that pneumatics can play

of the pneumatic actuator using a direct,

factory. In this increasingly digital manu-

a central role in advanced Industry 4.0

non-contact technology along the 32

facturing sphere, pneumatic systems will

methodologies, helping manufacturers to

to 256 mm detection length of the sen-

no doubt continue to see a trend towards

improve their operations.

sor. This transfer of positional data, via

the adaptation for real-time process data

analog outputs or IO-Link, upgrades the

through the incorporation of networked

Manufacturing will continue to adopt

functionality of the pneumatic cylinders

nodes and sensors.

smart products that offer traditional con-

by making them far more intelligent and,

trol functions along with actionable intel-

as a result, more versatile.

ligence. In the factory of the future, man-

About the author: Richard McDonnell is Product Sales Manager (Smart & IoT) for Parker Hannifin Pneumatics Division and has more than 25 years of experience working on the development and commercialisation of technical solutions for difficult manufacturing problems. He has led numerous market development teams that identified unmet customer needs within diverse fields such as agricultural machinery to factory automation applications.

That makes for an exciting time for pneumatic innovation and, as such, this tried

ufacturing personnel will become more

Meanwhile, the IO-link-enabled H-Uni-

and trusted technology will be around for

dependent on real-time operating sys-

versal solenoid valve manifold system is

a long time yet.

tems to enhance productivity and quality

a family of base-mounted valves availa-

control. End-users will be able to track

ble in five size ranges, with flow from 0.55

www.parker.com

uptime and the availability of the machines using more detailed datasets over time. The application of analytics to this pool of data – augmented by advanced concepts such as artificial intelligence, prognostics and machine learning – provides the potential to deliver significant ongoing cost-savings, as manufacturers strive to optimise fully their day-to-day operations.

How machine builders can future-proof their designs While the development of this kind of technology continues to progress, machine builders and their component suppliers need to make careful choices now to future-proof their designs. Parker firmly believes that low-cost, open-source Industrial Ethernet (IE)-based shop-floor connectivity will provide the best solution

dpaonthenet.net 19

Feature: Tubular linear motors

Where tubular linear motors blow away pneumatics

reliable level of pressure must be maintained, or pneumatics will work poorly or not at all.

Air leaks can be expensive. According to Kaeser Compressors, a leading compressor technology company, one leak in one unit costing 15 cents/kW/hr to operate will represent well over $2,000 a year to

F

or factory operators looking to save energy and costs, an obvious first place to look is compressed air. Compressed air is highly useful in many industrial applications, and some sites spend up to 30 percent of their electricity bill generating compressed air.

a power bill. With a single point of failure – for example, air leakage at one location – the air pressure of the whole plant will drop, and operations will be affected.

Then there is the noise “If you are working in or visiting a factory,

Pneumatic actuators, which run on com-

their penalties. Compressed air must be

you will usually hear a lot of noise – that’s

pressed air, have been around since the

generated to power them. Depending

one big advantage servo-controlled lin-

Second World War. They are well under-

on the expansiveness of a factory, this

ear motors have [over] pneumatics,”

stood, cheap and suited to harsh envi-

can mean numerous compressors and/

explains Heng Luo, Product Manager,

ronments. However, they also come with

or a complicated reticulation system. A

ANCA Motion.

20 dpaonthenet.net

Feature: Tubular linear motors Linear motors – for example, screw-driven and tubular linear kinds – are newer than pneumatic or hydraulic options but are preferred for

Webinar showcase

Virtual visits

certain applications. Instead of a piston in a cylinder, driven by compressed air or incompressible fluid, tubular linear motors use magnetic flux to create motion. They are not as cheap in upfront costs compared to pneumatics, but offer vast benefits in accuracy, cheaper operating costs, and flexibility.

Pneumatics can move quickly and forcefully from one point to another (and hydraulics more quickly and forcefully still, for the same size) but with little positional control along the stroke.

ANCA Motion’s LinX M-Series offers 10-micrometre resolution, as well as a velocity of up to 10 metres per second and maximum acceleration over 30G. The M-Series comes with an integrated position sensor with precise positional control. It can also achieve a continuous force of 90160 newtons and a peak force of 1,200 newtons. With the form factor and mounting design, the M-Series is a neat substitute for pneumatic cylinders and the estimated payback period is only 18 months.

Another area of obvious advantage over pneumatics is the ease of reprogramming between jobs. A recent application for a customer’s forming machine substituted pneumatics for LinX motors to move a cutting bed. Changes for different workpiece lengths could take six to eight hours for the painstaking recalibration of air pressure. Such adjustments are now a quick change in servo drive parameters – a matter of seconds. The improved positional control has boosted throughput

As an automation solution provider, Beckhoff Automation’s Virtual visits will cover every aspect of their product range, from industrial PCs to TwinCAT and motion control.

Taking place every Wednesday at 2pm, the webinars aim to provide engineers, technicians and industrial managers with practical information on key automation technologies and issues.

Previous session recordings on topics such as EtherCAT Diagnostics, Servo Drive configuration and tuning and the newly released TwinCAT Vision are available on the UK blog page. From the blog, you can also log in to the live Wednesday sessions and ask the experts any questions you have on the topics in an informal setting.

