DPA_20_10 by Modiconlv

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

Delivering the benefits of Single Pair Ethernet

26: Torque 17: Smart wiring solutions sensor Smarter wiring solutions for affordable robotics

Hydrogen car drives for efficiency world record

Contents

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

Editorial Comment:

Delivering the benefits of Single Pair Ethernet

04: Hyperloop A fast track to the future?

General Feature: 06: Gearbox purchasing

26: Torque 17: Smart wiring solutions sensor Smarter wiring solutions for affordable robotics

Hydrogen car drives for efficiency world record

Cover Story:

200717_9-2_Mill_DPA_UK_Snipe.indd 1

7/16/20 10:39 AM

Single Pair Ethernet will be one of the technological cornerstones to shape the success of the IIoT. Explore the features of HARTING’s T1 industrial connector. p.8 (Cover image: Harting)

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

Technical guides released to inform geared motor purchasing

Connectors & Couplings Special Report: 08: Cover story: Single Pair Ethernet

HARTING’s T1 Industrial delivers the benefits of Single Pair Ethernet

10: Motion control couplings Single sourcing vs sourcing from multiple manufacturers

12: IIoT connectors M12 connectors – A perfect fit for the IIoT

14: Industrial connectors Making sure your connectors are tough enough for industrial deployment

17: Smart wiring solutions

Smarter wiring solutions for advanced, affordable robotics

Sensors & Transducers Special Report: 21: Machine vision Autonomous machine vision can help ward off the looming recession

24: Smart sensors

Smart sensors in the food industry

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.

26: Torque sensor Hydrogen car drives for efficiency world record

Enclosures & Panel Products Technology Focus: 28: Waterproof enclosures Selecting the best enclosures for washdown environments

30: Food & beverage What does the future hold for food and beverage manufacturing?

32: Switches 10,000 Average net circulation Jan-Dec 2018

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

Switching in the time of COVID 19

34: Electrical connection enclosures Precast concrete installation made easier with electrical connection enclosures

35: Buyer’s guide

32 dpaonthenet.net 3

Editorial Comment

Hyperloop: A fast track to the future? I

magine being able to cut your travel time from several hours to mere minutes.

Sophia Bell, Assistant Editor

situated within a vacuum steel tube.

than aircraft, it promises to be an ideal mode of transport. The prospect of

Ever since its pivotal introduction in

a more sustainable transport system,

2012, the race to build the world’s first

operational system has been underway

appealing, considering the increasingly

The National Rail service is notorious

– with large global companies compet-

urgent need to tackle the climate crisis.

for long, tedious journeys. When I used

ing to pioneer the technology that is

to travel to university, my journey could

set to transform public transport.

take almost four hours by train. So,

There are many global projects – with Virgin Hyperloop One Systems and

when an article from RS Components

So, what would our journeys look like if

Hyperloop Transportation Technolo-

about how the Hyperloop could dras-

we were to replace our current rail ser-

gies (HTT) at the forefront – that are

tically reduce travel times crossed my

vice with the Hyperloop? Touted as the

committed to making this revolutionary

desk last month, I was immediately in-

fastest way to travel the earth, it would

mode of transport a reality. However,

vested in the prospect!

reportedly reduce the journey from Ed-

although progress is certainly being

inburgh to London to just 29 minutes,

made, could it feasibly function as an

Vacuum tube-based transport is not

saving you at least three hours and 51

alternative to rail, car and air travel in

a new concept. Isambard Kingdom

minutes. Other journeys, such as from

the near future?

Brunel’s innovative atmospheric rail-

Nottingham to London, would be up to

way, which ran from Exeter to Plym-

10 times faster, according to RS Com-

As many critics have pointed out, it

outh, experimented with using com-

ponents.

would demand a huge amount of re-

pressed air to transport carriages as early as 1847.

sources and investment, not to menThe drastically shortened travel times

tion the substantial political, technical

would revolutionise the way in which

and geographical challenges it faces.

Although Brunel’s project was ulti-

we live. It would make it much easi-

Is the Hyperloop on track to become

mately unsuccessful, it paved the way

er to visit friends and family who live

the next great transformation in mass

for entrepreneur Elon Musk to premiere

far away, and the reduced commut-

transport or is it merely a pipe dream

his idea of the Hyperloop more than

ing times would help many people to

that will never truly come into fruition?

a century later. This ground-breaking

achieve a better work-life balance. Do let us know what you think of the is-

mode of transport would see passengers travelling at speeds of up to

Faster than trains, safer than cars and

sue and if there are any specific topics

700mph in levitated pod-like capsules,

less damaging to the environment

you think we should be covering. Email me at sophia.bell@imlgroup.co.uk.

Connect with us on LinkedIn. Join us on Twitter.

4 dpaonthenet.net

WG20 Geared motor range available up to 18,000Nm with IE3 or IE4 efficient and hazardous area motors Designed with standard mounting dimensions, the geared motor is easy to install and perfect for replacing existing units. WG20 is compact, efficient and robust. Isn’t it time you changed?

Download a series of white papers discussing a range of topics from a technical guide to purchasing and maintaining geared motors at www.weg-wg20.com

General feature: Gearbox purchasing

User-friendly technical guides released to inform geared motor purchasing

EG has released two informative guides to make the geared motor buying process easier and more informed. Targeting decision-makers, technical buyers and design engineers, the guides are available to download for free. The first guide, titled What mechanical engineers and plant operators need to know about gears, explains the varied types of gears and their classification. The guide aims to help people to choose

The sequel guide, titled What mechani-

the industry has diversified over the last

the right gear type based on the applica-

cal engineers and plant operators need

decade,” explained Marek Lukaszczyk,

tion. It covers the following:

to know when buying geared motors,

European Marketing Manager at WEG.

• Helical gear units

builds on the first guide’s knowledge.

“There are more gearbox manufactur-

• Parallel shaft gear units

While the first guide helps a buyer and

ers, and while standardised mounting

• Bevel gear units

design engineers to understand the dif-

dimensions can give the impression that

• Worm gear units

ferent types of gear, the second guide in

two gearboxes are similar, they could

• Planetary gear units

the series helps a buyer to ask the right

have dramatically different quality and

questions in the buying process for their

performance characteristics.

Each one of the aforementioned gear

specific application and market.

types has its own configuration, features

“The guides are designed to give techni-

and benefits. To help buyers in the in-

These fundamental questions include

cal buyers an appropriately critical eye in

dustry make the right choice amid the

‘what are the exact power requirements

the buying process. Download them for

large range of options, the guide distin-

for the gear unit?’ and, further down the

free to reap the wealth of knowledge and

guishes between each type and gives an

line, ‘which efficiency guidelines and

experience the authors have to share

honest account of the pros and cons of

standards must be observed?’. The pur-

and look out for two more gearbox-fo-

each variety. For example, the bevel gear

chasing guide is set to help engineers

cused guides which will add to the series

units are available in a straight gearing

analyse the key technical criteria and

in the near future.”

design, but this is accompanied by rela-

areas of application before a purchase. To download the guides, visit

tively high noise emission levels. Curved gearing can counteract this problem if

“We’ve released these guides to help

www.weg-wg20.com. For further in-

required, as the guide explains.

engineers make informed decisions

formation on WEG, and the new WG20

surrounding gearboxes, particularly as

gearbox, email info-uk@weg.net.

6 dpaonthenet.net

Who says that strong has to be big? PRC series circular connectors Power has nothing to do with size: IP-protected circular connectors from Phoenix Contact are ideally suited for compact power transmission for use both indoors and outdoors. The PRC series is designed for currents up to 35 A and voltages up to 690 V, and is up to 75 percent more compact than conventional industrial connectors.

For additional information call 01952 681700 or visit phoenixcontact.co.uk/prc

Small digital pressure transmitters for your challenging project

Pressure transmitters and level sensors with digital interfaces are perfect for customised solutions. Their low supply voltage and optimised power consumption make them ideal for battery-operated and wireless applications. Pressure ranges: 0,3…1000 bar / ATEX Approval / Pressure and temperature data D Line pressure transmitters I2C interface up to cable lengths of 5 m 1,8…3,6 V (optimised for button cells) 20 μW at 1 S/s and 1,8 V Total error band ± 0,7 %FS at -10…80 °C

X Line pressure transmitters RS485 interface up to cable lengths of 1,4 km 3,2…32 V (optimised for 3,6 V lithium batteries) 100 μW at 1 S/min. and 3,2 V Total error band ± 0,1 %FS at -10…80 °C

keller-druck.com

Cover story: Single Pair Ethernet

HARTING’s T1 Industrial de the benefits of Single Pair E E

xperts have suggested that Single Pair Ethernet (SPE) will be one of the technological cornerstones that help to shape the success of the IIoT. The factory of the future will require high data streams and the industrial sector needs connectivity solutions which adapt themselves to increasingly growing demands.

Up until now, industrial Ethernet has only been able to reach the control level before it needs to switch to BUS systems via gateways. SPE, delivered via HARTING’s T1 Industrial connector, allows equipment to connect via end-to-end IP-based communications right up into the field level.

