Worldwide Engineering Magazine - July 2023

Accurate humidity measurements improve baking efficiency and consistency

Bühler, a leading producer of commercial food equipment including baking ovens, employs Vaisala technology in its Meincke Turbu ovens, including Vaisala’s dew point/temperature probes and industrial transmitters

Environmental concerns and rising energy prices are driving demands for improved efficiency across all industries. This is particularly the case in food production, and especially in processes involving baking ovens, which can run at temperatures of up to 325°C.

Bühler’s cutting-edge Meincke Turbu indirect-fired convection ovens, aim to increase efficiency in line with the company’s strategic commitment to help its customers make substantial savings in energy, water, and product wastage.

One customer was using natural gas at an average annual cost of €10 million before ordering the ovens, but with accurate humidity

measurements a reduction in gas consumption of as much as 20% was achieved.

Ensuring consistent reliable baking product quality

The advantages of accurate monitoring are explained by Morten Bøgild and Christoffer Bay, Senior R&D Engineers at Bühler’s biscuit business unit in Denmark. “By measuring the humidity levels inside the oven, you can control the process to maintain a consistent baking profile, even with fluctuations in other factors like ambient conditions or ingredient quality,” explains Morten. “This enables a more consistent product

in terms of spread, thickness, colouring, and other important quality parameters, thereby minimising wastage.”

In addition, Christoffer says: “An oven with built-in measurement technology gives our customers the opportunity to control the humidity of their ovens themselves, as well as the temperature, which can be particularly valuable for those producing multiple products with different baking profiles.”

The Vaisala DRYCAP® Dew Point and Temperature Probe DMP6 is designed for in-line humidity measurement at very high temperatures and a wide dew

point range. It has a passive cooling function that draws heat away from the probe to reduce the temperature to within the sensor’s optimal range, making it ideal for the extreme environment of an industrial baking oven. This robust technology enables Bühler to offer its customers more accuracy and flexibility when setting up their ovens. In addition, the DMP6 measurement probe can be connected to a Vaisala Indigo500 series transmitter, which enables real-time data visualisation and probe configuration.

Consistent moisture levels improve production efficiency

The monitoring of moisture levels also helps to shorten the time needed to bake the perfect product. “When baking cookies, an oven typically operates with a dewpoint of 60–70 °C, but our Meincke Turbu ovens allow the humidity level to be higher,” explains Morten. “Consequently, there is less cold air to heat up, because when we regulate the moisture content, less air exchange is necessary. In addition, a dryer oven requires higher temperatures to achieve the same heat transfer, while excessive humidity can damage the oven – so with a higher moisture level that is kept consistent and within safe limits, thanks to accurate monitoring, we can achieve substantial reductions in the energy bills of our customers.”

In addition to reduced gas consumption, the conveyer carrying the baked goods can also move through the ovens at a faster rate because the products are ready sooner, resulting in a more efficient throughput.

From automation to digitalisation

Bühler is at the forefront of the fourth industrial revolution in its industry, incorporating smart technology into existing automated production facilities to improve performance through enhanced monitoring, reporting, and artificial intelligence techniques. “The market has slowly embraced this

transition, and by recognising the efficiency benefits of having more accurate data and knowing how to use it, we are driving real change in the industry,” Christoffer explains. “Humidity measurements provide one of the most important insights when it comes to making the baking process more efficient and building an understanding of how heat flow within the oven contributes to final product quality.”

Morten sees Vaisala as the ideal partner for Bühler, helping customers to achieve ambitious efficiency targets. “Vaisala technology is crucial to our efforts, because the sensors are easy to calibrate and use, and robust enough to withstand extreme conditions,” he explains.

“Flemming Bøge of Brdr. Jørgensen Instruments, Vaisala’s partner in Denmark, worked closely with us to help identify the ideal solution; and we also received useful guidance from Vaisala’s own application experts on how to calculate humidity values. This greatly benefited our technicians, which use the equipment daily.

“Even before we chose Vaisala as a preferred supplier, we had customers specifying the company’s equipment in their orders. With an increasing demand for digitalisation and AI-enabled functionalities, this need is only going to increase, so we’re excited to see where this collaboration can take us.”

IVX-1000: Rugged In-Vehicle Computing Workstation for Railway & AIoT Applications

Powered by the latest Intel 13th Gen Core i9, i7, i5, and i3 processors 16V to 160V DC input, 500V surge protection, rugged M12 connectors

Impulse Embedded, are pleased to introduce the IVX-1000 from Vecow, an updated, in-vehicle computing workstation powered by the latest Intel 13th Gen Core i9, i7, i5, and i3 processors. The innovative, EN50155compliant system is rich in features and is easily deployable for railway applications.

Featuring a wide, 16V to 160V DC input with 500V surge protection, rugged M12 connectors, and flexible storage options, the IVX-1000 is a resilient AI-enabled solution for in-vehicle applications such as ADAS (Advanced Driver Assistance Systems), public safety, and mobile communications, as well as AIoT/ Industry 4.0 applications.

The IVX-1000 has an LGA1700 CPU socket that can support Intel’s 13th and 12th Gen Core processors, (code names Alder Lake and Raptor Lake) including the highperformance 24 Core i9-13900E processor, a clever mixed core CPU, with eight Performance hyperthreaded cores and eight Efficient cores. The E cores can focus on background tasks, whilst the P cores will be available to run the

more demanding applications uninterrupted. The IVX-1000 also features two DDR5 SO-DIMM slots supporting up to 64GB of 4800MHz DDR5 memory.

Comprehensive I/O and Expansion Options

The IVX-1000 is packed with a wide range of high-speed I/O such as four 10Gbps USB3.2 Gen2 ports, and nine 2.5G Network ports, supporting TSN (Time Sensitive Networking), a crucial step forward in high-speed Edge communication standards, allowing critical information to be transmitted and acted on in realtime.

Moreover, eight of these ports feature X-coded M12 connectors to maintain and secure connection in high vibration areas. For those users who have the latest IP cameras and other PoE-powered devices, four of the M12 ports offer PoE+, with 25.5W / 48V per port power.

In addition to its high-speed I/O options, all the IVX-1000 variants feature an M.2 3042 B-key socket, suitable for 5G modules, one M.2 2230 E-key for Wi-Fi, and one mini PCIe slot for expansion modules. Quad display output is also standard, via two DisplayPort outputs and two HDMI ports.

For storage, there are two SATA III ports, one mSATA connector, and one M.2. 2280 M-key (PCIe x4) socket, with some models offering

removable storage via easy to access front mount caddies.

A Powerful, Connected All-Rounder

In conclusion, the IVX-1000 from Vecow is a cutting-edge, invehicle computing workstation that brings advanced capabilities to railway applications and AIoT environments. Powered by the latest Intel processors, it combines ruggedness with AIenabled features, making it ideal for ADAS, public safety, mobile communications, and Industry 4.0 applications.

With comprehensive I/O options, expansion capabilities, and highspeed connectivity, the IVX-1000 ensures seamless, real-time communication, and reliable performance in demanding environments.

Impulse Embedded Systems Capabilities

Impulse Embedded can fully configure all of their embedded systems to customer’s exact specifications in their UK-based engineering facility with a wide choice of processor, memory, storage, peripheral cards, and operating system.

Impulse Embedded create reliable, repeatable, and revision-controlled systems aimed at reducing project costs and development time. With our team of in-house engineers and specialists, all with decades of experience, we can offer you fully deployable embedded computing solutions straight out of the box.

For more details regarding Impulse Embedded’s embedded systems capabilities please click here or call +44 (0)1782 337800

InfraTec’s New Infrared Zoom Camera: Small, Light, Universal

Smaller, lighter and without time-consuming lens changes – this is how InfraTec’s latest infrared camera comes across: ImageIR® 6300 Z, now available in the UK and Ireland through QDUKI. The compact zoom camera for precise thermographic temperature measurements is suitable for numerous fields of application. Its excellent price-performance ratio and its remarkable user-friendliness result from the consistent use of innovative technologies in optics, detector and electronics.

The ImageIR® 6300 Z is equipped with an integrated 7.5x zoom lens as standard and allows, in combination with its motorised focus, fast and stepless adjustment to a wide range of object distances and lens sizes with excellent image quality and high measurement

accuracy. Furthermore, the zoom camera is radiometrically calibrated over the entire focal length range, thus enabling extremely flexible use.

