DPA_21_03

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

SEE PAGE 8

10: Motion control

24: Face mask detection

Trio Motion Technology: “Everything you need, nothing more”

Developing a deep learning face mask detection prototype in two days

Contents

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

Editorial Comment: 04: Remote working Remote working: The new normal?

Cover Story: 08: Driven track system

SEE PAGE 8

Hepco’s DTS on the front line against COVID-19 10: Motion control

24: Face mask detection

Trio Motion Technology: “Everything you need, nothing more”

Developing a deep learning face mask detection prototype in two days

Cover Story:

201016_9-6_Mill_DPA_UK_Snipe.indd 1

Drives & Motion Control 10/14/20 3:22 PM

HD Tech was tasked by a pharmaceutical company to create a production cell for assembling COVID-19 test kits. In need of a reliable solution quickly, HepcoMotion became the supplier of choice. p.8 (Cover image: HepcoMotion)

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.

Technology Focus: 10: Motion controllers

Trio Motion Technology: “Everything you need, nothing more”

12

12: Water-industry drives Jersey Water chooses Danfoss Drives for major upgrade

14: Drive controllers KEB F6 drive controllers allow for a cost-effective upgrade

16: Converters Matrix Converters on one of Europe’s largest network of escalators

General Feature: 18: Waterproof connectors Pisces corrosion and waterproof components for the oil & gas industries

20: VSDs & electric motors You don’t always get what you pay for – sometimes you get more

Rapid Prototyping & Simulation Special Report: 22: Post-production automation

14

Automating post-production to scale up additive manufacturing

24: Face mask detection Developing a deep learning face mask detection prototype in two days

27: Porosity Curing the porosity problem in additive manufacturing

30: High-precision drill caps 500 parts in two days: Airbus opts for 3D printing

Bearings, Belts & Chains Special Report: 32: Turntable bearings Bearings from Rodriguez prove first choice at Atlas Converting

34: Medical devices Thin section bearings boost medical device performance 10,000 Average net circulation Jan-Dec 2018

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

36: Simulation software Is industry ready for bearing simulation software?

38: Bullet train New-generation bullet train relies on NSK bearings

34 dpaonthenet.net 3

Editorial Comment

Remote working: The new normal?

I Sophia Bell, Assistant Editor

n March 2020, I joined the team at DPA as Assistant Editor. I had just two weeks in the office before, like many others, I was informed that I would need to work remotely for the next few months. Little did I know that, a year later, I would still be working from home with no immediate plans to return to the office!

conferencing platforms and webinars –

VR to host meetings, train new employ-

the number of employees able to work

ees using a virtual machine and tools, or

remotely has risen exponentially. As Dar-

allow multiple teams to collaborate on a

by reports, back in 2015, a survey of busi-

project from different locations.

ness owners by Virgin Media Business predicted that 60 percent of office-based

“Wearable devices can also improve col-

employees would regularly work from

laboration between factory workers and

home by 2022. This year, global disrup-

management staff who could work from

tion saw us prematurely exceed this fig-

home. For example, employers can ac-

ure, as businesses were forced to adapt

cess data from devices worn by factory

rapidly to new work practices to maintain

staff to visualise operations from their

productivity and their continued survival

homes and ensure that staff are produc-

in this tumultuous climate.

tive and safe. Factory employees can also use wearables and augmented re-

So, could remote working become ‘the

ality (AR) to access immediately real-time

new normal’?

data or information that can help them complete tasks, such as machine mainte-

Remote working certainly offers many

nance, accurately and quickly.”

An article from Alex Darby, Head of Peo-

benefits – including the ability to achieve

ple at EU Automation, recently passed

a better work-life balance, improved pro-

Whilst remote working is not feasible

my desk which provided useful insight

ductivity, flexible work practices and, of

for everyone, and it seems unlikely that

into what can we learn from the disrup-

course, the added convenience of not

physical workspaces will become obso-

tion triggered by COVID-19, and how we

having to commute.

lete any time soon, it’s clear that manu-

can apply it to our future working environment.

facturers will, and should, continue in this For the manufacturing sector in particu-

unprecedented shift towards increased

lar, working from home is not necessarily

digitalisation and adoption of new tech-

If this pandemic had taken place twenty,

practicable in the long term, due to the

nology. It’s time for industry to cast off old

or even ten years ago, it is hard to im-

need for factory workers to complete

and outdated work practices and usher

agine that the majority of people would

physical tasks using machinery that can-

in a new era of working that will see in-

have had the ability, or the resources, to

not leave the facility.

creased productivity, efficiency and flex-

work from home successfully. Yet, thanks to modern technology – including video

4 dpaonthenet.net

ibility.

However, Darby argues, “while a factory worker cannot complete all their tasks

Do let us know what you think of the issue

over a video conference service, facilities

and if there are any specific topics you

managers can invest in technology to in-

think we should be covering. Email me at

crease flexibility. Manufacturers could use

sophia.bell@imlgroup.co.uk.

Connect with us on LinkedIn. Join us on Twitter. Follow us on Instagram.

GFX AND XTS THE LATEST DEVELOPMENTS Join our industry experts from Hepco and Beckhoff to explore the latest collaborative developments aimed at expanding the market-leading capabilities of the GFX guidance system for the XTS transport system.

Find out more about the latest developments including hygienic systems, the new track management (lane switching) system, developments for high speed agile movers and systems for heavier loads.

25th March @ 15.00 BST 1 hour

Language: English

CLICK HERE TO SIGN UP

binder

M16 connectors - The perfect solution for applications that need high pin counts

F

rom its early beginnings in the audio industry more than 50 years ago – in fact the M16 connector was the first connector system binder manufactured - today’s M16 connector is very much a “go to” connector solution for a huge variety of indoor applications. Thanks mainly to continuous development and refinement, the M16 connector is now the ideal choice for specifiers looking for a cost effective, robust screw locking connector that can accommodate as many as 24 contacts - with or without EMI shielding.

comprehensive when it comes to the panel

Data transmission up to 10Gbits/s

receptacles with front or rear fastening as

One of the latest additions to binder’s M16

standard for solder bucket versions and

offering is an X – coded connector capable

front-fastening for dip solder and pre-termi-

of handling the data speeds demanded by

nated flexible PCBs.

today’s sensor-based automated production

are available and the options are as equally

facilities. Data transmission figures are up to This connector style, along with the ben-

an impressive 10Gbits/s.

efits of rugged design with good environM16 connectors were originally designed

mental resistance, have seen the M16

The combination of a high pin count with the

to meet the requirements of Deutsches

become widely used in instrumentation,

compact size of nominally 18.5mm diameter

Institut für Normung (German Institute for

measurement and sensors for indoor use

and 60mm in length means M16 connectors

Standardisation) that defined the standard

where there is a need for a higher pin count

offer an excellent alternative to more expensive

for circular connectors for analogue audio

than is offered by M8 and M12 sensor con-

connector systems. Special short versions

signals. These were used widely for many

nectors. Other applications include pneu-

and right-angled versions with a height of only

years and commonly known throughout the

matic controls, gas and pressure meas-

37mm mean M16 can be used in applications

audio industry and to the consumer as DIN

urement, torque sensors and motor speed

where space is very tight.

connectors.

regulators.

M16 connectors accommodate cables rang-

High pin count and protection up to IP68

Suitable for 5G roll out

ing from 4.0 to 10mm diameter, are rated to

The latest applications for M16 connec-

250V and can withstand an impulse voltage

“Although still available in its original un-

tors include the impending roll-out of 5G

up to 1500V, with current handling of up to 7A

shielded IP40 DIN formats, the latest M16

networks where binder’s ASIG-compliant

(at 40ºC). With increasing requirements from

connectors are far removed from the early

connectors are designed to provide high in-

equipment manufacturers for shielding against

audio versions”. says Sascha Döbel, bind-

ternational protection for selected outdoor

EMI more applications now require shielded

er’s Product Manager for M16 connector

installations. The AISG (Antenna Interface

cable systems with the requirement for connec-

systems. “Driven by market demands for

Standards Group) defines standards for the

tors with good shielding characteristics. For op-

lower contact resistance, higher pin count

control and monitoring of antenna line de-

timum results 360º shielding is required and this

and improved levels of protection, today’s

vices in the wireless industry.

is achieved by integral shielding rings, providing

M16 connectors are capable of accommo-

a high attenuation over a large frequency band.

dating between two and 24 contacts. They

binder’s Series 423 and 723 M16 connec-

are mainly housed in metal bodies, with or

tors, for example, are available in 8-pin DIN

To sum up binder’s M16 product offering,

without shielding from electromechanical

variants, of which four to five contacts are

Sascha Döbel comments “At binder we have

interference (EMI) and providing interna-

used. The products are AISG C485 com-

found that the flexibility provided by our com-

tional protection up to IP67 or IP68 for cer-

pliant and available as male and female

prehensive range of M16 connectors with the

tain versions”. Adds Sascha Döbel.

shielded cable and panel mount connec-

seemingly endless options at relatively low

tors .The connectors, which can be used

cost compared to other connector systems,

Versatility of application is assured as a

for all wireless networks, meet the require-

has led to its popularity continually increasing

range of alternatives are available for ca-

ments for protection class IP68 when con-

and its application range has extended re-

ble mounting with straight or right-angled

nected, offering maximum reliability even

markably from the humble 1960s microphone

connectors terminated by soldering, with

under extreme external conditions.

to the latest communications and security sys-

screws and crimp. Pre-moulded cables

6 dpaonthenet.net

tems that touch us all.”

M16 FAMILY

Screw Solder Crimp With single wires Data Transmission up to 10 Gbit/s

www.binder-connector.co.uk

Cover Story: Driven track system

Few of us could have anticipated the impact that Covid-19 would have on our lives when it was first reported at the end of 2019.

While vaccination programmes start to be rolled out across nations, testing will continue to be important in fighting the pandemic. South Korea has received international praise for the nation’s response to the pandemic – a quick roll out of large scale testing was an important part of the strategy. To become a reality, it was necessary that Korean pharmaceutical manufacturers quickly adapted to the demand for testing kits that the policy entailed. Machine Builder HD Tech was tasked by one of the leading pharmaceutical companies in South Korea to create a production cell for

assembling Covid-19 test kits.

In need of a reliable solution quickly, HepcoMotion, a British manufacturer of high quality linear transport and positioning systems, became the supplier of choice.

Efficiency is key HD Tech chose HepcoMotion´s ready-to-fit driven track system (DTS) as the transport and positioning system; this reliable system has been used for years across all industries.

In many applications it offers an economic and efficient alternative to turntable and linear indexing

Production cell assembling Covid-19 test kits, featuring HepcoMotion’s DTS track system.

8 dpaonthenet.net

systems. As the DTS comes as a complete package; including drive, rails, bearings, carriage plates and all other components, it reduces design and build time,

offering a significant advantage when time to market is so crucial. The “classic” DTS can reach up to 1m/s and is perfect for light to medium loads. This DTS version can be specified to include a trip latch mechanism that disengages and prevents damage in the event of system overload. The Korean manufacturer also required a positional accuracy of +/- 15 Microns at the different workstations. To accommodate this, the company opted to include the optional carriage locking system for the DTS, which aligns carriages to a repeatable position anywhere along any straight section of the circuit to +/- 0.05 mm.

