February 2021 The Engineer’s guide to new products & design ideas
Chains with brains 18: Smart enclosures
32: Data networks
Developing standard enclosures for smart technology, IIoT & automation
Westermo helps Anglian Water upgrade its data network infrastructure
Contents
February 2021 The Engineer’s guide to new products & design ideas
Paige’s Page 04: Editor’s comment 2021: The beginning of the future
Cover Story: 06: Smart plastics
Chains with brains
Smart plastics from igus can prevent downtime
18: Smart enclosures
32: Data networks
Developing standard enclosures for smart technology, IIoT & automation
Westermo helps Anglian Water upgrade its data network infrastructure
Cover Story:
201016_9-6_Mill_DPA_UK_Snipe.indd 1
Sensors & Transducers 10/14/20 3:22 PM
With its smart plastics, igus has developed smart solutions for energy chains, cables and plain bearing technology. p.6 (Cover image: igus)
Special report: 08: Laser sensors Laser treatment
08
10: Function blocks Making light work of function blocks
Group Editor: Paige West paige.west@imlgroup.co.uk Assistant Editor: Sophia Bell sophia.bell@imlgroup.co.uk Publisher: Andrew Quenault andrew.quenault@imlgroup.co.uk Production: Holly Reed holly.reed@imlgroup.co.uk Design: Graham Rich Design www.grahamrichdesign.co.uk Head Office: IML Group, Blair House, 184/186 High Street, Tonbridge, Kent TN9 1BQ Tel: 01732 359990 E-mail: dpa@imlgroup.co.uk DPA ISSN 0965-4747 Copyright in the contents of Design Products & Applications, its websites and newsletters is the property of the publisher. The publisher and the sponsors of this magazine are not responsible for the results of any actions or omissions taken on the basis of information in this publication. In particular, no liability can be accepted in result of any claim based on or in relation to material provided for inclusion. Design Products & Applications is a controlled circulation journal, published monthly. Completed print or online registration forms will be considered for free supply of printed issues, website access and online services. Annual subscription for non-qualifying readers is UK £121, EU £215.25, Airmail £315 and single copy price is £18.60 monthly.
12: Haptic testing Haptic testing makes sure that it feels “just right”
14: 3D inspection Automated 3D inspection solution for hot metal forging applications
Enclosures & Panel Products
Special Report: 16: DIRAK-SNAP-Technology DIRAK-SNAP-Technology from FDB
18: Smart enclosures Developing standard enclosures for smart technology, IIoT and automation
20: Cable accessories Why systems accessories for cabling are indispensable
Machine Building & Safety
12
Technology Focus: 22: Machine safety
Safer operator-machine interactions through enhanced control of machine stoppages
24: Standard components Machinery building: The future’s standard components
26: Functional safety Digital demands of functional safety
Water Supplement: 28: Pharmaceutical manufacturing Pure water – quality monitoring is key to optimising pharmaceutical production
10,000 Average net circulation Jan-Dec 2018
30: Water equipment upgrades Dealing with changing water demands
32: Data networks Westermo helps Anglian Water upgrade its data network infrastructure
Circulation Tel: +44 (0)1732 359990 Email: subscriptions@imlgroup.co.uk
34: Pumps Two pumps prove better than four in Anglian Water upgrade project
20 dpaonthenet.net 3
Paige’s Page
2021: The beginning of the future W
elcome to the February issue of DPA!
Paige West, Group Editor
however, required the usual amount of
We will see the knock-on effect in in-
upkeep, plus extra services such as dai-
dustry. The future will see energy and
ly deep cleaning and even extra mainte-
resource consumption data applied
nance for equipment pushed to its limit
intelligently. Companies will be able to
In 2020, manufacturing had to cope
to meet spikes in demand or make up
develop a strategy focused on efficien-
with the consequences of a global
for lost productivity. To do all this while
cy, electrification, circularity, and decar-
pandemic, unpredictable markets, and
reducing on-site personnel, companies
bonisation, which they then can execute
political instability, all while dealing
have increasingly turned to robots, with
and iterate.
with pressing issues that were already
the consequence of stock prices for ad-
troubling the sector before, such as
vanced robotics soaring in 2020.
the need to form sustainable produc-
The recent government announcement of a 10-point plan for building back sus-
tion practices. However, the sector
This trend will likely continue in 2021,
tainably post-Covid is more evidence of
has proven to be not only resilient, but
with companies purchasing advanced
this. As we move into 2021 and beyond,
ready to adapt and eager to innovate.
robots to automate routine tasks while
big businesses have a responsibility to
As a result, strategies that manufactur-
continuing to comply with social dis-
be aligned with the sustainability plans
ers implemented merely to stay afloat
tancing regulations.
for any countries in which they operate.
last year might turn into the winning
The coming year, we will see industry
formula for a successful 2021.
5G’s time to shine
I’ve spoken to a few industry experts, who have offered me their thoughts, and
(Rafi Billurcu, Partner, Head of Manufacturing at Infosys Consulting)
here are four innovations that I think will
The development of Industry 4.0 has
take this year by storm:
slowed somewhat in specific verticals,
define its contribution to net zero efforts.
Autonomous vehicle (AV) development will continue to evolve
due to the economic impact of the pan-
(Jay Alexander, CTO at Keysight, and Jeff Harris, VP of Marketing)
Advanced robotics
demic deterring some manufacturers
The automotive sector suffered head-
(Neil Ballinger, Head of EMEA at EU Automation)
from investing in new technologies. In
winds due to the pandemic, however,
2021, however, we’ll see things speed-
production and manufacturing will come
In 2020, many manufacturing plants
ing up again as the industry tries to get
roaring back. As the number of sensors
found themselves with emptied premis-
back to pre-COVID levels.
powering in-vehicle networks contin-
es, due to shutdowns, the necessity of
ues to escalate, in-vehicle networks will
staggering shifts or moving part of their
From big data analytics to connected
need to keep pace. Electronic vehicle
workforce to remote working. Plants,
devices, 5G, in particular, will provide
(EV) sales will increase, yet they are only
the key building block to next-genera-
a small percentage (three percent) of
tion factories, providing the ultra-relia-
total automotive manufacturing. While
ble low-latency connectivity on which
traditional vehicle manufacturing stalls,
Industry 4.0 depends. Thanks to the
interest in EVs will pick up as countries
speed and reliability of networks provid-
face more stringent emissions stand-
ed by 5G, manufacturers will be able to
ards. AV investment will be modest in
move closer to their vision of the smart
the first half of 2021 but could pick up in
factory, realising the full potential of dis-
the second half – it will be more aggres-
ruptive and digital technologies.
sive in Greater China as this region is committed to phasing out conventional
Sustainability as a business model
gas-burning vehicles by 2035. The U.S.
(Mark Yeeles, VP of Industrial Automation at Schneider Electric)
development in 2021 with the change of
The Covid-19 crisis has been a wake-up
ports these technologies.
will become more focused on AV and EV presidential administration which sup-
call. For many of us, the fundamental
4 dpaonthenet.net
threat to the way we live our lives has
I’d be interested to hear other people’s
translated into a greater concern for the
thoughts on what this year has in store
impact of global crises, such as climate
for us! Email me at paige.west@iml-
change, on our reality.
group.co.uk
Connect with us on LinkedIn. Join us on Twitter.
smart plastics Avoid unplanned downtime
Industry 4.0: smart plastics eliminate downtime Intelligent products give a maintenance alert ahead of time and can be integrated into standard predictive maintenance; smart plastics allow your equipment to run continuously as well as reducing maintenance costs.
igus.co.uk/smart
Cover Story: Smart plastics
Smart plastics fro can prevent do and make it po schedule main
S
ystem failure or unplanned machine downtime are among the industry’s most significant cost drivers. Hence, maintenance engineers are demanding more condition-monitoring systems and predictive maintenance solutions to make it possible to schedule maintenance and prevent unplanned failures. With its smart plastics, igus has developed smart solutions for energy chains, cables and plain bearing technology.
6 dpaonthenet.net
The digitisation of industry started a
bearings, the motion plastics specialist
long time ago. A product can be bought
is increasingly tailoring its mechanical
online with just one click and produced
products for use in a connected and
automatically within seconds. However,
smart factory. The aim is to make main-
more data also means more machines
tenance and repair work more efficient
that allow an automated process. In the
and cost-effective.
worst case, just one component failure standstill. With the help of IoT (the In-
Smart components reduce the risk of downtime
ternet of Things) machines and compo-
According to a study by FM Global, the
nents are meant to connect and com-
most common reason for system fail-
municate with each other and display
ure is insufficient maintenance. A lot of
possible error messages, giving people
companies don’t take their plants out
the chance to react in time. igus offers
of service for preventive maintenance
the possibilities of this networking with
in times of thriving economy or crisis.
its smart plastics. As a manufacturer
This attitude bears a certain risk and
and supplier of components made of
only works until problems arise that
high-performance polymers for motion,
lead to expensive repairs, drops in
such as energy chains, cables and plain
sales and potentially to the loss of
can cause production to come to a
Cover Story: Smart plastics
rom igus owntime ossible to ntenance
carriage, function and wear tests are
Predictive maintenance planning with IoT
carried out very simply at the push of
If the maintenance is to be predictive
a button. A sensor that is integrated in
and hence possible to schedule, the
the bearing surface provides informa-
isense sensors can also be integrated
tion about the condition. The flash of a
via the icom communication module at
green LED confirms the uninterrupted
all times. It is smart networking of indi-
work process of the linear carriage, the
vidual components that creates the sol-
red one recommends the replacement
id foundation for predictive maintenance
of the bearing. igus uses a similar prin-
concepts. This data can be used to pro-
ciple in its iglidur plain bearings. How-
vide information about the status of the
ever, the measured data from the sen-
component in question, which in turn can
sors can be integrated by the machine
be used to derive precise maintenance
and equipment operators into their
schedules that address problems ahead
systems in different ways. igus offers
of time. Defects in elements are detected
three readout units for this purpose:
immediately – and even before they ac-
either the user can manually read out
tually arise. This minimises damage and
all nodes, or install a control unit with
reduces downtime. For integrating data,
a red/green display on the machine,
users can choose one of the following
which provides information about
options: either they embed the sensor
the condition of the plain bearings. A
data into their own company network so
further option is adding an icom con-
as to monitor the condition, or they use
nection, with which a radio module
the IoT and connect to the igus Cloud.
