DPA_20_09

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

Going beyond IE5:

The gold standard in motor efficiency 08: Brainware

22: Cobot safety

Lenze in the UK: It’s all about the “Brainware”

Safety for robots in collaborative applications

Contents

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

Paige’s Page: 04: Editor’s comment Remembering William English, computer mouse co-creator

General Feature: Going beyond IE5:

The gold standard in motor efficiency

06: Remote working

08: Brainware

22: Cobot safety

Lenze in the UK: It’s all about the “Brainware”

Safety for robots in collaborative applications

Cover Story:

200717_9-2_Mill_DPA_UK_Snipe.indd 1

COVID-19 – An agent for change?

08: Brainware 7/16/20 10:39 AM

Atlas Copco Compressors examines IE5 and how it has been exceeded by the company’s own motor for air compressors. p.10

Lenze in the UK: It’s all about the “Brainware”

Special Report:

Group Editor: Paige West paige.west@imlgroup.co.uk

10: Compressor drive motors

Assistant Editor: Sophia Bell sophia.bell@imlgroup.co.uk

12: Motor control systems

Publisher: Andrew Quenault andrew.quenault@imlgroup.co.uk

16: AMCs

Production: Holly Reed holly.reed@imlgroup.co.uk

18: Angle sensors

Design: Graham Rich Design www.grahamrichdesign.co.uk Head Office: IML Group, Blair House, 184/186 High Street, Tonbridge, Kent TN9 1BQ Tel: 01732 359990 E-mail: dpa@imlgroup.co.uk DPA ISSN 0965-4747 Copyright in the contents of Design Products & Applications, its websites and newsletters is the property of the publisher. The publisher and the sponsors of this magazine are not responsible for the results of any actions or omissions taken on the basis of information in this publication. In particular, no liability can be accepted in result of any claim based on or in relation to material provided for inclusion.

Design Products & Applications is a controlled circulation journal, published monthly. Completed print or online registration forms will be considered for free supply of printed issues, website access and online services. Annual subscription for non-qualifying readers is UK £121, EU £215.25, Airmail £315 and single copy price is £18.60 monthly.

12

Motors & Motor Control

(Cover image: Shutterstock)

The ‘gold’ standard in compressor electric motor efficiency

Optical encoder feedback system for miniature motor-driven applications

Designs on electric hybrid cars: the benefits of AMCs

Choosing angle sensors for power steering, motors and robotics

Machine Building & Safety Special Report: 22: Cobot safety Safety for robots in collaborative applications

30

24: Machine safety The big picture

26: Battery systems Maximising safety in advanced battery systems

Fasteners & Adhesives Technology Focus: 28: Medical fasteners An increase in fastener demand during COVID-19

30: Two-part adhesives Tips for the precise dispensing of two-part adhesives 10,000 Average net circulation Jan-Dec 2018

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

32: Blooming in adhesives Blooming marvellous? Working towards a bloom-free manufacturing process

35: Buyer’s guide

32 dpaonthenet.net 3

Paige’s Page

‘A little brown box with buttons’ Remembering William English, computer mouse co-creator

I Paige West, Group Editor

n my column this month, I thought we could take a look at and celebrate the life of one of the key engineers who helped create the computer mouse – William English – who sadly passed away on 26 July at 91 years of age.

Through a series of tests, English

English was born in 1929 in Kentucky

The mouse was made public in 1968,

and studied electrical engineering at

at a demonstration. A live video was

university before joining the US Navy.

broadcast on the wall as Engelbart

demonstrated that his device could navigate a screen faster than any other device at SRI International. According to the BBC, his first version was a wooden block with a single button.

Underneath, two rolling wheels at 90º angles would record vertical and sideways movement.

Despite the mouse being a clear favourite in experiments, a paper by English and Engelbart was ignored for years.

explained the interaction between the

William English in 2008 (Credit: Wikimedia)

Whilst working with his colleague,

mouse and the computer screen. “As

Doug Engelbart, on early computing

it moves up or down or sideways, so

California as saying “it showed what a

at the Stanford Research Institute (SRI

does the tracking spot,” he revealed to

computer interface could – and should

International), English became the first

the audience. There was no doubt that

– look like.” Fairbairn worked alongside

person to use a mouse when he built

this demonstration wowed viewers as

English in the 1970s.

a prototype in the early 1960s. It was

it later became known as “the mother

Engelbart who envisioned a mechan-

of all demos”.

ical device moving a cursor across a

Neither could remember exactly why the device was called a “mouse” or

screen, selecting images or symbols,

The New York Times quotes Doug

who even decided on the name! The

yet it was English who brought this vi-

Fairbairn, a Director of the Comput-

BBC quotes English: “In the first re-

sion to life.

er History Museum in Mountain View,

port, we had to call it something. ‘A brown box with buttons’ didn’t work.”

SRI Computer Mouse (Credit: SRI International and Wikimedia)

The New York Times reported that his death was confirmed by his wife, who said the cause was respiratory failure.

English played a vital part in creating the technology that we now take for granted in the computers, tablets and smartphones of today.

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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Feature: Remote working

COVID-19 – An agent for c F

lame Hardeners Ltd., which provides heat treatment services to engineering companies, was not required to close during the COVID-19 lockdown and was positively encouraged by its trade association to stay open. The company did, however, follow government advice and encouraged working from home wherever possible. Managing Director, Roger Haw, explains how this was achieved, and reflects on how the changes made may affect the company’s operations going forward.

Our basic activity is to receive parts (rang-

capacity and specialised machinery – as

ing in weight from 0.2 kg to 20 tonnes each)

well as the supply of both electricity and

from our customers, process the parts,

specialist gases – it was not possible for

carry out testing and quality control proce-

employees engaged in production to work

dures, and then return them to customers.

from home.

To support this service, we offer advice about suitable materials and the materi-

Equally, physical quality control could not

al conditions that can be achieved, often

be undertaken from home, as testing of

working with customers at the design stage.

actual components is required. Receiving and despatch operatives also had to be

We are a small company with five main

on the premises.

areas of internal activity: • Production

However, we realised very quickly that all

• Quality control

the rest of our functions were operative

• Technical liaison

within our internal communications sys-

• Sales

tems and that modern technology would

• Administration

allow the transfer of all these functions to

Clearly, due to the requirement for lifting

home working.

Enclosure Climate Control Whatever the scale...... ......we have the solution ENCLOSURES

6 dpaonthenet.net

POWER DISTRIBUTION

CLIMATE CONTROL

Feature: Remote working directly into our bank account by our

we would perhaps introduce is having

customers. Orders, enquiries and invoic-

one half-day per week for all involved to

es are all received by email.

get together to preserve the team spirit and interact with colleagues still work-

Outgoing communications are usually

ing full-time on the premises; otherwise,

by email or the internet; we pay our bills

the ‘improvements’ would only become

automatically and send invoices, quality

divisive. Real benefits can be seen dur-

certifications, and quotations all elec-

ing the winter period when bad weather

tronically.

causes people to be late for work and introduces a requirement for early fin-

Like many others, we have a network

ishing.

computer system with a central server,

change?

which our staff could access from their

The present crisis has surely given all of

own laptops or PCs at home.

us much to think about when looking at how we live and work.

In many ways, the people working from home found that their work/life bal-

www.flamehardeners.co.uk

ance was considerably enhanced as they could base their daytime activities around their family life and interests.

Modern telephone systems can divert

There was some regret about reduced

incoming calls to remote personnel at

social interaction with colleagues, but

the push of a button. Likewise, it is easy

this was offset by not having to spend

for one member of staff to communicate

anywhere between an hour and two

with another member of staff either by

hours travelling to and from work each

telephone or internet connection.

day.

We concluded, therefore, that quality

It was also a very pleasant surprise that

control documentation, technical liaison,

the level of customer service and satis-

sales enquiries and other functions could

faction did not decline.

very easily be undertaken remotely, and this led us to examine how we commu-

So, we have to ask, is this the ‘new nor-

nicated with the outside world.

mal’ and the way forward?

Basic incoming communications are

Certainly, we are considering a change

done either by telephone, email or the

in how we operate the company, and the

internet; letters are very rarely received

thinking is that a remote office would be

these days. Payment for services is paid

an improvement. The one modification

IT INFRASTRUCTURE

SOFTWARE & SERVICES

www.rittal.co.uk

About the author: Roger Haw is Managing Director of Flame Hardeners Ltd. Having worked as a design engineer and projects engineer in both heavy vehicle transmissions and domestic gas products, Roger took a general management appointment in surface treatments.

He now has over 40 years’ experience in flame and induction hardening practice, and in offering appropriate advice in the application of these techniques on both large and small components (1gm to 25 tonnes+).

Roger is a Chartered Engineer and a Fellow of the Institution of Mechanical Engineers; he is also a former Chairman of the CHTA and the BGA.

