FEN June 08 by Reed Business Information RBI

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M A N U F A C T U R I N G

June 2008

Vol. 42 No.006 |

Print Post Approved PP255003/00541

featuredproducts Sustainable design Free tool for sustainable materials

p.16

Intelligent positioning Digital positioning motor control

p.30

Medium frequency welding Medium frequency welding inverter

p.35

Flow measurement Magnetic-inductive flow meters

p.37

EXPERT TIPS

inside

to save you time and money

Challenges ahead Subdued manufacturing growth Page 4

Synchronous design History-free digital design Page 14

Welding productivity Get the most out of welding gas Page 24

A tough nut to crack Polymer piping alternatives Page 36

MOTORS DRIVES TRANSMISSIONS guide

PLUS

AWARD WINNING SUSTAINABLE TECHNOLOGY POWDER COATING OF PLASTIC COMPONENTS PAGE 3

alsoinside News ........................p.3 Insight ......................p.9 Robot Files .............p.10 Computers ..............p.14 Product Focus ........p.39 New Products .........p.40 Coming Events .......p.43

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EDITED BY DANIEL HALL

technews AUSTRALIAN AND INTERNATIONAL NEWS AUTOMOTIVE

INDUSTRY

Sustainable powder coating technology CSIRO and Dulux Powder Coatings have developed an award winning, sustainable powder coating system. The system is set to revolutionise the way manufacturers use plastic parts and wet-paint coating. Daniel Hall writes.

OR many years the automotive, plastics, and manufacturing industries have been looking to overcome the serious longterm sustainability issue of wet paint finishing of plastic components. The Australian automotive industry uses around 10 million litres of liquid paint a year to coat the surfaces of new vehicles and plastic components including door trim panels, engine covers, body parts, and bumper bars. Up to 70% of this is lost as waste, posing serious concerns for the industry. The paints currently used to spray plastic components contain solvents which release Volatile Organic Chemicals (VOCs) into the atmosphere. The wet paints also amount to around 2.5 million litres of solid waste a year. The CSIRO and Dulux Powder Coatings have developed an award winning technique to replace wet paint finishes on heat-sensitive substances, such as plastic components, using powder coating technology. The CSIRO- Dulux partnership has recently been

Dr Voytek Gutowski, leader of CSIRO’s team, with Dulux Powder Coatings technical manager Bill Matthews.

awarded the 2008 Premier’s Sustainability Award for products or services by Sustainability Victoria. According to research partners CSIRO and Dulux Powder Coating, the technology is much needed as the number of plastic components grows in the automotive industry. “Cars, planes, and manufacturing industries using plastic parts have products with an aesthetic exterior that typically involves some surface finishing and painting,”

CSIRO Materials Science and Engineering chief research scientist Voytek Gutowski told FEN. “Until now painting was done with wet paints, which contain pigments, resin and solvents. “Depending on the complexity of that component, only small percentage of the paint stays on the part when it is sprayed. The rest of the paint is wasted.” The new powder coating technology eliminates solvent and VOC emissions being

Opposite charges attract, so the powder sticks to the component, which is then heat treated.

released into the environment. “Powder coating is 100% solid and does not contain solvents, which instantly gives the industry a saving for the environment” Dulux Powder Coatings technical manager Bill Matthews told FEN. “Most liquid coating, once they have been sprayed onto the components, can’t be recovered and are collected as waste. “Around 95% of the powder coating products can be recovered and reused.” Powder coating relies on

the powder to be sprayed carrying one type of electrical charge and the material coated carrying the other. Opposite charges attract, so the powder sticks to the sprayed component, which is then cured using heat to form a smooth finish. While plastics used to make automotive components are not conductive, the technology developed by Dulux and the CSIRO modifies the component’s surface without

continued on page 4

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technews Challenges ahead for manufacturers THE Australian manufacturing sector has experienced subdued growth for the fourth month in a row, according to the Australian Industry Group - PricewaterhouseCoopers Australian Performance of Manufacturing Index (Australian PMI). The Australian PMI rose slightly by 0.4 points in April to 52.7, remaining above the key 50.0 level separating expansion from contraction. Australian Industry Group (Ai Group) Chief Executive Heather Ridout said the conditions facing the Australian manufacturing sector continue to constrain growth. “Growth in manufacturing activity was lacklustre again in April, albeit characterised by a mixed performance, with some sectors doing better than others, and mining and infrastructure development in particular putting a floor under activity,” she said. “Weaker global growth is clearly creating more uncertainty in the Australian sector, together with the impact of

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interest rates and recent growth of input costs. MAustralian manufacturers are waiting for something to happen and are uncertain about when solid growth is going to reassert itself.” PricewaterhouseCoopers Global Leader of Industrial Manufacturing Graeme Billings said that the Australian PMI result for April shows that the outlook for manufacturing profitability in 2008 is a tough one. “Rising input cost pressures - notably in terms of energy and labour costs and the uncertainties around the outlook for interest rates due to ongoing inflationary pressure - will all put pressure on manufacturer’s profitability. There is currently little sign of these pressures easing in the near future. Ongoing attention to raising productivity and cutting operating costs will be critical during 2008 and beyond,” Billings said. Australian Industry Group 1300 78 38 44 www.aigroup.asn.au

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Sustainable powder coating technology continued from page 3 changing the component’s appearance. This provides electro-conductivity which is required to create electromagnetic attraction between objects. “Any industries that make non-conductive products, industrial, automotive, or otherwise, will be able to use the product,” Gutowski said. “Powder coatings are much more durable than wet coatings, and until now only manufacturers of metallic products have been able to benefit from the high-scratch resistant, impact resistance, and durability of powder coating.” The technology will require a change in spraying equipment for some manufacturers. “Companies spraying wetpaint coatings would currently have various spray booths and wet-paint guns that are designed for liquid coatings and not powder,” he said. “Powder coating would require different spray guns and booths, and sprayed components require a heating

The Australian automotive industry uses around 10 million litres of liquid paint a year to coat the surfaces of new vehicles and plastic components for aesthetic reasons.

facility to melt, flow, and cure the coating on the plastic.” Plastic components that are not coated with paint and require colouring often contain pigments and colouring agents throughout the plastics. “This is not always necessary because people only see the surface of the plastic component. Applying a colour coating on the surface can actually make a big pigment saving.” Seminars will be conducted with the Australian automotive

industry and sub contractors to OEM manufacturers over the next few months to explain the technology and try to demonstrate its applications. “This is more than a serious competitor to traditional liquid style coatings,” Matthews said. “Not only is there an environmental benefit, it also makes good economic sense.” CSIRO 03 9252 6083 Dilip.Manuel@csiro.au www.csiro.au

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technews National materials handling contract SCHNEIDER Electric has contracted Toyota Material Handling (TMH) as a key supplier for its manufacturing and distribution centres around Australia. The company will supply and maintain more than 170 Toyota, BT, and Raymond brand forklifts, reach trucks, stock pickers, and walkie stackers under the agreement. Schneider Electric’s growth in Australia was underscored in 2003 by its acquisition of Clipsal, the number one brand of electrical accessories in Australia and Asia. The company’s national responsibilities for same or next

Toyota will supply and maintain more than 170 Toyota, BT and Raymond brand forklifts.

day FIS delivery of electrical products throughout Australia expanded to cover more than

3500 locations as a result of the acquisition. After a 12 month research and evaluation program, followed by a competitive tendering process, Toyota Material Handling was awarded a national contract to supply its Toyota, BT, and Raymond equipment. “We were looking for a supplier with access to the latest technology and with the resources to supply and service us nationally across all material handling equipment types,” Ross Carter said. Toyota Material Handling www.toyotamaterialhandling .com.au

Generation F answer skills shortage RECENT research has uncovered a new generation of workers that will rival Generation Y as the solution to the nation’s skills shortage. The Equal Opportunity for Women in the Workplace Agency’s (EOWA) report, Generation F: Attract, Engage, Retain, has identified that women aged between 16 and 65, dubbed Generation F,

remain significantly overlooked and untapped. Despite record education levels and rising numbers of women entering the labour market, the EOWA research shows that employers are failing to provide workplaces that enable women to fully participate and fuel the growth in the Australian economy. Despite a shift in focus away from careers and towards a

family and work life balance by both men and women across all income, education and lifestyle groups - workplaces are still not providing the level of flexibility required, according to the report. The report found 83% of women consider organisational support of work/life balance to be important, however, 42% feel that they do not have access to flexible work conditions.

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“Now that technicians and operators meet regularly, maintenance flows are much smoother. Everyone knows what has to be done, priorities can be made and planning has become more efficient.” Per Oxelgren, Technical Director V&S Absolut Spirits

www.IFSWORLD.com

IFS sprint Growth Business Edition

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Built to last... Just like our compressors.

The GA Compressor from Atlas Copco provides efficient, clean and reliable compressed air through: Assured Reliability The GA is designed, manufactured and tested in accordance with ISO 9001, ISO 14001 and ISO 1217, Ed. 3, Annex C. Ensuring a long and trouble free life at the lowest operating cost.

Reduced Energy Costs Our GA VSD compressors can reduce energy costs by an average of 35% and overall compressor lifecycle costs (LCC) by an average of 22% by tuning compressor capacity to the air demand.

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For more information 1800 023 469 ausairinfo@au.atlascopco.com www.atlascopco.com.au

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technews Chinese export success

MADE TO ORDER • Design and Manufacture • Fast turn around times • Low minimum order quantities

GOULBURN Valley based Furphy Engineering, one of regional Victoria’s major engineering and fabrication companies, has made its first major export delivery to China. The company has recently completed fabrication of a large galvanising ‘kettle’ or bath for a privately owned galvanizing company based in Guandong Province of China. The export order valued at around $150,000 is for a steel bath 13 m in length, 1.5 m wide, and 2.6 m deep, with a shipment weight around 41 tonnes. The galvanizing bath will contain the molten zinc into which steel is dipped for long term corrosion resistance.

The company’s client is a fabricator of steel power transmission towers and sought out the company to supply the bath over alternative fabricators in Europe and the USA. “Over the past fifteen years Furphy’s have fabricated about 120 similar kettles or baths, of which about two thirds have been exported to galvanizing contractors around the world,” J Furphy & Sons managing director Adam Furphy said. “We are recognised for our skills, innovation, and capacity in heavy duty steel fabrication for the galvanizing industry. “We have been alert for some time to the significant potential in China where there are some

1,500 galvanizing plants, most of which are seeking to improve their efficiency, environmental performance, and the finished quality of their galvanized steel products in particular.” The company believes further opportunities will open up in China, with the major development of national infrastructure continuing in the region. The galvanizing bath was fabricated from 50 mm thickness of low silicon Xlerplate steel supplied by Bluescope Steel. “This is a consistent specification heavy duty steel plate which we cut, press, and weld to form the large bath,” Furphy said. 컄 J Furphy & Sons www.furphys.com.au

• Competitive tooling costs • Wide variety of materials For more information

NPA PTY LTD 10 Gray Street, KILKENNY SA 5009 Tel: (08) 8268-2733 Fax: (08) 8268-1455 email: sales@npa.com.au Website: www.npa.com.au Furphy Engineering’s 41 tonne galvanizing bath ready for transport to Melbourne and export to China.