sends the sensor data wirelessly to the
That way, they receive up-to-date and
communication module. From here,
precise information and calculations re-
the integration of data to the IoT, the
garding the service life of the products
cloud system or to the customer net-
they use. Live data can always be called
work is possible. igus also relies on
up and viewed via a dashboard or per
sensors in energy chains and cables.
e-mail/SMS. Replacement parts can be
Energy chains that are used on cranes
ordered automatically with a connection
in ports, in steel works or in mining
to an ERP system. Maintenance can be
can be equipped with the new sensor
planned in advance and special mainte-
EC.PR. It measures the push/pull forc-
nance teams can be organised in time. In
es in gliding applications on long trav-
the long term, this not only achieves sig-
els and, in the case of an emergency,
nificant cost savings but also makes life
recommends a shutdown. Sensors of
easier for shift supervisors, maintenance
the EC.B series enable a breakage de-
crews and warehousing teams.
igus. With the new drylin isense linear
tection on the e-chain, EC.W sensors measure the wear of the crossbar and
“Predictive maintenance helped us avoid
market share, because the companies
sensors on the CF.P series measure
the replacement of a 240m e-chain worth
are not able to fulfil their orders due to
the cables’ tensile forces.
about £35,000 at Tata Steel in India,”
system failure. Hence, predictive main-
notes Leonard.
tenance is essential. igus has therefore
“By using smart plastics condition
equipped its e-chains, cables and poly-
monitoring, the system shuts down
mer bearings with optional sensors that
automatically and prevents expensive
Integration and maintenance service
can either monitor the condition or can
subsequent damage or total damage.
During the technical design and retrofit
be used for predictive maintenance via
The repair can be carried out quickly,
of a system with smart plastics, the igus
a data connection.
so that production can restart quickly,”
experts support users directly with the
explains Justin Leonard, igus Product
planning, design, assembly and integra-
Condition check at the touch of a button
Director for energy chains.
tion of the sensors and data. In addition,
While smart plastics monitor the com-
“That way, long and expensive system
nance engineers regularly check mechan-
ponents, they provide information
downtime can be avoided, at an invest-
ical functions, control bolted connections,
about their wear. They immediately
ment that is low compared to the price
assess wear-resistant parts, remove con-
report the occurrence of an unexpect-
of the plant.” The operation takes place
tamination and document everything.
ed operating status, turn themselves
without additional modules to process
off or sound an alarm. This is also the
external data.
case with the smart linear guides from
igus offers a maintenance service. Mainte-
https://www.igus.co.uk/info/predictive-maintenance-smart-plastics
dpaonthenet.net 7
Feature: Laser sensors
Laser treatm
T
ime-of-Flight laser sensors can reliably detect objects of various colours and materials, based on the time difference between the emission of light and its return to the sensor. Martin Wyatt, Business Development Manager at Carlo Gavazzi UK, outlines some of the benefits and applications for these compact devices.
Laser ToF sensors can also be used as a cost-effective alternative to ultrasonic devices on automated guided vehicles (AGVs), or service robots, where they can detect objects in the vehicle’s path. Similarly, they can be used for automatic door control and other proximity sensing applications.
Bats sense distance using sound. They
both the presence of an object and its
emit sound waves and receive reflected
distance from the sensor to be detected
ToF sensors can even be used in car tyre
waves. The time it takes for the wave to
and measured.
manufacturing plants because, unlike
bounce back provides the bat with in-
standard photoelectric sensors, the ToF
formation on both an object’s presence
Laser ToF sensors work regardless of
laser sensing technology is virtually un-
and its distance.
the object’s colour or surface charac-
affected by the tyre’s matt black surface
teristics, and they are unaffected by
finish.
Laser Time-of-Flight (ToF) sensors work
humidity, air pressure and temperature.
similarly. Instead of sound waves, Laser
This makes them ideal for applications in
ToF technology has developed rapidly in
ToF sensors measure the actual time for
food and beverage production facilities
the past decade. ToF chips are increasingly
a single laser pulse to leave the sensor
where ToF sensors can provide a low-
used for motion sensing in gaming devices
and be reflected from an object back to
cost and contactless means of detect-
and aiding the autofocus feature of many
the sensor’s receiver. Because light trav-
ing objects of varying sizes and colours
mobile phone cameras. Consequently, the
els at a constant speed, the time lapse
on a conveyor, for example, or measur-
controls industry is now reaping the ben-
between the emission of the light pulse
ing liquid levels in a flask.
efits of rapid technological improvements
and its return to the sensor enables
8 dpaonthenet.net
and large-scale chip production.
Feature: Laser sensors LD30 sensor to detect objects of any
mode, for example, long-distance de-
colour, material and surface finish at dis-
tection can be used to slow down an
tances from 50mm up to 1000mm in a
AGV while the short distance mode is
single, compact, cost-effective device.
used to bring the vehicle to a full stop. • Timer functions: on-delay, off-de-
A major benefit of Carlo Gavazzi’s LD 30 sensor, for example, is that it can operate in standard I/O mode and, when connected to an IO-Link master, it then
lay, one-shot leading edge or trailing edge • Logic functions: AND, OR, X-OR and SR-FF
switches automatically to IO-Link com-
• External input
munication.
• Logging functions: maximum temperature, minimum temperature, oper-
IO-Link is an open standard communi-
ating hours, operating cycles, power
cation protocol that allows for the bi-di-
cycles, minutes above maximum
rectional exchange of data from the ToF
temperature, minutes below minimum
sensor to the IO-Link master device and
temperature etc.
from the master to the sensing device.
ment
Communication is point to point, not
Using the LD30 sensor in IO-Link com-
on a network, so each ToF sensor talks
munication mode enables the sensor
directly to the IO-Link master control-
outputs to be monitored, or its operating
ler. This master can then transmit the
parameters to be adjusted from virtually
sensor’s data over various networks or
anywhere, to enable operators to make
fieldbuses to make it available for im-
decisions based on real-time data from
mediate action or save it for long-term
the sensor to help improve efficiencies,
analysis in the future.
minimise downtime and, hence, costs. It also enables problems to be speedily
In IO-Link mode, the LD30 sensor be-
identified and resolved the moment they
comes an intelligent device, which is
are detected by the sensor.
easily customisable to meet an OEM’s requirements. Once the sensor is con-
Carlo Gavazzi’s LD30 Time-of-Flight
nected to the IO-Link port, it enables
photoelectric laser sensors are inde-
access to a multitude of configuration
pendently certified for compliance with
parameters and advanced functional-
CE, UL, ECOLAB, TüV and FDA stand-
ities. These settings can be stored in
ards. The compact device measures
The laser technology used in many ToF
the master controller and can always be
just 11 x 31.5 x 21mm and weighs less
devices has advanced significantly too.
changed if the need occurs, or they can
than 100g, making it suitable for use in
Carlo Gavazzi’s LD30 Time-of-Flight
be smoothly transferred to a new sensor
confined spaces. It is available in both
photoelectric laser sensor, for example,
in the case of a sensor replacement.
an ABS and in a robust stainless steel
uses a low-power Class 1 infrared la-
IP69 housing to withstand high-pres-
ser light source driven by a modulated
The LD30 sensor parameters that are
pulse. This makes it safe under all con-
adjustable via the IO-Link interface in-
ditions of normal use because the max-
clude:
For more information on how Carlo
imum permissible exposure cannot be
• Sensing distance and hysteresis
Gavazzi’s IO-Link enabled ToF sensors
exceeded when viewing the laser with
• Sensing mode: single-point, two-
can work for your business, visit www.
the naked eye. The laser enables the
point or window mode. In two-point
1557 Polycarbonate IP68 and ABS IP66 enclosures
sure cleaning processes.
carlogavazzi.co.uk.
! w e n
Learn more: hammfg.com/1557 Contact us to request a free evaluation sample. uksales@hammfg.com • 01256 812812
About the author: Martin Wyatt is Business Development Manager at Carlo Gavazzi UK.
Feature: Function blocks
Making light work of function blocks I
f you’ve ever had to integrate an IO-Link device into any kind of automated system, the chances are you’ll have had to create a function block. Time savers as they are, function blocks are still rather a tedious part of the job.
Information capsules
I’ve had function libraries sent over to me
block as well as the full supporting docu-
Function blocks are capsules of informa-
that have been created in a rush by a col-
mentation.
tion that simplify PLC programming and
league to help me solve a problem. Without
can even replace hardwired physical com-
the documentation to support the block,
Let’s imagine a production line, where there
ponents for common tasks like timers or
I’ve needed to spend considerable time
is a conveyor system with hundreds of di-
counters.
understanding how to incorporate it into
verter stations. You may want the sensors
my code. If specific types of data struc-
at each station to be used in very similar
To create a function block, an engineer will
tures have been used in the function blocks
ways. Using a function block ‘factory’ gives
write some code and specify the inputs
that are not already part of the library, then
us a chance to create the control code very
and outputs to that set of instructions.
you must spend extra time creating them
quickly for all the sensors, while still having
Then, the whole thing is compiled into a
before you can get moving with the project.
the ability to tweak each one’s exact opera-
library, along with any other supporting
tion, depending on the inputs selected.
files that help it to work. Once it has been
Time-saving innovation
fully tested, the function can be called on
New web-based software technology is
Critical data can be extracted from the sen-
repeatedly by the PLC without needing to
being developed that creates IO-Link func-
sors automatically via the function block. If
repeat the base code. The function block
tion blocks and integrates device data into
we monitor the level of dirt build-up, for ex-
must be fully documented so that anyone
a wide range of common PLC control sys-
ample, the data allows us to make very ac-
who uses it later also understands how it
tems in a matter of minutes. You can follow
curate predictions about how long we can
works.
a step-by-step process in a web-browser
expect the sensor to perform at acceptable
dashboard and create a fully tested func-
levels, before it fails and we incur downtime.
tion block ready to use in your code.
We can schedule maintenance in advance
All this takes time, and that means cost. You might have invested hours, and more
to clean the sensors when it causes us the
likely days, depending on the task in hand
You don’t even need to be experienced in
absolute least downtime, so, throughput
and the complexity, to write and test func-
IO-Link and there’s no need to start search-
is maintained and efficiency increased. Al-
tion block functionality. Even then, you still
ing for parameters, indexes and data for-
ternatively, if a failure is imminent, the data
need to create the library and document
mats. You can download a library with all
enables us to intervene as soon as practical
the block.
the software you need to install the function
to prevent unscheduled stops.
