DPA_20_11 by Modiconlv

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

Powering a coal-free future 07: Sandwichstacking robot

14: Virtual reality

Robot stacks sandwiches in 800 milliseconds

Highways England trains control room operators virtually

Contents

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

Paige’s Page: 04: Editor’s comment Police bust an alleged drug deal in China using a drone

Robotics

Powering a coal-free future 07: Sandwichstacking robot

14: Virtual reality

Robot stacks sandwiches in 800 milliseconds

Highways England trains control room operators virtually

Cover Story:

201016_9-6_Mill_DPA_UK_Snipe.indd 1

Special Report: 07: Sandwich-stacking robot 10/14/20 3:22 PM

Robot stacks sandwiches in 800 milliseconds

08: Disinfecting robot

Simone Bruckner, Managing Director of Cressall, explains why the country no longer depends on burning coal that has, for so long, been the backbone of Britain’s power. p.28 (Cover image: Shutterstock)

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

Rapid Prototyping & Simulation

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

Shark Robotics enhances Boston Dynamics robot to fight COVID-19

10: Final Trim & Assembly

Special Report: 12: Simulation technology Smoke control: Upgrading the rail commuter experience

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

14: Virtual reality

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

16: Product design

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

Highways England trains control room operators virtually

Re-imagining product design – 3D printing and the CMF opportunity

Linear Motion Technology Focus: 18: Robot envelopes Taking robot envelopes to new heights with Güdel linear motion tech

21: Workpiece carrier systems

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.

Final Trim and Assembly get the robot touch

Independently controlled workpiece carriers

24: Linear guide system Long, difficult and dirty: A linear guide system for a complex setup

26: Ball screw technology

Long-stroke ball screws drive optimisation of 5G fibre optic filament production

Energy Supplement: 28: Coal-free power generation Powering a coal-free future: Is the UK’s coal-free hiatus here to stay?

30: Compressed air 10,000 Average net circulation Jan-Dec 2018

The other side of the compressed air story

32: Hydropower

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

Back to the future: Improving the efficiency of our hydropower network

34: Buyer’s guide

26 dpaonthenet.net 3

Paige’s Page

Big brother is watching: Police bust an alleged drug deal in China using a drone

W Paige West, Group Editor

elcome to the November issue of DPA! I read an interesting story a few weeks ago. Regional media reported that police used a drone to capture footage of an alleged drug deal taking place in the southern city of Guilin.

The use of drone technology has real-

by the BBC, Silkie Carlo, Director of Big

ly taken off in the UK (excuse the pun).

Brother Watch, called the move a “leap

The West Midlands police force is using

forward for intrusive surveillance technol-

drones to target criminals. Fitted with the

ogy.” She said, “It’s particularly worrying

latest high definition cameras and ther-

that the UK and China are almost neck-

mal imaging technology, the drones are

and-neck in the race to monitor citizens

designed to help the police cover more

with new tech.

ground on their patrols. “Drones are an extreme, militaristic form Back in August, the Cheshire police an-

of surveillance. We’ve seen too many ex-

nounced a new piece of kit – the Matrice

amples of police using them aggressively

300RTK drone – that will equip the front-

in place of measured public health com-

line with a useful and powerful tool that

munications.

can support officers in their daily duties. The drone will assist with searching for

“Police using drones to surveil and bark

In a video shared with state broad-

missing and wanted people, aerial im-

orders at members of the public is usu-

caster CCTV, police were depicted

agery for crime scene investigations and

ally excessive and counterproductive.

following a suspected drug dealer into

even identification of cannabis farms.

Parliament should introduce stronger

an abandoned brick factory. It showed

safeguards to circumscribe their use.”

suspects exchanging what the police

Last year, in the first initiative of its kind in

have said were illegal drugs and money.

the UK, police in London launched a new

Will we be seeing more drones in our

trial that used drones to catch speeding

skies, helping to keep people safe? I sup-

drivers.

pose the real question is, will it actually

The drone operation was live streamed to nearby officers on the ground, who then moved in to arrest four people.

make us feel safer or will it feel like Big While this all may sound like a wonderful

Brother is watching…?

idea, some have voiced concerns about Reactions on the Chinese social media

the government having “eyes in the sky”

Do let us know what you think of the issue

platform Weibo were largely positive

at all times.

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

and praised the police for using such advanced technology.

When asked about the drug bust in China

paige.west@imlgroup.co.uk.

Connect with us on LinkedIn. Join us on Twitter.

4 dpaonthenet.net

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Feature: Sandwich-stacking robot

Food for thought: Robot stacks sandwiches in 800 milliseconds

rowing production demands and a major labour shortage motivated a large-scale sandwich producer to automate a high-speed sandwich stacking application.

To resolve the challenge, TechBrew Robotics, a Kawasaki Robotics Preferred Integrator, designed a custom solution using Kawasaki’s R series robots and F60 controller. The robots’ task may seem simple: after the sandwiches are halved in the cutting machine, the robots need to stack one half on top of the other, making it easier for human workers to package them manually. However, this application was tricky to automate. Sandwich halves vary in their position as they come out of the cutting machine, so the robot would need some sort of vision intelligence to recognise

To save space, twin Kawasaki R Series robots are mounted inboard of the conveyors carrying the sandwich halves which need positioning

the location of each half on the conveyor. They also needed to stack the sandwich-

TechBrew designed a custom gripper.

es in practically the blink of an eye.

The pneumatic end effector is controlled

and food-grade plastic.

directly by the F60 controller, allowing for

Kawasaki’s AS programming language

To integrate its solution into the customer’s

quick movements. A controllable pressure

and its F60 controller easily handled the

existing production line, TechBrew had to

plate comes down to hold the product in

project’s complexities. The company

make creative use of limited space. The

place as two stainless steel paddles slide

could program this application directly on

R series robots are inversely mounted on

under the sandwich half to lift it. Once

the robot, without a co-processor, which

a cantilever beam attached to the cutting

lifted, the actuator spins the sandwich at

reduced costs and simplified the installa-

machine, and the F60 controllers’ compact

180°, and force dampers at the end of the

tion. The Kawasaki F60 controller’s high

size saves further space by stacking the

rotation keep it intact.

processing speed handled real-time scan-

sandwiches on top of the sandwich cutting

ning and data analysis on the sandwich

machine itself. To maximise throughput, the

TechBrew had to consider national food

halves and output the robot coordinates

robots face outward, stacking sandwiches

safety regulations, so chose the clean-

in under 200 milliseconds, while process-

on two different conveyors which are run-

room version of Kawasaki’s 5kg payload

ing a queue of sandwiches at a rate of 60

ning simultaneously. TechBrew used a laser

RS005L general-purpose robot. It offers a

per minute.

range finding system with conveyor track-

pressurised cavity, ISO Class 5 cleanroom

ing to detect the shape and location of the

specification, and comes with an alumin-

The entire sandwich stacking process

sandwich halves as they emerge from the

ium arm cover, rubber outer seals and a

takes just 800 milliseconds. It didn’t take

cutting machine. Once the sandwich halves

chemical resistant epoxy paint finish for

the customers’ line managers long to ad-

have been stacked, they travel down the

easy wash down. The patent-pending end

just to their new robotic co-workers and

conveyor to a place where human workers

effector’s tool-less design makes it easy

throughput has increased significantly.

are waiting to place the product into trian-

to disassemble for cleaning purposes,

gular cardboard boxes.

and it is constructed with stainless steel

https://robotics.kawasaki.com/en1/

dpaonthenet.net 7

Feature: Disinfecting robot

Shark Robotics enhances Boston Dynamics robot to fight COVID-19 S

hark Robotics, French and European leader in Unmanned Gr ound Vehicles, has announced a disinfection add-on for the Boston Dynamics Spot robot, that is designed to fight the COVID-19 pandemic. The aim is to provide an autonomous and agile robotic solution that can spray a disinfectant to minimise human exposure to the virus and efficiently clean surfaces.

In practice, the Spot robot with Shark’s purpose-built

disinfection

payload

can decontaminate up to 2,000 m² in 15 minutes, in any space that needs to be sanitised – such as hospitals, metro stations, offices, warehouses or facilities. The sanitising operations can be done autonomously or remote-ly controlled. The payload consists of a five-litre tank and 12 micro-spraying nozzles for disinfectant solutions. This system allows a 360° diffusion. Spot’s unique mobility enables the robot to decontaminate many types of surfaces without leaving traces on the ground. Unlike most sanitising robots, Spot can navigate complex environments with steps, stairs and uneven floors, and avoid obstacles with great reliability and consistent quality.

8 dpaonthenet.net

Feature: Disinfecting robot “It is very exciting to work with a compa-

Many scientific studies, such as the

ny as prestigious as Boston Dynamics.

US Centres for Disease Control and

We share the same objectives: innovate

Prevention (CDC), prove that COV-

and offer efficient robotics solutions to

ID-19 could remain on surfaces for

help humans,” said Cyril Kabbara, COO

17 days. That is why Shark Robotics

and co-founder of Shark Robotics. “With

decided in February 2020 to respond

a complementary approach, Boston Dy-

to this problem by developing the dis-

namics and Shark Robotics provide an

infection robot, Sanitising Rhyno Pro-

efficient and highly mobile disinfection

tect – which was designed and proto-

solution able to fight COVID-19 in all

typed in less than three weeks. This

kinds of environments.”

tracked modular robotic platform can sanitise up to 20,000 m² of sur-face

“Since the outbreak of the pandemic,

area in three hours.

many Boston Dynamics customers have explored how to use mobile robots to

“As we observed the spread of COV-

reduce exposure to health risks,” said

ID-19 around the world, we felt that

Michael Perry, VP of Business Devel-

we needed to react quickly by finding

op-ment for Boston Dynamics. “We’re

immediately a useful solution, rather

ex-cited to see Shark Robotics provid-

than suffer from the crisis,” said the

ing a disinfection payload for customers

two co-founders of Shark Robotics.

look-ing to limit the spread of the virus.” Customers can contact Shark Ro“Disinfection has become a necessity

bot-ics to purchase the Spot disinfec-

in a post-COVID-19 world, and robotics

tion solution.

now plays a key role in removing people from dangerous areas,” said Jean-

https://www.shark-robotics.com/

Jacques Topalian and Cyril Kabbara, the two co-founders of Shark Robotics.

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They can be deployed quickly in stand-alone warehouse applications, as well as integrated into a total automation concept that combines motion, safety, vision, control and robotics, providing a complete solution from one source.