General feature: Brainware

Lenze in the UK: It’s all about the “B P

aige West, Group Editor of DPA, spoke with Eric van den Broek, Managing Director at Lenze EMEA West (Benelux & UK), about the future of UK manufacturing and how the company is helping machine builders and OEMs to climb the Industry 4.0 ladder.

name Simplatroll Ltd. It rebranded as Len-

“However, what really differentiates us from

ze in early 2000. In 2015, Lenze realised its

others is our brainware,” says Eric van den

current business model had a challenging

Broek. “Our daily task is to create value

future – it was just selling products which

with our technology. The knowledge we

had limited added value. Take a stand-

put into our technology comes from the

ard AC module produced in Europe, for

knowledge of our engineers. It means we

example – to differentiate the technology

can make machines better, quicker, more

from others, the approach needs to be

reliable and sustainable. Industry 4.0 to

solution-based, not product-based. This

Lenze is not an interface to the Cloud, it’s

challenge was not specific to the UK, it

our brainware!”

How long has Lenze been in the UK and what services do you offer?

was global, which meant that the company

Lenze is a leading automation compa-

product-based.

company’s portfolio includes high-quali-

Lenze realised that anyone who cooper-

ty mechatronic products and packages,

ates with customers on a solution-based

powerful systems consisting of hardware

level will always win against their com-

The UK market for machine builders and OEMs has seen a number of dynamic changes in the last year. Can you give us some examples of how Lenze is working with machine builders and OEMs in the UK?

and software for machine automation, as

petitors. Its new strategy is built on three

“There is a future for UK manufacturing,

well as digitalisation services in areas such

pillars: mechatronics, systems automation

but a huge change is needed from the

as big data management, cloud or mobile

and digitalisation/servitisation solutions. It

OEM market. The question is, are they

solutions, and software for the Internet of

aims to help customers by using all three

willing to invest in more productivity?” says

Things (IoT).

pillars to provide innovative mechatronic,

Van den Broek.

had to start to approach total solutions to get application benefits that were not just

ny for the machine building industry. The

automation and digital services – coupled Lenze, founded in 1969 in the UK, acted more or less like a distributor under the

8 dpaonthenet.net

with engineering expertise.

OEMs and machine builders, from mechanical/electrical designers to software

General feature: Brainware Product Lifecycle Management (PLM),

Overall, business strategies will be adapt-

Inventory Management, and CRM and

ed to earn money using software and

Demand Planning. In fact, the spend in

services.

the industrial and manufacturing sector on these applications is set to grow from

Let’s take another idea of a digital twin;

$18 billion in 2019 to just over $27 billion

digital twins are virtual replicas of physi-

in 2024, finds ABI Research.

cal devices that you can use to run simulations before actual devices are built

The problem is the lack of skilled engi-

and deployed. So, if you needed to test

About the author:

neers. The Engineering UK: The State of

a machine or process, this can be done

Engineering 2019 report forecasts that

in a virtual world, using software, before

there is an annual demand for 124,000

building the machine. You can let the

Eric van den Broek is Managing Director at Lenze EMEA West (Benelux & UK)

engineers and technicians with core en-

machine run virtually first at much higher

gineering skills across the economy.

speeds, allowing you to save time, invest less money and even test out Batch Size

Van den Broek says, “The idea behind

1 production.

Lenze’s new business model is that we provide the resources, not just the

“So, ‘do more with less’ is a phrase we

components. Seven years ago, we had

often use at Lenze. Words such as reus-

almost no IT engineers – now we have

ability, scalability, modularity and connec-

250+. Besides that, we have about 400

tivity are no longer buzzwords,” notes Van

software (OT) engineers worldwide and

den Broek.

a network of approximately 1,000 ap-

Brainware”

plication engineers who can provide

Lenze has produced a series of whitepa-

expertise on specific topics, like cyber

pers that provide a helpful blueprint about

security. We often utilise these engineers

Industry 4.0 and digitalisation, as well as

to help our UK customers.”

business cases that prove the technology works.

Lenze also has a huge training programme which aims to give specific

Van den Broek concludes, “The demand

training to customers and upskill as

of the consumer is changing; OEMs and

many people as possible.

machine builders need to adapt to this

designers, must learn to focus because the

and if they don’t, their business model can be outdated quickly. If a company

bots – that can fulfil market requirements,

Which industries are seeing the most growth and innovation in the UK?

like Batch Size 1. Business models are

Van den Broek doesn’t name a spe-

a management layer, entrepreneurship

changing, so the approach is changing too.

cific industry, he claims the situation

today is important; if you don’t make any

we’re in is driving all industries to adapt

innovations and investments, you need

Many are starting to turn to software

their business models. “If OEMs don’t

to ask yourself what’s your position in

applications such as Electronic Re-

change their business model in the next

the future [of] this rapidly changing in-

source Planning (ERP), Manufacturing

few years, surviving will be difficult be-

dustry?”

Execution Systems (MES), Manufac-

cause of the changing global competi-

turing Operations Management (MOM),

tiveness.”

market requires not just standard machines but more specific automation, such as ro-

wants to have a prominent role in the future, then innovation speed is key. From

https://www.lenze.com/en-gb/

Industrial enclosures.

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Feature: Motor efficiency

Going beyond IE5 – the ‘gold’ standard in compressor electric motor efficiency A

ndy Pulley, Team Leader and Product Specialist at Atlas Copco Compressors, examines IE5, regarded as the IEC’s gold standard in motor efficiency, and how it has been exceeded by the company’s in-house designed motor for air compressors.

EC regulations and IEC standards

IE1 – Standard Efficiency

The European Commission has passed

IE3 – Premium Efficiency

regulations that stipulate the minimum

IE4 – Super Premium Efficiency

efficiency levels for LV electric motors

IE5 – Ultra Premium Efficiency

IE2 – High Efficiency

produced and supplied within Europe.

The substance of the regulations focuses

When it comes to compressor drive mo-

on the energy usage and energy efficien-

tors, there is a close correlation between

cy of induction motors used in industrial

the electric motor technologies and their

environments. In the UK, EU Regulation

efficiency level capabilities. First of all, sin-

640/2009 and the 04/2014 supplement

gle-phase induction motors are limited to

defines the minimum efficiency levels for

levels IE1 and IE2, whereas three-phase in-

induction motors.

duction and switched reluctance synchro-

As part of a concerted effort world-

nous motors can meet the IE1, IE2, IE3 and,

wide to reduce energy consumption,

To aid conformity to the regulations, the

CO2 emissions and the impact of

International Electrotechnical Commis-

industrial operations on the environ-

sion (IEC) prepares and publishes interna-

The introduction of permanent magnet

ment, regulatory authorities have in-

tional standards for all electrical, electron-

(PM) motors has considerably increased

troduced legislation to encourage the

ic and related technologies. The scope of

the opportunities for achieving the IE4 Su-

manufacture of higher efficiency elec-

these standards defines efficiency levels

per Premium Efficiency level. Moreover,

tric motors. Atlas Copco has not only

in tandem with advances in motor tech-

the pursuit of the ‘holy grail’ of IE5 opti-

taken these efficiency considerations

nology developments and innovation.

mum classification has driven innovative

on board but has gone even further to

in some cases, the IE4 category criteria.

developments of this technology. Howev-

achieve the highest efficiency class –

At present, the efficiency classifications

er, it has also revealed the energy-saving

equivalent to IE5 – in its compressor

comprise five levels as defined in IEC

limitations of more traditional motor prin-

technology.

60034-30-1:

ciples and design.

10 dpaonthenet.net

Feature: Motor efficiency Alternative technology

result, has up to 30 percent lower losses

considerations on board in its latest ad-

With AC induction motors operating with-

than conventional motors.

vance in compressor technology.

most power ratings, there may not be

Promoting high efficiency

Some 90 percent of electric motor appli-

much more room for the development of

There are other specific features relating

cations, such as elevators, crane lifting

this type of motor to produce higher ener-

to the motor that contribute to the over-

or conveyors, require variable torque and

gy efficiencies.

all efficiency of the compressor, including

constant speed. Air compression, howev-

true direct drive. If the rotor of the motor

er, requires constant torque and variable

This is where alternative motor designs,

is coupled directly to the male rotor of the

speed; whether a VSD compressor is

such as permanent magnet (PM) rotor

compressor element, there are no drive

running at 20 or 100 percent of its speed,

technology, come in. Unlike induction

losses associated with gears or belts –

the torque is actually the same. This has

motors which induce a secondary mag-

and no shaft seal.

been one of the main drivers for Atlas

in the 90 percent-plus efficiency band for

netic field in the rotor, PM motors use

Copco to develop its own Neos converter

high-performance magnets attached to

Equally, if the motor is cooled by the com-

and IPM motor in house, exclusively for

the external surface of the rotor to create a

pressor oil, which is effective at all running

air compressor operation, unlike most

magnetic field that is always present. This

speeds, there is no need for a cooling

other compressor manufacturers, who

eliminates the rotor losses found in the in-

fan which consumes power and reduces

purchase general-purpose motors from

duction-motor design, resulting in higher

motor efficiency. This is especially evident

major international suppliers for inclusion

efficiency and a better power factor.

when the motor is running at a low speed.

in their offerings.