10 dpaonthenet.net
Feature: Function blocks Function Block Factory SICK’s Function Block Factory is the first web-based service of its type that enables users to create function blocks automatically for most common PLCs. It will work for any IO-link device with an I/O device description (IODD), no matter what the device type or its manufacturer. To create a function block, users simply sign in to the SICK 24/7 web service, select the IODD file for the IO-link device and the chosen PLC system. The name of the function block can be edited to suit your naming conventions. Then, the IO-Link parameters and key features of the function block are selected, and it is ready to go. The function block handles the entire acyclic IO-Link communication, including data interpretation, index and sub-index resolution, as well as byte-swapping, if required. The data structure already contains all required variables, so the need for manual variable declaration is eliminated. The scope and content of libraries can be defined individually through a free selection of the available device parameters and can be adjusted at any time. Additionally, process data parser functions can be generated, speeding up PLC programming considerably, as well as helping to avoid errors. Enumerators (enums) replace meaningless numbers with names. This not only accelerates the development process as it’s no longer necessary to look anything up, but the source code becomes easier for third parties to read at a later point in time. A subindex access function reduces data loss and communication length. Instead of complete, complex variables, it’s possible to read out defined sub-variables or change them via a ‘write’ function. The entire record, therefore, doesn’t have to be transmitted back and forth; only a fraction of it must be transmitted, namely the sub-variable. All previously selected variables and parameters can be deselected with only one command with auto-deselection. This accelerates the definition of new read areas in the function block, and, since each selection doesn’t have to be deleted, there’s no possibility of overlooking one.
Scope for automation The potential to create function blocks quickly and reliably unlocks many more benefits for IO-Link integrations. It invites users to expand the scope of their automation projects and to try out new ideas. What will your next project be? www.sick.co.uk
About the author: Charlie Walker is Product Specialist for Presence Detection at SICK UK, providing customers with application and technical support for a broad range of sensors and sensing systems. Charlie’s expertise is particularly focused on real-world sensor integration, especially the implementation and application of IO-Link devices, working with common PLC control environments. A graduate of Lancaster University, Charlie’s broad career experience also encompasses running a production engineering department.
dpaonthenet.net 11
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Feature: Haptic testing
Haptic testing makes sure that i “I
f it feels right, it is right” was an old engineers’ mantra which was effective on relatively simple components but is no longer good enough to meet the demands of increasingly complex assemblies that not only must feel right but be right, consistently. Compare the “feel” of the controls and switches on a 1980s car, which were perfectly acceptable, with the “feel” of the controls on today’s cars to understand just
variations in the forces needed to operate
in the automotive sector, and machinery
how much the “feel” of the switches and
a component – be it a simple switch or a
outages must be avoided at all costs. In
other controls has advanced. Much of this
multi-function rotary actuator – precisely
all the years we’ve been working together,
advance has been market driven, espe-
and reliably over the long term.
we’ve never had a Kistler sensor fail.”
German company Schuhriemen Maschinenbau, a major supplier of test systems
Machines are replaced – but the sensors are kept
Haptic testing, a quantitive analysis of
to the automotive industry for over 30
The end-of-line testers developed by
“feel”, aims to minimise any variation in
years, works in cooperation with Andreas
Schuhriemen
the “feel” of mass-produced compo-
Borrmann, owner of engineering consul-
since 1989 have so far performed over a
nents. On many cars, several on-board
tancy, Ingenieurbüro Borrmann. Borrmann
billion haptic tests on vehicle control el-
systems, from integrated navigation to
says, “We’ve been using Kistler sensors in
ements. Schuhriemen also began using
air conditioning and radio, are controlled
our machines since 1990. The key ben-
Kistler sensor technology back in 1990.
by intuitively turning, tilting or pressing a
efits for us are overload protection, wide
“We’re highly satisfied with these prod-
single rotary actuator. To ensure the qual-
measuring ranges, rigidity and – above
ucts – so, until further notice, we shall
ity of these control elements, suppliers
all – long service lifetimes.” Hans-Ju-
be using Kistler sensors again for every
use automated end-of-line haptic testing.
lius Schuhriemen, CEO of Schuhriemen
new order. It’s clear that end customers in
Maschinenbau, added, “Plant safety and
the automotive sector are changing their
reliability are absolutely the top priorities
product versions more and more often. At
cially on “big ticket” items, as consumers correlate feel with quality and reliability.
Haptic test systems must identify small
Maschinenbau
GmbH
QUICK DATA FLOW. EASY WORKFLOW. ENCLOSURES
POWER DISTRIBUTION
CLIMATE CONTROL
Feature: Haptic testing
it feels “just right” present, an automated end-of-line tester
the haptic measurement of the tilting
will be in service for seven or eight years.
movement is performed on the test
After that, the machines are scrapped be-
bench. What design challenges had to
cause converting them is not cost effec-
be overcome here? “The rotary actuator
tive, but the sensors are removed first and
is considerably larger than on previous
placed in storage for maintenance.”
products. So, when horizontal movement takes place, the disruptive transversal
A recent project involved designing an au-
forces acting in the vertical direction are
tomated test for the tilt-turn-press move-
compensated by vertical compensation
ment on the rotary actuator of a central
elements,” Andreas Borrmann explains.
control unit. The automated tester built
“A design of this sort is extremely difficult,
by Schuhriemen Maschinenbau GmbH
so we’re pleased that Kistler offers a wide
comprises eight stations that capture up
choice of many different product versions
to 450 test characteristics. Based on a
and installation options.”
revolving transfer table, a test cycle lasts about 20 seconds, corresponding to an
If any one of the eight stations returns a
annual output of over 300,000 actuators.
value outside the defined limits, an as-
Kistler’s piezoelectric force or torque sen-
sembly error or material defect is indicat-
sors are used in three of the eight stations.
ed and the product under test is rejected.
At station four, a piezoelectric torque sensor with a resolution of up to 0.1Nmm
The aim of end-of-line automatic test-
tests the number of “clicks” and the
ing is to ensure that any variation from a
torque when turning the rotary actuator.
defined tolerance is detected with absolute surety, without causing damage to
At station five, vertical compression is
the component being tested. When an
tested using Kistler force sensors with a
eight-station test system based on a re-
resolution of 0.02N and displacement sen-
volving transfer table completes a cycle
sors with 0.002mm resolution. “High reso-
in just 20 seconds, there is no room for
lution and accuracy are critical reasons for
error. Schuhriemen Maschinenbau relies
using Kistler’s products in our machines,”
on Kistler sensors to provide the highest
says Hans-Julius Schuhriemen.
level of measurement precision.
The same is true of station seven, where
https://www.kistler.com/en/
VX25. SYSTEM PERFECTION. There are always two versions of this enclosure - real and digital. The maximum data quality of the VX25 ensures greater flexibility for configuration, manufacturing and assembly. And with the “digital twin”, the person who knows your company best – you yourself – can plan, order, process and do much more besides.
IT INFRASTRUCTURE
SOFTWARE & SERVICES
www.rittal.co.uk
Feature: 3D inspection
Developing an automated 3D inspection solution for hot metal forging applications A
nyone who works with metal pieces is familiar with the phenomenon of metal glowing red-hot when heated to a high temperature – and with the inspection challenges that this poses. Production mistakes or flaws that may be easily spotted, even by a casual observer, when the metal is cool, may be impossible to detect while the metal is red-hot. In addition, the extremely hot environmental conditions of the production process make real-time visual inspection
At this point, it is typically too late to cor-
be employed directly in the harsh man-
almost impossible.
rect the defects, so the workpiece has to
ufacturing environment
be declared as scrap and needs to be
•Achieve a measurement time of five
melted down and reforged.
to 30 seconds
However, many industries – such as forging, heavy industry, and the automo-
• Be simple to operate
tive sector – require accurate inspection
Not only is this inefficient and time-con-
• Be rapidly adaptable to new work-
of metal pieces during the high-temper-
suming, it also wastes energy, and there-
pieces
ature manufacturing process, to ensure
fore increases fuel costs; the energy used
• Deliver precise measurements for a
control of both dimensional accuracy
to manufacture the scrap workpiece has
and surface quality.
been wasted, and the whole process
To ensure accuracy and safety in the
very low cost of retrofitting.
needs to be carried out again – with no
conditions of extreme heat, HMP also
Without this inspection capability, mis-
greater guarantee that the required quali-
looked to create a fully automated solu-
takes are often not recognised until
ty will be achieved.
tion that did not require any hands-on
hours, or even days, after production,
human operation.
when the metal has returned to room
To overcome this challenge, SmartRay’s
temperature.
partner, system integrator HMP Technol-
Developing a solution
ogie GmbH, began to investigate whether
With these objectives in mind, Smart-
SmartRay’s modern, contactless 3D la-
Ray and HMP utilised their combined
ser technology could be used to provide
experience in 3D vision solutions to de-
production-integrated measurement of
velop the Theta 3D orbital measurement
high-temperature workpieces.
facility.
HMP set a number of development goals
Theta 3D is a roll-ring testing station de-
for the project. It determined that the
signed specifically to meet the needs of
solution had to be able to:
customers in the forging industry. It uses
14 dpaonthenet.net
• Measure a wide range of workpieces
a robotically directed test probe that can
• Operate at temperatures of up to
measure workpieces with a range of dif-
1000ºC
ferent diameters, in temperatures of up to
• Use a standard installation that could
1000ºC.
Feature: 3D inspection SmartRay’s SR9600 sensor was select-
To facilitate this, SmartRay ensured
of the sensors is made easier by the
ed for this system. Usually, this sensor
the sensor was fully compatible with
SmartRay DevKit, which supports a
uses a 660nm red laser, but for this ap-
third-party software from Vision Tools,
range of third-party vision libraries.
plication, it was fitted with a blue laser
delivering a complete inspection solu-
that could be easily seen against a glow-
tion.
ing red metal surface.