Feature: Final Trim & Assembly automation

Filling the missing piece: Final Trim and Assembly get the rob W

hile many of the tasks involved in vehicle production have been automated, the Final Trim and Assembly stage has remained largely manual. Nigel Platt, Lead Business Manager for ABB Robotics UK and Ireland, explains how developments in robotic automation are helping to fill this missing piece.

turers’ desire to produce many different

this increases production times and cuts

models of vehicles on the same assem-

productivity.

bly line. Add in the installation of cockpit, several different specification options and

Meeting the movement challenge

colours – and the complexity grows.

The challenges of FTA have been solved

seats, carpets and windows – each with

by ABB, which uses technologies such Using robots is challenging because of

as its IRB 6700 and IRB 2600 robots,

variations in the production line’s speed

advanced image processing, sensing,

and the inherent vibration of the AGVs or

and the safety-certified SafeMove2 hu-

conveyors used to transport the car body

man-machine collaboration software.

to the FTA station. Automotive manufacture is the classic use

The Dynamic Assembly Pack is a new cell

case for robotic automation; robots are

For successful assembly of components

solution that uses many of these technol-

used to weld car bodies, paint them and

by a robot, the system must be able ac-

ogies. It allows the robot to work in con-

install heavyweight items. Speed of pro-

curately to follow a moving body. It must

cert with a moving car body and adapt

duction, accuracy, and repeatability – to-

be capable of continuously adjusting the

its motions to assemble components

gether with the avoidance of injury through

position and speed of approach to avoid

precisely. The cell uses a Universal Vid-

arduous tasks – have seen them become

collision with the vehicle, which could

eo Tracking (UVT) camera that allows the

widespread in these applications.

damage the paintwork. With cycle times

robot to track the position of the car body

of assembly tasks just 60 seconds, the

as it enters the workstation.

Yet, the complexity of assembly tasks

robot must hit the exact spot to secure

and speed of Final Trim and Assembly

the component to the body or interior.

(FTA) production lines mean that less than

As the robot travels parallel to the AGV, the tracking system synchronises its

five percent of today’s lines benefit from

These factors have made it difficult to

speed with the AGV. The camera also re-

robotic automation.

align parts with the car body, necessitat-

ports the colour of the body, ensuring that

ing slowing down or pausing production

the vehicle model is fitted with appropriate

for them to be fitted properly. Inevitably,

components.

One of the main challenges is manufac-

10 dpaonthenet.net

Feature: Final Trim & Assembly automation robot can sense its way around assem-

A safe distance between operators and

bly operations with a precision that can

the robot is maintained using safety

be measured in millimetres. The robot

sensors, laser scanners and light bar-

adapts its programmed lane and speed

riers. Sensors in the robot cell allow the

based on feedback from the sensor, al-

system automatically to reduce the ro-

lowing it, for example, to hang a door

bot’s speed when a worker approach-

exactly in the hinges provided.

es. The robot controller means the robot can operate only in predetermined

The force control sensor is mounted on

spaces, forcing it to come to a com-

top of the sixth axis, directly between the

plete stop when this invisible boundary

robot and the gripping system, meaning

is crossed.

the system can always accurately measure the force. The sensor also needs to

If the operator leaves the defined safe-

react to changes at any time, for instance,

ty area, the system continues its task

when the robot must slow down because

at its initial set speed. Up to four robots

the AGV is running more slowly. For the

can be monitored for tool position, tool

system – and hence, the robot – to sense

speed, and tool orientation. With SafeM-

its way through an assembly situation

ove2, car manufacturers get a system

and dock with no more than the neces-

that minimises the cost of FTA safety

sary force, the optical system and inte-

enclosures and can reduce total invest-

grated force control must harmonise ex-

ment by up to 30 percent.

actly with one another – a feat achieved through appropriate programming.

Advanced cells that can work safely in a highly adaptable system allow man-

bot touch Additionally, the cell allows the robot to

Moving safely

ufacturers to make a range of different

The requirements for automated assem-

models to meet market demands.

About the author: Nigel Platt has over 30 years’ experience helping manufacturing companies around the world to improve competitiveness, quality and consistency, through investment in robot-based manufacturing systems. He joined ABB in 1990, beginning his career as Account Manager for the South East Region. Before becoming Lead Business Manager in 2017, Nigel held a global role across 40 countries as Business Line Manager for welding and cutting.

bly in a continuously moving process if car models are created on a common

Driving towards greater certainty

platform, all having the same body and

With today’s vehicle manufacturers fac-

points of connection to the grippers.

ing an unprecedented raft of challenges,

are complex. Yet, they can be reduced

compensate for any unexpected move-

the inherent speed, efficiency and flex-

ments or vibrations. Once the car body

This model platform concept allows car

ibility afforded by robotic automation

reaches a pre-defined position, the Com-

makers who are building completely new

represent an ideal way of responding

pliant Vision Guidance (CVG) camera –

manufacturing facilities to construct an

to sudden changes in demand. As the

mounted on the robot arm – scans it for

open system, avoiding the need to in-

needs of the Final Trim and Assembly

consistent reference points, such as door

tegrate individual automated processes

stage are now addressed by a robotic

edges. By taking images at a rate of 30 to

into existing lines. For FTA, open systems

solution, automotive companies can fi-

40 frames per second, the CVG camera

mean that AGVs approach individual au-

nally move towards enjoying the benefits

determines whether any adjustments are

tomated assembly stations as required.

of totally automated production lines.

These open systems also use ABB’s

For more information, visit www.abb.com.

needed. To compensate for any inaccurate po-

SafeMove2 software, which has speed

sitioning caused by ambient lighting

limits, standstill monitoring, safe axis

affecting image quality, both cameras

ranges, and supervision of position and

incorporate LEDs to provide consistent

orientation, to allow operators to work

illumination.

safely with the robot system at high speed during high cycle times.

Feel the force However, basic physics dictates that these cameras will lose focus as soon as the arm of the robot gets close to the vehicle. It is here that the system switches from one that is vision-controlled to one that relies on a mechanical sensor. Integrated force control technology allows the robot to respond to its environment even when the cameras cannot see. The

dpaonthenet.net 11

Feature: Simulation technology

Smoke control: Upgr the rail commuter expe A

s half a million Tube passengers travel through central London every day, the capital’s jam-packed train carriages are already at overcapacity. Transport for London (TfL)’s Crossrail project needed to ensure that all standards for smoke ventilation were met. To put the right smoke control system in place, Kernow Controls and Intecre turned to Beckhoff’s simulation technology. With this, the proposed controls installation was signed off the first time – a rarity in today’s strictly regulated rail industry.

“A correctly working SCS redirects haz-

management-level equipment,” contin-

ardous smoke and fumes in the instance

ued Dorling.

of a building fire, to ensure a smoke-free pathway for first responders, fire officials

Before now, system simulation and vir-

and members of the public,” said Drew

tual commissioning have been predom-

Dorling, Managing Director of Kernow

inantly associated with the improvement

Controls.

and optimisation of systems belonging to the “smart factory”. Today, the full extent

“There’s an added complexity here, as

of the technology’s capabilities is being

the SCSs need to be integrated with the

demonstrated beyond a manufacturing

Crossrail control centre for remote override

environment.

and control. Responses to events must be coordinated on a system-wide level.”

Central platform Building on Beckhoff’s core principle of

Choosing automation

building all automation functions into a cen-

It became apparent during the design

tral platform, TwinCAT incorporates a pro-

development phase that the project’s de-

grammable logic controller (PLC), motion

mands would necessitate a robust system

control, robotics, high-end measurement

operation. This led the Kernow team to

technology, the Internet of Things (IoT) and

Beckhoff’s offering.

human-machine interfaces (HMIs).

serve 200 million people a year, includes

“Having worked with Beckhoff’s team

For the Elizabeth line, Beckhoff’s automa-

ten newly built and 30 upgraded stations.

before, through Intecre Limited, we were

tion-level controllers have been integrat-

These span more than 100 kilometres (62

already aware of the company’s extensive

ed using industry-standard protocols to

miles) from Reading to Heathrow. Kernow

product range and its offering of supple-

the management-level HMI. At this level,

Controls, a buildings control specialist, was

mentary software. More importantly, we

intuitive touch screens provide real-time

brought in to deliver the scheme design for

knew that Beckhoff’s equipment offers

and historical data, status, alarms, and

the smoke control systems’ (SCS) automa-

flexible integration paths to third-par-

graphical visualisation of the smoke con-

tion solution at Whitechapel Station.

ty systems and field devices, as well as

trol system.

London’s Elizabeth line, which aims to

12 dpaonthenet.net

Feature: Simulation technology Reduced costs

The Kernow Controls team was able to

“By using Beckhoff’s cutting-edge tech-

develop its SCADA systems against these

nologies, with Kernow Controls’ domain

simulations. The resulting suite of soft-

expertise and Intecre’s modular software

ware has become a powerful tool, ensur-

and modelling approach, we can identify

ing that every single alarm and feedback

issues within an environment with com-

signal can be tested. The effects of that

plex interfaces across many systems,”

signal across the station systems can

said Mark Lazarides, Managing Director

also be assessed, and the impact of late

of Intecre Limited. “The modelling and

changes to alarm signals or equipment

simulation of systems, and their physical

lists is mitigated.

responses, offer valuable insight before any change becomes costly.”

Overcoming complexity Following the project’s success, a sys-

grading erience

Intecre developed the TwinCAT software

tems integrator for another Crossrail

in line with object-oriented program-

station procured the automation pack-

ming (OOP) principles. While this offers

age from Kernow Controls. Intecre’s

many benefits for testing small units of

modular approach to the software en-

the software, it also results in much less

sured a high degree of reuse of tried and

code being written, thereby improving

tested software, which was adapted to

the quality and maintainability.

the third-party system integrator’s requirements in consultation with Kernow

Lazarides explained: “We extended the

Controls.

concept of mocking up test objects to build full simulations for each compo-

As the demand for increased rail capac-

nent that ‘touches the real world’ – like

ity continues, complex projects like the

differential pressure sensors, fans and

Elizabeth line offer more than an alter-

more.

native route for London commuters. By choosing the right automation solutions

“By simulating each of these objects,

provider, the journey to completion can

Kernow Controls suggested including au-

we were able to quickly begin simulating

be de-risked and delivered with higher

tomated test routines for all safety-critical

whole stations with multiple controllers.

quality, the first time. With an optimised

equipment. This was adopted by Cross-

We made sure that each simulation ob-

smoke control system in place, travellers

rail’s Chief Engineering Group (CEG) after

ject had realistic timings and introduced

also benefit from safer and well-ventilat-

all initial tests were complete, and instruct-

a range of failure modes for each. We

ed train stations throughout their journey.

ed across all the station’s SCSs. Intecre’s

needed to test failure modes to ensure

modular software approach ensured a sim-

the robustness of our solution.”

https://www.beckhoff.co.uk/

pler implementation of the operational system software, with no rework to the core smoke control. Full regression tests of the core functionality and all new functionalities were carried out in a simulation. It was a powerful demonstration of the system’s robustness, maintainability and flexibility. The result allows London Underground to conduct regular system tests, activated manually or scheduled automatically, to ensure that all components within the system are health checked. Combined with the automated test results, this solution provides documented evidence for compliance, fault identification and reporting. This data details compliance with relevant standards in a format that doesn’t require the station manager to have specialist engineering knowledge.

dpaonthenet.net 13

Feature: Virtual reality

Highways England tr

control room operators v

ne of the great strengths of virtual reality (VR) is its ability to allow users to experience real-world training scenarios, without endangering themselves, colleagues or the general public.

to a training centre and paying for accommodation, we were able to bring the training scenarios to them, with the timings of each session planned around the operational priorities on the day.