Innovative XBn detector

The heart of the infrared camera is the new SWaP camera core. It consists of a cooled MWIR focal plane array photon detector with innovative XBn (HOT) technology in the format of (640 × 512) IR pixels, designed for demanding requirements and operating in snapshot mode. The XBn detector material with higher operating temperatures (HOT) of 150 K allows the use of a new linear cooler generation, which is characterised in particular by a substantial smaller design, lower power consumption and long service life. This – in combination with a very

small pixel pitch of 10 µm – reduces the dimensions and weight of the ImageIR® 6300 Z and significantly extends its maintenance-free service life.

The maximum IR frame rate of 180 Hz can be increased up to 600 Hz with the binning function in high-speed mode. Switching between the two speed modes is conveniently done via software and allows precise metrological tracking of fast thermal processes.

By using its powerful image processing electronics, the camera can output the IR image data in real time to several video and data interfaces as well as record and evaluate it independently. Alternatively, large amounts of data can be stored directly on the integrated SSD. Its web interface also enables the camera to be controlled via smartphone or tablet and, due to the battery operation option, it is also suitable for outdoor use.

Wide range of applications

The ImageIR® 6300 Z is predestined for demanding applications in research and development as well as for stationary or airborne inspection and monitoring tasks. Further applications can be found in quality assurance, materials testing or in a wide range of OEM integration solutions.

Quantum Design represent InfraTec in the UK and Ireland.  Please contact Luke Nicholls or call 01372 378822.

Discover our full range of leading edge high-tech instrumentation at https://qd-uki.co.uk/?utm_ source=advertorial&utm_ medium=link&utm_ campaign=worldwideengineering&utm_term=infratec6300z.

The NEW ImageIR® 6300 Z

Compact zoom camera and new SWaP detector (Size, Weight and Power)

Smaller, lighter and without time-consuming lens changes. The ImageIR® 6300 Z is predestined for demanding applications in research and development as well as for stationary or airborne inspection and monitoring tasks. Further applications can be found in quality assurance, materials testing or in a wide range of OEM integration solutions.

Features:

■ Cooled focal plane array photon detector operating in snapshot mode with (640 × 512) IR pixels

■ Standard built-in 7.5x zoom lens with motor focus

■ Focal length of (15 ... 115) mm or (25 ... 170) mm

■ Operation via smartphone or tablet with integrated web interface

■ Compact size and low weight for space-saving system integration

■ Storage of large amounts of data on the integrated SSD

RPI launches new metrology-grade rotary axis table for Portable CMM’s which improves productivity by up to 40%

RPI, leading provider in rotary measurement and angular positioning devices, have expanded their metrology product range with the launch of OctoScan, improving productivity by up to 40%.

OctoScan is a highly accurate rotary axis enhancing the measurement capability of portable measurement arms. It enables objects that are larger than the standard reach of the portable arm to be easily and accurately recorded.

This new rotary positioning system provides additional flexibility to the measurement process, minimising errors and increasing accuracy for otherwise difficult to reach areas with an overall increase in measurement volume.

OctoScan is also built with convenience in mind with wireless functionality and highly portable around a production line. It can be integrated with any measurement arm or portable CMM (coordinatemeasuring machine).

For example, LK Metrology’s Freedom Arm measuring system, which was demonstrated at Control, had a fully integrated OctoScan via PolyWorks software.

The universally compatible design enables very easy set-up. Additionally, OctoScan has been designed so that parts can be fixed into place in many different ways. Its built-in magnets and multiple threaded fixing holes allow for an element of bespoke fixing.

Octoscan’s high accuracy and portability mean that it is one of the most efficient rotary positioning systems commercially available.

It has been shown that, thanks to its full access to, say, larger parts, and using only a single set up, OctoScan is able to increase overall workplace productivity by up to 40%, whilst also significantly minimising human error and fatigue.

This is due to it eliminating the need for repeat measurements of certain parts that would typically stand outside the measurement range. Octoscan has a radial and axial runout of 1 micrometer and coning of axis +/- 0.5 arcseconds.

Peter Marchbank, RPI’s Managing Director, said: “The launch of a new line of products is always an interesting time for both us and our customers and with OctoScan, I can already envision how it will influence workflows in many industries.

“The one thing people are going to notice almost immediately is the increased efficiency it brings to the workplace and when considering its increased measurement volume and enhanced accuracy, repeat measurements and human error will become less of a problem.

“Its ergonomic design is allowing it to be moved all over the production line, almost anywhere that it is needed.

“All in all, OctoScan is an extremely promising new addition to our already great product line-up and having already received our first orders follow the launch I am confident it will become a staple of our client’s standard tools in the very near future.”

For more information please visit: www.rpiuk.com/products/octoscan/

SPP Pumps Engineering Services Division: - The Pump & Valve Specialists

Total Capability for Pumps, Valves & Rotating Equipment

The Engineering Services Division of SPP Pumps Limited is a global business that can repair or refurbish any piece of rotating equipment and associated ancillary equipment, no matter what make, model or size.

The Engineering Service Division operates Five regional service centres across the UK at Coleford, Hyde, Aberdeen, Glasgow, and Belfast.

In addition, the Engineering Services Division has field service support through a team of specialist highly trained service engineers.

Specific Services Offered are: -

- Replacement pumps

- One of the largest OEM test facilities in Europe -Pump performance testing– rigorous duty tests, Energy Efficiency tests and much more.

- Pump alignment using the latest laser technology.

- Pump upgrades and refurbishment

- Rotating equipment repairs (Fans Gearboxes, Mixers, Screens)

- Replacement valves, valve repairs, certification, and testing

- Machining & welding facilities

- Re-engineering and casting –using 3D Laser capture technology to copy and manufacture any component as an exact replacement

- Protective coatings – applying specialist coatings to repair, protect and improve the longevity of existing and new pump casings.

- Pump performance testing, monitoring, and root cause analysis

- Re-rating and system optimisation – to reduce energy costs and increase service life

- Hydraulic Modelling and Computational Fluid Dynamics (“CFD”) Analysis – for optimising pump efficiency and performance.

- Hydraulic and structural calculations.

- Specialist material upgrades –using in-house design capability to increase longevity of rotating equipment with both metallic and non-metallic substrates

- Design upgrades

- Site installation and commissioning

- Fire pump service contracts –including planned contractual maintenance, technical performance analysis, control cabinet upgrades and repair, and remote monitoring

- Technical advice and support for all pumping systems (including SPP product support).

75% of all Pumps & Valves overhauled in our service centres are Non SPP products.

Pumps regularly refurbished and upgraded are:

Flowserve, Flygt, Grundfos, Harland, Ingersoll Dresser, KSB, Lowara, Mather & Platt, Sulzer, Warman, Weir, Worthington Simpson, plus many more

Call us today, I am sure you will be impressed: - 01594 832701 Or email enquiries@spppumps.com

Pumping particles is no problem

By Matt Hale, International Sales & Marketing Director, HRS Heat Exchangers

Pumps are an integral part of many food processing facilities, but care must be taken to select the correct pump for both the product being moved and the process requirements. Physical damage to the product, as well as the influence of factors such as pressure and shear stress must all be taken into account. When you wish to pump large solid items, such as fruit and vegetables, these challenges become even greater.

There are many types of pump on the market, including rotary lobe, rotary piston, reciprocating positive displacement, progressing cavity, peristaltic hose and air-operated double diaphragm designs. However, not all of them are capable of maintaining product quality at a reasonable cost while keeping the required pressure in

the system (in particular, progressive cavity pumps can break the product, while double diaphragm pumps result in a low pressure drop). Furthermore, traditional pumps can be expensive to maintain while lobe pumps have low flow rates.

To overcome these difficulties, HRS developed the BP Series of hygienic reciprocating, positivedisplacement pumps, which are suitable for a wide range of difficult to handle food products, including whole peppers, strawberries and baby carrots, as well as sauces, dips, fruit purées, and many others.

Positive displacement pumps have an expanding cavity on the suction side of the pump and a decreasing cavity on the discharge side. Liquid flows into the pump as the cavity on the suction side expands and is forced out of the discharge side as the cavity collapses. The HRS BP

Series Piston Pump is operated either hydraulically or pneumatically (depending on available air supply pressure), and incorporates a separator fitted between the piston and the hydraulic chamber to ensure that there is no contact between the product chamber and the hydraulic oil (if fitted).