The oil cooling the motor warms the lubriHowever, by going beyond the PM motor,

cating oil before it reaches the compres-

The performance of this innovation sig-

it’s possible to take greater steps towards

sor element and helps prevent condensa-

nificantly exceeds the equivalent of the

meeting, or even exceeding, the IE5

tion under low load conditions.

minimum IE5 standard for Super Premium

standard. This has been made achievable

Efficiency − the highest classification for

by the introduction of the IPM (interior per-

The high torque capability of an IPM mo-

manent magnet) motor concept.

tor allows the compressor to start whilst

motor efficiency in the UK.

still pressurised, hence there is no need to

In the Atlas Copco concept, the patented

The advantages of the IPM motor

blowdown the compressor when it stops

IPM motor is directly coupled to the com-

in standby mode. As a result, air that has

pressor element. Both components were

A conventional PM motor – or SPM (sur-

already been compressed, and for which

developed specifically for the company’s

face permanent magnet), to be precise

the user has paid for in energy consump-

GA VSD+ rotary screw stationary com-

– only uses magnetic torque to operate.

tion, is not wasted.

pressor range.

Although this technology overcomes rotor losses, it imposes speed limitations to

Conventionally

compressor

When combined with the company’s own-

secure the rotating magnets and reduce

motors have two bearings, one for the el-

designed

brand integrated Neos inverter drive in the

the risk of them being peeled off by cen-

ement drive end and another for the non-

GA37L VSD+ to GA110 VSD+ range mod-

trifugal force.

drive end. If the drive end is supported on

els − already proven to produce energy

the compression element bearings, the

savings of up to 50 percent − it is possible

The IPM motor, with its embedded per-

motor only needs one bearing – resulting

to achieve IES2 standard, which is the high-

manent magnets rotor, does not have this

in a significant reduction in friction losses.

est efficiency class defined in IEC 61800-9-

problem. It can operate at higher speeds,

2 for a combined motor and drive.

enabling direct coupling to the compres-

Atlas Copco goes beyond IE5

sion element on a 1:1 ratio and, as a direct

Atlas Copco has taken all these efficiency

www.atlascopco.com

dpaonthenet.net 11

Feature: Motor control systems

Fast-reacting optical encoder feedback system for miniature motor-driven applications M

otor rotation information such as position, speed and direction must be accurate to produce precise drivers and controllers across a wide variety of emerging applications; for example, in pick-and-place machines that mount microscopic components in the limited PCB area. Recently, motor controls have been miniaturised, enabling new applications in surgical robotics for healthcare and in drones for aerospace and defence.

The challenge for designers is to meet the high accuracy requirement of the position feedback sensor in a high-speed application, while infusing all components into the limited PCB space to be fit inside tiny enclosures, such as a robotic arm.

Position-feedback system In a lower-end application, an incremental sensor along with a comparator may suffice for position sensing, while a higher-end application will require more complex signal chains. These feedback systems comprise the position sensor, followed by analogue front-end signal conditioning, the ADC and its driver – before data gets into the digital domain. One of the most precise position sensors is the optical encoder. An optical encoder is composed of an LED light source, a marked disc attached to the motor shaft, and a photodetec-

Motor control

pick-and-place machine for the assem-

tor. The disc features a masked pattern

Motor control loops, as seen in Fig-

bly of a tiny surface-mount PCB. All

of opaque and transparent areas that

ure 1, are mainly made up of a motor,

these applications require accurate po-

obscure the light or allow it to pass

a controller and a position-feedback

sition measurement information about

through. The photodetectors sense the

interface. The motor turns a rotating

the rotating object.

resulting light and the on/off light sig-

shaft that causes the arms of a ma-

nals are converted to electric signals.

chine to move accordingly. The motor

The position-sensor resolution must

controller tells the motor when to apply

be very high – enough to detect ac-

As the disc turns, the photodetectors –

force, stop, or continue rotating. Mean-

curately the motor shaft position, and

in conjunction with the patterns of the

while, the position interface in the loop

pick up and place a tiny component on

disc – produce small sine and cosine

provides rotational speed and position

a board. Also, higher motor rotational

signals, in the mV or µV level. This sys-

information to the controller. This data

speeds lead to higher loop bandwidth

tem is typical in an absolute position

is central to the proper operation of a

and lower latency requirements.

optical encoder. These signals are fed

12 dpaonthenet.net

Feature: Motor control systems to an analogue signal conditioning cir-

tor control applications that require

cuitry, usually consisting of a discrete

high-accuracy

amplifier or an analogue PGA to gain

The optical encoder resolution can

the signal up to the 1V p-p range –

be based on the number of slots in-

commonly to fit an ADC input voltage

scribed from fine lithography in a disc,

range for maximum dynamic range.

usually hundreds or thousands. Inter-

Each of the amplified sine and cosine

polating these sine and cosine signals

signals are then acquired by a simulta-

to a high-speed, high-performance

neous sampling ADC’s driver amplifier.

ADC will enable the creation of higher

position

detection.

resolution encoders – without requirThe ADC must feature simultaneous

ing system changes to the encoder

sampling on its channels, such that

disc. For example, when an encoder

the sine and cosine data points are

sine and cosine signal is sampled at

taken at the exact same time, as that

a slower rate, fewer values of the sig-

In Figure 3, when the ADC samples at

combination provides the shaft posi-

nal are captured, as shown in Figure

a faster rate, more detailed values of

tion information. The ADC conversion

3; this also limits the accuracy of the

the signal are captured, and a higher

results are passed to an ASIC or micro-

position cap.

accuracy position is determined. A

Figure 1: Closed-loop motor control feedback system

controller. The motor controller queries the encoder position every PWM cycle and uses this data to drive the motor based on the instructions it receives. In the past, system designers would have to trade ADC speed or channel count to fit restrictive board footprints.

Optimising position feedback The demands of evolving technology have resulted in innovation in mo-

Figure 2: Position feedback system

Increased Performance for Connected Hardware Designed to perform in high vibration environments.

With surface mount solder tabs for additional board retention strength, Archer Kontrol can withstand lateral and twisting forces in high vibration environments.

Ensuring reliability in the next generation of connected devices. n

Temperature range of -55°C to +125°C

n

Assists with blind mating

n

Fully shrouded connector system

n

Tested to perform up to 500 operations

n

Up to 3 Gbit/s data rate

harwin.com/archer-kontrol

Connect with confidence Harwin Archer Kontrol DPA Sept 20.indd 1

05/08/2020 09:27

Feature: Motor control systems in a small 3mm × 3mm LFCSP package. The on-chip 2.5V reference would allow minimum component requirements for this circuit.

The VCC and VDRIVE of the ADC and the supply rails of the amplifier driver can be powered by an LDO regulator, such as the LT3023 and LT3032. When these reference designs are interfaced (for example, with a 1024-slot optical encoder that produces 1024 cycles of sine and cosine in one revolution of the encoder disc), the 16-bit AD7380 samples each encoder slot at 216 codes – increasing the encoder resolution up to 26 bits.

The 4 MSPS throughput rate ensures that detailed sine and cosine cycles

Figure 3: Sampling rate

are captured, and encoder positions are up to date. The high throughput

allows oversampling, further improv-

Optical encoder position feedback design example

ing the noise performance and re-

An example of an optimised solu-

which reduces the time penalty of

moving some digital postprocessing

tion for an optical encoder position

digital ASICs or microcontrollers

needs. At the same time, it reduces

feedback system is shown in Figure

feeding the precise encoder position

the output data rate from the ADC;

4. The circuit can be easily inter-

to the motor. An extra benefit of the

that is, it allows for slower serial fre-

faced to an absolute type of optical

AD7380’s on-chip oversampling is

quency signals, hence simplifying the

encoder, where differential sine and

that it allows for an additional 2 bits

digital interface. The motor position

cosine signals from the encoder can

of resolution, which can be easi-

feedback system is mounted in the

be easily captured by the circuit.

ly used with an on-chip resolution

motor assembly, which can be fairly

The ADA4940-2 front-end amplifier

boost feature. The resolution boost

small in certain applications. So, size

is a dual-channel, low-noise, fully

can further improve the accuracy up

is vital to fit in the limited PCB area of

differential amplifier that drives the

to 28 bits. Application note AN-2003

the encoder module. Multiple channel

AD7380 – a dual-channel, 16-bit, ful-

details this oversampling and resolu-

components in a single, tiny package

ly differential, 4 MSPS, simultaneous

tion boost feature of the AD7380.

are best suited for space saving.

sampling SAR ADC, that is housed

high-speed sampling rate of the ADC

rate enables oversampling on-chip,

Conclusion Motor control system demands for higher accuracy, higher speed and miniaturisation are increasing. Optical encoders are used as motor position-sensing devices. To do this, the optical encoder signal chain must have a high level of accuracy when measuring the motor position.