Cover Story: Driven track system In this application, each production cell comprises of a 1.5m long, oval DTS. Each DTS accommodates 18 carriages with a pitch of 200mm. They are rigid and made to suit the larger, rectangular nest needed to accommodate 10 testing kits.

The total payload amounts to two kilos.

Eight workstations, mounted along each straight edge of the system are needed for the entire assembly process, starting from loading the bottom plastic base of the test kit, to finally unloading the

mounted test kit. The use of both long sides of the DTS as a complete assembly line effectively doubles the output per system.

This is made possible thanks to the large internal space of the DTS, which can accommodate workstation components, such as robotic arms. This efficient use of space also minimises the overall footprint of the cell, allowing more machines in the space available at the pharmaceutical company,

An assembled Covid-19 test kit produced by HD Tech.

further increasing vital output.

Reliability 24/7 To meet demand, each system is in operation 24 hours a day, 7 days per week, producing 5,000 kits per day.

With a requirement for minimum maintenance, this demand could provide a challenge for most systems.

The DTS, however, relies on HepcoMotion’s V guide technology that is inherently low maintenance. The V guide technology functions on the basis of tight geometrical control over matching slide and bearing V’s.

In turn this provides a wiping action that expels debris, keeping machines running and reliable.

In addition, V guide technology encompasses hardened V edges on both track and the bearing to ensure a longer system life. If wear does occur, HepcoMotion bearings feature eccentric adjustment, meaning they can

be quickly adjusted against the track, preventing costly downtime required to replace the entire system – as would be the case in systems using recirculating ball bearings. Built in bleed lubrication means there is optimal and constant lubrication to the running surfaces, again contributing to longer system life, as well as removing the need to halt vital production for regular lubrication intervals.

Bottom line Thanks to Hepco’s 50 years of experience and expertise in the field of linear motion and transfer technology, the UK based company were able to meet the demanding production schedules of this application.

Outside of Korea, Hepco’s high speed transfer products have also been a ‘go to’ solution for test kit production and general testing applications. At a time when many large pharmaceutical companies are under pressure to produce reliable, low maintenance machines quickly, Hepco’s trusted technology and reputation for outstanding performance is proving critical in the fight against the pandemic.

To meet demand, each system is in operation 24 hours a day, 7 days per week, producing 5,000 kits per day.

dpaonthenet.net 9

Feature: Motion controllers

Trio Motion Technology: “Everything you need, nothing more” D

PA speaks with Tom Alexander, President of Trio Motion Technology, and Dave Greensmith, Product Manager, about the expansion of its motion controller range, business during the COVID-19 pandemic, and the importance of the UK market.

and commissioning for OEMs in industries such as packaging, medical, metal, CNC, robotics and 3C. The DX4 servo drive operates at 200V AC and its power extends from 50W to 3kW.

Trio is a specialised provider of high-per-

is in China, where the company’s motion

formance motion control technology,

control capability has enabled Estun to

But why launch a new product now?

encompassing the systems involved in

become a major player in the country’s

Well, as Tom Alexander notes, “People

moving parts of machines, robots and

automation market.

have had a lot of time to look and reflect on

motors in a precise and controlled man-

new ways of doing things over the last few

ner. The main components involved typ-

Trio also has a dedicated in-house re-

months”, and this is the type of solution for

ically include a motion controller, drives

search & development team that designs

which customers have been asking.

and motors, or actuators.

controls as solutions for customer applications.

Trio has been manufacturing high-quality

Businesses have increased their adoption of automation products and solutions during the COVID-19 pandemic – and

a comprehensive range that allows eco-

A plug-and-play motion solution

nomical, flexible and seamless control of

Trio has recently expanded on its motion

down! Alexander continues, “People didn’t

one to 128 axes of servo motors, stepper

controller range – which the company

tend to spend money on automation be-

motors, piezo motors and hydraulic sys-

brands ‘Motion Coordinators’ – with the

cause they couldn’t afford it. Now, they’re

tems.

launch of a servo drive and motor pack-

thinking about it because it provides them

age.

with some throughput they can guarantee

motion controllers since 1987, and has

With offices in Tewkesbury (UK), Pitts-

it doesn’t look like they’re going to slow

and protect, and it means they can reduce

burgh (USA), Pune (India) and Shanghai

The launch of the new DX4 servo drive

(China), Trio supplies its entire product

and MX servo motor series expands Trio’s

staff exposure.”

range worldwide via a network of fully

machine solution and makes it faster and

Also, Trio has something unique to of-

supported distributors.

easier for OEMs to utilise the high-perfor-

fer: good integration and simple ways

mance motion control available from Trio’s

of getting your motion going. Alexander

In 2017, Trio was acquired by the Estun

range of Motion Coordinators. The DX4

believes that this will make the company

Group, which is supporting Trio in its

servo drive has plug-and-play compati-

more competitive with the big players in

growth. Trio has exceeded 15 percent

bility with Trio’s controllers and slice I/O

the market: “People are always looking for

growth year on year since the acquisition.

systems, all programmed within a single

good value and one of the things Trio can

In addition to the primary global markets,

software, Motion Perfect 5. This increas-

guarantee is products of significant value

a significant proportion of Trio’s business

es the speed of application development

at a good price.”

10 dpaonthenet.net

Feature: Motion controllers “Everything you need, nothing more”

established and those new to the organ-

About the authors:

isation, have a great deal of experience

“Everything you need, nothing more”: This

– with regard to UK OEMs’ needs and

is the ethos of design for Trio. The idea is

ways of working.

Tom Alexander, President, Trio Motion Technology With over 30 years in the automation industry, Tom Alexander is now Trio’s President, after previously leading the company’s global business development. Tom is also Chief Strategy Officer for Motion Control at Trio’s parent company, Estun. Formerly, Tom was Vice of President of Technology at the Emerson business and drives manufacturer, Control Techniques, a role he held for over 10 years. Latterly, Tom moved to the position of Vice President Business Development, using this experience to manage Trio’s strategy and international sales. Tom holds a BEng degree in Electrical and Electronic Engineering from Staffordshire University.

to look at the design of the product and simplify it as much as you can – basical-

At the same time, awareness of the Trio

ly taking out anything that can be added

brand is, in many ways, greater in interna-

centrally. This maximises functionality and

tional markets such as the USA, Italy and

saves cost. When it comes to Trio’s new

China. In the case of China, Trio’s promi-

DX4 servo drive, the company has removed

nence was the reason for Estun’s original

all functionality that is already included in its

interest in the motion technology special-

motion controllers.

ist, where its motion controllers are still sold carrying only the Trio logo, despite

Trio’s motion control solutions are scalable

the power of China’s home brand. Now,

and additional functionality can be quickly

with Trio’s new capability as a machine

added when required. Flexslice I/O mod-

solution provider, the brand has a new

ules, covering a broad range of control

opportunity with UK OEMs looking for a

functionality, are easily clicked into place

motion-first machine solution.

David Greensmith, Director of Product Management, Trio Motion Technology Product managing motion and servo drive systems, David has over 30 years’ experience in the automation industry, specialising in motion control technology. As a Technical Manager at HMK Technical Services (focusing on motion solutions), David moved to Baldor as International Business Development for motion control products. Latterly, David headed ABB’s Product Management & Marketing for servo motion control products, before taking his experience to Trio in 2020. David holds a BEng degree in Electrical & Electronic Engineering from Staffordshire University.

using Motion Perfect and Trio’s program-

and programmed through Motion Perfect 5.

ming language.

The Motion Perfect 5 software is available

Training

free of charge, and the competitively priced

The current situation regarding the world-

The course is based upon practical

Motion Coordinators mean that Trio offers

wide spread of coronavirus has been a

worked examples of each topic, to ena-

the lowest cost-per-axis motion control at

challenge for most. To help its customers

ble the attendees to gain some valuable

64 axes.

during this period, Trio has created a set

hands-on experience of using Motion

of videos taken during the last training

Perfect to develop applications.

Focusing on Trio’s new servo drive and

course held in the UK.

motor package, absolute encoders elimi-

These videos are free to view here:

nate homing cycles, autotuning is simple

The 18 videos are designed to provide an

http://www.triomotion.uk/public/

and effective, and Safe Torque Off (STO)

overview of the Motion Coordinator prod-

support/training.php

minimises downtime. Scalable functionality

uct range and to introduce programming,

has been designed for cost-effectiveness; this means there is no keypad or complex display, and the OEM only pays for the capabilities they need.

Trio designs and manufactures its own motors, which means that it can optimise the motor speed torque characteristics, and therefore the current and voltage characteristics, to match the drives – squeezing out the maximum performance.

How important is the UK market?

Firstly, it’s the company’s ‘home market’ of which Trio’s engineers, both those

Stocked metallic industrial enclosures Environmental sealing up to IP68

Learn more: hammfg.com/uk-ind uksales@hammfg.com • 01256 812812

IP66 EJSS Stainless Steel

IP68 1590Z Aluminium

Feature: Water-industry drives

Jersey Water chooses Danfoss Drives for major upgrade F

or a recent major upgrade to its La Rosière desalination plant, Jersey Water chose VLT AQUA Drives from Danfoss. The principal reasons for choosing these versatile drives, which provide dedicated water-industry functionality, are excellent harmonic performance, high efficiency, compact construction, proven reliability, value for money, and the availability of versions for operation from 690V supplies.

The current desalination plant is the sec-

was that the drives should produce the

was made available by this. The inherent-

ond on the La Rosière site, which is in the

lowest possible level of harmonics in the

ly compact construction of the VLT AQUA

south-west corner of Jersey, the largest of

supply system. From my own experience,

Drives was an important benefit in achiev-

the Channel Islands. It was opened in 1999

I was confident that the Danfoss drives

ing this and further space was saved by us-

as a replacement for an earlier distillation

would meet this requirement – over the

ing IP54 versions of the drives which require

plant that had reached the end of its life. Af-

many years I’ve worked with them, I have

no additional enclosure for protection.

ter the new plant had been in service for al-

never had a problem with harmonics. In

most two decades, the ever-growing need

contrast, with drives from some other sup-

Although the VLT AQUA Drives offer ex-

for water on the island, due to population

pliers, distortion of the electrical supply has

cellent harmonic performance without

growth and climate change, led to the de-

been evident by its effect on nearby instru-

the need for external filters, Jersey Water

cision to undertake a major upgrade. This

mentation and computer equipment.”

decided that, because minimal harmonic

would increase the plant’s capacity from 6

generation was such an important require-

Ml/day to 10.8 Ml/day, which is sufficient to

The largest of the new drives were required

ment for this project, it would still be de-

meet around half of the island’s daily de-

to control two high-pressure pumps with

sirable to install filters as a precautionary

mand for water.

