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
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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
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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/
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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
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Wood Working
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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/.
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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
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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.
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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
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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