For more information visit www.beckhoffblog.co.uk/events

by 50 percent, with the massively improved precision allowing the process to be confidently sped up.

ANCA Motion’s linear motors were originally developed for sister company ANCA CNC Machines’ FX Linear and MX Linear tool and cutter

Machine safety standards are changing

grinder machines. ANCA is a leader in CNC tool grinding technology. The M-Series has been developed within a culture of world-class engineering, developing machine tools where micron-level precision is essential. Furthermore, the LinX M-Series Tubular Linear Motor has a failure rate of less than 0.03 percent.

Robust support is offered through an international network of 125 engineers in strategic locations.

Visit ANCA Motion’s website (https://motion.anca.com/) to learn more about the LinX M-Series.

What does it mean for you? Both ISO 13849-1 & IEC 62061 are being revised and we can help you get ready. Phoenix Contact invite you to join our online seminar on 20th August at 11am.

Get an insight into new the machinery standards that will begin to come into effect later this year and learn how these significant changes will affect how cyber security is managed in relation to machinery safety. Other changes focus on requirements for safety software and risk assessments.

We will be hosting an online discussion on this subject with Carsten Gregorious from Phoenix Contact Germany. Carsten is a TUEV Expert with over 25 years’ experience in machinery safety and functional safety as well as being an active member of several standardisation committees such as EN ISO 13849 & IEC 62061.

Visit our website to register your place: https://bit.ly/2C5yDBX

dpaonthenet.net 21

Feature: Disc springs

Fully automatic handling and testing of disc springs A

spring manufacturer recently commissioned servo press and automation specialist, IEF-Werner GmbH, to develop a complete solution that involves the fully automatic testing of punched disc springs for characteristic values. The result is a system that consists almost entirely of IEF’s own automation components and runs reliably at high cycle rates around the clock. Solutions from IEF-Werner are available in the UK from value-added reseller, RARUK Automation.

tomer requirements and regardless of

metal at high cycle rates and fed into the

complexity.

IEF-Werner system according to type.

There, the springs are transported via a

“In many projects, we’re on board from

conveyor system to a spiral bowl convey-

initial contact to final commissioning,”

or which separates them accordingly.

says Frank Neugart, Product Manager for Servo Presses at IEF-Werner. This strat-

“For the pick and place mechanism, we

egy proved no different when a request

developed a vacuum gripper that picks

arrived to provide a completely automat-

up disc springs from the separation

ed solution for the testing of disc springs.

area,” explains Mr Neugart. “Springs are handled gently by the vacuum solution

Once the initial concept and design had

without imparting any additional force.”

been agreed upon, the test system was set up at IEF-Werner’s technical centre in

The gripper places disc springs back on

Furtwangen, where the implementation

the conveyor system, for which IEF-Wer-

process began in close co-operation with

ner specified its euroLINE 120 linear

the customer.

direct-drive unit with four independent carriages that serve as pushers. The euro-

Show of strength

LINE 120 acts as an axis for transporting

Every machine and device is born from

One of the principal challenges in manu-

disc springs to the subsequent stations.

an idea. In the development process, this

facturing disc springs is that the charac-

Notably, several slides on the euroLINE

idea takes shape and finally becomes a

teristics (e.g. strength) of each spring can

120 can be moved independently of each

production-line reality. The engineers at

differ greatly, which means that testing

other, which means that several springs

IEF-Werner GmbH adopt this ethos for

is crucial. On the customer’s production

can be fed and discharged simultane-

every project, in line with specific cus-

line, disc springs are punched from sheet

ously in subsequent stations.

22 dpaonthenet.net

Feature: Disc springs Pressed into shape As springs are often deformed after punching, they must be pressed into shape before testing. Thus, when disc springs arrive at the testing system, a slide

Virtual fair showcase

Welcome to the NEW Weidmuller virtual fair

pushes and positions them under a servo press from IEF-Werner’s aiPRESS series. This press loads the spring with the force required to bring it into a defined shape.

Next, the second slide pushes two components in a double cycle to two further servo presses of the same series. These test presses conduct a defined measuring load between 16 and 32N, and then measure the height. Once complete, parameters are switched over to measure the test force (200 to 7,000N), depending on the previously captured height dimension.

IEF-Werner servo presses are ideally suited to this application because the drivetrain consists of a servo spindle with a matching servo drive integrated into a solid and torsion-resistant steel C-frame. Importantly, the system includes a direct optical-path measuring system on the press ram to avoid positioning errors.

In order to monitor the process and display the progress graphically, IEF-Werner has equipped its servo press series with the intelligent aiQ-CONTROL force-path monitoring system. Also integrated is aiLIGHT: energy-efficient, four-colour LED technology that signals system status to plant operators. An industrial PC from Beckhoff communicates with a higher-level controller using the OPC-UA interface. Warning and fault messages with the message number or time stamp are stored.

Visit Weidmuller’s new virtual fair stand with up-to-date information on their range of products and services. The entrance is free for all and you can visit at your convenience as it is open 24 hours a day 365 days of the year. Simply register just as you would be in a normal exhibition and a verification link will be sent to your email (remember to also check your junk mail folder). The system is optimised for the following web browsers: Google Chrome, Microsoft Edge, Mozilla Firefox.

