Worldwide Engineering Magazine - August Issue

August Issue FPT Industrial powers the first LNG trucks on Indian roads

WIDIA Introduces New Chipbreaker for machining aluminum

When the chips are down, call on Scorpion Vision

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worldwide-engineering.com

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Siemens Congleton on track to hit carbon neutral target in 2022

Drax expands its operations into Asia to support region’s renewable energy

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FPT Industrial powers the first LNG trucks on Indian roads

WIDIA Introduces New Chipbreaker for machining aluminum

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Integral Powertrain Limited launches corporate rebrand as Helix.

When the chips are down, call on Scorpion Vision

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5 reasons to upgrade your legacy CHP engine

SICK launches costcutting real-time energy monitoring of compressed air

Worldwide Engineering Magazine Providing timely industry news, exclusive features on advancing technology, equipment, materials, show previews, content marketing services for our valued clients and much more!

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Atlas Copco compressed air/argon pipework system plays a vital role in Hitachi Rail’s new £8.5 million UK welding and painting facility Hitachi Rail has invested £8.5 million to create bespoke welding and painting facilities within its Newton Aycliffe factory, thereby extending its UK role from assembly-only to the complete fabrication and fit-out of units - the first time in decades that a new train welding facility of this type has been created in Britain. Atlas Copco’s successful bid for the design and installation of the 450metre compressed air and argon supply network has played an important role in the company’s on-shoring of crucial high-value aspects of its manufacturing process.

In 2015, Hitachi Rail’s £110 million investment established its highly advanced Northeast manufacturing base with a 700 strong workforce to build 122 pioneering trains as part of the UK government’s Intercity Express Programme, along with 70 zeroemission Class 385 regional trains for Scotland.

The new welding and painting facility now allows Hitachi Rail to complete the build of the high-tech aluminium carriage shells of the next generation of intercity trains for East Midlands Railway and Avanti West.

Commenting on the expansion project’s contribution to output, Hitachi Rail facilities manager, Colin Trevor said “We can now design, fabricate, paint, assemble and test trains at this facility, allowing us to be more globally competitive, with the capacity to build a wide range of products, from metros to commuter and high-speed trains”.

Atlas Copco’s role The new welding and painting production plant is installed within a 194 x 40 metre warehouse 4

conversion adjacent to the main assembly area. This development came with a requirement for a compressed air supply for painting operations and an argon gas feed for the TIG welding workstations.

Wearside Pneumatics, Atlas Copco Compressors’ Gateshead-based premier distributor, was called upon to produce the design, specify the pipework system, and to carry out the installation of dual ring mains to link the air and gas supplies from the existing assembly plant to the new production workstations.

The recommendation to Hitachi Rail’s production management was twofold: Firstly, a 100mm diameter aluminium 180 x 40 metre ring main to deliver 7bar compressed air at the rate of 474 l/s (1705m3h) to 40 drops within the weld operation area. In parallel with the air requirement, the argon supply structure to feed the welding workstations would comprise a 35mm stainless-steel ring main designed to deliver gas at 7bar pressure, at a flow rate of 20l/s (71 m3h), direct to 40 drops within the TIG welding process area.

Furthermore, Wearside Pneumatics would also install a Unistrut channel containment at a height of nine metres, sited between the plant’s overhead crane system and the factory roof space.

The whole project required close coordination with the timing and progress of the new facility’s capital plant installations and was completed over a total period of twelve months.

The AIRnet system - aluminium piping for industrial reliability Although galvanised steel compressed air pipework has

been the industry standard for many years, major industry players worldwide like Hitachi Rail are replacing it with Atlas Copco’s AIRnet – a lightweight, durable aluminium/polymer component network which, by minimising pressure drop penalties, contributes substantially to energy savings, air quality and production efficiency.

Steel pipe is heavy, its threaded joints require careful preparation, and its inner surfaces are not smooth. As a result, this restricts flow and promotes pressure drop, which equates to energy loss.

In contrast, Atlas Copco’s AIRnet lightweight, highly durable modular network system of corrosion-resistant aluminium pipes, together with self-aligning, fully sealed polymer fittings with integrated O-rings, eliminates the possibility of costly leaks – and they can be significant.

A pressure drop of 1 bar can result in a 7% increase in energy consumption.

Size for size, AIRnet pipework, constructed in ISO 8573-1certified 1:2:0 class aluminium, weighs 5 times less than its steel equivalent. It is extremely robust and quick and easy to install.

Fitting the pipework takes about one third of the time compared to that for a conventional system.

Also, there is no time-consuming screw cutting and no need for any special tools or lifting equipment. AIRnet pipes can be simply pushed into the polymer fitting, tightened by hand and secured with a spanner. When the aluminium AIRnet pipe is cut to size, there is no risk of corrosion of the exposed metal and thus no risk of leakage.

The AIRnet system offers pipework with smooth, anodised internal surfaces as standard, which minimises pressure drop penalties and performs a vital role in ensuring that the air supply is kept clean to protect downstream equipment and sensitive production processes.

Furthermore, the piping system can be connected to any existing network and can be modified easily to meet any changes on the industrial floor layout. AIRnet answers these needs with a wide range of interchangeable and reusable fittings designed to support upgrades in layout and capacity.

AIRnet stainless steel installation In the same way as the AIRnet aluminium compressed air network, the new fabrication area’s 35mm argon supply ring main is constructed in EN10088 standard stainless steel with push fit connection to achieve a non-corrosive, durable system that does not affect the quality of the gases transported. This minimises maintenance costs and the costs related to protection of downstream equipment, processes, and applications. The system is conceived to offer high performance over decades that assists in achieving strict quality control within production operations.

Performance and productivity benefits With regard to Atlas Copco’s product standards and overall progress with the AIRnet pipework installation process, Colin Trevor, said: “The company’s co-operation and timing, plus the product quality, performance and productivity benefits of the Atlas Copco pipework system installation has contributed substantially to the success of this project”.

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Siemens Congleton on track to hit carbon neutral target in 2022 eight years ahead of goal Partnership between Siemens Digital Industries and Smart Infrastructure businesses accelerates factory towards net zero Sustainability milestone paves way for UK manufacturing sector Siemens’ Congleton factory is on track to achieve carbon neutrality this year - eight years ahead of its original target.

The operation, which manufactures more than 1.2m controls and drives each year, is inching its way to the major milestone after deploying a range of sustainable solutions for energy generation and demand with support from Siemens’ energy and performance services business, Smart Infrastructure.

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These include generating 75kw of renewable energy through a hydro-electric plant at Havannah Weir on the river Dane and using carbon neutral, certified biogas to power its on-site gas engine.

These measures alone saved over £250,000 pounds a year and took the 80% power-independent factory off the grid.

Beyond these innovations, Siemens Congleton adopted a building management system which automatically adjusts to drive energy efficiency improvements, while modern windows and LED lighting have reduced the total energy bill by 13% and 30% respectively.

Combined with reducing waste to landfill to zero and EV charging for

staff and visitors, the Cheshire site is eight years ahead of Siemens’ original 2015 commitment to ensure carbon neutral operations by 2030.

Commenting on the achievement, Andrew Peters, Managing Director of Siemens Digital Industries Congleton, said: “Siemens believes that sustainability is a force for good and can deliver value for all its stakeholders. We want to help customers achieve sustainable growth and to transform their industries through decarbonisation.

The first step of that is for us to achieve these ambitions in our own operations.

“I am delighted that by leveraging a culture of continuous improvement and sustainability - the vital components to Siemens’

Congleton’s long-term success - we have achieved carbon neutrality, a major milestone in our ambitions to reach net zero emissions by 2030.”

The 50-year-old Siemens Congleton factory began its sustainability journey in 1990 when it began manufacturing drives to meet the demands of industry.

In 2018 the factory became fully digital by embracing lean manufacturing methods to achieve continuous improvement and by adopting leading-edge Industry 4.0 processes.

Using advanced manufacturing methods include Virtual Reality, Digital Twin, the Industrial Internet of Things (IIoT), Advanced Robotics, Cloud Technology and Additive Manufacturing, it has mastered producing up to 50,000 variations of its products to fulfil the shifting demands of its customers and markets, increased productivity by driving down costs, and improved efficiency.

