Worldwide Engineering Magazine - August Issue

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Featuring within this issue

August Issue 2020

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Contents

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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26 NSK shares tips Tips for replacing wheel hub bearings

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What can we learn from COVID-19

Altair partners with Ducati

How can this help us look to the future?

Altair named corse technical partner for team in MotoGP

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Intelligent image processing

Prevent the spread of COVID-19

supports production workers in industrial 4.0 applications

How can holding open doors affect the spread?

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Electro overband magnet

Thermal imaging to screen

Bunting protects gold mine

For elevated skin temperature

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What can we learn from COVID-19 to help us look to the future?

COVID-19 has seen all businesses and individuals make rapid adaptation to day to day life.

Interaction as we knew it on a personal level has changed in an unprecedented way and business have had the shutters pulled down without a minute’s notice leaving loyal staff and owners vulnerable. Business owners have had the power taken out of their hands and the nation now rests in the hands of the Government to guide the country out of this pandemic.

We have all learnt a lot about ourselves as we have navigated COVID as individuals, employees, business owners, families and as a nation and one thing is evident, no one is unaffected.

As a plastic injection moulder and toolmaker, facilitating the production of medical products into the health care system and frontline services we have continued to operate throughout the pandemic.

Embracing a new way of working to incorporate social distancing measures and facilitating the shielding of our more vulnerable team members, we have been able to fulfil increased demand for medical moulding production, including ventilation components.

As we begin to see a glimmer of light at the end of the tunnel, what can we learn from COVID-19 which will benefit our business in the future?

1) There is nothing that cannot be changed…

All too often in businesses including our own there can be a resistance to change, for one reason or another many of us do not like change. Maybe due to a fear of the unknown with suggestions for change often be met with ‘No, we can’t change that because…’ when in fact being adaptable and open to change is the very thing that is going to see you through and help you to realise your strength and potential for growth as an organisation. Everything you think you can’t change; it turns out that you can, procedures and processes rapidly adapted to facilitate a safe working environment, shift changes, working remotely and even temporary role changes we have done it all. Having the ability to change and adapt at the drop of a hat has been one of the essential elements that has been installed in our COVID-19 toolbelt.

How will this help in the future?

We will all be a little less fearful of change, knowing its all for the greater good and will enable the company to continue to perform at to its potential. Change is not permanent…… that is why it is called change.

2) Teamwork is essential…

Pentagon could not have

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continued to operate through this pandemic if it were not for the dedication, trust, and flexibility of our entire workforce.

Our staff have embraced social distancing following government guidelines without question to safeguard in the workplace and facilitated change in shift patterns to help colleagues accommodate individual childcare and family needs. Meeting a high increase in production demand for the medical sector our team has given us everything they have got, and we could not be prouder of each one of them.

What can we take from this for the future? We are humbled by the efforts of our staff and the commitment they have shown is second to none, this is a culture we want to take forward as we grow in staff numbers. Staff who look out for one another, provide emotional and practical support, and understand the business needs are invaluable.

3) UK Supply Chain…

With an instant rise in demand for the manufacture of ventilation equipment and PPE to help the fight against COVID-19 the UK found that there are some rather large holes in the UK supply chain system. Much of the manufacturing process is undertaken offshore, not because we cannot make it here in the UK but because it can be done at a lower cost or a faster turnaround in other countries.

The lack of PPE and massive demand for ventilation saw UK manufacturing come out of the shadows, work collaboratively, and throw everything it has got to offer into supporting the country at the worst time. Many manufacturers adapted their usual production lines including clothing, vacuum, automotive, to name but a few changing their focus to help meet the needs of this national emergency. These combined efforts have humbled us and made us prouder than ever to be a part of this great British industry.

What will this mean for the future? The key word for manufacturing should be ‘supply’ over cost or time. Bringing manufacturing back to our own shores will give greater control to production supply, consistency in quality requirements and will ensure we always have access to products.

This can avoid the need to travel through boarders or be declined for not meeting quality standards whilst also lowering the carbon footprint, a win-win. By keeping manufacturing onshore, we can limit interruptions to the supply chain providing an incredible impact on helping the UK out of any future issues such as unprecedented levels of unemployment! Increased demand in UK manufacturing will in turn deliver greater employment opportunities across the country.