600kW motors operating at 690V, which

measure. Accordingly, Danfoss supplied

are fed from a custom 11kV/690V trans-

active harmonic filters for use with the larg-

The upgrade involved the installation of a

former. For these, 630kW VLT AQUA Drives

est drives.

large number of new pumps, almost all of

were chosen.

which would need to be controlled by AC

“We are very happy with the Danfoss

variable speed drives. After investigating

Other drives for the project operate from

products, as well as with the service and

the available options and going through

400V supplies and include three with

support the company has provided,” said

a competitive tendering process, Jersey

160kW ratings, as well as nine with ratings

Malcolm Berridge. “In particular, com-

Water decided that the Danfoss VLT AQUA

between 55kW and 18.5kW. For all these

missioning the new drives was fast and

Drives were the most suitable choice on

applications, VLT AQUA Drives were used.

straightforward, thanks to the intuitive user

both technical and commercial grounds.

In addition, Danfoss supplied two 110kW

interface and the dedicated pump func-

Accordingly, these drives were specified

VLT MCD-series energy-saving soft start

tionality provided by the VLT AQUA series.

for all applications related to the upgrade

units for the seawater-intake submersible

The upgraded plant has now been in ser-

project.

pumps. Because these drives and soft

vice for many months, and the drives have

starts would be used close to the sea, print-

fully lived up to expectations in terms of

“We have been using AC variable speed

ed circuit boards were specified to provide

performance and reliability. They are also

drives from Danfoss for many years, and

additional protection against corrosion.

making a big contribution to the enhanced

we have always been happy with their

energy efficiency of the plant, which has

performance and reliability,” said Malcolm

As part of the project, an existing motor

increased by between 36 percent and 38

Berridge, Chief Engineer & Water Supply

control centre was decommissioned and

percent since the upgrade.”

Manager for Jersey Water. “One of the ma-

removed, and it was essential that the new

jor requirements for this project, however,

drives should fit into the limited space that

12 dpaonthenet.net

https://www.danfoss.com/

 HMI Enclosure & Support Arm Systems  Front Sheet Customisation Available  Full Factory Support

sales@lamonde.com www.lamonde.com +44 (0)20 3026 2670

 Short Lead Time  Great Style, Price & Function

Lamonde Automation Limited Quality Products: Expert Advice

Feature: Drive controllers The COMBIVERT F6 range of drive controllers from KEB Automation

KEB F6 drive controllers allow costeffective upgrade of high-bay warehouse storage & retrieval machine

K

EB Automation has helped a customer in Germany to convert its high-bay warehouse storage and retrieval machine from oldgeneration frequency inverters to the new COMBIVERT F6 drive controller from KEB. The warehouse is owned and operated by a mail order business that was looking for a modern, costeffective retrofit solution that would not require the existing motors to be replaced.

other competitors also submitted bids

in automated, safety-oriented machines.

for their products, but the statements

The drives provide optimal motor con-

from them were always the same: ‘we

trol in real time, as well as integrated

cannot work with your existing motors’.

safety functionality. The drive controllers

At KEB, this was not an issue at all from

are 100 percent in-house designed and

the start. They said it didn’t matter what

built by KEB Automation. The drives are

kind of motor was there, we can run all

available in seven different enclosure

motors with our COMBIVERT F6.”

sizes and power ranges from 4kW up to 400kW.

With the COMBIVERT F6, users can operate KEB’s own motors as well as a

The drives are air- or liquid-cooled (inte-

variety of other motor types from differ-

gral or push-through mounting) and can

ent manufacturers. “That’s how it turned

be customised with a variety of design

out. It was very easy to get the existing

options to suit the specific application.

motors working with the inverters, us-

Safety functionality can be selected in

ing automatic calibration. The aim was

modules to suit the requirements of the

The high-bay warehouse currently com-

to replace only the frequency inverters,

machine. In addition to the control of

prises nine aisles. Each aisle has 106

from the COMBIVERT F4 series to the

widely supported motor types (such as

positions along its length (on both sides

F6,” adds Jorg Buchwald-Hörnchen.

synchronous, asynchronous, permanent

of the aisle) and 28 positions in height

magnet, synchronous reluctance, linear,

Optimal motor control

high-torque motor and high-speed mo-

The COMBIVERT F6 high-performance

tor), the COMBIVERT F6 offers addition-

Jorg Buchwald-Hörnchen, PLC Techni-

single-axis drive controllers are extreme-

al functions such as automatic anti-cog-

cian at the warehouse, comments: “The

ly compact, energy efficient and flexible

ging and optimised torque pre-control

main focus was on costs. Of course,

for a wide variety of control applications

for linear and non-linear kinematics.

(on both sides).

14 dpaonthenet.net

Feature: Drive controllers Futureproof storage and retrieval system

cessful very quickly and it all worked

KEB Automation’s regional industrial

the hardware installation.”

well. Vogul-Hemer supported us in

partner, Vogel-Hemer, assisted the customer by installing the new hard-

He continues, “With KEB’s complete

ware in the warehouse, including the

know-how about frequency inverters

F6 drive controller, S6 servo drive and

and the interface to our control sys-

a C6 industrial PC. Manfred Vogel

tem, I was then able to completely

explains, “Using modern drives here

reprogram the storage and retrieval

is a win-win situation. It is also clear-

machine, so that we could restore the

ly noticeable in the wallet. For many

interface and now work on a Profibus

customers, loss of time is very deci-

system.”

sive. Operational safety was also a concern for the customer. The system

Integral safety functionality is also

must run 24/7. The bottom line is that

important to the customer. “As we

the solution must fit the customer. I

have already equipped the F6 drive

think we’ve done an optimal job here.

controllers with the latest safety tech-

The project proceeded without inter-

nology, we intend to use this in the

ruption, everything worked perfectly.”

future. We have therefore installed the safety module level three, so that

Jorg Buchwald-Hörnchen says, “We

we can also use the ‘safe speed’

also work with an interface from KEB,

and ‘safe brake control’ safety func-

the C6 – a small industrial PC. This

tions in the future,” says Jorg Buch-

quickly proved to be cost-neutral. We

wald-Hörnchen.

then simply started a test at our desk to see whether we could connect the

For more information on the F6 range

new drive controller to our existing

of drive controllers from KEB, please

control system. This was also suc-

visit www.keb.co.uk

The high-bay warehouse is owned and operated by a mail order business that was looking for a modern, cost-effective retrofit solution

PRECISION MOTION CONTROL As an advanced motion control technology distributor and manufacturer, Mclennan supplies and fully supports a wide range of precision motion control components from its distribution partners - and also has the capability to combine these products with its own design and build service for bespoke and turn-key motion sub-systems - for applications across industry and research.

CUSTOM ENGINEERED MOTION SYSTEMS ExpoPharma’s Process Analytical Technology (PAT) powder-stream conditioning chute is a full-scale development platform for characterising analytical sensors for use in continuous pharma manufacturing processes.

Mclennan worked with ExpoPharma to supply an Ethernet-based threeaxis micropositioning motion sub-system as a Modbus TCP protocol network segment. The system includes integrated microstepping motors with built-in motion controls, precision planetary gear units, an HMI and a temperature controller.

The motors microposition special ‘wheels or flipper-shaped’ end-effectors that are designed to collect sample material from the powder stream for analysis by various imaging tools and spectroscopic equipment.

Servo motors & drives Stepper motors & drives Synchronous AC motors

As part of the Mclennan supplied system, the pre-programmed HMI selects individual motion sequences stored in the each intelligent drive with corresponding end-effector temperature settings and communicates the positional and temperature information via the Modbus TCP protocol network to a higher level controller.

Feedback devices Gearboxes Motion controllers & software Mechanical components Custom engineered motion systems

sales@mclennan.co.uk

Call us or visit our website for more information

www.mclennan.co.uk

+44 (0)1252 531444

Feature: Converters

More ups than downs using Matrix Converters on one of Europe’s largest network of escalators O

perating Germany’s largest escalator network in Munich, which transports over half a billion people through the Bavarian capital’s subway system every year, means the scale of any technical innovations can be immense.

el of reliability is extremely important and

pendent escalator control system, which

it’s also strategically significant. It’s not

it developed itself. This means each esca-

just a question of addressing the passen-

lator can be maintained by in-house per-

ger’s needs for comfort and convenience,

sonnel, faults can be rectified faster and

it’s also an important operational matter

costs for spare parts and conversions are

because without the escalators, the pas-

minimised.

sengers cannot enter and exit the stations at the required speeds.”

Exploring the benefits of inverter drives

Innovation and in-house control optimises reliability

MVG has been using inverter drives since

reliability, any technical change can bring significant savings, or additional costs.

With exacting demands in terms of safety

trol system. The benefits over conven-

Consequently, the technicians in charge

and reliability, and the need to maintain

tional drives quickly became apparent in

take great care when making decisions.

hundreds of escalators, any technical

everyday operation on upward escalators.

That’s why they opted for the gradual

change has significant implications, so

The inverter control enables variable start-

deployment of Yaskawa’s U1000 Matrix

the escalator engineers are meticulous in

up and stopping, which not only means

Converters.

assessing any new optimisation oppor-

better comfort for the users, but also pro-

tunities. The reality is that it’s an ongoing

tects the mechanisms. However, MVG

Under the motto ‘Simply Mobile’, the

process of modernisation in an environ-

had been searching for a suitable solution

network operators Münchner Verkehrs-

ment that is highly resistant to standard-

for downward escalators. While many

gesellschaft (MVG), a subsidiary of

isation because, after all, the service life

systems work with conventional braking

Stadtwerke Munchen (SWM), deploys

of an escalator is around 30 years. At any

resistors, the resulting waste heat has

trains and buses in subway and tram

one time, multiple generations and mod-

to be dissipated safely. The motor wind-

stations. It also has 770 escalators, com-

els from different manufacturers are in use

ings can also serve as ‘braking resistors’,

pared with around 450 currently operating

across the network, while the individual

converting energy into heat, but only to a

on the entire London Underground.

spatial conditions are equally diverse.

limited extent and not continually. It would

Mario Princip, Head of the MVG, has to

MVG tackles this challenge by drawing

er drive with an additional regenerative

ensure that the system operates around

on its own powers of innovation, with one

unit, but this is not feasible due to limited

the clock without interruption: “A high lev-

example being the manufacturer-inde-

space in escalator control cabinets.

With exacting demands for safety and

before the development of the new con-

also be possible to supplement an invert-

16 dpaonthenet.net

Feature: Converters The solution Eventually, a solution was found in the technology that is still rarely used in low-voltage applications – a matrix converter that combines the inverter and regenerative unit in a single device. In the spring of 2016, MVG tested the capability of the few market-ready options

SMART AND DIGITAL AUTOMATION SMART AND DIGITAL AUTOMATION

available, using its own simulator. Among the specific escalator requirements was a flying start function to ensure synchronised startup after automatic deactivation, and all electrical components have to operate year-round at outside temperatures. Yaskawa’s U1000 was one of the units tested and, as far as MVG were concerned, it ticked all the boxes. First introduced by Yaskawa in 2014, the U1000 matrix converter is a highly efficient, regenerative direct inverter for powering induction and permanent magnet machines, with or without speed sensors.