Areas on the stand include: • Smart factory • Smart floor • Shop Floor – Panel Building for the Future • Seamless Connections and Interfaces • Product Innovations

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Measured values are transmitted to a QS system through a so-called Q-DAS interface. Parts are 100 percent checked, with results stored in random samples.

Sorting good from bad In the case of bad parts, the machine distinguishes between rejects and disc springs that can be reworked. Springs exhibiting the correct measured values

EPLAN hosting virtual fair on digitalisation and automation

are transported by an IEF-Werner MINITRANS flat belt for further processing.

“With a few exceptions, all of the components come from our company, even the motors and encoder cables,” reports Neugart. “The customer not only gets a servo press, but a complete process based entirely on our know-how. We relieve the client of any responsibility.”

IEF-Werner has also trained customer personnel and, according to the maintenance contract, comes twice a year to clean, check and (if necessary) calibrate the system. Today, the machine runs across three shifts, seven days a week. www.rarukautomation.com https://www.ief.de/en/

EPLAN will be hosting its fifth Virtual Fair on 15th September which focuses on cutting-edge trends for digitalisation and automation, with sixteen hours of live presentations, demonstrations, management discussions and customer presentations all part of the day’s multifaceted programme.

Attendees can expect fascinating presentations with live discussions on how EPLAN’s cloud solutions improve collaboration within industrial automation.

Register here: https://www.eplan.co.uk/company/ events/view/eplan-virtual-fair-2020/

dpaonthenet.net 23

Feature: Simulation and digital twins

MapleSim is a highly efficient simulation tool used to create detailed models of machine components

Faster to a finished machine

M

anufacturing OEMs are faced with the challenge of building increasingly customised, specialised machines – and getting them up and running as fast as possible. With no time to spend wrapped up in testing, how can they get their machines to market faster? The answer: using simulation and digital twin technology.

A digital twin is an exact digital duplicate of a real machine. It behaves and functions exactly like its sibling, eliminating the need to build hardware prototypes as the machine is being developed. The real, physical machine is not built until everything is functioning smoothly in virtual form, performing just as the cus-

We’ve all been there – you get to the end

– neither the machine builder (who would

tomer imagined it. This saves time and

of a long and frustrating project only to

have developed an entire machine for

money.

discover it doesn’t meet the specified

free, so to speak) nor the machine opera-

requirements or work the way it was in-

tor (who would be unable to start produc-

Digitising an idea

tended. Suddenly, you’re back to the

tion until a new machine was built).

Depending on the task at hand, there are

drawing board. These situations are par-

a variety of simulation tools available.

ticularly devastating when you’ve just

Digital machine testing

B&R makes full use of all the possibilities:

spent months and months building a very

To avoid ending up in this dead-end street,

“The scope of simulation tools we’ve built

complex, very expensive machine. If de-

machine builders rely on simulation. Differ-

into our systems covers the entire devel-

velopers were, instead, able to test a virtu-

ent simulation tools can be used to create

opment process from start to finish,” says

al version of the machine in advance, they

digital twins of individual mechanisms, en-

Zehetleitner.

could identify potential errors and correct

tire machines or even complex plants, and

them before the machine was ever built.

use them to test all sorts of different man-

In the earliest phase of development,

ufacturing processes. “A good idea is only

the focus is on individual functions and

When a customer orders a new machine,

good if it actually works in practice,” says

mechanisms – the fundamental concepts

they want it to be up and performing as

Kurt Zehetleitner, head of B&R’s simula-

behind the machine. MapleSim is the ide-

expected as soon as possible. Nobody

tion and model-based development team.

al simulation tool for that. “We’ve had very

can afford to get to the unveiling of a

“Simulation and digital twins give you the

good experiences with MapleSim in this

finished machine, only to discover that it

tools you need to make good ideas work –

area,” says Zehetleitner. “It’s a very effi-

fails to deliver on the original requirements

quickly, easily and inexpensively.”

cient way to make very detailed models

24 dpaonthenet.net

Feature: Simulation and digital twins Sensor integration flow wrapping example

of machine components along with the torque and other forces that affect dimensioning.”

When the developer imports the CAD data for a mechanical part into MapleSim, all the information needed to create a digital model comes right along with it.

They can easily define which parts should be moveable without having to work directly with all the complex calculations themselves – that’s MapleSim’s speciality. Movement sequences and pivot points can be defined with a few clicks of the mouse.