A high-speed, high-throughput ADC accurately captures information and feeds motor position data to the controller. The AD7380’s speed, density, and performance answer the industry’s demand while enabling higher levels of accuracy and optimisation in the position-feedback system.

Figure 4: Optimised feedback system design

14 dpaonthenet.net

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Feature: AMCs These gains could have a worthwhile impact on performance and range.

The exact weight savings depend on which of the three most common types of AFM is used. In AFMs with electrical steel cores, the weight saving would be 45 percent per motor; in AFMs with soft magnetic cores, the saving is 50 percent and in AFMs with a Halbach Array, the saving is 73 percent.

Beyond the motor It’s not just motors in EV applications that could benefit from adapting a hybrid material. The creation of a prototype sand-

Designs on electric hybrid cars: the benefits of AMCs R

ichard Thompson, Commercial Director of aluminium matrix manufacturer, Alvant, discusses how a new breed of materials could unlock significant improvements in power density and transient response for electric and hybrid vehicles.

wich of AMC fibre-impregnated sheets with an AMC foam filling (similar to a bullet-proof vest) has helped protect EV batteries at a fraction of the weight of a steel casing. It’s a potential that is worthy of further investigation to see what more can be saved.

A cool solution Further benefits of AMCs for EV and hybrid vehicles include heat conduction; AMCs conduct heat, but only expand a little when compared to steel or aluminium, which is an important consideration for precision components. The stiffness of AMCs makes them ideal not just for increasing structural integrity but also for reducing noise vibration. AMCs can also

About the author: Richard is a technology commercialisation professional, specialising in strategic market development, innovation and new venture growth. He joined Alvant in October 2017, from Williams Advanced Engineering. He has worked for a range of high-performance engineering businesses and new venture companies, developing and commercialising intellectual property.

Richard was appointed as Commercial Director in February 2018.

Aluminium matrix composites (AMCs)

A solution tailor-made for EVs

be applied as discrete inserts into a com-

first appeared in automotive applications

AMCs radically improve the efficiency and

ponent where an array of similar inserts

in the 80s, but as carbon composites

responsiveness of the electric rotors used

meets the performance requirements.

became more widely adopted, they were

in electric and hybrid vehicle motors. In

This approach reduces costs as the AMC

soon forgotten. However, almost four dec-

conjunction with UK motor manufactur-

material is only used where it is needed

ades later, subsequent R&D investment

er, Yasa, engineers at Alvant developed

most, while the rest of the component can

into their manufacturing has resulted in

a rotor that is 40 percent lighter than the

be made from a cheaper conventional

significant progress. AMCs are now firmly

original. It also had an increased power-

metal.

back in the game.

to-weight ratio, made possible by the stiffness of AMCs, which can reduce the air

Up until now, the transition from the inter-

Made from aluminium alloy mixed with

gap between the rotor and stator in axial

nal combustion engine to electric drive-

particles or long or short fibres, they are

flux motors.

trains has seen an increase in total kerb

an exciting option for designers and en-

weight, heavily attributed to the weight of

gineers looking for the seemingly impos-

The improvement in strength and stiff-

key components such as electric motors.

sible: lightness, stiffness and strength.

ness means the rotor speed can be in-

OEMs have been compensating for the

Compared to unreinforced metals, AMCs

creased which, in turn, increases power

increased weight to power by reducing

can also have superior wear resistance,

density by a massive 225 to 300 per-

weight in other areas, such as body and

lower coefficients of thermal expansion

cent. Now things get interesting! If the

chassis – as well as suspension and in-

and superior electrical conductivity.

rotors in axial flux motors (AFMs) that

teriors. Now, it seems that AMCs could

are suitable for passenger cars were

turn the tables on weight versus power, as

Customisable, AMCs can be stronger

made from AMCs (rather than steel),

well as helping OEMs to reduce CO2 and

than steel and less than half the weight, as

mass and inertia would be reduced by

increase range without exorbitant costs.

well as up to 50 percent stiffer and almost

45 to 73 percent and, overall, motor

300 percent stronger than carbon fibre.

weight would be reduced by 19 to 25kg.

16 dpaonthenet.net

www.alvant.com

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Feature: Angle sensors

Choosing angle sensors for power steering, motors and robotics A

s factories and vehicles become more automated, accurate and low-latency sensing of motor shaft speed and position is critical for process control, system reliability, and safety. To address these needs, designers require angular rotation sensors that are fast and precise, with the flexibility to address magnetic field variations and axial misalignment.

Figure 1: Designers can choose a magnet-to-sensor position based on design considerations such as the required level of immunity to external field disturbance and air gap tolerance. (Image source: Monolithic Power Systems)

Complicating the issue for designers are

They determine the absolute angular po-

ever-present cost and time pressures.

sition of a diametrically magnetised cyl-

Furthermore, the nature of the operating

inder on a rotating shaft by detecting the

environments for industrial and automo-

orientation of an applied magnetic field

tive applications can be challenging in

and measuring its sine and cosine com-

terms of chemicals and oils, as well as

ponents. As the shaft may be rotating

temperatures and EMI.

at high speed, the data from the sensor must be acquired and processed quickly,

The role of angle sensors

with minimal latency.

Angle sensors are used to sense motor shaft position, speed variations for steer-

One of four magnetic technologies – Hall

ing angle sensing for automobiles, and

effect,

high-precision control in robotic systems.

(AMR), giant magnetoresistance (GMR),

anisotropic

magnetoresistance

and tunnel magnetoresistance (TMR) – is typically used. When using any of these technologies, designers must first determine a suitable distance from the magnet surface to the sensor based on specific parameters, such as magnetic properties, sensor specification and assembly tolerFigure 2: The side view (left) of a dual die angle sensor (right) for safety-critical applications, which uses top-bottom placement to shrink space and save on cost by using an inexpensive ferrite magnet. (Image source: Infineon Technologies)

18 dpaonthenet.net

ances.

This air gap must be consistent with pa-

Feature: Angle sensors

IN THE DRIVE SENSORLESS SAFETY

Figure 3: The AMR based angle sensor is designed for 180˚ angle measurement, but it can be used to measure through the full 360˚.

(Image source: Infineon Technologies)

V

V

t

t1

rameters such as magnet size and remanence, also known as residual

t1

STO

V

t2

SLS

V

t

magnetisation. Designers must also ensure that air gap variations don’t result in magnetic fields that are either too low or too high. This requires careful consideration of the appropriate magnet for the application’s air

t1

SLA

t

t2

1 0

V

SAFETY INSIDE

t

SMS 1 0

V

gap (Figure 1). t1

That said, angle sensors can support a wide range of spatial configura-

t2

SSM

tions, on-chip non-volatile memory is used to store configuration param-

SDLC

V

V

tions and magnetic field strengths, including both off-axis or side-shaft mounting and end-of-shaft configurations. To help accommodate varia-

t

t

STO

t1

SS1

t2

Brake active

t

SBC

t1

t

Safety over

eters such as reference zero angle position, ABZ encoder settings, and phase information for the motor windings.

Next, the device’s ability to detect various magnetic field strengths allows developers to customise the angle sensor for specific functions like diagnostics and axial movement sensing. The availability of programmable magnetic field strength thresholds also facilitates the implementation of a push or pull button function outputted as two logic signals.

However, while features like speed, low latency and resolution depend on application requirements, safety is at the heart of angle sensor designs.

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Meeting functional safety requirements The angle sensors used in automotive applications require a high degree of precision, down to 0.1˚, to help ensure compliance with the ISO 26262 functional safety standard in the face of a highly demanding operating environment. The applications for these sensors include position measurement in brushless DC (BLDC) motors for pumps, wipers, brakes, valves, flaps, pedals, and the steering angle. The accuracy of 0.1˚ applies across the entire temperature range and product lifecycle. Moreover, at low magnetic flux densities, between 10 millitesla (mT) and 20 mT (where the angle error significantly increases), angle sensors serving automotive

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and industrial designs must still achieve angle errors as low as 0.2°.

Additionally, angle sensors should be easily integrated into safety-critical designs, such as electric power steering (EPS) systems which are crucial for autonomous features like automated parking and lane-keeping.