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

8 dpaonthenet.net

POWER DISTRIBUTION

CLIMATE CONTROL

Cover story: Single Pair Ethernet Innovative aspects of the T1 include the

large volumes of data, right down to the

space-saving and weight-reduction bene-

printed circuit board.

fits achieved by the move to a single pair of wires. This means the compact T1 can

Aside from the benefits for the IIoT, there

be easily incorporated into smaller products

is immense potential for this new technol-

and Ethernet interfaces can be designed

ogy across a range of industries. As sen-

onto simple sensors, cameras, reading/ID

sors, actuators and network nodes can be

devices or similar miniaturised equipment.

networked and supplied with power via the T1, there are applications in automa-

Furthermore, by reducing the amount of

tion technology, robotics, machinery, and

copper wiring required, the T1 delivers

plant manufacturing. Other potential uses

weight savings of 1.6kg for every 100 me-

being explored include traffic control, in-

tres of cable used.

telligent lighting, smart farming and mobile machinery.

HARTING is also a founding member of the

delivers Ethernet

SPE Industrial Partner Network, an associa-

Within transportation, an Ethernet cable

tion of companies who are working togeth-

weighs approximately 4.6kg per 100 me-

er to promote Single Pair Ethernet technol-

tres, whereas an SPE cable weighs only

ogy. The aim is to offer an SPE ecosystem

3kg. Over 40 years – an average train car-

by pooling the knowledge of infrastructure

riage lifetime – each kilogramme of saved

providers and bringing people together,

weight delivers savings of around £12,000

on the device side. This open environment

per carriage. When you consider how many

approach allows standards to be devel-

miles of cable are found in trains for enter-

oped and advanced. It also means those

tainment, safety and control technologies,

customers who are keen to invest in SPE

it soon becomes apparent that significant

are guaranteed solutions which will work in

cost and weight savings are possible.

combination, because of the single standard, T1 Industrial-style connector face.

In industries such as robotics, where the cables are subjected to strong torsional

For maximum flexibility, the T1 mating face

forces, the reduced number of wires means

can be integrated into standard housing

thinner and more flexible cables, which pro-

The T1 Industrial supplies both data and

forms as required. As the product family

longs their service life.

power via Power over Data Line (PoDL)

expands, there will be interfaces in M8 and

across a single pair of wires in an IEC

M12 housings, as well as other designs.

To learn more about the HARTING T1

63171-6 industrial interface. This brings

HARTING not only has connectors and oth-

and SPE, please visit

Ethernet from the cloud to every sensor

er components in mind, but a complete Sin-

www.harting.com/UK/en-gb/single-

– enabling Industry 4.0.

gle Pair Ethernet system which will quickly

pair-ethernet or get in touch via

and securely deliver higher bandwidth and

salesuk@HARTING.com.

IT INFRASTRUCTURE

SOFTWARE & SERVICES

www.rittal.co.uk

Feature: Motion control couplings

Motion control couplings: Single sourcing vs sourcing from multiple manufacturers M

otion control couplings are one of the most common industrial components and there is a diverse base of manufacturers from which to choose, giving original equipment manufacturers (OEMs) many options when selecting a coupling.

This supplier diversity is a benefit during the design phase. However, it can present supply chain problems to OEMs once machines reach production volume, including inconsistent quality, poor service, minimal global support, long lead times, and constantly changing delivery dates. These problems are exacerbated by the current COVID-19 pandemic and have caused companies to reevaluate their supply chain.

About the author: Robert Watkins is Vice President of Sales and Applications at Ruland Manufacturing. Bobby joined Ruland in 2003. He has extensive mechanical application experience and assists engineers around the world to specify the right coupling for their design. Prior to joining Ruland, Bobby worked for THK as a District Sales Manager with responsibility for strategic accounts, sales management, and employee development. He also has extensive industrial distribution experience with Kaman and Atlantic Tracy.

Switching to a single source for couplings

than just the convenience of a one-stop

of the new manufacturer. There will also

presents different challenges, but many

shop, though the associated time savings

be no impact on existing operations. If a

OEMs see supply chain improvements

should not be understated. Many sys-

mid-cycle switch must be made due to is-

when switching – without compromis-

tems, such as those found in semicon-

sues with existing suppliers, there is cost

ing system performance. Most coupling

ductor, solar, and test and measurement

associated with retesting and possibly

manufacturers, even big ones, choose

equipment, will require multiple couplings

recertification (industry dependent). The

to specialise in one or two types of cou-

that perform different functions – wafer

OEM will rarely make a mid-cycle switch

plings. While they may offer a wider range

handling, ball bonding, optical inspection

unless there are severe quality or lead-

of “standard” styles within the one or two

etc. One or two coupling styles cannot

time issues that cause consistent delays

types, these highly engineered solutions

adequately meet the varied needs of each

in delivering equipment.

must be offered to accommodate for per-

type of system. This forces the OEM to

formance deficiencies that are solved by

decide between sourcing couplings from

Jumping from one motion control coupling

standard couplings not in their offering.

multiple manufacturers and single sourc-

manufacturer to another (and then anoth-

For example, a manufacturer of beam

ing. When single sourcing, the OEM must

er) creates transactional relationships with

couplings may have an expansive range

weigh the risk of that manufacturer poten-

no guarantee of quality or service. OEMs

of stainless steel options to offer higher

tially failing to meet lead times, maintain

that consolidate their supply chains can

torque and torsional stiffness than their

quality standards and stay in business.

form collaborative relationships with the

aluminium options. Stainless steel beam

Working with a trusted manufacturer can

manufacturer and increase their chanc-

couplings have high inertia, can limit sys-

often alleviate these concerns.

es of long-term success. By identifying

tem performance, and can be significantly

a coupling manufacturer the OEM trusts

more expensive than jaw or disc cou-

The best time for an OEM designer to con-

and sticking with them, they can enjoy the

plings offered by other manufacturers.

sider switching to a single manufacturer is

benefits of consistent product quality, ser-

during new design work. This gives them

vice, and lead times.

A comprehensive motion control cou-

the opportunity to test the product, cus-

pling line offers more benefits to the OEM

tomer service and logistics capabilities

10 dpaonthenet.net

www.ruland.com

M8 12 contacts

Cable & panel mount connectors

IP67

PUR-/PVC cable

www.binder-connector.co.uk

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Feature: IIoT connectors

M12 connectors – A perfect fit fo I

t is generally recognised that, by the end of this year, more than 20 billion devices will be connected to the Industrial Internet of Things (IIoT) and it will be a market worth $200 billion by 2021. In basic terms, the IIoT represents real-time data connection, driven by processing and transmitting data at faster speeds, on progressively smarter and smaller machines.

safety, and maximise overall equipment effectiveness (OEE).

Introduced in 1985, the M12 connector A comprehensive view of a manufactur-

is a reliable product for industrial appli-

ing process or assembly line is accom-

cations. Originally used by car manufac-

plished by placing networked sensors

turers, the M12 has become the industry

on physical equipment to collect data.

standard in factory automation, autono-

These sensors perform condition moni-

mous robotics, communication, meas-

toring, analysing constant input like tem-

urement and control, and many other

perature, vibration, or sound frequen-

applications.

cies. This data is transmitted back to a central location or cloud where deci-

On the plant floor or in the field, person-

sion-makers can access it. This process

nel need to be able to disconnect ex-

requires reliable high-speed connec-

isting connectors for maintenance and

The true value of the IIoT, however, goes

tions, often in environments that include

install new connectors on newly laid ca-

beyond data collection and transmis-

dust, noise, temperature changes, and

bles quickly, especially where connec-

sion. It embraces the complete visibility

vibration. In industries such as food and

tions must remain dust- or water-tight.

and control of virtually all electrome-

beverage, there is the additional chal-

M12 connectors are easily installable

chanical factors in the manufacturing

lenge of frequent washdowns.

and clearly coded to reduce the chance

process, allowing companies to move beyond

M12-T coded for power applications

M12 connectors are the perfect fit

descriptive

and

diagnostic

of accidental mismating.

Connectors are the vital link

analysis to predictive intelligence and

Connectors act as the vital link between

M12 connectors are available with three,

preventive action. Plant operators can

the cables carrying data and the devices

four, five, eight or 12 pins. The ideal

discover unused capacity, reduce main-

that record and communicate information.

pin count depends on the application.

tenance costs and downtime, improve

The demand for faster data transmissions

For example, most sensors and power

that can accommodate visuals has driven

applications use three or four pins,

the development of connectors that are

whereas Profinet and Ethernet use four

able to support the gigabit data require-

and eight pins.

ments for the latest sensors. To add to the complexity, machines are getting smaller,

Locking systems

putting pressure on component makers to

There are three basic types of locking

deliver greater speed, power and capacity

systems on an M12 connector:

in an ever-shrinking footprint.