Combining full HD image processing, scanning and evaluation speeds up to
Conclusion
10kHz, and high-speed Gigabit Ether-
The SR9600 is a compact sensor capa-
By combining their expertise and intro-
net interface for real-time data trans-
ble of measuring up to 1272 points to
ducing third-party software compat-
mission, the ECCO 3D laser sensors
create a 3D profile. Typically, operating
ibility, SmartRay and HMP were able
provide the comprehensive features re-
temperatures for the sensor are be-
to develop a unique, patented solution
quired for highly future-proof inspection
tween 0-40ºC, so adaptations needed
that successfully delivered automated
solutions.
to be made to ensure it operated effec-
inspection of hot metal pieces. www.smartray.com
tively in high-heat conditions. The Theta 3D orbital measurement faDuring testing, the sensor returned
cility can be used by a range of indus-
measurement times of between 15
tries to save time and money in their
and 45 seconds, depending upon the
inspection processes, while protecting
inspection criteria that were set. This
the environment by reducing waste en-
allowed 40 to 80 workpieces to be in-
ergy use.
spected by the system every hour. Future solutions may be able to take To meet application requirements, the
advantage of SmartRay’s ECCO range
Theta 3D testing station needed to offer
of 3D sensors, which are even more
a comprehensive library of inspection cri-
compact than the SR9600, and ca-
teria, including outer and inner diameters,
pable of solving a multitude of forging
circularity,
industry inspection tasks requiring mi-
out-of-roundness,
heights,
surface defects, and flash defects.
crometre-level precision. Integration
High power AND reliability? You wanted more current per contact from our hi-rel connectors. You wanted ease of use and great performance in vibration conditions. You wanted Harwin’s high quality standard.
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n
Shock to 100G
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n
Operating temperature up to 150°C
harwin.com/kona
Connect with confidence
Feature: DIRAK-SNAP-Technology
DIRAK-SNAP-Technology from FDB – a simple, secure alternative approach to installation of panel hardware
F
DB Panel Fittings and sales partner, DIRAK, became aware of customer feedback which indicated that customers in the areas of furniture, lighting, electrical housings, electronics, building fixtures and fittings, were tired of wasting time dealing with screws, washers, back nuts and other loose parts. It seemed that assemblers and installers would welcome a simple click fit and a comprehensive programme of enclosure/cabinet hardware – without all the fiddling about. By connecting ideas in a new way,
create the perfect solution, simply and se-
an optimal solution.
curely, in seconds. Error-free and reliable, DIRAK-SNAP-TechCustomer Matt Jackson, Operations Man-
nology ensures proper installation – greatly
ager at Environ Group, explained, “We like
reducing the risk of assembly errors, such
the D-SNAP system because we can just
as improper torque specs. An audible
send one complete component that snaps
click confirms proper assembly, which is
into place on site and can be used imme-
especially helpful in applications which
diately – there are no screws, washers or
are hard to access. Safe and convenient
nuts to get lost or take up time in assem-
removal is assured with either standard or
bly. The end user can even do it – we do
DIRAK-specific tools.
not have to send out an engineer to complete the housing. [It is] a very strong and
The DST series offers an unlimited va-
excellent product [which offers] a simple
riety of possible hardware components
solution to blind installation. This means
with a well-engineered fastening tech-
that we can send equipment without locks
nology that ensures quality assemblies.
and handles, which minimises transit
DIRAK-SNAP-Technology combines flex-
damage.”
ibility, convenience and security in every
the engineering team developed DIRAK-
application, without the need for tools,
SNAP-Technology (DST). The resulting
Environ Group manufactures sheet metal
as these products slide perfectly through
system offers easily made high-strength
acoustic and electrical enclosures for ex-
the panel cut out and snap into position.
panel connections, without the use of any
ternal situations, such as rooftops, where
A strong and secure fixing is created with
tools, so that specialist panel builders can
they use D-SNAP handles and hinges for
no possibility for loosening or turning.
16 dpaonthenet.net
Feature: DIRAK-SNAP-Technology The design concept is based on the
hinges, removable pin hinges, external
flexible in application to accommodate
same principle as a slam-latch, similar
hinges for surface mounted doors, lift-off
individual application requirements, with
to those used in a door. It is made up
hinges, adjustable hinge, bridge and bow
reinforcement plates available to increase
of two wedges with ramped edges, and
handles, finger pull handles, slam latch,
strength and load capacity.
a spring set into a window within the
recessed pull handle, tubular handle,
wedges. These components are then
stainless steel hinges. A true alternative
Where electrical continuity is required,
inserted into the hardware and secured
to the rather fiddly traditional nut and
safe and reliable electrical grounding
with a plastic plug to keep them in place.
screw approach.
is achieved with easily fitted grounding
As the DST component is pressed into
clips. Where additional security is re-
the sheet metal cut-out, the ramps on
Any new system has to be comparable
quired, components requiring special-
the wedges allow them to retract against
to the existing one in critical areas, so it
ised DIRAK tools are available to address
the spring. When the ramps pass their
was important to ensure that it provided
cases where vandalism or theft are con-
apex, the spring pressure spreads them
high strength and secure locking, able to
cerns.
back outwards, resulting in the distinctive
withstand high-load conditions and guar-
“SNAP” sound. The “SNAP” component
antee connection and pull forces equal
is thereby secured into the sheet metal,
to traditional fastening solutions. DST
resulting in a secure, high-strength con-
products are rattle, vibration and shock
nection which naturally tightens.
resistant, with the ability to withstand the
www.fdb.co.uk
heaviest strains without compromising The DST series includes captive fasten-
their high-strength locking. Many DST
ers for lightweight sheet materials as well
products are tested according to DIN EN
as for heavier gauge materials and heav-
61373 for vibration and shock and GR-
ier duty applications, e.g. enclosures and
63-CORE, Issue 4 for earthquakes.
cabinets. Conceived as a complete system, there is a full range of components,
To enable the joining of different types
such a cam catch, clamping handle,
of materials, various DST products were
clamping latch, compression latch, quar-
devised to accommodate sheet metal,
ter-turn locks, swinghandles, concealed
plastic or wood, and to be sufficiently
Flat Top Chain Conveyor System Economical realisation of complex track designs Simple and fast configuration and commissioning Modular system of standardised components
www.mkprofiles.co.uk
mk Profile Systems Limited a company of the mk Technology Group
Feature: Smart enclosures
Developing standard enclosures for smart technology, IIoT and automation I
ndustry 4.0 automation and other smart technologies are inspiring a revolution in the design of electronic enclosures. New high-performance housings are now more specialised – but no less versatile, writes Robert Cox, Marketing Director of OKW Enclosures Ltd.
OKW EASYTEC pole/wall mount enclosures
Manufacturers of electronics products are benefiting from huge leaps forward in enclosure design. IoT/IIoT and other smart technology applications have ushered in a wealth of new opportunities for OEMs. Enclosure designers at OKW are capitalising on surging demand for smart technology and advanced automation. This rapidly expanding market has prompted them to create advanced
So why is discretion so crucial in en-
or screwed in place quickly and easily.
enclosures that are ideal for specialised
closure design? It is essential that
This dramatically speeds up installation
roles, but still suit a wide cross-section
the enclosure you specify looks pur-
times – a real boon, given the huge
of applications.
pose-manufactured for your product
number of sensors that proliferate in to-
– and no other. These days, it doesn’t
day’s smart factories.
Elegant wall-mount enclosures, such
take much to achieve that: a few ma-
as SMART-PANEL, exemplify this new
chined cut-outs, a touchscreen/key-
Add to that the fact that it speaks the
breed of housings for modern digital
pad, some corporate branding – and,
same design language as OKW’s EVO-
control electronics. Designed specifical-
suddenly, your enclosure is a one-off.
TEC table-top plastic enclosures, and
ly for intelligent building control systems,
Best of all, improvements in technology
suddenly you have sensor enclosures
SMART-PANEL addresses the needs of
have made this customisation viable in
that perfectly match their desktop con-
futuristic commercial, smart factory, and
much lower volumes, thanks to low set-
trollers.
home automation applications.
up costs.
That is because it adheres rigorously to
contours more important than in the
the first rule of standard enclosures: it is
Aesthetic curves and smart design
incredibly discreet in design. That is to be
You could be forgiven for thinking that
closure that sits close to the body for
expected – enclosures don’t come more
modern aesthetic curves and smart de-
long periods must be so comfortable
understated than one which flush-fits
sign features are reserved only for the
that it is barely perceptible.
into standard cavity wall boxes. Howev-
most expensive enclosures. You’d be
er, that hasn’t stopped SMART-PANEL
wrong: they’re also available in some of
For that reason, OKW created BODY-
from demonstrating its aesthetic cre-
the simplest (but no less vital) housings.
CASE. It fits a standard 18mm watch-
Nowhere are ergonomic curves and
dentials with modern curves and glass
world of wearable electronics. Any en-
strap but can also be worn on a lanyard
panels for premium-application touch-
EASYTEC is a flanged enclosure for
or wrist strap, clipped to a pocket, or
screens and displays.
IoT/IIoT sensors. Thanks to its clever-
carried loose. BODY-CASE meets the
ly designed lugs, it can be cable-tied
growing demand for personal electron-
18 dpaonthenet.net
Feature: Smart enclosures ics; applications include GPS tracking of
PROTEC
is
another
wall-mounted
become an increasingly popular feature
About the author:
vulnerable workers, overcrowding pre-
enclosure that can also be specified
in modern enclosures. NETBOX has no
vention/safe distancing, safety alert sys-
for desktop electronics – thanks to a
visible screws at the front – just two be-
tems and emergency call technology.
choice of three versions that offer either
low that are all but invisible.
Robert Cox is the Marketing Director at OKW Enclosures Ltd. He has more than 40 years of experience in the electronics industry, notably in the design, manufacture and marketing of enclosures. Robert was instrumental in the launch of OKW in the UK (Fareham, Hampshire) and the USA (Bridgeville, PA).
a recessed interface area, a covered re-
Pioneering an enclosures revolution
cess or a deep extended cover that acts
OKW has gone to even more further
as a desk stand.
lengths with other models. SYNERGY
There’s so much more to today’s stand-
enclosures – which combine aluminium
ard enclosures than ergonomic con-
Deep recesses with protective covers
and plastic – feature column-based con-
tours and discrete design (as important
are a key design feature for enclosures
struction, enabling the fixing screws to
as they are). Anyone who has watched
that house wall-mounted controls or
be hidden away on the bottom section.
the enclosures market will have noticed
network nodes for building manage-
a quiet revolution taking place. Key as-
ment, Industry 4.0, data systems engi-
However, the last word goes to
pects include:
neering, and access control. NET-BOX
SMART-PANEL. It has removed the need
• advanced materials – high-perfor-
has a large recess for connectors and
for fixing screws altogether. Instead, it
mance plastic blends, innovative
cable glands – but hides them beneath
snaps together, to be opened by a plas-
combinations of plastic and alumin-
a clip-on trim that provides added pro-
tic tool (supplied as an accessory).
ium
tection.