4) Everyone has a different approach to risk…

As individuals and businesses, we all have a different approach to risk, some incredibly fearful of the unknown and others bulldozing ahead not worried about the consequences. Neither of these approaches are wrong, they are just different. In the work place we have seen some of our team needing to shield in accordance with Government advice, some requiring isolated working areas and others, battle on sword in hand ready to take on the virus head on. With these varying approaches to risk the Pentagon team have shown nothing but respect for one another and differing approaches to the risk of COVID-19, not judging nor being dismissive.

What does this mean for the future? We hope people in general will be a little less judgemental be it to risk, choice, lifestyle, or business decisions.

5) Plastic is good not something to fear…

There is no denying that Plastics has taken a media whipping over the last few years and has been an unrelenting enemy of the world. As a plastic injection moulder, we are only too aware of the negative reputation of single use plastic. Much of it emanating around drink bottles, bags, coffee lids, straws, and other plastic packaging with little thought to the wider use of plastics. The hospital equipment, the PPE, aircraft, freight the very things that we have all relied on to support us throughout this crisis to supply us with food, medicine, and essential equipment. None of the products that we produce here are for the single use market, all products produced are customer owned and of a technical nature serving industries including aviation, medical, construction and security.

What does this mean for the future? It certainly does not mean that its ok to litter and allow our environment and marine life to deteriorate and suffer. What it does mean though is that in the future we should always look at the bigger picture and have an informed, measured and educated opinion considering all factors before calling out the bad guy. After all, as COVID has shown us all, one day it may be something you come to rely on!

6) No business is untouchable in a crisis…

Even though we have continued to work through the UK’s biggest crisis of modern times it has become wholly evident that no matter what industry you are in, no organisation is untouchable. Although we have seen a sharp rise in our medical production lines, the aviation sector has fallen to an all time low.

Aviation makes up approximately 30% of our production and the slowdown is having an impact on the business.

We are fortunate enough not to have closed our doors like many others have in this crisis, therefore the true impact will be drawn out over a longer period. With the re-establishment of travel and hospitality still a relative unknown we have contingency plans in place to manage this drop in demand.

What does this mean looking forward?We are not too proud to say that this does not cause us a level of concern as we look to the future. However, we are adaptable, resilient, and strong in our business sector.

We will continue to support our diverse customer base now and beyond COVID-19. COVID-19 will be the biggest challenge many of us have and will experience in our lifetime on both a personal level and as businesses, lets hold on to this experience and learn from it as we emerge, reset, and look to the future.

For more information on Pentagon Plastics Group head over to www.pentagonplastics.co.uk

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The all-seeing detector

SensoPart’s new laser proximity sensor FT 55-RLHM with background suppression (BGS) detects surfaces of any kind and identifies the smallest objects with remarkable reliability.

“Detect all” is one of the operating modes of SensoPart’s new BGS sensor and is a function to be understood quite literally. Indeed, the FT 55-RLHM can cope with any type of target object, whether it is brilliant metal, transparent or black against a black background. The sensor responds to all deviations from a given reference – such as a change in object distance, a different surface finish or even a deflected laser light beam.

In this mode the sensor has no blind zone, i.e. objects are detected from 0 mm.

Even exceedingly small parts are reliably identified within the defined detection range, including objects at acute angles. The FT 55-RLHM not only uses the distance value but can also integrate the energy remitted from the target object in the detection process.

Thanks to its high level of detection efficiency, FT 55RLHM can also be used to check the stack height of parts and identify multiple layers, for example when stacking cardboard packaging. Here the sensor automatically detects the presence of too many or too few layers.

Maximum operating range, minimum hysteresis A further highlight besides excellent object detection is the FT 55-RLHM sensor’s very wide operating range of up to one metre. The switching hysteresis is simultaneously minimal, so that even the tiniest objects are reliably detected from a long distance – for example, a sheet of paper at 250 mm. The determined object distance is shown on an integrated display screen, which considerably facilitates the set up of the application.

In addition to user-friendly operation via soft keys, the sensor also offers two independent switching outputs, as well as a digital IO-Link interface – exceptional in this

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price category. It also comes with additional useful functions for the configuration of switching outputs, such as switch-on/switch-off delays.

This comprehensive range of functions, combined with a high-quality metal housing and non-hazardous laser class 1, makes SensoPart’s new laser proximity sensor with background suppression ideal for diverse industrial automation applications, whether in machine construction or in the automotive, plastic, pharmaceutical or packaging industry.

