DPA_21_01

January 2021 The Engineer’s guide to new products & design ideas

SMART AND DIGITAL AUTOMATION SPECIALISING IN SOLUTIONS

Packaging Machinery

Theatre Systems

Metall Processing

Textile Machinery

Process Engineering

Lift & Escalators

Intralogistics

Plastics Machinery

Wood Working

Wind Power

e-mobility

Automotive

10: Measuring 26: Springs Lee Spring employees join the www.keb.co.uk Automation with Drive exercise COVID-19 fight Ltd. 5 Morris Close A ‘hole’ lotKEB of(UK) trouble for loco rebuild fixed 2020_205_297_portfolio-specialized.indd 1

Park Farm Industrial Estate

Wellingborough NN8 6XF

Tel: 01933 402220

info@keb.co.uk

08.12.2020 08:38:23

Contents

January 2021 The Engineer’s guide to new products & design ideas

Editorial Comment:

SMART AND DIGITAL AUTOMATION SPECIALISING IN SOLUTIONS

04: Green revolution Looking ahead: The race to zero

Cover Story:

Packaging Machinery

Theatre Systems

Metall Processing

Textile Machinery

Process Engineering

Lift & Escalators

Intralogistics

Plastics Machinery

Wood Working

Wind Power

e-mobility

Automotive

06: The design cycle

10: Measuring 26: Springs Lee Spring employees join the www.keb.co.uk Automation with Drive exercise COVID-19 fight Ltd. 5 Morris Close A ‘hole’ lotKEB of(UK) trouble for loco rebuild fixed

Park Farm Industrial Estate

Wellingborough NN8 6XF

Tel: 01933 402220

How much does it cost to ask for help?

info@keb.co.uk

2020_205_297_portfolio-specialized.indd 1

08.12.2020 08:38:23

Cover Story:

201016_9-6_Mill_DPA_UK_Snipe.indd 1

10/14/20 3:22 PM

Mark Checkley of KEB Automation discusses the pitfalls associated with engineers calling suppliers late in the design cycle, as well as the benefits to be gained if they were to engage earlier.

(Cover image: KEB)

Test & Measurement Supplement: Graphene comes of age, thanks to large-area production process

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

10: Measuring exercise

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

14: Battery challenges

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

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

08

08: Graphene

A ‘hole’ lot of trouble for loco rebuild fixed

Battery challenges in test and instrumentation equipment

16: 5G Measuring the impact of 5G

18: Test cells Improving production test throughput using a robotic test cell

Springs & Shock Absorbers Technology Focus: 20: Complex springs

24

Modelling a complex spring in Spring Calculator Professional

22: Wave springs The benefits of wave springs for medical applications

24: Complex wire forms Springing into action saves the day for tier one automotive manufacturer

26: Springs Lee Spring employees join the COVID-19 fight

Motors & Motor Control Special Report: 28: Ex-rated motors

10,000 Average net circulation Jan-Dec 2018

Taking responsibility for repairs to Ex-rated motors

30: Sizing motors When a servo motor that’s big enough isn’t big enough

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

33: Motors WEG products used to create innovative jaw crusher unblock system

33 dpaonthenet.net 3

Editorial Comment

Looking ahead: The race to zero H

appy New Year and welcome to the January issue of DPA!

2. Hydrogen: Working with industry aim-

carbon dioxide by 2030, equivalent to all

ing to generate 5GW of low-carbon hy-

emissions of the industrial Humber today.

drogen production capacity by 2030 for industry, transport, power and homes,

9. Nature: Protecting and restoring our

As per New Year tradition, I thought I’d

and aiming to develop the first town

natural environment, planting 30,000 hec-

start off this year by looking to the future.

heated entirely by hydrogen by the end

tares of trees every year, whilst creating

of the decade.

and retaining thousands of jobs.

positive effects of the pandemic on the

3. Nuclear: Advancing nuclear as a clean

10. Innovation and finance: Developing

environment and celebrated Britain’s

energy source, across large scale nucle-

the cutting-edge technologies needed to

milestone in reaching two months of

ar and developing the next generation

reach these new energy ambitions and

coal-free power generation. However, I

of small and advanced reactors, which

make the City of London the global centre

pointed out that, whilst this was an im-

could support 10,000 jobs.

of green finance.

will need to put in place a clear and prac-

4. Electric vehicles: Backing our world-

However, the plan has been criticised for

ticable plan if we are to meet our net-zero

leading car manufacturing bases, includ-

not being ambitious enough in its aims to

targets”.

ing in the West Midlands, North East and

tackle the climate crisis, especially com-

North Wales, to accelerate the transition

pared to our European neighbours, and

November 2020 finally saw Prime Minis-

to electric vehicles and transforming our

climate experts claim it is a far cry from

ter Boris Johnson outlining such a plan to

national infrastructure to better support

what is needed to achieve the govern-

set the green industrial revolution in mo-

electric vehicles.

ment’s net-zero goals.

In my first-ever column, I discussed the Sophia Bell, Assistant Editor

pressive achievement, “the government

tion and help to rebuild the economy.

5. Public transport, cycling and walk-

Nonetheless, the government’s policy

The plan identifies ten key areas for sus-

ing: Making cycling and walking more at-

document claimed that “this is only the

tainable development:

tractive ways to travel and investing in ze-

start. Over the next year, we will work with

ro-emission public transport of the future.

industry to devise further sectoral plans

1. Offshore wind: Producing enough off-

and meet our carbon budgets and target

shore wind to power every home, quadru-

6. Jet Zero and greener maritime: Sup-

pling how much we produce to 40GW by

porting difficult-to-decarbonise indus-

2030, supporting up to 60,000 jobs.

tries to become greener through re-

As Nicola Shaw, the UK Executive Direc-

search projects for zero-emission planes

tor of National Grid, said, “Industry and

and ships.

government must work together to turn

of net zero by 2050”.

this ambition into reality, with transforma7. Homes and public buildings: Making

tional investments to deliver real change,

our homes, schools and hospitals green-

which will create jobs in every part of the

er, warmer and more energy efficient,

country.”

whilst creating 50,000 jobs by 2030, and a target to install 600,000 heat pumps

Here’s to a greener 2021!

every year by 2028.

Do let us know what you think of the issue 8. Carbon capture: Becoming a world-

and if there are any specific topics you

leader in technology to capture and store

think we should be covering. Email me

harmful emissions away from the atmos-

at sophia.bell@imlgroup.co.uk.

phere, with a target to remove 10MT of

4 dpaonthenet.net

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Cover Story: The design cycle

How much does it cost to ask for help?

M

ark Checkley of KEB Automation discusses the pitfalls associated with engineers calling suppliers late in the design cycle, as well as the benefits to be gained if they were to engage earlier.

ask for help from and so limits the exper-

which is why it’s often best to ask for our

tise they’ll receive. Second, there’s often

help and guidance. For 50 years, we’ve

a power play between the design engi-

developed variations to our catalogue

neers and their purchasing department,

items to enable us to provide a complete

which is a slightly different issue, but one

technical system solution for certain ap-

which, as suppliers, we need to be aware

plications or industry sectors. Whilst we

of. Thirdly, credibility and reputation are

can demonstrate some of this knowledge

key factors, not just the obvious reputa-

and expertise online, we always encour-

Over the years, there has been an in-

tion of the supplier, but often of the engi-

age customers to contact us direct to

creasing trend for engineering suppliers

neer who is looking at these designs for a

gain access to our expertise and to ben-

to be called later into the design cycle,

new product development.

efit fully from our application know-how.

product costs or some elements of the

Company culture

Purchasing without design

design having to be reworked. So what’s

Whilst the reasons above are understand-

If a company purchases or tests a suppli-

holding engineers back from engaging

able, they can also create problems. In

er’s product without any upfront technical

earlier with suppliers?

my experience at KEB over the last five

discussion, it could prove to not be quite

years, most customers mainly look online

right or a failure, which costs time and

There are many reasons why this is hap-

just for supplier products. Their research

therefore money, as well as causing po-

pening, but I see three main recurring

is therefore limited to the catalogue prod-

tential disruption or delays in getting the

ones. First, it’s about company culture

ucts displayed, which as we all know, are

new machine or technology launched. At

and the growing trend to reduce their

not always the ‘best fit’ for a new machine

KEB, we’ve had calls from new potential

number of suppliers and establishing a

or new product development. This isn’t a

customers when this has actually hap-

limited preferred supplier list. However,

criticism of the customer’s engineers,

pened, not with our products, but with

this does limit which suppliers they can

but they are not experts in our products

products from other suppliers. They have

which can lead to project delays, higher

6 dpaonthenet.net

Cover Story: The design cycle a bad experience with a product or tech-

Responsibility is also key. Not just about

relationships with customers who are in-

nology and then come to us late in their

the supplier being a responsible com-

terested in using new technology. If they

design cycle for help and they are really

pany – socially or environmentally – but

are successful, so will we be. Therefore,

up against tight deadlines. Additionallly,

about the advice and proposal and not

our solutions have to be good technical

this bad experience can develop an inher-

selling for the sake of selling. We need to

solutions, at the right price, providing our

ent resistance to the product/technology,

acknowledge that design engineers have

customer with advantages they can use.