Today, the range covers a wide power range of 2.2 to 500kW, and is capable of direct regeneration and doesn’t require any DC bus capacitors. No space is needed for an additional regenerative unit and, like all Yaskawa 1000 Series drives, the U1000 is designed for 10 years of maintenance-free, continuous operation.

Application-specific benefits The regenerative energy that can be fed back into the system to meet other needs in the building, such as lighting, can be a significant benefit. However, this was not the main reason that prompted MVG to select the U1000 for its escalator application. More importantly, the

SPECIALISING IN SOLUTIONS SPECIALISING IN SOLUTIONS

U1000 removed the need for regenerative resistors, greatly simplifying the cooling or ventilation of the system. Another advantage of the Yaskawa system was the upkeep of the grid quality during regeneration. The line currents during operation of the U1000 are nearly sinusoidal in both motor and regenerative mode, and harmonics are reduced to a minimum. Whilst this reduces losses in network components, such as transformers, cables and lines, it improves the efficiency of the whole system. Furthermore, this significantly reduces

Packaging Machinery Packaging Machinery

Theatre Systems Theatre Systems

Metall Processing Metall Processing

Textile Machinery Textile Machinery

Process Engineering Process Engineering

Lift & Escalators Lift & Escalators

Intralogistics Intralogistics

Plastics Machinery Plastics Machinery

Wood Working

Wind Power

e-mobility

Automotive

Wood Working

Wind Power

e-mobility

Automotive

potential interference with other system components which, in turn, helps to prevent failures and subsequently removes the need for complicated procedures and the unavoidable downtimes associated with identifying the cause.

The U1000 already features an integrated EMC filter, removing the need for external components such as DC reactors or LC filters. Nevertheless, the space requirements are still up to 50 percent, with conventional integrated solutions with sinusoidal input and regeneration.

It also features a built-in SIL3 STO input to allow for high machine safety requirements, and Yaskawa also offers options for all common fieldbuses, making connection to EtherCAT, Powerlink, Profinet, Profibus, Ethernet IP and other systems extremely straightforward.

The future Following testing of the latest U1000 matrix converters at new subway station locations where space is even more limited, the converters have been duct mounted on the side wall of control cabinets, meaning the cooling module is on the outside. The device is connected to the MVG control system, so that the current operation status can be monitored in real time, providing reliable test data at all times.

More information at: https://bit.ly/3ax24Lo

dpaonthenet.net 17

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

Feature: Waterproof connectors

Pisces corrosion and waterproof components for the oil and gas industries

I

ntelliconnect (Europe) Ltd has provided a new design of rugged corrosion and waterproof connectors to a UK start-up company, who manufactures a unique system for remote monitoring the wall thickness of pipelines used in the petrochemical, oil and gas industries.

a wide range of environments – in oil

• A custom connector quadraxial (4-

refineries or on pipelines, from desert

way) design needed to be aesthetical-

to near arctic conditions. The system

ly similar to the TNC adaptor design,

needed to be waterproof and capable

with the ability to ensure that the cor-

of withstanding ingress of liquids sand

rect device was fitted to the correct

and dust. A range of waterproof TNC/

TNC bulkhead adaptor.

MCX bulkhead mount adaptors, waterproof TNC plug connectors and water-

Solutions

proof quadraxial (4-way for signal and

This project was a development from

data lines) connectors were required

existing TNC/MCX adaptors, plus a new

– all of which would have to be ATEX

design of quadraxial connector. Stand-

approved by the customer. There were

ard and reverse polarity designs en-

The end system uses discrete RF

also a number of internal cable assem-

sured that incorrect device connection

modules that are directly connected

blies requiring ATEX approval, which

could be eliminated, and the materials

to specific points on an installation, to

called for a careful selection of heat

data and samples were submitted to

provide remotely managed continuous

shrink sleeves.

undergo ATEX approval testing.

line wall thickness. Traditionally, this

Challenges

The adaptors were waterproof at the

activity is carried out manually, with

The project faced the following chal-

bulkhead and were sealed internally to

inspection staff regularly having to ac-

lenges:

prevent moisture ingress through the

cess the relevant areas over a complete

• An outdoor environment with an oper-

internal connector components when

installation or site. This can be a very

ating temperature of up to 200ºC, for

costly, time-consuming and potentially

an ultrasonic thermocouple tempera-

measurement and monitoring of pipe-

error-prone procedure.

ture unit

unmated.

A mating TNC plug connector, sealed to

• It needed to be waterproof to IP68, im-

IP68 rating, was specially developed and

Brief

pervious to liquid, sand and dust, and

assembled, with a 200ºC rated cable

The measuring equipment is designed

capable of meeting ATEX approval

(approved by the customer) designed to

to be installed indoors or outdoors in

(material selection, cable assemblies)

meet the specific requirements.

18 dpaonthenet.net

Feature: Waterproof connectors A custom-designed 4-way mated pair of connectors were designed, developed and prototyped to be submitted for customer approval and qualification. The design in ATEX-approved materials required a specially designed alignment feature to ensure the successful mating of the four contacts, whilst still providing an IP68sealed connector.

Summary With the end customer’s product qualification finalised and certified, the measuring system entered the marketplace after a relatively long development cycle, caused mainly by the launch of the new manufacturing company.

The Intelliconnect TNC/MCX adaptors (standard and reverse polarity) are now

About the author: Roy Phillips, Founder and Managing Director of Intelliconnect (Europe) Ltd, has been involved in the RF and Microwave interconnect sector for almost 40 years. His extensive portfolio of industry experience includes Greenpar, Radiall and Midwest Microwave (now Cinch).

He founded Intelliconnect in the UK in 2003 and in the USA in 2005.

firmly established as a standard production Pisces adaptor. Similarly, the mating half TNC plug connector is now in full production and is a standard item in the Pisces waterproof connector range.

The 4-way connectors are housed in an identical TNC adaptor body and are currently in production and available for other applications.

The same IP68 rating applies, ensuring that the connectors are sealed in their unmated condition, as well as when connected to the bulkhead panel.

Intelliconnect (Europe) Ltd. is the largest UK-based manufacturer of RF, microwave, waterproof and cryogenic connectors and cable harnesses, which are suitable for applications such as wearable technology, medical, telecoms, satcoms, military, aerospace, space, general microwave communications, rail traction, oil and gas and marine.

The power to connect

In addition to manufacturing the Pisces range of waterproof RF connectors and value-added service, Intelliconnect can deliver cus-

The world is going electric

tom-designed connectors in just eight to 10 weeks from the customer approval of a design drawing.

At Phoenix Contact we are part of the solution.

Its recently launched and fast-growing cryogenic cable assembly business, CryoCoax, supplies the growing market for quantum computing, medical, research, test and measurement and the emerging low-temperature computing markets.

From energy generation to consumption, we understand the challenges faced by a drive towards a more sustainable electric future.

Intelliconnect’s cable division are specialist manufacturers of affordable, high-quality, high-frequency microwave cables, including triaxial assemblies, semi-rigid, semi-flexible and cryogenic cables as well as standard RG/LMR type products. Cables can be waterproofed to IP68 and include special features, such as phase matching and ruggedised assemblies for use in harsh environments.

For more information, call +44(0)1245 347145, email sales@intelliconnect.co.uk or visit www.intelliconnect.co.uk.

For additional information call 01952 681700 or visit phoenixcontact.co.uk/p2c

dpaonthenet.net 19

Feature: VSDs & electric motors

One of the breakthrough technologies of recent years, which has helped make the intelligent powertrain affordable, is the smart sensor

You don’t always get what you pay for – sometimes you get more W

hen making any purchase, price clearly matters. However, when it comes to variable speed drives (VSDs) and electric motors, as ABB’s David Hughes explains, the price tag does not always reflect what is included with your purchase.

while a solid infrastructure with trusted suppliers can ensure that only approved equipment and parts are used. A manufacturer that maintains a network of local providers can ensure that field engineers are up to date with all the latest prod-

There are many factors to consider when

VSD or motor to arrive. If the VSD is a

uct developments, legislation and best

engaging a VSD and electric motor sup-

replacement, or is intended for use in a

practices, ultimately ensuring a better

plier. Reliability, efficiency and ease of

critical application, any delay can have

service for customers.

use of both the product and the sup-

big implications on productivity. Us-

plier are critical factors. But, for many,

ing a company with an established UK

Remote condition monitoring

the overriding factor often comes down

distribution network can mean a wider

Once installed and commissioned, the

to price, based on capital (capex) and

choice of VSD and motor types and rat-

uptime of the VSD and motor is of par-

operating (opex) expenditures. When

ings available off the shelf, along with

amount importance. Today’s VSDs and

comparing two VSDs or motors with

rapid delivery – but your provider must

motors have come a long way and are

similar technical specifications, it can

offer more than just good products and

no longer “dumb” standalone devices.

be tempting to opt for the lowest price.

efficient delivery.

They are now an integral player within an

However, this can overlook the many

intelligent powertrain comprising VSDs,

value-added services that manufactur-

To get the most out of any application,

ers make available to users, not only

the VSD and motor need to be installed,

before the equipment is installed and

commissioned and maintained to the

By their very design, VSDs are digital

commissioned, but, more importantly,

highest levels and to the standards of

devices, loaded with performance data

throughout its lifetime. Certain services

the original manufacturer. Many com-

and have had the potential to interact

are sometimes not widely known, which

panies can service VSDs, but not all will

smartly with other equipment for a long

is why it is important to consider your

have official accreditation to do so for a

time. In the past few months, with per-

options carefully, as they could end up

particular brand.

sonnel access to production lines cur-

being a key differentiator.

motors, bearings and the load itself.

tailed, interest in remote condition moniAn accredited network, therefore, brings

toring of VSDs used on key applications

Local stockholding, availability, delivery and support

some guarantees that other channels

has gained momentum.

cially trained and supported to provide

Remote condition monitoring helps in

Nobody wants to be kept waiting for a

expertise for a particular manufacturer,

predictive maintenance planning by us-

20 dpaonthenet.net

cannot provide. The network is spe-

Feature: VSDs & electric motors ing remote data to identify early signs of

Repairs, spares and beyond

Some services do not become appar-

possible system failures or production

Choosing a VSD and motor suppli-

ent until you suddenly need them. For

problems. It delivers accurate, real-time

er with local workshops and service

instance, for companies or sites with a

information about VSD events and helps

teams means that repairs are carried

large installed base, it can be difficult to

to predict maintenance needs, opera-

out in a timely manner at factory-lev-

keep track of the maintenance require-

tional risks and possible system faults. It

el standards. The VSD or motor does

ments and upgrade strategy of each

allows applications to perform efficiently

not have to be sent outside of the UK,

one. Companies like ABB allow you to

and last longer by keeping production

which, in light of the increased friction in

register your drive for a Life Cycle As-

About the author:

running as planned. The service pro-

cross-border trade, could end up saving

sessment (LCA), which allows the man-

vides an expert analysis report on the

a vast amount in time and costs.

ufacturer to keep track of its condition

David Hughes has had a long and distinguished career working across many sectors, including Utilities, Renewables, Rail, and Food and Beverage. He joined ABB UK in 2003 and held senior positions in four divisions (Power Products, Power Grids, Motion, Robotics and Motion), before being appointed as UK Chief Executive Officer in October 2019. Before ABB, David worked for Rolls Royce and studied electrical engineering at Sunderland University, having started his career as an apprentice.