In 1990, 400 workers made 50,000 variable speed drives and controls a year. Today, a similar number

of workers produce 1.2 million electrical devices - including 600,000 variable speed drives (VSDs). What is more is that it has been achieved within the same physical footprint. The factory is bounded by industrial units and housing estates, with no room to expand, meaning Congleton has one of the highest productivity rates per m2 of any Siemens’ sites.

Faye Bowser, Head of Siemens’ Energy & Performance Services GB&I, said: “The climate emergency puts the demand on businesses of all sizes and sectors to really accelerate their efforts for decarbonisation. But a challenge is that often decarbonisation isn’t their core business. So, at Energy and Performance Services we make it our business to use our skills, our knowledge and our tools to help our customers transition to net zero in a way that contributes to their business priorities.

“Despite us being from the Siemens family, we have approached working with Congleton the same we do with any organisation. It has been fantastic. In Andrew Peters you have a leader in a business which has put continuous improvement and

sustainability at the heart of their longterm success. Our job was to apply those components to their energy system and their energy strategy. What we ended up with is an engineered roadmaps to net zero that considers timelines, finance, digital services, all there to safeguard business continuity, and to have a method to continuously identify more opportunities to reduce carbon on site.”

The Congleton factory is leading the way for Siemens which has committed, as a global organisation, to ensure all its operations are carbon neutral by 2030 and for all production facilities and buildings to achieve net zero-carbon footprint by 2030.

In the UK Siemens’ progress has been recognised by The Carbon Trust, an expert partner for supporting organisations to achieve sciencebased targets. In June it awarded Siemens its Route to Net Zero Standard tier one certification for ‘Taking Action’.

Commenting on this milestone achievement, Olivia Whitlam, Head of Sustainability, Siemens Plc said: “Siemens is taking a holistic approach to achieving net zero and we are pleased to be guided by the Carbon Trust who helps us monitor our progress each year.

“We have 8,600 people spread across offices and 11 manufacturing sites across the UK and we are creating innovation up and down the country with sustainability at the core of our operations and services. Our Congleton factory is paving the way for sustainability whilst setting a great example on how manufacturers can join this amazing journey to net zero.”

Congleton’s trailblazing story will be shared at Siemens’ two-day conference and exhibition, Transform 2022 at Manchester Central on July 12 and 13.

The event will bring together hundreds of industry leaders, influencers and regulators from across the UK and Ireland to collaborate and solve some of the most pressing organisational challenges.

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Motorcycle exhaust manufacturer takes brakes off innovation and growth with Made Smarter A manufacturer of high-quality motorcycle exhausts is unlocking its capacity to innovate and grow with the support of Made Smarter.

Fuel Exhausts, based in Kendal, is investing in a 3D scanner to capture digital versions of parts and components, 3D CAD software, and a 3D printer for producing prototypes of end caps and parts for exhausts. The £30,000 integrated digital design solution, which has been match funded by the Made Smarter Adoption Programme in the North West, will enable the business to design and test product ideas in virtual reality before manufacturing them.

It will radically change the way the business operates, making the prototyping process 14 times quicker, increasing productivity, eliminating waste, reducing costs, and increasing profitability.

Meanwhile, 3D scanning technology will introduce reverse engineering

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of parts into the business, opening new markets.

The investment will also create two new production operative jobs.

Damian Turner, who runs the business with wife Louise, said: “We are a small but very dedicated team who strive to provide a fantastic product with second to none customer service.

“Over the two decades we have been trading, digital technology has moved to the forefront in many areas of manufacturing, with the support of Made Smarter we are ready to embrace the opportunity it offers to manufacture prototype parts and new products in-house and move into other areas of production for parts and accessories to complement our current range of exhausts.”

The 3D scanning technology will allow Fuel Exhausts to scan a motorbike to give it the capability

of reverse engineering of parts and components. It will also enable the business to test new products and design in a virtual environment, before using 3D printing to produce prototypes quickly and cheaply.

Donna Edwards, Made Smarter’s North West Adoption Programme Director, said: “We are delighted to be supporting Fuel Exhausts on its digital transformation. It is a superb example of a business using technology to transform how it designs, tests and manufacturers products.

“Fuel Exhausts is among hundreds of manufacturers in the region grasping the opportunities offered

by Made Smarter which include expert, impartial technology advice, digital transformation workshops to help take that first step to transform a business, a leadership programme, and funded digital technology internships.

I would encourage other SME manufacturers to do the same.”

Drax expands its operations into Asia to support region’s renewable energy transition Renewable energy company Drax Group is expanding its operations into Japan as part of its ambitions to increase sustainable biomass sales to support energy security and decarbonisation in Asia.

To celebrate the launch of Drax Asia and the opening of a new Drax office in Japan, more than 160 guests including government officials, major trading houses, energy businesses and shipping companies, attended a reception at the British Ambassador’s residence in Tokyo.

At the reception, British Ambassador to Japan Julia Longbottom said: “The global issues facing us today highlight the importance of clean and secure energy supply chains. We are happy to support Drax in their expansion into Japan.”

Drax Group, the world’s leading producer and user of sustainable biomass, aims to increase its wood pellet production capacity

to 8 million tonnes a year by 2030 from 5 million tonnes a year currently, supporting global efforts to displace fossil fuels and decarbonise energy systems.

As a supplier of sustainable biomass pellets to customers in Asia and Europe, and with more than a decade of experience in converting the UK’s biggest coal-fired power station to use sustainable biomass, Drax is uniquely placed to support Japan as it further decarbonises its economy and energy system.

The British-headquartered company is also pioneering bioenergy with carbon capture and storage (BECCS), an essential carbon removals technology which provides renewable energy while also permanently removing carbon dioxide from the atmosphere.

Drax Group’s Managing Director for Asia, Yasuhisa Okamoto, who is based in Tokyo and will oversee

the company’s ambitious plans for growth in Japan and the region said: “Drax’s unrivalled expertise across the entire biomass value chain - from sustainable fibre sourcing, pellet manufacturing, supply chain management, biomass power generation and BECCS - can support Japan’s climate targets, accelerating the move away from coal and enabling investment in clean energy technologies.

“We look forward to continuing our partnership with Japanese companies, supporting them as they decarbonise their businesses, using sustainable biomass.”

Drax’s conversion of its UK power station to use sustainable biomass instead of coal is Europe’s largest decarbonisation project, reducing fossil fuel emissions from Drax’s power generation by over 95% since 2012.

The day after the reception in Tokyo, a team of Drax executives visited a standalone biomass power plant that Drax supplies with biomass.

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FPT Industrial powers the first LNG trucks on Indian roads FPT Industrial and Blue Energy Motors have signed an agreement with the goal of deploying the very first LNG trucks in India, powered

by FPT N67 NG BSVI compliant engines, on the country’s roads by the end of the year.

Headquartered in Pune (India), Blue Energy Motors is a Zero Emission truck technology company engaged in manufacturing of clean energy trucks, and its vision for LNG truck production involves partnerships with world-class suppliers such as FPT Industrial.

The companies are both committed to an active and swift decarbonization path in the commercial transport segment, and share the same strong belief that LNG trucks are a sustainable option for the market.

This agreement is the first step in a potential long-term partnership, based on the specific characteristics of the Indian commercial transport market. With a total truck fleet of about 3.5 million vehicles and buying decisions driven by TCO, the adoption of LNG technology is expected to be rapid once it passes the TCO parity threshold.

In addition, increasingly stringent emission standards in India - BSVI being the equivalent of Euro VI – will increase the competitive advantage of LNG vehicles.

“We are pleased and proud that Blue Energy Motors has chosen us for this major evolution in Indian commercial transport,” said Sylvain Blaise, President of Iveco Group Powertrain Business Unit.

“This agreement is of the utmost importance for FPT Industrial, now and in the future, as we want our leading technologies to play a key role to support the ecological transition of one of the world’s largest vehicle markets.”