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Worldwide Engineering Magazine | 7

Intelligent image processing supports production workers in industrial 4.0 applications

Automation plays a major role in Industry 4.0. Cost reduction, increased productivity and zero-defect quality are factors that are increasingly prompting companies to digitise their processes.

But often full automation also means high investments. At the same time, the focus will continue to be on the human being in the interaction between man and machine. Given the prevailing shortage of skilled workers and high standards of industrial safety, this is no easy task for companies. Additional challenges for a successful process optimisation are a large number of variants, complex tasks and processes, as well as increasing quality requirements.

How can this succeed?

With the assistance system “Clever Klaus”, the German company Optimum datamanagement solutions GmbH has developed a smart solution: The easy-to-integrate, camera-based assistant uses digitisation to optimise and simplify manual inspection

processes. By combining industrial image recognition using a high- resolution USB3 industrial camera from IDS and an intelligent database, the assistance system recognizes every step and assists the employee in real time during the entire assembly process.

According to the simple principle: Instructing - checking - confirming - documenting even these complex processes become manageable.

The intelligent assembly assistance system “Clever Klaus” guides employees step by step with digital assembly instructions. The worker scans the order document and the assembly process begins. An IDS camera installed above the worktable records the workpiece or individual parts to be mounted. Both operating instructions and error messages appear on a touch monitor in real time: After each successful work step the worker receives a confirmation. Once assembly is complete, the system provides evidence of fault-free production.

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“The camera generates the digital shadow”, explains Wolfgang Mahanty, managing director of OPTIMUM datamanagement solutions GmbH. All digital data of the process - when and how what is done - is recorded and processed. This enables the creation of a knowledge base and the subsequent transfer of knowledge to all. “The camera has to capture many details and a wide range of variations and provide stable images. Sensory recognition must be reliable, i.e. the sensor must be able to cope with poor or changing lighting conditions,” says Mahanty, summarising the demands on the camera. The reason: “In today’s factory, the employee should get as much daylight as possible, which can affect the quality of the recording.”

No problem for the USB3 industrial camera UI-3590CP from IDS. The light-sensitive AR1820HSSC00SHEA0 rolling shutter CMOS sensor from ON Semiconductor uses BSI (“backside-illumination”) technology to ensure outstanding image

quality even in low light conditions. Even when capturing the smallest details, extremely high-resolution images with low image noise are produced. With a resolution of 18 MP (4912 x 3684) it reaches a frame rate of 21 fps. ”Products are detected with deviations of 1mm on DINA 3”, confirms Wolfgang Mahanty. Moreover, the small, compact size as well as the easy integration of the camera convinced the team of “Clever Klaus”.

The German, Ludwigsburgbased company Mann + Hummel, world market leader and expert in the field of filtration, also appreciates the advantages of the assistance system optimised with the IDS camera model. Peter Sawatzky, Technical Manager at Mann + Hummel, also relies on the use of the “Clever Klaus”. “During the final assembly of our filter components, many manual activities are required. This demands changing devices with very complex and therefore failure-prone sensory queries.

The assistance system has convinced us because we make far fewer mistakes.” New variants can be easily learned during work preparation and can be installed by the worker on the same day. “Our variant management has thus become much easier,” underlines Sawatzky.

Additional benefit: The system can be integrated very easily into the respective production facility and even the use of several camera models is possible very simply and costeffectively if the customer

application requires it.

Employees learn new procedures quickly and safely with Klaus’ help through the digital step-by-step instructions. The relief of the worker through the individual assembly assistance system as well as easier work organisation allow a significant increase in productivity. Assembly costs are reduced, at the same time complaint costs are minimised by the increased quality assurance. “Since ‘Clever Klaus’ has been supporting our workers during assembly, the number of complaints has fallen significantly,” confirms Sawatzky.

Outlook Particularly in the electronics and automotive sectors, assistance systems such as the one from OPTIMUM datamanagement solutions GmbH are increasingly accelerating processes and ensuring increased efficiency and quality. Manufacturing processes run almost flawlessly, are fully documented and can be traced. In this way, they help companies to increase

productivity and, if necessary, to gain a competitive advantage.

Simple, intuitive operation is an important basis for the successful introduction of Industry 4.0 and the associated.

Optimum is therefore constantly working on how the system can be easily taught.