12 dpaonthenet.net

1. Push-pull: Locks easily and securely

Feature: IIoT connectors jects, while also protecting against impact, vibration, UV exposure, and temperature changes

plug and receptacle housing • Panel-mounted receptacle has a good galvanic connection between

• Minimum IP67-rated ingress protection against dust and water

the metal receptacle housing and the metal panel surface.

• Additional options with IP68 and IP69K ratings for demanding wash-

Compact size – Increasingly smaller

down environments

devices and sensors are transmitting more data, which requires more con-

Mating cycle ratings are another impor-

nection points, meaning that connectors

tant consideration for machine builders.

have to deliver the same (or more) power

Ratings are determined by the material

density in a smaller footprint.

used for contacts and plating, as well

or the IIoT

as the thickness of the plating. Cheaper

Originally designed to reduce the size of

connectors, made with tin plating and

the 7/8” connector, which was standard

copper alloy contacts, will not perform

at the time for sensors, the M12 con-

as well as those made with corrosion-re-

nector has an outside diameter locking

sistant materials such as thick gold

thread of just 12mm. Its small footprint

plating and beryllium copper contacts,

makes it well suited for applications with

which are typically rated for >100 mat-

little free space, such as automation

ing cycles.

control systems, telemetry modules, compact LED lighting fixtures and value

EMI shielding – Hard-wired connec-

actuators.

tions offer some advantages over wireless connections, including the intrinsic

M12 technology continues to evolve.

with an audible click indicating that

security of physical connections and

Machine designers and OEMs are in-

the proper connection has been es-

the avoidance of wireless interference.

corporating M12 connectors into new

tablished.

This is especially important because the

machines, as well as updating existing

2. Threaded coupling: A threaded nut

new IIoT-enabled factory is often filled

infrastructure. With backwards compat-

on the plug is mated with a corre-

with electromagnetic interference (EMI),

ibility, replacing older and less robust

sponding set of threads on the re-

also called radio frequency interference

technology is relatively simple and cost

ceptacle.

(RFI). Unseen and unheard by people,

effective. Manufacturers of M12 con-

3. Bayonet: An interconnect mating

this electronic noise pollution frequent-

nectors continue to innovate, adding

design that uses pins on the re-

ly interferes with high-precision sensors

new features to meet the quickly chang-

ceptacle and ramps on the plug for

already taxed by the physical noise and

ing needs of the robotics, automation,

quick connect and disconnect cou-

vibrations of a busy factory floor.

food and beverage, alternative energy,

pling.

and cellular communication industries. The increasing pervasiveness of EMI

Positionable, lockable and field-wireable

M12 connectors are the smart choice for Industry 4.0

places an additional burden on man-

connectors, that are capable of trans-

ufacturers to design equipment that

mitting impressive amounts of data and

Though M12 connectors were availa-

generates as little EMI as possible and

power, ensure that the M12 will continue

ble decades before the IIoT was even

ensures that their equipment has rea-

to be an essential component of Indus-

a concept, they have become the pre-

sonable resistance against it, so that

try 4.0 and beyond.

ferred connector for today’s industrial

operation isn’t affected. www.binder-connector.com/uk/

Ethernet. In order to satisfy these requirements, Here are three key reasons why M12

manufacturers need connectors and

connectors are the smart choice for In-

connecting

dustry 4.0:

shielding properties. Good shielding is

cables

with

sufficient

achieved when the following conditions Unrivalled ruggedness – Compared to the RJ45, the other most commonly used data connector, M12 connectors offer higher performance in harsh conditions due to: • The circular design that shields

are met: • Cable shield is terminated to conductive (metal) housings • Cable shield is carefully secured to the connector to provide 360° shielding

contacts from contaminants such

• Mated connector pair has a secure

as dust, moisture, and foreign ob-

galvanic connection between the

M12-A coded for signal and power

dpaonthenet.net 13

Feature: Industrial connectors

Making sure your connectors are tough enough for industrial deployment T

he use of industrial connectors in an industrial context is certain to set some challenges. There are likely to be a number of factors that could have a detrimental effect on the smooth operation of these components. These include challenging temperature levels, shocks, vibrational forces, torsion forces, high humidity, etc. In addition, the connectors may need to deal with regular mating/un-mating and poor treatment of equipment by machine operatives. Let’s look at what needs to be considered when specifying connectors for industrial applications. 14 dpaonthenet.net

Industrial connectors must be robust in

print and can withstand a greater pulling

various ways. Coping with the ongoing vi-

force. This helps prevent the cable as-

brations caused by heavy machinery is an

sembly being pulled off the PCB. When

important point to consider and the se-

greater strain relief is required, it may be

lected connectors should be adequately

necessary to apply an epoxy resin com-

resilient. Tests relating to the EIA-364-28D

pound to the connection points of the

Condition IV standard expose connectors

cable assembly to fill the rear of the cable

to vibrational frequencies cycling from 10

connector. Known as backpotting, this is

to 2000Hz, with a 1.52mm vibrational am-

of particular value in applications where

plitude, for a period of 12 hours to ensure

there are complex, repetitive movements

that no break in electrical contact occurs.

involved – such as robotic systems.

Connectors that comply with this stand-

Latching or screw-locking between con-

ard are recommended.

nectors also prevents accidental or vibration disconnection between cable-to-

Other mechanical stresses may need to

board mated pairs.

be considered. Forces could be present that put cabling at risk of being pulled

Connectors intended for industrial usage

out, so it is essential that effective strain

should support a broad working temper-

relief is in place. Connectors featuring

ature range as they often need to cope

surface-mount hold-downs should be

with higher heat levels. Heat can be gen-

sourced, as these add to the overall foot-

erated by machinery while it is running or

Feature: Industrial connectors created due to the processes undertaken.

Given that there are so many different

right angle). Their working tempera-

Depending on the particular application

aspects to consider when choosing

ture range spans from -55 to 125°C,

conditions, a temperature range covering

the best connector for industrial im-

and they meet EIA-364-32C Condition

-55 to +125°C should be sufficient. The

plementation, it is important to have

III thermal shock requirements. They

thermal shock testing outlined in EIA-

access to all the necessary information

comply with EIA-364-28D Condition IV

364-32C Condition III could be of bene-

before making your choice. Both the

in terms of vibration resilience. Thanks

fit when it comes to ensuring continued

electrical performance characteristics

to a fully shrouded design – with built-

interconnect integrity. This test proce-

and the environment characteristics

in polarisation – their contacts are

dure cycles connectors between -55 and

should be fully understood.

protected against the possibility of

+125°C 10 times (spending 30 minutes at these points on each occasion).

damage, enabling them to support 500 Combining

construction

mating cycles. They have a retention

with appealing price points, the Archer

heavy-duty

force of at least 3.9N per contact. In

The mating tolerance of the connector is

Kontrol series from Harwin has been

addition, they have an insulation resist-

also an important aspect to consider. The

designed to meet the expectations of

ance of >1000MΩ to prevent crosstalk

connector may need to be mated and dis-

modern

implementations.

occurring. The Archer Kontrol series is

connected many times by operatives on

These 1.27mm pitch connectors have

accompanied by both off-the-shelf and

the shop floor during procedures such as

a current rating up to 1.2A per contact

custom-designed cable assembly op-

recharging, carrying out firmware updates

and are able to deliver the 3Gbps data

tions – ready-made and fully inspected

or re-configuring equipment. Any damage

rates now mandated by industrial auto-

and tested for immediate usage.

to the contacts from this mating/un-mat-

mation network infrastructure. A variety

ing activity can shorten the connector’s

of different stacking heights are offered

By considering each of the different el-

longevity and you might need to carry out

to address acute space constraints.

ements discussed in this article, match-

industrial

replacement work much sooner, increas-

ing a connector to different industri-

ing CAPEX and OPEX costs. Damage is

Archer Kontrol connectors are availa-

al-oriented applications is much more

likely to be even more serious in blind mat-

ble with between 12 and 80 contacts,

straightforward.

ing situations where the operative cannot

covering all board-to-board config-

see the mating pair directly, as mating ac-

urations (parallel, edge-to-edge and

www.harwin.com

curacy is reduced. However, features can be incorporated into connectors to protect them from mating-related damage. Leading edges on both the male and female elements can assist with guiding them together. This is particularly helpful when blind mating occurs as it lowers the chance of contacts being broken or dented. It is worth checking the manufacturer’s datasheet to see if the connector can accept a certain degree of angled misalignment. Shrouded connectors are a very attractive option when looking to avoid mating issues, as these will guarantee that the mating position is correct. Polarisation or keying can also be employed.