About the author: Toby Pettinger is Managing Director of MXTreality UK, a business set up to create immersive experiences in alternative realities: virtual, augmented and mixed. A regular writer and speaker on the subject, Toby is able to make the complicated subject of immersive technology simple, helping more organisations recognise the real benefits of virtual worlds in which to train, learn, play, work and rehabilitate.

That is why Highways England (HE)

MXTreality Managing Director, Toby Pet-

“Our business is focused on what we

turned to VR specialists, MXTreality,

tinger, explains, “Training programmes

can deliver using the capabilities of VR

when a new training programme was

of this nature are typically delivered

to achieve the desired outcome. It’s

required to help control room operators

in the classroom, often taking people

far less about the equipment which, to

better understand the impact of their

away from their day job, with a lot of

the average client, should be irrelevant

actions on the customer satisfaction of

paper-based collaterals, training vide-

once they’re past the initial excitement

motorists who are using the strategic

os and whiteboard sessions. Despite

of working with immersive technolo-

road network.

the best efforts of trainers, engagement

gies.

can be a challenge, especially with drier This was the first such training pro-

subjects.

gramme delivered by HE and it quickly

“Working closely with the HE training team, we devised five common re-

demonstrated the advantage of not just

“But HE is an innovative organisation

al-world scenarios, which would be ex-

explaining how Variable Signs & Signals

and recognises the benefits afforded

perienced by the operators in an immer-

(VSS) work, but also allowing operators to

by VR. Instead of taking more than 400

sive environment – using headsets and

experience the effect on traffic flow and

mission-critical operators out of their

binaural audio through integrated head-

how decisions impact driver satisfaction.

control rooms for a day, sending them

phones to increase the sense of realism.

14 dpaonthenet.net

Feature: Virtual reality

rains virtually

narios were run, they were always the

All the operators were surveyed after

same and this 100 percent consistency

they had undertaken their training and

of delivery ensures the performance of

the collated results highlighted over-

operators in different locations. Training

whelmingly positive feedback, with

at different times can be compared to

responses double the average – com-

their colleagues, to provide the trainers

pared to classroom-style training pro-

with valuable feedback.

grammes.

“For most operators, using VR was a

Pettinger concludes: “Of course, one

new approach to training and, [by] lis-

of the major advantages of devising,

tening to them discuss their experienc-

creating and implementing VR training

es with colleagues during and after the

programmes is the significant cost re-

training, it was obvious virtual reality

duction and lack of disruption to normal

had brought them closer together and

operations.

improved the team ethos.” “When all the advantages are considThe decisions made by operators in the

ered in the context of improved learn-

control rooms can have serious impacts

ing, better user experiences and cost

on the roads and the motorist’s journey.

savings, the argument for virtual reality

Yet, setting the VSS is not always an

training solutions becomes increasingly

automatic process. It can be quite sub-

compelling.”

jective, so getting the operators to discuss the solutions to the scenarios was

https://mxtreality.co.uk/

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Feature: 3D printing

3D printing gives designers the tool fully to integrate CMF into the ongoing design process (prototypes printed on the Stratasys J55 3D Printer)

Re-imagining product design – 3D printing and the CMF opportunity

n the 21st century, product design is central to driving revenue – it provides an opportunity to connect to consumers, increase sales, and personify and build a brand. The CMF design process – colour, material, finishing – is an essential part of product design but, for various reasons, remains a challenge for designers to integrate easily into the design process. In this feature, Yariv Sade, Director of Applications Engineering at Stratasys, looks at the potential of full-colour 3D printing to unlock CMF for the design process, and overcome barriers of traditional design tools.

the correlation between product design and business success, it was found that design-led companies have 32 percent more revenue and 56 percent total returns of shareholders than companies that place less focus on design. The results demonstrate that companies that monitor consumer behaviour and understand a product’s look and feel – from colour choice to surface finish – are ahead of the competition.

While a product’s engineering has histor-

something is to enjoy the all-important

The designers behind product concepts

ically taken centre stage when it comes

successful launch, then it is the product

are therefore under more pressure to de-

to bringing it to market, the 21st century

design that’s king.

liver the winning design. The processes

takes engineering excellence and product performance for granted. Today, if

16 dpaonthenet.net

and tools at their disposal are numerous. In a recent McKinsey study looking at

However, there are still several barriers

Feature: 3D printing for designers in conveying realistic rep-

shape is kept in a 3D file, while the CMF

resentations of their ideas to potential

information is carried in other mediums

stakeholders and decision-makers. A

(images, slides, PPT, notes etc). Relaying

In terms of consumer behaviour and de-

crucial challenge for designers is the CMF

design information from one person to

signing a successful product, full-colour

process.

another is therefore difficult, and leaves

3D printed prototypes also open up the

room for error. With such huge cost and

opportunity of AB testing – the process

Understanding the way we design products

long waiting times, designers typically

in which consumers are presented with

only leverage this high-end outsourcing

visually different versions of the same

In design, CMF refers to the process

option to create a model of the finalised

product before the response and sales are

in which colour, material and finishing

product for marketing purposes at the

measured for each. The ability to under-

is determined and selected for a prod-

end of the design process.

take this market research with 3D printed

uct. Colour can refer to hues, saturation,

indistinguishable from the final product.

prototypes allows designers or stakehold-

the design; materials reflect the feel and

Introducing full-colour 3D printing

character; while finishing is the texture

The answer – full-colour multi-material 3D

and surface appearance. The challenge

printing – is straightforward, yet still not

Looking ahead

many designers often face is that CMF

that widely used within the design world.

For designers, full colour, multi-material

is not integrated enough into the product

Only a few leading corporations have lev-

3D printing is the tool that enables design-

development process – it is often only re-

eraged the potential of this technology for

ers to overcome existing CMF design bar-

flected perfectly in the finished product’s

their in-house design requirements. Those

riers and realise product designs exactly

look. This is largely because – if they are

that have can quickly create ultra-realistic

as they envisaged.

using it at all – design facilities in enterpris-

3D printed design prototypes, which can

es, design studios or SMEs often rely on

be adapted to deliver visually impactful

One such technology that can unlock CMF

single-colour 3D printing to create physi-

designs. One such technology is Strata-

and endless design possibilities for de-

cal representations of their digital designs.

sys’ J-Series PolyJet 3D printing, which

signers is the new J55 3D printer. Allowing

The absence of an easy, fast and afforda-

enables PANTONE validated full-colour

ownership of designs from start to finish

ble solution to create full-colour concept

capabilities and a choice of up to seven

and cost-efficient model development in-

models to test and present a product’s

different polymer materials – all united in

house, the J55 provides designers access

geometry, functionality, look and feel is an

a single print.

to an office-friendly, compact, ultra-quiet

shading and colour combinations within

inherent issue.

ers to decide on the most popular CMF design for the new product.

Yariv Sade is a Senior Product Manager and entrepreneur with an industrial design and product development background. He leads product development projects for technology and consumer goods global companies, from concept stage to product launch and go-to-market. Yariv is the inventor of a dozen patents and the winner of the world’s most prestigious product design awards (IDSA, Reddot, IF, and more) and a Design Thinking and Design Management lecturer.

and affordable prototyping technology. Providing up to 500,000 distinguishable

Design concepts are therefore split over

colour combinations, the J-Series tech-

McKinsey’s 2018 study highlights that

several mediums. Designers utilise textile

nology not only has unparalleled design

‘research, early-stage prototyping and

samples and PANTONE colour charts, as

freedom but also gives designers the tool

iterations’ are some of the key pillars in

well as printed and online images to de-

to integrate CMF prototypes fully into the

driving business success through design.

termine CMF for new product designs.

ongoing design process. This saves both

In markets where competition is fierce

Additionally, the product’s measurements,

time and money, thanks to quicker deci-

and true-to-life design even more vital, the

geometry and build are reflected in a 3D

sions, improved CMF design iterations,

final go-to-market products must have the

file that can result in a physical single-col-

and no external lead times for models.

best colour, material and finish, in addition

our 3D-printed prototype – which can be

to faultless engineering.

painted to reflect the design idea more re-

Designers can use ultra-realistic 3D print-

alistically. This not only makes it difficult to

ed prototypes to convey and sell their de-

translate the design idea quickly to stake-

sign ideas. This can also raise confidence

holders, but it also denies easy design

in the design idea, without dependence

iterations and accurate testing among

on different digital mediums to present a

focus groups or potential buyers.

design – or relying on other people’s imag-

https://www.stratasys.com/

ination to envisage the final product’s look. To have a prototype final product at the end of the design process, some design

A material world

studios outsource the creation of full-col-

This capability to combine different mate-

our prototypes to global suppliers. This

rials in a single print pushes the bound-

is a $5.3 billion market, yet the delivery

aries of design realisation and allows for

for models usually takes several weeks.

improved design representation. Combin-

Furthermore, the associated cost can be

ing this with PANTONE validated colour

several thousand dollars (for a 10-15cm

spectrums brings CMF directly into the

long model). An added challenge comes

prototyping process and enables design-

with communicating the exact CMF look

ers to create 3D printed prototypes with

to the external supplier – as the geometric

such true-to-life accuracy that they are

Providing up to 500,000 distinguishable colour combinations with PANTONE validation, the J-Series 3D printing technology opens up unparalleled design freedom

dpaonthenet.net 17

Feature: Robot envelopes

Güdel TMF floor-mounted robot track

Taking robot envelopes to new heights with Güdel linear motion technology

obots are an integral and essential part of many manufacturing processes, undertaking a wide range of tasks from highprecision assembly to simple pick-and-place operations.

and transfer operations within the process cycle times of the different workstations. Mounting the robot to a linear track then opens up a range of alternative concepts, as the track could be floor mounted, wall