To address ease of use, Infineon’s XENSIV TLE5109 and TLE5014 angle sensors are available in both single and dual die versions, and integrate both the sensing and logic elements on a single chip (Figure 2). Dual die versions are more suitable for ASIL-D safety applications.

dpaonthenet.net 19

Automation with Drive

www.keb.co.uk

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

Feature: Angle sensors

Figure 4: The contactless MagAlpha MA730GQ-Z features 14-bit resolution and provides digital readouts over the SPI link. (Image source: Monolithic Power Systems)

Figure 5: AK7451 enables designers to program 16 ABZ output resolution settings and eight UVW output pulse number settings via EEPROM. (Image source: AKM Semiconductor)

The TLE5109A16E2210XUMA1 is part of a

For example, high-accuracy readouts are

Zero-latency angle sensors

line that comprises high-precision AMR fast

crucial for automotive and industrial en-

The AK7451 is a 12-bit angle sensor that

analogue angle sensors with an error angle

vironments, despite harsh environmental

detects rotation speed and angles by

of 0.1°. Although AMR-based angle sensors

conditions. This means factors like ther-

measuring the intensity of a magnetic

are designed for 180° angle measurement,

mal stability and air gap tolerance are vital

field. It features a combination of magnets

they are also applicable for 360° measure-

in an angle sensor’s ability to meet accu-

operating parallel to the IC surface, while

ment in motors with an even number of pole

racy objectives without adding cost and

offering tracking speeds of up to 20,000

pairs because the AMR sensing element ac-

complexity to the system design.

rpm. After detecting the magnetic field

tually measures the double angle, sine and

vector parallel to the IC surface, it out-

cosine (Figure 3). Their small angle error also

To meet such requirements at mini-

puts the absolute angular position of the

makes them suitable for a broad array of

mal cost, Monolithic Power Systems’

magnet and< subsequently, the relative

magnetic fields, with flux densities ranging

MagAlpha magnetic position sensors

angular position.

from 10mT to more than 500mT.

– MA302GQ-P, MA702GQ-P/Z, and MA730GQ-Z – can be mounted on the

The AK7451 employs the tracking servo

The TLE5109 angle sensors operate from

edge of the board for both end-of-shaft

system architecture to ensure zero-laten-

3.3-volt or 5-volt supplies. Other features

and side-shaft (off-axis) configurations.

cy rotation angle sensing. The zero-laten-

include a short start-up time of between 40

For speed, the contactless sensing and

cy angle sensor can output up to eight-

microseconds (µs) and 70µs, to ensure min-

12-bit resolution absolute angle encoder

pole UVW winding phases (Figure 5).

imal latency and support for speeds of more

allows MA302 sensors to provide accu-

than 30,000 revolutions per minute.

rate angle measurement from 0rpm to

Also, the expansion of the ABZ phase

60,000rpm. The MagAlpha MA730GQ-Z

output resolution setting from four to 16

The TLE5014C16XUMA1 is one of a line

features 14-bit resolution and provides

types enhances motor control usability.

of GMR sensors that can be programmed

digital readouts over the SPI link (Figure

It also allows AK7451 angle sensors to

About the author:

to accommodate a wide range of applica-

4).

facilitate rotor position detection in DC

Rolf Horn, Applications Engineer at Digi-Key Electronics, has been in the European Technical Support group since 2014 with primary responsibility for answering any Development and Engineering related questions from final customers in EMEA, as well as writing and proof-reading German articles and blogs on DK’s TechForum and maker. io platforms. Before Digi-Key, he worked at several manufacturers in the semiconductor area with a focus on embedded FPGA, Microcontroller and Processor systems for Industrial and Automotive Applications.

tions by storing the required configuration

brushless motor-driven operation without

onboard EEPROM. These sensors boost

However, for slow operations like hu-

flexibility and ease of use by also offering

man-machine interface (HMI) or manual

Hall IC installation.

a choice of interfaces that includes PWM,

controls where the rotating speed remains

Conclusion

SENT, SPC, and SPI.

below 200 rpm, the company offers the

While greater accuracy and smaller form

MagAlpha MA800, a digital magnetic

factors largely drive the features of an-

The TLE5014 angle sensors typically draw

sensor designed to replace analogue po-

gle sensors for automotive and industrial

25 milliamps (mA) from supply voltages of

tentiometers or rotary switches. It’s used

applications, compliance with function-

up to 26 volts (absolute maximum) and meet

with a diametrically magnetised cylinder

al safety standards sums up the overall

ISO 26262 ASIL-C for the single die and ISO

of 2-8mm, and its magnet configurations

value proposition of these high-precision

26262 ASIL-D for the dual die versions.

and shapes are flexible.

devices. However, to leverage their capabilities fully, designers need to con-

Key performance parameters

The MA800 has a lower resolution (8 bits)

sider specific application requirements

To realise fully the ability of angle sensors

but does feature on-chip non-volatile

carefully to get clarity on performance

to reduce audible noise and optimise motor

memory and programmable magnetic

parameters, such as appropriate air gap,

smoothness and torque, designers should

field strength thresholds. These make it

magnetic field strength, rotation speed,

carefully consider the key parameters: accu-

suitable for applications that require the

and angle error.

racy, speed, latency, axial misalignment, and

implementation of push-button readouts

magnet drift.

via register bits as well as output signals.

20 dpaonthenet.net

www.digikey.co.uk

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Feature: Cobot safety

Safety for robots in collaborative ap I

n industrial production, smart machines have been integral to many plants for a long time. Today, original equipment manufacturers, as well as other tier suppliers, are making use of new technologies for collaborative robot applications. The challenge is to guarantee safety and minimise the chance of injury when people and machines work together.

mable, multipurpose manipulator pro-

ciated with industrial robot systems led to

grammable in three or more axes, which

the development of EN ISO 10218:2011,

may be either fixed in place or mobile for

an international and European standard

use in industrial automation applications.”

which covers the safety requirements for industrial robots. The standard replaced

Cobots are designed to work alongside

the 2006 version, and is in two parts:

humans in a ‘collaborative workspace’,

• EN ISO 10218-1:2011 Robots and ro-

an area where the robot and the hu-

botic devices – Safety requirements

man can perform tasks simultaneously.

for industrial robots: Part 1: Robots.

This means that, unlike more tradition-

• EN ISO 10218-2:2011 Robots and ro-

al machines which are ‘caged’ by a

botic devices – Safety requirements

guarding mechanism, robots used in

for industrial robots: Part 2: Robot sys-

collaborative applications often oper-

tems and integration.

ate in the human-occupied workspace Robots designed for use in collaborative

without safety fencing. However, not

In order to ensure that humans are not

applications, sometimes referred to as

all ‘collaborative robots’ are guard-free,

exposed to unacceptable risks when

cobots, are expanding the possibilities

depending on their function and safety

working

of automation, as they are often easier to

requirements. Besides the robot itself,

standards describe four separate meas-

deploy and use. As obstacles like system

the collaborative robot might include an

ures that can be used to provide risk re-

interoperability are overcome, manufac-

‘end effector’, that is the tool adapted

duction. It is required that at least one of

turers will integrate increasing numbers of

on the robot arm with which the robot

these is fulfilled, in addition to having a

robots. Consequently, flexible production

performs tasks. In tandem with this new

visual indication that the robot is in a col-

automation will become more accessible

way of working, there comes new safety

laborative operation.

to a larger number of businesses.

concerns.

ISO 8373 defines an industrial robot as:

The increased need for adequate protec-

1. Safety-rated monitored stop

“An automatically controlled, reprogram-

tion of people from the safety risks asso-

This measure requires that when a hu-

collaboratively,

the

current

The four measures are:

22 dpaonthenet.net

Feature: Cobot safety robot actuators need to be monitored

requirements for the sphere of collabora-

by safety-related control systems to

tive robots, with the most relevant pub-

ensure that they are within the limits

lished guidance being contained in EN

established by a risk assessment.

ISO 10218.

In all four of the measures described

Guidelines from HSE

above, the safety-related control system

Published in 2012, a Health & Safety Ex-

that provides this functionality needs to

ecutive (HSE) Research Report, (RR906)

meet either:

– Collision and injury criteria when work-

• Safety Performance Level d (PLd), with

ing with collaborative robots, also offers

Category 3 architecture (the identified

some useful guidance.

level to which the safety-related parts of a control system resist faults and

The introduction to the HSE report states

their subsequent behaviour if a fault

that “this study explored the safety, re-

occurs), as outlined within the stand-

liability and evidence for the force lim-

ard EN ISO 13849 or;

its defined by the draft TS 15066, and

• Safety Integrity Level 2 (SIL 2) with

of the methods for testing them. It also

hardware fault tolerance (HFT) 1, as

addressed whether the proposed ap-

set out in EN [IEC] 62061.

proach in the draft TS 15066 is likely to

About the author: Stewart Robinson is Principal Engineer and Functional Safety Expert at TÜV SÜD, a global product testing and certification organisation.

adequately protect people from the risks.

pplications

Safety first

Risk assessment of potential collision

While EN ISO 10218 contains some

scenarios, human reliability and behav-

guidance on the use of collaborative ro-

iour issues, and equipment failure modes

bots, with the rapid pace of technological

and rates are discussed, as is the ade-

development, it was widely acknowl-

quacy of personal protective equipment

edged that this guidance needed to be

against collision injuries.”

enhanced. Consequently, a Technical Specification (ISO/TS 15066 Robots and

The report identifies several areas, with-

robotic devices – Safety requirements for

in ISO/TS 15066, that the HSE believes

industrial robots: Collaborative operation)

need more consideration. For example, it

was published in 2016.

concludes that the psychological, behav-

man has been detected entering the

ioural and organisational aspects affect-

collaborative workspace, the robot

ISO/TS 15066 covers:

ing the level of human-robot collision risk,

shall be stopped. The stop condition

• The design of the collaborative work-

along with the effects of human move-

shall then be maintained until the human leaves the workspace.