This is done using CAD data, intelligent filters or even artificial intelligence. A further step on the way to digitisation is also the possibility of virtual commissioning. The assistance system must be designed so intuitively that every employee from the maintenance or work preparation department can operate it himself.

No doubt: Digitisation is advancing all the time, and the need for solutions to increase efficiency and quality in the factory of the future is growing.

With individual, easily integrated assistance systems and intelligent image processing, it can be covered quickly and easily. An investment that pays for itself in a short time.

Client Optimum is specialised in intelligent image processing that combines digitisation, database management and camera technology. The IT expert team from Karlsruhe has been automating and optimising the processes of leading industrial companies for over 26 years. Today, Optimum is a leading supplier in the field of camera-based assistance systems with its camera-based assistance system “Clever Klaus”, which has won several awards.

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Bunting electro overband magnet protects gold mine

The largest Electro Overband Magnet ever built at the Bunting manufacturing plant in Redditch, UK is destined for installation in a gold mine in Northern Finland. Over a twelve-month operating period, the Overband Magnet will lift and separate damaging tramp metal from approximately 2.7 million tonnes of conveyed ore, protecting crushers, screens and other up-stream process plant.

Bunting is one of the world’s leading designers and manufacturers of magnetic separators for the recycling and waste industries. The Bunting European manufacturing facilities are in Redditch, just outside Birmingham, and Berkhamsted, both in the United Kingdom.

The Electro Overband Magnet uses high-strength magnetic forces to lift and then automatically discard tramp ferrous metal present in

conveyed ore. In operation, the large Electro Overband Magnet is suspended in a crossbelt orientation across the non-magnetic head pulley of a conveyor transporting mined ore. Any tramp ferrous metal entering the deep and strong magnetic field is attracted to the face of the electro magnet and lifted up and onto the surface of a continuously-moving selfcleaning rubber belt. Reinforced and heavy-duty rubber wipers on the belt catch the captured metal, transferring it to the side and away from the conveyed ore. As the wipers move the ferrous metal out of the Overband Magnet’s magnetic field, it drops under gravity into a collection area.

This latest Electro Overband Magnet is part of a major plant expansion and upgrade at the Kittila Gold Mine in Northern Finland. When initially contacted, Bunting engineers worked closely with the mine

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operator to design a bespoke Overband Magnet for the difficult application. Design considerations included the width of the conveyor, the volume of conveyed ore, and the size and shape of the tramp ferrous metal. With these details, the Bunting design team calculated the minimum magnetic field and force density for optimum separation using an in-house developed Electro Overband Magnet Selection Programme. These criteria provided the basis for the design of the electromagnetic coil by the Bunting-Redditch engineering team.

The final design is a model 205 OCW50 Crossbelt Electro Overband Magnet. The 17 kW electromagnetic coil, generating the strong magnetic field, is cooled using recirculated oil. Efficient cooling of the electromagnet is critical as the magnetic force decreases proportionally to the rising

temperature of the coil. The Overband Magnet is 4.2m long, 3m wide and 2.2m high, weighing just over 13 tonnes, and was built at Bunting’s UK magnetic separator manufacturing facility in Redditch.

The Electro Overband Magnet is designed for positioning in a crossbelt orientation over the non-magnetic head pulley of a 1600mm wide conveyor, inclined at 12° and travelling at 0.75m/sec. The conveyed ore has a particle size range of between 70 and 400mm, varying in conveyed capacity between 450 and 765 tonnes per hour (equating to 2.7 million tonnes per year).

The tramp iron ranges widely in size and nature and includes steel rebar (2400 x 20mm dia.), cable bolts (600 x 15mm dia.), steel mesh, and broken drill bits. With a maximum working gap of 600mm (distance between the magnet face and the bottom of the ore conveyor), the Electro Overband Magnet is designed to lift and separate the tramp metal through a splayed burden of up to 500mm.

This requires a substantially deep and strong magnetic field and related force density.

“Large mining projects, such as this, often require bespoke solutions,” explained Adrian Coleman, the General Manager of Bunting’s Redditch facility.

“Over 40 years we have gained considerable experience in designing and building large Electro Overband Magnets.

However, this was the largest we have ever manufactured at Redditch, presenting many challenges, which were overcome.

And the design and manufacturing process all took place during the Covid-19 crisis.”