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! w e n

About the author: Wendy Preston is the Content Marketing Specialist at Harwin. She has worked for Harwin since 1995. Her role includes responsibilities for the product database behind the website, the catalogue, other technical and product launch documentation, and informative articles for publication on Harwin.com and beyond.

n: s s io f i m oo My e-pr ure r u t ct Fu s tr u T a r f In I IO for d le vel l e fie h t in

HARTING T1 Industrial: Ethernet delivered via one pair of wires Standardised Single Pair Ethernet (SPE) interface to IEC63171-6 Modular interface for IP20 - IP67 housing Remote Powering (PoDL) for data and power via one pair of wires 1GBit/s over 40 metres, 10MBit/s over 1000 metres 30% weight saving thanks to single pair cables www.HARTING.com/UK/en-gb/single-pair-ethernet

Feature: Smart wiring solutions

Smarter wiring solutions for advanced, affordable robotics Figure 1: 885031K03M020MicroChange M12 Chordset. (Source: Molex)

iniature industrial robots, including desktop-sized SCARA units and collaborative robots that can work safely alongside humans, are making advanced automation practicable for a wider range of applications. Easy-to-use graphical programming tools add to the attraction, giving owners control and flexibility, without requiring heavy investment in specialist skills or training.

Wiring challenges in industrial automation Wiring can be a challenge for automation of any type, whether robotic or otherwise. A complex machine or assembly line may contain hundreds of IOs, or

The market for industrial robotics is

parts and ensure easier assembly can

more, and each requires a reliable and

showing double-digit growth and could

accelerate manufacturing and ease pro-

secure connection to a power panel or

exceed $40 billion by 2025. With com-

duction logistics. They can also deliver

control cabinet. Traditional hardwiring is

mercial opportunities for drones also tak-

reduced commissioning time, easier

highly labour intensive, involving strip-

ing off, buyer power will pressure robot

maintenance, and greater reliability.

ping, soldering and possibly crimping a

suppliers to produce more units, reduce

huge number of point-to-point contacts.

ownership costs, and introduce new fea-

A systematic approach to wiring could

tures and capabilities more quickly.

help realise these gains by minimising

After all the connections are wired and

the time to install power, signal, and IO

tested, disassembly for shipping is sub-

To meet these demands, robot makers

connections throughout the machine.

sequently followed by reassembly in situ.

need to increase their own productivity,

For drones, a connector system can

Often, this commissioning must be man-

which calls for efficiency gains, such as

help lower airframe weight by providing

aged by sending valuable, trained staff

reducing the time to build and test each

components, such as distribution units,

to the customer’s site, which adds to the

unit. Among these, design changes

that minimise the number of cables and

supplier’s overheads. In addition, each

that minimise the number of individual

cable run lengths.

wiring and unwiring carries the risk of

dpaonthenet.net 17

Feature: Smart wiring solutions incorrect installation or damage to con-

and easier access for maintenance and

The Brad M23 series provides fast,

nections. Fixing mistakes adds time and

troubleshooting. Technicians can quick-

modular connectivity for motor control

expense to the commissioning process.

ly disconnect machines using modular

and power distribution in synchronised

Worse, if problems are not discovered

assemblies with custom configurations

robotic systems. The system contains

until the machine goes live, the remedial

and plug directly into portable testing

field-attachable connectors and recep-

costs may be higher still. Subsequent-

equipment. In addition, the overall stabil-

tacles for signal and power applications

ly, throughout the machine’s lifecycle,

ity and performance of the machine and

in 6-pole to 19-pole configurations for

routine maintenance and emergency

its many connections can be increased,

front- and rear-mounting applications.

troubleshooting in a plant with multiple

and customers can benefit from greater

The Brad power connector system pro-

motors and drives might require discon-

productivity, thanks to increased relia-

vides a “soft wiring” system designed to

necting and reconnecting hundreds of

bility and minimal downtime. Moreover,

meet the needs of robotic applications

contact points to address an issue.

a modular connector system provides

and includes modular M23 power con-

flexibility and scalability quickly to modify

nectors capable of handling up to 28A.

Taking advantage of a modular connec-

or expand machines and product lines.

tor system can help streamline machine

The Brad family also includes connec-

assembly and maintenance, delivering

While providing convenient, efficient

tors in the M12 threaded format, includ-

advantages such as reduced assem-

and, in some cases, weight-saving con-

ing harsh-duty receptacles that offer a

bly time, shorter commissioning time,

nectivity, connector systems must sat-

sealed connection with EMI/RFI shield-

isfy additional criteria, such as special

ing and vibration resistance, and Brad

requirements of the food and beverage

Hybrid connectors that combine power

industries – which demand compatibility

and data connections to save space and

with cleaning chemicals and the ability

cut installation time.

to withstand stringent washdown procedures. Other valuable features may in-

On the other hand, while threaded cou-

clude support for PROFINET Fast Start-

plings provide a secure and reliable inter-

up (FSU) and Ethernet/IO QuickConnect

connect, mating and un-mating during

in industrial Ethernet networks.

production or maintenance can be time consuming and physically challenging

Interconnect system efficiencies

if the connector is in a location that is

Molex’s Brad interconnect systems are

ible Brad Ultra-Lock system (Figure 1)

already used throughout the industrial

gives the ease of a push-pull connector

automation world. Their modular de-

for easy, safe and reliable connection of

sign ensures flexibility and ease of use.

sensors, actuators, and other control

It also enables secure assembly and

devices.

not easily accessible. The M12-compat-

disassembly without special tools. The

18 dpaonthenet.net

connectors meet applicable industry

When installed, industrial automation

standards, such as NFPA 79 and IEC

– including robotic systems – may be

specifications, and withstand harsh en-

subjected to severe washdown proce-

vironmental conditions inside factories

dures, sometimes with harsh or corro-

and in outdoor environments.

sive cleaning agents added. Automation

Feature: Smart wiring solutions actuator level. The module capabilities are enhanced when used in combination with Brad IO-Link digital IO Hubs and analog adapters. Concentrating machine information into one network functional node, the Brad IO-Link Solution is ideal for conveying line, robotic, filling station, labelling, palletising, and end-of-arm tools.

About the author:

Conclusion Market opportunity and commercial pressure are two sides of the same coin. To take advantage of the currently burgeoning market opportunities for advanced robotic automation, suppliers must respond to commercial pressures that demand lower unit costs and lower maintenance in the food and beverage

Auto tool-change compatibility

overheads, combined with assurances of

industry is a prime exam-

For larger machines or higher I/O counts,

high reliability and performance.

ple. Mobile robots such

active networked Brad HarshIO modules

as drones and autono-

can help concentrate cables and are

Modular power and connectivity solu-

mous vehicles can also expect frequent

compatible with the M12 Ultra-Lock sys-

tions designed for rapid commissioning

cleaning with a pressure washer before

tem. The range includes compact mod-

of complex machines and robotic sys-

being quickly returned to service. An in-

ules that are only 30mm wide.

tems have a key role to play in achiev-

tegrated radial seal designed into Brad

As Mouser Electronics’ Technical Marketing Manager for EMEA, Mark Patrick is responsible for the creation and circulation of technical content within the region – content that is key to Mouser’s strategy to support, inform and inspire its engineering audience. Prior to leading the Technical Marketing team, Patrick was part of the EMEA Supplier Marketing team and played a vital role in establishing and developing relationships with key manufacturing partners.

ing these goals. In addition to reducing

Ultra-Lock components ensures very

Supporting all major industrial communi-

labour on the production line, the elec-

high ingress protection for connectors,

cation networks and protocols, including

trical commissioning time of industrial

cordsets and distribution boxes (Figure

PROFIBUS-DP, DeviceNet, CANopen,

machinery and automation systems can

2). Units are rated to IP69K, which spec-

Modbus TCP, EtherNet/IP, and PROF-

be reduced by up to 80 percent and the

ifies exposure to a high-pressure water

INET IO, these machine-mountable mod-

total installed cost can be 50 percent

jet up to 100 bar at 80°C ±5°C. Also, in

ules also support the PROFINET FSU

lower. At the same time, cutting size and

line with the requirements of the food

and Ethernet/IP QuickConnect systems.

weight can deliver important advantag-

and beverage industry, these connec-

This makes them ideal for use in robots

es for mobile robots such as drones and

tors have no threaded grooves as found

with automatic tool changeover that are

autonomous vehicles. Moreover, future

in conventional M12 hardwired connec-

deployed in high-speed assembly appli-

generations of compact and agile robots

tors, and feature smooth-surfaced stain-

cations.

could extend the benefits of advanced

less steel couplings that have a broad

FSU and QuickConnect meet demands

automation to an even wider customer

compatibility with cleaning chemicals.

that originated from the automotive

base, including companies operating in

industry, which called for data com-

small and space-constrained premises.