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We believe that the fight against climate change is fundamental for the future of all of us, and Blue Energy aims to be part of this climate initiative and believes in innovation driven sustainability,” says Anirudh Bhuwalka, CEO Blue Energy Motors. “We are working to deliver a zero-tailpipe-emissions transport solution, and to do so we need all the experience and expertise of the world’s leading producer of lowemission engines: FPT Industrial. In India, Governments, fleet owners, and other stakeholders are demanding near-zero-emissions solutions, and with FPT Industrial’s NG engines we can deliver this solution now.”

The FPT N67 NG BSVI compliant engines will equip Blue Energy Motors clean energy trucks, delivering the very high torque needed in India for transport industry applications.

The most powerful natural gas engine on the market and compatible with CNG, LNG and biomethane, the N67 NG uses stoichiometric combustion to assure best-in-class fuel consumption and lower noise than diesel engines, with up to 40% fuel expense reduction versus diesel equivalents in the Indian market and 28% less CO2 emissions.

New partnership agreement helps to move Europe closer to large- scale battery cell production.

“Industry and government both agree on the need to establish battery cell production in Europe.

It is essential to meet demand and establish production independence for the EU trading bloc.” Roald De Meyer, Co- Founder at Novali.

The signed memorandum of understanding between Belgium based battery company Novali and industrial automation solution supplier Mitsubishi Electric Europe B.V. demonstrates quite how soon that agreement may be realized.

Novali was set-up to finance and deliver multiple ‘giga factories’ across Europe, with production scheduled to start in 2025. In order to meet these deadlines Novali has signed a technology partnership agreement with Mitsubishi Electric Europe.

‘The relationship will encompass fast deployment of existing automation solutions for battery cell production, and then collaboration to build the value chain for the next generation of batteries manufactured in Europe.’

Klaus Petersen, Director Lithium Battery Industry EMEA, Mitsubishi Electric Europe BV Mitsubishi Electric has long term experience in supplying automation solutions in the lithium cell manufacturing industry in Asia, and a well- established customer base of machine builders in Europe. While the value chain in Europe still needs to be built up, the partners aim at creating a network of local machine builders capable of delivering a complete cell manufacturing line at gigawatt hour (GWh) scale. The focus will be on building best in class cells while avoiding wastage within the process, something that has so far been a challenge in the sector.

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‘Lithium battery cell manufacturing is a relatively new field in Europe that is being built-up quickly.

Any lessons already learned by our partners that we can take advantage of can help us to reach start of production (SOP) quicker.

Scaling-up a factory to GWh capacity is ambitious and Novali sees this as an opportunity to build up a local value chain. That is why this project is so important in our opinion as the whole European electrification initiative will profit from that.’ Thomas De Clippeleer, Co- founder.

The company also believes that its mission goes beyond commercial necessities and extends to the general challenge of sustainability. The target is to achieve CO2 neutral manufacture of batteries. One of the key aspects is reducing consumption of energy and raw materials, which is also why a high-level of factory automation is required. The cell manufacturing process itself is challenging and Mitsubishi Electric’s automation solutions have already proven how well they can manage this task, setting high production quality standards while still prioritizing energy efficiency.

Big plans and the benefits of being agile ‘Novali provides a platform for scaling up manufacturing of next generation battery technology.

On the one hand we partner up with technology companies that are frontrunners in their respective field, and on the other hand we work together with automotive and industrial partners like Mitsubishi Electric for developing the supply chain and bringing the batteries into mass production.

As a startup, we are agile and able to quickly set up collaborations with technology companies. This allows us to jointly offer automotive vehicle OEMs flexibility and a future-proof mix of different technologies.

We plan to manufacture four generations of battery cells. Lithium iron phosphate (LiFePO) or (LFP) cells for low-cost market segments, state- of-the-art nickel manganese cobalt (NMC) cells transitioning to high voltage cathodes and silicon anodes for mid-market segments.

Solid state or lithium metal batteries we predict will enter the market at premium.

Another important aspect is that the batteries should be available at a high volume. This requires record investments in cell manufacturing and the downstream supply chain. We are working together with global investment funds and industrial partners setting up joint ventures with automotive companies to achieve this.

Manufacturing equipment and general factory automation is a crucial element in the supply chain.

Mitsubishi Electric has decades of experience supplying automation products to all the incumbent cell and equipment manufacturers in Asia. The goal of this alliance is to tap into this expertise for establishing a local ecosystem of European manufacturers.’ Roald De Meyer. www.MitsubishiElectric.com www.novali.energy 13

Precision Industries LLC “PI” chooses Nidec Leroy-Somer alternator for DG Set in onshore oil & gas installation - Onshore Project for Oil Field – Abu Dhabi, UAE A customized alternator at a high humidity, sand-laden location for demanding applications.

When UAE Dubai-based Precision Industries LLC (PI) won a bid for a very high capacity – 3000 kVA (Medium Voltage 3.3 KV) – generating set for a diversified and integrated group of energy companies in Abu Dhabi, it did not have to look far for the perfect alternator.

As a leading manufacturer of Diesel Power Generating Sets, PI has been working with Nidec Leroy-Somer as an OEM for other projects, and instinctively knew they could rely on Nidec Leroy-Somer to supply the required alternator.

Nidec Leroy-Somer is a French company who has more than 100 years of experience to manufacture high output industrial alternators, along with the supporting peripherals.

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Brief description about the project The project site – an onshore oil & gas installation – located in Abu Dhabi, UAE, has an ambient temperature range up to 55°C and high humidity above than 95%, and is also marred by sandstorms.

The requirement was for three customized generating sets of varying power capacity with tight delivery schedules.

Requirement as per project for Generating set: The power generation requirement for the largest of these three units is 3000 kVA Prime rated generating set with 10% over loading – a 3300V, 50Hz, IP55 alternator with a matching prime mover mounted in a totally enclosed, within customized heavyduty enclosure (IP55). The current and voltage transformers used in this generator are equipped with highly advanced protection including differential protection

(Class PX), restricted earth fault protection and short circuit protection, advance Digital AVR, customized Terminal Boxes to accommodate oversized armored Power Cables.

The Alternator Engineers at Nidec Leroy-Somer studied the requisition for the customized alternator: LSA 56 BL75 / 4p 3000KVA 3,3KV 50Hz Class H/B @ 55°C IP55 CACA totally enclosed machine with very special options.

After detailed deliberation with PI and the end user, we finalized the design. Once built, the alternator was subjected to the Factory Acceptance Test at the Nidec Leroy-Somer works in France, on a unique special test platform, where it is subjected to a closed loop test at full load. The acceptance test was witnessed by customer representatives and other parties.

The Nidec Leroy-Somer alternator

was then shipped to UAE for the assembly of the generating set.

“This is alternator not something that many companies can deliver.

We are proud that Nidec LeroySomer is one of the few companies who can meet such stringent specifications for an alternator. This also applies to Precision Industries, who then took over the job and put in a lot of effort in integrating the alternator in the generator set. There is a huge amount of engineering that has gone into this project”. says Nawar SHUBBAR of Nidec Leroy-Somer.

The generating set Precision Industries went through complete process for Project Management that includes engine sizing and selection, alternator sizing, cooling system, containerization, fire detection and suppression and complete integration of control and protection systems.

The engine is equipped with After treatment for emission control with Selective Catalytic Reduction (SCR)

system – an advanced active emissions control technology – as the customer insisted on emission control in view of environmental concerns.

The fully welded, totally enclosed Drop Over Type Enclosure – rated IP 55 on standby, and IP 44 in operation condition – with a dimensions (LxWxH) 16m x 4m x 4m has been designed and fabricated in-house by PI in UAE. The fire detection and suppression system are IG-541 inert gas protection system, which is a complete autonomous system without human intervention.

Complete Genset Control and Protection system with a local control panel located in the generator unit and a remotecontrol panel in the sub-station with an interface between the two, with connectivity with the SCADA system of the site was manufactured in house by PI. This system includes high end parameters for control, complex operation philosophy based on site requirement, High end protections

with redundant serial communication and complete controls over the generator unit.