The standard BP Series has an adjustable flow rate of between a minimum of 200 litres/hour and a maximum of 12,000 litres/hour, and features a high pressure drop of up to 30 bar.

It is suitable for a wide range of high viscosity, shear sensitive and large particle-containing fluids. Clap valves allow pumping of whole fruits or vegetables, and an alternative piston pump with a pneumatic cylinder can be supplied for low pressure applications of less than 5 bar.

Over the years three additional models have been added to the BP Series range:

- BPM Series – a skid-mounted, mobile version allowing it to be used across multiple production lines

- BPSC Series – designed for highly viscous products, and those which are produced and packed at low temperatures, it features a screw conveyor to feed the pump inlet

- BPH Series – a horizontal version with a vertical inlet and a ball valve instead of a clap valve

If you have experienced product issues using other pumps, then chances are the HRS BP Series will be able to meet the challenge whether processing whole fruits or vegetables, delicate dairy products like creams and sauces, highly viscous materials such as humous, or larger particles such as coleslaw or fruit compote.

ATEX Triplex Plunger Pumps for MEG Injection in Green Hydrogen Production

The Project

Recently North Ridge Pumps tackled a project for a client who was looking for 3 High Pressure Pumps to be used for a mixture of Mono Ethylene Glycol (MEG) and Water at pressures over 40 Bar and flows up to 300L per minute.

Mono Ethylene Glycol (also known as MEG) is typically used as a component of coolants, antifreeze, and de-icers as well as in the manufacture of polyester fibres. In this case, MEG is being used in the process of producing Green Hydrogen, which is a more efficient method of production in terms of cost and environmental protection.

Pumps being used within a Hydrogen plant are required to be ATEX rated due to the presence of gasses and other environmental hazards and be suitable for extended operation over long periods of time.

With all this taken into considering, it’s quite a tough project to undertake! Fortunately for the

client, it’s something North Ridge Pumps specialise in. So, what was the solution?

The Solution

We specified and supplied 3 CAT Triplex Plunger Pumps in AISI 316 Stainless Steel, with the head driven via a speed reducing belt drive transmission system. The unit was mounted on a steel baseplate, with the belt protected by an AntiSparking Brass Coupling Guard.

Due to the location of the motor an IP65 rated 22Kw motor was selected which was ATEX rated to EXd IIb T4. We always recommend that triplex plunger pumps are used in conjunction with a regulator and relief valve.

The Reason

So why was this pump picked? Triplex Plunger pumps are designed differently to piston designs in that the plunger slides back and forth within a stuffing box which controls the working volume as opposed

to a piston sliding back and forth within a hollow cylinder. Triplex Plunger designs are suited for higher pressures than that of piston models and meet the pressure metrics needed, that suits two of the requirements.

A regulator valve sets and maintains consistent system pressure. In applications where process flow is abruptly stopped such as in trigger gun applications, it helps maintain the desired system pressure with flow via a bypass port, improving safety and maintenance.

A relief or unloading valve protects a system from over pressurisation protecting components and pipework. If pressure spike occurs (flow in outlet pipe stopped) low flow of low-pressure flow to cycle reducing wear on components, essential for the environment the pump will be in.

With this pump configuration every key specific is met. ATEX requirements, uninterrupted long operation, pressure, and volume handling metrics met and above all reliability in a trusted design.

The Conclusion

With the pumps on their way to their new home and likely busy at work by the time this article is wrote, it’s hard to say what our world will look like in 10, 20 or 50 years, but one can be certain. These 3 Cats’ will still be doing their job without hitch, just as they did on day 1.

We’ll be staying up to date on this project as we dive deeper into a case study with the on-going findings from the project over the years. If you have a project yourself or need technical advice. North Ridge Pumps are only a quick, email, phone call or online message away!

NORD at the IFAT 2022: Drive systems for wastewater handling

Efficient pumping, mixing and agitating for wastewater & water treatment

From 30 May to 3 June 2022, the IFAT will take place in Munich. NORD DRIVESYSTEMS, too, will be present again this year after the pandemicinduced break, presenting innovative and intelligent drive technology for water, wastewater, waste and raw materials management at the world’s leading trade fair. Among other things, the spotlight will be on the patented wash-down-capable DuoDrive geared motor and the SAFOMIIEC adapter for optimised use of MAXXDRIVE® industrial gear units in mixing and agitation processes.

Transport and distribution of drinking water, conveying of wastewater, circulation of activated sludge or comparable process engineering applications: Pump systems, as well as mixers

and agitators, are elemental components in process and wastewater and engineering systems, and ensure the smooth operation of sewage treatment plants, waterworks systems and production plants. They often have to circulate large volumes of liquid or highly viscous substances. Therefore, availability, reliability and a long service life are the top priorities. As a system supplier, NORD offers fully matched drive systems consisting of gear unit, motor and frequency inverter that are tailored to the respective requirements of the customer application. NORD drive solutions can be networked, operate autonomously, and their functions and performance are scalable.

The new DuoDrive: Gear unit and motor combined

The innovative and patented DuoDrive geared motor in robust

and hygienic wash-down design integrates a high-efficiency IE5+ synchronous motor into a singlestage helical gear unit. This not only guarantees a compact size and minimal noise emissions but also high power density and overall high system efficiency. As a system, the very compact DuoDrive concept achieves a significantly higher energy efficiency than the already proven drive systems with IE5+ synchronous motor and bevel gear unit. At up to 92%, DuoDrive currently offers the highest system efficiency on the market in this power class, and achieves very high efficiency in the partial load range. Together with its simple plug-and-play commissioning, the complete DuoDrive solution results in a significant reduction in Total Cost of Ownership (TCO) compared to other drive systems.

SAFOMI-IEC adapter for agitators

NORD has developed the SAFOMIIEC adapter specifically for agitators. If it is used for an agitator drive instead of a standard IEC adapter, a higher operational reliability and less maintenance will be achieved. However, its main advantage is an integrated oil expansion volume. Therefore, oil tanks and hoses as well as the radial shaft seal, which is subject to leakage and wear between gear unit and IEC cylinder, are not required. SAFOMI is available for MAXXDRIVE® parallel gear units in sizes 7 to 11 and covers maximum output torques from 25 to 75 kNm. The compact combination of a MAXXDRIVE® industrial gear unit, the SAFOMI-IEC adapter and a drive motor is the best choice for mixer and agitator applications to reduce wearing parts and attached components.

Experts from NORD DRIVESYSTEMS will give their advice on these and further drive solutions for the industry at the IFAT in Munich on stand 314 in hall A1.

RINGSPANN (U.K.) LTD. was founded in 1970 in Bedford. Since then we have grown steadily by o ering world-class products & customer service.

Our warehouse is stocked with the vast majority of the items you nd in our catalogues for next day delivery, with backup stock available from our international factories if required.

We have a dedicated team of experienced engineers to cover each of our product areas Power Transmission, Workholding and RCS® Cables & Controls.

,

Our Power Transmission range incorporates Freewheels, Industrial Brakes, Shaft Couplings and Shaft-Hub-Connections for use in many torque transmission applications such as industrial gears and geared motors, energy generation, material handling and food and packaging applications.

RINGSPANN workholding solutions specialise in clamping and centering of cylindrical internal and external surfaces. Typical components include automobile, gear and aircraft components.

RCS® Cables cover both push / pull and pull only types and provide possibilities for con guration during manufacture. Thus creating a solution that ts the exact customer speci cation. Typical applications include high-end sports cars, mechanical safety devices and rail applications.

Whatever your application or situation, please contact one of our team. In most cases we will be able to help you by telephone, email or fax, we can also o er a site visit if required.

We look forward to hearing from you soon …

Tony Gillard General Manager

Power Transmission Components

The One-Stop-Shop for your application

Brakes

The universal concept of the RINGSPANN Brakes ful lls various functions including emergency stopping, control braking and holding applications.

Freewheels

Wide selection of Complete and Integral Freewheels to prevent reverse motion of conveyor belts, elevators, pumps, blowers and electric motors.

Shaft-Hub-Connections

Cone Clamping Elements for internal and external clamping provide the highest transmissible torques with shaft sizes up to 600 mm and Shrink Discs with transmissible torques up to 4225000 Nm.

RCS® Cables

Remote Control Systems

Push and Pull Cables and Pull

Only Cables manufactured to the customers exact dimensions providing the highest e ciency without a stick-slip e ect.