In situations where space can be tight

munication to be established more

or overall weight must be minimised

quickly than conventional industrial Eth-

(such as in small machines or drones),

ernet protocols allow, each time a tool

an M12-compatible distribution solu-

is changed. Both systems introduce an

tion reduces single wiring distances and

additional, dedicated hardwired con-

home-run cable sizes, as well as saving

nection to signal the main controller as

installation time. The Brad Multi-Port

soon as the new tool is connected.

www.mouser.com

Interconnection System (MPIS) concentrates the sensor/actuator signals

Machine builders looking for cost-ef-

into a single home-run cable for better

fective, high-density, high-performance

mechanical infrastructure wiring on the

and seamlessly integrated fieldbus con-

machine. There are flexible options for

nectivity in harsh environments can fulfil

terminating the cable, including M16/

system requirements using Brad IO-Link

M23 connector, field-terminated screw

Master Modules on EtherNet/IP and

terminal, or direct mounting. In addi-

PROFINET, combined with IO-Link Dig-

tion, built-in diagnostic power and sen-

ital Hubs. The modules support the IO-

sor LEDs help quickly detect machine

Link communication standard to extend

states and failures on devices.

the digital link down to the sensor and

Figure 2: The Brad M12 cord sets and rugged MPIS Safety Box simplify wiring in harsh factory environments. (Source: Molex)

dpaonthenet.net 19

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Feature: Machine vision

How autonomous machine vision can help ward off the looming recession

he Great Depression that hit the US in the 1930s was probably the worst economic recession ever registered. To guide the country out of it, President Roosevelt launched a series of programmes, public work projects and financial reforms known as the New Deal. While the economic implications of COVID-19 threaten to shadow the Great Depression, Harel Boren, CEO and Co-Founder of Inspekto, explains why Autonomous Machine Vision (AMV) could be the new New Deal.

plant managers need ready-to-use,

Today, we are facing a risk of a major

To ward off its negative impact, ‘af-

tonomous in every way, releasing plant

global recession as the result of the

fordable flexibility’ is key. Manufactur-

managers from lengthy and expensive

COVID-19 pandemic. As manufac-

ers need the ability to adapt, adjust

contracts with external third parties,

turers are planning the resumption of

and modify their production lines cost

such as systems integrators. It is highly

work after the shutdown period, ex-

effectively. This will allow them to meet

versatile in that it can be used to inspect

perts predict that a major global re-

changing needs in a dynamic and com-

any product, in any industry, produced

cession might be inevitable.

petitive environment. Most importantly,

with every manufacturing technique.

out-of-the-box technology that delivers added value right away, and that they can manage on their own without any help from external experts. For industrial inspection, Autonomous Machine Vision (AMV) – a new category in machine vision for visual quality assurance (QA) – offers this and much more.

It’s good to be autonomous (it’s cheaper, too) The INSPEKTO S70, the first Autonomous Machine Vision product, is au-

dpaonthenet.net 21

Feature: Machine vision The installation is quick, easy and fun.

be installed while the production line is

As AMV products are cost effective

Thanks to Inspekto’s Plug & Inspect

running, causing zero downtime.

and extremely quick and easy to set

technology, the plant’s own personnel

About the author: Harel Boren is the CEO and Co-Founder of Inspekto. Prior to co-founding Inspekto, Harel held key executive roles in tech start-ups and corporations, including two major technology exits (NASDAQ, M&A). A mentor to tens of technology start-ups, Harel was among the first to lead the way for Israeli tech into the European industrial and investment communities. Harel holds a B.Sc. in Economics and an LLB in Law from the Tel Aviv University.

up, plant managers can position a

can install an AMV system in just 30 to

This out-of-the-box system comes

QA station at every junction of the

45 minutes, with no external interven-

with everything QA managers need to

production line, instead of just at the

tion. The user simply presents an aver-

perform accurate and effective visual

end – realising what Inspekto calls To-

age of 20 to 30 good samples to the

QA right away. Also, with the INSPEK-

tal QA. This minimises scrap because

system, which will automatically learn

TO S70, there’s no need to invest in

resources will not be wasted on items

what a gold-standard product should

training. Thanks to its self-adapting

that are destined to be defective from

look like.

and

the very beginning.

self-learning

capabilities,

the

product operates in complete autonMuch like a human being, the INSPEK-

omy, communicating directly with the

Over time, Total QA allows manufac-

TO S70 knows when it has enough

programmable logic controller (PLC),

turers to see where defects are more

information about a part to start in-

without any intervention from the

likely to occur, so that they intervene

specting it. After inspection begins,

plant’s personnel.

in the most appropriate way. In times

the system will alert the user to every

of financial instability, it is paramount

Less scrap equals more profit

that plant managers identify every op-

Minimal investment, maximal result

If the country hits a phase of economic

processes, working at full potential to

recession, cutting costs is not enough.

outrun the competition.

In times of financial instability, the first

Manufacturers should also enhance

thing plant managers do is keep their

profitability by reducing scrap and

Investing in your people

budgets under control. The INSPEK-

waste, identifying defective items as

AMV allows manufacturers to free per-

TO S70 requires minimal initial invest-

soon as possible and optimising their

sonnel from tedious QA procedures,

ment because it can be purchased for

production lines so that the same de-

whether these are manual inspection

less than one-tenth of the cost of tradi-

fect doesn’t keep happening.

tasks or the maintenance of complex

deviation from the defined standards.

tional QA solutions. In addition, it can

portunity to improve their production

machine vision solutions. Manual visual inspection carries an error rate of up to 25 percent and keeps employees busy on a task that does not add value to the business. Consider this example from the automotive engineering sector: in the UK, the average value added by each employee in this sector is £100,000 a year, so manufacturers lose millions by assigning several shifts of employees to tedious inspection tasks. By investing in an Autonomous Machine Vision system, manufacturers can move those employees into productive roles that create value for the business. A small investment in an INSPEKTO S70 can save a plant hundreds of thousands per year. It’s clear that automotive manufacturers in particular, but also industry overall, could save millions by reducing the number of detectable faults in their products. The New Deal that AMV provides could certainly be the boost that the economy requires. https://inspekto.com

22 dpaonthenet.net

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Feature: Smart sensors

A wide range of sensors from ifm electronic are suitable for the food industry and meet the corresponding requirements of a hygienic design

Smart sensors in the food industry T

he food industry often presents challenging environments for components and, in particular, for the sensors used in process control applications. In addition, users’ expectations of sensor technology are continually increasing. These considerations mean that the future belongs to smart sensors that not only offer outstanding performance and reliability but also deliver substantial added value, says Andy Walker of ifm electronic.

Sensors with added value Many sensor products are now available in hygienic versions designed specifically for food industry applications, and manufacturers of these sensors are increasingly focusing their development efforts on applying innovative technology to provide added value for users of their products. A good example of these innovations is

Automation systems in the food manu-

cations for these sensors are the same as

a new generation of level sensors that

facturing and processing sector rely on

those in any other process industry, but,

operate on the guided wave radar (GWR)

data from a huge number of sensors. The

in the food sector, hygienic design is of-

principle. GWR sensors are installed

most important parameters monitored by

ten an additional and critical requirement.

vertically at the top of a tank and emit high-

these sensors include pressure, temper-

In some cases, the sensors must also be

frequency electromagnetic pulses that are

ature, flow and level. Many of the specifi-

suitable for use in hazardous areas.

guided downwards along a stainless steel

24 dpaonthenet.net

Feature: Smart sensors rod. These pulses are then reflected from

devices and systems has never been more

sensor data to ERP and other high-level

the surface of the medium, back towards

important. Communication at sensor level

corporate systems. A convenient way of

the sensor. The transit time of the pulses

is the basis for comprehensive commu-

achieving this is to use an agent connec-

is used to evaluate the distance to the

nication infrastructures that extend all the

tivity port, which is a software gateway

surface and thus, the level in the tank.

way up to corporate level and beyond.

that supports bidirectional communication

This measuring technology provides im-

For many users of industrial automation

This makes possible communication be-

portant benefits over other types of level

systems, sensor level communication

tween ERP systems and devices at the

sensors. GWR sensors are unaffected by

means IO-Link and the latest generation of

field, control and process control levels.

changing media (provided that the dielectric

sensors use this digital protocol, as well as

Implementations specifically designed for

constant is >5), changing temperature, gas

providing conventional analogue interfac-

the capture and transmission of data from

blankets or vapours, and by the build-up of

es. With IO-Link, interference on the con-

IO-Link sensors are available and, with

product on the probe itself. In addition, they

necting cable to the sensor has no effect

these, data can be transmitted directly

can accurately and reliably measure liquid

on the accuracy of the measurement. This

from sensors to the ERP system without

levels in many foaming applications.

is a big benefit compared with analogue

the need for it to pass through a PLC.