“Precision Industries LLC is a specialized manufacturer of customized power generating sets for the Oil & Gas industry, Utility, infrastructure, Telecom, Data Center and other vital governmental sectors, they are known for High End Engineering Capabilities and State of Art manufacturing process within region. This is a generator set with a very high-power rating – 3000 kVA – equipped with a remote radiator and many other special features like the fire detection and suppression system as well as emissions control technology.

“We are very pleased and proud to be working with Precision Industries, the only Emirati company, and for us, a local partner in this highly specialized field of generating sets.

It is very important for us to support UAE enterprises in their plans to localize the industry, and transfer the knowhow,” concludes Nawar SHUBBAR of Nidec Leroy-Somer

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WIDIA Introduces New Chipbreaker for machining aluminum AL Geometry ISO turning insert is cost-effective, universal solution for medium to finish turning applications on aluminum and other non-ferrous materials WIDIATM has added an AL Geometry to its ISO Turning portfolio, strengthening its broad offering of affordable tooling solutions for small to medium sized machine shops, machining aluminum and non-ferrous materials. The AL Geometry insert is offered in two grades for increased machining versatility: an uncoated microfine carbide WU10HT grade and the PVD AlTiN coated grade, WU05PT. Each grade is available in all popular styles, including C, D, R, T, and V inserts to increase customer tooling options.

In addition to enhanced product versatility from multiple grade and

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style offerings, the AL Geometry insert offers additional benefits. A highly polished rake face improves chip flow, resulting in shorter set up times due to less manual retrieval of chips following each cut. The periphery ground insert also features a sharper cutting edge to increase overall tooling precision and reduce cutting forces. Reliable tooling performances means customers can dedicate more time to machining and less time to post-machining deburring operations because of the reduction in built-up edge “The AL Geometry portfolio offers tooling versatility when machining different components and workpieces, while also providing more precise and reliable machining performance,” said Anil Kumar,

WIDIA Global Turning Portfolio Manager. “By focusing on both tooling performance and value, we’re helping our customers maximize their return on our products.”

Versatile, reliable, and costeffective – the AL Geometry is the universal solution for customers seeking lower cutting forces, extended tool life, and greater tooling productivity when machining a variety of non-ferrous workpiece materials, particularly aluminum. Orders for new AL inserts and other WIDIA metal cutting tooling can be placed through any WIDIA authorized distribution partner.

Click here for more information on AL Geometry.

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Integral Powertrain Limited launches corporate rebrand as Helix.

The launch of the new corporate brand, including a new website and logo, aligns with the strategic transformation from consultant to full-service supplier of premium electric powertrains and marks another major milestone in the evolution of the organisation. Helix is investing and gearing up as a technology-driven global company targeting new markets and sectors.

Driven by a shared passion for innovation, the founding directors established Integral Powertrain Limited (IP) in 1998.

Quickly gaining recognition for its internal combustion powertrain consultancy work, IP realised the emerging requirement for highperformance electric drivetrains.

The directors set the company on a dynamic new course as a technology and market leader in the electric drivetrain space. In developing the world’s most power-

dense motors and complementary inverters, IP demonstrated its performance leadership in the very first hybrid and EV hypercar applications and in premium motorsport. In 2015, it completed its first manufacturing programme, delivering the final SPM150 for a pioneering hypercar application.

Luke Barker, one of the founding directors says, “Whilst always maintaining our course of innovation, we have evolved rapidly. Now we are more than an electric powertrain consultancy; we are a world-class supplier to a growing global market, providing straightforward access to the most powerful, compact, efficient electric powertrains available. Investments in our new Shenley Technical Centre, our unique Scalable Core Technology (SCT), and our Flexible Manufacturing Facility sit at the heart of this ambition.

“Recognising these strategic changes, today we are relaunching Integral Powertrain as Helix. This is a natural evolution of our DNA, reflecting upon our progression from a high-tech engineering consultancy to a full-service supplier of world-class electric powertrains. The primary expression of that DNA is in the Helix Scalable Core Technology.”

Delivered through three Product Levels, Helix SCT ensures customers across all markets and/or sectors can achieve a competitive edge by accessing proven, world-class technology.

Helix also continues the cycle of innovation by introducing its X-Division, an advanced technology development group. In search of tomorrow’s competitive advantage, X-Division will focus the full extent of Helix’s experience on developing unique, nextgeneration solutions to rapidly emerging customer requirements.

Encapsulated under the Helix brand, a unique, game-changing approach will enable clients of all sizes to access electric powertrain technology that is perfectly matched to their needs and manufactured to the highest industry quality standards.

Alongside the brand, the www.ehelix.com website has been launched providing insight into Helix’s business and products.

Helix represents a strong, recognisable brand in the marketplace. It stands for the highest performing electrical powertrains made accessible to growing markets through its innovative business model, comprehensive application expertise and great user experience.

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NORD DuoDrive now with powers of up to 3 kW Patented geared motor for ultimate energy efficiency The patented DuoDrive from NORD DRIVESYSTEMS is a revolutionary integrated gear unit/motor concept in a hygienic washdown design that now covers power ranges of up to 3 kW. The seamless integration of the gear unit and motor into a drive system is a quantum leap and sets new standards with regard to userfriendliness and efficiency.

The fewer interfaces, the higher the system efficiency: NORD DuoDrive integrates a high-efficiency IE5+ synchronous motor into a singlestage helical gear unit, and with a system efficiency of up to 92%

achieves one of the highest efficiencies on the market in this power class. Very high system efficiency is also achieved in the partial load range. It is thus futureproof and a real cost reducer.

The constant motor torque over a wide speed range allows for consistent version reduction and reduction of operating costs.

Together with the simple plug-andplay commissioning, this results in a significant reduction in the Total Cost of Ownership (TCO) in comparison with existing drive systems. DuoDrive is suitable for use in food and pharmaceutical industries as well as in intralogistics.

Full compatibility with market standards In addition to the high system efficiency, the smooth, unventilated and compact design as well as the quiet running with minimum noise emissions are further important features. Elimination of many wearing parts results in lower maintenance. The patented geared motor is now available for powers of up to 3 kW with a continuous torque of up to 250 Nm and speeds of up to 1,000 min-1, and covers gear unit speed ratios of i=3 to i=18. Marketcompatible connection dimensions facilitate the replacement and the integration into existing plant designs.

Like all products from the NORD portfolio, DuoDrive is also compatible with NORD drive electronics and can be equipped with all common hollow shaft dimensions (20 to 40 mm) and flange versions (B5 and B14), or a torque arm. Depending on the customer requirements, Harting HAN connectors, M12 round plug connectors or a terminal strip are provided for the motor connection.

Different options like encoder feedback or a holding brake are also possible with DuoDrive. Thanks to its design and operation with the frequency inverter, the DuoDrive can be universally used with the same motor variant worldwide.

Innovative geared motor in a hygienic wash-down design As it is easy to clean, corrosionresistant and wash-down capable, DuoDrive is also ideal for use in hygiene- sensitive and harsh environments, and ensures higher system availability and low cleaning costs through lower cleaning effort. The especially robust nsd tupH surface treatment is optionally available.

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Rohde & Schwarz and MediaTek verify 5G LBS Release 16 features on the R&S TS-LBS test solution Rohde & Schwarz and MediaTek have successfully verified new location based services (LBS) features for 5G NR as defined in 3GPP Release 16. These features will not only improve emergency caller location, but also support upcoming LBS-related use cases in challenging indoor and outdoor environments with both, satellite based and terrestrial technologies.

Rohde & Schwarz has extended the R&S TS-LBS test solution to support these and other Release 16 network based positioning features.

of arrival in uplink and downlink (UL- TDOA and DL-TDOA), or angle of arrival and departure (AoA and AoD), and which meet the 5G requirements for indoor and outdoor positioning use cases. With the new option for the R&S TS-LBS supporting these features, mobile device and chipset manufacturers, test houses and network operators are able to carry out chipset and mobile device verification for GCF, PTCRB and network operator certification, using a single test solution.