• greater use of tamperproof and concealed fixings
Visit the OKW website for further inforConcealed fixings such as this have
mation: www.okw.co.uk
• higher levels of ingress protection (such as IP65 as standard). It started with materials. Until a few years ago, robust ABS was the plastic of choice for most plastic enclosures – but not anymore. It has been superseded by ASA and blends such as ASA+PC-FR, which offer superior UV stability, greater strength and easy cleaning/sterilisation when offered with a high-gloss finish. ABS remains a good choice. You will still see it as standard in tried and trusted designs – but seldom in OKW’s newer models. So why would enclosures that never venture outdoors need enhanced UV stability? You would be surprised how much damage UV light can do to some plastics – even indoors. The enclosures revolution has continued with the use of tamperproof Torx screws as standard on enclosures such as the wedge-shaped SMART-CONTROL, for corner-based electronics. Torx screws are a must for medical devices, a key market for OKW. Why would an enclosure like SMART-CONTROL – which is destined to sit high in hard-to-reach ceiling corners – need tamper-proof screws? The answer is that SMART-CONTROL also doubles as an ergonomically inclined desktop enclosure. OKW SMART-CONTROL corner-mount enclosures
dpaonthenet.net 19
Feature: Cable accessories
Why systems accessories for cabling are indispensable S
witch and control panels protect electrical devices in a hostile environment. They prevent damage from moisture, dust or contact. But that is not enough. Accessories are often used for ease of use and to make the assembly of panels simpler and clearer. It is important that they meet the same requirements as those that apply to building the panel.
Cable routing at moving parts The IEC standard states that “connections to appliances mounted on doors or other moving parts are made using flexible current conductors […], allowing regular movement of the part”. Pipes must be secured to the fixed and moving part.
Accessories for VX25 and AX
the switchgear. Solenoid valves must
Because cable hose holders have the
Various materials are available for the
therefore be kept apart from other elec-
same hole pattern as the cabinet frame
VX25 add-on unit series to keep elec-
trical components by placing them in a
of the VX25, the door profile in the AX,
trical and pneumatic components sep-
separate compartment made with rail
as well as the mounting rail and system
arate from each other – think of rail sys-
systems.
chassis, they can be mounted there eas-
tems, mounting profiles, system chassis and mounting rails.
ily and quickly. The plastic cable hose System chassis, which are used in the
makes it easy to establish a reliable
door of the VX25 to make optimal use
connection with flexible current conduc-
applianc-
of cabinet space, can sometimes also
tors. This also fulfils the requirement that
es that do not belong directly to the
be used for the AX wall and floor cabi-
“sufficient mechanical strength must be
electrical equipment cannot simply be
net series. The same applies to different
provided, without compromising proper
placed within the housing containing
mounting profiles.
functioning”.
Non-electrical
20 dpaonthenet.net
parts
and
Feature: Cable accessories Cable entry and protection class
Cable glands, modular cable glands or
method is to fix the cables with cable
connector glands are also used for the
clamps. These are available in different
The cable entry into a switch and
AX wall and floor cabinets. The basic re-
designs and sizes, allowing the use of a
control panel is also important. Main-
quirement is the same: maintaining the
universal profile.
taining the IP protection class is par-
protection class.
amount. The IP value says something
Also consider the slide rail for the mount-
about how well a cabinet can keep out
For machines with cable tray systems,
ing plate with the VX25 extension unit.
threats such as dust and water. The lat-
it is advisable to apply additional edge
When the plate is in its final position,
About the author:
est standard does not allow openings
protection over the parts where cables
these rails are, in principle, unnecessary.
in the enclosure (such as those for the
are pulled with a plastic protective edge,
Nevertheless, due to the C-shape of the
passage of cables) to impair the degree
grommet or rounding. Simply deburring
system chassis, they can be used for ca-
of protection.
sheet metal edges is often not sufficient
ble fixation with clamps for C-rails. These
to prevent damage to the sheaths of
cable clamps are, of course, provided
lead-through cables.
with a plastic part to protect the cables
Emma Ryde is Rittal’s Product Manager for Industrial and IT Enclosures. She has a wealth of experience gained over 20 years, developing technical sales in a range of industries, including food and beverage, automotive and transport. Her sales and engineering experience as a key member of the Rittal team resulted in her being appointed as Product Manager for Industrial and IT Enclosures. Her remit extends across support for Rittal’s customers in existing markets, as well as developing new opportunities as they arise. She has an HNC in Mechanical Engineering.
At the same time, openings for on-site cable entry must be easy to open again.
from damage.
The VX25 wall cabinet has sliding metal
The bottom plates of the VX25 are dou-
bottom plates, which create an open-
ble-folded and have a rounded edge,
Cable fixings can also be placed in
ing for cables. Additional provisions are
preventing a cable from being damaged
mounting rails. Cable ties are very use-
therefore required for correct and safe
when being fed in from below. These
ful for quickly securing cables to system
cable entry. An elastic clamping profile
plates are extra sturdy and resistant to
chassis, mounting rails and profiles to
seals the opening. This creates a flexi-
bending, making a substantial contribu-
the cabinet frame of the VX25. These ca-
ble cable entry that guarantees that the
tion to the protection class.
ble ties are easy to press into the round
issued protection class remains intact.
system bore, after which it is a matter
Variants that can be made on this in-
Cable support and rails
of bending and securing the cable. The
clude a profile for cable entry between
Finally, the connections of cables must
cable tie is also suitable for securing ca-
bottom plates (symmetrical) or between
be sufficiently supported to prevent me-
bles in the cable hose holder.
enclosure frame and bottom plates
chanical stress on the connections of
(rear).
current conductors. A frequently used
www.rittal.co.uk
ULTRA-FAST PRESSURE TRANSDUCER SERIES M5
EXTREMELY COMPACT DESIGN 50 kHz • Operating -50...180 °C • Linearity 0,1 %FS • IP65 Pressure ranges of 3 bar, 10 bar and 30 bar absolute. Media compatible with oil, fuels, gases and coolants. Test benches • Leakage • Wind tunnels • Aviation • Compressors • Explosion waves
keller-druck.com
Feature: Machine safety
Enabling safer operator-machine interactions through enhanced control of machine stoppages
A
s packaging line machinery has become more sophisticated, it’s also become more complex. This increased complexity, coupled with a high number of interactions between operators and machines, increases the potential for safety incidents.
In the packaging world, for example,
talisations and 57 percent of all reported
production lines may stop for manual
amputations – the highest proportions
loading 10-30 times per shift, each time
for all industries.
necessitating some form of interaction that exposes operators to possible risk
Safeguarding people and assets remains
and increases the potential for a safety
a challenge for end users and original
incident.
equipment manufacturers (OEMs) that must account for a seemingly infinite
Guarding against these risks isn’t easy;
number of variables, including machine
when changes are made to improve a
complexity, operator interactions, work-
machine’s safety, operations can be-
place culture and individual attitudes.
come even more complex or more restrictive. These safety measures often
However, by implementing the right
incorporate procedures to stop machine
technologies, OEMs and end users can
operation, isolate energy, resolve issues
create safer manufacturing environ-
and restart processes – all of which
ments without compromising productiv-
translate into lost production time. Frus-
ity. Specifically, innovative technologies
trated by these disruptions, operators
such as zoned safety and uninterruptible
may look to bypass safety measures to
control power solutions offer enhanced
keep the line moving and meet through-
control of machines during stoppages
put expectations – exposing themselves
and power disruptions. These help to
to unnecessary risk in the process.
minimise the impact of these events on operations, resulting in more predictable
The consequences can be significant:
machines that improve operator safety.
an operation can experience damage
seriously, injury to its personnel and
Safer operator interactions through selective shutdown of machine zones
even loss of life. A recent study by the
When operators interact with machines,
Occupational Safety and Health Admin-
they can be exposed to increased risk. If
istration reveals manufacturing account-
something goes wrong, they can be hurt
ed for 26 percent of all reported hospi-
or damage can occur, causing produc-
to equipment, unforeseen costs, loss of productivity from shutdowns – and most
22 dpaonthenet.net
Feature: Machine safety tion to come to a grinding halt. This es-
percent, while allowing for multiple and
ment during a disruption. Uninterruptible
pecially holds true for pneumatic control
independent safety functions such as
power supplies offer a means of achiev-
sections of machines in a packaging op-
‘stop motion’, ‘return home’, ‘exhaust
ing this by allowing machines to keep
eration. Traditionally, ensuring operator
air’, ‘unclamp’, ‘remain clamped’, etc.
their field power supplies, programma-
safety of these machines has required
ble logic controllers (PLCs) and communications devices functioning during an
Lock Out Tag Out (LOTO) applications,
Intelligent shutdowns and restarts for improved operator safety
that shut off the air supply, dump air, and
Power disruptions represent another
In the event of a power disturbance, this
disable operation of the entire machine.
critical area of concern. For operators
technology provides immediate back-
employing discrete safety circuits with redundant dump valves, designed for
unexpected outage.
who rely on electronically driven au-
up AC power so that processes can
This approach wastes energy by re-
tomated packaging systems, power
continue or be intelligently shut down
peatedly dumping all the compressed
disruptions can occur with little or no
without causing unsafe conditions.
air in the whole machine and forcing op-
warning, and the sudden machine stops
These units also enable operators to
erators to wait for extended periods as
that result from these disruptions can be
control the restart of power safely, with-
entire systems restart. Furthermore, it
dangerous, time consuming and costly.
out accidental re-energisation of circuits
adds significant complexity and unnec-
As well as potentially exposing opera-
before it is safe to do so. With the ability
essary cost to machine design because
tors on a packaging line to unsafe condi-
to provide status updates of the UPS
it requires complicated control struc-
tions, these stops can lead to damaged
while it’s running, these power supplies
tures to be in place and more expen-
equipment, ruined product, material
help operators to prevent equipment is-
sive components. Without these control
pile-ups, and product backorders.
sues that can lead to potential hazards.