Clamping Fixtures

Precision Clamping Fixtures based on the unique method of RINGSPANN clamping for thin or thick walled workpieces with long or short clamping lengths.

Couplings

RINGSPANN o ers a wide range of Couplings for applications where it is critical for torque to be transmitted to a torsionally rigid connection without backlash or misalignment

Workholding Solutions

Large laundry

Intelligent robotics for laundries closes automation gap

The textile and garment industry is facing major challenges with current supply chain and energy issues. The future recovery is also threatened by factors that hinder production, such as labour and equipment shortages, which put them under additional pressure. The competitiveness of the industry, especially in a global context, depends on how affected companies respond to these framework conditions. One solution is to move the production of clothing back to Europe in an economically viable way. Shorter transport routes and the associated significant savings in transport costs and greenhouse gases speak in favour of this. On the other hand, the related higher wage costs and the prevailing shortage of skilled workers in this country must be compensated. The latter requires further automation

of textile processing. The German deep-tech start-up sewts GmbH from Munich has focused on the great potential that lies in this task. It develops solutions with the help of which robots - similar to humans - anticipate how a textile will behave and adapt their movement accordingly.

The German deep-tech start-up sewts GmbH from Munich has focused on the great potential that lies in this task. It develops solutions with the help of which robotssimilar to humans - anticipate how a textile will behave and adapt their movement accordingly. In the first step, sewts has set its sights on an application for large industrial laundries. With a system that uses both 2D and 3D cameras from IDS Imaging Development Systems GmbH, the young entrepreneurs are automating one of the last remaining manual steps in largescale industrial laundries, the unfolding process.

Although 90% of the process steps in industrial washing are already automated, the remaining manual operations account for 30% of labour costs. The potential savings through automation are therefore enormous at this point.

Application

It is true that industrial laundries already operate in a highly automated environment to handle the large volumes of laundry. Among other things, the folding of laundry is done by machines. However, each of these machines usually requires an employee to manually spread out the laundry and feed it without creases. This monotonous and strenuous loading of the folding machines has a disproportionate effect on personnel costs. In addition, qualified workforce is difficult to find, which often has an impact on the capacity utilisation and thus the profitability of industrial laundries. The seasonal nature of the business also requires a high degree of flexibility. sewts makes IDS cameras the image processing components of a new type of intelligent system whose technology can now be used to automate individual steps, such as sorting dirty textiles or inserting laundry into folding machines.

“The particular challenge here is the malleability of the textiles,” explains Tim Doerks, co-founder and CTO. While the automation of the processing of solid materials, such as metals, is comparatively unproblematic with the help of robotics and AI solutions, available software solutions and conventional image processing often still have their limits when it comes to easily deformable materials. Accordingly, commercially available robots and gripping systems have so far only been able to perform such simple operations as gripping a towel or piece of clothing inadequately.

But the sewts system VELUM can provide this. With the help of intelligent software and easy-tointegrate IDS cameras, it is able to analyse dimensionally unstable materials such as textiles. Thanks to the new technology, robots can predict the behaviour of these materials during gripping in real time. It empowers VELUM to feed towels and similar linen made of terry cloth easily and crease-free into existing folding machines, thus closing a cost-sensitive automation gap.

The software suite developed by sewts combines commercially available robots, grippers and cameras into an intelligent system. In the search for the right camera modules, several criteria were decisive for the Munich-based company in addition to uncompromising industrial suitability: “We need a 3D camera that is cost-effective because we use two to three 3D cameras depending on the system configuration. In addition, it must above all ensure high accuracy of the depth data,” explains Tim Doerks.

“Beyond that, we need 2D cameras that are light sensitive, deliver high dynamic range and are suitable for use in a multi-camera system.” The founders found what they were looking for in the IDS portfolio: For the VELUM multi-camera system, the choice fell on the new Ensenso S10 3D camera as well as models from the uEye CP camera series. Their task is to identify, both in 2D and 3D, interesting features and gripping points of the textiles that are fed into the system after washing and drying in an unordered manner in a container or on a conveyor belt. The shape and position of the individual objects cannot be predicted. The cameras capture the different textures of the materials. They distinguish which hems there are on a towel and where corners are.

We match the images from the 2D and 3D cameras to have a higher 2D resolution together with the 3D data. So we use the respective advantages of the 2D camera, in this case the higher resolution, and the 3D camera, i.e. the precise depth data”, Tim Doerks, co-founder and CTO at sewts mentiones. Equipped with a 1.6 MP Sony sensor, the Ensenso S10 uses a 3D process based on structured light: A narrow-band infrared laser projector produces a high-contrast dot pattern even on objects with difficult surfaces or in dimly lit environments. Each image captured by the 1.6 MP Sony sensor provides a complete point cloud with up to 85,000 depth points. Artificial intelligence enables reliable assignment of the laser points found to the hard- coded positions of the projection. This results in the robust 3D data with the necessary depth accuracy, from which VELUM extracts the coordinates for the gripping points.

The complementary GV-5280CPC-HQ industrial camera with GigE Vision firmware is equipped with Sony’s IMX264 2/3” global shutter CMOS sensor. It delivers nearnoise-free, high-contrast 5 MP images in 5:4 format at 22 fps at full GigE speed in applications with fluctuating lighting conditions. The uEye CP camera offers maximum functionality with extensive pixel pre-processing and is perfect for multi-camera systems thanks to the internal 120 MB image memory for buffering image sequences. At around 50 g, the small magnesium housing is as light as it is robust and predestines the camera for space-critical applications and for use on robot arms.

Software

Depending on customer requirements or configuration, two to three uEye 2D or Ensenso 3D cameras are used - both models can be seamlessly integrated into VELUM. “We are experts in preparing the generated data, which is especially important when working with 3D point clouds. This pre-processing is an important

component of our systems in order to generate suitable input for our artificial intelligence,”

Tim Doerks emphasises. The AI developed by sewts processes the data supplied by the uEye CP or Ensenso S cameras. The intelligent software analyses the topology of the textiles using features such as the course of the seam, local elevations or the relative position of seams, classifies them according to textile type and class using various textures and embroidery patterns and translates these findings into robot commands.

The data is processed via Convolutional Neural Networks (CNN) and classical image processing. “We use IDS peak, the software development kit from IDS. We connect to our system via Python and the IDS Library,” reveals Till Rickert, co-founder and CPO of sewts. “The added value of the IDS software package for us lies primarily in the ease of calibration and integration into our High Tech Vision System,” he continues.

“AI is at the core of our technology. Intelligent algorithms are needed to build adaptive systems that can cope with non-deterministic automation processes. That’s why we use the latest findings from AI research, refine them for our needs and finally put them together into a big whole,” adds Till Rickert. It receives various sensor data (e.g. optical information), draws conclusions from them on a human-like cognitive level and translates them into robot commands. In this way, systems like VELUM perform tasks that previously required the human mind. This is exactly what sewts’ corporate philosophy is all about: “Our goal is to transform complex manual work into smooth automation”.

Outlook

With systems like VELUM, laundries can significantly increase their throughput regardless of the staffing situation and thus increase their profitability. “By closing this significant automation gap, we can

almost double the productivity of a textile washing line,” assures CEO Alexander Bley.

IDS cameras can also be used for clothing such as shirts and trousers in the future. “It is important to understand the properties of these materials in order to implement robust processes.

We achieve this through sophisticated material simulations. In order to simulate the behaviour of textiles, we create special FE simulations using the finite element method,” explains Alexander Bley. But the Munich-based company has an overarching vision: “We want to make it possible to automate the production of clothing and move it back to the point of use in a costefficient way. In this way, we shorten transport distances, create more reliable supply chains, save CO2 emissions and combat the problem of overproduction.” Additionally applications with materials that are not textiles are also planned for the future.

There are many potential use cases for technologies like these, and image processing will always play a significant role. Artificial intelligence will accelerate this development.

Cameras

Ensenso S: 3D laser point triangulation with artificial intelligence

- Ultra-compact and cost-efficient

- High 3D data rate and accuracy through AI support

- Robust 3D data even in low ambient lighting

- Structured light with AI-based laser dot pattern triangulation

- Suitable for applications in logistics automation, robot vision, obstacle detection, monitoring and horticultural automation, etc.