The developer quickly and easily specifies exactly how the component will be

From MapleSim, they can export an FMU to transfer the model along with all the equations and CAD data to B&R’s Automation Studio engineering environment

able to move. All the forces that affect the machine are also simulated, so it’s easy

The developer tests the automation soft-

to test all sorts of load scenarios – even

ware for the digital model of the machine

New machine generation born from a digital twin

scenarios that would otherwise consume

directly on their laptop with no need for

A digital twin doesn’t stop being useful

time and resources or be unsafe. At a

real hardware. Once they are satisfied

once the machine is built and out the door.

glance, the developer can see whether

with the results of the simulation, they can

It can be used throughout commissioning

the machine can handle a given load.

transfer the software to the actual control-

and even later for online troubleshooting.

ler. Thanks to B&R Scene Viewer, they can

Software updates and potential solutions

Selecting components

view a 3D visualisation of the digital twin

can be tested first on the digital model –

Once the digital twin of the machine com-

as they test and optimise the solution’s

and only transferred to the real machine

ponent has been completely set up and

hardware and software components. An

once they’re working smoothly. Beyond

all movement profiles have been defined,

actual prototype is not built until every pro-

that, the digital twin and control software

the next step is to select the correspond-

cess in the machine is running smoothly.

continue to serve as a platform for ongo-

ing motors and drives. To do this, B&R

“B&R Scene Viewer also comes in handy

ing optimisation of the machine and de-

has coupled MapleSim with the SERVO-

throughout the development process for

velopment of future generations.

soft drive sizing tool. “All of B&R’s prod-

giving the customer periodic previews of

ucts are available in SERVOsoft. Once

how the machine will move when con-

it gets the information from MapleSim,

trolled by the machine software. This way,

the drive sizing tool recommends all the

the machine builder can be confident that

drives that would be suitable for the mod-

the final result will reflect the customer’s

el. Undersized or oversized automation

expectations,” says Zehetleitner.

www.br-automation.com/en/

About the author: Carola Schwankner, B&R

components are a thing of the past,” explains Zehetleitner.

Parallel development of hardware and software FMUs can be exported from MapleSim to transfer the model – along with all the equations and CAD data – to B&R’s Automation Studio engineering environment.

“You’re able to develop the software and hardware in parallel before any single part of the machine has actually been built,” says Zehetleitner. The data can be easily updated with any necessary adjustments.

Since all the systems are interconnected, the digital twin adapts along with it. This process not only saves a lot of time, but also reduces the cost of prototyping.

FMUs can be exported from MapleSim to transfer the model – along with all the equations and CAD data – to B&R’s Automation Studio engineering environment

dpaonthenet.net 25

Feature: Additive manufacturing

Automotive in the additive manufacturing lane T

he automotive industry is widely considered to be one of the pioneers of additive manufacturing (AM). Way back in 2018, BMW was already producing over 200,000 3D-printed car parts a year (a leap of 40 percent compared to the previous year).

In tooling, AM is even more prevalent.

today’s increasingly complex manufacturing and assembly lines moving.

Automotive tooling The global tooling market is estimated at $200bn – over half of which is attributable to the automotive industry.

Michelin 3D prints (in metal) over one

and, of course, cutting costs both in the

million siping tools a year for use in its

production line and in the supply chain.

tyre manufacturing line. The industry’s

The cost of tooling for OEMs alone (i.e. not including tooling used by their

adoption of AM is not surprising, as

The automotive 3D printing market is

suppliers) is estimated to be $550 per

the technology provides the solution

currently estimated at $1.4bn and is

car. Some of these tools are already

to OEMs’ biggest challenges: keeping

forecasted to grow to $9bn by 2025. A

additively manufactured but there is

a lid on production line downtime, in-

significant part of this market is attrib-

much more to come. The ability to 3D

creasing

possibilities,

utable to tooling – the jigs, gauges and

print jigs and fixtures onsite (or local-

reducing waste and carbon footprint,

fixtures that are so critical to keeping

ly) and on-demand can reduce tooling

customisation

costs considerably as well as cutting lead times from days, or even weeks, to hours. In addition to minimising production line downtime this way, AM also allows manufacturers to respond quickly to part failures by either redesigning or re-printing the part, as required. The reduced lead time gives the flexibility to accept and respond quickly to any changes needed to the production or assembly line. For example, Ford’s partnership with Trinckle is reported to have cut the time it takes to design a new jig from four to six hours to just 10 minutes.

This, together with onsite 3D printing,

26 dpaonthenet.net

Feature: Additive manufacturing means that in any failure or redesign event, Ford can get its production lines up and running in a matter of minutes, instead of hours or even days.

Repeatability and protecting digital assets Repeatability is a hallmark of manufacturing and assembly lines, especially

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in the automotive industry. Aside from envy-inducing, highly customised supercars like the Bugatti Chiron, most cars are mass-produced. This means that every car of a particular make and model must be identical, and so must the tooling that enables their production. Therefore, it is essential they are made in a way that is both consistent and repeatable.

However, while this sounds like a no-brainer, it is a challenge for AM – where parts are produced in small batches (or even batches of one), potentially in different factories or even in different countries. This makes it difficult to ensure that parts are always produced to the same specifications. Any variance in the 3D printer settings or other parts of the workflow can result in a faulty part or weak tooling that breaks and stops the assembly line. Therefore, with a digital inventory of AM-produced parts, jigs, or

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fixtures, repeatability is key – whether a file is printed once or a thousand times, in one location or dozens. This relies on securing AM blueprints and ensuring that parts or tooling are produced in exactly the same way with exactly the same settings, regardless of where or when the digital turns

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Keeping production moving At present, LEO Lane estimates that AM accounts for around $2bn of the tooling market

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across all industries. To increase this penetration, as well as AM use for end parts, manufacturers will have to maintain repeatability and consistency – and the good news is that there are Software-as-a-Service solutions that enable them to do exactly that! With so many reasons to expand the use of AM, there is no doubt that the innovative automotive industry will continue to find

About the author:

more ways to use secured AM technology to im-

Lee-Bath Nelson is Co-Founder and VP Business at LEO Lane.

prove the production of both end parts and tooling, without sacrificing quality or repeatability.