air into a pneumatic system can cause
These disruptions can be caused by a
The right thing to do
unintended motion of components, in-
wide range of power issues, including
Ensuring machine and operator safety
creasing the risk of damage to the ma-
voltage sags and surges, brownouts,
in today’s increasingly complex pack-
chinery itself or causing the machinery
power interruptions, and low- and
aging lines will remain a growing chal-
to drop products – resulting in spills,
high-frequency voltage transients – and
lenge, especially as operations seek
lost product and scrap. In an attempt
no operation is completely immune.
to maintain production standards and
to avoid this damage and maintain their
Compounding the problem are ageing
meet customer expectations. Those
expected output, operators may allow
plant electrical systems that provide
expectations, along with the subse-
some machinery to remain live at times
power to advanced machinery with
quent pressure felt by operators to
when it shouldn’t be active, inadvertent-
electronic control systems, which are
“keep the line moving”, aren’t going
ly exposing themselves and their opera-
highly sophisticated but also highly sus-
anywhere. Still, manufacturing compa-
tions to increased risk.
ceptible to the impacts of a disruption.
nies must ensure the safety and health
Simply put, damaged control systems
of their employees who are engaged in
Zoned safety technology offers a bet-
can plunge a line into a state of chaos,
the installation, operation, adjustment,
ter approach to machine safety during
causing machines to act unpredictably,
and maintenance of production equip-
manual interactions, while meeting the
with components crashing into each
ment. It’s simply the right thing to do –
requirements of the Machinery Directive
other, products breaking, and operators
and technologies that offer enhanced
and ISO 13849-1.
caught in the crossfire.
control of machine interruptions make
Zoned safety technology simplifies the
Preventing this chaos requires maintain-
design of a redundant pneumatic safety
ing critical, electronic-based plant equip-
structures, the sudden reintroduction of
it possible. https://www.emerson.com/en-gb
circuit. A single manifold system can be configured to shut down air and power only to the group of valves that controls the machine’s specific motion in the operator’s vicinity, while the rest of the machine remains in operation. This ensures operator safety and allows the rest of the machine to keep producing, even though these safety circuits are enabled. Multiple independent safety circuits and standard valve functions can easily and cost effectively be designed into a single pneumatic valve manifold. This reduces complexity and the number of safety system components by up to 35
dpaonthenet.net 23
Feature: Standard components
Machinery building: The future’s standard components D
esigning machinery for future performance is always difficult, with many different factors to consider, such as emerging technology, manufacturing and assembly. To reduce the uncertainty, it is always advisable to use standard components, explains Martin Ahner, Product Trainer and Head of norelem ACADEMY.
components if they fail, or if the machine
3D printing has allowed the industry to
will need to be renewed entirely.
leap forward into a new age of technology and efficiency. By being an additive
Given the constant pressure for manu-
process, it reduces material waste, pro-
facturers to innovate and for design en-
cessing time and required equipment.
gineers to create those visions and ma-
Nonetheless, there are some factors
chinery, the use of standard components
which may not suit certain companies,
can help to make those ideas a reality.
such as design inaccuracies, copyright
Furthermore, standard components can
issues, and a reduction in manufacturing
help to extend the lifespan of a machine
jobs, resulting in processes having less of
and increase its return on investment.
a human touch.
Trends in future-proofing machinery
Robotics and automation also have
components is becoming increasingly popular within the manufacturing and
All companies are potentially at risk
they can bring efficiency, reliability and
engineering industry. Ensuring efficient
when it comes to machinery downtime
consistent output and lower production
processes are put in place to minimise
and production standstill, which is why
costs; however, they require hefty invest-
disruption and interruptions is vital, as
future-proofing processes are essential.
ment costs as well as bringing job uncer-
production interruptions mean product
These include additive manufacturing
tainty for employees.
delays. In turn, this leads to frustrated
and 3D printing, robotics and automation,
customers and consumers.
IoT investments, and even wearable tech-
Future-proofing your machinery and
nology. Guaranteeing future performance of your
similar advantages and disadvantages;
Challenges in future-proofing machinery To protect themselves from potentially cat-
most prized assets is especially difficult
In some instances, new technologies
astrophic global disruptions, manufacturers
when using bespoke parts. In five, ten, or
open the door for progressive manufac-
need to take measures to ensure the flexibil-
twenty years, these custom components
turers to release innovative offerings of
ity and resilience of their manufacturing op-
may no longer be available, and it is al-
their own. However, choosing which ones
erations. This means that you need to move
most a complete guessing game as to
are best for you is tricky and clearly needs
your manufacturing supply chain from a glo-
whether you will be able to replace those
reason for such investment.
balised approach to a more localised one.
24 dpaonthenet.net
Feature: Standard components A large investment is also a key challenge for manufacturers who wish to upgrade to the next digital age. Ensuring your data and technology is based on a platform that can accommodate the latest technology is crucial. However, investing in new technology is the way of the future. Anything that’s true of the benefits of intelligent and flexible automation in normal circumstances is doubly true now: it enables more efficiency, lowers cost, increases output and quality – and, importantly, it lowers reliance on manual labour. Mechanical standard components do not require a wealth of expert knowledge from the outset – they can be easily operated with basic knowledge, which can be helpful for companies who want to
must internally train their employees to
configured or tailored to different appli-
future-proof their process.
gain new skills for new technology.
cations are a cost-effective method of
The uses and benefits of standard components in engineering and machinery building
The future of a business is always reflect-
can cater to a wide range of requirements
ed in the innovative strength of its prod-
while reducing the complexity of machin-
ucts. Only by accepting new trends and
ery building and maintenance. norelem
putting them into practice can a company
sees itself as a system supplier and full-
A report published by McKinsey on future-
grow and survive on the market.
range provider with a goal to provide the
future-proofing. Extremely flexible, they
proofing operations states, “New mar-
designer with all the products they need.
ket dynamics and technology trends are
There will always be a place for standard
The focus is not on the individual com-
emerging at an increasing pace. These
components, and by learning how to use
ponent, but on the complete package, so
rapid developments are driving the im-
these efficiently, engineers can increase
that the designer has everything from a
portance and urgency of mastering mat-
their skills and select the right compo-
single source.
ters related to product complexity, de-
nents for the right applications. They can
mand fluctuation, and asset utilisation”.
even go on to transfer this knowledge to
The norelem ACADEMY offers effective
build fully automated machines or pro-
and individual instruction with its own
Although it’s vital for companies to be
duction lines, and eventually begin the
training platform, and is designed to sup-
running efficiently, it’s also crucial that
journey of future-proofing the manufac-
port pupils, students and specialists with
machinery and production lines are reli-
turing process.
free expert lectures on all aspects of me-
able. Standard components, whether for
chanical engineering.
new or old machinery, can reduce retool-
Although machines are getting smart-
ing times, tooling changes or even the
er and are increasingly networked with
For in-depth product knowledge, the
time to swap out workpieces for machin-
each other to pass on certain information
ACADEMY helps engineers to under-
ing or fabrication.
to generate an optimal workflow, it’s im-
stand product innovations more quickly
About the author:
portant to have standard components to
through application examples. In mi-
This then improves productivity, extends
progress with certainty and reassurance
cro-learning units, the user can quickly
machinery lifespans, and reduces down-
into a new phase of technology.
see all information and examples of how
Martin Ahner is a Project Engineer at norelem. With a degree in mechanical engineering, Martin has been with norelem for almost four years and can often be seen at global trade fairs and exhibitions, providing technical support to customers. When not flying around, Martin is in the norelem ACADEMY, collaborating with schools and colleges to deliver technical training and develop engineering exhibits.
time. By using standard components, you
the product is also used in practice.
are future-proofing your operations and
Conclusion
machinery.
There’s no doubt that manufacturing
For products that require more explana-
companies are now starting to shift to-
tion, norelem ACADEMY offers product
Tools, knowledge and assets that engineers need to future proof machines
wards a more digital way of working. With
training. The integration of the standard
several options to take to future-proof
parts in construction is crucial for a com-
operations and machinery, it’s important
petitive product.
The skills gap within the manufacturing
to ensure that you are investing in reliable
industry is not a new development, espe-
products and systems.
cially in recent years. Due to the existing shortage of skilled workers, companies
To find out more about norelem’s range of standard components, visit:
Standard components which can be
www.norelem.co.uk
dpaonthenet.net 25
Feature: Functional safety
Digital demands of functional safety I
n the machine industry, the significance of functional safety has grown continuously as a result of advancing digitalisation. The increasing connectivity of systems and plants, plus the growing possibilities of remote control, has seen a paradigm shift away from the prevention of access and reliable shutdown of machines to the reliable identification of people and continued operation. For example, due to the growing trend of people collaboratively working with robots, both possible damage events and the safety-related parts of control systems
of integration of smaller structures.
have become more complex.
ification measures necessary to ensure up-to-date knowledge. Further elements
In addition, adequate verification ap-
that must be defined within the scope of
The main requirement for complex sem-
proaches, which show the effectiveness
the safety life cycle include the type and
iconductors, that are used in functionally
of safety measures, must be developed.
scope of the required documentation
safe embedded systems, is a high degree
Due to massively increasing system com-
and quality assurance. Functional safety
of miniaturisation with the goal of reducing
plexity, a high-quality development and
management should also have numer-
area and cost. Furthermore, modern de-
life cycle process is therefore required to
ous interfaces with the higher-level quality
sign requires compatibility, reusability and
ensure a low level of systematic faults.
management system which is typically in
embedded safety features. The challeng-
place within an organisation. It is also vital
es in this domain are short innovation cy-
The assessment of design and manufac-
to remember that functional safety is not
cles, a high degree of design complexity
turing processes is another key factor in
solely the responsibility of the component
and increasing integration density.
avoiding the consequences of system-
or system supplier alone, but also that of
atic faults. Those using semiconductor
the future owner of these systems.