Safe at work awards MINISTER for Industrial Relations, John Della Bosca, has invited entries from NSW employees and employers for the 2008 WorkCover SafeWork Awards. “There are brilliant safety initiatives in workplaces all around the State and the individuals and teams who devised them deserve to be recognised,” Della Bosca said. “The annual WorkCover NSW SafeWork Awards showcase innovation and excellence and recognise best practice by highlighting industry achievement.” Categories include: • Best workplace health and safety management system • Best solution to an identified workplace safety issue • Best workplace safety practices in small business • Public sector leadership award for injury prevention and management • Best individual contribution to workplace health and safety 컄 Safe Work Awards www.safeworkawards.com.au 8 FEN |

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therobotfiles

Brought to you by

Problem Solver The Robot Files Application: Automotive components welding CLIENT An Australian metals and plastics fabricator

meant that operator movements were minimised in the applications loading and unloading operation.

INTEGRATOR Machinery Automation and Robotics 02 9748 7001

PROBLEM Continuing pressures are placed on automotive companies to manufacture light and efficient vehicles while maintaining high safety levels. These requirements have led to the development of a new pressed and formed vehicle components. All safety-critical welds need to be monitored, and the quantity of welds and the various welding parameters necessitate the use of robot welding systems. Ergonomic considerations

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THE SOLUTION EQUIPMENT Two ABB IRB2400L robotic systems, each equipped with MIG welding equipment. One high speed rotating positioner system with two jig stations. Dual channel weld monitoring system. Forkliftable safety cell for fast installation Man machine interface The company developed a solution where the operator loads the individual components of the product into the jig and steps back behind the safety light curtain.

JUNE, 2008 | WWW.MYFEN.COM.AU

The man machine interface graphically confirms that all components are in position, allowing the operator to start the operation cycle on the machine. The jig is automatically rotated into the cell where the robot ABB IR B240 systems complete the 0L Ro bot sy stems welding, during which with M IG we all individual welds are lding e quipm ent. monitored for integrity. The two robots weld the product in a programmed sequence to ensure that thermal stresses are balanced and do not distort the product. BENEFITS positioner system the robots While the robot systems are highly productive and the • Continuous output are welding, the operator operator is able to load and then moves to remove the • Consistent level of quality unload the product while completed product at the • All welds are monitored guarded from the robot syssecond station, and repeats • Reduced labour skill tem, arc flash, and welding. the loading cycle. required By using the dual station • Safer environment

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insight Q&A Ask The Expert

More Sensing Solutions

Manufacturing logistics solutions Each month, we ask experts for their manufacturing insights. This month we talk to Dematic industry logistics manager David Rubie.

common challenges that Australian manufacturers are facing with logistics solutions? Market and customer demands are placing enormous pressure on manufactures today. Warehouses are bulging with additional inventory not being carried by major end customers, often leading to off-site storage requirements and inefficient handling within the supply chain. The increased cost of suitable land and scarcity of labour in capital cities is also causing a rethink of traditional warehouse solutions and supply chain networks. More onerous requirements in occupational health and safety, product recall legislation, and other external influences are all causing impact to manufactures and how they operate their supply chain.

Q. How are manufacturers responding to these challenges? Supply chains are being consolidated and manufacturers are seeking warehousing efficiency by leveraging centralised volume. Optimisation of existing warehousing space is becoming an attractive option. An increased uptake and consideration of automated warehousing solutions, particularly suiting multiple shift operations, provides consistent outcomes, information capture, and improved quality. These solutions reduce traditional labour intensive applications, manual handling, and wheeled equipment processes. Automated warehouse solutions are the key to improved supply chain velocity, as it allows manufacturers to focus on responsiveness, inventory, and

Q. What are manufacturers demanding from logistics and materials handling providers? Manufacturers are looking for solutions that provide faster, reliable, and cost effective warehousing outcomes. Locally, this is most often delivered with a combination of automated and manual processes, with logistic solutions aligning automated aspects against volume, repetitious, or unhealthy work processes. The incorporation of complimentary manual processes around these warehouse solutions often provides a healthy balance of flexibility, particularly for applications that are subject to significant peak periods or are costly to automate. As service level for manufacturers is a key market differentiator, the ability to access real time information across the logistics operation in becoming more common place. Smart conveyor systems that link production and logistics provide feedback on status and tracking of products. Warehouse technology like voice and RFID are being

widely deployed to improve picking accuracy, inventory control, and operator productivity. Control platforms like order management systems and warehouse management systems capture this information and provide a mechanism for managers to optimise operators and processes.

Q. What tools and services are available to help manufacturers streamline their logistics solutions? There are many avenues for manufacturers to review current and proposed logistics solutions. One key development in this area is powerful simulation and modelling tools. Simulations of sub system elements or complete logistics solutions can enable important understanding of warehouse capabilities and limitations. Once developed in simulation form, solutions can be subjected to sensitivity tests and analysis, allowing greater understanding of stress locations. Quality simulation packages are very different to simpler animations and they require extensive input of equipment and resource to build realistic models. Often this requires engineering experience

• Inductive • Photoelectric • Capacitive • Laser • Ultrasonic • Fibre optic • Vision • Distance measurement • Pressure • Flow • Level • Temperature

• High power • Ruggedized • Cordsets • Junctions • Limit switches • Encoders • Resolvers • Linear transducers • Counters • Timers

KEY CONTACT Contact David on 02 9486 5555, or email David.Rubie@dematic.com.

No Welding! No Cleaning Up

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from 0.8mm to 6mm wall thickness for square, rectangular or round tubes. Here are some popular sizes: Square: 25 x 25 x 1.0 - 3.0mm 40 x 40 x 1.25 - 4.0mm 50 x 50 x 0.8 - 2.5mm 75 x 75 x 2.0 - 4.5mm from 20 x 20mm up to 100 x 100mm Rectangle: 50 x 25 x 1.0 - 3.0mm 75 x 50 x 2.0 - 4.0mm 100 x 50 x 2.0 - 4.0mm from 37.7 x 19mm to 150 x 100mm Round: 25 o.d. x 1.0 - 4.0mm 33.7 o.d. x 2.6 - 4.0mm 48.3 o.d. x 1.2 - 5.0mm 60.3 o.d. x 1.5 - 5.0mm from 16mm o.d. to 114.3mm o.d.

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1300 36 26 26

FENFLE2OCT-01

Q. What are the most

improved service levels. The requirement for real time information and the integration of information systems within the supply chain enables intelligent supply chain decisions in a dynamic market place.

become more important to Australian manufacturers in the last five to ten years? Smart logistics solutions are more important than ever. An efficient, cost effective, and responsive supply chain is increasingly becoming an important tool for market differentiation in the competitive local manufacturing market.

Q. Have logistic solutions

Email us for more information at: sensors@micromax.com.au

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technews 10 things you didn’t know about…

Hearing protection 1

The World Health Organisation (WHO) states that safe levels for noise exposure is 85 DBA over an 8 hour exposure period.

Removing hearing protection for short periods can be very detrimental to the health of one’s hearing.

Electronic ear-plugs technology enables face to face speech, two-way radio and mobile phone communication.

Each 3 DBA increment over the 85 DBA threshold halves the safe time exposure threshold.

Binaural technology allows users to retain the ability to detect the direction of background noise.

9 10

Noise Induced Hearing loss is the world’s most common occupational illness and is preventable, but cannot be cured.

Hearing protection technology can enable connection to mobile phones.

Higher rated hearing protection can render the wearer effectively deaf and robs them of one of the most important senses.

The most common reason people remove hearing protection is the need communicate with co-workers.

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Rechargeable elec tronic ear-plugs reduces wastage from continually replacing batteries. .

Binaural technology allows users to retain the ability to detect the direction of background noise and tell which direction noise is coming from.

컄 Sensear 03 99352781 greg.beale@sensear.com www.sensear.com

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ontheweb www.myfen.com.au

Safe workplace reward

Challenges ahead

Chinese export success

MINISTER for Industrial Relations, John Della Bosca, has invited entries from NSW employees and employers for the 2008 WorkCover SafeWork Awards. “There are brilliant safety initiatives in workplaces all around the State and the individuals and teams who devised them deserve to be recognised,” Della Bosca said.

MANUFACTURERS experienced subdued growth in April, according to the Australian Industry Group PricewaterhouseCoopers Australian Performance of Manufacturing Index (Australian PMI). Activity growth has subdued for the fourth consecutive month with the Australian PMI rising slightly by 0.4 points to 52.7, remaining above the key 50.0 level separating expansion from contraction.

GOULBURN Valley based Furphy Engineering, one of regional Victoria’s major engineering and fabrication companies, has made its first export delivery to China. The company has recently completed fabrication of a large galvanising ‘kettle’ or bath for a privately owned galvanizing company based in Guandong Province of China.

Future supply chains STRATEGIC Futurist Marcus Barber will be opening the 2008 Supply Chain and Logistics Conference on Thursday, 31 July, at the Sofitel Hotel, Brisbane. Marcus Barber is one of Australia’s top Value Systems specialists.

Survey under threat Rudd chairs council THE Prime Minister has chaired his first meeting of the Prime Minister’s Science, Engineering and Innovation Council (PMSEIC).

RECENT events have shown that even the Australian Bureau of Statistics (ABS) is not safe from the national skills crisis, with the ABS flagging cuts to key data

series, including the monthly labour force survey. Cost pressures have caused the ABS to flag cuts to the series, and plans to upgrade and redesign the 2011 census will be scrapped.

Sustainability preview AUTODESK has launched a Sustainable Materials Assistant software add-in to incorporate environmental considerations into design. The product is available from Autodesk Labs as an extension to its digital prototyping solution.

MANUFACTURING NEWS UPDATED DAILY ON AUSTRALIA’S PREMIER MANUFACTURING NEWS WEBSITE: WWW.MYFEN.COM.AU

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computers

HARDWARE AND SOFTWARE FOR MANUFACTURERS

Clever design with synchronous technology User speed is paramount with the Product Lifecycle Management industry’s first history-free, feature-based modelling technology. SIEMENS PLM Software, a

business unit of the Siemens Industry Automation Division, with Solid Edge, has announced a breakthrough in digital product development with synchronous technology. The technology is said to be the Product Lifecycle Management (PLM) industry’s first history-free, featurebased modeling technology, which provides users with up to 100 times faster design experience than ever before. The company’s technology combines constraint-driven techniques with direct modeling, and is being integrated into the company’s next versions of NXTM and Solid Edge(R) software.

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“Siemens recognised the huge potential of synchronous technology during the due diligence process of acquiring UGS,” Siemens Industry Automation Division Anton Huber said.

Accelerated innovation The technology is said to be the first design solution that simultaneously synchronizes geometry and rules through a decision-making inference engine. It accelerates innovation in four key areas: - Fast idea capture: Synchronous technology captures ideas as fast as the user thinks them, with up to 100 times faster design experience. - Fast design changes: The

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technology automates the implementation of planned or unplanned design changes to seconds versus hours through ease of editing, regardless of design origination, with or without the presence of a history tree. - Improved multi-CAD reuse: The technology allows users to reuse data from other CAD systems without remodeling. A technique, called suggestive selection, automatically infers the function of various design elements without the need for feature or constraint definitions. - New user experience: The technology provides a user interaction experience that simplifies CAD and makes 3D as easy to use as 2D.

SIEMENS PLM Software’s history-free, feature-based modelling technology.