About the author: Andy Walker is a Product Sales Manager at ifm electronic.

for a wide range of different interfaces.

interfaces, where measurements can be The probes for the food industry versions

severely affected by interference. Further,

This direct path for sensor data which by-

of these innovative sensors are made of

with IO-Link, multiple values from a single

passes the control level is referred to as “Y

high-grade stainless steel, and all other

sensor can be transmitted simultaneously,

communication” because the data splits

components follow hygienic design princi-

adding even more value to the user.

like the letter Y, flowing via one branch to

ples to meet the requirements of EHEDG.

the PLC and via the other branch to the

Probes with different lengths are available

IO-Link also has benefits during mainte-

ERP and other corporate systems. This

and can be easily interchanged by the

nance and repair. Since sensors can be

solution opens up possibilities that would

user to meet the needs of the application.

configured via IO-Link, should it become

be hard to implement with conventional

The probes can also be cut to length if no

necessary to replace a sensor, the con-

sensors and analogue interfaces. Data

suitable standard length is available. This

figuration data can be transferred directly

logging, condition-based maintenance

modular design maximises versatility and

to it. The time-consuming process of set-

and improvement of energy efficiency are

reduces costs. The best of these sensors

ting up the sensor on site is eliminated,

just some of these.

also have an IO-Link interface.

which means that the time needed to put

Another example of sensors that offer

reduced. Users can even access self-di-

The future belongs to smart sensors

added value is provided by temperature

agnostic data from sensors that have an

Smart sensors offer many advantages

sensors that incorporate two sensor ele-

IO-Link interface, making the location of

for the food industry and can significant-

ments with opposing temperature charac-

faulty devices faster and more certain.

ly reduce costs. Today, many automation

teristics. The elements – Pt1000 and NTC

Once again, this helps to reduce plant

solutions still use analogue sensors, but

thermistor – operate independently and

downtime.

the adoption of sensors with IO-Link inter-

the plant back into service is significantly

are continuously monitored by a micro-

faces is increasing rapidly, as more users

that the measured temperature value is

Data transmission to an ERP system

valid based on a user-defined temperature

Another important aspect of digital sen-

differential or “drift” between the two sen-

sor communication is the transmission of

processor within the sensor. This verifies

become aware of the added value they provide. www.ifm.co.uk

sors. If the internal drift is exceeded, then it is signalled immediately via a separate diagnostic output. Both measured temperature values, the differential value as well as the diagnostic value, are available via IO-Link. The use of these sensors in temperature-critical processes provides assurance of measurement (and therefore, process performance) between calibration intervals and may reduce requirements for costly calibration.

Communication via IO-Link With the growing interest in and adoption of Industry 4.0, communication between

Many processes in the food industry require accurate control of the temperature of fluids

dpaonthenet.net 25

Feature: Torque sensor

Hydrogen car drives for efficiency world record B

y using a British torque sensor, a team of Dutch engineers competing to develop the world’s most efficient hydrogen-fuelled car has determined that their next-generation vehicle needs a custom-designed and built hub motor.

most appropriate torque sensor and opted

ed were based on data from previous car

for the RWT 410-420 from partner compa-

races, such as the Shell Eco-Marathon

ny, Sensor Technology.

2019 and the Drivers’ World Championship 2019.

“The big advantage of the RWT 410-420 is that it has a very easy interface with which

After experimentally determining the effi-

we can easily and accurately read the data

ciency, the students can compare the ide-

digitally,” says Team Manager Tony Kouze-

al theoretical model with the experimental

To measure the efficiency of the car’s

lis. “It also measures rotational speed and

data.

drivetrain, Green Team Twente has built a

torque at the same time, which ensures

bespoke test rig based on the TorqSense

the accuracy of our efficiency calculations.

Test results

torque sensor made by Sensor Technolo-

This is very important because we are in

The tests showed that the drivetrain per-

gy Ltd of Banbury in the UK.

competition with other very good hydro-

formed better in theory than in practice

gen power cars, so the winning margin will

and, therefore, that there was room for im-

be just a few percentage points.”

provement. However, the team also had to

Green Team Twente is committed to developing the most efficient hydrogen car

consider the mechanical limits of the mo-

in the world. The multidisciplinary team

Test set-up

tor, which cannot be redesigned within the

consists of staff and students from two

Using the rig, the students tested the an-

current system.

universities in the Netherlands, Saxion Ho-

gular speed of the shaft and the actual

geschool and the University of Twente. It

torque generated. By measuring the input

Based on the test, the team looked for

develops a new hydrogen car every year,

current and voltage of the motor control-

alternatives and made simulations of dif-

building on the design of the previous year.

lers, they could determine the combined

ferent options. Ultimately, the choice was

mechanical and electrical efficiency of the

made to develop a new hub motor, in

At the start of this academic year, there

drivetrain. Varying the load on the motor

which the optimum efficiency is geared to

was an important choice for the mechan-

with an eddy current brake simulates the

the desired range.

ical engineers in the team to make; could

conditions of a race. The power supply of

they gain more efficiency by further opti-

the motor controllers and torque sensor

“After the new motor has been developed

mising the current drivetrain of the car or

can be read using the integral LabVIEW

and the controller has been tuned to it,

should they move to another technique?

software. The input and output power, with

the efficiency of the motor can be tested

The drivetrain consists of four DC motors

the associated efficiency, can be digitally

in practice,” explains Kouzelis. “Then, we

that power the rear left wheel via a Cardan

processed and stored with this software.

can compare the test results with the old

shaft and custom-made gearbox.

drivetrain to see how much efficiency is With the test set-up, the team measured

improving with the new drivetrain. This is

In order to decide, it was necessary to

the efficiency of the drivetrain at as many

a significant step in our on-going objective

assess and quantify objectively the capa-

points as possible. The team then derived

of developing the world’s most fuel-effi-

bilities of the existing drive chain, so the

the three-dimensional efficiency curve by

cient car.”

first job was to design and built a suitable

fitting the measured points. The condi-

test rig. The students set out to identify the

tions under which the tests were conduct-

26 dpaonthenet.net

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Feature: Waterproof enclosures CamdenBoss general enclosures

Selecting the best enclosures for washdown environments I

n many industries, including the food and beverage industry, electronic devices need to withstand washdown conditions. Within a busy industrial kitchen environment, electronic devices may come into contact with a variety of substances. These could include oil and grease, food and other debris that need to be cleaned on a daily basis to ensure the smooth operation of equipment and to stop the spread of bacteria and germs.

Cleaning with the use of pressurised

CamdenBoss manufactures a wide

water is a common and effective way of

range of waterproof enclosures, de-

cleaning down areas quickly and easily.

signed to meet the requirements of dif-

However, when we introduce water to

ferent electronic devices, applications

electrical components, damage is in-

and working environments. This article

evitable – creating system failures, ex-

will look at the characteristics that en-

pensive repair costs or even hazards to

closures should have, the protection rat-

nearby operators.

ings required and the material options, as well as suitable enclosure recom-

In areas where washdown is a daily

mendations.

routine, a suitable waterproof enclosure

resistant against corrosion and/or sub-

What makes an enclosure suitable for washdown environments?

mersion, which provide increased ben-

Out of the many features and benefits

efits, depending on the end application.

that an enclosure may possess, the

needs to be specified and designed. This can include enclosures that are

most important factor for a washdown 90 series application

electronics enclosure is to ensure it has a suitable waterproof gasket seal. A gasket seal follows a path around the entire edge of an enclosure, between the lid and base. Once both halves are screwed together, the pressurised gasket forms a seal that keeps out water and solid objects, such as dust and other particles. Gaskets are generally made from a robust material like EPDM. Whilst many types of gasket seals are available in today’s market, the most important thing to consider is the IP rating that is provided once the gasket is in place.

28 dpaonthenet.net

Feature: Waterproof enclosures There are also other features that will

The X Series range of heavy-duty en-

The 88 Series IP67 Heat Sink Enclosures

help improve the enclosure’s effective-

closures are manufactured in either a

are manufactured using an extruded al-

ness in wet, washdown areas, such as:

polycarbonate or ABS material, with

uminium technique. Heat sink fins have

an IK08 rating and sealed to IP67. The

been incorporated into the design actively

series is split into three types of enclo-

to combat against internal heat concerns,

sures: the X6 Electrical Knockout En-

without compromising the IP67 rating. Al-

closure, the X7 Electrical Heavy-Duty

uminium provides natural EMC shielding

• Clear lid, allowing electronics to be

Enclosure and X8 Electrical Hinged Lid

and is more robust than plastic enclosures.

read whilst remaining closed and

Enclosure. The X6 Electrical Knockout

A wall mounting option is available.

dry

Enclosure is suitable for junction type

• Using corrosion-resistant materials – stainless steel or aluminium • Protected

corrosion-resistant

screws, recessed

• Space for waterproof cable glands

electronics and control devices due to

Should you not be able to find a suita-

• A secure mounting mechanism

its metric sized knockouts located on

ble off-the-shelf enclosure, using our

the base. The X7 Electrical Heavy-Duty

Smartboxx technology, a fully fabricat-

What specifications should you look for?