PROFINET to PROFIBUS Gateways: For people responsible for the design, commissioning and support of PROFINET networks, explaining how to integrate existing PROFIBUS DP and PROFIBUS PA devices.

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dpaonthenet.net 27

dpaonthenet.net 27

Feature: Factory simulation

A no-nonsense approach to adopting new digital tools F

or over 50 years, Genlab has designed and manufactured industrial and laboratory ovens, incubators, drying cabinets, water baths and other associated thermal products.

empower a highly skilled workforce with new information for rapid and better decision making.

Working closely with Genlab, the VEC

Genlab recognised the benefits of employ-

ing Centre worked with Genlab to evalu-

studied the existing floor plan and fac-

ing a variety of new technologies within the

ate how the highly skilled but traditional

tory machine layout, evaluating process

business but did not have the capacity or

approaches it employed could benefit

times at different workstations. Using

the specialist knowledge to explore how

from new digital technologies.

this high-level production data and lay-

new tools could support a push toward greater efficiency and innovation.

outs, the VEC created a full model facOpportunities for innovation included

tory simulation using specialist software,

utilising the Industrial Internet of Things

SIMIO. The results enabled Genlab to

It wanted to explore how the existing

(IIoT) for preventative maintenance, ex-

explore alternative layouts, helping them

factory layout and current processes

ploring improving connectivity of prod-

to understand which layout gained max-

could be optimised to improve efficien-

ucts, and exploring how the current fac-

imum efficiency.

cy and meet growing customer demand

tory layout and manufacturing process

for its products, without compromising

could be changed to improve productiv-

Benefits

its handcrafted approach or having to

ity. The business produces highly cus-

Using a virtual factory model allowed

make greater financial investments.

tomised products, with complex com-

Genlab to complete this task without

ponents and processes. The current

risk or interruption to daily operations, as

Partner support

processes are not highly automated and

well as allowing them to test a number of

Liverpool University’s Virtual Engineer-

the challenge was to look for methods to

solutions quickly and easily.

28 dpaonthenet.net

Feature: Factory simulation The factory simulation provided insight

visibility of work in progress. This will

into optimum staffing levels and demon-

allow it to optimise its operations with

strated how better to deploy staff to

supply chain partners, reducing lead

maximise throughput and predict the

times between the company and its

consequences of staffing shortages

customers.

throughout weekly production.

This approach paves the way for fuThe simulation also confirmed that a

ture innovation by highlighting how and

change in the position and layout of just

where to collect further valuable data,

the store’s area could improve output

giving operational managers greater in-

by five percent per annum. The simula-

sight for improved production planning

“With the VEC’s support, Genlab is ex-

tion highlighted ways that Genlab could

and future changes to processes, to in-

cited to explore how Industrial IoT and

improve assembly time by 30 minutes,

crease productivity even further.

virtual prototyping can further help us

which increased capacity by 20 percent,

create a new generation of products

without any additional investment in

Phil Crompton, Finance Director at Gen-

and to better meet our automotive and

new tools or automation.

lab said: “Working with the VEC has in-

industrial clients’ demand.”

troduced the company to a no-nonsense

Working to the future

approach to adopting new digital tools

Genlab has identified a number of op-

as a means to improve productivity.

portunities for change within its existing factory layout. This allows it to remove

“Factory simulation has brought into fo-

any constraints and improve efficiency

cus and validated our ambitions to grow

and productivity levels, offering easi-

the business. We have explored new

er access to machinery and improved

possibilities without the risk that normal-

communication.

ly comes with change management by using virtual tools and identified the path

Based on the real-time quality data now

to a 20 percent increase in productivity

being collected, Genlab can improve the

using the factory simulation.

www.virtualengineeringcentre.com

About the author: Dr Andy Levers is Executive Director of the University of Liverpool’s Virtual Engineering Centre. With a strong industrial background in the aerospace sector, he sets the strategic and technical direction for the Virtual Engineering Centre (VEC) and Digital Innovation Facility (DIF) that sit within the University of Liverpool’s IDEAS (Institute of Digital Engineering and Autonomous Systems).

To advertise here contact Andrew Quenault on 01732 359990 or email andrew.quenault@imlgroup.co.uk

datafocus Increased demand for OKW’s CARRYTEC medical handheld enclosures

Gerromatic radial shaft seal minimises wear and maximises service life

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The Gerromatic radial shaft seal from Freudenberg Sealing Technologies comprises a stainless-steel retaining element and a high-performance PTFE wave-shaped sealing lip that runs in a novel sinusoidal pattern on the shaft surface. As the shaft rotates, each point of the sealing lip repeatedly covers a new area of the shaft that is wetted with medium. The Gerromatic radial shaft seal is available via Dichtomatik Ltd, the exclusive provider for Freudenberg’s food and beverage related sealing products in the UK.