VSD’s condition and proactive e-mail

and life cycle for you, prompting main-

alerts regarding potential faults or limit-

Counterfeit or substitute components

tenance when needed, while reducing

ed availability, ensuring that equipment

are a growing issue, particularly in the

the likelihood of an unexpected failure.

is available, reliable and maintainable.

VSD repair market. These can put entire

It helps to establish a pathway for up-

The service can spot overheating, which

production lines or even lives at risk, with

grades and replacement, ensuring that

could cause unplanned production

potential downtime costing thousands

obsolete or damaged equipment is re-

breaks and eventually damage the drive.

of pounds per hour. Furthermore, many

placed promptly with an appropriately

It can also prevent some semiconductor

VSD manufacturers specify that the use

specified product.

faults.

of non-approved components will immediately invalidate the drive’s warranty.

The future

From smart sensors to powertrains

Reputable manufacturers will routinely

2020 was a game changer, where digi-

invest extensively in testing to ensure

talisation met maintenance head-on for

One of the breakthrough technologies of

that safety and performance standards

many companies. While the technol-

recent years, which has helped to make

are met both at a component and device

ogy means different things to different

the intelligent powertrain affordable, is

level – which cannot necessarily be said

companies and people, one thing is for

the smart sensor.

for cheaper, non-approved spare parts.

certain: rapid and efficient response can

The device converts traditional motors,

right support infrastructure or ecosys-

pumps and mounted bearings into

Reactive and proactive service

smart, wirelessly connected devices by

VSDs have few parts that need frequent

that can respond instantly, around the

simply attaching, without wiring, to the

maintenance, but components will in-

clock.

surface of the product. It measures key

evitably wear out over time and need to

parameters, such as temperature, vibra-

be regularly checked and maintained or

tion, noise and energy consumed, which

replaced. Service contracts offering a

can be used to gain valuable information

tiered approach can allow flexibility to

on the condition and performance of the

suit the needs of individual customers,

equipment. This enables users to identi-

depending on how much support they

fy inefficiencies within their system and

need, or the state of their in-house main-

to reduce risks related to operation and

tenance resources and skills.

only ever be achieved if you have the tem that is right on your doorstep – one

www.abb.co.uk/energy Watch DPA’s Editor Paige West and ABB’s David Hughes speak further on this topic in an exclusive video interview. You can find this on the DPA website or by following this link: http://www. dpaonthenet.net/video/183634/Motors-drives-Net-Zero-CarbonReduction.aspx

maintenance.

It is these smart sensors, together with cloud connectivity, which are used throughout the powertrain. Data gathered from VSDs’ inbuilt sensors and loggers, together with that collected from the smart sensors, can be aggregated, stored and further accessed via the cloud. The ability to gather and analyse this data can reveal information on the status and condition of installed equipment. Maintenance can now be planned according to actual needs rather than based on generic schedules.

This extends the lifetime of equipment, cuts maintenance costs, and reduces or prevents unplanned downtime due to breakdowns.

Choosing a VSD and motor supplier with local workshops and service teams means that repairs are carried out in a timely manner at factory-level standards

dpaonthenet.net 21

Feature: Post-production automation

AM-Flow’s ‘stack’, is a range of modular solutions that enable users to integrate almost every element of an AM production workflow

Automating post-production

to scale up additive manufacturing I

t is no exaggeration to say that additive manufacturing (AM) has revolutionised the way that products are designed, manufactured and distributed. Unshackled from the limitations associated with traditional production processes, AM has made the leap from prototype to end-part production, and continues to open up exciting opportunities around localised production, digital inventories and ondemand manufacturing.

Can you start by giving our readers a quick overview of who AM-Flow is and what the company does?

new printers and expanding their use of

We provide an end-to-end digital manufac-

only going to increase, and as it does so,

turing solution that enables 3D print pro-

labour costs will rise exponentially. That is

ducers to automate AM post-processing.

simply not viable for companies looking to

Or, to put it another way, we allow compa-

scale up 3D print production, and so they

nies to create a truly automated 3D printing

must find a way to automate the process.

workflow. 3D printing is a highly automat-

We, therefore, expect to see companies

ed process – right up until the point when

move away from investing predominantly

the print leaves the machine. After that,

in printing technology, to investing in the

everything else, from picking and sorting

overall production workflow.

materials as required, rather than concentrating on the overall production process.

We expect that the use of 3D printing is

to packing, is done manually. That is highly es vulnerable to human error. Our solutions

What makes post-production in AM such a challenge?

inefficient, expensive and leaves processenable companies to address these chal-

The main advantage of 3D printing is its

Yet, despite the technology’s many ad-

lenges and will, we believe, finally enable

ability to produce any object, i.e. infinite

vantages, post-production remains a

3D printing to deliver on its promises of the

geometries. However, that is also exactly

labour-intensive and costly process that

last decade.

what makes post-processing so challeng-

presents a major barrier for companies

ing. A single production line may produce hundreds of different geometries, even

change, and how this will, in turn, enable

That sounds logical. Yet, many companies have been using 3D printing, whether to produce prototypes or end-use parts, for years. Why are they only thinking about post-production now?

3D printing finally to become a fully digi-

Most AM production environments have

for AM, and it is clear that things have to

tal, fully connected part of the factory of

grown organically. Companies have been

change. By applying machine learning and

the future.

focused on the printing technology, adding

an Industry 4.0 approach from the ground

looking to scale up their AM operations.

We caught up with Stefan Rink, CEO of AM-Flow, who explained how advances in post-processing software and hardware mean that this is finally about to

22 dpaonthenet.net

within a single batch. This poses difficulties in terms of identification, sorting, quality control, handling, transportation and packaging 3D printed parts. Add to this the pressure to reduce the cost per part

Feature: Post-production automation up, AM-Flow can deliver modular solutions

menting different elements of the AM-Flow

name suggests, provides fully automated

that, when combined, provide a complete

stack into their post-production processes.

bagging and labelling capabilities to AM

end-to-end workflow solution that over-

These include major players from indus-

environments. The new solution perfect-

comes the challenges I have outlined.

tries as diverse as automotive, aerospace

ly bridges AM-pick and AM-Route, and

and medical, and include BMW, Midwest

exemplifies our continued quest to pro-

Prototyping, Oceanz, Shapeways, Materi-

vide a full ‘end-to-end’ post-processing

alise and Marketiger.

solution to manufacturers and service

So, what exactly does the AMFlow proposition include?

We have developed what we call the AM-

bureaus. We are now looking forward to introducing a further new addition to our

element of an AM production workflow. The

All these industries must have different digital environments.

How do you cope with that?

beating heart of the system is AM-VISION,

To go back to my earlier point, most AM

which enables rapid and reliable identifi-

production environments have grown or-

cation of 3D printed parts based on their

ganically over time to meet specific needs

Finally, can you summarise AMFlow’s long-term objective in just one or two sentences?

geometry. Next comes AM-LOGIC, which

or challenges. As a result, the landscape

Our goal is to create the full AM end-to-end

is very much the digital brain, nervous

is extremely fragmented – nothing is

automated production line, i.e. automate

system and muscle of the outfit, enabling

standardised and there are a lot of pro-

all steps after the printer. We are still quite

the operator to view and control the whole

prietary systems in place. Therefore, all

a long way away from a ‘lights out’ factory

post-production workflow via a simple user

AM-Flow modules are designed to ‘plug

but that is definitely the point in the future

interface. Of course, once you can identify

in’ to whatever is out there. They are com-

for which we are aiming.

parts, you can sort them (using AM-SORT)

patible with all existing MES and ERP

and transport them via the use of cobots

software and can also be integrated with

(AM-ROUTE). We also market AM-PICK,

external systems, such as cleaning and

which enables operators to go from batch

part quality-enhancing, post-processing

process to single-part process. In addition

hardware – enabling a swift and smooth

to these modules, which are already availa-

transition to full automation.

Flow ‘stack’, a range of modular solutions that enable users to integrate almost every

stack early next year.

https://am-flow.com/

ble on the market, we have several more in development, so watch this space!

Whom do you see as being a typical customer for your product? Do you have any customers now?

With so much information being collected, how do you ensure intellectual property is protected?

That’s a question we get asked a lot, but, actually, all designs are completely se-

Any company in an AM growth environ-

cure. Our analysis is purely on the data

ment. That may be a service provider, or

sets required to feed identification and

it could be an OEM who is dealing with

our machine learning process, and that

high-volume, high-mix output from their

data cannot be translated back into a de-

machines. Typically, they have a minimum

sign. It’s just not going to happen.

of three 3D printers, and anything above that, which may be SLS, MJF, FDM or anything else. Our software works with all types of 3D printing technology and all materials, including metals.

You mentioned plans to add further modules to the AM-Flow ‘stack’. Is there anything you can tell us about now?

Absolutely.

We have several customers who are imple-

We

recently

introduced

AM-BAGGING, a module that, as its

AM-VISION automates the identification of unique parts, cutting time and labour intensiveness

Feature: Face mask detection

Developing a deep learning face mask detection prototype in two days F

ace masks are a critical tool for fighting the spread of COVID-19 and are proven to be most effective when face coverings are worn universally.

As stores and businesses reopen, ensuring that all occupants wear a face mask is essential.

solutions are capable of automatical-

masks, those who weren’t, and those

ly detecting anyone in violation of face

who were wearing them incorrectly, in

mask guidelines, saving employee time

different environments. Blackfly S GigE

and ensuring safer environments.

is another camera that is suited for this purpose. For more information about

Deploying deep learning

FLIR machine vision solutions, contact

Deep learning is a form of machine

sales.

learning that uses neural networks with many ‘deep’ layers between the input

An adaptable solution

and output nodes. By training a network

Each image in the face mask dataset

However, the additional resources re-

on a large data set, a model is created

was annotated with bounding boxes

quired to monitor patrons can further

that can be used to make accurate pre-

that showed object locations and class

strain businesses that are already strug-

dictions based on unseen data. In this

labels, indicating whether face masks

gling to meet other sanitation and social

case, the network can be trained to

were worn appropriately. Deep learn-

distancing guidelines. Deep learning

detect not only the face masks them-

ing developers and solution integrators

selves, but also whether they are worn

can easily expand this solution to cover

correctly on a person’s face.

more complex and robust use cases for deployment in the real world. For

A fully functioning deep learning system

example, the neural network can be

can be developed and deployed in a

trained to detect face shields, gowns,

matter of days. Using a FLIR Firefly DL

gloves, and other PPE within high-risk/

camera, FLIR engineers developed a

high-traffic environments like hospitals

system for detecting compliance and

and airports.

flagging users who may be in violation

24 dpaonthenet.net

of PPE (Personal Protection Equipment)

Learn more about building a deep

guidelines. The face mask detection da-

learning solution on a budget, getting

taset used two publicly available librar-

started with the Firefly DL, and FLIR

ies with over 1000 images to provide

temperature screening solutions at

examples of people who were wearing

https://www.flir.co.uk/.