Rohde & Schwarz and MediaTek are further advancing LBS testing with the successful verification of 3GPP Release 16 positioning features on a 5G chipset from MediaTek using the R&S TS-LBS test system. The two companies verified the NR positioning reference signals (NRPRS), which are central to networkbased positioning features, such as roundtrip time (RTT), time difference

The R&S TS-LBS is a test system for testing GNSS and network-based positioning. It consists of an R&S CMX500 OBT one-box signaling tester as the network simulator and an R&S SMBV100B GNSS simulator.

The R&S CMX500 OBT setup provides full network simulation capabilities including the support of multiple 4G or 5G cells at a time.

In addition, it provides LBS

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assistance data to the DUT while the R&S SMBV100B simulates the GNSS satellites. The R&S TS-LBS test system can be used for R&D related pre-conformance tests and to obtain GCF and PTCRB certification as well as network operator specific certification acceptance and validated tests.

Christoph Pointner, Senior Vice President Mobile Radio Testers at Rohde & Schwarz, says: “Adding network based positioning features such as DL-TDOA based on NR-PRS to the existing satellite based location signals shows the advanced level of our test solution. We are happy to continue our collaboration with MediaTek to push 5G location based services further for 3GPP Release 16.”

For more information on the R&S TSLBS test system, visit: www.rohdeschwarz.com/_63493-32127.html

DFI New-Gen ADS Series Embedded Computing Solutions for Intelligent Workload Optimization DFI is releasing the new ADS Series of embedded computing solutions powered by the 12th Gen Intel® CoreTM SoC processors The new hybrid architecture combines the P-Core and E-Core for intelligent computing resource allocation to increase visual computing efficiency by 50%, significantly enhancing the performance and efficiency of automated production lines and graphic applications simultaneously.

The new-gen ADS Series computing solutions are available with industrial motherboards and embedded systems, covering various form factors from SBC, Mini-ITX, microATX, ATX to fanless computers. These solutions are designed to meet the needs of industrial control, surveillance, traffic flow analysis and other vision computing at the edge.

Industrial Motherboard 3.5” SBC: S53-ADN 4” SBC: ADP253 Mini-ITX: ADS101/ADS103, ADP171/ ADP173 microATX: ADS310-R680E/ Q670E ATX: ADS630-R680E/Q670E Computer-on-module COMe Compact: ADP968 COMe Mini: ADP9A2 HPC Embedded Systems Fanless: EC500-ADS, EC510/EC511ADS, EC543-ADS Mini-ITX System: WM120-ADS ATX Walk Mount: WM343-ADS

The Intel® Alder Lake processorbased ADS Series utilizes the all-new hybrid architecture of Performance Cores and Efficient Cores (P-core and E-core) to achieve highperformance computing with lower power consumption and intelligently make instant, optimal adjustments to workloads and workflows. With Deep Learning Boost (DL Boost) and Vector Neural Network Instruction Set (VNNI), deep learning can be further accelerated and provides accurate and fast inferencing results for visual computing applications such as defect inspection and AGV/AMR. Besides the new hybrid architecture, the ADS Series also supports PCIe 5.0 high-speed signal transmission for the first time, achieving a data transfer speed 2X faster than the previous-gen PCIe 4.0. Faster DDR5 memory is also supported to boost data read and write speeds up to 4800MT/s, accelerating the processing speed of numerous data and images for AI and computer vision.

Numerous data transfers, shares and backups are processed through the high-speed 10GLAN on the ADS Series Computers, significantly improving operating efficiency. Also, the wireless high-bandwidth Wifi 6E is supported for the first time with speed transmission up to 6GHz (1.4X faster than Wifi 5 and Wifi 6), making device deployment more flexible and collaboration more real-time and seamless.

In addition, the ADS Series supports 8K resolution with clarity and precision, surpassing the resolving power of the human eye by more than ten times. The result provides greater detail for image processing as well as streaming video and enhances the accuracy of the image and visual computing.

The new ADS Series is designed to help integrators maximize the use of each device, reduce configuration, and lower costs.

While improving overall computing performance and efficiency, the ADS Series is also equipped with I/O virtualization of GFX SR-IOV for the first time. It allows the GPU of a virtual machine (VM) to be distributed at near-native performance levels, significantly reducing the latency caused by the software- based virtual machine.

The proof of concept (POC) of SRIOV with Intel also confirms the VM frame rate remains at 60fps, equal to the native GPU performance (the traditional software-based performance is 28 fps frame rate).

DFI’s new ADS Series of industrial computers offers a full range of performance and efficiency optimizations. From data reading/ writing speeds to the transfer to AI computing, the new-gen computing brains will bring unprecedented intelligence and speed to the heavy workloads of AI vision applications, factory automation, medical and retail industries.

Key Features: Powered by 12th Gen Intel® CoreTM with the hybrid architecture of CPU and GPU Intelligent work sequencing to optimize workloads Optimal AI technology, supporting AI accelerator cards for accurate inference Support PCIe 5.0, DDR5 high-speed data reading/writing Ultra HD 8K display Support high-speed 10GLAN, 2.5G LAN and 5G, Wifi 6E wireless networks www.dfi.com

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When the chips are down, call on Scorpion Vision While camera manufacturers and distributors across Europe are plagued by supply issues, Scorpion Vision Ltd has unfettered access to immediate stock, thanks to its relationship with HIKROBOT - part of the world’s largest camera manufacturing company. Logistics operators, manufacturers and systems integrators who choose to work with Scorpion can progress inspection, robotic and other visionassisted automation projects secure in the knowledge that they won’t encounter hold-ups or delays with sourcing industrial cameras or optics.

The stock issue has reached a critical level in the industrial camera industry, with suppliers of cameras and optics quoting lead times of anywhere from 5 to 20 weeks. The delays are due to a global shortage of components, primarily the semiconductors or chips that are used in imaging sensors and LCD screens.

Fortunately, Scorpion Vision, via its relationship with Chinese machine vision and robotics manufacturer HIKROBOT, is insulated against these shortages. With distribution rights for the HIKROBOT range in

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the UK and Ireland, Scorpion can source machine vision area scan and linescan cameras, machine vision lenses and embedded control system PCs within 3-4 weeks. It can either supply these as components to OEMs and system integrators or design and build application-specific visiondriven automation solutions to processing, warehousing and logistics problems.

HIKROBOT benefits from the purchasing might that comes from being part of the largest camera manufacturer in the world and a major player in surveillance cameras.

The group is a large buyer of imaging sensors - components that are common to both surveillance cameras and industrial applications. In addition, having both its manufacturing and its supply base concentrated in China gives HIKROBOT complete control over its supply chain.This in turn minimises its vulnerability to freight issues, supply chain disruption, political instability and market forces in other parts of the world.

“We’ve been a distributor for HIKROBOT since 2017. At that time, there was some resistance to using cameras and optics manufactured in Asia, due to perceptions of inferior quality and ‘copycat’ design. However, because we are experts in imaging we know exactly what we are looking for when selecting hardware partners, and we knew that we had hit on a gem when we found HIKROBOT,” says Paul Wilson, Managing Director of Scorpion Vision.

He continues: “Since then, HIKROBOT has emerged as an innovation powerhouse on the global stage; 800 of its 1,000 employees are R&D engineers, and the company has product development capabilities that are unrivalled in the field of machine vision. It is no coincidence that it has 487 patents to its name and has won multiple awards for its advancements. I think this has helped to change the market view and businesses are recognising that in these uncertain times, supply chain security is king, whether that means sourcing cameras from Europe or the Far East.”

5 reasons to upgrade your legacy CHP engine Combined heat and power (CHP) engines are one of the most crucial components on an anaerobic digestion (AD) plant, converting biogas into usable heat and electricity. As the UK AD industry continues to mature, many of the CHPs originally installed on biogas plants across the country are now reaching 48,000 hours of operation, at which point they require an E70 service. But with technology evolving at such a rapid rate, this major servicing milestone also represents an opportunity to bring your legacy engine into the digital era.

Here, James Thompson, Managing Director of Gen-C, an independent CHP parts and service provider, explains five key benefits of combining your E70 service with a biogas-specific engine upgrade…

1. Access your own engine for freedom of choice If you’re tied into an expensive, long-term, monthly engine service contract, the E70 milestone (when

contracts are usually up for renewal) is the ideal moment to choose an alternative servicing option that works for you.