Robots are recognised as being ex-

lows robot working ranges to be expand-

mounted or even inverted. This may also

tremely flexible, with their working en-

ed in both the horizontal and vertical

allow easier access for operators or main-

velopes generally impressive in relation

plane – taking robot working envelopes

tenance personnel, and even save valu-

to their size. Nonetheless, the traditional

to new heights.

able floor space – whilst still significantly

concept of fixed installation (either floor,

enhancing the robot’s working range.

wall or ceiling mounted) places limita-

Those seeking to introduce robots as

tions on the maximum working envelope

part of an automated solution will expect

In applications where there may be larger

and, in certain applications, the ultimate

the maximum return on their investment,

components, and therefore greater dis-

capabilities of the robot.

and that means ensuring maximum utili-

tances between workstations, the linear

sation of the technology. In some cases,

track allows the robot to move rapidly be-

However, combine the flexibility of the

multiple robots may seem to be the op-

tween the different process steps, whilst

robot with linear motion technology, in

timum solution, especially if several dif-

maintaining control of the part. This elimi-

the form of tracks or gantry systems, and

ferent operations are to be performed, or

nates the need for conveyor systems and

this creates a new range of possibilities

parts transferred between several work-

other component location or orientation

for automation specialists, system build-

stations.

fixtures. One example of this is a manu-

ers and end-users.

facturer of truck sidesteps, where several However, there are often instances where

robot systems move on Güdel TrackMo-

In this article, Will Bourn of Güdel UK

a single robot, mounted to a linear track,

tion units to transfer components between

explains how this clever combination al-

could perform all the required handling

different pressing and assembly stations.

18 dpaonthenet.net

Feature: Robot envelopes Will Bourn explains: “The previous

allowed six-axis robots to be moved

require accuracy and repeatability to

manual set up within this facility was

in two planes, [allowing] them to oper-

produce reliable load-bearing beams.

both cumbersome and inefficient and

ate across the full surface area of the

therefore, an obvious candidate for

part to be processed. As for all Güdel

Such are the benefits of combining

automation. As part of the system de-

TrackMotion installations, the tracks

six-axis robots with linear motion sys-

sign process, the decision was made

are interfaced to the six-axis robot

tems that many of the world’s leading

to use Güdel’s linear track technology,

controller as auxiliary axes, to allow

robot integrators turn to Güdel when

which reduced the number of robots

full programmable control of all axes

they need to enhance the working

required – whilst maximising the flexi-

in the system.”

range of their systems. The flexibility

About the author:

of the Güdel TrackMotion range is at

Will is the UK Sales Manager for the business and is responsible for sales and marketing of the company’s gantry robot systems and linear motion technologies, such as robot tracks, etc.

bility of the cell. Using track-mounted robots to transfer, rotate and align the

A futuristic example, which combines

the heart of some truly innovative con-

rail assemblies significantly reduced

six-axis robots and linear motion tech-

cepts.

the cost and complexity of the solu-

nology, can be seen at the ETH Uni-

tion, even in an application involving

versity in Zurich, where a new building,

As manufacturers in all sectors seek to

large parts and complex station lay-

the “Arch-Tec-Lab”, was designed to

introduce automation, Güdel’s range

outs.”

explore the impact of digitisation and

of linear track systems will certain-

automation on the construction sec-

ly become an increasingly important

The robot work envelope can also be

tor. The Robotic Fabrication Laborato-

part of many manufacturing automa-

moved in the vertical plane to accom-

ry, or RFL, is a unique robotics labora-

tion systems.

modate applications on tall compo-

tory, in which four six-axis robots hang

nents which may require processing

from a ceiling-mounted Güdel surface

in multiple areas between the bot-

gantry. Together, the installation is

tom and top of the item. Will Bourn

based on 36 system axes that can be

continued: “There have been several

used to place objects with a precision

instances in both aerospace and au-

of half a millimetre at any location in

tomotive applications where we have

the 45 x 17 x 6-metre work envelope.

supplied combinations of vertical

This laboratory aims to develop com-

and horizontal linear axes. This has

plex 3D wooden structures which

https://uk.gudel.com/

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Feature: Workpiece carrier systems

Independently controlled workpiece carriers: The bullet train of automation M anufacturers are increasingly requesting maximum flexibility from their OEM suppliers. Plants where products are moved with rigid timing between coupled subsystems do not provide this flexibility, whereas independently controlled workpiece carriers (WPC) can make all the difference. The added flexibility can bring enormous benefits for both manufacturers and their OEM suppliers. That’s what plant builder K&S has proven with its new assembly machine, featuring B&R’s long-stator linear motor transport system, SuperTrak.

Higher flexibility with SuperTrak

Shortly before an already completed as-

“The customer was clear that they want-

about the product’s final specifications.”

sembly line was scheduled for delivery,

When the aforementioned medical technology producer turned to K&S for an assembly line to produce a new flow

component, the company began the search for an optimal solution. To gain the freedom to send workpiece carriers to different processing stations as needed, K&S decided to use the independently controlled shuttles of B&R’s long-stator linear motor-based SuperTrak transport system.

ed a state-of-the-art assembly line that

K&S sales colleagues, Michael Fritsch

The rigid timing of the conventional

would stand up to future challenges,” re-

and Simone Schuster, received a phone

workpiece carrier systems widely used

calls Schuster. “But when we started, we

call informing them of an urgent change:

in production and assembly lines limits

still had no idea what specific variants it

the system would need to produce a

the potential for flexibility. In these sys-

would need to assemble.” Nor did they

second variant of the medical technol-

tems, the maximum output is always

know what specific demands the as-

ogy component for which it had been

determined by the slowest processing

sembly and quality assurance process-

designed and built.

station. If the second stage of expan-

es would place on the machine. Since it

sion requires higher, all process stations

was a new product, it was also unclear

Flexibility is the key

must be created twice so that two parts

what quantities would be needed.

Last-minute changes like this come with

can be processed at the same time. This

the territory, says Fritsch: “We design

is also the case for stations that could

No pre-production required

solutions that are tailored to each cus-

easily achieve a higher throughput with-

K&S designed the system to be released

tomer’s needs. Those needs can change

in the system cycle time. In such cases,

in two stages. The first stage would be

unexpectedly, however, since the prod-

independently controlled workpiece car-

designed to fill the predicted market

ucts being assembled are entirely new.

riers, driven by long-stator linear motors,

demand, with the option to upgrade to

We start designing the machine at a time

create greater system flexibility for plant

double the output. “Producers would

when there are still a lot of unknowns

builders and their customers.

typically use a pre-production assembly

dpaonthenet.net 21

Feature: Workpiece carrier systems Quality assurance at its best K&S took advantage of the flexibility offered by the independently controlled shuttles to boost the availability of the assembly line. For quality assurance, the inspection stations are checked regularly, using special dummy workpieces. In systems with rigidly linked workpiece carriers, an operator usually has to perform this step manually. Since that means disrupting the entire production process, it is done as infrequently as The ability to control the shuttle-mounted workpiece carriers independently makes the assembly line highly flexible

possible.

in such cases, but that’s not necessary

stations located around the oval-shaped

With SuperTrak, the dummies are soft-

anymore,” notes Fritsch.

track. The values for direction, accel-

ware controlled – they’re automatically

eration, speed and target position can

added to the carriers at a pick-and-

K&S used a closed, oval-shaped track

be programmed individually for each

place station and then transported to

consisting of two 180-degree curved

shuttle. Integrated collision avoidance

the processing station to be tested.

segments and eight straight segments

prevents the shuttles from direct contact

Once the test has been completed, the

(one metre each) from B&R’s SuperTrak

with each other and ensures automatic

dummy is taken back to the pick-and-

system, mounted on a stable, six-me-

and safe queueing in front of the pro-

place station and removed from the line.

tre-long machine base. This setup offers

cess stations.

Without the need for manual interven-

enough space for about 20 standard

tion, the system is more available. Since

modules from K&S. In the first-stage var-

To produce a different product variant or

the automated tests using SuperTrak

iant, 14 of those stations are occupied.

expand the system with minimal effort,

have so little impact on productivity, they

it’s possible to skip certain processing

can be performed more frequently – and

Integrated collision avoidance

stations, stop at additional stations or

that increases process reliability.

Shuttles holding custom workpiece

move to multiple positions within a giv-

carriers are guided through processing

en station. This gives the customer the

On top of that, faulty workpieces are

advantage of being able to adjust output

prevented from causing downstream

over the first few phases of the product

damage. They are sent directly from the

lifecycle.

testing station to the removal station without stopping at any assembly sta-

Higher output with hardly any work

tions along the way.

SuperTrak brings the customer even

B&R as a reliable partner

more savings when they chose to in-

“Due to their numerous advantages,

crease the output of their system. In

we have used long-stator linear motor

many applications, it’s only a small

systems to transport workpiece carriers

number of stations that are time critical.

in other lines before. Yet, this medical

SuperTrak makes it easy to boost output

equipment assembly line is the first time

quickly and cost effectively, simply by

we’ve used such a system from B&R,”

doubling up these time-critical stations

says Fritsch. One reason K&S decid-

and adding a few more shuttles.

ed on B&R was the availability of two long-stator linear motor systems, Super-

Machine builders also benefit from Su-

Trak and ACOPOStrak. The B&R portfo-

perTrak’s flexibility. If they plan in enough

lio also makes it easy to create perfectly

extra space, they’re able to make

orchestrated complete solutions which

any changes that become necessary

make it possible to do things like syn-

throughout any stage of the project with

chronise other motion control axes with

relatively little effort. “That paid off when

the shuttle movements. All in all, K&S

we received that last-minute request to

enjoys new dimensions in design free-

equip the line for an additional product,”

dom and can respond to its customers’

recalls the K&S team. All that was need-

needs with much more flexibility.

ed were a few more shuttles and an additional processing station.

22 dpaonthenet.net

https://www.br-automation.com/en/

Reliable Plant availability thanks to Automatic lubrication

Automated relubrication Schaeffler DuraSense monorail guidance systems are designed for convenience and efficiency, providing you with a reduction in operating costs for your plant and machinery. The sensor transmits data to the pre-processing unit to determine the precise lubrication requirements and thus provides automated needs-based relubrication ensuring lower maintenance costs and reduced downtimes. With Schaeffler DuraSense the lubricant requirement can be reduced by up to 30% meaning that availability of machinery and plant increases. www.schaeffler.co.uk

Feature: Linear guide system

Long, difficult and dirty: guide system for a complex S

pie GmbH is responsible for the repair, maintenance and refurbishment of machinery for a leading train manufacturer in Germany. It was faced with a difficult problem: an old DUO welding system was breaking down more than it was in operation – and it was giving the company a constant headache.