The interaction paradigm merges historically independent 2D and 3D environments, providing the robustness of a mature 3D modeler with the ease of 2D. New inference technology

automatically infers common constraints and executes typical commands based on cursor position, making tools simple to use for occasional users. 컄 Siemens www.plm.automation.siemens.com

Lifting solutions tailored to your needs. CRANES, MONORAILS, OISTS AND VACUUM LIFTERS H Imagine the perfect lift every time, all the time. GIS Hoist and Crane systems can be tailored to meet your lifting needs up to 5 tonne. Quality Swiss manufacturing means that the GIS system can handle even the toughest situations and environments. Bridge Cranes

Vacuum Lifters

Workstations

For a free consultation contact Hasemer T: (02) 9519 8188 F: (02) 9519 4538 E: sales@hasemer.com.au www.hasemer.com.au

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computers Sustainable design tool

FREECALL 1800 99 22 11 MELBOURNE, SYDNEY, BRISBANE, PERTH, ADELAIDE & NZ

The Right Advice, The Right Solution THE RIGHT CHOICE Vacuum lifting devices VacuMaster are the ideal tools for the handling of sheets of metal, wood, glass and stone slabs, weighing up to 2000kg. Product can be handled horizontally, or turned through 90º or 180º.

VACUUM SHEET LIFTERS JUMBO ERGO & HANDY The Vacuum tube lifter is particularly suitable for frequent and fast lifting and moving of porous and non - porous cardboard boxes, sacks, barrels, sheets of wood and many other objects weighing up to 300kg. Also for Explosion Hazard Areas

WORKSTATION CRANE Lifting, Shifting and precision placement of product at the workstation and the job made light and simple with Millsom low friction track.

JIB CRANE Standard, low head room or wall and column mounted. Capacity from 80kg up to 5 tonnes with jib length from 1.5 to 6 metres.

ELECTRIC CHAIN HOISTS Our electric chain hoists can be customised to suit your particular needs. For this purpose, "SWF Krantechnik" offers a wide range of accessories and optional equipment. Challenge us - we are sure we will be able to provide you with a suitable solution!

ROTO LIFT - Pallet Elevator Rotating table and elevating table for loading and unloading of pallets and stretch wrapping.

NEW PRODUCT

email - sales@millsom.com.au 16 FEN |

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Autodesk’s Sustainable Materials Assistant software add-in.

AUTODESK has launched a Sustainable Materials Assistant software add-in to link manufacturer’s incorporate environmental considerations into design. The product is available from Autodesk Labs as an extension to its digital prototyping solution. The software is designed for use with Autodesk Inventor 2009 software and includes an expanded materials library and a sustainability report function. The expanded materials library adds new property fields for materials that are included in the Inventor materials library. Inventor software users can populate these new fields with information about the toxicity, recyclability, carbon footprint, and regulatory

compliance issues of any of these materials. The software’s sustainability report function is accessible from the Inventor software’s Bill of Materials Editor and analyses and aggregates properties based on the materials and components that comprise design options. Users can output a report in HTML format to document, compare, and communicate the sustainability of their designs with key stakeholders, helping design teams make informed, environmentally responsible product decisions. The add-in is available as a free technology preview downloadand is not compatible with Inventor LT software. 컄 Autodesk christine.stoner@autodesk.com www.autodesk.com

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MOTORS & DRIVES

MOTORS DRIVES TRANSMISSIONS guide

FEN asks the experts for their top tips to save time and money with motors, drives and transmissions.

Top ways to save time and money with motors, drives and transmissions ● Consider the complete machine. ● Consider the application and the load characteristics first. ● Plan ahead. ● Ensure that products have a good service and back-

up infrastructure. ● Establish a systems solutions mindset. ● Consider ancillary equipment. ● Consider using motors designed for use on VSD. ● Consider the benefits of a single source supplier. ● Incorporate motion control and PLC logic on

board the drive. ● Get motor and drive sizing right. ● Use one software tool for all engineering applications. ● Consider Ethernet solutions. ● Conduct a risk assessment. ● Use a brake with air motors. ● Plan ahead for maintenance.

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N ANY modern industrial application it is important to consider the hidden costs that may affect the installation or the user. “With production running costs representing a significant part of a manufacturing plant’s overall running costs, and the modern emphasis on energy savings and the reduction of carbon emissions, optimal savings can be made with correctly designed drive trains and motor control,” Mitsubishi Electric product sales engineer Grant Millard told FEN. “Not only can energy costs be reduced, but improved machine diagnostics with inverter and fieldbus technologies can minimise machine downtime.” “Hidden costs can represent a much larger impact than the initial purchase price when they are truly

accounted for,” WEG Australia automation product manager Sean Richardson told FEN. “In many instances hidden costs take the form of lost productivity, excessive maintenance requirements, and on-going running costs. “By combining the latest technology in place of drive sprockets and chains, users can easily achieve significant efficiency savings on a machine.” As in many manufacturing applications, the total cost of ownership is the most important factor when purchasing motors, drives and transmissions equipment. In this special feature, FEN asks the experts for their top tips to save time and money with motors, drives and transmissions, as a guide to simplified manufacturing success.

Mitsubishi Electric product sales engineer Grant Millard COMPLETE MACHINE It is important to consider the complete machine when looking to optimise a product line. Cost savings can be made with electrical controls, motors, chains, sprockets and transmission elements. Combining inverter control, high efficiency motors, geared motors or gear reducers in place of drive sprockets and chains can achieve significant efficiency savings on a machine. INVERTER CONTROL When choosing inverter control, consider the application and the load characteristics to determine what is needed. If changing from direct online control it is always

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feature MOTORS AND DRIVES

FR-E700 FR-D700 THE NEW POWERHOUSE IN COMPACT DRIVES

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MOTORS & DRIVES

and pre-warning of machine component failure. Fieldbus systems such as DeviceNet, profibus, and Ethernet minimise wiring and offer fast, trouble-free control with accurate feedback of the machine status. Safe stop functionality can be configured to bring a machine to a safe controlled stop in the case of emergency, allowing the inverter to be incorporated easily into category rated safety systems.

Mitsubishi Electric’s latest range of inverters.

important to consider the starting torque required by the application. A direct on-line machine start will allow a much higher starting current to be drawn. It is important that this is taken into consideration when sizing an inverter to ensure the correct kilowatt inverter size is selected. Inverters like any control component are available in many different models with

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different functions and options. The model which is required is determined by the machines characteristics. FORWARD PLANNING Machine downtime can be minimised with forward planning, and safety can now be incorporated with the new inverters. Fieldbus control methods allow for easier diagnostics

JUNE, 2008 | WWW.MYFEN.COM.AU

WEG Australia automation product manager Sean Richardson TECHNICAL SUPPORT Manufacturers should ensure that motors and drives products selected have a good service and backup infrastructure. The saying goes “fail to plan, plan to fail”. High level technical knowledge must be available on site regardless of the requirements or application, so the best advice is to research how the suppliers can meet the manufacturer’s needs as they arise.

SYSTEMS SOLUTIONS Manufacturers should establish a systems solutions mindset when evaluating a proposal or upgrade. When evaluating a proposal or upgrade, or even when considering top ways to save time and money, the manufacturer should evaluate a combination of ideas rather than simply picking one solution as more important than others. ANCILLARY EQUIPMENT Consider ancillary equipment to improve system performance. There may be a multitude of products or ancillary items that will benefit the overall drive system solution. AC Reactors may improve Total Harmonic Distortion (THD), smooth supply voltage variations, and protect against mains current surges. DC chokes can smooth DC bus voltage and reduce harmonics, and sinus filters and output reactors can assist in the reduction of adverse affects of pulse width modulated supplies. RFI filters for electro-magnetic conformity and various control, communication, and

logic cards specific to the VSD can extend I/O enhancement, encoder feedback, and Fieldbus communications. VARIABLE SPEED Consider the use of a motor designed for use on VSD. Today, there are only a few suppliers of special wire for motors supplied for VSD, commonly referred to as spike resistant wire. This is typically due to cost, but when a motor is connected to a VSD, the motor insulation can be adversely affected. The motor insulation system becomes subjected to high rates of voltage rise, and voltage spikes of 1500 V, with transients of 5000 V/µs. These occur at the switching frequency of the drives output, typically 4 kHz to 8 kHz, and with some drive manufactures trending towards higher switching frequencies to reduce audible noise, the issue can become worse. MATCHED PACKAGE Manufacturers that produce or supply motors and drives are going to be able to ensure

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MOTORS & DRIVES

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matched performance and design considerations on products with more certainty. When different manufacturers supply a mixture of machines to the user, the onus to ensure compatibility generally falls onto the purchaser. If machines are tested for compatibility with each other and are designed for use in conjunction with each other, the application will benefit from cohesive design, additional features, and reduced start-up and commissioning time. If the motors electromagnetic model is automatically incorporated into the VSD's vector control software, then multiple benefits are potentially available. The purchaser or specifier should always ask and be appraised of the advantages on this multiple line item supply philosophy both technically and commercially.

Bosch Rexroth electric drives and controls national manager Peter Sammut MOTION LOGIC DRIVES Manufacturers should incorporate motion control and PLC logic on board the drive. The drive integrated motion logic reduces or even eliminates the need for higher level control systems. Standardised programming languages like IEC 61131-3 and standardised interfaces help keep training and engineering costs to a minimum. Ready to use function block libraries allow users to reduce engineering costs and

implement a system solution faster. CORRECT SIZING Correct drive and motor dimensioning saves users time and money. Software tools are available to simplify the design of motors and controls for specific applications, allowing users to get the system’s dimensions right. This permits a systematic reduction in overall energy consumption and space. Software selection tools make it easier and faster to calculate the optimum motor drive combinations and specific configurations for applications like winders, cross cutters, press feeds, and ball screw applications. This software is available free of charge from company websites. COMMON SOFTWARE Having one software tool for all engineering applications eliminates the need of various software packages and eliminates compatibility issues. One software tool for all engineering applications also reduces software costs and engineering time. These engineering frameworks bring together all the tools required for configuring, programming, parameterisation, operation, visualisation, and diagnostics in one software package. ETHERNET SOLUTIONS An OPC server, combined with motion logic drives, makes for simple integration with industry standards like SCADA and laboratory test

software. This substantially improves engineering time and diagnostics ability. The technology allows users to improve communication between their drives over plant networks or wireless routers. For critical, high-speed data, UDP/IP communications can be established where no Fieldbus is available. This includes peer to peer communications between drives and motions controllers around a plant.

Assembly Technologies sales manager Paul DeRossi AIR MOTORS The starting point for any air motor selection is the required speed and the power of the motor. Other factors also need to be considered including air consumption, service life, start torque, stall torque, and shaft loading. Perhaps the most common use for air motors is in hazardous environments, where the risk of explosion is present, however, other conditions should also be considered. The manufacturer should consider if the environment is wet or dusty, if the motor could be submerged in water or acid, and if the motor body should be stainless steel. RISK ASSESSMENT Air motors do not overheat, burn out, or throw sparks, making them suitable for use in hazardous environments. A risk assessment should be done on any piece of equipment going into a hazardous workplace. If the workplace is likely to have an explosive atmosphere due to dust or gases, the use of ATEX approved air motors will give the risk assessor a higher level of confidence about the motor. The ATEX approval is a European standard for equipment that is used in explosive atmospheres. BRAKE MODULES A common method of stopping or holding a load with an air motor was to supply air to the forward and reverse ports of the motor. This has two problems. Firstly, while both ports are supplied with air, the motor is wasting expensive compressed air.

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Mitsubishi Electricâ&#x20AC;&#x2122;s D700 inverter.