Despite reports of long waits for engineer callouts and delays for engines to be restarted, many CHP operators stick with substandard servicing contracts because they cannot access their own engine’s control panel; only the service provider can. Quite simply, they feel they don’t have a choice.

By replacing your legacy engine control panel with a smart, openaccess Motortech version, we can unlock your engine’s controls and put the power back in your hands.

Bringing engine management into the digital era, it enables you to restart your own engine instantly and remotely, increasing CHP uptime. Most importantly, it also gives you the freedom to choose a flexible, pay-as-you-go alternative approach to engine servicing, without being locked into a restrictive long-term contract.

2. Navigate staffing issues with remote control Covid has accelerated the trend of remote working, with plant owners keen to ensure their workforce is kept safe. In addition, Brexit and the pandemic have combined to create an unprecedented labour shortage.

As a solution to help reduce staffing levels while maintaining business continuity, our open-access control panel upgrades include remote CHP monitoring and control as standard, helping to relieve labour pinch points at AD plants around the country.

Enabling you to get on with the job of running your AD plant or farm without fear of constant process interruptions, you’ll receive an instant alert on your phone or laptop any time your engine shuts down.

You can then simply dial in and remotely restart your CHP yourself within seconds, increasing engine availability, requiring fewer staff to be on site and enabling the workers that do exist to be redeployed to more value-added tasks.

3. Benefit from technological advances to reduce emissions If your engine is reaching its E70 servicing milestone, it may be six years or more since it was last updated. Technology is evolving at a rapid pace and the advances that have occurred during that time are considerable. Regulations have also evolved, meaning that your legacy engine may no longer be compliant with the latest emissions targets, or those expected to come into force over the next few years.

Coinciding your E70 service with a biogas-specific upgrade (and thereby limiting the time it’s out of action) will ensure your CHP engine is ready for the digital era. As well as open-access control panels, it can be brought up to date with a range of smart, responsive biogasspecific parts such as fuel mixers, ignition controllers, knocking

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control systems and speed controls that can be programmed to accurately match the composition of the biogas being processed.

The result is a finely tuned, biogasspecific, emissions-compliant CHP engine with fewer process interruptions, lean energy utilisation and optimised electricity production.

4. Increase engine uptime Reaction times from large engine service providers can be slow, with reports of plant operators waiting hours and sometimes even days for an engineer to arrive and manually restart their CHPs. Upgrading your legacy engine with a digital, openaccess control panel will greatly boost your engine’s uptime, cutting that wait time to just seconds.

In addition, all our open-access control panels come with the IGSLOG as standard. An intelligent CHP monitoring system, the IGS-LOG constantly tracks live data across 32 parameters that can be individually set by the operator via a user-friendly touch screen (such as fuel ratio, oil quality and battery voltage). It uses this data to inform operational decisions and assist with process improvements, ensuring downtime is kept to an absolute minimum.

5. Facilitate predictive maintenance Unlike a mechanical system (when problems are only discovered once something breaks down and performance is already impacted), the fact that our upgraded engines comprise the digital IGS-LOG system means they are generating constant, real-time feedback. This can help you to run your plant better by pre-empting engine failure and identifying deterioration in performance before it affects your bottom line.

Bring your legacy engine into the digital era and enjoy the benefits of smoother operation, fewer process interruptions, faster restarts and NO monthly service fees! To find out more, go to www.gen-c.co.uk

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Rise of the Internet of Things Jobs An appliance is just an appliance – until it gets smart.

Connect an air conditioning unit to the internet or a private network, and you can control it from an app on your phone; improving its capabilities, and making your life easier. In an age of hyperconnectivity, what is the end goal? To create a smart home, or smart workplace, filled with internet-connected appliances by connecting digital data to the physical world.

Known as the Internet of Things (IoT), there are now over 30 billion items with the ability to connect digitally, and the industry continues to grow, thanks to the skills of trained professionals. The development of IoT jobs and their crucial role in keeping up with demand has meant that there is no shortage of job opportunities on the horizon.

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In 2019, nearly two-thirds (61%) of companies globally implemented IoT applications, and that number continues to grow as the world evolves.

total active listings still saw a slight increase at 53,192. In comparison, May saw the highest number of positions closed, with 20,436 IoT roles filled within the month.

With this in mind, Distrelec has analysed the companies recruiting for IoT jobs, the total number of active listings globally, and the most desirable jobs in 2022.

Of the Top 100 IoT companies in the world, just over half are based in the USA, with PTC, Intel and Honeywell all making the Top 10.

Named ‘Industrial Internet of Things Company of the Year’ in 2017 and known globally for its ThingWorx technology, PTC has changed the game in digital transformation across the years. This technology has since become widely used in Industrial IoT to aid in the development of smart products and solutions.

In March this year alone, almost 23,000 IoT jobs were newly listed around the world, with companies recruiting for Senior Firmware Engineers, Systems Engineers, UI Developers and more. In that same month, 19,224 positions were closed, whilst there were 53,181 total active listings, signalling that IoT technologists were in high demand.

Although new job listings dropped slightly throughout April of this year, the number of closed positions also declined slightly, meaning that the

According to research by Intel, 55% of all data is forecast to be generated by IoT in 2025, with 43% of AI tasks projected to happen on edge devices in 2023. In response, the company has produced

processors with IoT applications in mind. Honeywell, based in North Carolina, operates primarily in aerospace, building technologies and productivity solutions.

Providing products ranging from airflow sensors to snap action switches, the company is ranked 6th in the world for IoT solutions.

Germany follows behind, with 11 companies present throughout the list. Siemens, with headquarters in both Munich and Berlin, places first in the world. Siemens is responsible for MindSphere, the cloud-based IoT operating system that enables users to collect data from sensors in real-time, most prominently used throughout the industrial and manufacturing sectors.

Also present in the list is SAP, which offers a Business Technology Platform, and Bosch which has developed ‘The Bosch IoT Suite’; a software platform created to provide users with the technological basis needed for IoT solutions. Japan is currently home to six companies ranked in the Top 100, with Mitsubishi Electric placing first in the country. Meanwhile, Huawei takes the top spot in China.

UK companies present in the Top 100 include Vodafone, Arm, Telit and Eseye.

As the highest-rated IoT provider in the UK according to this list, Vodafone recently released a new ‘Vodafone Heat Detection Camera’ in response to the COVID-19 pandemic, marketed as a tool to help employers identify one of the symptoms in a safe and effective way. The technology also extends to different working sectors including, but not limited to, ‘Smart Offices’ for office workers and fleet analytics for tracking ambulances and other emergency vehicles within the Healthcare sector.

Specialising within industrial and manufacturing sectors, Siemens is the top IoT company in the world for Connected Machines.

The market is segmented into hardware, software 29

and services, and Siemens provides the MindSphere software that allows manufacturing professionals to access insights from real-world use and be provided with feedback in realtime.

ABB, based in Switzerland, is a provider of industrial IoT applications. Focusing strongly on connected oil and gas production and extending to connected renewables, vessels, mines and paper mills among other industrial industries.

American provider of industrial automation, Rockwell Automation, places third. Their aim is to make the world more productive and sustainable through IoT solutions, working with sectors from Infrastructure to Pulp and Paper.

General Electric, also based in the USA, provides services, solutions and equipment to those within the energy sector. GE Digital, a

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subsidiary of the multinational conglomerate, utilises its ‘Predix Platform’ technology to host applications such as Asset Performance Management (APM) and Operations Performance Management (OPM), providing data connectivity and analytics processing to users.

When taking a look at the most desirable IoT jobs, Engineer takes the top spot with 30.20% of jobs analysed including this title; most notably IoT Research Engineers and IoT Software Engineers.

Research Engineers provide data-driven solutions, whilst developing products, processes or technology.

Automation accounted for 16.60% of jobs advertised, including the role of a Technical Automation Consultant. As specialised engineers, it is the responsibility of the Automation Consultant to

see through the maintenance of industrial automation systems from design to installation.