Bunting-Redditch has a history of designing and building large Electro Overband Magnets for the mining industry. This latest project relied on the vast experience of both the engineering and production team to produce the largest ever manufactured at the Redditch facility. Bunting Redditch website – www.mastermagnets.com

Ferrous, Non-Ferrous & Electrostatic Separation

Submit your material samples for testing in our state of the art test facility

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FERODO® expands braking portfolio with first-to-market brake fluid formulated for electric and hybrid vehicles

FERODO®, a preferred partner to vehicle manufacturers in the development of premium friction products for more than 100 years, has introduced the first brake fluid formulated specifically to address the unique demands of hybrid and electric vehicles (EHV). FERODO FBE050 DOT 5.1EHV brake fluid offers a variety of enhanced characteristics designed to help optimise overall brake system performance on these vehicles.

Brake system requirements for electric and hybrid vehicles are different than those for vehicles equipped with conventional powertrains. Because EHV models feature large, heavy batteries, extra stopping power is needed in certain operating situations. Additionally, intermittent engagement of the vehicles’ regenerative braking systems can prevent proper heating of brake pads and discs.

To absorb this added stress, EHV models need an enhanced brake fluid with high dry and wet boiling points. Also, because regenerative braking systems can help extend the service life of brake pads and related components, the brake

fluid is likely to be replaced less frequently, possibly leading to corrosion issues. Another concern are the potential electrical currents near the braking system, which may occur if the brake fluid has moderate to high levels of electrical conductivity.

“FERODO FBE050 brake fluid is the first fluid formulated specifically to address each of these concerns and contribute to improved brake system performance and reliability on hybrid and electric vehicles,” said Ronald De Wilde, Brand Manager FERODO, DRiVTM Motorparts.

“Vehicle service providers and their customers rely on FERODO to gain the power of performance in every area of braking system technology, including the highly specialised demands of vehicles equipped with electric powertrains.”

FERODO FBE050 DOT 5.1EHV brake fluid offers several features and benefits ideally suited to EHV applications: - High dry boiling point (274° C)

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- High wet boiling point (184° C) - Enhanced corrosion resistance - Reduced conductivity - Low viscosity (meets ISO 4926 Class 6) - Meets and exceeds DOT 3, 4, 5.1 and 4LV specifications In addition to the new, FBE050 brake fluid, FERODO offers quality replacement brake pads for 98% of electric and hybrid passenger vehicles on European roads. The brand’s ECOFriction® brake pad is highly efficient for electric cars, hybrids and vehicles equipped with electronic parking brakes.

To learn more about FBE050 DOT 5.1EHV brake fluid and other FERODO products, visit www.ferodo.com.

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Schaeffler gives cobots greater range with plug-and-play linear actuators For applications that require extremely high carrying and moment-load capacities, customers have the option of running the guide carriage on a KUSE-XL six-row linear recirculating ball bearing and guideway assembly in premium X-life quality.

Increasing cobot range The linear axes are available in a range of lengths, depending on the drive being used. They can even be implemented as multipart axes for added range in applications that involve longer travel paths. This flexibility means the compact linear axes be can easily integrated into new and existing automation solutions. As a further option, Schaeffler also offers an assembly and installation service.

Industrial robots have long been established as the technology of choice when it comes to efficient automation solutions for a wide range of handling and processing tasks. Now, thanks to a new innovation, owners and users can significantly extend the working range of their robots and cobots (collaborative robots) by installing Schaeffler driven linear units as horizontal axes.

Plug-and-play linear axes made-to-order Schaeffler offers its customers linear actuators as customised turnkey solutions. The compact, ready-to-install linear axis solution developed by Schaeffler consists of a MDKUVE tandem actuator, a corresponding adapter plate for the cobot, an appropriate motor/gearbox unit, prefabricated motor cables, a drag chain for all of the cobot’s supply lines/cables, and a motor controller. The solution comes complete with Profibus, Profinet, and EtherCAT interfaces for connection to the customer’s control system. The

linear axis solutions have various options for connecting to the motor/gearbox units. Customers also have the option of using their drive technology instead of the Schaeffler drive solution if they so wish.

Depending on customer requirements, the linear axis can be supplied in various lengths and can be driven by a MDKUVE-KGT ball screw drive, a MDKUVE-3ZR toothed belt drive, or a linear motor.