Enclosure is robust, has a deep inter-

ed enclosure solution is also available,

nal space and can be used for all types

leaving you to choose the aesthetics of

As previously mentioned, the gasket

of electrical systems. The X8 Electrical

your electronic housing. Not only can

is responsible for the overall effective-

Hinged Lid Enclosure uses a hinge and

you achieve a high IP rating but there is

ness of an enclosure’s ability to keep

latch system for its lid and is most suited

a variety of easy-to-clean or scratch-re-

water out. To remain competitive and

to centralised IoT units, control points

sistant finishes from which to choose,

to provide customers with a trustworthy

and distribution electronics.

ensuring your product can tackle day-

product, manufacturers design and test

to-day cleaning in any environment.

their enclosures to different levels. The

The 71 Series IP66 Flanged Enclosures

Looking for an antimicrobial material?

protection ratings for ingress are ‘IP’ or

and the 72 Series Wall Mount IP66 En-

CamdenBoss can manufacture your

‘NEMA’.

closures both come pre-moulded with

housing in this specialist material for ap-

flanges so that they can be easily wall

plications such as equipment operating

There is a variance in the capabilities of

mounted outdoors. They are manufac-

within the food industry, providing an ex-

each rating, so the correct level should

tured with a UV stable polycarbonate

tra barrier of protection against bacterial

be selected. Levels of protection to look

material, ideal for outdoor electronics in

and dirt.

out for are:

direct sunlight, as ABS will warp and can

• NEMA 4, 4X, 6 or 6P enclosures all

lead to enclosure failures. Both the 71

To discover all of the waterproof

possess a waterproof gasket seal

Series IP66 Flanged Enclosures and the

enclosures available from CamdenBoss,

and are tested to some degree of

72 Series IP66 Wall Mount Enclosures

visit: https://www.camdenboss.

protection. NEMA 6P, for example,

are ideal for outdoor use. If you need a

com/discover-page/waterproof-

protects against full, prolonged sub-

heavy-duty handheld enclosure that can

enclosures/

mersion, whereas NEMA 4X pro-

also be used outside, the 90 Series IP67

tects against pressurised water, but

Handheld Enclosure is an ideal option.

Or alternatively, view the whole range of

not submersion.

It is manufactured in ABS UL94-V0 and

CamdenBoss’s electronic enclosures

comes with a variety of battery compart-

here: https://www.camdenboss.com/

ments and coloured rubber sides.

discover-page/our-full-range-of-

• IP ratings, such as IP65, are split into two digits. The first digit indicates protection against solids like

enclosures/

fingers, tools and dust; the second digit indicates water protection. For washdown applications, the second digit needs to be six, which is the

X6 Electrical Knockout Enclosure

protection against direct high-pressure water jets.

Are CamdenBoss enclosures suitable for washdown environments? CamdenBoss manufactures enclosures with many different grades of IP protection, which lend themselves to different electronic device applications and working environments. Here are just a few that are suitable for washdown and typically wet areas.

dpaonthenet.net 29

Feature: Food & beverage

What does the future hold for food and beverage manufacturing? F

ood and beverage manufacturers of all sizes are facing huge operational challenges right now. Sudden increases in consumer demand, shifting expectations, changes in food safety legislation, and emerging technologies all require companies to be responsive, agile and flexible.

Let’s consider how each of these three

Even in our current outcomes-based

factors can impact day-to-day opera-

regulatory framework, reducing cleaning

tions on the production floor, and how

time and ensuring impeccable hygiene

leading manufacturers are adapting to

standards continue to be key areas

win.

of focus. As the physical landscape of manufacturing shifts to accommodate

Standards and legislation

the increased presence of technology,

In recent years, food and beverage man-

so too will our approaches to safety and

ufacturing regulations have changed sig-

cleanliness.

nificantly across the globe due to technological and scientific advancements.

This leads us to our next topic: the pres-

There is also the matter of ensuring

Europe has long been at the forefront of

ence and proliferation of technology in

seamless production continuity, to en-

these legislative changes and success-

food production spaces.

sure consumer confidence around main-

ful companies will likely be those who

taining food and beverage supplies.

stay ahead of the curve by implementing changes sooner rather than later. These

Food sustainability and corporate responsibility

As digital technologies continue to trans-

companies will avoid both production

There’s no denying that we all have a

form global markets, no industry remains

downtime and the potential for higher

responsibility to implement sustainable

untouched, and food and beverage

costs associated with refits, when new

environmental practices. From a com-

manufacturing is certainly no exception.

legislation eventually passes.

30 dpaonthenet.net

Feature: Food & beverage mercial perspective, it’s also worth your

them quicker and easier to clean. HD

dustry; their delicate circuitry and sen-

time to embrace sustainability as mil-

enclosures are typically power washed,

sors must be on the production floor

lennials and Gen Z begin to dominate

so reducing the time it takes to clean

but must also be protected from con-

the consumer market.

them will lower both water and energy

taminating or being contaminated by

usage.

the manufacturing process.

huge value on environmental sustaina-

In order to offset the cost increases as-

Additionally, these complex computer

bility, and they’ll also go out of their way

sociated with making these transitions,

systems need to be compliant with cur-

to support companies who follow envi-

industry leaders are continuing to refine

rent and future food safety regulations

About the author:

ronmentally friendly practices.

efficiency-boosting practices to make

and be well suited to withstand increas-

production facilities greener.

ingly ambitious CIP procedures.

Technology and digital transformation

Now is the time to consider how you

es that reflect this shift in consumer priorities and effectively communicate the

At this point, we can consider the mas-

ing systems to try and account for the

changes that have been made. To do

sive impact that the Internet of Things

changes that are taking place in the in-

this, you’ll need to streamline every as-

(IoT) will have on manufacturing.

dustry. Whether it’s investigating new,

Emma Ryde is Rittal’s Product Manager for Industrial and IT Enclosures. Emma has a wealth of experience gained over 20 years, developing technical sales in a range of industries including food and beverage, automotive and transport. Her sales and engineering experience resulted in her being appointed as Product Manager for Industrial and IT Enclosures. Her remit extends across support for Rittal’s customers in existing markets, as well as developing new opportunities as they arise. She has an HNC in Mechanical Engineering.

The consumers of the future will place

Manufacturers that want to reach this audience will need to implement chang-

can update your existing manufactur-

pect of your business with a new focus on environmental sustainability.

sustainable production methods or Telstra puts it very clearly when it states

investing in physical infrastructure that

that, “In an increasingly automated

supports new technologies, now is the

Whether it’s recycling production ma-

manufacturing

time to move confidently forward or get

terials to close the loop on waste out-

multiple machines communicating with

puts, or reducing the energy consumed

each other and being managed and di-

during cleaning, every part of your pro-

agnosed remotely offers benefits that

Optimising every piece of the manufac-

cess should be moving towards a more

are self-evident.”

turing puzzle is essential to maintain a

environment,

having

sustainable future, either directly or in-

left behind.

competitive advantage.

directly. For example, Rittal’s HD enclo-

These smart machines pose a unique

sures are specifically designed to make

challenge to the food and beverage in-

www.rittal.co.uk

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Feature: Switches

Switching in the time of

COVID-19 C

OVID-19 has brought into sharp focus the confidence that people have in Human Machine Interfaces (HMIs), such as push-button switches, joysticks and other controls subject to operation by numerous people. Controls such as door-opening buttons on public transport, touchscreens on vending and ticketing machines, and machinery adjustment mechanisms used by multiple

EAO Series 56 Universal switch

workers in a factory setting can all be a source of contamination.

Sensor switching As I write, there are several technologies

need for physical contact. Capacitive

HMI technologists, such as EAO, are striv-

believed to be compatible with non-con-

sensors can be incorporated into the

ing to develop machine controls that resist

tact body part switching. Each technology

body of a panel or a switch to provide

the spread of infection and improve the

has its own set of pros and cons in terms

the necessary signals, but a minimum

confidence that users have in their equip-

of reliability and operational distance:

distance must be maintained between

ment interfaces. EAO is approaching the

the multiple switching functions to avoid

problem from multiple angles, depending

Radar sensing is a particularly promising

cross interference between individual

on the nature of the interaction between the

technology for non-physical contact me-

switch elements.

control function and the human that oper-

chanical switch replacements. It works

ates them, asking:

using a radio frequency transmitter that

• Can the need to touch the equipment be

bounces a signal off an object. The re-

completely avoided using sensing tech-

flected signal is gathered by a receiving

nology to initiate a switching function?

aerial and the data is then validated and

• Can the actuator be redesigned to op-

the switching function initiated. Radar-

erate the equipment using a part of the

controlled switches can be tuned to work

body that is less susceptible to infection

at close proximity, i.e. a hand operating an

(e.g. the elbow), or with the aid of an

electrical switch, and over longer distanc-

inanimate object commonly carried on

es. They are not unduly affected by mois-

the person, such as a pen or a key?

ture and temperature and offer a long and

• Can the switch actuators be manufac-

reliable life.

tured with antibacterial/antiviral chemicals within the plastics, or as bonded

Capacitive sensing is widely used in touch

coatings that inhibit the growth of virus-

screens of all sizes but can also be tuned

es and bacteria?

to detect human proximity without the

32 dpaonthenet.net

Feature: Switches Passive Infra-Red (PIR) sensing technology is already commonly used in intruder alarms, security lights and applications such as a door opening on approach, but proximity actuation of precise machine control functions over short distances is proving problematic as it doesn’t currently offer tuneable distance sensing.