even if an alternative supplier can provide

a responsibility to their company through

the tailored solution utilising them.

their selection of products, especially if

How much does it cost to ask?

they are being sourced from a new sup-

Most engineers would say it costs noth-

Credibility & reputation

plier and particularly if it is relatively un-

ing to ask for help and advice. Others

If we are called in late to a design cycle,

known within their company. Again, it’s

would say it costs their time. However,

understandably the customer can be re-

about developing a trust and confidence

consider the time that would be lost when

luctant to relook at the design as it can

in our advice and recommendations, es-

you’re not 100 percent sure or aware of

lead to project delays, increased costs

pecially when they are not standard cat-

all the facts – it will often end without any

and a later time-to-market. These issues

alogue products or if there has been little

clear results or conclusions. By asking

can ultimately damage the reputation and

experience in those products.

a supplier whose aims and goals are as

credibility of the customer, as well as its

mentioned above, you are guided and led

design department. The associated impli-

The customer’s culture can sometimes

to the right technical solution, often in a

cations of this can even delay or prevent

be a hurdle for suppliers, particularly if

shorter time frame.

future re-investments in new machines or

the culture is to use limited preferred sup-

product developments.

pliers. A design engineer who can see the benefit of a technology or product

What will early engagement save the customer?

So what hurdles need to be overcome

and can navigate around their company

By engaging with the supplier earlier in

to improve the situation? There are obvi-

policies, will only do so if they trust and

the design cycle, customers can benefit

ously several. In our experience, there are

believe in it and the advice given.

in a number of ways. In addition to the

three main ones: reputation, responsibility

Mark Checkley is the Sales and Marketing Manager for KEB UK Ltd. He has over 25 years’ experience within the industrial automation industry, covering a wide breath of its technology and applicational requirements.

research time they will save, they will

Trust and confidence

receive a technical solution that actually

For me, trust and confidence are key in

solves their problem. By having access

It’s important for suppliers to enhance

the relationship between suppliers and

to the manufacturer, they will benefit from

their reputation by portraying their tech-

customers (both new and existing). It ob-

advice and guidance on the full range of

nical capabilities and customer-focused

viously takes time to build, as it’s the cus-

products that can be produced, as well

solutions in an informative way, without

tomer’s name on the machine and their

as access to their experience and know-

hard-selling their products. But we also

reputation in the marketplace. As a sup-

how in providing a tailored solution that

recognise that the design engineers are

plier, KEB has found that it’s about con-

solves customers’ applications. A tai-

putting their reputations on the line by

sistently dealing with customers in the

lored solution often has other benefits,

approaching a new supplier and asking

right way through a technical, consulta-

including reduced design cycles, faster

for help. Do they trust the supplier to ask

tive approach. Our portfolio is very broad,

time-to-market and gaining an edge over

for help and advice? How is it taken if we

from mechanical products, covering

their competitors. Ideally, this could result

say ‘no’ (with an explanation) when what

brakes and clutches through to electri-

in increased sales and market share for

they require cannot be acheived using

cal/electronic and automation products,

our customer and on a personal level, the

our technologies or solutions but could

including motors, inverters, IPC/PLC

design engineer can gain in reputation,

be with a modification to their design? Ul-

controllers, safety controllers and HMIs

recognition and trust – all this from simply

timately, the engineer and supplier have

as well as software. So, we have to take

asking for help earlier in the design cycle.

to work together so there is trust in the

the technical approach. Our goal is not a

recommendations and advice.

one-off quick sale but to build long-term

and culture – of both parties.

About the author:

www.keb.co.uk

dpaonthenet.net 7

Feature: Graphene

Graphene comes of age, thanks to large-area production process tomised, and are also often made up of multiple layers. This means it is not really a practical basis for mass-producing electronic devices.

The second approach to making graphene is to deposit it onto a metal substrate, such as copper foil, and then transfer it onto an electronics-compatible substrate, such as silicon. Unfortunately, the various wet and dry processes involved in making the transfer can leave copper atoms behind, affecting how the graphene functions in an electronic device.

This lack of a contamination-free, transfer-free, large-area graphene manufacturing process has limited the material’s adoption in mass-market electronics. A

Paragraf scientists performing electrical measurements of packaged devices

new approach is needed.

C

ambridge-based technology company Paragraf has developed a better way to make graphene, unlocking its potential for electronic applications.

That something is the lack, to date, of that can coexist with the manufacturing

Novel technique holds real promise

processes used in the semiconductor

Enter Paragraf who has developed a

industry. Geim and Novoselov famous-

way to make large areas of high-quality

ly made their graphene samples by lift-

graphene. The proprietary technology

It’s been 10 years since Andre Geim and

ing monolayers of carbon atoms from

enables the production of high-quality

Konstantin Novoselov, then scientists

the surface of a block of graphite using

graphene on semiconductor wafers of

at the University of Manchester, were

sticky tape. Although this served their

up to 8” diameter.

awarded the Nobel Prize in Physics for

research needs, it’s not a practical basis

their work on graphene. The extraordi-

for the mass manufacture of large areas

The Paragraf chemical vapour deposi-

nary capabilities of this two-dimensional

of perfect graphene layers.

tion technique doesn’t need the transfer

a way to make large areas of graphene

material, which is made up of a single

processes commonly applied in most

layer of carbon atoms bonded in a hex-

The key to unlocking the potential of

large-area graphene synthesis meth-

agonal array, led to a burst of interest in

graphene, therefore, is to find a way to

ods. Instead, graphene is produced in

graphene.

make it in large volumes with high con-

a uniform layer directly on semiconduc-

sistency and purity. Most commercially

tor-compatible substrates such as sili-

This excitement about graphene led

produced graphene today is created in

con, silicon carbide, sapphire, or gallium

to the creation of a dedicated lab at

one of two ways.

nitride. The resultant graphene monolay-

the university to study the material, the

er is also free of residual metal atom con-

launch of a number of start-ups, as well

The graphene produced by “exfoliat-

taminants present in other techniques

as further academic work on character-

ing” graphite (the technique Geim and

that employ a carrier foil.

ising its properties. Yet, we are still to see

Novoselov used) is of good quality. The

the promise of graphene widely exploit-

drawback with this approach is that it

This approach overcomes many of the

ed, especially in the electronics industry.

produces very small areas of graphene,

obstacles to developing graphene for

Something has been holding it back.

which lack homogeneity, cannot be cus-

electronics applications. The next step is

8 dpaonthenet.net

Feature: Graphene to demonstrate this by identifying suita-

conventional semiconductors. Graphene

Field tests provide validation

ble applications and then bringing com-

sensors can work at cryogenic tempera-

Field tests with partners have proven

mercially viable products to market.

tures of less than -271°C, which is use-

the advantages of the Paragraf Hall-ef-

ful in superconducting environments.

fect sensor. Paragraf is working with the

To do this, Paragraf has developed a

They can also be used at up to 150°C.