Secondly, if the air supply is lost, the load could fall or move causing injury or damage to the machine. The safer option is to use a brake. MAINTENANCE Preventative maintenance on motors will save downtime and money. One of the advantages of air motors is that they can be safely serviced by a mechanical fitter. If motors are not maintained correctly, the damage will be far more than the small amount of time invest-

ed to keep them in good condition. Correct lubrication is important and good air motor oil should be resin free and include a rust inhibitor. General statements on the frequency of maintenance intervals for pneumatic motors are hard to give, however, the correct selection and use of motors are vital for determining a service and maintenance interval. *With thanks to Mitsubishi Electric, WEG, Assembly Technologies and Bosch Rexroth. For contact details visit www.myfen.com.au.

Electric Drives and Controls

Hydraulics

Linear Motion and Assembly Technologies

Pneumatics

Service

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Powerhouse compact and micro-inverters WITH 11 million frequency inverter drives already sold, Mitsubishi Electric now introduce its latest generation of compact inverter, the FRE700, and the ultra compact FR-D700 series. In addition to additional features and improved performance, the new series is also more compact and easier to install. The drives include an integrated USB port, an integrated, one-touch digital dial control with a display, improved power usage at low speeds, and an expansion slot compatible with cards from the 700 series. The range includes intelligent functions for diverse applications. A sensorless vector control system in the FR-E700 and FR-D700 series provides improved speed and torque performance. This technology makes it possible to achieve increased speed and torque performance, even with motors without encoder feedback loops. The drives also include an auto tuning function that can read necessary parameters directly from the motor in less than a minute, even when the motor is not running. The range increases the

Mitsubishi Electric’s FR-E700 inverter, and the compact FR-D700.

maximum short-term overload capacity to 200% for three seconds for the FRE700, and 0.5 seconds for the FR-D700 version. The drives also feature improved torque and current limiting during start up, and deceleration ensures better protection for machines. Applications like gate drives, hoists, cranes often need an additional brake to cope with suspended loads. The FR-E700 series support connection of an external mechanical brake controlled by the inverter. An integrated control unit with a one-touch digital dial on both inverter models gives the user direct access to important parameters.

In addition to entering and displaying parameter values, the integrated display is used to monitor and check operating values and alarm codes. The FR-E700 and FR-D700 inverters can be connected to RTU Modbus and the FRE700 supporting network systems like Profibus/DP, CCLink, DeviceNet and Lonworks. Additional functions can be added to the FR-E700 with option cards and I/O modules. The range conforms to international standards including CE, UL, cUL, CTick, and GOST. 컄 Mitsubishi Electric 02 9684 7316 MillardG@meaust.meap.com www.mitsubishielectric.com.au

Gear reducer POSIPLAN’S range of gear reducers has been expanded to 12 sizes, with peak torque now up to 89 000 Nm and ratios from 13:1 to 10,000:1. Continuing development will see larger sizes being released in the future. The compact design means they can fit restricted spaces such as screw conveyors, travel cranes, and continuous casting machinery. A hybrid design, which combines planetary with helical gears, or planetary and bevel-helical gears, allows the gear reducers to provide reliability, with little maintenance. Efficiencies at greater than 97% for two-stage units are typical, with slightly lower efficiencies for three and fourstage units. All units come with a torque arm, and optional accessories include shrink discs, common bed frames, back stops, and brakes. 컄 Brevini Australia 02 9671 1000 www.brevini.com.au

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A new age of electric motor efficiencies Alongside moves to harmonise efficiency standards on a global scale over the coming years, innovative research and new directions are already emerging. SEW Eurodrive engineering manager Frank Cerra writes.

Why settle for MINIMUM EFFICIENCY when

HIGH efﬁciency Will save you more Ex-stock to 187kW

A conveyor head-drive installation in the Australian mining sector.

THE Australian introduction

BROACH

of Minimum Energy Performance Standards (MEPS) for electric squirrel-cage induction motors is, in some respects, old news. This Australian Greenhouse Office (AGO) initiative, which was first legislated in October 2001, represented an important first step for Australia. Since this inauguration, the Australian and international MEPS scenes have been anything but stagnant. In April 2006, the two Australian efficiency levels were taken up a notch. A revised edition of the AS/NZS1359.5:2004 standard saw the previous ‘high efficiency’ (HE) levels specified in AS/NZS 1359.5:2000 effectively become the new MEPS levels (often referred to as MEPS2).

IT WITH

The new HE level targeted a further 15% reduction in losses on the 2001 MEPS ‘high efficiency’ levels. In the long-term, these new standards should reduce total Australian energy consumption by 8900 GWH, and cut the country’s greenhouse emissions by 7.7 MT. Internationally, there are moves to harmonise the disparate electric motor efficiency standards, such as those of the US and Europe, into common International Electrotechnical Commission (IEC) standards over the coming years, however, R&D is already being undertaken by global industry bodies that goes beyond the bounds of the electric motor itself. This work is looking to explore the domain of what is often described as ‘total drive efficiency’.

Beyond MEPS While current MEPS-compliant electric motors realise a 2% to 3% efficiency improvement over old, standard efficiency motors, it is valuable to see how such figures sit within the context of a total drive train efficiency upgrade. While MEPS compliance is vital, it is equally vital to look beyond the motor itself and consider the drive train as a whole. The figures shown above depicts a real-world example of a total drive train efficiency upgrade, drawn from the Australian mining industry. The top illustration in the figure shows the pre-upgrade conveyor head-drive installation of a very old system. Originally, the drive train comprised a MEPS-compliant motor, coupled to the head-

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continued from page 27

Levelling feet light • medium • heavy duty Flexliner stock a wide range of metric tilting and nontilting levelling feet of varying thread sizes, lengths, base diameters and load capacity. This range is complimented by round, square and rectangle threaded tube inserts plus drive-in threaded “T” nuts and weld-on or screw-on threaded plates

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Threaded tube inserts for levelling feet ROUND - 35 sizes from 20mm O.D. x 1-2mm x M8 thread to 60mm O.D. x 1.5-2mm M20 thread

drive via a vee-belt, worm-gear unit, and chain-sprocket drive. The inherent efficiencies across the three-stage drive train resulted in an overall drive efficiency of 60.8%. A high-efficiency helicalbevel gear unit, close coupled to the MEPS-compliant motor, replaced this inefficient drive train. The resulting efficiency of this replacement assembly was 88%. Based on an energy cost of $0.10/kWh, the new installation saves almost $2500 a year in reduced energy costs. The estimated return on investment in this scenario is around two to three years. There would also be a significant reduction in greenhouse gas emissions. The average life expectancy of a typical induction motor can be up to 20 years. More telling is just how this total drive train efficiency might vary if MEPS compliant motors were not used. Using a pre-2006 MEPScompliant motor (non-compliant by today’s rulings), the total drive train efficiency with the close-coupled helical-bevel gear unit would only drop to 86%. This figure is still significantly higher than the vee-

SEW-Eurodrive’s Engineering Manager, Frank Cerra.

belt, worm-gear, chain, and sprocket combination with MEPS-compliant motor. This underscores the importance of looking beyond the motor itself and considering the entire drive train. Towards the future These ‘total drive efficiency’ perspectives are central to studies currently being undertaken by a wide range of influential industry groups and conferences. These include the European Commission’s Energy Usage Product Directive, the International Copper Association’s Energy Efficiency in Motor Drives Systems (EEMODS), and the AsiaPacific Partnership on Clean Development and Climate (AP6) initiative. The latter is most important from an Australian envi-

ronment perspective, as it represents the major industrial groups from Australia, China, India, Japan, Korea, and the United States. The results of these studies will pave the way for the future, and could represent the foundation for a new wave of global total system MEPS standards. A 2007 study from the European Commission’s Energy Usage Product Directive notes that energy costs for an electric motor in continuous operation represents 96% of its total life-cycle costs. This suggests that the performance-class of the electric motor, and the design of drive-train to which it is coupled, need to be carefully selected and implemented. Initial capital expenditure will typically be a negligible factor in terms of total lifecycle expenditure. The MEPS world is fast moving towards a uniform standard. The next challenge will be to address life-cycle and drive train efficiency issues. The potential benefits and ramifications, environmentally and economically, are substantially greater than those capable from a focus on the electric-motor alone. 컄 SEW-Eurodrive www.sew-eurodrive.com.au

Electric motor products SQUARE - 44 sizes from 16 x 16 x 1-2 x M6 thread to 50.8 x 50.8 x 1.6-2mm x M20 thread

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JUNE, 2008 | WWW.MYFEN.COM.AU

BALDOR has published its first catalogue of stocked electric motor products following its acquisition of Reliance. This 580-page volume details thousands of Baldor Reliance motor choices in virtually every application area including premium efficiency, severe duty and explosion proof, wash down, DC, vector and brake, plus many application-specific types including pump, HVAC ,and farm duty. Power ranges for stocked lines range from 0.015 kW to 750 kW. Both IEC and NEMA frame types are detailed, but Baldor Reliance’s American heritage means there is a choice of NEMA types providing in-depth support for automation builders who export to North America and allied markets. 컄 Australian Baldor 02 9674 5455 sales.au@baldor.com www.baldor.com.au

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Miniature two-wire motor Two-wire motor turns detent-free, with electronics integrated in the motor. MAXON has released the ECmax two-wire motor which turns detent-free. The commutation electronics are integrated in the motor, which is only 16 mm in diameter and 33.5 mm long, with a nominal output of 5 W. The reduction to two connection wires allows brush motors to be directly replaced. The stainless steel motor housing, when combined with the metal flanges, provides a high degree of temperature stability, heat elimination, and shielding against electrical fields. The integrated electronics allow direct control with an operating voltage of between 5 V and 15 V. The motor turns proportionate to the applied voltage with

proven dependability and more than 1.5 million units in service

The reduction to two connection wires allows brush motors to be directly replaced.

the relevant speed in a given direction. The electronics have protective circuits to protect the motor against polarity reversal, overheating, axle blocking, and under-voltage. With a nominal output of 5 W, the motor generates continuous torque of up to 3.4 mNm. A 16 mm diameter plane-

tary gear head can be added to increase inertia to a maximum of 0.3 Nm. The motor can be used in any application where a long service life but simple controls are required, such as hand-held tools or automation systems. Maxon

Motor 02 9476 4777 www.maxonmotor.com.au

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TAII • An all-new backstop concept and new patented sealing system. • A totally new steel motor mount system. • A state-of-the-art, totally modular design with an expanded ratio range to 40:1.

LED and discrete component mounts BIVAR has release the Extruded Nylon Mount (ENM) series of high temperature, self-retaining extruded mounts for improved LED and discrete component mounting. This answers the need for a method of component mounting with the higher temperatures encountered in the leadfree soldering process. Extruded from high temperature, 94V-0 rated Nylon, the ENM Series offers a 260°C rated alternative to the existing ELM 4, 5, 7 Series. The material has been coloured blue making it easy to distinguish from standard mounts. The lead-free nylon mounts provide permanent fixed positioning and compo-

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• A new patented twin tapered bushing system - 1" to 7" and metric sizes. • Ratings to 300kW and 57800Nm. • All-new, highly efﬁcient helical gearing. ENM mounts provide permanent fixed positioning and component alignment solutions for simplified assembly processes.

nent alignment solutions for simplified assembly processes. The 3.8 mm diameter mount is designed for lead centres of 2.54 mm. The unit allows LED placement in vertical slots featuring a selfretention design to securely

retain LEDs or other discrete devices. The ENM Series is manufactured in compliance with RoHS specifications. M

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Mounted Industrial Bearings • Single and double row high capacity spherical roller bearings and ball bearings. • Patented adaptor mount systems improve concentricity, reduce vibration and shaft damage, and deliver frustrationfree 15 minute fit and removal. • Patented triple lip seal. • Bores to 7" and 125mm, pillow block, flanged, piloted flanged, SAF split housing and take-up styles.