In the tandem actuator, which forms the basis of the linear axis, the guide carriage runs along two parallel KUVE-type monorail guidance systems (four-row linear recirculating ball bearing and guideway assemblies). Due to its compact design envelope, the tandem actuator is ideally suited for use in applications involving high carrying and moment loads – such as collaborative robots. Tandem actuators offer maximum reliability in these applications when used in conjunction with triple toothed belt drives.

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Tandem actuators driven by ball screw drives are available in a range of lengths up to a maximum of 5.9 metres and offer repeat accuracy of 0.025 mm and a maximum linear speed of 1.7 m/s. Tandem actuators driven by toothed belt drives, on the other hand, can be implemented as multi-part axes with lengths of up to 18 metres for applications where especially long travel paths are required.

These longer implementations support very high linear speeds of up to 5 m/s and offer a repeat accuracy of +/- 0.1 mm.

Due to their compact, highperformance design, these plug-and-play linear axes also have applications in areas other than collaborative robots, most notably in the periphery of handling and assembly equipment and in factory automation.

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Nanofabrica to demonstrate effectiveness of direct rapid soft tooling injection molding is tantalising for many industry players.

The added benefit of using Nanofabrica technology is that it can achieve high surface finish as well as tiny features and complexity which are effectively impossible using conventional machining of mould tools.

To achieve the successes that they have, the team at Nanofabrica has focussed on optimising the design of the DRST and also improving the materials that the tools are made of to make the more robust.

Manufacturers are invited to engage with leading microadditive manufacturing technology innovator Nanofabrica and assess the effectiveness of direct rapid soft tooling (DRST) made on the company’s Tera 250 AM machine.

Nanofabrica has devoted significant time and resource over the last few years perfecting the manufacture of DRST, and are confidently claiming that they are now securing a position for AM to be a true volume manufacturing technology.

Tovit Neizer, VP of Business Development says, “We know that there has been a lot of publicity about the advances we have made in manufacturing DRST, and now is the time to demonstrate our successes and to help move companies on to fully embrace and exploit the opportunities presented by using AM produced mould tools. And so, as of today we are inviting all companies with a product or component they have in development or production to approach us and we will manufacture it using DRST that we will make on the Tera 250. We will send you partsby return to assess the quality and repeatability of the parts produced.”

Jon Donner, CEO at Nanofabrica continues, “Until now, AM produced DRST has been regarded as sub-optimal when viewed through the prism of surface finish, precision, accuracy, and repeatability and also in terms of the limited number of materials that can be processed. Nanofabrica’s AM process reaches micron level resolution which means high surface finish, and the requirements of tooling can be achieved without the timeconsuming and costly need to cut steel. Today, we are well positioned to lead the market of soft molds for micro injection.”

Nanofabrica has achieved ground-breaking successes shooting towards 1000 parts off a single DRST made using its technology. The company has succeeded in injecting PP, PE, and ABS into a 3D printed mould, which was manufactured with a new material that the company has developed. Moulds typically take about an hour to manufacture, costs in the order of $20, and have been used on an Arburg 35 ton injection moulding machine using pressures of 400 bar at 230oC. The ability to now really think of volume production without the necessity to fabricate timely and expensive hard steel tools for

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“Multiple tools can be made in a single build, so it is easy to see how the manufacture of DRST can suddenly be an eye opener.

For the price of one $10,000 hard steel mold tool you can produce 500 AM manufactured soft tools, and if each produces 1000 parts, that is 500,000 parts produced extremely quickly compared with injection molding, with the added benefits that tool design can be adapted and evolved with ease to cater for individual customer preferences, or changes in market requirements,” Donner concludes.

Through its work in this area, Nanofabrica is stimulating the business case for a process chain that includes DRST, with a dramatically shorter lead time of about 2 hours from file to injected part and at costs reduced from thousands of dollars to tens.

Companies interested in trialing the Nanofabrica produced DRST should contact Tovit Neizer at tovit@nano-fabrica. com. It is likely that there will be considerable demand, so early applications are encouraged to avoid delays in engagement.

Denchi Applies its Expertise to Powering Stairlifts customers with a far lower total cost of ownership, and that’s what really matters.

Furthermore, supply continuity and first class engineering support are completely assured.”

Always looking to provide the market highly-optimised energy storage solutions, Denchi Group has secured a large-scale contract with DC motor system manufacturer Lemac. Based in Scotland, Lemac produces the motor systems incorporated into a leading brand of stairlifts.