“The problems we faced with the machine were multi-faceted. From a construction point of view, the key difficulty was that the existing welding system from the 1990s had been built with an inadequate drive and guidance system. [This was] not suitable for heavy loads or such a dirty working environment.

“We had to visit the customer almost

The welding system is enormous – 30

The existing rail systems had also been

every week, with two men working two

metres long and 10 metres wide. On

mounted on milled surfaces that were

or three shifts to maintain the welding

each of the two welding machines, four

not perfectly flat. In addition, the guide

machine. This was not economically via-

robots are mounted, two on the lower

rails were heavily worn due to the loads

ble for us and it was a huge problem for

and two on the upper level. In a slow but

they had seen,” explains Becker. This

our customer as these failures meant the

constant movement, the robots weld

not only caused the drive motors to fail

machine was often at a standstill, with

aluminium assemblies of up to 28 me-

regularly but also meant that the seams

a knock-on impact on other plant pro-

tres long to a wagon shell. The robots

were not neat. Furthermore, dirt parti-

cesses,” explains Günter Becker, Depu-

are mounted to individual rack-driven

cles made their way into the recirculat-

ty Branch Manager of Spie GmbH.

carriages, each driven by a motor, which

ing ball bearings in the guide blocks for

run on two guide rails.

each welding robot – a common issue in this type of environment. This accelerat-

Repair – yes, standstill – no

ed wear and contributed to the frequent

“We were looking for a linear guidance

blocking of the motors.

system that could operate in a very dirty

24 dpaonthenet.net

environment, under constant load and

HepcoMotion’s GV3 system

with an unusually long track length. We

“For us, the question arose of how to

needed a long-term solution that could

obtain a smooth-running and reliable

be installed on the existing machine,”

system without having to change the

says Becker.

entire machine. This would incur high

Feature: Linear guide system pany that offer[s] the flexibility to adapt

V guide systems can be quickly and

to different sizes and lengths, whilst

easily adjusted to remove any play that

coping with mechanical stresses and

has occurred – thanks to the eccentric

loads of the welding robots,” explains

adjustment facility.

Becker. The Spie team had to update the maThe rails, including carriages and bear-

chine whilst production continued;

ings specified by Spie, are from Hepco-

work was carried out whenever a weld-

Motion’s GV3 system. Approximately

ing robot was not in use. “The old rails

500m of single-edge slides were used

had to be disassembled and the mount-

in the new design; the upper slides in

ing surface fully cleaned so that 5,500

each assembly were supplied with a

new holes could be drilled for mounting

rack to drive the carriages by a mo-

the new guidance system – and all by

torised pinion. Double-row bearings,

hand! HepcoMotion’s rails are supplied

which are made in a single piece, were

in a maximum length of four metres,

used on the carriages.

but are easily joined to make the total 30m length of the system. Alignment of

A linear x setup

“The one-piece design ensures no

each rail was of particular importance

dirt can penetrate the bearings. The

to ensure a good join between teeth in

V-guide principle also ensures that dirt

the rack and provide a smooth move-

particles are transferred away from the

ment of carriage across each joint in

running surface as the bearings move

the slides. With the assistance of a Lei-

along the slide,” explains Thorsten

ca laser tracker for surveying, we were

Pfau, Sales Manager for HepcoMotion

able to align the rails with a deviation of

in Germany. “These bearings have high

[fewer] than 50 microns per slide. This

load capacities, especially in the radial

means the systems are running com-

direction. In this case, this was of great

pletely trouble-free!” says Becker.

importance – the mass of the welding robot and carriage is about 220kg.”

It was a lot of work, but the investment paid off quickly – trouble-free running

costs, probably in the region of two

“We worked in close collaboration with

of the welding robot was one of the

million euros, and extended production

the Technical Sales team in Hepco’s

main criteria for Spie’s customer. The

downtime,” says Becker. A linear guid-

German office. They were extremely

machine could be updated without

ance system was required that could

helpful in solving this challenge and en-

production downtime and there was no

operate in a very dirty environment,

suring longevity of the system can be

need to purchase a replacement ma-

under extreme and constant load. It

achieved,” explains Becker.

chine. “Of course, it was great that not

had to have a long rail length, minimal

only did we get great quality from Hep-

maintenance and had to be installed on

It was also important that the bearings

coMotion, but also a reasonable price

the existing machine without interrupt-

could be manually re-adjusted, without

for the components,” adds Becker.

ing production.

great effort, to take away any play that develops as a result of wear from the

This is where HepcoMotion came into

https://www.hepcomotion.com/

continuous high load. HepcoMotion’s

play: Becker was familiar with the British linear guidance systems manufacturer from his previous employment at a specialist machine builder. “Our plan was to swap the existing guides one by one with a more appropriate system.” Becker worked on the project for over four months to ensure everything functioned correctly, so that he could convince his manager and customer of the feasibility and profitability of the project. “Due to the very special requirements of this application, only HepcoMotion came into consideration. To my knowledge, [it is] the only com-

dpaonthenet.net 25

Feature: Ball screw technology

Long-stroke ball screws optimisation of 5G fibre op filament production

Thomson ball screws are available in lengths of up to eight metres, diameters of 80mm or more and pitch up to 25 x 50 mm, making them the ideal ball screw for applications such as fibre optic filament production

undamental ball screw technology hasn’t changed much since 1929, when Rudolph G. Boehm patented what he called an “antifriction” nut. The ability to move heavy loads smoothly and precisely is a key process which continues to enable engineering innovation today. Nowhere is this more evident than in the production of fibre optic filaments, where ball screws are helping manufacturers to meet the growing demand for fibre optic cable generated by 5G communications. 26 dpaonthenet.net

Delivering fibre optic strands for 5G communications Wireless carriers are just beginning to roll out 5G communications, but even the most conservative estimates are projecting at least a tenfold speed increase over 4G. This will impact everything from mobilephones and laptops to driverless cars. The realisation of 5G communications is boosting the demand for

Feature: Ball screw technology

drive ptic

Selecting ball screws for fibre optic drawing towers

Driving next-generation communications

In a typical ball screw configuration, the

Automated production of fibre optic cable

feed mechanism anchors to the ball screw

is just one way that ball screws are ena-

nut with a rod. The nut rides down the

bling a new generation of communications

vertically oriented ball screw, carrying the

technology. Thomson Industries, for ex-

preform feed mechanism with it toward the

ample, has customers using ball screws

heating unit. Requisite travel distance from

on the doors of furnaces that are used to

the top of the drawing tower to the furnace

process sapphire for mobile phone screen

is six to eight metres, which requires a long

protectors and feeding electrodes to wind-

screw.

ing machines for lithium batteries that will be used in electric cars.

To optimise production of fibre optic cable, three important factors must be taken into

Although the fundamentals are the same,

account:

ball screw technology continues to ad-

high-bandwidth fibre optic cable, which

• Pitch diameter – Speed control and ef-

vance in flexibility and applicability. Com-

requires continuous improvement in the

ficiency are impacted by pitch. Standard

panies such as Thomson are supporting

manufacturing process. This begins with

dimensions, such as 50 x 10 mm, 63 x

even more advanced innovation in other in-

the creation of preforms – highly treated,

10 mm and 80 x 10 mm, are ideal to en-

dustries by consistently pushing the enve-

multi-layered silicon rods. These provide

sure slow and steady fibre optic filament

lope in heavy load handling, stroke lengths,

the silicon that will eventually be drawn

production.

compactness and onboard intelligence,

into filaments that are approximately the

• Long strokes – Travel length of the

which will provide the motion control need-

width of a human hair. They are joined

preform from insertion to heating the el-

ed to support the emergence of 5G and

with hundreds of similar strands to pro-

ement is about six metres. It is best to

future generations as well.

duce the fibre optic transmission cables

do this with only a ball screw, which re-

that will carry the 5G signals.

quires shafts of up to eight metres long. • Diameter – The diameter of the screw

To start the conversion of the preform

is also a factor in the robustness, op-

into a single strand, a technician climbs

eration, stability and durability of the

to the top of a drawing tower and loads

motion. Diameters of 50, 63 and 80mm

it into a feed mechanism that will low-

are best to avoid screw bend due to the

er it into a high-temperature furnace.

long stroke.

https://www.thomsonlinear.com/en/ index

Once the preform arrives at the heating element, gravity takes over, and the molten silicon drips and narrows to its intended diameter. As it cools and hardens, the filament passes through a laser micrometre to assure 99 percent width consistency. It is then pulled onto a takeup spool that will gather as much as 10 kilometres (6.2 miles) of filament before being transferred to a fabricator for incorporation into the final cable. Critical to the success of the process is the control over the speed with which the system feeds the preform. Due to the thin nature of the fibre, slow and steady movement of the feed unit (one metre per hour) ensures that the production is stable. Any faster than that, and the furnace will be unable to melt the preform fast enough. Anything slower will break the continuity of the stream. Many of the world’s leading fibre optic wire producers accomplish this with ball screw technology, which provides high stability and smooth movement at such low speeds.

Final stages of production, in which silicon filament narrows to its desired width, cools and passes through a laser micrometre before being pulled onto a take-up spool

dpaonthenet.net 27

Supplement: Energy

Powering a coal-free future: Is the UK’s coal-free hiatus here to stay? B

ritain passed a significant landmark in June 2020: the nation went for two months without burning coal to generate power. A decade ago, around 40 percent of the UK’s electricity came from coal and, while the recent plummet in demand accounts for some of the success, it isn’t the full story. Here, Simone Bruckner, Managing Director of Cressall, explains why the country no longer depends on burning coal that has, for so long, been the backbone of Britain’s power.