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MOTORS & DRIVES

Intelligent positioning controller depending on software commands. A variety of operating modes means that they can be used flexibly in drive systems in automation technology and mechatronics. The controller, with 32-bit digital signal processor technology, supports motion control functionalities, which can carry out complex mathematical algorithms efficiently. The unit offers security and protection against electromagnetic interference as a result of potential-separated digital inputs and outputs. The controller can syn-

MAXON Motor has released

a digital positioning controller designed to control brush and brushless DC motors with encoder. The EPOS2 controllers are suitable for applications that require decentralised drive intelligence. These modular digital positioning controllers, based on CANopen standard, cover a performance range from 1 W to 700W. The controllers can operate in position, speed, and current control mode, and can be configured to operate with DC and EC motors,

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chronously run a path specified through interpolation points dynamically and accurately because of Interpolated Position Mode (IPM). With a suitable master, coordinated multi-axis movements can be carried out in a one-axis system. The upgraded regulation tuning functionality is an effective and time-saving tool for adjusting power, speed, or position control. A USB to CAN and RS232 to CAN gateway function has been integrated into the product, and online commands are carried out

using CAN Master (EPOS P, SPS, Soft SPS) or PC, using the USB or RS232 interface. Several drives can be networked and coordinated through the standardised CANopen interface. The device can be used in

areas such as tool building, production machinery, automation tasks, and anywhere requiring decentralised drive intelligence. Maxon

Motor 02 9476 4777 www.maxonmotor.com.au

Flux vector drives SANTERNO has released a range of flux vector drives and three Sinus models with power ratings ranging from 0.4 kW to 2 MW and supply voltages up to 690 V AC. Each drive has a variety of I/O configurations in digital and analogue control, with optional expansion cards available for more demanding applications. The devices have the ability to integrate with a variety of fieldbus communication protocols including DeviceNet, Profibus DP, Ethernet and Modbus, plus they have a minimal footprint size. The range has the ability to program the drives, save configuration files, perform data logging functions and graphically view real-time data using the ‘Remote Drive’ software. The Nano is available from 0.4 kW to 2.2 kW to suit a single phase 200 V to 240 V AC supply. The range also contains front panel controls and a

The range has the ability to program drives, save configuration files, perform data logging functions and graphically view real-time data using ‘Remote Drive’ software.

panel-mounted potentiometer for speed control. The Nano drive is suitable for basic motor starting requirements, and operates in basic V/f operation or in sensor-less flux vector mode for improved torque control. The Micro is available from 0.4 kW to 7.5 kW in singlephase 200V to 240V AC and three-phase 380 V to 480 V AC models. The Micro has firmware capability and the same features as the Nano, making the drive suitable for use in HVAC installations. The Micro also has 200%

starting torque capability, built-in dynamic braking, and the ability to use additional brake resistors to achieve higher breaking torque. The Penta is available from 4 kW to 1100 kW in threephase 380 to 500 V AC supply and 75 kW to 2 MW in threephase 525 V to 690 V AC supply. The IP54 drive is a standalone wall-mounted device which can be expanded to include a choke, push buttons, and switches without affecting the IP rating. NHP

03 9429 2999 www.nhp.com.au

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MOTORS & DRIVES

Selectable vector drives WEG Australia has released the CFW09 series of Selectable Vector Drives with patented Optimal Flux Technology to eliminate the need for forced cooling on motors at speeds down to 10 Hz. The technology is said to decrease installation and ongoing costs and extend motor service life when used on the company range of W21 series motors. The W21 series is now supplied to the Australian market under AS-NZS 1359.5-2004 (MEPS2). The Optimal Flux Technology regulates the time between pulses of the Variable Speed Drives’s (VSD) Insulated-Gate Bipolar Transistor (IGBT) to minimise voltage surges. This decreases possible surge magnitude by 50%, reducing the detrimental dV/dt effects to motor insulation, even with longer motor cable runs. CFW09 series of Selectable Vector Drives with patented Optimal Flux Technology.

WEG

07 3265 9800 www.weg.com.au

New sales manager to drive growth EXPANDING industrial drives organisation Bonfiglioli Transmission has appointed a new national sales manager, Wilfred Krog, to direct the major areas of the company’s growth in Australia. Krog has more than 15 years experience in major areas of Bonfiglioli’s business, including industrial, mining, and materials handling projects. The company’s Australasian managing director Malcolm Lewis says Krog has an ideal combination of hands-on experience and professional attributes, having complemented his mechanical engineering qualifications with international marketing management studies. “Krog will head an expanding Australian team of 10 sales staff, complementing and supporting the company’s distributor networks in Australia and New Zealand, and supporting the national sales manager of the company’s NZ branch office, Neil Pollington,” he said. “His appointment comes at a time of vigorous growth in our business as Bonfiglioli celebrates its 20th anniversary of operation in Australia,” said Lewis. The global Bonfiglioli group, which has grown 75% over the past five years to sales exceeding $1 billion, is investing extensively in increased stock, and assembly and testing technology in Australasia to further enhance product innovation and service and delivery times.

Bonfiglioli Transmission national sales manager, Wilfred Krog.

Bonfiglioli

02 8811 8000 malcolmlewis@bonfiglioli.com.au www.bonfiglioli.com.au WWW.MYFEN.COM.AU | JUNE, 2008

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WELDING

Concern over shielding gas productivity The right mix of welding gases can improve productivity by up to 30%, but a recent survey shows low recognition of the opportunities to improve welding productivity.

On the left, pure argon is being used as a shielding gas, which can lead to defects (porosity, fusion defects). The addition of special additives such as helium (shown on the right) can influence the arc characteristics, reducing defects and improving welding performance.

A RECENT survey by gas and engineering company BOC has identified that only 18% of users measure the productivity of their gas-shielded welding processes. According to BOC South Pacific technical manager for industrial products Nic Both-

ma, an expert on shielding gas and the welding industry, this is a cause for great concern for industry. “It is shocking that the cost-effectiveness of gasshielded welding processes is hardly being measured at all,” Bothma said.

“The cost-efficiency of welding can be improved by up to 30% if the right gas mixture is used on the right base material using the right process. “Tailoring the gas mixture continued on page 34

ISO inserts with PVD coating

ULT ULTRACUT LTR RAC RAC A UT ACU LONGLIFE L LONGLIF ONGLIF ONG LIFE A heavy duty metal cutting ﬂuid A bio-stable, extreme pressure (EP) water soluable oil formulated to provide long sump life, good cutting performance and excellent corrosion resistance. Suitable for medium/severe duty machining and sawing over a wide range of ferrous and non-ferrous metals including copper alloys.

For more information contact ITW Polymers & Fluids Phone: 1800 063 511

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WALTER has introduced a range of indexable inserts with PVD aluminium oxide coatings for use in turning applications. The Tiger.tec WSM30 includes PVD aluminium oxide coatings to combine the toughness of conventional multilayer PVD coatings on a TiN, TiAlN or TICN base with the thermal resistance of CVD coatings. The WSM30 product line includes all standard ISO insert shapes in positive and negative geometries to ensure the tool exactly matches the application. Primary application fields include high-alloy and stainless steels, and materials with difficult cutting properties such as titanium alloys, or superalloys such as Inconel. 컄 Walter Australia 03 8793 1000 service.au@walter-tools.com www.walter-tools.com

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WELDING

continued from page 32 can provide a quicker and higher quality result.” According to Bothma, the best possible weld is achieved when base material, shielding gas, welding wire, and equipment are properly matched. “The research indicates a low recognition of the opportunities that exist for industry to improve its welding productivity by taking advantage of advanced, premium gases, which are better suited to many types of welds,” Bothma said. “The good news is that 90% of Australian respondents said they would consider changing or trying another type of shielding gas.” Although most global respondents did not believe they could achieve great improvements in productivity by changing shielding gas, 58% said they are likely to use a different shielding gas in the future. The research is an independent study commissioned by BOC. It surveyed 284 production and technical staff in global organisations that use gas on a regular basis. The research also found that of those that do measure gas shielded welding productivity, 48% said they measure

the number of components produced per hour, 24% measure the number of welds per welder, and visual weld inspection alone is used by some respondents. Respondents also indicated that two out of three users of gas buy argon-only shielding gas, one in three buy an argon-CO2 mix only, and one in four buy CO2 only. Around one third of respondents said they found it difficult to distinguish between different types of shielding gas, and MIG/GMAW was clearly the most popular form of welding, with over 40% of respondents using this method. According to Bothma, an important cost consideration beyond the welding parameters is the non-welding costs, including welding preparation

and post-weld cleaning. “These costs are minimised by the application of the right shielding gas,” Bothma said. “Labour is by far the most significant cost in mild steel and stainless steel welding applications. “Labour can represent more than 74% of the cost to produce a weld.” According to Bothma, using the right shielding gas can increase welding speed, reduce clean up from spatter minimisation, improve weld quality to reduced weld rejection, reduce inefficient deposition of wire due to excessive spatter and convex bead shape, and enhance operator satisfaction. “To get the best results and value for money, plant operators should get the advice of a welding gas specialist to audit the welding job and recommend the right gas, equipment, and approach for the work,” Bothma said. BOC is a member of The Linde Group which supplies compressed and bulk gases, chemicals and equipment around the globe. The company develops safe, sustainable, and innovative solutions for customers in many specialty sectors. BOC

131 262 Iwww.boc.com.au

Cutting fluid for hard metals THE Tap Magic range of cutting fluids has been expanded to include Tap Magic Xtrathick for hard metals. The Xtra-thick version for hard metals is effective on inconel, titanium, stainless steel, or metals up to 45 Rockwell hardness. The product virtually eliminates work hardening, and a clinging action means the fluid is not prone to sling off. The cutting fluids penetrate right to the cutting edge of the tool to provide superior lubrication, precision and longer tool life. The company’s fluids are available from industrial distributors in a range of pack sizes including 120 ml and 472 ml spout top cans, 354 g aerosol cans, and 5 L and 25 L bulk plastic container supplies. Precision Specialty Tooling info@pretooling.com.au www.pretooling.com.au

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WELDING

Welding blankets

Medium frequency welding

JACKSON Products has introduced a range of welding blankets for a variety of welding and cutting applications. The Weld-O-Glass welding safety blankets are designed for use while welding and cutting to protect component surfaces and work areas against spatter, slag and sparks that may cause damage to components or cause fires. The blankets, which can also be used as a vertical protective screen, are available in a number of different weaves, material weights, and sizes. The range provides protection against temperatures ranging from 400°C to 1500°C. Specially treated Silica cloth is available for heavy duty welding, cutting, and gouging. A non-coated fibreglass material blanket providing working temperature protection up to 420°C is available for use when grinding and cutting where minimal spatter is produced. A coated fibreglass material is used for medium-duty applications. The blankets with coated fibreglass material provide resistance against abrasion and are easily cleaned, while uncoated blankets are more pliable and are better suited for draping over components. Non-coated blankets should be considered for stress relieving super-heated components as the coating has a lower heat resistance and may smoulder under prolonged heat contact. The company’s safety welding blankets are self-hemmed and stitched with high strength fibreglass thread to prevent fraying. The blankets are also available with eyelets to secure two or more blankets together or hanging.