Magnetic Measurement Laboratory of

graphene-based magnetic field sensor

Graphene sensors are also resistant to

CERN (the European Organisation for

that uses the Hall-effect, in which a po-

electrostatic discharge, doing away with

Nuclear Research), which has tested

tential difference is formed in a conductor

the need for protection circuitry.

the sensors to map accurately the mag-

that is subject to a perpendicular mag-

netic fields formed within its cryogenic

netic field. Silicon Hall-effect sensors al-

Graphene Hall-effect sensors benefit

electromagnets. The tests show that

ready exist, but their sensitivity, accuracy

from very low power dissipation, limiting

Paragraf’s sensor has a negligible planar

and the range of field strengths they can

the extent to which they will heat cryo-

Hall-effect and therefore only considers

measure are limited.

genic environments.

magnetic field components along the

The graphene Hall-effect sensor offers

These properties mean that the Paragraf

considering using Paragraf’s Hall-effect

better measurement performance than

Hall-effect sensor offers better perfor-

sensors to build a stacked system that

silicon devices, for a number of reasons.

mance in a broad range of applications

will provide a very accurate three-di-

Graphene is a better sensing medium

than current devices, according to Dr Si-

mensional map of the field within its cry-

than silicon because it has a lower “sheet

mon Thomas, the company’s CEO.

ogenic electromagnets.

fewer electrons available to carry charge

“The sensor’s resolution, combined with

Paragraf has also been working with the

through the material than in competing

the lack of a planar Hall-effect, gives it an

UK’s National Physical Laboratory to

materials. This gives graphene a sensitiv-

accuracy that is way beyond what is pos-

investigate the suitability of its sensors

ity to magnetic or electrical fields that is

sible with any other Hall-effect sensors

for use in extremely harsh environments,

30 to 50 times greater than that of silicon

on the market. Considering this comes

and with Queen Mary University of Lon-

alternatives.

in a small package which is robust in ex-

don to study the potential of graphene

desired axis of measurement. CERN is

carrier concentration”, that is, there are

treme conditions, you end up with a very

to replace the indium tin oxide layers of-

Graphene is also a two-dimensional ma-

attractive device that offers comparable

ten used in touchscreens and displays.

terial, so it lacks the directional properties

performance to fluxgate sensors and

of bulk materials. In traditional Hall-effect

NMR probes.”

https://www.paragraf.com/

sensors, the sensing material’s threedimensionality means that stray magnetic fields, unaligned with the desired sensing direction, are also picked up. This “planar Hall-effect” causes measurement errors. Using a monolayer of graphene as a sensor limits the planar Hall-effect, enabling a more accurate measurement of magnetic fields in the desired direction.

Graphene also has practical advantages as a sensor. It is a strong and robust material, making it suitable for use in industrial environments. It also does not suffer from the same thermal effects as

Electrical measurements of a Hall-Effect sensor on a wafer

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Feature: Measuring exercise

A ‘hole’ lot of trouble for loco rebuild fixed A

steam train not seen since the 1960s is being rebuilt by a group of engineering enthusiasts with the help of industrial laser scanning experts at the University of Sheffield AMRC. The Standard Steam Locomotive Company group has set itself the ambitious challenge to recreate, operate and maintain a lost class of British steam train – a British Railways’ Standard Class 6 ‘Clan’. They will use the original 1950s

Image credit: Wikimedia/Ben Brooksbank

design drawings and 21st century en-

Dr Phil Yates is a Chartered Engineer at

thought to be due to the fact that, 80 years

gineering, incorporating modern design

the AMRC, working on regional and SME

ago, there was no direct link between the

and manufacturing techniques and

development within Factory 2050. He is

drawing office and shop floor as the lo-

technologies into the build.

a member of the volunteer group whose

comotive was designed and constructed

headquarters are located at specialist en-

in separate locations some 50 miles apart.

The University of Sheffield Advanced

gineering firm CTL Seal Ltd in Sheffield,

Manufacturing Research Centre (AMRC)

which has generously allocated an area of

“The Standard Class was designed at the

was involved in a major frame alignment

its shop floor to give the volunteer team a

drawing office of the Derby Works while

measuring exercise for the project after

dedicated space in which to assemble the

the locomotives were constructed at

a review of the build inventory showed

lost locomotive.

British Railways’ Crewe Works between

critical gaps in the documentation for

Simple

1951 and 1954. So, the drawing office

some of the key parts relating to the lo-

Dr Yates said the critical gaps in doc-

was nowhere near where they made the

comotive’s frames.

umentation for some of the parts are

locomotive and back then, people made

◾ Digital configuration ◾ Consistent data quality ◾ Intelligent engineering

Feature: Measuring exercise stuff based on what they knew rather than what was in the drawing. You have to bear in mind the drawing does not show how a part is manufactured.

“In some ways, the drawings were a wish of intent. By the time they got to the shop floor – some 50 miles away in Crewe – if there was a mistake, they would correct it and make a note of it in a little black book which, more often than not, never made it back to the drawing office for the error to be corrected in the original drawings.

“That’s what these errors are – they show the disconnect between the drawing office and the shop floor. In those days, people just had their little black books

on the frame and the frame extensions

As both the frames and their extensions

of how to make stuff. It was all the tacit

[were] not identical, so when the parts

had been laser profiled by separate com-

knowledge on the shop floor that actually

were aligned in CAD, the fastener holes

panies from the original drawing, it was

made it work. So, when people left, how

did not align. The maximum error on the

assumed that these errors existed in the

to make these bits just went with them.”

CAD components was 1.6mm.

parts. To ascertain the size of the error,

Further doubts on the functionality of

“The error was because the two original

were stored in separate locations, had to

the parts were raised when the original

drawings didn’t match. The person who

be measured.

1950s British Rail drawings were con-

did the drawing of the frame and the

verted and turned into CAD (comput-

person who did the drawing of the frame

To measure the frame extensions, which

er-aided design) models, as Dr Yates

extensions, one of them got something

were being stored at East Lancashire Rail-

explains.

wrong or different so they didn’t align.”

way works, Dr Yates and Factory 2050’s

“One of the main components that

Poor draughtsmanship and not under-

Hodgson, used a Leica Absolute Track-

caused serious concern [was] the frame

standing manufacturing methods can

er AT402 laser scanner combined with a

extensions: the CAD had been produced

lead to misinterpretation of drawings.

Leica B-Probe. The portable coordinate

after the part had been manufactured,

Understanding manufacturing methods

measuring machine, manufactured by

prior to the manufacture of the main-

is essential in dimensioning drawings

AMRC tier one research partner Hexa-

frame plates. The [ways in which] the fas-

with clarity.

gon Manufacturing Intelligence, enables

the frames and frame extensions, which

theme lead for inspection and AI, Tom

tener hole patterns had been datumed

extreme accuracy over large distances –

The new one: the AX/the KX. Opens up perspectives.

The new generation of compact and small enclosures.

www.rittal.co.uk

Feature: Measuring exercise Airbus A380 to a Eurofighter, but never a steam locomotive. Seeing first-hand the versatility of our Leica ATS600, and the flexibility that reflectorless scanning gave us, made it perfect as the measurement tool of choice.”

The Leica Absolute Tracker ATS600 is a metrology-grade large-volume scanner, combining scanning with tactile measurements seamlessly. It has a scanning range of 60 metres, a reflector range of one to 80 metres, a scanning rate up to 1kHz, and a scanning speed of up to 10sec/m2.

It offers true metrology workflows of integration of large-scale scan data in Spatial Analyser and Inspire Metrology software. ideal for the 13ft-long frame extensions of

shed, negating the need to find a dedicat-

Point cloud data from the ATS600 is also

a steam locomotive.

ed inspection room and giving us accurate

directly available within the application

data in the three planes, identifying the er-

software for immediate feedback, such as

rors which we were able to correct.”

build and inspect.

sions, they found themselves working in

Dr Yates added: “Because we knew this

Measurements from the first scan, which

the shadow of the Flying Scotsman, the

before assembly, we could work out a

consisted of 2,788 points, took just two

world’s first high-speed train – built in Don-

strategy for re-doing the holes and make

minutes and showed the frame had a

caster – which was in the Bury workshop at

slightly oversized fasteners for where the

significant bow in it. Further investigation

the same time.

holes were wrong.”

revealed the bow had been caused by a

Dr Yates said: “The frame extensions were

The frame comprises main frame plates

been fitted to allow for the removal and re-

over at the East Lancashire Railway works

held apart by fabricated steel frame

placement of one of the frame stretchers

and the Flying Scotsman was there at the

stretchers, cast steel frame stretchers and

for machining.

time, so it was nice to admire the world’s

pressed steel horizontal frame stretchers.

most famous passenger locomotive.

All these components were manufactured

“The maximum deflection caused by this

by different suppliers and, to ensure the

packing piece was 0.351 inches (8.9mm),”

“Tom Hodgson and I did the measurement

different components were all manufac-

says Yates. “The scan area was defined

work on the frame extensions. They were

tured to the same dimensional accuracy,

by selecting the regions of interest from

being stored in a freezing cold shed and

the project team needed confirmation of

the frame in CAD and then setting the

that was something we had to consider

the frame assembly dimensions.

spacing required. Key features such as

When Yates and Hodgson came to measure the 106 holes in the frame exten-

packing piece being left in situ, which had

because temperature can affect measurement work.

the horn guides and datum holes and refTo do this, Yates and the Standard Steam

erence nests were measured by probing

volunteer group enlisted further help from

with a Spherically Mounted Retroreflector

“Materials can shrink and grow with chang-

Hexagon

(SMR).”

es in temperature. Accounting for that in-

this time trialling a new type of targetless

volves some tricky maths and we’ve com-

scanning tracker – the Leica Laser Track-

By using the combined scan and prob-

pensated for it [the] best we can by gauging

er ATS600.

ing data, the rotational relationship of the

Manufacturing

Intelligence,

how much the material would move by a ten-degree difference in temperature.”

frames could be determined.