Renewable energy has undergone a massive scale-up in recent years. This is largely as a result of the Paris Climate Agreement, but also because new technologies have made it more possible for renewables to outshine fossil fuels. In solar panel developments, for instance, research into using waste heat emitted by solar panels could help to reduce solar costs even more, while doubling the effi-

Britain’s

new

coal-free

period

has

Furthermore, Drax, the UK’s largest power

ciency of solar cells. Photovoltaic tracking

smashed the previous record from June

plant, was once the biggest consumer of

panels have also become increasingly

2019, which lasted for 18 days, six hours

coal in the UK. Now, the plant is making

popular. These use tracking systems to tilt

and ten minutes. While that hiatus was

the switch to compressed wood pellets,

and shift the angle of the panel as the day

caused by the unprecedented shutdown

with the goal of phasing out coal entirely

goes by to best match the sun’s position.

of many of the National Grid’s coal-fired

by March 2021.

power plants, the disruptions in 2020 have

Wind turbines are much larger nowadays.

been even more remarkable. They are,

While some environmental activists ques-

One example is the 9.6-megawatt (MW)

however, by no means the sole contribu-

tion the efficiency of burning wood, which

turbine from Danish producer, MHI Ves-

tor to coal’s decline.

still produces carbon emissions, this

tas, that alone is able to power more than

change would leave the UK with just three

8,000 homes. Power storage is increas-

coal-powered plants.

ingly possible, and many companies have

Renewables on the rise Ten years ago, wind and solar ener-

partnered with battery producers to store

gy made up a meagre three percent of

Winds of change

extra power, so that it can be used on less

the country’s power mix. In the first six

There is one major reason why Britain’s

windy days.

months of 2020, however, renewables

2020 shift away from coal power will have

were responsible for 37 percent of the

more longevity than a passing trend: re-

Keeping technology turning

electricity supplied to the network – out-

newable technology is far more sophisti-

As renewable resources grow in sophis-

stripping fossil fuels by two percent.

cated than it was ten years ago.

tication, it is vital that other systems also

28 dpaonthenet.net

Supplement: Energy keep pace in order to manage effectively

Braking resistors can also be used on

The UK’s current coal-free reign may not

the power they create.

wind turbines, particularly on fixed-speed

last forever – at least not yet – but the

winder generators where sudden chang-

pause from burning fossil fuels certainly

For example, wind turbines are typical-

es in wind speed can have a detrimental

marks a brighter future. As renewable re-

ly connected to the distribution network

impact on the stability of the system. By

sources form an increasing part of our en-

through step-up transformers. When

inserting a dynamic braking resistor in

ergy mix, it will be ever more essential to

energised by high inrush currents, these

series with the generator circuit, design-

ensure that the technologies which power

transformers can experience overvoltage

ers can help the system to dissipate the

them, and those that manage the power,

on the distribution network. This can po-

excess power created by stronger winds,

support the nation’s net zero goal.

tentially damage equipment.

before it has a chance to damage the entire system.

About the author: Originally from Italy, Simone Bruckner joined Cressall Resistors as Managing Director in April 2015. Previously, Bruckner worked as a General Manager for SIEM Fusani, a leader in equipment and services for rail transport and another part of the Telema Group, which is also Cressall’s parent company. Today, he applies this wealth of experience to serve customers in the rail, power, automotive and general engineering industries.

https://www.cressall.com/

Overvoltage issues can be remedied by using technologies like pre-insertion resistors (PIRs). PIRs, such as those offered by Cressall, are three-phase resistors with a high thermal mass that allows them to absorb energy from high inrushes, while still being compact enough to fit efficiently in a transformer substation. Resistor technologies can also help to manage power in solar panels. One example is electric motors that help solar panels move to “track” the position of the sun. These motors can be fitted with braking resistors to ensure that the panels stop at the optimum angle when tracking the sun and achieve maximum efficiency.

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motors with hollow shaft right angle gearheads deliver high torque for driving the presses. Standard geared types are ideal for tension control of the packaging material, winding up waste material, and driving the completed tray conveyor. Variable speed BLDC motors are also used for positioning trays for sealing.

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Supplement: Energy

The other side of the compressed air story

ompressed air, whilst utilising a ‘free’ working fluid, is one of the highest energy-consuming utilities found in today’s industrial premises. Having spent 30 years in the energy field reviewing many industrial applications, Tony Baldwin CEMI, Energy & Resource Specialist, SMC Pneumatics UK Ltd, says that his first step most commonly involves looking at the generation and distribution of compressed air.

30 dpaonthenet.net

compressed air through a venturi orifice to create and maintain the vacuum force. Modern vacuum ejectors employ a sensing vacuum switch that isolates the compressed air line at the same time as a valve closes the vacuum line to the cup. This stops compressed air usage when the correct vacuum level is sensed. Should the vacuum pressure deteriorate, the solenoid switches

Recently, I’ve been made aware of sig-

the compressed air line back on to cre-

nificant technological advances that

ate further vacuum until the pressure

are now available from manufacturers.

is re-established. Switching vacuum

These can have a significant impact on

ejectors to the modern alternative can

the use and costs attributable to this

reduce compressed air usage by up to

utility.

90 percent.

Vacuum ejectors

Energy-saving cylinders

Vacuum ejectors are prevalent in many

Many pneumatic cylinders are pro-

factories for picking and placing prod-

vided with line pressure for both the

ucts. The typical vacuum ejector uses

power stroke and return stroke, even

Supplement: Energy though the return stroke may not be carrying a load. Therefore, the pressures for each stroke can be adjusted to provide compressed air savings that can be significant for large bore, large-volume displacements or high-frequency operations. For example, five bar may be required on the outward (power) stroke and a reduced five-bar pressure for the return stroke may be acceptable. When the volume of the cylinder is such, the volume saved in compressed air can be considerable and the number of strokes per hour can lead to a 20 to 30 percent reduction in air consumption. Furthermore, specific energy recovery cylinders that have the necessary integral porting can utilise the air from the power stroke to offset air usage in the return stroke of a cylinder. By doing so, compressed air can be reduced by up to 45 percent, compared to a standard cylinder.

Blow guns Blow guns, which are used for cleaning swarf, debris and particles from work surfaces, can be found in the majority of factory compressed air systems. The air consumption of blow guns can become a significant element of the overall factory energy air consumption. Modern blow guns are specifically designed to minimise the use of air during their operation. The use of high-efficiency nozzles, that entrain air through the Bernoulli effect, can reduce the air consumption by 30 percent, whilst having the same effective output. Air guns can be easily operated at or near factory line pressure. A simple on/off type of blow gun should always be used with a tamper-proof preset regulator, set at two bar. This is a value that has been long recommended by the American OSHA body, but does not negate the possibility of compressed air being injected through the skin.

Energy-saving blow guns Energy-saving blow guns are now being developed to prevent the continuous blowing of air. They utilise the integral reservoir of compressed air to permit the rapid-fire impulse method to displace fragments and flakes of material. Therefore, the use of three to four sub-second repeated air blasts can clear the equivalent material as a constant stream

One fits all

of compressed air at minimal consumption. Whilst we have just looked at three simple areas of air usage reduction, development in several areas is ongoing; from low wattage solenoids on air manifolds through to pressure boosters for high-pressure appli-

Cross-manufacturer compatible connectors M17-M40 PRO

cations, which allow lower factory line pressures to be set. Development of energy-efficient pneumatic components like those discussed above is helping end-users to lower dramatically their use of air usage and, therefore, energy consumption. It will always be necessary to evaluate the generation and distribution of compressed air to ensure that the delivery of air is optimum and not wasted. However, we must not forget that the components that affect the direct use have their role to play too.

M17-M40 PRO series circular connectors offer uniform solutions for signal and power transmission. Thanks to the unique ONECLICK fast locking system you can connect your device quickly and safely.

https://www.smc.eu/en-gb

About the author: Tony Baldwin CEMI, Energy & Resource Specialist, SMC Pneumatics UK Ltd.

dpaonthenet.net 31

For additional information call 0845 881 2222 or visit phoenixcontact.co.uk/proseries

Supplement: Energy

Back to the future: Improving the

efficiency of our hydropower network H ydropower is an extremely old source of energy, tracing its usage back to the watermills on which ancient civilians relied. Here, Marek Lukaszczyk, European and Middle East Marketing Manager at WEG, explains how plant managers can make today’s hydropower smarter and reap financial and carbon savings by embracing energy-efficient products and Industrial Internet of Things (IIoT) technology.

Most of the UK’s hydropower infrastruc-

Mechanical upgrades, such as energy-effi-

ture was constructed in the 20th century

cient hydro generators or motors, can also

– before modern environmental codes or

reap energy and cost savings. For exam-

energy-efficiency recommendations came

ple, WEG’s W22 IE4 standard motors offer

into force. Therefore, the industry focus

97 percent efficiency, depending on size.

has shifted from adding to the current

These machines, whether used as motors

capacity, to increasing the efficiency and

or adapted to become generators, satisfy

lifespan of the existing ageing network.

an attractive balance between high efficien-

This will lead to more flexibility on the pow-

cy, range, availability and value. When you

er grid, which is crucial, considering the

look at the total cost of ownership (TCO) for

increasing amounts of renewables being

one of the machines over its lifetime, the

integrated into the electricity system.

cost of acquisition typically represents only three percent of the total cost of ownership

So, what practical and cost-effective up-

of an electric motor.

grades can hydropower plants make to Hydroelectricity remains an attractive re-

support the UK’s effort to become a net

Additionally, investing in cost-effective IIoT

newable energy source, especially in Eu-

zero economy by 2050?

sensors allows plant managers to be more

rope which has a large network of hydro-

Marek Lukaszczyk is the European Marketing Manager at global manufacturer of motors and drive technology, WEG. With over 20 years’ experience at the company, he leads the marketing campaign across Europe and the Middle East region.

agile in their response to maintenance. This

power plants. According to the International

For larger facilities, small operational im-

is especially important in older facilities, to

Energy Agency, the global installed hydro-

provements can have significant rewards.

ensure reliability and increase service life.

power capacity in 2019 was 1307GW. Chi-

Upgrading plants to have variable or ad-

The early detection of problems such as

na, India and Brazil are expected to lead the

justed speed drives allows them to meet

bearing wear can alleviate future machine

growth in new hydropower facilities over

different kinds of demands, including more

failure and costly downtime.

the next five years, but many European

rapid response and variability manage-

countries already have a vast network of

ment.

established hydropower facilities.

In the coming years, hydropower is expected to remain the world’s largest source of

One area of hydropower that has seen re-

renewable electricity generation and will

For example, the UK has a total hydropow-

cent growth is micropower facilities. For

play a critical role in decarbonising the pow-

er installed capacity of over 4,600MW, in-

example, the variable speed of Archime-

er system and improving system flexibility.

cluding 2,744MW of pumped storage. As

dean Screw hydro turbines means that the

the fourth largest source of renewable en-

rotational speed of the screw can be ad-

For further information about WEG’s SH11,

ergy, as well as the most reliable, efficient

justed depending on the flow rate availa-

GH11 and GH20 hydro generator lines for

and hardy, it certainly has an important part

ble in the river. This allows them to operate

compact or large hydropower plants, visit

to play.

more efficiently.

the website.