2. Hand guiding

space • The design of the collaborative operation

ment velocities, are not strongly represented in ISO/TS 15066. The HSE also points out that the frequency of injury is

In this mode, the human can guide the

• Methods of collaborative working

not included in the criteria for acceptable

robot at the end effector, by hand. Ad-

• Changing between collaborative/

collision limits.

ditional requirements for safety include safe-limited speed monitoring, a local emergency stop and the use of an enabling device, which is a three-position

non-collaborative and different methods of collaboration • Operator controls for different applications

device that has to be held in the centre position.

While the advent of the cobots offers exciting possibilities for industry, some end effectors may create hazards – especially as contact between the col-

‘Speed and separation monitoring’ and

laborative robot and the operator can

3. Speed and separation monitoring

‘power and force limiting’ are particu-

lead to the possibility of collision. It is

In this mode, the robot must maintain

larly elaborated in ISO/TS 15066. This

vital that a complete risk assessment is

a specified separation distance from

includes recommendations for ‘biome-

undertaken before a cobot is deployed,

the human and operate at a predeter-

chanical limits’ of pain thresholds for

as with any machinery in the workplace.

mined speed. This measure requires

specific parts of the human body.

This must cover the intended use of the

careful risk assessment and needs

cobot, as well as any reasonably fore-

to consider safety distances, which

There are also working groups from the

seeable misuse. The basis for this risk

should include the speed of approach

standards organisations reviewing vari-

assessment must be EN ISO 12100, in

of parts of the human body, as de-

ous aspects of human-machine interac-

order to provide a presumption of con-

scribed in EN ISO 13855.

tions, which will inform the development

formity with the Machinery Directive.

4. Power and force limiting by inherent design or control In this mode, the power and force of the

of future standards. For now, EN ISO 10218 Parts 1 and 2 and the ISO/TS

www.tuv-sud.co.uk

15066 specification defines the safety

dpaonthenet.net 23

Feature: Machine safety challenges

The BIG picture G

lenn Moffat, Safety Specialist and one of the Business Solutions Team Managers at SMC Pneumatics (UK) Ltd, looks at the machinery safety challenges and opportunities now facing manufacturing companies.

Safety components

Solutions for achieving a machinery- and staff-safe environment Competition has never been greater across the global manufacturing industry and the temptation to cut corners when it comes to machinery safety is great.

gramme for both equipment and opera-

Safety challenges in the manufacturing environment

tors will not only help UK manufacturers

The most important first step for any

To combat this, SMC offers a long-term,

meet the latest legislation – which may

manufacturer looking at machinery safe-

partnership-based approach to solving

well change again following Brexit – but

ty issues is to understand what it means

machinery and operator safety challenges,

it should imbue a safe working culture

for them. While some major manufactur-

which is not just a quick-fix solution to an

throughout the organisation. When im-

ing operations have set up their own Site

immediate issue.

plemented as part of an overall business

Safety Specifications, it is more often the

strategy, it can also improve productivity by

case (particularly among SMEs) that they

Working in conjunction with a customer’s

introducing the use of safer, more efficient

are not entirely aware of all pertinent leg-

own risk assessment exercise, SMC’s

manufacturing components which reduce

islation and what they have to do to meet

Machinery Safety Solutions Strategy fo-

machinery downtime.

it. Increasingly tight safety legislation

cuses on four core elements of the manu-

means no business can afford to ignore

facturing process:

SMC supports many manufacturing industry

it, particularly given the widespread use

1. Equipment safety and productivity – iden-

customers and Tier One suppliers, advising

of manufacturing components from over-

tify the pneumatic products and control

how best to use the results from their own

seas suppliers where production stand-

systems that are key to optimising safety

risk assessments. Quite simply, these results

ards are not as rigorous as those in the

and productivity throughout your manu-

can be used to identify and mitigate poten-

UK.

facturing operation, from ingredient pro-

An effective safety management pro-

tial machinery and operator safety problems before they become a serious issue.

cessing to finished product packaging.

Every responsible business also has a

2. Operator usage and maintenance – as-

duty of care to employees working on

sess all aspects of operator usage and

This article reviews some of the most com-

their production line to ensure that the

machinery maintenance in your man-

mon machinery safety challenges and pre-

equipment they are using and how they

ufacturing chain and improve practice

sents some proven solutions for dealing with

are using it is safe. Enforcing appropriate

and resource deployment through PU-

them.

training is critical to delivering this.

WER training and partner seminars.

24 dpaonthenet.net

Feature: Machine safety challenges 3. Change attitudes – devise and imple-

mon way to stop a machine in an emer-

ment routes to optimise new attitudes

gency. This is done by fitting a safety

to machinery safety and maintenance

valve in the system, but what happens

within your management, workforce

if the valve develops a non-visible fault?

and sales team.

The machine won’t stop as expected

4. Embed safety management values –

and the consequences could be very

build an understanding of your busi-

serious. While a single safety valve sys-

ness’s safety management policy to

tem is acceptable under current legis-

ensure best practice across all as-

lation, SMC advised the customer that

pects of the manufacturing operation

the failure risks can be mitigated simply

and engineering staff training.

by fitting a double safety valve system.

This provides immediate back-up in

Based on the results of this comprehen-

the event of the failure of one part and

sive data collection exercise, SMC works

sends an alarm alert to the maintenance

with you to develop a durable business

team.

solution to your machinery safety management issues with defined goals and

As a result of this review, the customer

the right team of people to deliver them.

had double safety valves fitted on all the

Safety components

new machinery installed and onto older For example, a major UK-based snack

machines as they were upgraded.

manufacturer has devised its own set of Safety Standards which are implement-

To book an initial free, no-obligation con-

ed throughout the manufacturing plant.

sultation which includes a site visit and

These Standards are reviewed regularly,

assessment and an outline report on

and SMC has provided advice on best

your Machinery Safety Solutions Strat-

practice in relation to pneumatic control

egy, email Glenn Moffat on gmoffat@

systems on the production lines.

smc.uk.

In an environment with pneumatic control systems, dumping of air is a com-

www.smc.uk

We want a range of DC DC converters

but can’t

About the author: Glenn has a BEng Hons in Mechanical Engineering from Leeds University and is a Certified Machinery Safety Expert (CMSE). He has spent his career in Industrial Safety Management and Compliance, having worked previously with Pilz Automation Technology, Lorien Engineering Solutions and TUV Rhineland. Glenn joined SMC UK Ltd in 2017 as Safety Specialist for the SMC Business Solutions Team.

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Feature: Battery systems

Maximising safety in advanced battery systems I

n advanced battery systems, the quality of the power electronics helps determine the quality of the final product. This is emphasised in the latest battery power management and charging systems that use wide-bandgap semiconductors and improved power topologies. In such advanced electronics, if the safety systems do not work quickly and reliably, the entire battery system can suffer a catastrophic failure that could seriously impact the product and its user.

turers must integrate high-performance components into their designs.

Fuses, or similar devices, are required circuit-protection components that protect the system in the event of a short circuit by breaking the line under specific conditions.

There are many types of fuses, but the primary element in each is a piece of engineered conductor, usually metal and rated to fail (i.e melt) in a controlled manner under the raised line temperature conditions from

In life-critical application spaces such as

a short circuit. This destructive protection

automotive safety, the importance of fail-

method ensures the safety of the circuit by

safe subsystems is paramount. The battery

completely severing the power source.

system in an EV is similar to the petrol tank in a traditionally fuelled vehicle, in that the

However, this burn-out response has

stored energy needs to be safe. There is a

some drawbacks. Most notably, a power

considerable amount of energy in a mod-

circuit under load will not necessarily have

ern battery, and catastrophic failure can

a consistent flow of current. In designs

certainly lead to such things as thermal run-

requiring pulses of high power, the wide

away (better known as fire!).

operating range of the current drives the use of a higher current fuse to avoid nui-

26 dpaonthenet.net

Managing short circuits

sance tripping, but this leaves the system

The higher cell densities in advanced bat-

more vulnerable to overheating and ther-

tery systems demand proper safety proto-

mal issues. That, and the non-reversible

cols as the power levels involved present

aspect of fuses, has led to the increasing

a significant challenge when it comes to

use of electromechanical safety devices

managing short circuits. To create a robust

like circuit breakers, which can be reset as

and safe system that helps ensure reliabili-

they do not rely on destructive elements to

ty over a given vehicle’s lifetime, manufac-

function.