Its scanning ability was ideally suited to the task, says Yates, and Hexagon Manufactur-

Yates said: “This showed that the frames

Geoff Turner, the group’s Engineering Di-

ing Intelligence loaned one to the project,

were rotating around a point between the

rector, said that access to University of

along with the expertise of its application

second and third driving wheel. The point

Sheffield AMRC’s expertise and Hexagon

engineers, Tim Gears and Barry Dimelow.

at the exhaust steam spider was 0.119

Manufacturing

Intelligence’s

advanced

inches (3.02mm) high. The manufacturing

equipment allowed for fast, accurate data

Tim said: “Hexagon has been supporting

engineers were shown graphically the re-

to be collected and for the errors to be

AMRC through our tier one partnership

lationship between the two frames.

remedied quickly.

since 2013. We have been involved in many projects, but not one as interesting

“With the frames loosened and then re-

“The Leica AT402 was ideal for measuring

as scanning a 1950s steam locomotive.

aligned, a second scan was completed

the frame extensions in situ in the engine

“I have measured many things, from an

and that showed that the frames were

12 dpaonthenet.net

Feature: Measuring exercise aligned and they could progress to final

Engineering Director for the group, Geoff

Tim added: “The ATS600 has opened

bolting. The position and relationship

Turner, said the laser scanning survey

doors for us within new sectors where we

between the horn guides and the cylin-

proved to be another huge help to the

would not normally be active. Post-Cov-

der mounting points were also recorded

project: “It saved so much time com-

id-19, this is even more important for us;

so that in the final machining procedure,

pared with using traditional measuring

diversification is the battle cry for many

a probing and datuming section could

equipment and, crucially, it meant that

financial planners but this practice is true

be completed, thus saving time on the

real-time adjustments could be made as

of what solutions we can offer at Hexa-

machine.”

the survey was in progress.”

gon Manufacturing Intelligence.” www.amrc.co.uk

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Feature: Battery challenges

What are the battery challenges in test and instrumentation equipment?

M

easurement is a fundamental requirement of scientific and engineering disciplines. Without precise measurements as a basis, all future work is doomed to inaccuracy or ineffectuality.

The slight difference had a significant impact on the usefulness of the telescope, until it was balanced out three years later.

This led to a series of expensive launches to fit and replace instrumentation over the

As such, it’s vital that test and instrumen-

A few weeks after the $4.7 billion launch

tation equipment can be relied on to pro-

of the Hubble Space Telescope in 1990,

vide consistent, accurate measurements.

an error became apparent to the NASA

Although most instrumentation applica-

Here, Rob Brown, Marketing Executive

team: the images returned by the tele-

tions tend to be closer to home, the Hubble

at Accutronics, explains the role batteries

scope were not as sharp as had been

Space Telescope highlights how even slight

play in achieving reliable instrumentation

intended. This was caused by a problem

deviations in measurement can have signif-

and the challenges design engineers

with the telescope’s optic system be-

icant consequences.

should consider.

cause the outer perimeter of the primary mirror was 2,200 nanometres too flat.

subsequent years.

Design engineers working on test, measurement and instrumentation devices aim

An investigation into how this occurred

to guarantee precision by specifying high-

pointed to a reflective null corrector, which

quality components and ensuring designs

is a device that is used to test and prop-

are fit for purpose and functional. One of

erly shape non-spherical mirrors. This de-

these components is the power source.

vice had been assembled specifically for the telescope’s construction but had been

Power may not always be the first thing

done so incorrectly, with a lens 1.3mm out

design engineers think of when considering

of position.

how to ensure reliability and accuracy in test and instrumentation. Yet, if there were

14 dpaonthenet.net

Feature: Battery challenges to be a sudden loss of power, either due to

(used to measure earthquakes and other

It’s for this reason that, when Accutronics

a mains electrical fault or a battery failure,

seismic activity) can be set for long periods

works with design engineers on test and

then all results would be lost. Likewise, dips

in remote locations where they have limited

instrumentation projects, it is often to de-

in energy delivered to a digital device can

access to power and cannot be recharged

velop bespoke smart batteries that meet an

affect the recorded measurements.

or replaced. In these environments, prima-

application’s unique challenges.

When choosing the optimum power

ry (non-rechargeable) batteries with low

source, it is important to consider the de-

self-discharge rates are essential to provide

With years of experience developing and

vice’s intended application and the environ-

power across a period spanning several

manufacturing smart batteries to meet

About the author:

ment in which it will operate. If the device

weeks or months. The batteries will also

the complex requirements of many test

is manned, portable or in regular use, then

need to be ruggedised to withstand high

environments, Accutronics can develop a

a secondary (rechargeable) battery may be

pressures and shock.

battery that delivers reliable power and pro-

Robert Brown is Marketing Executive at professional battery manufacturer, Accutronics.

best suited because it can communicate

vides leading functionality. The company’s

information to the user, such as battery

Although each of the above applications is

Accupro bespoke service builds on this ex-

health and state of charge, to advise when

varied and requires different forms of pow-

perience to design, develop and manufac-

it needs to be charged or replaced.

er, what they have in common is the need

ture a custom battery or charger that meets

for reliable, high-performance batteries.

your application requirements and product

Alternatively, if the device is used in a loca-

If the batteries were suddenly to fail, then

development timeline.

tion where natural energy is available from

there would be no readings available, which

the sun or wind, it makes sense to harness

would hinder the research or monitoring

If we consider science and engineering as

that power. For example, a weather station

purposes of the devices.

our way of observing the fundamentals of

could use a secondary (rechargeable) bat-

the world around us, accurate measure-

tery that is charged by solar or wind power

One of the core challenges faced by batter-

ment is how we determine what those

and, therefore, can operate for many years

ies in test and measurement devices is that

fundamentals are. High-quality compo-

without the need for human intervention.

there is no single set of typical challenges.

nents, including batteries, are essential to

A portable vehicle emissions testing device

ensure that measurements are, and con-

Whilst some devices have the luxury of

will face very different operating environ-

tinue to be, accurate.

being able to scavenge renewable energy,

ments from a seismometer.

others like ocean-bottom seismometers

www.accutronics.co.uk

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Feature: 5G

Measuring the impact 5

G is coming. For many, that short statement is both a beacon of hope and a source of trepidation. This is especially true for test equipment manufacturers. While 5G offers the opportunity for healthy growth, there are several factors that will make reaping benefits from this generation of wireless broadband technology more challenging than it was for its predecessors.

advanced base stations and customer devices. The most substantial change to the 5G physical layer is the option for millimeter wave transmission coupled with adaptive beamforming requiring many antenna elements. While millimeter wave transmission is a familiar technology for point-to-point, line-of-sight wireless backhaul, using those frequencies in a

Let’s start with the current situation for

with delays in the deployment of LTE-ad-

cellular topology where each cell serves

electronic test and measurement (ETM)

vanced carrier aggregation in major mar-

hundreds or thousands of mobile users,

manufacturers. What generates growth

kets. The result is a slowing market for

and where many antennas will be inte-

in the wireless ETM business is the

LTE R&D and production test equipment,

grated into advanced device packaging,

combination of new handset models,

as the industry awaits the technology

is challenging and uncharted territory.

an increasing volume of annual handset

shift to 5G.

In order to research, develop, and test

shipments, and wireless technology ad-

the new technologies behind 5G, ETM equipment will have to deliver more ad-

equipment. We have seen a reduction

5G is coming – with challenges

in the growth rate of handset shipments

As wireless broadband technology has

ations. The ETM challenge is made more

and, at the same time, mergers and ac-

evolved from generation to generation –

difficult by the fact that the 5G standards

quisitions in the wireless infrastructure

and especially from feature to feature –

have not yet been finalised. Like previous

industry have reduced the number of

ETM manufacturers have often been able

generations of wireless technology, there

customers in that segment. Finally, ETM

to rely on software upgrades to adapt to

is the very strong desire by operators to

manufacturers have also been coping

changes. The move to 5G, however, is

be first with deployed networks, intensi-

seen as a giant stride forward that will re-

fying the need for ETM equipment early

quire new and far more complex solutions.

in the technology lifecycle.