For more information visit: www.sewts.com

SICK’s fill level monitoring keeps packaging machines topped up

A digital service that gives instant visibility to filling levels in packaging machinery has been developed by SICK in collaboration with industry end-users. SICK Filling Level Monitoring avoids machine stoppages by giving real-time data to operators via smartwatch or phone, so that levels of carton blanks, adhesive or film wraps, for example, stay topped up.

Instead of having to check each magazine or film roll level in person, machine operators monitor fill levels on their watch or phone and are alerted by SICK’s Filling Level Monitoring system before levels become critical. Machine downtime is avoided and staff walking routes can be planned efficiently to ensure optimum production uptime.

Industry Collaboration

The SICK Filling Level Monitoring digital service can be used with any SICK smart level sensors. Its first applications have been developed with packaging manufacturers and machine builders using SICK DT-50 laser distance sensors to output level measurements from carton magazines and film rolls. The measurements are routed to a SICK SIM1012 edge gateway, which aggregates and forwards

encrypted data via SICK’s LiveConnect digital interface, so that it can be easily accessed, managed, and processed online.

The SICK Filling Level Monitoring cloudbased dashboard provides easy-tointerpret graphical information about the real-time status of machines from any internet-enabled device. Automatic push notifications on the fill levels can be set up for smart devices to alert with an acoustic signal and vibration. Meanwhile, production managers can monitor the fill levels of all machines across a packaging line, shift or entire production facility. Analysis of historic trends can be used to optimise production processes.

Unexpected Benefits

Neil Sandhu, SICK’s UK Product Manager for imaging, measurement and ranging, said: “SICK worked closely with leading packaging end-users and machine builders in Europe to develop a cost-effective and easy-toimplement system.

“By using the smart watch alerts, our customers found that fewer operators were needed to keep cartoning machines replenished, so staff could be deployed more efficiently to other duties. What’s

more, the system brought unexpected benefits to overall production control. For example, the loads on packaging machinery lines could be monitored to identify over- or under- capacity.”

While initially developed for cardboard and film packaging materials, Filling Level Monitoring can also be adapted for liquids including adhesives, or granular raw materials. It is also possible to add customised services and analyses tailored to particular machinery or processes.

Up to six SICK sensors can be monitored by each SICK SIM1012 gateway, and more sensors, including third-party devices, may be added by connecting over OPC-UA. Sensors are also continuously monitored by the system in case one should go offline or need a replacement. The solution can be extended to meet the needs of customers on request, e.g. to customise and display additional data on the dashboard. Integration to third party ERP and MES software systems is also possible.

Digitilisation

Neil Sandhu concludes: “Cloudbased services such as Filling Level Monitoring illustrate how making reliable sensor data transparent enables digitalised machine operation as part of Industry 4.0. By combining smart sensors with intelligent software, critical processes can be visualised in real time and adapted for the needs of users.

“Early adopters are noticing new and unexpected production trends when they view and interpret their historical production data in easy-to-read graphical displays. As a result, they have been able to optimise production processes and deploy staff to achieve efficiencies never even expected.”

Mclennan helps STFC solve large load precision motion control for AGATA sensor array

Mclennan has recently completed the design and supply of a particularly challenging motion control system for the Science and Technology Facilities Council’s (STFC) Daresbury Laboratory, as part of the research council’s funding and collaborative support of the Advanced GAmma Tracking Array (AGATA).

With its objective to build and operate the ultimate gamma ray tracking spectrometer, AGATA is a partnership of over 40 institutions from 13 European countries that collaborate and share exciting research that will produce the most valuable understanding of the structure of atomic nuclei ever realised. At detection levels that are one thousand times more powerful than previous systems, the globe-shaped instrument will be transported and used across several European beam accelerator facilities for applications that will

advance many areas of research including medical imaging and environmental monitoring.

Mclennan’s work on the project with Daresbury Laboratory, which is located at Sci-Tech Daresbury, involved the design and supply of single axis servocontrolled motion system for the precise rotary positioning of the sensor array holding frame that guides and supports a matrix of encapsulated high-purity and highly fragile germanium crystal detectors. Mclennan had been involved in two earlier iterations of the AGATA project which has run for several years. The earlier motion systems were simpler and more traditional than the on-axis drive required for this latest holding frame design which measures approximately 2.5 metres over its largest diameter and weighs 7.5 tonnes when fully loaded with a complement of up to 180 large detectors.

The closed loop motion system needed to be applied through an existing slew ring gearbox that forms part of the holding frame’s power transmission mechanics and includes a large drive shaft supported on two bearing blocks. With such a large mass and an equally large total system inertia - plus the problems of lost motion/hysteresis, backlash, and compliance through the combination of the slew ring gearbox and bearing arrangement – accurate and stable rotary positioning for this huge spherical structure would present challenges for Mclennan. These challenges were compounded by the specification requirements and choice of technologies for the additional gear unit components and servo system performance.

Other design criteria included a requirement to use a stepper motor as part of closed-loop motion system which through its

characteristic holding torque had proved to be more stable in earlier projects. STFC had already specified and included a Renishaw RESOLUTETM series BiSS® C 26- bit absolute encoder to form a part of the closed loop motion system. This modular tape and reading head optical encoder system was placed around the outer diameter of the slew ring gear assembly to directly monitor the actual angular position of the load. The 26-bit resolution provided more than adequate angular positioning and accuracy capability with Mclennan’s servo system.

To maintain a stable closed loop system, reflected load to motor inertia matching is fundamentally essential and to suitably pair the huge inertia mismatch, avoiding a large, unwieldly and costly motor solution, Mclennan worked with its distribution partner Wittenstein to integrate two precision gear units that together provided an 80:1

reduction ratio. Wittenstein’s SP140S series at a 10:1 ratio and its NP025 series at 8:1 are inline planetary gear units that were supplied as a single assembly. This compact gear unit combination allowed the use of a comparatively small 34 NEMA frame stepper motor to adequately power the massive holding frame. With the reflected inertia taken care of and the closed loop to the load-located absolute encoder a critical factor, Mclennan specified a TXM34Q series StepSERVOTM integrated stepper motor from another of its distribution partners, Applied Motion Products.

StepSERVO technology combines the high torque capabilities of a step motor with the closed loop dynamic control of a servo system as an all-in-one housed solution. This drive solution features a digital drive, a motion controller and a selection of control and bus communications interfaces. Servo feedback is normally achieved

through an internally housed encoder, however for this project Mclennan’s own PM1000 series digital servo controller managed closed loop control with the absolute encoder, outputting step and direction pulses to the TXM34Q integrated stepper’s control interface. The PM1000 was modified with special firmware to accommodate the BiSS C absolute encoder interface. Overall control for the handling frame was manged by STFC’s supervising PC through motion commands to the PM1000 via RS232. Mclennan also interfaced a jog box to the PM1000, allowing manual control as part of the requirement specification.

The complete control system was housed in a 4U, EMC compatible 19-inch rack enclosure, complete with power supplies. The TXM34Q integrated servo included M12 connectors for all interfaces and all interconnecting cables were supplied for integration with STFC’s cable management system. The commissioning of the system was remotely guided by Mclennan engineers as the delivery requirements fell into COVID restrictions – normally all on-site commissioning and training is part of Mclennan’s terms of supply. Mclennan works closely with a selected number of distribution partners like Wittenstein and AMP, providing motion control and automation solutions from single components to complete systems - including stepper, brushed and brushless servo motors, integrated motors, and many other motor types along with drives, gear units, positioning stages, motion controllers, software, training and comprehensive after sales support.

For further information visit: www.mclennan.co.uk

Fluke tool helps medical facility improve safety and save energy with innovative maintenance program

Use of the Fluke™ ii900 Industrial Acoustic Imager for medical gas leak detection in Mediclinic hospitals has improved safety levels and cut costs while enabling the company to meet sustainability goals.

A pioneering application of the Fluke™ ii900 Industrial Acoustic Imager has enabled a world leader in patient care to improve safety levels across multiple hospital sites while also being able to meet its own demanding sustainability targets.

The Mediclinic Group, an international hospital group with operations in South Africa, Namibia, Switzerland, and the United Arab Emirates, is focused on continually improving patient outcomes. It is also committed to maximising safety levels in all its hospitals while improving sustainability to ensure a positive impact on the environment.