DC systems (rather than AC ones), are used in these stairlifts because they are inherently safer. Also power delivery is better regulated, resulting in a smoother ride for the user.

In addition, operation can still continue even if a power outage occurs on the mains supply. To complement the lightweight and streamlined motor systems Lemac provides for these stairlifts, compact high-density batteries are mandated. The company had previously used an offshore source for its battery units. However, there were some significant issues in terms of quality. Denchi was able to offer a much more compelling alternative, manufactured in the UK for only a marginal increase in cost.

Certain key criteria needed to be met by the substitute battery. It had to match the existing power delivery parameters, while fitting into a space-constrained enclosure. Maintaining the highest degrees of reliability was of course imperative too. This would mean that sending out service engineers and the cost of replacing faulty batteries

could be avoided. After a short consultation phase, Denchi was able to propose a new bespoke design to Lemac. This consisted of a pair of 12V batteries, each with dimensions of 220mm x 71mm x 23mm, allowing a 6Ah total capacity to be supported.

Thanks to the industry-leading power densities that Denchi technology can attain, it was possible to reduce the number of cells needed from 16 down to just 12 cells. This made the solution 25% smaller than the previous one, and reduced the weight too - thereby helping to improve system performance.

The units have exactly the same circuit protection mechanisms as those featured on Denchi’s military-grade battery products.

After the prototyping and field test work had been completed, it was not long before ramp up to high volume shipments began (covering both production units and spares).

Following on from this, Denchi and Lemac are now discussing future development projects.

“Often we see companies that went offshore to source energy storage solutions for their products coming to us when they suffer with technical and logistical problems, or experience a lack of responsiveness,” states Nick Simmons, Denchi’s Sales Director. “Thanks to ultra-reliable operation and exceptional longevity, our solutions present

As Liz Blunsum, Managing Director of Lemac, comments; “The Denchi team have been a real asset, helping us to resolve a very difficult situation.

We appreciate their efforts in providing a highly effective solution that has enabled us to upgrade our motor systems, and look forward to working closely with them in the years ahead.”

About Denchi Group Drawing on decades of engineering heritage, Denchi Group is a respected technology leader in the development and production of high-reliability batteries and their accompanying power management systems. Utilising various different battery chemistries (both primary and secondary), the company’s robust solutions all push the performance envelope and are capable of addressing a broad spectrum of application segments. Among the most prominent of these are military, industrial, renewables, oil/gas, avionics, medical, transportation and enterprise energy storage/ back-up power. Benefiting from unmatched in-house engineering proficiency, Denchi’s expanding portfolio of cutting-edge off-the-shelf products is complemented by highly-optimised custom-built ones.

To find out more please visit: www.denchigroup.com

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Digital and analog interface benefits all at once thanks to Dual Channel for both absolute and relative pressure measurement.

Enhanced process efficiency thanks to fusioned sensor data IO-Link allows for mutual and bidirectional sensor communication via the controller. This way, every sensor can utilize the measured values of other sensors to solve complex measuring tasks or for optimization of processes and production flow.

Digital communication opens up many opportunities – but only sensors that reliably deliver precise measured values offer real added value by IOLink. Well established and appreciated by many users, both pressure sensor PP20H and CombiLyz AFI conductivity sensor excel by outstanding measuring performance and IO- Link interface, but now they offer even more interesting features such as simple and fast parameterization- even during operation. This way, secondary data like different process data output simultaneously or diagnostic data only accessible this way can be communicated from sensor to controller or even retrieved from the sensor memory if required. Further to the digital interface, the sensors also provide one or more conventional analog outputs for maximum user flexibility.

Dual Channel - analog and digital interface in a single sensor Dual Channel enables analog as well as digital sensor operation or both at the same time - this way, Baumer process sensors such as conductivity sensor CombiLyz AFI and pressure sensor PP20H work both in conventional control topologies

and digital IO-Link control environments. In process automation, the proven analog interface is helpful for sensor integration into existing control concepts. Nevertheless, in sensor commissioning, IO-Link advantages such as easy and fast parameterization or access to secondary data are a valuable help. For process control, parallel readout of conductivity or pressure value is enabled via 4...

20 mA analog output.