Behind the faster speed, reduced laten-

Normally, this list of challenges would ex-

cy, increased capacity, and improved

cite and energise an R&D group. However,

reliability of 5G are new and less familiar

the slackening growth in LTE ETM equip-

technologies, such as millimeter wave,

ment has left some manufacturers with far

massive MIMO, and adaptive beam-

fewer resources to devote to 5G innova-

forming – all of which will demand more

tion and development.

vancements that drive new infrastructure

16 dpaonthenet.net

vanced capabilities than previous gener-

Feature: 5G better foothold in the 5G market by forming

foreseeable future, working with the right

partnerships and alliances with suppliers.

supplier is giving manufacturers access to high performance solutions across the en-

Moving supplier relationships from highly

tire signal chain, from millimeter wave to

transactional to being more collaborative

bits. In that way, even as the 5G standard

can bring greater effectiveness to ETM man-

changes, there will be no need to scrap

ufacturers. Knowledge sharing and close

the original hardware design.

collaboration with private companies, including operators and suppliers, is essential

Integration

to timely delivery of new test products with

ETM manufacturers will face increased

features that are best aligned with early mar-

demands for greater capabilities and low-

ket needs. Nondisclosure agreements and

er costs. As a result, test products for 5G

other proprietary arrangements are giving

will be far more complex than those of

manufacturers early access to new ideas

generations before. Looking beyond indi-

and emerging technologies that are further

vidual components to chipsets and sys-

enabling the technological breakthroughs

tem solutions is helping manufacturers

required to deliver 5G test capabilities.

squeeze more performance out of limited space and lower cost targets – something

Component suppliers are providing in-

especially demanded of modular instru-

formation to optimise the performance of

mentation. At the same time, this high lev-

existing products beyond published data

el of integration, as well as the increased

or are going a step further, such as creat-

signal chain count required for MIMO and

ing part derivatives to meet specific needs.

beamforming, is putting even greater de-

The right partnerships can bolster an ETM

mands on power. By working with sup-

organisation’s strengths with early access to

pliers, especially those with the broadest

A peek behind the curtain

advanced technology. Further, by transfer-

portfolio of products, it’s becoming pos-

While 5G introduces significant hurdles,

ring design work to experienced suppliers,

sible to change engineered components

they’re not insurmountable. New levels of

an ETM manufacturer can free up scarce

into complete signal chain solutions to

cooperation can be seen throughout the

engineering resources – allowing them to

meet the demanding performance, pow-

wireless industry. Instrumentation, wire-

focus on their strength of delivering val-

er, space, and time-to-market require-

less infrastructure, semiconductor, and

ue-added product features.

ments of tomorrow’s instrumentation.

gether with standards bodies, research

Combined, the partnering activities outlined

Ready or not

organisations, and government regulators

above are helping ETM manufacturers get

5G is an evolutionary leap rather than a

worldwide to ensure that 5G is a unified

the solutions they need, accelerating their

simple generational step up. While ques-

standard addressing the many challenging

own schedules, and helping them and their

tions remain about what 5G will be when

performance goals, including unprecedent-

customers succeed.

it arrives, there is no doubt that it’s on the

t of 5G software organisations are working to-

ed speed, connection density, and ubiquity.

way. Whether 5G becomes an opportunity for ETM manufacturers will depend heav-

try organisations and collaboration with

The challenge to develop ahead of standards

important research organisations and any

With the desire to reduce time to market

partnerships and alliances with key suppli-

of the numerous 5G research alliances is a

and meet the demands of 5G, ETM man-

ers will significantly help ETM manufactur-

first step towards a greater understanding

ufacturers need to develop equipment pri-

ers thrive in the coming 5G market.

of the 5G technology trajectory. In addition,

or to standards being finalised. Because

ETM manufacturers appear to be gaining a

5G standards will remain in flux for the

Association with important wireless indus-

ily on whether they are ready. Embracing

www.analog.com

Randy Oltman is Systems Applications Manager for RF and high-speed instrumentation at Analog Devices, based in ADI’s Wilmington, Massachusetts office.

Feature: Test cells

Shutterstock image

Improving production test throughput using a robotic test cell I

mplementing test into a production environment can prove to be a demanding task. Unlike testing during prototype development or for regulatory compliance, in production test, you are at the mercy of the manufacturing pulse through the factory.

The smart meter test function consisted

From an overall management perspec-

of a manually operated industrial PC set-

tive, the critical metric that was agreed

up with four separate test stations that

contractually with the smart meter cus-

performed a visual inspection of the LCD,

tomer was the first pass yield (FPY) rate.

conducted a high-potential (HIPOT) test,

With the need to increase production

checked the power line communication,

volumes, Sagemcom’s technology busi-

and completed a functional test.

ness unit – responsible for the turnkey test bench solutions – considered how to

Certain aspects of these test functions

meet the increased product test demand.

become automated over time, such as

What was clear was that the current setup

Smart meter manufacturer Sagemcom

using a Windows-based vision-image

was not reliable enough to be considered

knows this situation very well. Faced with

recognition software. This involved in-

as the basis for a duplicate production

increasing time-to-market pressures and

terfacing a camera, as well as the use of

test cell.

the need to ramp production volumes,

automation devices to operate smart me-

the existing production test facilities in its

ter controls, etc. Likewise, the HIPOT test

The Sagemcom technology team re-

factory in Tunisia needed a revamp.

involved injecting 3.2kV to the meter to

viewed the challenges ahead and doc-

check its immunity, whilst another test rig

umented the goals as the following: the

checked the power line communication

FPY rate needed to be enhanced, and

signals for correct modulation and signal

the production test facility had to be more

integrity.

robust in operation. Furthermore, the development time required to create a new

cRIO cell view

18 dpaonthenet.net

The industrial PC and automated test set-

test setup needed to be minimal, and the

up was not exceptionally reliable during

time for each test operation had to be

operation and suffered crashes which im-

much shorter to increase production test

pacted production test throughput. Also,

throughput. It was also apparent that the

there was a concern that the whole pro-

current process involved too much man-

duction test environment was susceptible

ual handling, constraining the throughout

to internet viruses which could severely

capability even further.

disrupt the test facilities.

Feature: Test cells After conducting some research and ro-

dustrial protocols such as RS-422, Mod-

of four seconds. However, with the Com-

botic simulations, the team decided to

bus TCP/IP, and DeviceNet.

pactRIO NI 9205 acquisition module

trial the use of a robotic test cell that used

and its measurement accuracy of 6mV

a central robot to handle the passing of

Also, the availability of a Vision Devel-

and a 100kHz sampling rate, tests were

products between each test. Smaller ro-

opment Module within the CompactRIO

performed accurately, rapidly, and relia-

bots would perform the four functional

platform suited all the image processing

bly. Using the CompactRIO, the narrow

tests in separate nodes and would be

tasks required with plenty of performance

trigger pulses could be captured the first

synchronised to maintain an efficient and

resources via a real-time processor and

time.

timely production test throughput. While

an FPGA. In particular, the FPGA pro-

the concept of a robotic production test

vided the possibility of conducting ac-

Overall, the move to an automated ro-

cell presented a viable solution, provision-

quisition tasks and tests in parallel, re-

bot-based production test cell and the

ing the automated control for the whole

ducing the test time considerably. With

use of NI CompactRIO reduced the test

test cell and each test node to achieve

its powerful dual-core Intel Atom E3825

time by 21 seconds which led to a 17 per-

the desired FPY and throughout required

processor and the Xilinx Kintex-7 FPGA,

cent productivity growth. This approach

significant consideration. The essential

the CompactRIO platform is more than

also required less control hardware, rep-

requirements of the control platform in-

capable for the required tasks. The Lab-

resenting a 50 percent saving on control-

cluded a vision-processing capability,

VIEW programming function significantly

lers. The automated vision processing

parallel processing of nodes, support for

eased the process of test configuration,

tasks accelerated by almost 38 percent

popular industrial networking protocols,

interoperability and scheduling.

compared to the previous arrangement,

and the ability to gather and distribute process information quickly and safely.

further improving throughput.

One of the tests the Windows-based system suffered from was accuracy and

Sagemcom met the goals set by the

Out of all the available control solutions

robustness of the PLC modulation. Also,

business with this new architectural ap-

considered, the NI CompactRIO cRIO-

the use of a PC-based architecture had

proach to functional test cells. From a test

9030 System came out as the optimal

proved to present a long-term technical

streamlining perspective, the parallel pro-

choice for a variety of reasons. Firstly, it

challenge for the measurement task, cre-

cessing capabilities of an FPGA-based

had the computation power required to-

ating high levels of false measurements.

system, together with the ability to offload

gether with support for all the industrial

With an average 700mV amplitude burst,

image processor tasks, proved to be in-

protocols needed. A number of the instru-

a 25-mV tolerance and a 10 µs trigger,

valuable.

ments used for measurement, in addition

capturing the measurement usually re-

to the control functions, used legacy in-

quired multiple attempts, taking upwards

www.ni.com

Shutterstock image

dpaonthenet.net 19

Feature: Complex springs

Modelling a complex spring in Spring Calculator Professional T

his article from the Institute of Spring Technology serves as a good example of how Spring Calculator Professional can be used to model more “unusual” springs.