These aspects have a massive impact on
components, therefore, need informative
the assessment of device functional safe-
and complete documentation in order to
To mitigate against systematic faults, the
ty, especially as new fault models caused
realise a safe and straightforward system
effectiveness of safety measures must
by new technologies must be considered.
design. This means that great care must
also be fully verified. This will confirm the
This is particularly the case for Systems-
be taken when generating the user docu-
robustness of components, as well as the
on-Chip (SoC), where dependent faults
mentation with respect the completeness
complete life cycle, and the development
have to be evaluated, and already known
of system integration. Consequently, the
process must also be considered during
failure modes – such as transient failures –
generic normative requirements should
such an assessment. A holistic approach
take on increased relevance in the context
be interpreted and extended, based on
to functional safety is therefore required,
the current state-of-the-art and specific
which requires expertise in various ap-
technology being considered.
plication fields across all project phases,
About the author: Stewart Robinson MIET MInstMC is a Principal Engineer and Functional Safety Expert at TÜV SÜD. He has been delivering training courses for more than 25 years on various topics, mainly concerned with industrial control systems but also on the general aspects of machinery safety.
26 dpaonthenet.net
from design and development to manuFunctional safety management is a key el-
facturing and installation, testing, certifi-
ement of relevant functional safety stand-
cation, placing into service, and decom-
ards. This includes the definition of the
missioning.
roles and tasks of the individuals involved, proof of their competence, and the qual-
www.tuvsud.com/uk
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Supplement: Water
Pure water – quality monitoring is key to optimising pharmaceutical production The multiCELL Transmitter/Controller conditions the water quality measurements clearly and supports the process of documenting them
T
hroughout pharmaceutical manufacturing, pure and ultrapure water is required for many processes and end products. Both OEMs of production skids and end users appreciate the importance of maintaining the water quality standards in the production loop. Using a proven and flexible monitoring system to collect sensor data, calculate differentials and communicate with a PLC can reduce the time for the initial build, as well as installation costs, and increase the speed of operation.
osmosis (RO) or electrodeionisation (EDI).
tent, as well as temperature and flow rate.
Water for injection (WFI) is the highest wa-
Any divergence from the pre-set limit val-
ter quality standard, using purified water
ues can require production to be halted
as the starting point. Either a multi-col-
while cleaning and disinfection procedures
umn distillation plant (MCDP) or vapour
are carried out. The resulting downtime
compression (VC) technology is used to
can have a significant impact, especially
create WFI. Highly purified water (HPW) is
on high-value production lines. Further-
unique to European pharmacopoeia and
more, if there is any doubt over the exact
must meet the same standards as those
timing of the drop in water quality, some
established for WFI. In both cases, the wa-
product batches may have to be rejected
ter must be protected against recontami-
to ensure absolute product safety.
nation and microbial growth. Typically, manual processes of monitoring
Increasing speed with automation
are not very efficient. Individual sensors
Process water is held in a storage tank that
various stations in the process. Readings
feeds the ring line where tapping points, ei-
must be taken from each sensor and the
Christof Kundel, Segment Manager Wa-
ther manual or automated, deliver the water
values then entered into the control sys-
ter for Bürkert, looks at the importance
to the production process. Unused water
tem. The additional displays make the
of monitoring water quality in production
goes back to the storage tank. It is essential
sensors more costly, both for the initial
loops and how this can be achieved cost
that all the water quality specifications are
purchase and if any replacements are re-
effectively.
upheld throughout this process.
quired. In addition, there are no automatic
Various grades of water quality are used in
Careful monitoring of water quality is cru-
sors, whose values could provide early
numerous processes in the pharmaceuti-
cial to ensuring process reliability, allowing
indications of malfunctions.
cal and biotech sectors, each with its own
any variations to be quickly identified and
production methods and specifications. At
resolved. The parameters being monitored
Building for the future
the lower end of the scale, purified water is
can include pH, conductivity, oxidation-re-
Production facilities will often operate
created using processes such as reverse
duction potential (ORP) and chlorine con-
multiple production loops, all of which
with their own displays are installed at
comparison functions between the sen-
28 dpaonthenet.net
Supplement: Water use purified water in one form or another.
reliability is increased through early detec-
local transmitter which, in turn, relays all
Continuous water quality monitoring with
tion and intervention.
the information to the PLC.
nel to take the necessary action before
For example, Burkert’s Type 8619 mul-
Once all the sensors are connected, the
an alarm point is reached. This ensures a
tiCELLl can be programmed to give an
parameters and calibrations need to be
much smoother operation and minimis-
alarm signal in case of a leak in the ring
completed. In the past, this could be a
es the number of alarms, which have the
line. This automated leakage monitoring is
time-consuming process, but now, as-
potential to halt production until the water
made possible by the mathematical and
suming all the skids will operate in the
quality issue is resolved.
Boolean functions that enable compari-
same manner, the settings for the first
sons in parameters. An alarm status can
transmitter can be copied to a memory
OEMs can build single or multiple skids
be quickly viewed by personnel in the field
card and transferred to all the other units.
that can be linked together, enabling com-
via the clear display. To set up leakage de-
munication between them and allowing
tection in a closed water circuit with tap-
Optimising operations
several water loops or production rooms
ping points, flow measurement in the sup-
For the personnel working in the process
to be monitored at the same time. The
ply and return lines is required. With the
rooms, both operational and maintenance,
addition of local visual displays makes
help of mathematical functions, the flow
it is important to have a clear indication of
monitoring easy for the production and
rates are compared and any unexpected
the actual water quality parameters. The
maintenance personnel; there is no need
water loss is calculated.
multiCELL offers intuitive functions and a
local displays enable production person-
to interrogate the PLC for the information on water quality.
About the author: Christof Kundel, Segment Manager Water at Bürkert Fluid Control Systems has worked with the company for more than 25 years.
clear visual display that can be customTo identify correctly a leak, and not a reg-
ised for each station, so that the most per-
ular withdrawal from the water circuit, the
tinent information is always available.
To deliver a comprehensive solution that
open status of the valves at the tapping
can improve manufacturing reliability and
points must also be considered.
meet the future needs of the facility, OEMs
To help both the OEM and the end users, any industry-standard sensor can be used
are able to use a multi-function transmit-
Using a combination of the mathematical
with the transmitter, enabling OEMs to re-
ter that can monitor several parameters
functions and the status of the valves, it is
tain any preferences for particular brands,
at once, calculate any differentials and
possible to achieve reliable and error-free
and customers to maintain brand loyalty or
communicate with the process PLC. In
leakage detection. For the end user, false
simplify parts inventories.
addition, as more industries are embracing
alarms are eliminated, reducing downtime
Industry 4.0, the transmitter also supports
from plant stoppages to investigate alarm
Offering a range of parameter values at a
PROFINET, EtherNet/IP and Modbus TCP
conditions. Additionally, verified leaks are
glance and automated calculations, the
protocols.
quickly detected, minimising any contami-
multiCELL helps to reduce installation
nation and water damage.
and operating costs, as well as optimising
Reducing downtime
maintenance interventions and expense.
The method of actually building the pro-
Simplifying installation
Together with industry expertise and ad-
cess skids and incorporating the water
When the time comes for installation and
vice on sensor selection and positioning,
quality monitoring system can also be
commissioning, the multiCELL delivers a
Bürkert offers a service that reduces costs
simplified. Bürkert’s Type 8619 multiCELL
number of savings. From the outset, the
and optimises production reliability.
is a multi-channel transmitter that can be
communications abilities significantly re-
pre-configured to individual specifica-
duce the amount of wiring that is required.
tions. Furthermore, its ability to handle six
Sensors only need to be connected to the
www.burkert.com
(or even more) sensor inputs such as pH, ORP, conductivity, flow, temperature, as well as level, pressure, turbidity, TOC and many more, means that one transmitter can handle the sensors from at least one process loop. The on-board mathematical functions (addition, subtraction, division, multiplication) are also giving additional value to many users, where today’s solutions can be very limited. These versatile functions help to define process sequences, detect sources of error at an early stage and make important comparisons in order to optimise processes. Also, system issues, such as leakages, are quickly detected, so process
A typical pure water loop monitored by MultiCELL
dpaonthenet.net 29
Supplement: Water
Dealing with changing
water demands I
n July 2020, the Met Office reported that most UK water companies have seen an increase in average water consumption during lockdown, especially those operating in suburban areas. It’s clear that COVID-19 measures around the world have resulted in societal changes that are directly impacting when and how much water people are consuming.
The totex-based approach for the water industry Firstly, it’s important to build an effective strategy. The totex (total expenditure) approach continues to reshape the water industry. This framework considers total cost throughout the life cycle of a project, allowing water com-
So, how do water companies prepare
The United Nations World Water Devel-
panies to be assessed against long-
for an unexpected surge or drop in de-
opment Report 2020 states that global
term outcome measures. In addition
mand? Here, Marek Lukaszczyk, Euro-
water usage has increased by a factor
to cutting costs, the framework looks
pean and Middle East Marketing Man-
of six over the past 100 years. Climate
to provide better value for consumers,
ager at WEG, explores three equipment
change is undoubtedly a longstanding
achieve better efficiency management
upgrades that water companies can
consideration for water management,
and operational efficiency. Predictabil-
make, which will increase their agility
but low rainfall, high population density
ity is therefore high on the optimisation
and efficiency.
and intensive agricultural or industrial
agenda, through close integration and
activity may also result in sustainability
collaboration with manufacturers at
issues – without throwing a global pan-
the design stage.
demic into the mix.
Cutting down wastage
30 dpaonthenet.net
Faced with these challenges and age-
Waste, in the form of unnecessary en-
ing infrastructure, the European water
ergy usage or pesky pipe leaks, can
industry is focusing on rejuvenating its
be a real problem, affecting a water
existing assets, building resilient sys-
company’s maximum output. Accord-
tems, and improving operational and en-
ing to the International Energy Agency,
ergy efficiency. So where should a water
a quarter of the electricity consumed
company start in implementing system
by the water sector is for wastewater
upgrades?
collection and treatment. For this rea-
Supplement: Water son, it is especially important that companies operating in this space consider investing in energy-efficient technologies. Reducing energy wastage not only offers environmental and cost-saving benefits, but also allows businesses to commit more resources to meet changing demands. Opting for an energy-efficient motor that conforms to IE4 and IE5 standards is a good place to start, but it’s also important to ensure that the motor is matched to the load. For example, at a water pump station in Surrey, UK, WEG supplied three 900kW W50 IE4 super premium efficiency motors with IP55 protection, operating at 96.9 percent efficiency. With new pump impellers, gearboxes, drives and the WEG motors, the facility was upgraded from its existing 400 megalitres per day capacity to 750 megalitres per day, with an efficiency increase from 80 to 86 percent.