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Robust CARRYTEC features an integrated handle with a comfortable soft-grip TPE insert. CARRYTEC’s large surface area can accommodate a large touchscreen or membrane keypad. There is ample depth for interfaces (which are protected by recessed areas on the underside).

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There are two standard colours: off-white (RAL 9002) and lava grey.

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dpaonthenet.net 29

Feature: Space & 3D printing

3D printing in space: What I learnt from my astronaut mission I

n December 2019, I embarked on a simulated astronaut mission in Hawai’i. The EMMIHS-II mission is a collaboration between the European Space Agency (ESA)-funded Euro Moon Mars Initiative (EMM), the International Lunar Exploration Working Group (ILEWG) and the International Moon Base Alliance (IMA). It took place at the renowned Hawai’i Space Exploration Analog and Simulation (HI-SEAS) habitat. For two weeks, our international crew of astronauts lived, worked and researched in this habitat just like astronauts on the moon.

approved extravehicular activities (EVA)

an extra-terrestrial destination, such as

while wearing spacesuits with integrated

the moon.

life support systems, and being restricted to eight minutes of shower time per week – all while conducting scientific experiments.

Replicating replacement parts, engineering tools, and a home away from home In the HI-SEAS habitat’s engineering

As a crew engineer, I was responsible

bay – in between spacesuits, life support

for fixing anything that broke in the hab-

systems and all kinds of technical tools –

itat and maintaining all technical equip-

METHOD found its temporary home on

ment. However, I also brought my own

the moon.

research to the base, including a collaborative project with MakerBot to investi-

The METHOD platform was tested and

gate how 3D printing could be used to

implemented as a tool for printing any

improve life on a moonbase. I decided

necessary replacement parts or miss-

to test the MakerBot METHOD 3D print-

ing appliances, such as drone propel-

er and its reliability on a space mission.

ler holders and tweezers. The need for

Our crew of six tested various opera-

propeller holders for the mission drone

tions, ranging from medical procedures

was an unexpected problem that was

In addition to being completely isolat-

to aspects of habitability and astronaut

efficiently solved in a few hours, thanks

ed from ‘Earth’, the simulation includ-

performance. The simulation was set in

to the availability of a 3D printer. Addi-

ed eating food made from freeze-dried

an isolated, confined and extreme envi-

tionally, the extruder camera made it

ingredients, leaving the habitat only on

ronment to recreate the harsh milieu of

possible for the team to monitor the

30 dpaonthenet.net

Feature: Space & 3D printing printer’s progress while working on other

important event of crew bonding. This

projects throughout the habitat.

break from scientific work and daily routines turned out to be a much-needed

On an actual space mission, the suc-

reprieve.

cess can hinge on the ability to solve pected situations. Even the failure of a

The challenges of printing in space

small, nondescript part can heavily im-

The HI-SEAS habitat lies at a high alti-

pact the situation, as receiving of a re-

tude of 2,500 metres. Printing at such

placement part would be completely de-

high altitudes required slight changes

pendent on a resupply mission launched

to the printer settings to ensure that the

from Earth. For a mission on the Moon,

objects would come out just as well as

this journey would take several days; on

they would in a standard environment.

Mars, it would take several months at

When I initially started printing with PLA,

best. With the possibility to design and

the prints came out warped or failed al-

print replacement parts, this dependen-

together. However, once I realised that

cy on resupply missions would be much

the issue was the altitude and I adjusted

improved.

the settings, the quality of the prints and

problems quickly and adapt to unex-

the reliability of the printer improved sigBeing able to 3D print objects on space

nificantly.

missions would also allow us flexibility in our solution-finding processes. Sit-

Additive manufacturing technology has

uations and conditions on a space or

been proven to be an important addition

analogue mission always vary to some

to space missions. It not only plays a

extent from what was expected during

big role in the design of future extra-ter-

the planning process. This can have a

restrial habitats, but the benefits of 3D

big impact on envisaged scientific ex-

printing have been successfully tested

periments or even make it impossible to

on the International Space Station (ISS).

conduct them. Having direct access to

ration, as they greatly contribute to the

a 3D printer would allow the crew to re-

astronauts’ mental health and psycho-

The ability to manufacture part of the

design and manufacture tools adapted

social balance – and thus can improve

interior fittings on-site, for example, will

to the new situation with relatively little

the crew’s productivity.

greatly minimise the payloads and, thus,

effort.

the costs and environmental impacts Each of us printed a personal object

of space missions. In future scenarios,

The second part of the experiment was

for recreational or decorative purposes.

on-site manufacturing could potentially

trying to improve the human factors in-

Creating a sense of home and comfort

be an integral part of the habitat design

side the habitat. Human factors address

inside space habitats is an important

itself. Access to a 3D printer bears the

the interaction of humans with systems,

goal in space architectural designs.

potential of much greater flexibility and

equipment and facilities. In any space

Being able to recreate traditions from

variety across applications, from engi-

mission, humans must be able to per-

Earth, like Christmas or other seasonal

neering to personal objectives.

form safely in the given environment.

holidays, helps relieve feelings of home-

This can be challenging – particularly on

sickness. Furthermore, the common ac-

long missions – and is, therefore, a vital

tivity of selecting potential items was an

About the author: Sabrina Kerber is currently doing a master’s in architecture, with a specialisation in space architecture at VUT (Vienna University of Technology). Sabrina has collected valuable experience in the space sector at the United Nations Office for Outer Space Affairs (UNOOSA) and with the European Space Agency’s EuroMoonMars (EMM) Team and International Lunar Exploration Working Group (ILWEG). In 2019, Sabrina was part of a lunar simulation at the renowned HISEAS habitat, where she acted as crew engineer. As founder and CEO of Explaneta Space Solutions, Sabrina has been working on leveraging the benefits of additive manufacturing for extra-terrestrial habitation.

www.makerbot.com

part in mission design.