The spring in question has unusual end fittings, dead coils and open coils within the main body.

About the author: Richard joined IST in 2005 as a software developer with a mechanical engineering background, helping to write v7 software.

Over time, he got involved in spring design services and other consultancy work, as well as delivering training. As Technical Director, Richard’s main focus is still on the development and support of IST’s software, but he also works closely with Dr. Conor McCaughey (Research Metallurgist) to plan out the company’s R&D strategy. Richard is also heavily involved in standardisation work, representing BSI on EN and ISO committees that are currently active in the worlds of spring design, tolerancing and measurement.

• Three coils each end used to screw in the eyes.

• Body length of 210mm.

loads given to design the spring. We use the “Set Initial Tension, 2 Parameters + 2 Loads/Lengths” input method, because we have everything we need to fully de-

Firstly, we need to understand how to

fine the spring.

deal with the ends. Because they are not a standard hook shape, we will

The drawings below confirm the shape

simply model the body of the spring

of the spring matches the drawing giv-

itself by setting the end loop to “No

en. The eyes are not present, but the free

loop”. The free length will be entered

length shows where their centres would

as specified; unusually, it is measured

be.

relative to the centres of the mounting The requirements given by the cus-

eyes, but this doesn’t matter as long

Animating the extension of the spring

tomer are as follows:

as we are consistent.

shows how the dead coils remain inac-

• Wire details: 5mm 17/7 precipita-

tive as the spring is deflected.

tion hardened stainless steel to EN

After setting the end loop, we define

10270-3 1.4568.

the dead coils as a total of six. This

For more information about Spring

• Outside diameter: 40mm.

same input window allows us to define

Calculator Professional, head over to

• Free length: 250mm (reference).

the body length.

www.ist.org.uk/software or email marketing@ist.org.uk.

• Working load 1: 220 N at 280mm.

• Working load 2: 900 N at 370mm.

The spring drawing

20 dpaonthenet.net

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Feature: Wave springs

The benefits of wav for medical applicatio T

here are more than 500,000 medical technologies on the market, from thermometers to mechanical ventilators. Products typically have a short lifecycle of around 18 to 24 months before an improved version becomes available; design engineers in this sector are constantly innovating to improve patient care. Here, Simon Ward, Technical Manager at fastening and fixing supplier TFC, explains how designers can reduce the size of their devices with wave springs.

ten challenged with device size, particularly when integrating all the mechanical components into a practical size. For example, traditional coil springs may be too large for medical technologies that are designed to be small and lightweight – causing the design engineer to consider alternatives.

What are springs used for?

Springs are used in numerous medical One example of rapid innovation is wear-

management of diseases. As the use of

products. They are commonly used as

able technologies, which are now availa-

digital technology in medical applications

a return spring on a function button, and

ble to track everything from patient blood

rises, engineers are designing new, inno-

they can also be used to maintain electri-

pressure to walking gait, electrolyte levels

vative products to aid patient welfare.

cal contact or to compensate for assem-

and heart rhythms. Across the board, we

bly tolerances. Traditionally coil springs

are seeing innovation in tools and tech-

When innovation makes technology

have been used in these applications, but

nology for the prevention, diagnosis and

more complex, design engineers are of-

the tides are beginning to turn.

22 dpaonthenet.net

Feature: Wave springs is aligned with the axis. A wave spring specialist like TFC can help point you in the right direction when designing the product into your application.

Custom options Smalley wave springs are manufactured in several different forms, with a range of spring characteristics. If there is not a suitable off-the-shelf option available, designers can opt for a custom wave spring – changing the number of turns or waves, material, size to meet specific product needs.

The most popular materials for wave springs in medical applications are 302

About the author: Simon Ward is the Technical Manager at TFC and has been part of the company for over 22 years. Simon is a leading authority on Smalley wave springs and retaining rings, having designed and developed products for major OEMs across all industry sectors.

and 316 stainless steel, as they can withstand the higher temperatures applied during cleaning and sterilisation processes, without any compromise to spring properties. They are also ISO 13485:2016 certified.

Wave springs in practice One example of a successful application was the design of Crest-to-Crest springs for insulin pens, which help to control and

ve springs ons

measure the dosage injected into a patient. TFC has also supplied springs for surgical and dental tools that use highspeed precision bearings It may take several design iterations before the wave spring is the perfect fit for the application. TFC recommends that design engineers work closely with a wave spring specialist for support and advice, to achieve the best possible solution.

An alternative option is a Crest-to-Crest

Choosing a wave spring

If you are looking for a wave spring for

wave spring which, like coil springs,

Crest-to-Crest wave springs are one

your medical application, TFC engineers

apply force axially when compressed.

option for medical applications that re-

can work with you to design a custom

Wave springs are a great space-sav-

quire lower spring rates. Another precise

solution. Visit https://www.tfc.eu.com/

ing technology, as they require less

and reliable option is a single-turn wave

and fill in an enquiry form or call 01435

than half of the space needed for a

spring, which is useful if the application

866011 to speak to a member of the de-

coil spring – providing the same spring

involves short deflections and low-medi-

sign team.

force at a smaller operating height.

um forces. If a straight load-bearing sys-

This, in turn, reduces the spring cavity,

tem is required, linear springs may be a

which is helpful when working with tight

good option.

space constraints.

However, engineers cannot simply swap Wave springs can therefore be a great

between a coil and wave spring. The de-

asset for a designer of handheld instru-

signer should be aware of the fact that

ments and tools, or wearable devices,

when a load is applied to a wave spring,

who is looking to design a lightweight,

the waves flatten to provide upward

compact and balanced product.

force, whereas a coil spring twists as it compresses, meaning not all of the force

dpaonthenet.net 23

Feature: Complex wire forms

Springing into action saves the day for tier one automotive manufacturer W

illiam Hughes has come to the aid of a tier one automotive seat manufacturer – a rescue mission that was only made possible by the company’s broad set of skills and advanced capabilities in the world of complex wire forms.

company possesses would enable the complex and large design, testing, manufacturing and delivery campaign to be achieved in a very short time.

“Our customer is delighted!” George Cairns elaborates. “We were able

The order, which was for seat frames

al of the frames also required welding.

to deliver 80 percent of the order a

and trim wires, comprised a number

The accuracy demands were such that

week ahead of schedule, which gave

of different complex parts, all of which

engineers used 3D scanners and Verni-

it enough capacity to meet the OEM’s

would be used in five different vehicle

er calipers to ensure the parts precisely

just-in-time delivery timescales. Al-

types, including SUVs and saloons. In

matched the customer specifications.

though scenarios like this are not good

addition to bending and forming, sever-

24 dpaonthenet.net

for the heart rate, it is reassuring to our “Although we had won the order a few

customers that we can merge our ca-

months previously, and had turned [a]

pacity with the skills and capabilities

round the prototype parts in just four

to make sure that rush orders – even

weeks, the customer hit a scheduling

ones as complex as this – have the

snag, which ended up with us having a

same level of well-deserved quality

very short time period in which to pro-

that more timely orders enjoy. We threw

duce the first thousand pieces,” explains

everything at this order to ensure the

George Cairns at William Hughes. “These

customer’s goodwill, and we would do

had to be delivered on time to ensure the

it again…just give us a chance to catch

product milestones were achieved.”

our breath first!”

William Hughes was chosen for the

For further details, contact William

task because the tier one automotive-

Hughes on sales@wmhughes.co.uk

seat manufacturer recognised that the

or visit its website:

capabilities, skillset and knowledge the

www.wmhughes.co.uk.

FAST - RELIABLE - SERVICE Flame Hardeners’ customers can rely on a level of service that is among the best in our industry As standard we provide* – • 3 day turnround on 80% of all jobs • Less than 2 days average time for bespoke tooling development • 4hrs maximum for written quotations on 80% of enquiries • Personal service – no automated call systems *Non-standard enquiries, large components or specialist requirements may take a little longer

Find out more at

WWW.FLAMEHARDENERS.CO.UK mail@flamehardeners.co.uk

FLAME HARDENERS LIMITED Incorporating Induction Hardeners Limited Shorter Works, Bailey Lane, Sheffield S1 3BL

The Data Driven Solution to Spring Design & Validation SPRING CALCULATOR PROFESSIONAL

Try free at ist.org.uk/worksmarter

tel: 0114 276 8167

fax: 0114 273 8657

Feature: Springs

Springing into action: Lee Spring employees join the COVID19 fight A

s COVID-19 impacts countries around the world, frontline workers continue to be crucial during this fight.