EAO Series 56 Universal Standard Symbols

the latest switches are IP sealed and built

compounds (like those used in medical

Active Infra-Red sensing also works on

using high-quality plastics and anodised

equipment), but until the new products

proximity. An IR LED emitter is placed

aluminium. Series 56 Universal switches

become available, designers are able to

next to an IR sensor. When an object

deliver multi-sensory feedback to the user

put their faith in switches manufactured in

passes in front of the emitter, the IR light

as soon as they’re pressed by delivering

medical-grade stainless steel.

is reflected from the object to the sensor

an audible and tactile ‘click’. The green il-

which detects the light and initiates the

lumination makes the switch easily identi-

EAO Series 82-66 switches

required function. In most AI-R sensing

fiable at low ambient light levels, while the

Where aggressive cleaning of the HMI

applications, the reflectiveness and size

red illumination provides the operator with

is unavoidable, switches with a high IP

of the objects that initiate the switching

feedback on the status of the switch.

rating and resistance to strong cleaning

need to be accounted for in the sensor design.

fluids have an important part to play in reLaser-etched lenses are available for

ducing infection transfer. EAO Series 82-

the Series 56 Universal switches, with a

66 switches are manufactured in medical

the

choice of 14 standard symbols and the

grade 316L stainless steel and high-qual-

short-term, continue to serve designers

full range of ISO 7000 icons. Custom

ity, chemical-resistant Triton plastics –

of COVID-resistant HMIs well. As an ideal

marking is also available subject to MOQ.

featuring IP67 sealing. A satisfying tactile

partner for human machines interfaces

Thanks to its standard M8 connector

‘click’ provides the operator with tactile

and a leading proponent on the use of the

(M8x1, 6-pin) and low mounting depth

feedback and, as with all EAO switches, a

HumanTouch, EAO is already developing

(27mm), the Series 56 Universal Switch

large range of laser-etched lens icons are

and testing HMI products that help miti-

offers easy plug & play installation. Com-

available ex-stock, but plain lenses can

gate the risk of infection from cross con-

bined with a wide range of front bezel

also be supplied.

tamination. The company has recently

colour options, the versatility of the Series

redesigned its door-opening switch range

56 switches enables application-specific

The quest for machine controls that resist

to facilitate safer switching in HMI appli-

HMI designs to be produced quickly and

the spread of infection and improve the

cations such as building access, ticketing

easily.

confidence that users have in their equip-

Electro-mechanical

switches,

and machinery control.

About the author: Robert Davies is Marketing Manager with EAO Ltd, the UK arm of Swiss HMI (Human Machine Interface) specialist EAO AG. Robert holds an engineering degree but, more importantly, has over 25 years’ experience in matching advanced switching solutions to demanding industrial applications. Robert can be contacted on +44 (0)1444 236 000 or by email at robert. davies@eao.com

ment interfaces is continuing apace. The innovations currently in development by

EAO’s new Series 56 Universal switch-

Antibacterial/antiviral coatings and plastic additives

es utilise a large 34mm diameter rugged

It should come as no surprise that HMI

major contribution, not only towards de-

metal ‘lens’ that stands 5mm above the

specialists, such as EAO, have recently

feating this terrible virus, but also to mak-

switch surface to make them easily ac-

ramped up their R&D into the manufac-

ing the new ‘normal’ – whatever it even-

tuated with the elbow, knee, back of the

turing of devices in plastics infused with

tually turns out to be – safer and healthier

hand, or even with the help of some in-

antibacterial/antiviral additives, and with

for everyone.

animate object carried on the person. To

coatings that do the same job. The current

facilitate thorough cleaning of the HMI,

focus is centred around the use of silver

EAO and others are destined to make a

www.eao.co.uk

Series 82 switches, manufactured in medical-grade stainless steel

dpaonthenet.net 33

Feature: Electrical connection enclosures

Precast concrete installation made easier with electrical connection enclosures T

he installation of precast concrete construction projects has been made faster and simpler, thanks to an increased use of a range of electrical connection enclosures. Spelsberg’s IBT range of enclosures retain their position under concrete pouring and cover a variety of applications – from junction boxes to LED luminaires. The enclosures are designed for use in a wide range of building types and are flexible for various mounting options.

Spelsberg’s IBT range of enclosures retain their position under concrete pouring and cover a variety of applications – from junction boxes to LED luminaires

As speed and efficiency become more

tleneck of various tradespeople requiring

All products within the IBT range are hal-

important for UK construction to meet

simultaneous access. The primary chal-

ogen-free and offer high temperature re-

demand, the use of precast concrete is

lenges surrounding the routing of elec-

sistance, which means they meet DIN, BS

increasing. Prefabricated concrete pan-

tric connections and components when

and NEMA standards.

els are quicker to install, with far less

using precast concrete are twofold. First,

preparation work required before instal-

it demands a high degree of planning to

Following the assurance of protection

lation. Crucially, with a widening skills

determine electrical architecture before

that the IBT System provides, the primary

gap, precast concrete also requires less

the building is constructed. However, this

advantage is the simplicity and speed of

expertise to install than casting concrete

level planning of planning can increase

installation. When formwork is removed,

on site. Combined, this not only gives a

the efficiency of installation and overall

the face of the enclosure is revealed and

construction project faster completion

efficacy of cabling and connection. Sec-

ready to be opened, ready for easy ac-

but can reduce the overall cost too.

ond, it means that electrical enclosures

cess to enable a rapid first fix of electrics.

must maintain their precise position with-

Multiple enclosures can also be easily

If required for a bespoke, highly specific

in the prefabricated panel, withstanding

connected into a grid via the support

and very large-scale design, cast-on-site

the effects of the concrete pour. Failure to

beam.

concrete can generally be moulded with

do so could impact wiring and therefore,

greater flexibility than the precast alter-

the integrity of the electrical circuit. Addi-

The IBT System is appropriate for a wide

native. Also, some precast forms may be

tionally, the electrical enclosures must be

range of building types and a variety of

too large or difficult to manoeuvre to or

able to resist any leakage of concrete in-

housings are available, including classic

around the site. However, another advan-

side the casing which would cause dam-

universal, transition and junction boxes,

tage of precast is that its strength is usu-

age to wiring and connections.

coming in a range of sizes. The IBTron-

ally far higher than cast-on-site concrete.

ic System is used to enclose electronic

Significantly, it’s also far easier to meas-

Spelsberg’s IBT System enclosures fit

components, from LED luminaires to

ure this strength. Both of these benefits

securely to formwork using high-strength

alarm speakers.

are the result of the greater precision of-

magnets. Designed specifically for precast

fered by a factory-controlled cure, where-

concrete installation, IBT enclosures re-

While on-site casting has traditionally

as on-site curing can remain at the mercy

tain their position after concrete pour and

meant greater flexibility in design, IBT

of the weather.

cure, aided through their patented sup-

enclosures can also be designed and

port beam design. A patented diaphragm

manufactured to offer a bespoke solution

Today, prefabricated concrete panels are

system seals against ingress of concrete.

to specified designs, with aftercare pro-

completed with the electrical connection

It reinforces the enclosure by expanding

vided to assist with installation if required.

routing, which speeds up the construc-

after the insertion and routing of conduit

tion process further still, avoiding a bot-

– with no further on-site sealing required.

34 dpaonthenet.net

https://www.spelsberg.co.uk/1/

Buyers Guide: Springs

Geared Motors – 12mm / 90mm dia

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Batteries & Chargers

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

Displays

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

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

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Web: www.mfacomodrills.com

01959 563345

www.review-displays.co.uk 01959 563345

Business Advice Consultants

http://www.mcs-corporate. com

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

To advertise here contact

Andrew Quenault

01732 359990 or email andrew.

quenault@imlgroup.co.uk

Fasteners & Fixings

• Tappex Thread Inserts Ltd – 60yrs+ of UK manufacturing excellence in Threaded Inserts for Plastics, Composites & Light Metal alloys • Tappex provide an Applications technical service, prototyping and bespoke installation tooling historically across multiple industry sectors: OEM/Automotive/ Medical & Industrial Equipment manufactures • Tappex offer fastening solutions produced from Brass, Steel, Stainless Steels & Titanium inserts with both Metric, Unified and British Standard threads Contact details: Tappex Thread Inserts Ltd Tel: +44 1789 206600 Email: sales@tappex.co.uk; New Website: www.tappex.co.uk

To advertise here contact

Andrew Quenault

Downloadable catalogues and applications advice on the website.

Smiths Interconnect – Partnering with global suppliers to eradicate a common enemy Smiths Interconnect is proud to be collaborating with leading medical technology organisations around the world to combat the ongoing COVID-19 pandemic. We’ve long been a trusted partner to key ventilator manufacturers, providing high reliability connectors renowned for their durability and unfaltering performance in critical environments. Currently our teams in Asia, the Americas and Europe are supporting programs to deliver connectors for ventilator production and delivery within those regions. This is a product that has been provided for many years, among others:

01732 359990

• KNB Series – a board-to-board connector with Hypertac hyperboloid technology utilised within a French- made portable ventilator found in ambulances, ambulatory helicopters and hospitals. or email For further details: Please visit our website www.smithsinterconnect.com

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