A 3D printer can help improve human factors on several levels. For example, the liveability inside an extra-terrestrial habitat can be greatly enhanced by the ability to manufacture objects adapted to personal habitability needs.

Astronauts can only bring very few personal items on a mission, in order to limit the payload that has to be sent into space. These items must be pre-selected on Earth. However, such objects are indispensable for manned space explo-

dpaonthenet.net 31

Feature: Aerospace manufacturing

Boom Supersonic uses Stratasys FDM equipment to produce dozens of prototypes, tools, simulator components, and parts for the XB-1

3D printing reaches new h in aerospace manufacturing T

he importance of additive manufacturing (3D printing) continues to be recognised within the aerospace industry. This is largely due to the highperformance aerospace-grade materials that possess the properties required to deliver in an array of application areas, together with inherent capabilities that drive other efficiencies across the manufacturing supply chain.

The relationship between the aerospace

been barriers to wider adoption in the past,

and additive manufacturing (AM) indus-

huge progress has been made in recent

tries is continually strengthening and

years in material development and spe-

evolving, with both sectors driven by inno-

cific solutions for aerospace. There are

vation and change. AM, using lightweight

now several aerospace-grade materials

materials, is able to produce complex ge-

that comply with the traceability standards

ometries not possible with conventional

outlined by regulatory agencies. For exam-

production methods, as well as offering

ple, Stratasys’ certification grade filament,

high levels of customisation. There-

based on ULTEM 9085 resin, is FST (flame,

fore, it caters to the needs of aerospace

smoke and toxicity) compliant, which is

manufacturers, who continually strive to

key to achieving Airbus material certifica-

achieve faster speeds and utilise complex

tion. Another example is Antero 800NA

part designs to increase efficiency.

material, which is based on the highly

Here, Scott Sevcik, VP Aerospace Busi-

chemical-resistant PEKK thermoplastic,

ness Segment at Stratasys, looks at some

While AM is still viewed as a relatively

making it appropriate for those parts of the

of the current trends and developments

young industry, both aerospace and air-

aircraft exposed to fuel or hydraulic fluid.

that highlight the technology’s ongoing

craft interior OEMs have been leveraging

ability to deliver opportunities for aero-

the most common additive manufacturing

Having materials that meet the required

space manufacturers and their suppliers.

technology, Fused Deposition Modeling

properties of in-flight applications is es-

(FDM), for the better part of 30 years for

sential, but production technologies also

prototyping. Fast forward a few decades

need to be trusted. Part of building this

and today, the portfolio of FDM materials

trust is demonstrating a level of repeata-

is expanding to meet the stringent require-

bility that can provide the basis for indus-

ments necessary to make interior aircraft

try standards. Repeatable performance

parts lightworthy. The level of repeatability

simplifies qualification and enables the

achievable by high-performance systems

development of process specifications

enables the production of parts with con-

that can be certified as easily as a more

sistent performance.

traditionally produced part. Developing these specifications in-house can be

Compressor Variable Bleed Valve Duct Adapter for BOOM Supersonic’s XB-1 test vehicle. 3D printed in Stratasys UTLEM 1010 resin

32 dpaonthenet.net

One of the greatest challenges faced by

time-consuming and expensive. Many

aerospace manufacturers looking to 3D

large companies will want to invest in

print flight-ready parts is certification.

their own specification development and

While this and material performance have

qualification process, which will support

Feature: Aerospace manufacturing To further increase accessibility, Stratasys

ogy within the production process. After

identified the need for product specifi-

all, every kilogram saved means a lighter

cation and qualification data available in

aircraft and more efficient fuel usage for

the public domain to meet the expected

their customers.

standards of the aerospace industry. For aircraft interiors, Stratasys has worked

These are just some of the developments

closely with America Makes, the US Air

that underscore the exciting turning point

Force, the National Institute of Aviation

that the industry is at right now. The tech-

Research, and the FAA to produce the Air-

nical maturity of FDM machines and mate-

craft Interior Solution (AIS). This package

rials is enabling aerospace manufacturers

provides customers with all the informa-

to move beyond prototyping and tooling

tion necessary to manufacture parts with

applications and into the production of

ULTEM 9085 resin that will perform with

certifiable production parts at a scale rap-

highly consistent results.

idly increasing year on year. Indeed, there are already tens of thousands of interior

heights

While certification is crucial, having the

aircraft parts flying today that have been

capacity to produce high-performance

produced using FDM.