Feature: Battery systems Electromechanical protection A contactor is another type of electromechanical protection device, but it differs from a circuit breaker in that it is not intended to interrupt a short. Designed to connect directly to high-current loads, contactors are high-power switching devices operated by an external control. Power contactors are preferred in demanding situations where circuit resetting is needed and high current levels are present. Though similar in operation to relays, contactors differ in robustness and available features to control and suppress arcs created when switching.

When it comes to battery systems, high voltage contactors provide safe circuit continuity in hybrid and electric vehicles, as well as in charging systems and high-powered industrial applications. These types of contactors can rapidly and securely connect and reconnect the circuit, managing arcing and inrush situations. For example, in EVs, normally open contactors safely join the battery pack to the system, disconnecting when the vehicle is not in use.

There are a variety of circuit protection solutions that can open a circuit faster than a fuse and can do so closer to normal operating conditions without nuisance tripping, resulting in less potential damage than if a thermal fuse were used. One such solution is the GigaFuse which is a fast-acting, hermetically sealed electromechanical device with low heat generation that allows for circuit trips at exact currents. It features a design that significantly reduces resistance, eliminates thermal ageing and increases system efficiency. Available in both passive and passive/active combinations, this device uses the magnetic field of the current – the Lorentz force – to trigger the device to open.

As the GigaFuse generates little heat in operation, it is immune to the thermal ageing and related nuisance tripping caused by hot/cool cycles in the circuit. Such temperature cycles would cause the conductor metal in fuses to become brittle over time, reducing operational life by compromising the physical integrity of the connection. The GigaFuse has fast and consistent clear times, regardless of ambient temperatures. These features allow the end-user to design a safe circuit, while reducing the performance requirements of the contactor.

Improving performance The GigaFuse can also improve the performance of the contactor in the circuit.

A contactor that is incorrectly paired with a fuse can actually prevent the fuse from doing its job. As the contactor levitates, it starts to dissipate some of the energy that should be available to trigger the fuse, instead, loadcontactor can prevent the fuse from “seeing” the short, which can result in catastrophic failure.

The ability of electrical protection devices to address circuit safety in high-power systems is not restricted to advanced batteries. A multitude

About the author:

of applications, from motion control to alter-

Markus Beck is a Business Development Director for Industrial Electrification at Sensata Technologies.

He has more than ten years of experience working with high voltage relays and contactors and has a bachelor’s degree from Princeton University.

a component’s efficiency, thermal performance, and speed. This type of fast-acting, hermetically-sealed electromechanical device is especially beneficial in situations where thermal ageing or nuisance tripping is a problem. www.sensata.com

There are many ways to add a PROFINET interface to an automation device, that it may seem daunting to know where to start. The starting point depends on the type of product, its existing design, quantity expected, and time to market needed.

PI North America are presenting this free-to-attend webinar to address these issues and more. This webinar will give you an overview of the seven steps to embed PROFINET in your product.

ing the current on the contactor. An overloaded

nate energy generation, can benefit from such

Webinar: Seven steps to develop a PROFINET device

dpaonthenet.net 27

Agenda: • Real-time requirements • PROFINET conformance classes • Implementation options • Development paths

• Development partners • GSD file • Product certification • Market launch • Live Q&A

Host: PROFIBUS and PROFINET North America and the PROFI Interface Centre Date: Thursday, September 10 Time: 10:00AM, MST (Mountain Summer Time, as in Arizona, USA) Cost: Free

Register here: https://register.gotowebinar.com/ register/4086235317217424399

Feature: Medical fasteners

An increase in fastener demand during COVID-19 F

or over 25 years, TR Fastenings has been working with healthcare organisations and their subcontractors as a total solution provider of fasteners and Cat C products. TR has geared up its capacity to support the medical technology industry during this critical time.

The outbreak of COVID-19 created an unprecedented demand for medical products. In response to the outbreak, the world turned to medical companies for help, which has galvanised the industry into action and to work in uncharted territories.

technical expertise, real-time inventory

products, plus specially manufactured

availability, a wide range of fasteners and

parts to be used in a range of medical

To meet the urgent global demand and to

an intricate global supply chain already in

equipment. This includes ventilators,

alleviate shortages, many manufacturers

place, TR has been able to accelerate time

medical beds and furniture, ultrasound

from outside of healthcare reconfigured

to market.

machines, medical imaging equipment,

their business to produce medical equipment and supplies.

defibrillators, incubators, medical computAlthough fasteners are typically the small-

er stands, volumetric pumps and infusion

est components in medical devices, they

devices, vacuum extractors, and many

The role fasteners play in medical devices

play an important role in the assembly,

other vital pieces of medical equipment.

Medical devices are playing a crucial role

device. Working directly with a knowl-

in the fight against COVID-19. The critical

edgeable fastener manufacturer early on

New medical hardware products introduced

products that require fasteners and com-

in the design stage mitigates the possibil-

TR has introduced two new products to

ponents are:

ity of a costly redesign after the product

its range – the L-bow Handle and a Face

1. Respiratory support and monitoring

has been launched.

Visor Kit:

functionality and structural integrity of the

equipment, such as ventilators, which

• The L-bow Handle can be retrofitted to

The challenges of working in a changing world

an existing compatible door handle and

such as face masks and protective vi-

TR’s fast-track approach to delivering

free” with your forearm, reducing the

sors.

a high volume of products, often within

risk of direct contact with viruses and

3. Diagnostic tests which identify those

hours, supported the sudden acceleration

bacteria on the handle. The door open-

infected and further limit the spread of

of customers’ needs. TR worked through

er is made from plastic with stainless

the virus.

weekends and bank holidays to respond

steel components and works on vari-

quickly and engage with various medical

ous door types with both horizontal and

companies around the world.

vertical handles, from 19 up to 22mm

help to treat hospitalised patients.

2. Personal Protective Equipment (PPE)

TR Fastenings responded to the UK Government’s urgent request to support the

in diameter. It is available from stock in

immediate needs of established medical

The main products that TR supplies are

equipment manufacturers and new com-

sheet metal fasteners, high-grade stain-

panies diversifying into this sector. With

less-steel fastenings, plastic and rubber

28 dpaonthenet.net

allows the door to be opened “hands-

black and to order on any other RAL colour (minimum 1000 pcs).

• The Face Visor Kit contains two poly-

Feature: Medical fasteners propylene clips and a 330mm elastic strap, which is quick and easy to fit.

This is a secure, lockable and adjustable method of attaching a strap to a face visor. The kit can be manufactured in various colours. It has a simple finger pressure closure and release mechanism. The standard 19mm elastic strap can also be provided in a 15mm width, and 1mm increments up to 19mm.

Application engineering has proven to be key In addition to choosing a high-quality fastener manufacturer and distributor with a diverse product range, it is also important to work with a company that offers application engineering expertise. TR engineers are fully engaged in the design and make critical recommendations for the interface

The future

between the fastener and the medical de-

As the medical landscape changes, pre-

vice.

paring for the future has never been so important. TR Fastenings is ready to meet

Due to COVID-19 lockdown restraints, TR

the challenge!

engineers have been using various methods of online virtual communication to

www.trfastenings.com/industries/

ensure the customer receives the highest

medical

level of service and technical support.

About the author: Jeremy Scholefield is a professional Global Business Director with 26 years of experience in the fastener industry, including 20 years with TR Fastenings.

He is highly experienced in local and global strategic business management along with extensive sales, technical and engineering knowledge in B2B, production and distribution environments in a variety of industry sectors. He works closely with a multi-disciplined, multi-cultural team of staff and colleagues around the world.

Some things need protection in harsh environments.

Then there’s Hepco.

Tel: 01884 257000 www.hepcomotion.com

Feature: Two-part adhesives

Precision in small doses: Tips for the precise dispensing of two-part adhesives W

hen dispensing small amounts of two-part adhesives or other materials, two key considerations are whether the material is mixed correctly, and the accuracy of the amount dispensed. Here, Paul Whitehead, Key Account Manager at Intertronics, shares his thoughts on the precise metering, mixing and dispensing of small amounts of two-part materials.

trically or thermally conductive variants.

air. Some suppliers offer respite from this

This is driven by manufacturers in the elec-

procedure by providing their materials in

tronics, medical device and automotive in-

a pre-mixed, degassed and frozen pack-

dustries requiring increased functionality in

aging. However, there are extra costs as-

seemingly ever-smaller formats. In parallel,

sociated with shipping and storage, which

these engineers are looking for high-accu-

are partly offset by the material being

racy material application in a robust and

ready to use after thawing.

consistent process. They want precise quantities, uniformly mixed in the correct

Once the material is mixed (or thawed),

ratio, to be applied in exact locations.

curing starts and the material’s viscosity will begin to increase. Changes in vis-

Two-part formulations can offer superior

cosity will mean the amounts dispensed

cured performance but can be difficult to

directly from the syringe, or through a dis-

process. A typical method involves weigh-

pensing valve using air pressure, will vary,

There is a growing demand for the precise

ing out the constituent parts, mixing in a

and it is difficult to maintain an accurate

metering, mixing and dispensing of small

container with a spatula and loading into

deposition. Moreover, the mixed material

amounts of two-part technical materials

a dispensing syringe barrel for applica-

will have a limited working life, which can

like adhesives, potting compounds, en-

tion. There may be a vacuum degassing

lead to waste as it cures too much for it

capsulants and sealants – including elec-

or centrifuge step to remove entrapped

still to be usable.