32 dpaonthenet.net

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A router for for Industry 4.0 4.0 A secure secure router A secure router for Industry Industry 4.0 IEC62443 is is the the standard standard for for “Security “Security for for Industrial Industrial Automation Automation and and Control Control IEC62443 IEC62443 is the standard for “Security for Industrial Automation and Control Systems” Systems” to to assist assist in in addressing addressing the the ever ever increasing increasing question question of of online online security security Systems” to assist in addressing the ever increasing question of online security with with Industry Industry 4.0. 4.0. with Industry 4.0. KEB’s KEB’s C6 C6 Router Router & & COMBIVIS COMBIVIS software software have have been been independently independently tested tested and and KEB’s C6 Router & COMBIVIS software have been independently tested and passed passed this this standard standard with with the the certificate certificate & & data data available available on on its its website. website. passed this standard with the certificate & data available on its website. First First look look at at the the C6 C6 Router Router shows shows the the body body is is only only 138mm 138mm high, high, 116mm 116mm First the C6 Router shows deeplook and at either 35 or or 45mm wide the body is only 138mm high, 116mm deep and either 35 45mm wide deep and either 35 or 45mm wide depending upon upon the the model model selected. selected. depending depending upon themade model selected. 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Thisservo demand is coming from motors; a variety VSD of industry sectors, approvals, with an IP20 approvals, with an IP20 protection drives with sensorless closed control, real Confidence itit is the result approvals, an ARM IP20 protection drives withplastics sensorless closed loop loop control,automotive real Confidence is is not not just just given given away, away, isInside the with result including and packaging machines, production rating. is an an CortexSafety A8 over rating. 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CC C6 HMI -- LC WITH TOUCH 5.7“ ... 15.6“ C6 HMI WITH TOUCH 5.7“ ... 15.6“ C C6 HMI -- LC LC WITH TOUCH 5.7“ ... 15.6“ C6 HMI LC WITH TOUCH 5.7“ ... 15.6“ HMI LC WITH TOUCH 5.7“ ... 15.6“ --C6combines control, visualisation and remote maintenance - combines combines control, control, visualisation visualisation and and remote remote maintenance maintenance --

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- combines control, visualisation and remote maintenance maintenance and and remote remote maintenance inEtherCAT-Master one unitwithout Spring-applied brake reduced overall length Closed Loop ain feedback device? things EtherCAT-Master KEB’s new Generation ofwith Drive Controllers from 0.75KW to 90KW. Se BIG can come small packages Se EtherCAT-Master Closed Loop without ain feedback device? EtherCAT-Master BIG things can come small packages Se and weight to suit disc motor applications EtherCAT-Master standardised process control, programmable with motion EtherCAT-Master process control, programmable with motion Feedbackstandardised devices IfIf yy standardised process programmable with motion Using decentralised architecture orcontrol, moving away from conventional standardised process control, programmable withcontrol motion Saf Feedback devices standardised process programmable with motion are the usual choice Using decentralised architecture orcontrol, moving away from conventional control Ifhoy control and I/O handling according to IEC 61131-3 All in One standardised process control, programmable with motion control and I/O handling according to IEC 61131-3 KEB Automation has cabinets? KEB’s new generation of DIN rail IPC is designed for this type of ho are the usual choice control and I/O handling according to IEC 61131-3 to help with motor cabinets? KEB’s new generation of DINaccording rail IPC is designed for this type of ho and I/O handling to IEC 61131-3 ne launched acontrol new springcontrol and I/O handling according to IEC 61131-3 installation. ne COMBIVERT F6 / S6 to help with motor Universal operations – open and closed loopconInte control, here MarkandMotor control I/O handling according to IEC 61131-3 installation. ne Th applied brake with reduced Th control, here Mark Today’s modular machine designs require decentralized architecture. Checkley from KEB Th wh Today’s modular machine designs require decentralized architecture. availability online overall length and weight trol for ASM, SM, IPM, SRM, including sensorless control SLI, wh availability online Checkley from KEB Conventional automation modules have begun to migrate from the KEB’s new Generation of Drive Controllers from 0.75KW to 90KW. UK explains why wh availability online bra Conventional automation modules have begun to migrate from the toUK suitexplains disc motors and availability online bra why availability online conventional control cabinet directly into the installation. The new generation of sensorless closed unit updating, machine diagnosis and monitoring down toofthe the bra -unit Dual encoder channels, selectable inputs including Re- to Rea availability online updating, machine diagnosis and monitoring down conventional control cabinet directly into the installation. The new generation other applications where Th sensorless closed unit updating, machine diagnosis and monitoring down to the KEB control DIN unit rail isIPCs is designmachine precisely for this type and of installation. 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The device takes uplower 47mm on the DIN high-end layout of the operating with scalable po solver, Endat, Hiperface, BISS, SSI, Incremental TTL / HTL symbols, trends, data logger, formula management and Re More than simply rotating a motor, the variable speed driveIt has long been rail and supports direct coupling with remote recognised as a critical piece of most modern machinery. offers a gateway high-end layout of the operating interface with scalable symbols, trends, data logger, formula management and po po rail and supports direct coupling with remote symbols, trends, data logger, formula management and po Hendrik Wieneke, Deputy Sales Manager, Magnet Technology atItKEB comments: recognised as a critical piece of most modern machinery. offers a gateway symbols, trends, data logger, formula management and I/O modules using built in EtherCAT. into the machine, capable of significantly increasing the performance of the po symbols, trends, data logger, formula management and In Air and Water cooling options, built in or through I/O modules using built in EtherCAT. integrated user administration CA symbols, trends, data logger, formula management and “The COMBISTOP 38S is ideally suited to disc motor applications. 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of unscheduled downtime. Thereviaare a variety of features offered by the integrated visualisation support a standard integrated visualisation viaare a standard of unscheduled downtime. There aat variety features offered by the manufacturers, which issupport worth looking moreof closely to understand which built in DVI-D interface. For information http://www.dpaonthenet.net/article/178832/ builtmore in be DVI-D manufacturers, which isvisit: worth looking would mostinterface. advantageous for themattomore use. closely to understand which Spring-applied-brake-with-reduced-overall-length-and-weight-to-suitFor more information visit: https://www. would be most advantageous for them to use. For more information visit: https://www. Click to read the full article: http://www.dpaonthenet.net/ disc-motor-applications.aspx keb.de/control-automation/produkte/ keb.de/control-automation/produkte/ Click to read the full article: article/123866/Closed-Loop-without-a-feedback-device-.aspx hutschienen-ipc/c6-smart/ http://www.dpaonthenet.net/ hutschienen-ipc/c6-smart/ article/123866/Closed-Loop-without-a-feedback-device-.aspx

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

C6 HMI HMI -- LC LC WITH WITH TOUCH TOUCH 5.7“ 5.7“ ... ... 15.6“ 15.6“ C6 C6 HMI -- LC WITH TOUCH 5.7“ ... 15.6“ C6 HMI LC WITH TOUCH 5.7“ ... 15.6“ C6 HMI LC WITH TOUCH 5.7“ ... 15.6“ -- combines control, visualisation and remote maintenance combines control, control, visualisation visualisation and and remote maintenance combines control, visualisation and remote maintenance --- combines remote maintenance combines control, visualisation and remote maintenance combines control, visualisation and remote maintenance -- combines control, visualisation and remote maintenance combines control, visualisation and remote maintenance