Welding inverters operate from 500 to 120 000 Amps. BOSCH Rexroth has introduced PSI 6000 Medium Frequency (MF) welding inverters with a performance spectrum ranging from 500 to 120 000 Amps, regardless of the welding type. Standard functions include content current regulation, pressure regulation, and an electrode care concept including tip dressing. The system is designed for direct current resistance welding, and comprises the PSI 6000 MF inverter range and the PSG6130 MF welding transformer. The company’s PSG 6130 MF transformer provides optimal power transfer and extra monitoring functions between the inverter and the transformer. The PSG 6130 allows weight reduction up to 30%, making it suitable for highefficiency welding, robotic, and manual gun applications up to 130 kVA. The transformer has plugin type connectors which can be used to detect voltage and current levels, and monitor temperature. The primary connection can be made with or without a junction box.

A removable plastic cover protects the integrated rectifier pack from spatter and other contamination. MF welding offers several benefits over traditional 50 Hz welding. Medium frequency welding allows direct current flow in the secondary welding circuit of the transformer. As a result, the inductive resistance of the secondary window loses its influence on the welding current. MF welding also reduces the amount of welding splashes and improves the quality of the spot weld. 컄 Bosch Rexroth peter.sammut@boschrexroth.c om.au www.boschrexroth.com.au

SPEED UP PRODUCTION with

Rivet Tools TAURUS (Pneumatic) Ergonomic, fast, reliable Built to last Low maintenance Almost undetectable recoil

ACCUBIRD

(Battery) Cordless freedom Set blind rivets anywhere, anytime Quick and effortless

GBM95 (Pneumatic)

Fast, reliable setting of rivet nuts Fully automatic wind on and off Also available battery operated

For further information on the complete range of Gesipa rivets and tools MF welding inverter.

Call 02 9874 5000

컄 Jackson Products +44 1384 286190 sales@jacksonproducts.co.uk www.jacksonproducts.co.uk

Jackson Product’s welding safety blanket. WWW.MYFEN.COM.AU | JUNE, 2008

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PUMPS

Tough, safe and colour coded A

PRODUCT

Australian-manufactured polymer pipe system is a durable, safe, and corrosion resistant alternative to PVC and metal piping.

WORLD leader in the design and building of industrial water and wastewater treatment plants has adopted an Australian-manufactured polymer pipe system to enhance durability, safety, and corrosion resistance in an $80 million refurbishment project. Veolia Water Solutions and Technologies is using Calair Pro-Pipe II to carry compressed air, water, flocculants solutions, and highly corrosive ferric chloride in the upgrade of water treatment facilities at Australia’s largest electricity generating company, Macquarie Generation. The contract, in which Calair reticulation systems service Actiflo high-rate clarifiers, upgrades water treatment facilities at Bayswater Power station to state-of-theart performance and increases the plant’s capacity to reduce salinity and increase water quality in Lake Liddell. Recycling 160 million litres a day, cooling water is recycled and treated to ensure no contaminants reach local waterways. The eight Actiflo clarifiers

Why use Mapress? Mapress is a mechanically joined pressure system, made from high quality grade AISI 316 stainless steel. Used extensively around the world, the precision connections provide a permanent, reliable and hygienic solution to industrial and commercial applications alike.

Under pressure?

on which the Calair systems are installed are part of a Veolia Water Solutions and Technologies portfolio of water and wastewater solutions designed for industrial customers. These technologies focus on reuse and desalination processes in industries such as power, mining and metals, pulp and paper, food and beverage, and pharmaceutical. “We were looking for reticulation systems that would be tough, non-corrosive, and colour-coded so contents would be easy to identify for safety,” Bayswater Power Station site manager Paul Hutton said. “When you are dealing with aggressive substances such as ferric chloride, you can’t have metal anywhere near it. We looked at PVC, but it’s brittle and easy to damage if someone drops a hammer on it, for example. In these situations, the Pro-Pipe would compress but not rupture.” The Bayswater project typically involves multiple runs of more than 100 m of pipe up to 40 mm internal diameter. Three types of Calair prod-

Mapress is approved for a working pressure of 16 bar, but has been safety tested up to 40 bar! 18 Benjamin Street, St Mary’s, Adelaide, South Australia, 5042 Tel: (08) 8277 3288 Fax: (08) 8276 4024 www.kdfisher.com.au

Need the right size? Mapress stainless steel tube & ﬁttings are available in a range of diameters from 15 to 108mm.

Syd Tel: (02) 9540 2511 Fax: (02) 9540 2911 • Melb Tel: (03) 9315 2688 Fax: (03) 9315 3663

Want to work safer? Installing Mapress eliminates the need for hot work permits and inspection delays.

Need approval? Recognised by numerous international approvals, including the WaterMark.

Want to save time? It takes only seconds to join, without the need for specialist trade skills.

NO WELDING REQUIRED! BLUCHER Australia Phone: (08) 8374 3426 e-Mail: blucher@blucher.com.au

www.blucher.com.au 36 FEN |

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LATH3369A

Stainless steel drainage and pressure systems

uct were used to service eight Actiflo units, including aqua for compressed air, green for water, and violet for acids and alkalines. “The colour-coding is great for safety, especially in a complex industrial site where you might be using a variety of pipes to carry different substances of different hazard levels. The company don’t want maintenance personnel having to waste time wondering what they are dealing with, or cutting into the wrong line,” Hutton said. The Calair system integrates with the existing metal

Quick hitch manifolds BRISBANE-based company Hyteco has released Quick Hitch Manifolds with 420 bar maximum input pressure. The product is designed to be easily installed into new or existing Quick Hitch Systems on excavators, backhoes and loaders. The product is ideal for operating low and medium pressure actuators in high pressure systems. The unit features an output press range from 35 bar to 90 bar, with rated flow at 12 L/min. The product’s body features steel and plated construction, with mounting via two 8.8 mm holes. The unit also includes 12 V DC and 24 V DC options, with dimensions of 183 mm x 76 mm x 40 mm. The unit weighs 2.5 kg. 컄 Hyteco Australia 07 3881 3312 sales@hyteco.com.au www.hyteco.com.au

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PUMPS

Veolia Water Solutions and Technologies uses Calair ProPipe II to carry compressed air, water, flocculants solutions, and highly corrosive ferric chloride in the upgrade of water treatment facilities at Australia’s largest electricity generating company, Macquarie Generation.

KOBOLD INSTRUMENTS NOW IN AUSTRALIA l DISTRIBUTORS REQUIRED

piping of older plant, and does not require specialist tools or skills to install. The system can also be easily reconfigured as production and process needs change. Being only one eighth the weight of equivalent steel piping, the job can be quickly and safely handled by existing staff. The system is also totally recyclable. Unlike metal welded systems, which have to be discarded when production facilities change configuration or location, the system can be dismantled, packed away, and reconverted to a new use.

The system is also designed for high security of product and minimal losses. A combination of plastic welded fittings and threaded connections was used where appropriate to ensure maximum durability for the pipe systems, which typically carry flows of up to 115 L an hour (chemicals), 120 L an hour (water), and operate at pressures of up to 10 bar (air). “Durability was a big plus of the Calair system – users can blow out the lines and not get any corrosion. Parts of the system have been in service for a year now without any problems,” Hutton said. 컄 Calair Pipe Systems 1300 304 246 sales@calair.net.au www.calair.net.au

Kobold Instruments is an international Market leader in Flow Control and Measurement Technology. Kobold Instruments has now brought to Australia the broadest range of Flowmeters, Level Controls, pressure switches and transmitters for all industrial applications.

KOBOLD INSTRUMENTS FOR • Flow • Humidity • Pressure • Rotation • Level • Conductivity • Temperature • PH-Value/ Redox • Turbitidy

Versatile flow measurement MID magnetic-inductive flow meters, recently released by Kobold Instruments, are designed for measurement in both directions. The products contain a free, unrestricted passage, making it possible to register media containing solids or contaminated with fibres. Characteristics such as density, viscosity, and temperature are irrelevant to measurement, with a minimum conductivity 20 µS/cm required for materials. The product is available with internal linings of PP, hard rubber, PTFE, PFA, or ETFE. The units are available with electrode material options including Hastelloy C4, stainless steel, Hastelloy B2, tantalum, titanium, or platinum. Depending on the design, pressures up to PN 40 and maximum temperatures up to 180 °C are possible, with

earthing washers in various materials also available. The electronics are located directly on the measurement pickup in the compact version, and the length of the connecting cable can be up to 300 m in the split version. Other functions include empty pipe sensing, display damping, and leak flow volume suppression. The product comes in standard sizes from DN 10 to DN 1000. The customer has a choice of steel and stainless steel flanges in DIN and ANSI for different pressure ranges. Customised versions up to DN 3000 are available on request, and electrode cleaning is offered as an extra to improve operation in problematic media. The protection class of the measurement pickup is IP 66/67 or NEMA 4 / 4X / 6 for remote versions. 컄Kobold

Instruments info.au@kobold.com www.kobold.com

FOR A FREE

CATALOGUE please email us or visit our website KOBOLD INSTRUMENTS PTY LTD 1-33 Daking Street North Parramatta NSW 2151 Phone: +61 2 9630 5444 Fax: + 61 2 9683 4499 Email: info.au@kobold.com Web: www.kobold.com

Manufacturer of Innovative Instrumentation... Measuring. Monitoring. Analysing. WWW.MYFEN.COM.AU | JUNE, 2008

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PUMPS

Variable pipe-mounted sensor EPCOS has introduced a pipe-mounted sensor designed for permanent mounting on pipe diameters from 12 mm to 20 mm. The product’s patented design, which features a plastic body and clip, makes it particularly easy to install. A spring in the clip provides the tension needed to create a good contact between the pipe and sensor element. The pipe-contact sensor is designed for a temperatures

Inline volumetric flow sensor

ranging from -5°C to 110°C in a dry environment. It has a response time of below three seconds. The sensor may be designed with identifying elements for various pipe diameters and can also be fitted with various connector systems on request. Pipes with diameters from 12 mm to 20 mm are common to most heating systems. 컄 Ramelec Electronics 1300 309 150 www.ramelec.com.au

FM RUMMAGER air or electric driven agitator.

Fork-mountable mixer MIXQUIP, a division of Teralba Industries, has introduced the FM RUMMAGER to their range of mixing equipment. This fork-mountable mixer can be easily moved from tank to tank, and are suited to most IBC type pallet tanks. The product incorporates the company’s high-efficiency Superflo fold-out propeller, which is designed to provide vigorous mixing for fluids up to 15,000 cPs. Mixing intensity can be

easily adjusted using the variable speed function mounted on the unit. These highly-efficient air or electric driven agitators can be set up ready to mix in less than five minutes. The pallet tank agitators have stainless steel wetted parts and have been successfully installed in pharmaceutical, beverage, process, chemical, food, and agricultural applications. 컄 Teralba Industries 02 4626 5000 Mixquip@teralba.com

Inoxpa

IFM has released a magneticinductive inline flow sensor, efector mid, with flow rate, totalising and temperature indication, that can be adapted to different conditions due to its flexible programming. The sensor is used for exact flow metering of conductive liquids including water, coolant, or oils. The temperature of the medium is detected at the same time. The unit includes a measuring range from 0 to 25 L/min, and features an accuracy of ±2% of the measured value. Mounting via R 1/2 or R 3/4 adapter ensures easy installation in the pipe. The electrical connection is made via the standardised M12 connector. The product’s four-digit alphanumeric display indicates the current volumetric flow quantity, the accumulated total quantity, or medium temperature. Switching, pulse, or analogue outputs are available for external evaluation. The diagnostic functionality of the unit allows users to monitor and ensure the safe operation of cooling circuits and systems. Continuous monitoring allows the sensor to be integrated in condition-based maintenance concepts. This permits longer maintenance intervals which, in turn, leads to lower costs. Necessary maintenance can be planned to improve the reliability of the system, reducing damage resulting from lack of coolants. 컄 IFM efector 1300 365 088 www.ifmefector.com.au

Stainless Steel Lobe Pump This synchronous, non contact action Inoxpa Lobe Pump makes it ideally suited to processing of thin or viscous products, as well as solids in suspension. It’s compact design achieves high pressures without front support bearings, providing an easy stripdown from the front to service both seals and seal casings and thus removing the need to disconnect any pipelines.