In the third spot sits Software.

Performing the work of building software, Software Engineers are responsible for the creation of desktop, mobile and webbased applications. The level of experience for this role can determine your annual salary ranging from $84,020 to $123,000.

Other prominent roles featured in our list include Developer, Consultant, Solution Architect, Sales, Account Manager, with Data, Cloud, UI, Project Manager, Full Stack, Analysts and Cybersecurity each taking up less than 5% of live vacancies.

Rodrigue Mao Author For more information visit: www.knowhow.distrelec.com

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White light interferometers with new multi-peak function measure multiple thin transparent layers in one measuring process Precision sensor manufacturer Micro-Epsilon has further developed its interferoMETER range of white light interferometers to include Multi-Peak systems, which enable high precision measurement of multiple transparent layers in just one measuring process. This further expands the range of potential applications, particularly in the semiconductor industry, as well as in the production of coated glass, batteries and plastic film.

The new interferoMETER Multi-Peak (MP) systems allow the measurement of multiple layers, substrates and coatings that are transparent to the 840 nm wavelength range.

This opens up applications in the semiconductor industry, where high precision solutions are required for positioning tasks, gap dimension inspection and measurements of extremely thin layers. In glass and plastic film production, MP systems can rapidly measure very thin or coated glass, as well as multiple bonded plastic films based on high process stability in the production line.

Two controller models are available for multi-peak distance measurement (IMS5x00-DS/MP) or multi-layer thickness measurement (IMS5400-TH/MP). The two system variants differ in that the layer thicknesses of the spacing systems are calculated from the respective distance values and measured directly in the thickness system.

Multi-peak distance Systems for multi-peak distance measurement are particularly beneficial in alignment and positioning tasks in which a distance is to be measured and a thickness determined at the same time. In a large measuring range of time. In a large measuring range of 32

2.1 mm, up to 14 layers with minimum thicknesses of up to 10 µm can be detected. Thanks to the absolute measurement, the system does not have to be referenced even after a signal interruption, for example, at steps or edges.

Multi-layer thickness Systems for multi-layer thickness measurement are always used when distance-independent thickness values for up to 5 layers are required.

In the thickness measuring range of 2.1 mm, individual layers of up to 35 µm are measured in a processstable manner. The large working range compensates for distance fluctuations of the measuring object, so that vibrations or other material movements have no influence on the measurement. A large base distance of up to 70 mm offers process reliability and protects the sensor from damage.

For easy set up and configuration, a modern, intuitive web interface is provided for all MP systems. In addition, various interfaces (EtherCAT, Ethernet, Profinet, EtherNet/IP, RS422, analogue) offer numerous integration options.

In addition to the MP systems, new sensor housings with a higher IP65 protection rating for industrial environments are also available, as well as the previous vacuumcompatible versions.

Unmatched accuracy The interferoMETER range of high performance white light interferometers from Micro-Epsilon provide unmatched accuracy levels in absolute non-contact optical distance and thickness measurement. With measurement resolution from 30 picometres and linearity from ±10nm, these interferometers represent a step change in accuracy from its confocal measurement systems.

The interferoMETER range comprises of a controller, a sensor and a fibre optic cable. Unlike traditional laser interferometers that use a single wavelength and only perform relative measurements, the interferoMETER range operates with a broadband super-luminescent diode (SLED) and can make absolute measurements, ideal for step height and surface measurements. The use of a longer wavelength, 840nm, allows for a greater overall measurement range.

In addition, being in the near-infrared part of the spectrum opens up the possibility to measure thicknesses of anti-reflective glass, plastics, reflective metals and coated objects.

For more information on the interferoMETER series from MicroEpsilon, please visit www.micro-epsilon.co.uk or call the Micro-Epsilon sales department on +44 (0)151 355 6070 or email mailto:info@micro-epsilon.co.uk

FANUC injection moulding machine sees output double in a shot for advanced plastics Stand B13, Plastics Live 2022, 5-6 July, Coventry Building Society Arena The UK’s first installed FANUC ROBOSHOT S450iA injection moulding machine has doubled output on a key range of moulded products for Advanced Plastics Ltd, a supplier of precision-engineered parts to OEMs in the automotive, medical, packaging, defence and consumer goods industries.

Installed in combination with the integrated FANUC M020iD35 robot, the success of the installation prompted Advanced Plastics to order a second machine-robot combination from FANUC UK, which has already been delivered and commissioned.

“The combination of the FANUC robot and moulding machine allows us to seamlessly integrate

our processes,” says Rob Anderson, Managing Director of Advanced Plastics. “This has resulted in a dramatic increase in our output from around 600,000 parts on a particular range up to a planned 1.3 million.”

A UK first Based in Hull, Advanced Plastics undertakes everything from initial design concepts to volume production of plastic mouldings and assemblies, structural plastic components and technical automotive components. The company has almost 10 years’ experience of using FANUC equipment, as Rob explains: “Our injection moulding machines produce high-level engineering parts in various grades of plastic.

Since we purchased the first

FANUC robot back in 2012, we now have nine ROBOSHOT machines and over 40 FANUC robots. We are proud to be the first company in the UK to purchase the FANUC ROBOSHOT S450iA. We purchased this machine on the back of our experience with FANUC, as we needed a bigger machine that gives us the sensitivity to protect very delicate tooling. This machine perfectly fits the bill.”

Winning combination The ROBOSHOT S450iA injecting moulding machine operates with a clamp force of 4,500kN, a double platen die height of between 350mm and 1m, and a clamping stroke of 900mm. Weighing 29.7 tonnes, it boasts a rated maximum injection speed of 180mm/s.

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FANUC’s M-20iD35 robot, meanwhile, is a high-inertia, highstrength model with a hollow wrist and base that delivers fast and efficient movement in all six axes. Its maximum load capacity of 35kg is more than sufficient for the lightweight plastic injection moulded components produced on the ROBOSHOT S450iA at Advanced Plastics. Similarly, its reach range of 1,831mm means it can easily cope with stretching into the ROBOSHOT S450iA to extract components and load them into a collection point or pallet – regardless of the dimensions of the moulded part.

“AI-Protect allows the moulds to open and close at fast speeds with full protection of the tooling.

The tooling can often be just as expensive as the moulding machines so we must protect it,” says Ed Darling, Advanced Plastics’ Process Manager.

Smart protection

Auto-adjustment and control

Like all of FANUC’s offerings, the solution provided to Advanced Plastics has a range of intelligent, digital features. In this instance, one of the key smart benefits is the FANUC AI-Protect system for both mould and ejector. This provides unparalleled mould protection, which in turn neutralises an important potential cause of downtime.

Other automated features include Clamp Force Adjustment, which checks and adjusts the minimum clamp force to provide increased security, eliminating the need to manually modify this critical parameter. Optimising clamp force also minimises mould wear and increases machine life, cuts component defects, reduces energy consumption and compresses start-up times.

By measuring the motor torque, AI-Protect immediately stops the machine if any restriction is detected, shielding the mould during the full opening and closing cycle while having no impact on clamp closing speeds. The same technology protects the ejector’s forward and reverse movement without affecting productivity. AI-Protect even alerts operators when greasing is required, or the mould is worn.

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To highlight the effectiveness of this feature, Ed outlines an incident when an apple was dropped between two surfaces of the mould: “Because of the accuracy of the AIProtect, the apple wasn’t crushed.

That shows the precision that we need on these moulding machines.”

The M-20iD35 robot at Advanced Plastics is controlled via the latest R-30iB control system. This integrates more than 250 software functions to ensure industryleading speed, accuracy and safety. This is all neatly packed into the FANUC A-cabinet, with a highperformance CPU and mainboard with increased memory, a compact

and stackable design, and the user-friendly iPendant Touch control interface.

As a result of the close integration of machine, robot and software, exceptionally fast cycle times can be achieved. As Ed Darling explains, this is a key benefit to Advanced Plastics: “I particularly like FANUC moulding machines because, being all-electric, they are economical to run; but mostly, I like them because we are a cycle time-oriented business.”