30 dpaonthenet.net

Feature: Two-part adhesives

QUALITY HINGES

One solution is to use a metering and mixing machine, where measured amounts of material are fed through a mixing nozzle and can then be dispensed directly to the part. Systems operating with gear pumps or

TALK TO THE EXPERTS.

piston pumps are readily available but are more suited to larger material quantities, such as potting transformers.

If the requirement is for the application of a few millilitres or even fractions of a millilitre, then another technology is considered: metering and mixing based on progressive cavity pumps. The pump comprises a specially shaped rotor inside an elastomeric stator, forming a series of tapering and overlapping spaces or pockets which progress through the pump as the rotor is turned – producing a pulseless material flow. Flow rate is directly proportional to the rate of rotation. Input pressure and material viscosity have no impact on the output of the pump and the system will achieve true volumetric output based on positive displacement. Dispensing at the point of mixing precludes variability, due to viscosity change, and reduces wastage. Materials may be purchased in larger package sizes, which can reduce purchasing costs.

01827 63391 sales@goldwassallhinges.co.uk

One example of such technology is the preeflow eco-DUO, a high-precision volumetric metering, mixing and dispensing unit, which integrates two preeflow eco-PENs through a manifold and static mixing nozzle. Suitable for a wide range of materials – with viscosities from water to pastes

Whatever your hinge requirements, we offer a solution.

Bespoke/Stock - UK maunfactured - Expert advice

– it enables flow rates from 0.1 to 32 ml/minute. It also offers a mixing ratio of up to 10:1, which can be changed depending on the project. The variable mix ratio means that unlike many other systems, the user can reconfigure it for different materials, rather than sending it back to the system manufacturer for modification.

The operator can control the flow to fine limits and calibrate the controller to the system for a very repeatable output. It is readily integrated into automation to ensure that, as well as dispensing volume, positioning is also extremely repeatable.

One customer success we have seen is with BPR Medical, which manufactures a valve to extinguish fires in the line between an oxygen concentrator and the user’s mask or nasal cannula – a lifesaving technology.

The customer was dispensing a two-part epoxy to bond two halves of the

Cartridge Check Valves

valve’s body in a precise repeatable volume – metered and mixed correctly. This had to achieve a bond integrity that conformed to CE marking under the Medical Device Directive. Testing revealed that the preeflow eco-DUO would provide an appropriate solution. The system has proven itself

Designed for Installation into Plastics

in their production line, with its dispensing accuracy also providing a rapid return on investment through a 16 percent material savings per part.

About the author:

When metering, mixing and dispensing small amounts of two-part materials, consistent mixing and precise application to the correct location can impact a project’s success and provide significant cost savings over the lifetime of production. For more information on the preeflow eco-DUO metering, mixing and dispensing system, visit www.intertronics.co.uk.

Paul Whitehead helps high-technology, high-performance manufacturers to maximise productivity through the use of adhesives, sealants and coatings technologies. He can be contacted at paul.whitehead@ intertronics.co.uk.

dpaonthenet.net 31

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Lee Products Limited, 3 High Street, Chalfont St Peter, Bucks. SL9 9QE

Feature: Blooming in adhesives

Blooming marvellous?

Working towards a bloomfree manufacturing process B

‘

looming’, for those who use cyanoacrylate-based adhesives, has been the talk of the manufacturing industry for many years.

It is the white staining of parts near where the adhesive is applied that detracts from the overall appearance of the assembled parts.

The types with volatility generate staining when volatiles condense on part surfaces. This is particularly noticeable on black or shiny parts, and on optically transparent parts – for example, lipstick cases, lenses and glass covers, high-end

In some cases, blooming is not an issue

the quality of the product or its brand.

as assembled parts may be subsequent-

writing instruments, perfume bottles and such like.

ly painted or finished. In other cases,

So, what causes blooming? From a tech-

such as in the manufacture of high-end

nical perspective, blooming occurs be-

Instant adhesive types

goods, aesthetic is everything. Clearly,

cause, depending on their composition,

Within the world of instant adhesives,

staining on expensive fashion accesso-

fast-reacting cyanoacrylate adhesives

there are two principal types, so-called

ries or equally costly consumer electron-

may comprise volatile ingredients, i.e.

‘Ethyl Cyanoacrylate’ and ‘Methoxyeth-

ics is not acceptable; it supports neither

they have significant ‘vapour pressure’.

yl Cyanoacrylate’, abbreviated as ‘ECA’

32 dpaonthenet.net

Feature: Blooming in adhesives and ‘MECA’. ECA-based adhesive prod-

Curing speed

in fact, it is almost the exact opposite

ucts are well accepted and well utilised.

The speed with which ECA-based instant

when using instant adhesives. Neverthe-

They are generally inexpensive to pro-

adhesive ‘cures’ (i.e. converts from its liq-

less, this requires very highly engineered

duce and have become the mainstay

uid form to a durable solid) also affects

products to assure quality. Controlling

of the adhesives industry, as they are

the extent of blooming that a manufac-

the volume of adhesive dispensed and

convenient and easy to use, and also

turer has to contend. Not all ECA-based

how accurately it can be applied is one of

provide strong and instant adhesion.

adhesives cure at the same speed; speed

the most difficult challenges that a man-

Nonetheless, they suffer two major dis-

is affected by the formulation type and

ufacturer faces but must be mastered

About the author:

advantages, both associated with their

the nature of the material to be assem-

to ensure a correctly designed instant

Polivio Goncalves joined Bostik in 2018 as the Head of Engineering Adhesives. His expertise comes from nearly 20 years of industry experience in supporting engineering leaders in solving technical adhesive challenges from Automotive to Packaging. His knowledge extends beyond adhesive technology to include full value chain understanding, cost structures, design and sustainability.

volatility: they create blooming and they

bled. ECA adhesives with volatility will

adhesive is used effectively. The use of

have an acrid odour and must be used in

generate more blooming when they are

odourless non-blooming MECA-based

a proper environment.

not rapidly converted to solids, for ex-

products gives end-users a margin with

ample, when bonding relatively passive

regard to the accuracy they require, de-

The new generation of MECA-based

parts. Such manufacturing scenarios can

pending on the nature of the parts being

products are designed to overturn these

be addressed with accelerants within the

assembled.

disadvantages completely – they have

formulation or by using additional agents

negligible blooming, are totally odour-

such as spray-on primers, but both ap-

MECA-based instant adhesives offer a

less and do not sting eyes, yet they still

proaches have disadvantages.

logical solution to the problems associat-

function as instant adhesives and can

ed with more traditional alternatives. They

bond multiple substrate types, without

ECA-based formulations contribute to

retain the advantages of rapid strong

the need for any additional chemicals.

blooming in end-use because it is almost

bonding on most materials, yet overcome

inevitable that excess adhesive squeezes

the disadvantages of part staining and do

Thanks to innovative technology, ME-

out from between the parts being assem-

not need special ventilated manufactur-

CA-based instant adhesives can now

bled. This exposes a volume of volatile

ing zones and expensive high-accuracy

be accessed with these advantages in a

material and white stains occur in the vi-

dispense equipment or post-cleaning.

cost-competitive manner. MECA-based

cinity of the joints, which is a particularly

They are an attractive option for man-

instant adhesives work so well because

difficult problem to manage when bond-

ufacturers of small electronic products,

of the design of the very molecules from

ing tiny parts and making fine joints – e.g.

high-end jewellery, exotic glass packag-

which they are formed – which have enor-

in the assembly of decals, decorative

ing and designer fashion accessories,

mously reduced volatility. This means that

parts, miniature camera pieces in mobile

who may have dismissed the use of such

blooming is designed-out at a fundamen-

electronics and so forth.

adhesives because no cost-effective al-

tal level because it cannot be countered

ternative was previously available.

by formulation alone, for example, with

It is tempting to think that the more ad-

odour-masking ‘workarounds’.

hesive used, the better the bond, when,

34 dpaonthenet.net

www.bostik.com

Buyers Guide: Springs

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Bringing power to your installation has never been easier!

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Automation and equipment need a lot of power. As installation concepts become more sophisticated, the number of field devices is increasing. Simple solutions are needed to bring energy to power hungry applications, an easy achievement with Murrelektronik’s standardized power connectors.

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