Toll Free 1800 242 933 www.johnson-pump.com An SPX Brand

38 FEN |

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WHERE IDEAS MEET INDUSTRY

Telephone (07) 3899 9933 johnsonpumpaust@johnsonpump.com.au

JP1717AW

Inoxpa Stainless Steel Lobe Pumps are sold and serviced by Johnson Pump Australia.

IFM's magnetic-inductive inline flow sensor.

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newproductfocus TEST & MEASUREMENT

Loop-powered analysis transmitter

Helium leak detection JOHN Morris Scientific has introduced Adixen’s ASM 142 Graph Series for difficult leak detection tasks, finding leaks as small as 10 mbar x l/sec. The ASM Series includes Adixen’s high compression and low rotational speed Molecular Drag Pump allowing the range to deal with accidental air in-rush, sudden shocks, or small drops during operation. The company’s ASM Graph Series features a second filament built into the analyser cell which automatically activates if the first filament fails. Filament changes can be done without the need of special tools or servicing skills, allowing a reduced cost of ownership and downtime. The ASM also offers a

unique operator interface with a touch-screen display. Additional features include an integrated 900-hour test memory, an animated system mimic diagram, and perfect connectivity to external data recording or control. The inherent characteristics of helium enable fast, precise and 100% safe leak location and qualification. Leak detection can be carried out under vacuum or pressure. Helium is the second lightest element and diffuses through test objects three times faster than air. Helium is non-flammable, non-toxic, and environmentally safe. 컄 John Morris Scientific 02 9496 4200 nswbo@johnmorris.com.au www.johnmorris.com.au

data. Apart from the process ENDRESS+Hauser has variable being measured, released the Liquiline CM42 MemoSens data includes diagtwo-wire, loop-powered transnostics including the status of mitter that powers MemoSens the electrode; the length of technology sensors. time used in the process; the This system allows the number of times over 80°C; transmitter to be located up to and impedance of the glass 100 m away from the measurelectrode which gives an indiing electrode, far from hazcation of its integrity. ardous applications. These diagnostics can be MemoSens technology prouploaded to MemoBase softvides a robust, contactless ware, which sets as a repositoelectrode-cable connection ry for measurement point point by using an inductive information. This enables the electrical connection, and cost and operability manageelectrode replacement takes ment of the sensor. only a few minutes. Liquiline M CM42 comes The product features digital with an IP67 rating, and its memory capability, allowing it housing design makes the unit to be calibrated in the workshop at the user’s convenience suitable for panel mount or and stored prior to installation. field mount. It is also compatible As soon as the electrode is with all communicaconnected, the calibration tion protocols including data is uploaded to the transHART, Foundation mitter automatically. Since it is an intelligent electrode, MemoSens holds a wealth of useful information. Partnered with Liquiline M The loop powered CM42, users now have easy Liquiline M CM42 analysis and direct access to all of this transmitter.

Fieldbus, and Profibus PA, and can be easily integrated into existing or new applications. The transmitter adopts a modular design making reconfiguration simple since the modules are clipped onto a common DIN rail in the unit. Simply changing the sensor module enables the pH device to be converted to conductivity or dissolved oxygen measuring systems. Modules to measure other parameters will become available soon. 컄 Endress+Hauser 1300 363 707 www.au.endress.com

Oscilloscopes for embedded systems designers

The DPO3054 digital phosphor oscilloscope.

TEKTRONIX has introduced the DPO3000 Digital Phosphor Oscilloscope (DPOs), a portable series that extends the advantages first introduced with the DPO/ MSO4000 series. The DPO3000 provides triggering and decode support for the most popular serial

buses used in embedded design applications. Additionally, the oscilloscopes offer 5M standard record length and use Wave Inspector navigation and search controls to simplify finding events of interest. The portable DPO3000 simplifies debug, and sets new standards for performance, value, and ease-of-use. The DPO3000 oscilloscope family consists of six models, ranging from 100 MHz to 500 MHz. At only 5.4 inches deep, it is the shallowest professional oscilloscope in its segment of the market, and requires less bench space than competing products, weighing only 4 kg. All models provide the TekVPI probe interface that fosters communication between the DPO3000 and TekVPI probes. 컄 TekMark Australia 02 9911 3888 enquiries@tekmarkgroup.com www.tekmark.net.au

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newproducts Auto saw for sectional and solid steels POWER Machinery has launched the Shark 410 CNC HS automatic band-sawing machine, capable of operating in both automatic and semi-automatic modes. The machine cuts both sectional and solid structural and stainless steels and light alloys up to 410 mm in diameter and with rectangular dimensions of 450 mm x 410 mm. The machine’s multi-microprocessor allows 32 different lots to be cut in varied lengths and quantities from the same

bar, while a self-aligning vice can also feed deformed and misshapen bars with a minimal rest piece of 100 mm. Bars weighing up to 3000 kg are fed into the machine by a brushless motor and screw/nut system and are cut by a cast-iron bow-head, allowing greater cut control and a longer blade life The ball motor and screw/nut system includes recirculating balls-crews and a 700 mm stepper motor. Rotation of a bi-metal band,

suitable for sections and solids, by a vector-inverter motor means the machines cutting speed can be adjusted from 15 m/min to 110 m/min. Comparative parameters for cutting load, cutting pressure, and cutting deflection are programmed in real-time through a programming console. The console comprises an LCD screen to display cautionary and diagnostic messages, and touch-tone polyester thermal shaped buttons. A movable control keypad

can be positioned to control and monitor cutting operations from a safe distance, while the control and function systems are protected from ingoing and outgoing electrical and electromechanical phenomena. The product also includes a chip collection drawer and optional chip evacuator, a motorised wire chip brush, an electromechanical actuator

Intelligent plant safety

Finding what you need has never been easier

NEW CATALOGUE NEW WEBSITE

YOKOGAWA has released an enhanced version of its ProSafe-RS Safety Instrumented System, with support for Windows Vista. ProSafe-RS R2.01.00 is integrated with the company’s latest production control system, Centum VP, and offers improved security. The system offers users enhanced security for PC components, and keeps plants secure by restricting communications, controlling access to folders and the registry, and preventing unauthorised access from outside sources. The system is designed for

use in oil, natural gas, petrochemical, and process industries that use systems for emergency plant shutdown, fire prevention and fighting, and burner management. The system helps prevent accidents by detecting unusual conditions in plant operations and taking emergency actions such as shutting down the plant. Unlike conventional safety instrumented systems, ProSafeRS and CENTUM series can be fully integrated. Yokogawa 02 8870 1100 www.yokogawa.com/au

EASIER TO FIND | EASIER TO COMPARE | EASIER TO CHOOSE

Easy access to over 200,000 electronic, electro-mechanical and process control & automation products

Visit RS Online or call to request a copy of the RS Catalogue www.rsaustralia.com 1300 656 636 Yokogawa’s ProSafe-RS safety instrumented system has been enhanced to run on Windows Vista.

Over 28 Years of Know-How in Fluid Mixing

1800 201 373 40 FEN |

(02)

JUNE, 2008 | WWW.MYFEN.COM.AU

4626 5000

DD1240

15-19 Kialba Road, (P.O. Box 1639) Campbelltown NSW 2560. Email: mixquip@teralba.com

Shark 410 CNC HS automatic band-sawing machine.

with dynamic control for blade tensioning. Power Machinery 02 9971 1755 ken@powermachinery.com.au www.powermachinery.com.au

Double handling saves time

The multi-pallet handler.

MEYER, the inventor of the multi-pallet handler, has released a new generation of multi-pallet handlers incorporating a unique shaft guide system. The guide system ensures easy handling, improved visibility, and exact arm travel. The modern bar-type design can lift two pallets side by side, even with a gap between them, or a single joined pallet. The synchronised movement of the bolt-on forks increases the efficiency and safety of the forklift. The fork arms are hydraulically adjusted by the driver using a single lever. The pallet handler series is designed with precision machined, chromed, and hardened shafts. The unit features synchronized fork movement and a separate side-shift provides constant side-shift fance regardless of the fork opening. The multi-pallet handler incorporates load back rests and self-lubricating polyamide side-shift bearing pads. The handler also includes bolt-on forks with specially reinforced heel area. Bolzoni-Auramo 0409 173 521 sales.au@bolzoni-auramo.com www.bolzoni-auramo.com

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newproducts Stay cool with membrane technology Expanded polytetrafluoroethylene (PTFE) membrane with 99% particle filtration efficiency improves thermal cooling capability. WL GORE and Associates has introduced a polytetrafluoroethylene (PTFE) membrane for its range of cooling filters, giving users up to 20% improved thermal cooling. The filters improve thermal cooling while reducing capital and operating costs in wireless base stations, base band units, power cabinets, switching systems, and other outdoor electronic enclosures. Constructed with a new membrane technology, the filter improves thermal cooling by allowing higher airflow through the filter. The membrane protects electronic components by preventing fine contaminants such as dirt, dust, and sand from entering the enclosure. By increasing airflow while reducing potential contaminant

amount of energy required by fans to efficiently cool sensitive electronics. The technology behind the filter is based on a proprietary expanded PTFE membrane. This micro-porous membrane allows cool, clean air to flow into the cabinet while filtering out harmful contaminants. Expanded PTFE membrane has 99% particle filtration efficiency at the 0.3 μm level. The filters can incorporate the

high-performance filtration media into either a lightweight frame or a rigid anodised aluminium frame, and cabinets fitted with the filters pass IP55 and NEMA 3R requirements. The filters can be customised to fit small to large base station units for mobile communications and wire-lined cabinets. WL Gore and Associates +1800 638 5300 industrialfilters.com@wlgore.com www.gore.com/coolingfilters

Gore Cooling Filters.

damage, the filter improves overall reliability of telecommunications infrastructure. The filter includes a lightweight frame designed into the filter, and is said last up to 20 % longer than its predecessor. Unlike bulky heat exchangers

and air-conditioning systems, direct-air cooling systems have very few moving parts, reducing equipment maintenance costs. The membrane technology reduces operating expenses by lowering the filter pressure-drop by 60%, which reduces the

Safety switch for harsh environments TREOTHAM Automation has released the Euchner Non-Contact Safety Solenoid Switch CET with die-cast housing for harsh environments. The safety switch includes guard locking, guard lock monitoring, and integrated transponder coding. The unit’s metal housing includes locking forces up to 5000 N, allowing it to be used on heavy doors, The switch is IP 67 certified. When closing a safety guard, the product’s spring-loaded transponder in the actuator is inserted into the cavity of the safety switch. A read-head integrated into the switch detects the closed safety guard in its locked position. The CES evaluation system enables the safety circuit when the safety guard is locked.