When a specialist thermography consultancy, KN Thermography, was called in to inspect the thermal efficiency of a South African Mediclinic hospital, it was using the Fluke ii900 Industrial Acoustic Imager. Discussions between the thermography company and Mediclinic Southern Africa’s

Sustainability Manager Petrus Swanepoel quickly identified the possibility of using the equipment to detect leaks of medical gases within the hospital.

Reducing waste

Mediclinic was aware that by fixing leaks in the distribution of oxygen and nitrous oxide across all their hospitals it could not only make significant improvements to patient safety but could also substantially reduce its carbon footprint and boost its sustainability levels by reducing the use of natural resources.

Nitrous oxide (N2O) and medical oxygen (O2) are used extensively in hospitals. High levels of energy are used to separate air and produce medical gasses. Preventing leaks in hospitals has positive implications for the environment but a significant leak of either gas in a hospital can represent a serious health hazard.

The ii900 Industrial Acoustic Imager has been used to carry out rapid visual inspections on all pipes that send nitrous oxide from hospital basements to operating theatres and

deliver oxygen to patient beds. This has enabled all leaks to be dealt with, reducing wastage percentages, and boosting Mediclinic hospitals’ levels of patient safety.

Improving sustainable operations

Committed to the efficient use of natural resources to improve patient care within Mediclinic, Petrus Swanepoel, said: “There is a pressing need for companies around the world to act more sustainably and the Fluke ii900 Industrial Acoustic Imager enabled us to do this by minimising the leakage of any medical gases and our increased use of oxygen during to the pandemic, with its associated costs, focused our attention on the benefits of identifying leaks. We are delighted that the equipment has been able to make such a big difference to patient safety and to minimising wastage.”

Francesco Pagin of Fluke added:

“The ii900 Industrial Acoustic Imager has become highly popular as a tool for detecting leaks in compressed air systems, so this innovative application at the Mediclinic hospitals for identifying medical gas leakage is a really interesting new area of use. It opens up opportunities for maintenance and sustainability teams across a range of other sectors to boost efficiencies and sustainability levels by incorporating this powerful yet easy to use tool into their inspection and testing regimes.”

With its seven-inch LCD touchscreen and battery life of at least six hours, the Fluke ii900 Industrial Acoustic Imager is designed for use in range of challenging environments where testing can be carried out from a safe distance. Using a SoundMap™ on a visual image for rapid identification of discharge or leaks between frequencies of 2-100 kHZ, the ii900 makes video recordings of up to five minutes.

Optimise your liquid batching system: 5 Flow Meter Considerations

Titan Enterprises, a leading provider of flow metering solutions, have been designing and manufacturing accurate and reliable flow meters for batch control systems for over 40 years. Titan reports on the considerations required when choosing a flow measuring device for batching control.

Titan has published a white paper on the use of ultrasonic flowmeters in high-speed batching but here we focus on the general batching system. We discuss five key considerations when choosing a flow meter that will ensure your batching process runs smoothly.

Probably the most recognised batch filling system is that of beverages, either directly into a glass or into bottles. But batching systems are also integral to the pharmaceutical and medical, and chemical and oil industries. Additive injection or chemical dosing are typical applications where flow meters are used to precisely control the amount of liquid dispensed, which is critical in such processes.

1. Repeatability is essential for a productive batching process

Multiple uncertainties can change the amount of liquid being dispensed,

causing a negative effect on the repeatability of the system. Controlling as many process variables as possible will help to ensure the accuracy and repeatability of flow measurement. Flowmeters, such as Titans’ mini turbines, can boast repeatability of 0.1% or better when operating under the same conditions.

2. The physical properties of the batch-filled liquid will dictate equipment requirements

The choice of flowmeter may be limited by the properties of the liquid – whether it is viscous, volatile, corrosive, flammable, or contaminated with particles, for example. An oval gear flowmeter would be ideal for batch-dosing high-viscosity liquids such as syrups, whereas a turbine flow device, such as Titan’s 800-series flowmeters, are more appropriate for water and beer dispensing.

3. Maintaining constant process conditions

Changes in flow rate, temperature and pressure may cause the flow meter to function in an unpredictable dynamic way. Although maintaining operating parameters at a stable point is optimal, this may not always be possible and fluctuating flow rates

for example, can be compensated for by using a higher specification measuring device, such as Titans’ Atrato® ultrasonic flowmeter.

4. Constant liquid flow or pulsations?

Keeping the overall flow constant and avoiding any pulsations within the batching system will prevent aliasing and incorrect flow readings over the batch operating cycle. If pulsation is inherent, the choice of flowmeter is crucial in mitigating the effects of pulsating flow.

5. Limiting system inertia

Simple adjustments to the batch system design, such as control value specification and the positioning of the flow meter, can help to offset the effects of inertia.

Choosing the correct flow meter for a batch system can be complex and Titan Enterprises are happy to help you find the best flow meter solution for your process and plant.

For further information on Titan’s flowmeter and instrumentation range or to discuss any process and technical issues, please contact Titan Enterprises on +44 (0)1935 812790 or sales@flowmeters.co.uk. Visit our website at www.flowmeters.co.uk

Innovative drive concepts from NORD : More efficiency in warehouse automation

E-Commerce is booming and so is warehouse automation. Flexible warehouse systems are also in demand in large grocery chain warehouses, and require environmentally friendly, sustainable and intelligent drive concepts. Drive specialist NORD DRIVESYSTEMS is highly familiar with the industry’s requirements and offers a variety of dynamic drive solutions which are suited for various applications and requirements in warehouse logistics.

NORD offers customised drive solutions for warehouse logistics for an optimum compromise between investment, operating and maintenance costs. With motor efficiency class IE4 and system efficiency class IES2, the drive units achieve excellent efficiencies – especially in the partial load and speed range. The latest generation IE5 permanent magnet synchronous motors achieve an even higher energy efficiency and significantly reduces the energy consumption.

The constant torque over a wide speed range allows for a targeted version reduction. This minimises administrative expenses, and enables leaner manufacturing, logistics, storage and service processes.

The decentralised NORDAC ON frequency inverter

The decentralised NORDAC ON frequency inverter has been developed for horizontal conveyor technology requirements in warehousing, and the NORDAC ON+ variant for interaction with the new IE5+ synchronous motor. It is characterised by an integrated Ethernet interface, its ease of maintenance through complete pluggability and an extremely compact design – providing an economical and intelligent plug-and-play solution for IIoT environments.

The compact, smart frequency inverter for decentralised use can be mounted directly on the geared motor. It covers lower power ranges of up to 2.2 kW and has an energy-saving function in the partial load range. The integrated Ethernet interface reduces the effort for integration into modern automation systems: Whether for ProfiNet, EtherNet/IP or EtherCAT, the required protocol can be easily set via parameters.

More efficiency in conveyor technology

The NORDAC FLEX SK 205E series is also ideally suited for applications in warehouse logistics.

The compact, decentralised and energy-efficient frequency inverter offers a wide power range of up to 22 kW and enables energy savings over the entire load range. The inverter can be used to control standard asynchronous motors, high-efficiency synchronous motors and brake motors. It can be installed close to the drive in the field or motor-mounted. Power and data cable connections are available as plug-in versions. The decentralised system enables short motor and encoder cables as well as short supply cables to sensors. Encoder feedback can be included, for example, for position-controlled transport systems. The large overload capacity of the NORDAC FLEX SK 205E makes dynamic movements with short start and stop times or cyclic operation possible. The integrated POSICON control enables high precision in synchronous and positioning applications.

Modular system for optimal drive solutions

Overall, NORD convinces with a wide range of products in the field of warehousing, including both established basics and high-efficiency products. Users benefit from tailored and reliable drive solutions which ensure an optimum system availability. The NORD modular drive system thus enables an optimum compromise between investment, operating and maintenance costs.

A new era of human-robot collaboration: the first pneumatic cobot

What if there was a robot that was easy to operate, did not require a safety fence and was also attractively priced? That would introduce a whole new era in humanrobot collaboration. This new era is now dawning – with the world’s first pneumatic robot from Festo.

Hardly any industrial market segment will grow as rapidly over the next few years as humanrobot collaboration. Cobots relieve employees of particularly strenuous or monotonous tasks, giving them new levels of freedom and making their work easier and healthier. And no other technology has such a sensitive and flexible approach to human-robot collaboration as pneumatics.