thermoplastic parts that can be fully char-

also vital. If a lightweight 3D printed ther-

Delivering improved efficiencies across manufacturing and the supply chain

moplastic part can perform in the most

AM is already having a significant impact in

demanding and rigorous applications, like

cases where retrofitting or reducing man-

a traditionally manufactured counterpart

ufacturing lead times are a priority. When

would with its additive benefits of design

we look at the needs of the industry today,

production within their supply chain, but

freedom and supply chain flexibility, it’s

the benefits of AM are not just felt in proto-

many smaller companies won’t have the

easy to see why aircraft manufacturers

typing or concept vehicles, but in changing

means to take on this challenge.

are increasing their use of FDM technol-

the economics of part production.

acterised and trusted to have consistent mechanical and geometric properties is

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Feature: Aerospace manufacturing world’s first new commercial supersonic

rail separating classes onboard. Tradition-

aircraft since Concorde. Boom is utilis-

ally the enclosure was constructed using

ing AM to produce dozens of prototypes,

several layers of laminated fibreglass and

tools, simulator components and parts for

required specialised aluminium tooling.

the XB-1. The ability to print these items

Diehl was able to assemble this part from

on-site, rather than purchasing from a

12 3D printed thermoplastic components,

supplier, significantly accelerates the de-

drastically reducing the tooling costs and

velopment process.

saving hours of workforce time. This piece is the largest fully 3D printed passenger

Transforming the in-flight experience via on-demand customisation

aircraft part ever produced and is being

The flexibility of AM’s high-performance, low-volume manufacturing also allows

The future for AM and aerospace

the creation of complex shapes without

Having worked closely with aerospace

the geometric restrictions of tooling and

manufacturers across the industry, there’s

moulds. This allows for in-cabin applica-

no doubt that additive manufacturing can

tions that can differentiate customer ex-

open up many new applications to improve

Traditional inventory and part production

periences. As lower-volume production

efficiency, increase customisability and

can be time and cost-intensive, and what

becomes more economically viable, man-

transform supply chains with digital inven-

is frequently seen in the industry is stock-

ufacturers can create customised parts

tory and on-demand production. Constant

piling of 20 years’ worth of spares when a

that are intended for specific classes with-

progress is being made in this area to chal-

part goes out of mass production to avoid

in aircraft.

lenge the capabilities of more traditional

NASA’s Orion spacecraft leverages a variant of Stratasys’ Antero 800NA to build an intricately-connected 3D printed docking hatch door

the expenses of retrofitting. AM can lead

About the author: Scott Sevcik leads the team responsible for the adoption of additive manufacturing in the aerospace industry. Additionally, Sevcik represents Stratasys on the Board of Directors for Additive Flight Solutions Pte Ltd. Sevcik’s background, spans the aerospace industry, with roles in System Engineering and Integration at Lockheed Martin and Engineering and Program Management at United Technologies Aerospace Systems.

Products Scott has helped develop or deliver are flying on nearly every modern commercial and business aircraft, as well as in orbit. Scott holds an MBA and an MS in Aerospace Engineering from San Jose State University and a BS in Aerospace Engineering from Iowa State University.

line-fit into A350s.

manufacturing processes and materials.

to a much more efficient approach, with

For instance, customers can print their

Stratasys continues to drive developments

the digitisation of spare parts allowing

branding and logos on aircraft compo-

to bring thermoplastics closer to and be-

much greater flexibility for operators.

nents or integrate unique decorative fea-

yond the capabilities of traditional manu-

tures, giving each airline or aircraft per-

facturing.

When it comes to 3D printed parts, we can

sonality. We’ve previously seen this done

challenge the way we think about produc-

in some VIP private vehicles, but, now,

Despite these incredible advances and the

tion processes altogether. Rather than de-

this can be applied to commerical aircraft

technology continuing to push boundaries,

signers making decisions based around

cost-effectively. This personalisation can

Stratasys still sees organisations that are

complicated manufacturing processes

even benefit pilots: China Eastern Airlines

not ready to take advantage of AM. For

or the limitations of tooling that can have

printed a common mount for their elec-

the industry to continue to progress, paral-

supply chain ramifications 20 years later,

tronic flight bags so pilots can mount their

lel advances need to be made in terms of

AM parts can be designed optimally for

tablet the same way regardless of aircraft.

education, design and analysis software,

their end-use and result in a more efficient aftermarket at the same time.

standards, and materials. The result will be Some of these applications are quite com-

continued blue skies for 3D printing oppor-

plex. Diehl Aviation recently utilised FDM

tunities in aerospace.

For example, Boom Supersonic uses

technology to produce a curtain header

a variety of Stratasys FDM equipment,

– an enclosure that sits above the curtain

www.stratasys.com

including an F900 3D Printer with the Stratasys Aircraft Interiors Solution, for the design and production of its XB-1 test vehicle. The XB-1 is intended to lead the way to Overture, the

34 dpaonthenet.net

3D printed curtain comfort header – the world’s largest 3D printed part fitted within a commercial passenger aircraft, produced by Diehl Aviation using Stratasys’ aerospace-grade ULTEM 9085 resin material. (Photo courtesy of Diehl Aviation)

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