Lee Spring is playing an active role globally in the manufacturing of critical components and supporting quick lead times that are essential to the pandemic response.

Lee Spring employees have sprung into

Steve Kempf, Lee Spring CEO, stated,

beyond to maintain a safe working en-

action to prioritise the critical products

“Our top priority has always been the

vironment and ensure that critical com-

that are needed for medical devices.

safety and well-being of our employees,

ponents have been delivered on time.

Many Lee Spring customers supply

customers and communities. We are fo-

It was clear early on that the need for

essential equipment for various fields,

cused on this now more than ever. While

medical devices, especially ventilators,

including life-saving devices, testing,

we have always known that our custom-

would be a high priority. Medical suppli-

diagnostic equipment, medical research

ers – and in turn, our springs – play an

ers from around the globe were in need

and development, and the general sup-

important role in people’s daily lives, the

of Lee Spings’ parts to fill their supply

ply for hospital equipment.

often critical nature of this role has been

chains quickly. Furthermore, testing

starkly revealed through the current

equipment has also become a major pri-

crisis, so we are very proud to support

ority around the globe and many require

them in every way possible right now.”

specialised and custom springs. These complex devices, which include various

Lee Spring has been supporting med-

spring types, are heavily engineered

ical customers for decades, and many

components.

of those customers are at the forefront of this pandemic fight. Lee Spring often

Lee Spring can help to design a spring

works on custom designs from incep-

and suggest materials and finishes, as

tion through research and development,

well as providing working prototypes

all the way to final long-run produc-

quickly. When long-range production

tion supply. Lee Spring engineers have

is required, Lee Spring can work with

worked closely with many of these crit-

customers anywhere in the world. This

ical medical products for years and, in

global flexibility allows Lee Spring to

many cases, have been involved in the

work with a design team in one part of

earliest designs and R&D stages.

the world and manufacture in another part of the world. This alignment is ideal

As critical needs have changed rapid-

for many global companies.

ly in the early stages of this pandemic,

26 dpaonthenet.net

Lee Spring has been able to shift man-

Further information on Lee Spring

ufacturing to meet those demands. Lee

products can be found on its website –

Spring employees have gone above and

www.leespring.co.uk.

Feature: Ex-rated motors

Taking responsi repairs to Ex-rated O

perating equipment in potentially explosive atmospheres comes with a certain amount of responsibility, not least to use correctly designed components for the environment. When maintenance and repairs are required, it is important that operators understand what is expected of them to ensure continued safety and reliability.

Potentially explosive atmospheres are

Equipment that is designed for Ex zoned

encountered in many industrial sectors.

areas uses a variety of protection con-

Specific areas that may be affected are

cepts to ensure safe operation. Different

zoned according to the potential risks,

concepts can be used in similarly zoned

and any electrical equipment in these ar-

areas, and it is important that site main-

eas must be designed and manufactured

tenance engineers understand them so

to specific standards.

that they do not compromise the equipment.

International standards Any business that has identified zoned

For example, periodic inspections and

areas within its processes is expected

maintenance checks that involve the re-

to adhere to several international and

moval of a terminal box lid from an Ex d

Karl Metcalfe, Technical Support for The

regional standards, including BS EN IEC

machine may discover corrosion. At this

Association of Electrical and Mechanical

60079-10:2019. This states the respon-

point, it may be necessary to check the

Trades (AEMT), looks at the knowledge

sibilities of operators, managers and re-

flamepath gaps and establish if they are

and responsibilities that are expected when

pairers to ensure that all equipment is fit

still sufficient for the zoned area.

managing electric motors in zoned areas.

for continued service.

28 dpaonthenet.net

Feature: Ex-rated motors to recovering the process will involve the insurance company. The investigation into the cause will start with the information dossier for all the equipment in the affected area, especially any component that is judged to be the root cause.

If any repairs have been completed by service centres that did not comply with the international standard, this could be seen as a failure to meet the terms of the insurance policy. This could have major implications for funding any repairs as well as increasing the cost of future insurance policies.

Improving knowledge Both managers and maintenance staff involved with Ex-rated equipment are encouraged to broaden their knowledge and attend training courses. This will enable the business to implement the necessary processes to comply with the international standard.

The AEMT Ex register (https://www.

ibility for d motors Repair essentials

A properly qualified repair centre will ask

When the time comes for a repair or

for this information and will also provide

overhaul, Ex equipment needs to be sent

all the evidence required to determine

to a repairer. The international standard

if it is qualified to deliver the repair. The

emphasises that it is the responsibility

owner of the equipment is responsible

of the operator to ensure that any main-

for establishing this fact and retaining

tenance work is delivered by those with

the evidence.

theaemt.com/atex-iecex/aemt-ex-register) lists all members that hold various certifications, including ISO 9001, and AEMT

Ex

Assessment

About the author: Karl has worked in the rewind industry since 1987. Starting his apprenticeship at Eclipse Engineering, Karl trained as a time served electrical rewinder and fitter, where he worked extensively with low voltage machines, pumps and gearboxes.

In 2011, he left Eclipse to move into sales, then moved on to Featherston as Workshop Manager, where he gained experience in handling medium to high voltage equipment.

He later became Works Manager of Kirkby Lindsey in 2015, where he was also the responsible person for signing off all Ex hazardous area equipment.

Certificates.

IECEx service centres are independently audited by a notifying body and maintain their three-year refresher training to achieve certified accreditation.

For more information or advice, contact the AEMT Technical Support group on 01904 674 897 or email technical@aemt.co.uk.

sufficient facilities and competencies.

Minimising risks Moreover, each piece of equipment

Following the guidelines goes a long

should have its own dossier containing

way to minimising the risks. Failing to

all the required paperwork, including de-

adhere to the international standard

tails of any previous repairs and inspec-

could severely damage the business.

tions. A copy of this should accompany the equipment to any approved service

In the event of an incident involving

centre, ensuring that all information is

equipment in a zoned area, assuming

on-hand for the repair process.

no injuries were sustained, the first step

dpaonthenet.net 29

Feature: Sizing motors

When a servo motor that’s big enough isn’t big enough I

t might seem a strange statement, but yes, you read that right – there are certain operating conditions where servo motors that should be big enough for an application are actually too small!

ly use an induction motor and inverter.

power as a way to specify a motor is

More often than not, the pumps would

appropriate.

be operating at a fixed speed and the motor-inverter combination would be

Servo motors can be operated over a

selected on that basis.

wide speed range, typically in the region of 1:5000, and the torque/speed char-

You would then select the motor, the

acteristics are very different. Let’s take

most common being two and four pole,

a servo motor with a stall, or holding,

That is, too small in terms of their pow-

the resulting speed of which, let’s say

torque of 7.5Nm and a rated torque of

er rating, which for most applications is

at 50Hz, would be approximately 2,850

4.8Nm at 6000rpm as an example.

a perfectly acceptable way of selecting

and 1,425rpm respectively.

the right size motor. But not all.

You could say that, based on those figThe available torque at the rated speed

ures, the power rating of the motor is:

For example, small, precision pumping

is what provides the power rating of the

nominal power (Pn) = (nominal torque

applications, such as dosing ingredi-

motor. So, as the motors are typical-

Mn x Nn nominal speed)/9550 = (4.8Nm

ents in the food industry, would typical-

ly operated at their rated speed, using

x 6000rpm)/9550 = 3.02kW.

30 dpaonthenet.net

Feature: Sizing motors However, you may be running the motor at 3,000 or 4,000rpm. What effect does this have on the power the motor is producing? At 4,000rpm the motor will deliver approximately 5.7Nm and 6.15Nm at 3,000rpm. This would equate to approximately 2.39kW and 1.93kW respectively.

SMART AND DIGITAL AUTOMATION

There are a number of ways you can harness the full power of the motor by using a gearing mechanism such as belts and pulleys or gearboxes.

But these mechanical devices may have restrictions on the speed.

In the case of our pumping example, which shall we say is destined for a production cell operating under ATEX conditions, the gearboxes are limited to an input speed of 2,300rpm. Even though the motor specification has rated power at 1.382kW, the power available at 2,000rpm is considerably less at 0.84kW. We can operate the pumps well within the gearbox speed restriction, but this means that we are not utilising the full speed range of the motor, hence we need a higher kW rating than is actually required were it not for the ATEX operating restrictions.

https://www.motec.co.uk/

SPECIALISING IN SOLUTIONS

Packaging Machinery

Theatre Systems

Metall Processing

Textile Machinery

Process Engineering

Lift & Escalators

Intralogistics

Plastics Machinery

Wood Working

Wind Power

e-mobility

Automotive

Automation with Drive

www.keb.co.uk

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

dpaonthenet.net 31

Feature: Motors

WEG products used to create innovative jaw crusher unblock system A

ccording to the Health and Safety Executive’s guidance for the safe operation and use of mobile jaw crushers, equipment operators may be subject to multiple risks, including exposure to dust, noise, whole-body vibration and being struck by objects ejected from the crusher.