SEW-EURODRIVE–Driving the world

LARGE GEAR MOTORS WITHIN 5 DAYS

* This offer applies to selected gearmotors from the large gear unit plant in bruchsal.

TO

Large gearmotors dispatched in just 5 working days.

We put your project business in motion, because we deliver our large gearmotors to you even faster.

Our ATO5 to go range for shorter delivery times makes this possible. All of our ATO5-enabled gearmotors from the tried-and-tested SEW-EURODRIVE modular system leave our plant for large gear units in Bruchsal just five working days after your order.

For more about large gearmotors to go visit our website at www.sew-eurodrive.co.uk and search ATO5-enabled

SEW-EURODRIVE Ltd Devilliers Way, Trident Park Normanton West Yorkshire WF6 1GX Tel - 01924 893 855 Fax - 01924 893 702 Info@sew-eurodrive.co.uk - www.sew-eurodrive.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

DIRECT IN-HOUSE SERVICE Flame Hardeners’ ability to respond quickly and efficiently to specialist enquiries is the result of our in-house policy • 100% of our bespoke tooling manufacture for both flame and induction hardening is carried out in-house by our own highly skilled tool-making team, all of whom have over 20 years’ experience.

As a result, the average time for tooling development is less than two days.

• Personal service – you will always speak directly to a member of our own staff; we do not use automated call systems

Find out more at

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

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

tel: 0114 276 8167

fax: 0114 273 8657

Feature: Porosity

Curing the porosity problem in additive manufacturing A

dditive manufacturing is becoming more commonplace across a wide range of industries, but is still subject to porosity, a well-known issue that causes leak paths and results in high-value components being scrapped. Gareth Ridge, Operations Manager at the Slough, UK branch of Ultraseal International, talks about how additive printing consultancy, Graphite AM, resolved this issue after partnering with Ultraseal International.

3D printing was once a revolutionary piece of technology but has now become a mainstream process in a number of industries. Due to its clean and simple process, additive manufacturing produces high-quality components and removes the need for expensive tooling and machining.

In most cases, porosity is caused either

can reduce the waste, cost and produc-

However, while some industry pain

by the powder used in the process, or

tivity impact of porosity. By partnering

points are removed as manufacturing

the printing process itself. These mi-

with sealing experts, 3D printing man-

technology evolves, one legacy chal-

croscopic voids reduce the density of

ufacturers can prevent gases and fluids

lenge still remains: porosity. During the

components, leading to leaks, fatigue

from leaking through a component by

additive manufacturing process, mi-

and cracks. For parts that go into appli-

sealing any voids with a chemically and

croscopic holes that are invisible to the

cations that need to be air- or fluid-tight–

thermally resistant polymer sealant.

naked eye are formed within the body

for example, in fuel or cooling systems

of the part. Known as porosity, this is

– this can be an especially critical issue.

already an inherent issue with diecast

3D printing consultancy, Graphite AM, wanted to ensure that its customers were getting the best product quality,

application might be different, the result

Vacuum impregnation – a sealing solution

is the same – with components ending

Vacuum impregnation is one such way

rosity sealing partner in order to do so. It

in scrappage.

that additive manufacturing businesses

chose to partner with Ultraseal Interna-

components, and while the cause and

and realised it needed to work with a po-

dpaonthenet.net 27

Feature: Porosity tional, a company that develops, man-

First, components are placed into an au-

withstanding a certain pressure. Mean-

ufactures and supplies porosity sealing

toclave containing Ultraseal PC504/66

while, the leak test is to detect porosity

chemicals, impregnation equipment and

resin, a high-performance thermocure

and leaks within the component.

services.

sealant. Once the components are submerged, a vacuum is applied to evac-

Ultraseal design and manufacture ‘test

Porosity sealing for complex components

uate the air within the autoclave. After

tooling kits’ which are required to blank

20 minutes, the vacuum is released;

off holes and ports, while delivering air

Graphite AM specialises in complex

through the resultant change in pres-

or water into the part to search for the

About the author:

designs and high-performance compo-

sure, the sealant penetrates the mi-

leaks. Every component requires its own

Gareth Ridge is Operations Manager at the Slough, UK branch of Ultraseal International.

Graduating from The University of Birmingham and with over seven years of experience in vacuum impregnation and surface technology combined, Gareth is an expert when it comes to porosity sealing applications and production quality technologies.

nents in tailored materials, and primar-

cro-porosities and leak paths within the

test kit in accordance with its geometry

ily uses SLS (selective laser sintering),

3D printed part and seals them.

and features. The amount of pressure

an additive manufacturing process that

the component is subject to varies as

deploys lasers to sinter powdered mate-

The second stage involves a cold wash,

per customer request; this is often de-

rial, binding it together to create a solid

using standard tap water to remove the

termined by the operating pressure of

structure.

excess sealant from the component

the component when in the field. Histor-

surfaces and critical features such as

ically, these parts can be tested from a

threaded holes.

range of five PSI to 10,000 PSI.

rials – such as PA11 and PA12 – Graph-

The third process stage is a hot cure

These pressure tests produce critical

ite AM has developed its own range of

cycle. The hot water cure uses demin-

information as to whether the parts are

unique SLS blends, including the use of

eralised water in a 3,000-litre capacity

leak free and fit for purpose, or whether

fine graphite particles. As well as having

heated tank. This solution contains a

porosity is present, which would result

anti-static properties, the use of graph-

corrosion inhibitor to provide some cor-

in a failure in the field. Vital information

ite also improves impact and thermal

rosion protection for certain metallic ma-

can also be communicated to the man-

resistance (up to 170°C), meaning it is

terials. The water operates at 95°C and

ufacturer during this stage, such as leak

particularly suited to lightweight applica-

parts are submerged for ten minutes to

location and severity, which aids knowl-

tions where strength and performance

ensure the Ultraseal sealant polymeris-

edge and understanding of component

are critical factors.

es, which then becomes an integral part

quality going forward.

While the majority of 3D printing bureaus use standard or glass-filled nylon mate-

of the component.

Partnering with Ultraseal International

Today, Ultraseal delivers an end-to-end

Graphite AM chose to partner with Ul-

Tested for quality and assurance

traseal International due to its expe-

Once this process is complete, pressure

rience in the automotive industry and

testing is completed by either conven-

understanding of the component im-

tional air underwater testing or hydrau-

Making porosity problems a thing of the past

pregnation process. Ultraseal’s solution

lic testing, dependent upon customer

As additive manufacturing becomes

involves sealing the component using

request. There are two tests that can

commonplace in the manufacturing

vacuum impregnation, a process that

be conducted – either a ‘proof’ or ‘leak’

supply chains, so too will porosity seal-

uses three key stages to ensures the

test. A proof test is to ensure that the

ing technology. As a result, manufac-

highest quality component sealing.

component is structurally capable of

turers can drive up throughput, reduce

sealing service for Graphite AM from its UK Service Centre in Slough.

scrappage, minimise waste, and increase efficiency and value.

When considering vacuum impregnation equipment and sealants, there is a variety of flexible options that cater to a business’s operations. This includes onsite managed services, using external service centres, through to owning the equipment outright.

Ultraseal provides a range of best-inclass equipment and sealant solutions, as well as recycling and automated systems that can deliver efficiency and boost environmental credentials. www.ultraseal-impregnation.com

28 dpaonthenet.net

igus dry-tech ... lubrication-free bearings ®

®

Bend it like drylin

®

... drylin curved linear profiles ®

Curved rail profiles for the entire drylin linear system range made from hard anodised aluminium. Different curved directions possible. Customised project planning service. Ideal for use in control panels, moving screens, or machine adjustments. This motion plastics and further details at igus.co.uk/curvedrail ®

®

igus Caswell Road Northampton NN4 7PW Tel 01604 677240 sales@igus.co.uk ®

motion plastics ... for longer life ®

Feature: High-precision drill caps

500 parts in two days: Airbus opts for 3D printing P

recisely placing together complex structures, such as a digitally assisted assembly, robotic parts or machining equipment, is one of the greatest challenges of modern manufacturing. The Integrated Manufacturing Group is collaborating with industry partners to combine modern technologies and develop new, integrated systems. For this purpose, the group uses the “Factory 2050”, a futuristic facility, costing almost 48 million euros, within the Advanced Manufacturing Research Centre (AMRC) at the University of Sheffield.

made of carbon fibre, aluminium and ti-

had to cover it so that the cuttings from

tanium. Given the strict requirements of

the next hole would not contaminate it.

the aerospace industry, cross-contami-

When we realised we had very specific

nation between holes during these tests

requirements for our drill cap, we only

had to be avoided at all costs. Shortly

had a short time to develop a solution.”

after starting the project, the team realised that their solution could not fix the

Initially, the engineers used a small alu-

problem – threatening a delay of several

minium part with a rubber O-ring. How-

weeks in case they had to metal-cut or

ever, this solution quickly proved insuf-

injection-mould new spare parts.

ficient: it caused delays in the process and was subsequently dropped, due to

George Sleath, Project Engineer at the

the tight schedule.

Integrated Manufacturing Group, and his team turned to 3D printing to pro-

The team developed a second solution:

duce 500 high-precision drill caps. This

a small disc with a peripheral notch for

reduced the lead time from several

an O-ring. The tolerance requirements

weeks to three days.

were high. In case the notch became too big, the ring would slip on its side. It would not be the O-ring that would seal,

Airbus, Europe’s largest aerospace

A variety of methods to prevent cross-contamination

company, has commissioned the AMRC

“One of the most important requirements

range was about half a millimetre – or

research group with a challenging pro-

was to avoid any contamination of the

half the thickness of the O-ring.

ject – involving drilling and machining

holes during the drilling process,” says

work on tight-tolerance components

George Sleath. “After drilling a hole, we

30 dpaonthenet.net

but the resin. The acceptable tolerance

The variety of parts also created compli-

Feature: High-precision drill caps cations: “Our drilled holes were different

you don’t get the 500 parts for weeks

500 specific drill caps for an Airbus pro-

sizes, so we needed a variety of differ-

and then realise you have small chang-

ject in just two days. With the classic

ent drill caps,” Sleath says. “In virtual

es after all,” Sleath says. “I’ve come to

manufacturing method using injection

design, a dimension can be changed

really like using 3D printing to quickly

moulding, a new mould has to be made

quickly, but when the parts are all injec-

iterate through different designs. I print

for each part. With 3D printing, the differ-

tion moulded, you have to make a new

a part, test it and print an improved ver-

ent dimensions can be quickly adjusted

mould for each part first.”

sion straight away. I can sometimes get

in the virtual design software and printed

through two or three designs in a day,

immediately on site.