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Automation with Drive

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in one unit and remote maintenance in in one one unit unit KEB controllers (UK) Ltd. 5 Morris Close Park Farm Industrial Estate losses Wellingborough NN8 in one unit 360º solution for plastics injection moulding & Drive & filters minimise power EtherCAT-Master EtherCAT-Master AA Automation with Drive www.keb.co.uk Closed Loop without a feedback device? EtherCAT-Master things EtherCAT-Master KEB’s new Generation of Drive Controllers from 0.75KW to 90KW. BIG can come in small packages Selecting brakes EtherCAT-Master EtherCAT-Master Automation with Drive www.keb.co.uk Closed Loop without a feedback device? extruder machines EtherCAT-Master BIG things can come in small packages Selecting brakes EtherCAT-Master Automation with Drive www.keb.co.uk standardised process control, programmablewww.keb.co.uk with motion motion standardised process control, control, programmable programmable with with motion motion standardised EtherCAT-Master standardised process control, programmable with Automation with Drive process Feedback devices standardised programmable motionNN8 standardised process programmable with motion KE KEB (UK) Ltd. 55process Morris Close Closecontrol, Park Farm Farm Industrial Estate Estate with Wellingborough NN8 6XF 6XF Using decentralised architecture orcontrol, moving away from conventional control standardised process control, programmable with motion If you need toLtd. KE KEB (UK) Morris Park Industrial Wellingborough Feedback devices standardised process control, programmable with motion are the usual choice Using decentralised architecture or moving away from conventional control If you need to control and I/O handling according to IEC 61131-3 control and I/O handling according to IEC 61131-3 KE KEB (UK) Ltd. 5 Morris Close Park Farm Industrial Estate Wellingborough NN8 6XF All in One Safety standardised process control, programmable with motion control and I/O handling according to IEC 61131-3 control and I/O handling according to IEC 61131-3 KEB (UK) Ltd. 5 Morris Close Park Farm Industrial Estate Wellingborough NN8 6XF Tel Tel: 01933 402220 E-Mail: info@keb.co.uk cabinets? KEB’s new generation of DIN rail IPC is designed for this type of hold a load, you are the with usual choice KEB (UK) Ltd. 5 Morris Close Park Farm Industrial Estate Wellingborough NN8 6XF Tel Tel: 01933 402220 E-Mail: info@keb.co.uk control and I/O handling according to IEC 61131-3 control and I/O handling according to IEC 61131-3 to help motor cabinets? KEB’s new generation of DIN rail IPC is designed for this type of hold a load, you control and I/O handling according to IEC 61131-3 KEB (UK) Ltd. 5 Morris Close Park Farm Industrial Estate Wellingborough NN8 6XF Tel Tel: 01933 402220 E-Mail: info@keb.co.uk control and I/O handling according to IEC 61131-3 installation. Tel: 01933 402220 E-Mail: info@keb.co.uk need aTel:brake. F6 / according S6– opentoandIECclosed to helpCOMBIVERT with motor -here Universal operations loopconIntegrated functions STO-PLe/SIL3, SS1, SS2, SOS, SLS, SLP, 01933 402220 E-Mail: info@keb.co.uk control, MarkandMotor control I/O handling 61131-3 installation. need aTel:brake. 01933 402220 E-Mail: info@keb.co.uk The question is KEB (UK) Ltd. 5 Morris Close Park Farm Industrial Estate Wellingborough NN control, here Mark Today’s modular machine designs require decentralized architecture. Checkley from KEB The question is Today’s modular machineonline designs decentralized architecture. SDI, availability KEB’s availability trolwhy for SM, IPM, SRM, including sensorless controlto 90KW.SLI, SSM, SEL, SLA, SMS, SSR which type of SAR, online availability online availability online Checkley from KEBASM, Conventional automation modules have begun to migrate from the new Generation ofrequire Drive Controllers from 0.75KW UK explains which type of availability online availability Conventional automation online modules have begun to migrate from the availability online brake and why? UK explains why availability online conventional control cabinet directly into the installation. The new generation of unit updating, machine diagnosis and monitoring down to the sensorless closed unit updating, machine diagnosis and monitoring down to the brake and why? Dual encoder channels, selectable inputs including Re Real Time unit availability online unit updating, updating, machine diagnosis and monitoring down to conventional control cabinet directly into the installation. The new generation ofthe updating, machine machine diagnosis diagnosis and and monitoring monitoring down down to to the the sensorless unit updating, machine diagnosis and monitoring down to the KEB DIN unit railclosed is designmachine precisely for this type and of installation. The unit first thing loop control isIPCs updating, diagnosis monitoring down to the KEB DIN rail IPCs is design precisely for this type of installation. unit updating, machine diagnosis and monitoring down to the The first thing SMART All One Safety power unitEtherCAT, level with withProfinet, secure end-to-end end-to-end VPN-connection power unit level with secure secure end-to-end VPN-connection solver, Endat, Hiperface, BISS,end-to-end SSI,and Incremental TTLdown / HTLto the Real Powerlink,VPN-connection Varan and loop control isin unit updating, machine monitoring power unit level secure power level with VPN-connection you time need with chosen by customers The C6 isunit perfectly tailored todiagnosis the runtime environment and realpower unit level with secure end-to-end VPN-connection power unit level with secure end-to-end VPN-connection you need The C6value SMART isunit perfectly tailored to the runtime environment and reallevel with secure end-to-end chosen by to decide is functions STO-PLe/SIL3, SS1, SS2, SOS, SLS, SLP, power unit level with secure VPN-connection toCONTROL add and time capability with a powerful processor forend-to-end -customers Universal Motor operations – open and closed loopconIntegrated VISUALISATION REMOTE -power Air and Water cooling options, built in orVPN-connection through CAN, or simply serially. to decide is power unit with secure VPN-connection KEB Automation offers alevel complete tailored solution for machine VISUALISATION REMOTE time capability with a powerful processor forend-to-end to add value and whether you aCONTROL competitive CONTROL VISUALISATION REMOTE performing complex automation tasks. The MAINTENANCE whether you manufacturers. performing complex automation tasks. The MAINTENANCE a competitive trol for ASM, SM, IPM, SRM, including sensorless control SLI, SDI, SSM, SAR, SEL, SLA, SMS, SSR powerful graphical design powerful graphical design mount. want the brake advantage to their MAINTENANCE powerful integrated micro UPS and spacious on board powerful graphical design want the brake graphical graphical design design integrated micro and spacious on board powerful graphical design advantage to their When it comes toUPS selecting drives, controls, automation systems and software to bepowerful applied powerful graphical design machines. memory make the C6 SMART a robust, reliable powerful graphical design to be applied Dual encoder channels, selectable inputs including Re Real Time high-end layout of the operating interface with scalable high-end layout ofaextruders the operating interface with scalable memory make the C6layout SMART robust, reliable The powerful design high-end of the operating interface with scalable high-end of the operating interface with scalable machines. for plastics machinery –graphical such as and injection moulding machines when there is nolayout system. device takes up 47mm onvariable the DIN New drive controllers and motor filters for high frequency (HF) applications from high-end layout of the operating interface with scalable high-end layout of the operating interface with scalable More than simply rotating a motor, the speed drive has long been when there is no high-end layout of the operating interface with scalable system. The device takes up 47mm on the DIN – KEB Automation can provide a complete tailored solution for machine high-end layout of the operating interface with scalable power, or when solver, Endat, Hiperface, BISS, SSI, Incremental TTL / HTL symbols, trends, data logger, formula management and symbols, trends, data logger, formula management and Real time with EtherCAT, Profinet, Powerlink, Varan and More than simply rotating a motor, the variable speed drive has long been KEB Automation are helping customers develop highly efficient machine concepts rail and supports direct coupling with remote recognised as a critical piece of the most modern machinery. It with offers scalable a gateway high-end layout of operating interface symbols, trends, data logger, formula management and symbols, trends, data logger, formula management and power, or when rail and supports direct coupling with remote manufacturers, servo motors, gearmotors, permanent magneta gateway symbols, trends, logger, formula management and symbols, trends, data logger, formula management and power is applied. recognised aincluding critical piece of most modern machinery. It offers symbols, trends, data logger, formula management for turbo CNCdata machine tool spindles. I/O using built in EtherCAT. intomodules the machine, capable ofadministration significantly increasing the performance ofand the power applied. symbols, trends, data logger, formula - as Air and Water cooling options, built in or through integrated user administration I/O modules using built in EtherCAT. integrated user CAN, orisblowers simplyand serially. brakes, drive controllers (with integrated functional safety ifmanagement required), PLCs,ofand symbols, trends, data logger, formula management and In most cases integrated user administration integrated user administration into the machine, capable of significantly increasing the performance the machine as well as offering sophisticated monitoring of the process, e.g. In most cases integrated user administration integrated user administration The objective is to increase performance and protect the motor windings at output AHMIs C6 Monitor can besoftware. incorporated to the user administration andintegrated you want to hold the load when power is off, but there are applications like A C6 Monitor can incorporated toproblems the monitoring integrated user administration machine asapplication well asbe offering sophisticated of the e.g. mount. highlighting the onset of mechanical that could beprocess, the source you want touphold the load frequencies to 2,000 Hz. when power is off, but there are applications like decentralized installation using the SMART’s integrated user administration gates and turnstiles, where the brake must disengage in the case of a power decentralized using the SMART’s highlighting theinstallation onset of mechanical problems that could be the source

Automation with Drive

of unscheduled downtime. Thereviaare a variety of features offered by the integrated visualisation support a standard integrated visualisation viaare a standard of unscheduled downtime. There aat variety features offered by the manufacturers, which issupport worth looking moreof closely to understand which For more information visit: http://www.dpaonthenet.net/article/178382/ built in DVI-D interface. built in DVI-D interface. manufacturers, which is worth for looking KEB-Automation-provides-360-degree-solution-for-plastics-injectionwould be most advantageous themattomore use. closely to understand which For more information visit: https://www. would be most advantageous for them to use. For more information visit: https://www. moulding-extruder-machines.aspx Click to read the full article: http://www.dpaonthenet.net/ keb.de/control-automation/produkte/ keb.de/control-automation/produkte/ Click to read the full article: article/123866/Closed-Loop-without-a-feedback-device-.aspx hutschienen-ipc/c6-smart/ http://www.dpaonthenet.net/ hutschienen-ipc/c6-smart/ article/123866/Closed-Loop-without-a-feedback-device-.aspx

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

Automation with Drive

gates and turnstiles, where the brake must disengage in the case of a power failure. Power-to-energise brakes are also used in process control often in For more information visit:brakes http://www.dpaonthenet.net/article/179770/ failure. Power-to-energise are also used in process control often in conjunction with a clutch to give a stop-start action. Drive-controllers-filters-minimise-power-losses-in-high-speed-machineconjunction with a clutch to give a stop-start action. Click to read the full article: http://www.dpaonthenet.net/ tool-spindles-and-turbo-blowers.aspx Click to read the full article: http://www.dpaonthenet.net/ article/133837/Selecting-brakes.aspx article/133837/Selecting-brakes.aspx

www.keb.co.uk

-- combines control, visualisation and remote maintenance nance nance - combines combines control, control, visualisation visualisation and and remote remote maintenance maintenance nance nance nance in one unit nance in in one one unit unit KEB (UK) Ltd. 5 Morris Close Park Farm Industrial Estate Wellingborough NN8 6XF Tel: 01933 402220 info@keb.co.uk EtherCAT-Master Automation with Drive www.keb.co.uk EtherCAT-Master Automation with Drive www.keb.co.uk brakes 0KW. Selecting Selecting brakes EtherCAT-Master Automation with Drive www.keb.co.uk Automation with Drive www.keb.co.uk Selecting brakes Automation with Drive www.keb.co.uk standardised process control, programmable with motion nn Automation with Drive www.keb.co.uk standardised process control, programmable with motion standardised programmable with motionNN8 you need toLtd. KEB KEB (UK) 55process Morris Close Park Farm Industrial Estate Wellingborough nnn Safety IfIf you need KEB (UK) (UK) Ltd. Ltd. 55 Morris Morris Close Close Park Park Farm Farm Industrial Industrial Estate Estate Wellingborough Wellingborough NN8 NN8 6XF 6XF KEB (UK)to Ltd. I/O Morris Closecontrol, Park Farm Industrial Estate Wellingborough NN8 6XF 6XF Ifhold you need to control and handling according to IEC IEC 61131-3 KEB (UK) Ltd. 5 Morris Closeinfo@keb.co.uk Park Farm Industrial Estate Wellingborough NN8 6XF (UK) Ltd. 55 Morris Close Park Farm Industrial Estate Wellingborough NN8 6XF aaKEB load, you n and I/O handling according to 61131-3 KEB (UK) Ltd. Morris Close Park Farm Industrial Estate Wellingborough NN8 6XF Tel: 01933 402220 E-Mail: Tel: 01933 402220 E-Mail: info@keb.co.uk holdcontrol load, you KEB (UK) Ltd. 5 Morris Close Park Farm Industrial Estate Wellingborough NN8 6XF Tel: 01933 402220 E-Mail: info@keb.co.uk Tel: 01933 402220 E-Mail: info@keb.co.uk control and I/O handling according to IEC 61131-3 hold aaKEB load, you (UK) Ltd. 5 Morris Close Park Farm Industrial Estate Wellingborough NN8 6XF Tel: 01933 402220 E-Mail: info@keb.co.uk Tel: 01933 402220 E-Mail: info@keb.co.uk need brake. 01933 402220 E-Mail: need aTel: brake. 01933 402220 STO-PLe/SIL3, E-Mail: info@keb.co.uk info@keb.co.uk Integrated functions SS1, SS2, SOS, SLS, SLP, need aTel: brake. The is Tel: info@keb.co.uk The question question is402220 KEB01933 (UK) Ltd. 5E-Mail: Morris Close Park Farm Industrial Estate Wellingborough NN8 6XF Tel: 01933 402220 info@keb.co.uk The question is which type of availability online SLI, SDI, SSM, SAR, SEL, SLA, SMS, SSR which type of availability online 90KW. which type of

Automation with Drive

www.keb.co.uk

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