Here’s how WEG’s premier distributor, Technidrive, developed an energy-efficient automatic jaw crusher unblock system using WEG products.

Commonly used in the quarrying, mining, recycling of demolition waste and chemical industries, jaw crushers are a reasonably difficult application for systems integrators, due to the large inertia of the flywheel, cyclic loading and differences in materials with which customers feed them.

This didn’t prove to be a problem for Technidrive, who was initially approached by a customer looking to implement a new motor in their jaw crusher machine.

Using a combination of WEG products, Technidrive was not only able to improve the efficiency and reliability of the motor, but the efficiency and safety of the entire

opening. Ensuring that the size of raw

Technidrive wanted to develop a system

jaw crusher system. WEG was asked to

material is appropriately matched to the

that was highly energy efficient and, cru-

supply the motor, control and alternator

jaw opening can alleviate blockage inci-

cially, removed operators from the dan-

for the project due to the quality, versatility

dents. This can be achieved by remov-

gerous job of manually removing blocked

and energy efficiency of its product line.

ing oversize products prior to processing

material from jaw crusher machines.

and careful control of the crusher feedCrushing is an important process in turn-

er; however, blockages do still occur. To

Technidrive started this project by carry-

ing rock into a useable product. Rock

unblock a crusher, a plant must be shut

ing out power torque and speed calcula-

enters the jaw crusher from the top of the

down and the system must first be isolat-

tions to decide upon a suitable selection

machine and gets compressed between

ed. However, despite these precautions,

of WEG electric motor and gear units.

two surfaces – the fixed and moveable

a crusher can still be a serious risk to per-

The electric motor was selected based

jaw. The rock will continue to be crushed

sonnel due to the amount of kinetic en-

on its power and speed, and further me-

until it is small enough to fall through the

ergy that is released during unblocking.

chanical calculations were carried out to

dpaonthenet.net 33

Feature: Motors ensure the motor shaft could cater for

project was the level of control that was

Another very important part of the sys-

the high radial loads the application can

achieved through an innovative piece of

tem was the alternator, which is vital for

impose. The WEG W22 motor was even-

software, which Technidrive developed.

achieving an efficient and reliable sys-

tually selected for its cast iron frame, in-

tem. According to the International Ener-

verter rated windings and insulated non-

On a normal start from empty, the VSD

gy Agency (IEA), 16 percent of motor fail-

drive end flange.

ramps up the crusher on a slow ramp

ures are caused by external conditions,

time, restricting the absorbed current

such as contamination, so ensuring

The next vital part of the system is the

due to the high inertia of the application.

application suitability was essential. The

control of the motor, which can incorpo-

This not only keeps the power supply re-

alternator selected was from the WEG

rate a soft start or variable speed drive

quirements low for a more efficient sys-

G-line range with some special features,

(VSD) to control the motor starting speed

tem, but also reduces the stress on the

such as a dust filtering system to allow it

or torque, for example. The VSD model

mechanical system. Over time, this can

to operate in a dusty quarry atmosphere,

selected was a CFW11 WEG inverter

lead to significant maintenance cost sav-

without the risk of foreign particles en-

with built-in soft programmable logic

ings and extend the life of the machine.

tering the system. The alternator also in-

control (PLC) functions. There were sev-

It’s estimated that a 10°C reduction in

cluded a digital input AVR to allow remote

eral advantages to this selection, includ-

operating temperature typically doubles

voltage adjustment, a standard I-PMG

ing the standard DC bus chokes which

the motor’s lifetime.

auxiliary winding system feature to allow

reduce harmonics. The inverter was se-

a dynamic response to load change, and

lected with an output sinusoidal filter to

The innovative software allowed for a

a short envelope compared to traditional

create a nice sine wave, reduce output

special start-up function when starting

external PMG alternators.

current and reduce electrical noise.

the jaw crusher from full. If the crusher

Electrical disturbances, however, aren’t

is stopped full, the VSD can be remotely

“The complete drive system was expertly

the only consideration, crusher blockag-

activated in an unblock mode, with a very

selected to work in harmony to address

es can be a real problem for operators,

fast ramp time in forward or reverse, de-

many issues manufactures in the indus-

resulting in periods of prolonged down-

pending on the position of the crusher. It

try come across,” explained David Strain,

time. One of the main advantages of this

will continue automatically to control the

Technical Director at Technidrive. “The

direction, current, ramp times, DC bus

added unblocking feature transforms the

voltage, torque, position and speed, un-

starting of the application, an often en-

til the product in the chamber has been

ergy-intensive process, and provides a

cleared and the crusher has run empty

unique benefit for system safety. With the

for a set period.

system supplied, we are able to provide a three-year warranty for the motor and inverter and ensure the three main parts to the drive system all work together for optimum performance and reliability. Since our first jaw crusher project, we have had much interest from other businesses in the quarrying industry. We treat each project on an individual basis, to offer bespoke turnkey systems.”

“WEG offers specialist products that are developed specifically for the rock crushing industry,” explained Russell Maccabe UK Sales Manager at WEG. “It’s vital that manufacturers and suppliers both have extensive product, application and systems integration knowledge, and that’s why this project with Technidrive proved to be so successful.”

If you’re looking to increase the efficiency of your processes, contact WEG at info-uk@weg.net.

For further information about Technidrive’s range of products and services visit www.technidrive.co.uk.

34 dpaonthenet.net

Buyers Guide: Geared Motors – 12mm / 90mm dia

Displays

Batteries & Chargers

Displays Displays Touchscreens Displays Touchscreens Industrial Pc’s Touchscreens Industrial Pc’s Display systems

Display systems Industrial Pc’s Display Review Display Systems Ltd systems Offer Truly Economical

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

www.review-displays.co.uk 01959 563345 Springs

MANUFACTURERS OF SPRINGS PRESSINGS • WIRE FORMS T: 0118 978 6573 F: 0118 989 4434 E: sales@simpsonsprings.co.uk www.simpsonsprings.co.uk

To advertise here contact

Andrew Quenault on 01732 359990 or email andrew.quenault@ imlgroup.co.uk

Solutions to drive

problems with Ltd aapplication comprehensive range of motors, geared motors and accessories.

Hybrid solutions also available at moderate cost.

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

Robotics, laboratory equipment, surveillance cameras, slot machines, shop displays,vehicle equipment, telecoms equipment,lighting and ventilation control.

Locking mechanisims, machinery activators, shop displays etc etc.

MFA/Como Drills Felderland Lane, Worth, Deal, Kent CT14 0BT Tel: 01304 612132

Fax: 01304 614696

Business Advice Consultants

http://www.mcs-corporate. com

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

Web: www.mfacomodrills.com

Fasteners & Fixings

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

To advertise here contact

Andrew Quenault

Downloadable catalogues and applications advice on the website.

datafocus Smiths Interconnect pushes performance in wafer testing solutions

on

New Volta 180 supports Wafer Level Packages and Known Good Dies test businesses

Smiths Interconnect, a leading provider of innovative solutions for critical semiconductor test applications, announces the expansion of its Volta product line to incorporate Volta180 probe heads, to support the Wafer Level Packages and Known Good Dies test businesses.

The recent acceleration of the digital age is creating a huge demand for new consumer/commercial electronics to incorporate expanding functional needs into reduced space, in a cost-effective manner. This has resulted in a huge growth in Wafer Level Packages and Known Good Dies.

“The technical challenges and increases in packaging costs are fueling the growth of Wafer Level Packages and Known Good Dies,” said Bruce Valentine, Vice President Business Development at Smiths Interconnect. “Smiths Interconnect’s Volta 180 Series addresses the market’s needs for reduced test time and increased throughput with a cost-effective, high-performance option, ideal to achieve high bandwidth, high reliability, low contact resistance and long life”.

For more information visit our Volta Series Probe Head page.

For further details contact: Please visit our website www.smithsinterconnect.com

01732 359990

or email andrew.quenault@imlgroup.co.uk

Completely compatible!

Power Supply Systems

Reliable energy supply for machines and systems

by Murrelektronik

Transformers, effective filters, powerful switch-mode power supplies, reliable buffer modules and innovative current monitoring systems create a completely compatible power supply system.

www.murrelektronik.co.uk