About the author:

3D printing: 500 drill caps in two days

thanks to the speed and low cost.”

The team needed around 500 small drill

3D printing is transforming production processes

change mass production: on demand,

caps within ten days, which practically eliminated all other manufacturing op-

This shows that even large quantities

the rest of the production line is linked

tions from the table. This left 3D printing.

can be 3D printed on site within a very

to mass production. With desktop 3D

short time and immediately adapted

printers, companies can react variably

Sleath asked three external printing

or customised as needed, solving time

to demand and even reduce downtime

service providers. However, their costs

bottlenecks. Companies no longer have

– faulty printers are simply replaced and

significantly exceeded the value of the

to wait weeks for the delivery of certain

do not stop the entire production. 3D

parts for the overall project. He then

individual parts and put up with the as-

printers have long since ceased to be-

looked for ways to manufacture the

sociated delays in the production pro-

long to dusty basements or experimen-

parts in-house.

cess and rising costs.

tal laboratories. This technology brings

When his colleague, Mark Cocking,

Using a fleet of Formlabs 3D printers,

Head of the Design and Prototyping de-

engineers at the University of Sheffield’s

partment, got back to Sleath 24 hours

Advanced

later, he simply wrote: “We’ve already

Centre (AMRC) were able to produce

The digital workflow has the potential to special batches can be made while

great advantages to manufacturing

printed half the caps.” Sleath was surprised – 250 drill caps in 24 hours? As a matter of fact, Cocking delivered all the

Manufacturing

Research

companies. https://formlabs.com/uk/

Stefan Hollaender is Managing Director EMEA at Formlabs.

He has more than 20 years of management experience, most recently as Senior Vice President of Partner Management at T-Systems International. There, he worked on building a strategic partner ecosystem for Deutsche Telekom’s digital business.

With positions at Hewlett-Packard, SONY, Microsoft and T-Systems, Hollaender has a knack for general and product management, marketing, sales and leadership. He studied technical business administration at the University of Stuttgart.

parts within two days.

“An amazing throughput,” says Project Engineer, Sleath. “For us, that meant not only that we got the parts faster and could work with them, but also that we could concentrate on other things.”

In-house 3D printing workstation: flexibility and capacity for iterations Using a digital production line of 3D printers, the engineers added attachment points to the parts for a tool, which they also additively manufactured. This made the caps quick and easy to insert.

“The feedback from our testers was overwhelmingly positive. The majority of the caps worked exactly as intended and none broke during operation,” Sleath reports.

In addition to fast turnaround times and low cost, flexibility was a key benefit of on-site 3D printing. “If the design hadn’t worked in the field test, we could have quickly given the feedback to the designing process and adjusted the parts – instead of the usual process, where

dpaonthenet.net 31

Feature: Turntable bearings & spur gears

Bearings from Rodriguez prove first choice at Atlas Converting R

.A. Rodriguez (U.K.) Ltd is supplying large turntable bearings and steel spur gears for use in a new generation of slitterrewinder machines being built by Atlas Converting Equipment Ltd. Machines of this type are used for the processing of products such as flexible packaging materials, film and laminates. The quality and lead time of the turntable bearings and spur gears, alongside selection advice provided by R.A. Rodriguez (U.K.) Ltd, led to the initial purchase decision.

Converting enables complex products to be processed in their optimum condition, ensuring good quality rewind reels, maximised production, and minimised waste. Further market demand is seeing more and more converter shops seeking compact solutions.

“We are world-known as producing well-engineered, quality slitter-rewinders, but we have chosen to introduce

Atlas Converting Equipment Ltd is a

Increasing demand for thinner BoPET

an entry-level version of our well-test-

global supplier and provider of solu-

(biaxially-oriented polyethylene tereph-

ed dual turret machine to better serve

tions in slitting and rewinding technol-

thalate) films and clear barrier coatings,

customers working with certain budget

ogy, as well as finished roll-handling

as well as a trend towards sustainable,

constraints,” explains Andrew Wood,

systems. The company’s Atlas and Ti-

biodegradable and compostable prod-

Marketing & Communications Manager

tan brands are recognised around the

ucts, means that new challenges are

at Atlas Converting. “As a result, we set

world, with over 4,000 installations of

emerging for convertor shops world-

about developing our brand-new Titan

primary and secondary slitter rewinders

wide. Developing into new markets

ER610-DT.”

in over 80 countries.

with extensive research and development, the latest technology from Atlas

32 dpaonthenet.net

From three years in research and de-

Feature: Turntable bearings & spur gears velopment, and a multi-million-pound

“They wanted a solution that was ca-

advantageous due to their ability to

investment in new parts design and

pable of turning quite a large load, but

absorb small centre distance errors,

processes, this new Compact Dual

without any compromise in accuracy,”

while the thick roots of the teeth add

Turret Slitter Rewinder demonstrates

states Dave Young, Bearings Product

strength.

unparalleled build standards, with solid

Manager at R.A. Rodriguez (U.K.) Ltd.

and dependable engineering from the

The Rodriguez turntable bearing and

outset. The ER610-DT project ensured

A KDM medium-series, four-point-con-

spur gear form part of the ER610-DT’s

unequalled combinations of operator

tact bearing was recommended as it is

dual-turret winding module. In essence,

safety, yet huge productivity improve-

robust and proven in the toughest ap-

the machine has four rewind shafts for

ments and reduced machine download

plications. KDM turntable bearings al-

high productivity, with each turret con-

times.

low for a compact design with a signif-

taining two rewind shafts. The turrets

icantly higher load performance rating,

are of a cantilevered design, eliminating

To arrive at the solution, Atlas Con-

as axial and radial loads – and tilting

the need for centre cross shafts. Wind-

verting called upon the full support

moments – can be absorbed.

ing takes place on two rewind shafts,

of its supply chain. As a customer of

while the other two shafts can be load-

R.A. Rodriguez (U.K.) Ltd for the past

For the Titan ER610-DT, a 644mm di-

ed with cores, enabling a fast changeo-

21 years, the company had no hesita-

ameter bearing was specified with

ver upon completion of winding.

tion when it came to enquiring about a

standard clearance (diameters from

turntable bearing and spur gear for the

less than 100 to higher than 6,000mm

Although the machine has only recently

Titan ER610-DT.

can be supplied).

been launched, sales volumes are ex-

R.A. Rodriguez (U.K.) Ltd is highly

Featuring

experienced in supplying turntable

bearings can be supplied un-geared

bearings for demanding applications.

or with gear teeth as an integral part of

Assistance in selecting the bearing

either the inner or outer ring. For Atlas

For more information on the new

and pinion gave Atlas Converting the

Converting, an external steel KHK spur

ER610-DT online launch, please see

necessary confidence and trust for this

gear, featuring an involute tooth shape,

https://www.atlasconverting.com/

important project.

was delivered. Involute tooth forms are

titan-er610dt-launch-page.

pected to ramp up. Indeed, Atlas Conhardened

raceways,

the

verting has already re-ordered for the next phase of build.

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.

We listened. n

60A per contact

n

Shock to 100G

n

Stainless steel mate-before-lock fixings

n

Operating temperature up to 150°C

harwin.com/kona

Connect with confidence

Feature: Medical devices

Blood centrifuges are just one of many medical device applications in which thin-section bearings from Carter have delivered design advantages

Thin section bearings boost medical device performance W

ith hospital space at a premium, even before the advent of any surges in demand, the need to maximise ward, bed, theatre and laboratory space by minimising the size of medical machinery has rarely been of greater significance than it is today.

So, when a well-respected manufac-

The first application was a medical

turer of proprietary disinfection and

decontamination device for the con-

decontamination cells recently needed

tainment of potentially contaminated

to design all-new medical devices as

matter in the form of human tissue or

part of a larger installation, attention

blood samples from patients. In this

turned to an aspect of design frequently

project, the bearing was required to

overlooked in many industrial applica-

facilitate precision rotation in a design

tions where size doesn’t really matter.

that permitted ease of operator use, to

The challenge was finding the thinnest

reduce the possibility of human error.

possible bearing that could also allow

The second application in the cell was

Unsurprisingly, just as personal elec-

the critical machinery in which it was

on an associated blood analyser, which

tronic devices and household electrical

installed to deliver the highest positional

called for a super thin bearing that

items have got both smaller and thin-

accuracy over an extended lifetime. The

could provide the required accuracy

ner in recent times, the combination of

design brief centred around applying

and precision to the testing element of

clever design and advances in materials

these joint demands of reduced space

the analyser. High positional accuracy

technology has seen the physical size

and high precision into two key parts of

was vital in order for the unit to provide

of many vital medical and laboratory

the new cell.

accurate test results whilst, at the same

devices reduce too.

34 dpaonthenet.net

time, streamlining workflow and easing

Feature: Medical devices maintenance. The design of both de-

ent in one direction, the A-Type angular

in our (readily available and free) data

vices demanded ultra-high positioning

contact ball bearing is recommended,

sheets. We can provide application ad-

precision, combined with the ability to

and this bearing also works well in radial

vice on all aspects of thin section bear-

deliver consistent repeatability over a

or combined radial-thrust applications.

ings and are particularly well set to deal

long service life. The design brief also

However, Silverthin points out that the

with design challenges where space is

required the smallest possible physical

A-Type bearing should never be used

at a premium and repeatability with ab-

size for the machines, together with a

alone to support moment loads or re-

solute accuracy is vital, over prolonged

stipulation that the blood analysing de-

versing axial loading. For these applica-

periods of time with high usage.”

vice was required to spin inside a maxi-

tions Type-C Radial Contact bearings

mum radius of just 14”.

are recommended: they are designed

Thin section bearings from Silverthin are

with deep ball grooves specifically to

supplied by Carter in sizes from 1” ID

Engineers at the Silverthin Bearing com-

withstand high loads. Although this

to 40” OD and have been specified for

pany (part of the Mechatronics Group

bearing is used primarily in applications

uses that are as light as miniature gim-

and represented in Europe by Ox-

with radial loads, it can also withstand

bal mounts on satellites, right up to 40”

ford-based Carter Bearings) conducted

moderate axial loads, reversing axial

OD items used on large rotary tables, in

trials using a shortlist drawn from its

loads, and moment loads too. How-

both civilian and military applications.

range of potentially suitable high-pre-

ever, for applications where significant

cision thin section bearings, before rec-

moment loads will prevail, Silverthin

ommending the perfect match for the

recommends that designers consider

application.

its Type ‘X’ 4-point contact precision products.