Repeat custom For Rob Anderson, meanwhile, the success of the first system quickly led to the company placing an order for a second: “We went for the second machine due to the easy installation of the first. The short lead times offered by FANUC meant we could get products to market extremely quickly. At Advanced Plastics, we like to experience new technologies and look at innovative technologies where we can achieve better results for our customers.

In essence, the FANUC ROBOSHOT S450iA was the only machine that could do the particular job that we needed it to do ¬– and it does it very well.”

To find out more about FANUC’s range of ROBOSHOT injection moulding machines, visit the FANUC UK stand B13, Plastics Live 2022, 5-6 July, Coventry Building Society Arena

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Fluke® helps customers put environmental and financial value on aircompressor maintenance with new tool Working with Fluke’s new online CO2 emissions calculator, the LeakQ™ creates detailed air compressor leak reports from images captured by Fluke ii900 or ii910 acoustic imaging cameras.

Fluke, a global technology leader in the manufacture of compact, professional electronic test and measurement tools and software, has today launched a new CO2 emission indicator to the online LeakQ reporting tool. In addition to the existing estimated leak size and costs, this new feature adds a third element: the estimated electricity related CO2 emission in relation to the identified leaks.

Maintenance engineers and sustainability managers who work

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with compressed air and gas distribution systems every day can be unaware of exactly how much gas and energy is wasted due to small leaks in the system. For compressed air applications, LeakQ used in conjunction with Fluke’s online CO2 emission calculator enables users to quantify the financial value and environmental impact of detecting and fixing leaks in the system by creating detailed reports from images that have been captured using the Fluke ii900 Industrial Acoustic Imager and ii910 Precision Acoustic Imager.

Environmental impact Approximately 90% of all processing companies use compressed air in some aspect of their operation,

such that it is sometimes referred to as the fourth utility. It is estimated that if there were no maintenance systems in place at all, the losses due to leaks in the network would be between 25-30%. Whilst desirable, it is highly unlikely that any plant will achieve an 100% leak free compressed air system.

Compressing air is an energy intensive process and as such any leaks in compressed air systems mean a significant proportion of the electricity used by a compressor to compress the gas should be perceived as energy waste. Due to the energy intensive process, and the potential environmental impact of electricity production, the ability to quantify the environmental and financial

value of maintenance is helping companies drastically reduce their energy (costs) use and carbon footprint.

Detailed leak detection Typical leaks to focus on are quick connect leaks in a joint or interface that isn’t threaded, open end leaks in large holes or open-ended pipes, threaded coupling leaks via metallic threads or weld cracks, and leaks in rubber, flexible and plastic hoses and pipes. Standard leak detection tools only measure dB on a narrow frequency band but LeakQ carries out an automatic scan of the full frequency spectrum and captures the actual frequency range that the leak is generating.

This makes estimations far more representative of the real leak rate than those that are achievable using more traditional measuring tools.

data from the ii900 or ii910 to a computer, where they can be dropped into the online LeakQ report generator. The user then inputs the operating variables such as gas type, pressure, cost of electricity and System Specific Power ratio, which is a measure of compressor efficiency. The report generated will include a summary of all the leaks listed as well as their estimated individual and annual volumes, costs, and emissions.

Leak images are also inserted into the report which can be shared as a PDF or downloaded as a .CSV file for importing into existing maintenance systems. A feedback option enables users to relay their experiences directly back to Fluke so that the company can continue to make the leak detection tool better and easier to use.

Prioritising maintenance

Report generator To develop a report and estimate the potential costs of leaks, the user simply transfers inspection

Tako Feron, Global Product manager Acoustic Imaging at Fluke said: “Being able to prioritise, quantify and cost leaks in such a

simple way is a game-changer for maintenance engineers who will be able to see the full financial and environmental impact of even the smallest leak in a compressed air system. Having the ability to reduce electricity usage is clearly a major bonus at any time but particularly in this challenging climate regarding the cost of energy. At the same time, it is essential to minimise leaks in compressed air systems if we are to meet our crucially important sustainability targets.”

Feron adds: “It’s estimated that around 90% of companies use compressed air in some aspect of their operations and the majority of this is generated on site. That means it is down to the user to keep the costs of compressed air as low as possible and the LeakQ™ leak detection reporting tool provides an extremely powerful means of helping them to achieve that goal.”

Learn more about the LeakQ™ report generator here.

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SICK launches cost-cutting real-time energy monitoring of compressed air As manufacturers face rising energy bills, SICK has launched the FTMg with Monitoring App, an Industry 4.0 solution that helps them see the data they need to reduce energy consumption through better control of compressed air.

The SICK FTMg with Monitoring App enables production and maintenance teams to monitor compressed air continuously so they can reduce leaks, improve operating efficiency, and cut costs.

Compressed air is the ‘fourth utility’ of manufacturing. According to the British Compressed Air Society, it accounts for 10% of energy use in a typical operation and rises to 30% in heavy use industries.

Using data from strategicallypositioned SICK FTMg flow meters, the cloud-based SICK FTMg

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Monitoring App visualises a wealth of both real-time and historic data about compressed air usage.

It enables continuous energy management, condition monitoring and predictive maintenance of compressed air systems from any internet-enabled device.

Targeted Energy Reduction The SICK FTMg with Monitoring App is a scalable system that can target the compressed air energy use of individual machine cells through to entire production or logistics halls.

With no programming needed, it can quickly start visualising continuous compressed air data in a way that is easy to use and interpret. As well as enabling more sustainable use of resources, the data insights support better operational efficiency and

help achieve reduced carbon targets, contribute towards ISO50001 Energy Management certification or compliance with the UK Government’s Energy Saving Opportunity Scheme (ESOS).

Darren Pratt, SICK’s UK Product Manager for Industrial Instrumentation explains: “Compressed air is one of the biggest consumers of energy in manufacturing and logistics, and costs are skyrocketing. Many production teams are currently restricted to conducting periodic spot checks, and all too-often, not enough is known about where leaks are, or which machines are the biggest consumers.

“We are already seeing how early adopters of the FTMg Monitoring App are gaining remarkable, and

sometimes unexpected, insights.

They have been able, for example, to make start-up and shutdown management of processes and machines more efficient, improve compressor control and manage peak loads.”

Continuous Compressed Air Monitoring The SICK FTMg is a multifunctional flow sensor that enables the measurement of live values for compressed air energy in kWh. Data from the FTMg flow meter is presented via the SICK FTMg Monitoring App, which has been developed from SICK’s proven Industry 4.0 Monitoring Box condition monitoring platform.

As well as values for pressure, temperature, flow velocity, mass flow rate and volumetric flow rate in real time, it provides totals for energy use, volume and mass over a pre-defined period.

The user-friendly dashboard makes it easy to interpret data to detect leaks or overconsumption and

to look for changes and trends.

Email alerts can be set up for maintenance reminders or to give pre-defined warnings with job recommendations, for example when data strays beyond predefined limits. Users can drill down to identify costs, for example for individual production centres or by shift.

Secure Connectivity Up to eight FTMG flow meters can be configured via each SICK Smart Services Gateway, which collects data, aggregates and encrypts it before sending it securely via the customer’s own IT infrastructure through a firewall to the SICK cloud.

Alternatively, it is possible to bypass the IT infrastructure by using mobile communications over 3G or 4G. Individuals then have access through a personal SICK ID from any device with a web browser.

The SICK FTMg, which stands for Flow Thermal Meter for inert gases, uses the dynamic calorimetric principle for precision

measurement, enabling it to detect even the smallest changes reliably.

Its straight measurement channel design ensures highly-accurate measurement with almost zero pressure loss as gases flow through the sensor during measurement.

SICK also offers alternatives for customers who do not require the FTMg Monitoring App. For customers wishing to integrate SICK FTMg flow meters into their own IT systems, one or more devices can be used with an IIoT gateway, such as the TDC-E from SICK, for data pre-processing and integration into customer-specific MES, cloud or energy management systems.

The FTMg flow sensor also features an onboard web server or a variety of Industrial communication outputs. This flexibility in communication technology enables easy integration into existing control or data acquisition architectures. www.sick.co.uk

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