When moving parts and machine come to a standstill, a solenoid integrated into the switch is activated by a safe standstill monitor or a timer relay. The plunger of the magnet then raises the spring-loaded transponder, allowing the safety guard to be opened. The electromagnetic devices interlock movable safety guards so that dangerous work on machines can only be carried out if the safety guard is closed and locked. The safety guard cannot be opened when the machine is running. Treotham Automation 02 9907 1788 info@treotham.com.au www.treotham.com.au Euchner Non-Contact Safety Solenoid Switch CET.

For those who demand the best in caps and plugs. At Kelvindale we’ve been designing and manufacturing quality caps and plugs for 57 years. It’s what we do best. Created to perform, you’ll find plugs and caps to suit the hydraulic, pneumatic, mining manufacturing, engineering, aviation, automotive, and refrigeration industries plus many more.

Ask about our FREE samples and catalogue.

Call Kelvindale Products on (02) 9638 0100 or visit www.kelvindale.com.au

Modular pallet wrappers WULFTEC has released modular pallet wrappers with steel construction for the first time in Australia. The wrapper includes factoryset 250% pre-stretch, a maintenance free AC motor, a safe loading process and powered pre-stretch carriage. The product also includes an AB Micrologix 1200 PLC and film tension adjustment capability. The product’s modular design allows customers to customise their pallet wrapping machine by removing the old module and attaching a new one. AWS sales@austwarehouse.com.au WWW.MYFEN.COM.AU | JUNE, 2008

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newproducts Continuous gas analysers ABB has released the Easyline EL3000 Series of continuous gas analysers (CGAs) for applications such as emissions monitoring, biofermenters, landfill, combustion processes, ambient air monitoring, purity measurements and gas filling. The product includes an optional profibus interface for simple data transfer to a control system or PLC. The optional interface allows users to improve plant communication. Updated software provides two measuring ranges per

component, and the addition of the zirconium dioxide oxygen trace analyser provides users with added flexibility for configuration. The gas analysers have automatic calibration, are suitable for flammable gas applications, and are TUVcertified to meet strict European standards for Continuous Emissions Monitoring (CEM) applications. ABB Australia 03 8544 0127 henning.vonhoersten@au. abb.com www.abb.com

The analysers have automatic calibration and are suitable for flammable gas applications.

Robotic part loading system MIDACO Corporation has released a series of robotic part loading and unloading systems adaptable to most CNC lathes and vertical machining centres. The product is suitable for use with a variety of robot brands, and can load and

unload one or two machines at the same time. Mounted on linear guides, the system can be moved out of the way when not in use to facilitate conventional operation of the machine tool. The unit features optional conveyor parts and a push-

Next generation pick and place robot

Ducting accessories

ABB Australia has released the second generation FlexPicker pick and place robot, with 20% cycle time improvement. The IRB 360 robot includes increased speed, higher payload, and a smaller footprint. The robot’s design features 50% higher payload capacity and ability to accommodate a range of grippers for handling diverse products. The robot succeeds the company’s FlexPicker IRB340 system and has a wide range of movement over a fourth axis. The unit’s theta axis is made with a stainless robust variant suitable for the food industry. The robot includes PickMaster software that enables modelling for varied applications and assists with the optimisation of multiple robot installations.

EXIMO has launched a range of accessories for its 2mm-gauge solid ducting line, called Speedlock 2. Accessories for the products include standard lock rings, lever lock rings, wide lock rings, flexible hose spigots, flanges, hanging brackets and bracket legs, worm drive clamps, duct end seals, and weld ends. The accessories also include straight pieces, bends at 90°, 60°, 45°, 30°, 15° and 7.5°, and telescopic pieces which can be put into ductwork to eliminate cutting and beading. The company has also released branch pieces, Tpieces, Y-pieces, reducing cones, and blast gates (manual and pneumatic) for the range. The 2 mm-thick ducting is suitable for most industrial applications where durability and applicability are required. Provided in diameters ranging from 100 mm to 1000 mm, the ducting is hot-dip galvanised for durability and works in conjunction with a quick-lock system. The product line is suitable for all industries where ducting is exposed to high flow rates and constant use. The system can be used in general industrial applications, agricultural and milling use, indoor and outdoor environments, steelworks, food manufacture and around high temperatures. Eximo 02 9757 1233 m.short@eximo.com.au www.eximo.com.au

ABB Australia’s IRB 360 pick and place robot.

The robot’s IRC5 controller is now available in a compact panel-mounted version that offers easy integration into machines and production lines. ABB Australia 03 8544 0112 Derek.ford@au.abb.com www.abb.com

Low profile computer brackets KEYSTONE Electronics has released a range of universal computer brackets in low profile and standard configurations designed to fit any PC computer or peripheral. The brackets feature a variety of holes and cut outs and are manufactured using .032 premium steel. The steel is finished with nickel for enhanced durability. All low-profile and standard types conform to a vast majority of universally required cut

outs and, together with special types, are fabricated to exact requirements. In order to ease the selection process, the company provides complete specifications for its brackets, cut outs, standard international symbol markings and custom requirements incorporated into computer bracket worksheets. NPA PTY LTD 08 8268 2733 info@npa.com.au www.npa.com.au

Easily installed dust collectors EXIMO has released an easy to install dust collector that separates 98% of the content before it reaches the filter. The collector does not use the reverse air concept because, with this technology, the filtration media blocks and the devices cease to work. The collector is portable and supplied in modular flat packs so it is easy to assemble. It works on a small footprint 42 FEN |

JUNE, 2008 | WWW.MYFEN.COM.AU

button lock pin that accurately positions the unit. The company’s full line of pallet changers and machine tool accessories are available globally. Midaco Corporation midaco@midaco-corp.com www.midaco-corp.com

and can be mounted above machinery from which it is cleaning dust output. Due to its design, long or large diameter ducting is not required. The product allows the factory or plant to have several smaller dust collectors, meaning only a limited amount of ducting is required. Eximo m.short@eximo.com.au www.eximo.com.au

Suitable where ducting is exposed to high flow rates and constant use.

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comingevents Conferences, Seminars & Workshops

June

Editor — Daniel Hall T: (02) 9422 2478 F: (02) 9422 2966 E: daniel.hall@reedbusiness .com.au

26-27: Reliability National Forums Series - Planning4Reliability workshop will be held at Hotel Conrad, Gold Coast, Queensland. Contact Anna Civiti at SIRF Rt on 03 9697 1105 or email anna.civiti@sirfrt.com.au.

New Products Editor — Peter Tyldsley E: peter.tyldsley@reedbusiness.com.au NSW Advertising Sales Manager — Hayden Reed T: (02) 9422 2110 F: (02) 9422 2966 M: 0422 920 422 E: hayden.reed@reedbusiness .com.au VIC Advertising Sales Manager - Lisa Hodgson M: 0408 260 928 F: (03) 9328 8560 E: lisa.hodgson@reedbusiness.com.au

July 21-24: Foodpro 2008 will be held at the Sydney Convention & Exhibition Centre, Sydney. Contact Peter Petherick on 03 8420 5402 or email peterpetherick@dmgworldmedia.com.

QLD Sales Manager — Sharon R. Amos T: (07) 3261 8857 F: (07) 3261 8347 M: 0417 072 625 E: sharon.amos@reedbusiness .com.au SA & WA Advertising Manager — David Murray Smith T: (08) 8371 5800 F: (08) 8371 5900 M: 0411 748 213 E: david@agsmedia.com.au

31: Queensland Supply Chain & Logistics Conference will be held at the Sofitel Hotel, Brisbane. For more information or to register email info@qldscc.com or visit www.qldscc.com.

Production Co-ordinator — Tracy Engle T: (02) 9422 2707 F: (02) 9422 2655 E: tracy.engle@reedbusiness.com.au

August 12-14: WA Safety Show and Conference will be held at the Perth Convention Exhibition Centre, Perth. For more information or to register contact 03 9654 7773, email safety@aec.net.au or visit www.wasafetyshow.com.

September 1-2: Reliability National Forums Series - Electrical Maintenance & Safety will be held at Star City, Sydney. Contact Anna Civiti at SIRF Rt on 03 9697 1105 or email anna.civiti@sirfrt.com.au.

Graphic Designer — Nicolle Lawson E: nicolle.lawson@reedbusiness.com.au Publisher — Chris Williams RBI Manufacturing & Electronics Subscriptions — $140 incl GST; NZ $A150 & OS $A165

The latest events, conferences, and manufacturing news updated daily at www.myfen.com.au 7-9: National Truck & Commercial Vehicle Expo will be held at the Homebush Exhibition Precinct, Sydney Olympic Park, Sydney. For more information email info@exhibitionmanagement.com or visit www.sydneytruckshow.com.au.

October 7-9: AUSPLAS will be held at the Melbourne Exhibition Centre. For

more information email info@exhibitionmanagement.com or visit www.ausplas.com. 21-23: QMAN Queensland Manufacturing Technology Exhibition 2008 will be held at the Brisbane Convention & Exhibition Centre, Brisbane. Contact John Delpeche on 02 9422 2568, or john.delpeche@reedexhibitions. com.au.

28-29: Reliability National Forums Series - Condition Monitoring & Lubrication - will be held at the Sebel on Albert Park, Melbourne. Contact Anna Civiti on 03 9697 1105 or email anna.civiti@sirfrt.com.au. 28 -30: The Sydney Safety Show & Sydney Materials Handling will be held at Sydney Olympic Park, Sydney. For more information or to register contact 03 9654 7773, email safety@aec.net.au.

Circulation/Customer service T: (02) 9422 2666 T: 1300 360 126 Contents Copyright. Published monthly by Reed Business Information, a division of Reed Elsevier Pty Ltd; (ACN 008 427 067) Tower 2, 475 Victoria Avenue, Chatswood NSW 2067; Locked Bag 2999, Chatswood Delivery Centre, Chatswood, NSW 2067 T: (02) 9422 2999 F: (02) 9422 2922 web: www.reedbusiness.com.au

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ACN 000 146 921

Supply chains of the future STRATEGIC Futurist Marcus Barber will be opening the 2008 Supply Chain and Logistics Conference on Thursday, 31 July, at the Sofitel Hotel, Brisbane. Marcus Barber is one of Australia’s top Value Systems specialists. He is the facilitator of the strategic futures block at the Centre for Defence and Strategic Studies in Canberra, the premiere management training program for the Department of Defence that brings military personnel from around the globe to a year-long residential strategy training program. Marcus is the co-presenter on the National Geographic Channel’s TV Future Matters series, and author of The Money Tree and How to Grow One - Creating Success in Your Business. 컄 QLDSCC info@qldscc.com www.qldscc.com

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You’d better cross your fingers if you still depend on washers, locknuts or other mechanical devices to keep your fasteners tight. Fact is, they do little to prevent fastener loosening - one of the leading causes of catastrophic equipment failure. There’s a better way to secure fasteners. Use Loctite® threadlockers. You’ll get a solid,

Loctite® threadlockers come in a variety of strengths to match your application. They lubricate for easy assembly, seal against leakage, protect from rust and corrosion, and improve breakloose and prevailing torque strengths - all for about one third of the costs of mechanical devices. So don’t take chances. Reach for the sure thing, Loctite®.

dependable threaded assembly that won’t loosen and cause breakdowns. That means more uptime and productivity.

Phone: 1300 LOCTITE I www.loctite.com.au Email: loctite.enquiries@henkel.com Removable

High-Strength

Penetrating