Mel Meader, Technical Operations Manager at Carter Bearings and UK Silver-

The X-Type, or 4-point contact, ball

thin expert, observed, “All Silverthin

bearing is ideal for moment loading ap-

bearings are manufactured to ABEC

plications and is designed with ‘gothic

Standard, using premium quality mate-

arch’ raceways to create four con-

rials that are sourced only in the United

tact points between the balls and the

States. This provides users with an ab-

raceways. This design is stated to be

solute guarantee of the material integrity

excellent for moment loading and also

and the longevity of a Silverthin bear-

for reversing axial loading. Carter says

ing, and is a key reason why they have

that the X-Type bearing can be used

achieved such a reputation for high

for other light loading conditions, but is

accuracy and long service life.” Meader

not recommended in place of the C- or

points to another recent medical device

A-Type bearing for pure radial loads.

https://www.carterbearings.co.uk/

Thin-section bearings from Carter are available in sizes from 1” OD up to 40” OD

application as a further example of the accuracy that can be delivered by Sil-

As a general rule, Silverthin advises that,

verthin bearings. “They were specified

when specifying this type of bearing for

for use in a laser eye scanning machine,

use with axial or moment loads com-

helping to move the scanner from the

bined with radial loads, the application

absolute centre of one eye across to

speed (rpm) should be carefully con-

the precise centre of the other, with po-

sidered. The engineering department

sitioning measured to within microns,”

at Carter’s Oxford facility has extensive

he says.

data available and can supply information on combined load and limiting

Silverthin precision thin section bear-

speeds. Carter can also advise on radial

ings are manufactured in a variety of

bearing use with combined radial loads

standard configurations and can be

with axial or moment loading, and for

specified as either sealed or unsealed

limiting speeds and separator selection.

units, depending on individual design requirements. In the case of the medi-

Mel Meader continues, “Although, in the

cal device applications mentioned here,

medical applications discussed here,

sealed units were specified, given the

single thin section bearings were used,

environment in which the machines

it is not uncommon for two A-Type bear-

must work. Precision thin section bear-

ings to be used as a duplex pair to suit

ings from the company are available in

the demands of certain installations.

four types to suit most applications.

There are many different configurations for duplex bearings which designers

In environments with axial loads pres-

can benefit from, and these are shown

dpaonthenet.net 35

Feature: Simulation software

Is industry ready for bearing simulation software?

B

earing buyers often request bearings with a lifespan of up to 100,000 hours of operation. While the bearing manufacturer has done its own testing to validate the lifespan against different loads, this doesn’t paint the whole picture of how a bearing will endure the buyer’s specific application.

help to predict and counteract this small

This will give engineers the information to

percentage of failures that cause havoc on

modify the bearing design to accommo-

processes?

date better the stresses resulting from the application.

Using bearing simulation software, bearing performance, life and reliability can be ex-

Another clear advantage is that simulation

tended beyond what was achieved a dec-

software can reduce the amount of time

ade ago – without undertaking expensive,

and resources spent on the testing phase.

time-consuming laboratory or field tests.

This not only speeds up the development

Advanced, integrated analysis of rolling el-

process but also reduces the expenses in

Here, Chris Johnson, Managing Director at

ement bearings can give unrivalled insight

the process. These tools will provide engi-

SMB Bearings, explains how sophisticated

into bearing performance, enable optimal

neers with the insight required to design

bearing simulation software can be used to

bearing selection and avoid premature

and select bearings for optimum perfor-

support application-specific bearing de-

bearing failure.

mance and durability, as part of a whole

sign and analysis processes.

system model. It also allows better collabBearing simulation software is not only

oration between bearing designers, original

Bearings can be plagued with numerous

useful in the bearing sizing and selection

equipment manufacturers (OEMs) and end

causes of failure across their lifespan, in-

stage, but also in identifying potential

users.

cluding misalignment, reverse loading,

equipment problems. For example, if an

false brinelling, overheating, contamination

increase in heat or vibration were detect-

Bearing simulation software can be benefi-

and lubrication failure. The sheer number

ed within a machine, bearing software

cial to design engineers working in a wide

of variables in a given bearing application

analysis could be used to identify how the

range of sectors, including automotive,

can make bearing failure difficult to predict.

components in the bearing were moving in

marine, mining and food applications. The

For example, a bearing used in a robotic

response.

software is able to provide valuable insight

application may outlive the equipment in

into the finer details of the application. This

which it is installed. Yet, the same bearing

While single-shaft simulation software may

is particularly important in demanding hos-

used in the same robot in a high-tempera-

be more user friendly, complex software

tile environments. As software continues to

ture application could fail, due to unsuited

can allow engineers to build and simulate

become more sophisticated, it will play an

lubrication.

models with motors, gear, shafts, housings

integral role in ensuring bearings perform

and bearings. Advanced fatigue life meth-

optimally in the design and testing stages.

More positively, approximately 90 percent

ods can allow the accurate prediction of

of bearings outlive the equipment in which

element and raceway stresses, rib contact,

For further information about SMB

they are installed and only 0.5 percent of

edge stress, and contact truncation. They

Bearings’ product range, visit http://

bearings are replaced due to damage or

also allow full system deflection, load anal-

www.smbbearings.com/ or call +44 (0)

failure. So, how can simulation software

ysis and bearing misalignment analysis.

1993 842 555 to speak to an expert.

36 dpaonthenet.net

Advertorial

When performance and reliability really count

M

edical devices From specialised patient beds to ventilators, the IKO C-Lube M Linear range has proved to be an excellent choice for a few reasons: the range of sizes and configuration, the maintenance-free capability, the low torque smooth motion and the compactness of the units. These units can be modified to handle high temperatures and chemical wash down where required in the form of stainless steel versions.

the broad range of the products. The CRB range has a super slim S type with a width of 5mm and a thickness of 5.5mm, the F type flanged bearing with mounting holes for easy installation, the excellent sealing properties and smooth motion under complex loads. The cam follower (CF) range has now been extended to incorporate the C-lube technology, maintenance free SG type and the additional add-on of the CL unit to lubricate the outer ring making it totally maintenance free.

Surgical tools From oncology equipment to surgical robots, IKO’s CRB and CF series have been the go to products for many because of

Life science equipment From sampling to automated analysing equipment, the IKO C-lube MAG Ball-Spline units and BWU high rigidity precision slides come into their own. MAG utilises the maintenance-free system, with four point contact giving added rigidity, the standard low frictional resistance and smooth movement. BWU simple limited stroke, stainless steel unit, for fluctuating and complex loads with speeds up to 3m per second.

The old adage is that a bearing is a bearing is a bearing. But is it right? Well over the years IKO has seen a distinct change in how it categorises bearings, especially in the linear

business. They would be transit linear and precision linear and IKO would fall into the precision end of the market. The processes used in the manufacturing of IKO’s products are to a standard that would probably fall into the over-engineered category but that’s why IKO sits where it does in the market.

IKO knows that when it works with customers on applications such as the examples above (plus many more industry sectors) not only has it got the application knowledge to make suggestions, but also the company knows that the product will always back it up. www.iko.co.uk

dpaonthenet.net 37

Feature: Bullet train

New-generation bullet train relies on NSK bearings

H

igh-performance bearings from NSK are now operational in the newly developed N700S Shinkansen (bullet train), which began service on the Tokaido Shinkansen line between Tokyo and Osaka on 1 July 2020.

the progression in design, technology and comfort. High-performance bearings from NSK can be found in the gearbox, axle and traction motor assemblies.

For the axles, the NSK double-row tapered roller bearings used in the previous

Regarding the gearbox, the N700S is the

Shinkansen have been further improved to

first Shinkansen to replace helical gears

deliver even higher reliability and reduce

with herringbone gears, which offer in-

maintenance costs. Lower heat generation,

The N700S marks the start of a new era,

creased reliability and lower noise output.

leading to longer life, is a particular attribute.

being the first completely new Shinkansen

Gearbox bearings are subject to intense

design from the Central Japan Railway

shocks and vibration, so exhibiting a long

Concerning the N700S’s traction motors,

Company in 13 years.

operational life under these conditions

NSK cylindrical roller bearings and deep

is a priority. NSK has been supplying ta-

groove ball bearings feature outer rings

NSK bearings underpin the train’s no-com-

pered roller bearings for helical gears in

that are plasma-sprayed with a ceramic

promise focus on safety, stability, comfort

bullet trains for decades. Drawing on this

coating. This coating increases reliability by

and environmental performance. Bearings

experience, the company has designed a

preventing any opportunity for electrolytic

for railway applications contribute directly

special flanged cylindrical roller bearing for

corrosion, an unwanted effect that occurs

to safe operation and travel. High reliability

the N700S’s herringbone gears, that deliv-

due to the transfer of electrical current

is key, as is the ability to support elevated

ers longer life, lower heat generation and

through the inside of uninsulated bearings.

speeds, improve energy efficiency and

reduced maintenance compared with the

reduce maintenance requirements. The

previous generation product.

demands placed on railway bearings are

NSK has been supporting the advancement of the global railway industry since

especially apparent in bullet trains, which

Further benefits of the gearbox bearings

the company first became involved with

transport large numbers of passengers at

used on the N700S include improved sei-

the sector in 1932. The company’s prod-

high speeds over long distances. Applica-

zure resistance, which has been achieved

ucts are used by high-speed rail operators

tions of this type call for highly efficient and

by optimising the design of areas that do

throughout Europe. Close ties with partners

durable bearings, along with meticulous

not contact the flange face. In addition, a

in the European OEM and aftermarket sec-

quality control in all production processes.

high-strength machined brass cage, op-

tors help create products that bring about

timised with NSK’s proprietary R-pocket

notable advances in this important industry.

The ‘S’ suffix of the new-generation N700S

technology, reduces internal stress in the

bullet train stands for ‘Supreme’, signifying

cage structure.

38 dpaonthenet.net

www.nsk.com

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

Displays

Batteries & Chargers

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

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

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

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

Ltd

drive application problems with a comprehensive range of 3v to 24v DC motors, geared motors and accessories.

Hybrid solutions also available at moderate cost.

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

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

Locking mechanisims, machinery activators, shop displays etc etc.

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

To advertise here contact

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

datafocus

MFA/Como Felderland Lane, Worth, Deal, Kent CT14 0BT Tel: 01304 612132 Email: info@mfacomo.com Web: www.mfacomodrills.com

Fasteners & Fixings

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

To advertise here contact

Andrew Quenault on

01732 359990 or email andrew.quenault@imlgroup.co.uk

MVK Fusion – Revolutionary 3-in-1 Module IO-Link valve islands

IO-Link button systems

Emergency stops Key and selector switches

Safety valves

Double safety valves IO-Link analog converters

Foot switches

Smart IO-Link sensors Enabling switches

DC motors

IO-Link grippers

IO-Link temperature sensors

Safety door systems

Door switch

IO-Link hubs

IO-Link inductive sensors

Valves

Safety command devices

IO-Link distance sensors Two-handed devices

IO-Link pressure sensors

Light curtains

IO-Link transponder systems

Digital sensors

Laser scanners

02 Safety

IO-Link

03 01

Standard IO

IO-Link inductive couplers

Three basic functions on one module 01/ standard digital sensors and actuators 02/ safety digital sensors and actuators 03/ IO-Link devices The PROFINET/PROFIsafe MVK Fusion module standardizes three components, opening the door to a one-module strategy.

www.murrelektronik.co.uk