The benefits of pneumatics

The Festo Cobot owes many of its advantages, such as its sensitivity,

weight and value for money, to the benefits of pneumatics. The direct drives in the articulated joints are very cost-effective and particularly lightweight because, unlike electric solutions, no heavy gear units or expensive force-torque sensors are required. The world’s first pneumatic cobot is a result of the exceptional expertise in controlled pneumatics from Festo.

Cost-effective option – even for small and medium-sized companies

The Festo Cobot even makes using cobots cost-effective for small and medium-sized companies, which often rely on manual work processes. Its flexible application options mean that small batch sizes or work steps can now be processed automatically. Thanks to its uniquely intuitive

and simple commissioning and programming, it is quick and easy to get to grips with so extensive training is not required.

The pneumatic Festo Cobot will be cheaper than electric cobots in the same class. It will provide excellent value for money in its main application area of small parts handling with payloads of up to 3 kg. “When it goes on sale in 2023, the Festo Cobot will set new standards in human-robot collaboration with its ease of use,” explains Dr Frank Melzer, Member of the Management Board for Product and Technology Management at Festo.

Easy to operate and flexible to use

The Festo Cobot consists of the hardware itself, a handheld module and the Robotic Suite – software for intuitive commissioning and programming. This package makes it possible to commission and program the Cobot in less than an hour. Prior knowledge of robotics is not required either, because the self-explanatory “Robotic Suite” software contains clearly visualised and standardised function blocks. Pneumatic drives enable the robot arm to be guided by hand easily and without any resistance so that waypoints or paths can be taught quickly and precisely.

For small and medium-sized companies in particular, cobots are only attractive if they can adapt quickly to take on a new task and are not just permanently used for the same purpose. The Festo Cobot meets this requirement as it doesn’t require an additional control cabinet (which can be difficult to connect and cumbersome). The compact controller that is integrated in

the Cobot’s own base makes it particularly flexible. Simple connections also allow it to be used ad hoc without long changeover times. Common bus standards enable fast connection to higher-order controllers. It also requires less space.

Thanks to state-of-the-art, lightweight construction methods, the Festo Cobot weighs in at well under 20 kg so that it can be deployed quickly and flexibly at other locations.

Working safer and faster

With a length of 670 mm, the Festo Cobot is just like a human arm and has the right reach for it to be perceived as a helping third hand when working with a member of staff. It moves – like a real colleague – within a

manageable radius. Thanks to the flexibility of the pneumatic drives, the cobot acts sensitively – at a speed appropriate to the situation and with fluid, harmonious movements. It is as soft to the touch as human contact.

The cobot’s pneumatic direct drives and its light weight reduce its contact energy. Says Christian Tarragona, Head of Robotics at Festo: “Thanks to precise pressure regulators in the articulated joints, the robot recognises when it is being touched and responds with appropriate safety functions.” Employees can work together with their careful technical colleague in complete safety.

For more information about Festo products and services, visit: www.festo.com/gb

Playing the long game: why manufacturers must prioritise TCO when specifying automation

After lagging behind their international counterparts for many years, UK manufacturers are finally waking up to the benefits of automation, prompted in part by labour shortages as a result of Brexit and the pandemic. With the vacancy rate reaching a record high of 4.1 at the start of 2022, increasing numbers of firms are now looking to automate their more repetitive or mundane tasks, freeing up employees for more value-added roles.

In the face of this shift towards automation, Shinichi Tanzawa, European President & CEO of leading robotics and automation specialist FANUC, warns UK manufacturers to avoid falling into the trap of prioritising purchase price over total cost of ownership,and outlines his company’s commitment to customer service…

Prioritising TCO

When it comes to automation, quality is as important as functionality and pricing. As the world market leader with over 810,000 robots produced to date, we strive for long-term, trusting relationships with our customers, because it usually takes eight to 10 years to realise the extensive benefits of our high-quality and durable products. This is largely thanks to our low total cost of ownership (TCO). Even after five, 10 or 20 years of operation, the reliability of our robots means our customers pay almost nothing for maintenance.

This is not the norm. In fact, our robots last twice as long as most of our competitors’, where maintenance costs usually exceed

the purchase price of the robot itself. This is why manufacturers must look at more than just the initial purchase price when investing in automation. We recommend considering three crucial elements: functionality, price and quality. When developing our solutions, we focus on the areas of cost reduction, higher reliability and fewer parts. We try to simplify our products to reduce costs and increase reliability, as fewer parts mean fewer failures.

Maximising uptime

One of our key preventive maintenance solutions for our robots is ZDT, short for Zero Down Time. The servo motors that are integrated into our robots produce a lot of data which is collected and analysed by ZDT software solution. We use this information to alert our customers before a robot breaks down, so that it can be serviced in time; ideally with two weeks’ notice so that its use can be optimised but any downtime minimised. We also follow a strict ‘service first’ policy that includes maintaining a large network of field service technicians and high availability of spare parts. Across Europe, the average time between a customer’s call and the successful repair of their robot is less than 20 hours.

In addition, we keep in stock spare parts that cover 99.97% of all the products we have ever manufactured. A total of 360,000 spare parts are held at our European warehouse alone and including stock at other European locations, we have access to more than 700,000 replacement components, despite the fact that many of these parts are only required after several years or even

decades of operation. Over the past five years, we’ve improved the availability of spares from the original 99% to 99.97% and my personal goal is to reach 100%. We currently only miss one out of every 4,000 spare part requests.

Futureproofing operations

Collaborative robots (cobots) are generating a lot of excitement within the industry, but as yet, they are not widely seen in UK factories. Most cobots currently available on the market are suitable for use in laboratories but not industrial environments because it is difficult to balance the required level of sensitivity and durability. However, our new lightweight CRX cobots successfully combine both these characteristics, as well as ease of use. As a result, we’re starting to see real demand from manufacturers.

In the past five years, our robot sales in Europe have increased by more than 10% every year and if this trend continues, we will double our robot sales within the next 10 years. However, as a matter of principle, we only advise automation if the investment pays off for our customers. This is also how we conduct business in our own factories. Almost 5,000 of our own robots are now in use day and night at our manufacturing plants – no other robot manufacturer uses robots on this scale within their own production facilities. This strategy has provided us with greater flexibility in our manufacturing operations and helped us to overcome the skills shortage that is affecting so many businesses today. And as we know our own products first-hand, we can support our European customers with suitable solutions for their automation needs.

Raptor Combi delivers on productivity promise

In 2019, total factor productivity in food and drink manufacturing increased by 1.8 per cent with UK factories striving for greater processing efficiency. Fortress Technology critically establishes itself as a crucial contaminant detection specialist and high-profile UK food manufacturers are expressing strong interest in its performance-driven Raptor metal detector and checkweighing combination machine.

Flexible, fast and affordable,

The Raptor Combi is Fortress Technology’s first fully integrated checkweigher and metal detector. Winner of Food Processing’s Lean Manufacturing award in 2021, judges commended the Raptor Combi for its “innovation and useful range of food production solutions”, highlighting the natural synergy between checkweighing and metal detection.

Unbeatable price-performance ratio

meats and fish, cheeses and ready meal products), Fortress has engineered a technologicallyadvanced machine able to match the high-end results seen in expensive combination equipment, at a better price to performance ratio.

Notably, the Raptor Combi has the ability to accurately inspect and check the weight of large size package formats weighing up to 8kg and measuring 300mm by 400mm. Inspecting up to 150 packs per minute, the Raptor checkweigher also calculates Average Finished Weight Variance to maximise productivity.

Solving several issues that the combination inspection market previously failed to address, the Raptor Combi answers demands from UK-based food factories for more innovative fixings and connection features, such as interlocking infeed and outfeed panels, allowing processers to customise the machine to their production layout. The Raptor Combi also introduces a unique tight-fitting conveyor and

‘no-tool’ maintenance concept. Overcoming the longstanding industry challenge of loosening belt tension during machine sanitation, operators can unclip and disconnect the conveyor motor and lift out the entire conveyor assembly for maintenance and cleaning in seconds.

Diligent digitisation

As well as offering cost savings for end-users, the Fortress machine proves the power of systematic digital data capture. For UK food processors supplying multiple retailers, the Raptor Combi introduces a failsafe and fullyauditable Code of Practice (COP) test routine to further fine-tune productivity processes. Instant HACCP and COP compliance was a key rationale for an Ireland-based bioceutical start-up Soothing Solutions installing the Raptor Combi for their new Tonstix innovation. Company founder Sinéad Crowther comments: “The Raptor Combi is very user friendly. It is the smartest piece of technology on our new production line. The screen collates all the production data we need. It ensures full weighing accuracy, extremely sensitive metal contaminant detection levels, full traceability and exceeds all of our COP compliance requirements.”