Condition monitoring To ensure that motors are running optimally, water plant managers can retrofit sensors. By using smart technology such as Industrial Internet of Things (IIoT) data, water companies can monitor their assets
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and processes in real time, allowing them to ensure that their systems are performing optimally and respond quickly to unexpected events. A different kind of Interconnect Solutions Provider
Key metrics such as vibration and temperature changes can be early indicators of more serious system faults. This predictive maintenance approach reduces the risk of downtime and consumer disruption.
RF and Microwave Connectors, Adaptors and Cable Assemblies
www.intelliconnect.co.uk
Using a variable speed drive (VSD) Pumps consume a large proportion of the energy usage of electric motors. Upgrading to a VSD instead of a fixed speed motor allows
IntConn_CustomRF_Electronics.indd 1
19/05/2020 15
companies to account for varying process loads. A VSD can automatically control the speed of the motor and rapidly respond to the required demand. This also allows for a more efficient operation, instead of continually operating at a water flow designed for maximum demand of the system. Going one step further, companies can invest in sophisticated process control software, such as WEG’s Pump Genius. This built-in VSD software enables engineers to increase their process accuracy and protection, while offering system monitoring. The software allows one VSD to control up to five pumps, monitoring the operating hours and adding and subtracting pumps as demand changes. Automatic broken tify fluid leakage and adjust motor performance accordingly. To facilitate the successful implementation of equipment upgrades in the water industry, it’s important to have strong partner-
About the author:
ships with reliable equipment manufactur-
Marek Lukaszczyk is the European Marketing Manager at WEG. With over 20 years’ experience at the company, he leads the marketing campaign across Europe and the Middle East region.
intelligent design decision making can be achieved, which will give water companies of all types, added flexibility, better performance and superior cost savings. www.weg.net
To celebrate its anniversary, Connectivity brings you a special print version. It contains some of the best content published over the last two years, ranging from tutorials, case studies, technical articles, opinion pieces and industry focuses.
pipe detection in the VSD can also iden-
ers. By implementing the totex framework,
YOUR INDUSTRY 4.0 & IIOT GUIDE
dpaonthenet.net 31
Covering topics on Cybersecurity, Big Data, Predictive Maintenance, Robotics and much more, it gives readers a real insight into the Industry 4.0 and IIoT space and acts as an ideal guide to those starting on their Industry 4.0 journey.
To request your personal print copy please email paige.west@imlgroup.co.uk Or you can view the digital issue here: https://bit.ly/37uU8qB
Supplement: Water
Westermo helps Anglian Water upgrade its data network infrastructure M
ission-critical systems, such as water purification systems, require secure and reliable data networks to ensure that they perform efficiently, effectively and without interruption. At some of Anglian Water’s sites, there was automation equipment that was installed over 30 years ago. This was problematic, as it did not provide suitable infrastructure for the transition to modern IP-based communication networks.
Westermo helped to design the new data communications network
In the autumn of 2019, Anglian Water
network could continue to function using
select different paths for network traffic
wanted to upgrade the data networks
the 4G communications and a primary
and the VPN provides an added layer of
for one of its sites and enlisted the help
link could be added as they went, allow-
security for the network. This complex
of Westermo. The network connected
ing commissioning, testing and firewalls
setup required a clear understanding of
ten remote pumps back to a main wa-
to be implemented on a ‘per site’ basis.
the network structure to determine how
ter plant near King’s Lynn using a series
Once the single-pair high-speed digital
the data will be routed should there be a
of RS485 cables. One option was sim-
subscriber line (SHDSL) was operating,
failure at any point on the SHDSL.
ply to replace the existing ageing data
the Westermo Wolverine line extenders
communications equipment with similar
would automatically reconfigure the net-
To help the customer to commission the
devices, but that would not satisfy the
work to operate via the SHDSL.
network, Westermo provided supporting
requirement for network redundancy
documentation, which was produced
and modernisation. In addition, Anglian
The solution needed to be implemented
using Westermo’s WeConfig software
Water wanted to use the existing cables
within a tight schedule and start imme-
configuration tool. The report function of
to minimise the cost of the project and
diately without any issues. Collaboration
the software pulled together the whole
to implement a 4G network to provide
was key to understand properly the net-
network to present a clear overview,
communication redundancy.
work requirements. Most importantly,
providing confidence during testing and
the remote pumping stations needed to
commissioning stages. WeConfig also
remain fully operational during commis-
allowed a full backup of the whole site in
sioning.
one sweep, and a detailed overview of
Network design and installation phases Working with Anglian Water engineers,
physical connections.
Westermo designed a data network that
The network is predominantly construct-
utilised the existing multiplexer network
ed of Westermo WeOS devices, which
Each site required Anglian Water to in-
and RS-485 cables to provide a back-
are using the non-propriety Open Short-
stall new external antennas to provide
bone for Ethernet communication, and
est Path First (OSPF) routing protocol
it with suitable 4G coverage. Once the
added a new 4G cellular network to pro-
and support virtual private networks
4G network was available and operat-
vide redundancy. With this design, the
(VPN). OSPF provides a mechanism to
ing, this allowed the twisted pair cables
32 dpaonthenet.net
Supplement: Water to be updated one at a time. Once the
reuse many types of pre-existing copper
SHDSL links were commissioned, the
cables which can lead to considerable
network could reroute traffic via the
financial savings. All Wolverine devices
SHDSL backbone to Anglian Water’s
are powered by Westermo’s WeOS op-
central site.
erating system, which enables complex networking functions to be configured
Unexpected circumstances during commissioning
easily.
The 4G network was included in the
10 of Westermo’s MRD-455 routers
plan simply to provide redundancy, but
were installed, one at each site, to cre-
it offered an unexpected benefit. Dur-
ate the 4G network. As well as forming
ing commissioning of the network, the
the 4G network, the cellular routers pro-
COVID-19 pandemic hit the world. This
vide a gateway to the IP network, and
made it very difficult for support person-
a unique method for port forwarding to
nel to go on site safely and accelerated
allow remote support and monitoring.
the need for remote management to
Westermo’s MRD-455 4G router
monitor the sites.
A Westermo RedFox RFI-211-T3G industrial routing switch was installed at
of the firewalls was performed using
the central site, providing the necessary
Fortunately, the new network was de-
commands via the 4G communications
layer 3 functionality required for this type
signed and configured to enable remote
and was completed at the central site
of application. All the Westermo devices
access, using the 4G communications.
first to ensure that communication to
were delivered pre-configured to save
Originally this was to support network
all of the remote sites was working cor-
time and reduce project risk.
management tasks, but this also pro-
rectly, before rolling out a full secure net-
vided a method for engineers to con-
work. The remote sites were then added
Result
nect remotely to the network from within
one at a time to reduce risk. Implement-
Despite the challenges caused by the
the Anglian Water system to assist with
ing the firewalls was challenging for both
COVID-19 pandemic, Westermo was
any technical issues during and after
Anglian Water and Westermo, with every
able to develop a stable, secure and ul-
the network was configured. Westermo
command needing to be accurate.
tra-robust network with remote access
technical engineers were able to provide
support as an alternative to on-site sup-
support to the customer via this method,
Products used in application
port. This has ensured the network has
ensuring the network was up and run-
In total, 12 Wolverine DDW-142 and
operated smoothly without any interrup-
ning and all members of staff involved
DDW-225 line extenders were installed
tions. As a result of this successful net-
were safe.
to enable the existing cables to be re-
work upgrade, the local area can con-
used to create effective Ethernet net-
tinue to enjoy clean and uninterrupted
Monitoring the system
works over long distances to the re-
water supply every day.
In addition to designing the network and
mote sites. The Wolverines use SHDSL
configuring the network devices, West-
technology, which makes it possible to
www.Westermo.co.uk
ermo also configured the ability to monitor the 4G communications and SHDSL port status using Simple Network Management Protocol (SNMP). By monitoring the network, Anglian Water could determine if the connection was using the primary Ethernet backbone or 4G cellular network. This helps the company to understand if a fault has occurred on one of the SHDSL lines.
Additional support Once the network was in place and operating, firewalls were added. Due to the pandemic, it was not possible to have support on site when adding the firewalls, which meant remote support was the only option. Every firewall modification had to be carefully planned to ensure that support engineers were not locked out during testing. Configuration
Example of the redundant topology
dpaonthenet.net 33
Supplement: Water
Two pumps prove better than four in Anglian Water upgrade project R
eplacing four fixed-speed pumps with two variable speedcontrolled pumps has increased pumping capacity, improved reliability and significantly reduced noise for Anglian Water’s Kentford Moulton site, near Newmarket.
The four old pumps ran simultaneously, generating high noise levels and disturbing local residents. The two replacement pumps are run in a duty-standby configuration, meaning only one pump is typically running at a given time, significantly
Four 11kW line shaft-driven pumps, first
savings, as the ABB drives ensure that
reducing noise levels. The load is shared
installed in 1992, were running without
the pumps only operate at the speed re-
between the two pumps via switching,
any form of variable speed control. They
quired. Prior to the upgrade, the average
spreading wear between the pumps
have been replaced with two 45kW sub-
pump running time was 14 hours per
more equally.
mersible sewage pumps, the flow rate
day. Following the upgrade, the average
of which is controlled by two ABB water
run time was reduced to three hours per
The project was part of a large pump
drives.
day. This reduction in energy led to an
upgrade at the Kentford Moulton site
estimated £4,000 annual saving for An-
and carried out by ABB Value Provider,
glian Water.
Gibbons Engineering Group. The site
The upgrade increases pumping capacity and delivers substantial energy
needed to remain fully operational while the upgrade took place, so Gibbons connected the new VSDs to temporary pumps while the old pumps were replaced. This ensured that customers received no interruption in service. According to Mark Dorrell, Project Engineer at Anglian Water, maintenance requirements are substantially reduced. “In the previous configuration where we had four inefficient pumps running all the time, we were typically calling out the operations team four or five times a month for maintenance. Since the installation was completed, this has now dropped to zero.” “This project is a great example of how variable speed drives can help water companies achieve their AMP7 objectives,” says Matthew Gibbons for Gibbons Engineering Group. “Using a drive to control pump motor speeds is one of the best ways to improve energy efficiency, whilst reducing strain on pump components lowers the need for maintenance, building better resilience for the pumping station as a whole.” https://new.abb.com/uk https://gibbonsgroup.co.uk/
34 dpaonthenet.net
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