Featuring a swipe touchscreen HMI and paperless audit software with unlimited pre-programmed COPs, the robust Raptor Combi captures the data required to guarantee food-brand integrity and absolute traceability. The machine automatically alerts the Quality Assurance manager each time a test is overdue and an in-built USB means Fortress Technology simply issues an upgrade as new COPs are introduced.

The award-winning Raptor Combi combines affordability with a digitised and futuristic approach to inspection, making the entire system is secure, hygienic and fully engineered for optimum efficiency.

New 8-bit MCU development board connects to 5G LTE-M Narrowband-IoT Networks

The AVR-IoT Cellular Mini Development Board is the latest to join Microchip’s AVR® family, providing developers an easy blueprint for building IoT devices

IoT network developers are looking for an easy path to implement a secure cellular connection in their design applications but are faced with design complexities and high deployment costs. To offer a solution for network designers who need the ultimate in location flexibility, low-power consumption and deployment simplicity, Microchip Technology Inc. (Nasdaq: MCHP) today announces the AVR-IoT Cellular Mini Development Board based on the AVR128DB48 8-bit microcontroller (MCU). This solution provides a robust platform to start building sensor and actuator nodes on 5G narrowband IoT networks.

The AVR-IoT Cellular Mini Development Board is a small form factor board making it an ideal solution for developers who want to connect IoT devices to an available 5G network. This is an essential feature for devices on the go or located in remote areas with limited availability of Long Range (LoRa®) networks or other Low Power Wide Area Network (LPWAN) solutions.

Customers can tap into the flexibility and ease of design offered in the latest AVR128DB48 8-bit MCU family, including security protection with Microchip’s

ATECC608 CryptoAuthentication™

device. The ATECC608 device can easily be configured to most major cloud service providers through Microchip’s IoT Provisioning Tool.

“Microchip continues to expand its family of AVR® 8-bit MCUs for developers to implement a variety of embedded designs with ease and flexibility,” said Greg Robinson, vice president of marketing for Microchip’s 8-bit MCU business unit. “The ability to connect remote and mobile devices to a 5G narrowband network with an 8-bit MCU opens up new opportunities for batteryoperated devices because of key factors such as low power combined with high-quality analog peripherals.”

The AVR-IoT Cellular Mini Development Board comes preconfigured to send data from on-board light and temperature sensors to the cloud, viewable using Microchip’s sandbox portal. The sandbox portal provides customers with the ability to track and monitor their device in real time from a remote location.

This functionality covers the core requirements of many applications in various industries including agriculture, industrial and energy, as well as consumer spaces such as transportation of goods, alarm systems, building automation and remote monitoring.

To provide an even easier, more efficient and more costeffective solution for developers to connect IoT devices to 5G using the AVR128DB48 MCU, Microchip partnered with Sequans to include its Monarch 2 GM02S single-chip radio equipped with 5G LTE-M and narrowband IoT. Microchip also partnered with Truphone to provide the SIM card for cellular service that offers reliable coverage worldwide.

“The Monarch 2 GM02S is a 5G-ready LTE-M and narrowband-IoT solution on a single-chip, which we designed specifically for narrowband IoT applications, including sensors, wearables and other low-data, low-power devices,” said Didier Dutronc, executive vice president of partnership strategy at Sequans. “By partnering with Microchip on its AVRIoT cellular board, we are simplifying and lowering the costs of IoT device design.”

“We are committed to reinventing the way in which people, things and businesses connect through our ground-breaking embedded SIM (eSIM) technology,” said Steve Alder, chief business development officer of Truphone. “Owning and operating all elements of the eSIM ecosystem in-house coupled with access to a large number of low-power cellular networks through a single SIM SKU, provides Microchip customers looking to connect IoT devices a future proof cellular service.”

The AVR-IoT Cellular Mini Development Board is a great solution for makers and hobbyists as it fits the Adafruit Feather form factor. It features a Qwiic/Stemma I2C connector for easy functionality extension, creating a clear path to production. It is also Arduino®compatible and is supported by Microchip’s Github Library which provides functionality for HTTPS, MQ Telemetry Transport (MQTT), low power and more.

Block-based Editor: Create vision apps without programming knowledge

The current software release 2.6 for the AI vision system IDS NXT focuses primarily on simplifying app creation.

The initial phase in development is often one of the greatest challenges in the realisation of a project. With the help of the new Application Assistant in IDS NXT lighthouse, users configure a complete vision app under guidance in just a few steps, which they can then run directly on an IDS NXT camera. With the Block-based Editor, which is also new, users can configure their own program sequences with AI image processing functions, such as object recognition or classification, without any programming knowledge. Users create simple sequences in a few minutes with this visual code editor without having to know the syntax of a specific programming language.

With the Use Case Assistant, IDS supports users in creating Vision

App projects. They simply select the use case that fits their project. With queries and tips, the assistant guides them through the process of creating the Vision App project and creates the code, just like in an interview. It links existing training projects with the vision app project or creates new training projects and data sets in IDS NXT lighthouse if required.

With the combinable blocks and the intuitive user interface of the Block-based Editor, anyone can realise their own projects using AIbased image processing (such as object detection or classification) as an individual vision app without having to know the syntax of a specific programming language. Using the predefined blocks of the code editor, users build their vision app graphically, including processes such as loops and conditional statements. How this works is demonstrated, for example, in the IDS Vision Channel

(www.ids- vision-channel.tech). The session “Build AI vision apps without coding – xciting new easyness” is available for viewing as a recording.

IDS NXT is a comprehensive system with a wide range of workflows and tools for realising your own AI vision applications. The intelligent IDS NXT cameras can process tasks “OnDevice” and deliver image processing results themselves. The tasks of the cameras are determined by apps that are uploaded to the cameras and executed there. Their functionality can thus be changed at any time. This is supported by software such as IDS NXT lighthouse, with which users can not only train neural networks, but now also create their own vision apps. The system offers both beginners and professionals enormous scope for designing AI vision apps.

Learn more: www.ids-nxt.com

Automating battery production for eMobility applications

Sensors for the Relevant Process Steps

Powerful batteries for electromobility applications are manufactured in highly automated processes. Numerous sensors using various measurement procedures ensure efficient control of machines and plants. Pepperl+Fuchs has decades of experience in the automotive industry and electrical engineering, so it can offer all relevant measuring instruments for battery production from a single source.

Rotary Encoder ENI190

Coated foils are the most important source material for lithium ion batteries. They are delivered in large rolls from which they are processed during production. The unwinding speed of the rollers is measured using high-precision rotary encoders. The winding distance and material stock can be calculated using the speed. The speed value is also used to control the material supply and allows the correct web tension to be set. The

new, extra-rugged ENI90 rotary encoder series is ideally suited for this task.

Ultrasonic Double Sheet Sensor M18

In the next step, pieces of foil roll that are suitable for the battery to be produced are punched out and assembled into battery cells. The punched material feed is monitored using ultrasonic double sheet sensors, such as those from the UDC-18GS series. These sensors are equipped with two ultrasonic transducers and detect if one, two, or even zero sheets are in the sensing range. If the sheets have been incorrectly double- stacked, the process is stopped in time.

This prevents the battery capacity from being reduced by having two layers with the same polarity next to each other. Using an ultrasonic solution double sheet detection means the process is not affected by ambient conditions or the optical properties of the material; although the films are often glossy, they are still reliably detected.

SmartRunner Explorer 3-D

Bonding the foil layers together creates cells, which are then joined together to form the finished batteries. In this step, it is important that all the required cells are actually available and in the right position in the specified grid. To verify this, a SmartRunner Explorer 3-D sensor creates a precise 3-D point cloud image so that the actual situation can be matched with the required positioning. The process step to connecting the cells is only initiated when everything is in the correct position.

Pepperl+Fuchs sensors have been part of the standard equipment in the automotive industry for decades. This is also true for factory automation in the field of electrical engineering: In both areas, customers benefit from the comprehensive expertise of the Mannheim-based company. A broad portfolio of proven standard devices is available for high-performance electric-vehicle-battery production. Pepperl+Fuchs also offers custom automation solutions for specific applications.