More information, more process effectiveness IO-Link provides access to valuable secondary data: process data including sensor temperature respectively process temperature of PP20H. Such information allow for interesting conclusions, e.g. unusual temperature rise in containers or pipes. And, such data are basic for predictive maintenance. CombiLyz AFI conductivity sensor delivers information on media concentration in addition to media conductivity. By doing so, the medium in process and its concentration is precisely identified. Pressure sensor PP20H delivers ambient pressure information in addition to process pressure. Therefore, the sensor can be deployed

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Using conductivity sensor AFI for example, transmission of the measured temperature value would reduce response times of temperature compensation to 15 seconds or even completely circumvent them. In level detection in closed tanks, two fusioned pressure sensors enable direct indication of the filling level.

The head pressure sensor transmits the measured value to the pressure sensor at the tank bottom for zero point adjustment. This way, the actual pressure is determined.

With CombiLyz conductivity sensors and PP20H pressure sensors now featuring this digital communication interface, Baumer further adds on their portfolio of IO-Link process sensors. And, solutions for flow and level detection using this digital communication standard are also available. Further information here: baumer.com /io-link-process-sensors

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LSAH 44.3 - an alternator designed for cogeneration applications in district heating

The LSAH 44.3 has been designed to be packaged into small natural gas generator sets built for combined production of heat and electricity. The main application of these gensets are residential and public buildings central heating.

In order to maximize the heat recovery process, the LSAH 44.3 has been designed with a high-performance liquid cooling circuit that connects directly to the heating piping system. The LSAH 44.3 has therefore also been optimized and qualified to operate at high temperature, with a maximum operating temperature set at 80° C. The LSAH 44.3 delivers a rated power between 50 and 94 kVA at 50 Hz in continuous service (from 62 to 117 kVA at 60 Hz). The alternator is fitted as standard with an AREP excitation system and a D350 regulator. Paralleling with the public network for the resale of electricity production surplus is also possible.

Thanks to its cooling and heat recovery system, the LSAH 44.3 offers top performance, especially in situations of intensive use: - The electrical efficiency reaches 97% and generally remains above 95%. These high values allow optimized operation and quicker profitability.

- Thanks to the optimized cooling system, the lifespan of the machine is increased and allows intensive operation of the system without any risk of failure due to hotspots.

- Water cooling also allows the use of the LSAH 44.3 in non-ventilated – and silent – generator sets, making their integration in buildings much easier with and without noise pollution for the neighborhood.

From a mechanical point of view, the LSAH 44.3 offers two-bearing or single-bearing coupling and regreasable bearings. The machine structure has also been strengthened and stiffened for better resistance to vibrations caused by gas engines, and the machine itself has been optimized to limit generated vibrations.

Other alternators using the same technologies will be gradually introduced by Nidec Leroy-Somer, fleshing out a complete range covering all market requirements.

“This alternator is a real innovation” said Franck Broussard, Project Manager “We really focused our design efforts on the integration of the alternator as a component in a system, thinking about ways to optimize the global thermal and electrical performance.

The result is a product that fully meets market expectations. “ The LSAH 44.3 also offers great versatility. As a synchronous machine, it allows both network paralleling and island modes.

This is an additional advantage compared to asynchronous products traditionally used on this market.

The LSAH 44.3 offers compatibility with the most demanding Grid Codes or network requirements.

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About Leroy-Somer Electric Power Generation Leroy-Somer Electric Power Generation Europe and Asia Pacific (EPGE), a business unit of the Nidec Group, is a leader in industrial alternators with power ranging from 10kW to 25MW, focusing on Europe, Asia and Africa markets. With its two leading brand, LeroySomer and Kato Engineering, EPGE works with generator set manufacturers and electric power producers in these areas to help the industry provide reliable and efficient power solutions. EPGE has over 2,000 employees, 7 production sites worldwide and a global service network. For more, visit www.leroy-somer.com/epg About Nidec Nidec, the parent company of Nidec Leroy-Somer Holding, was established in Kyoto, Japan in 1973 by its Chairman and CEO Shigenobu Nagamori.

In 1979, Nidec became the first company in the world to successfully commercialize a direct drive spindle motor for HDDs based on a brushless DC motor. Since then, the company has grown into a worldleading comprehensive motor manufacturer encompassing more than 300 subsidiaries employing over 100,000 people throughout the world and with annual sales exceeding €11B. Nidec\’s motors, drives, generators and related products are found in a diverse range of applications including computers, smartphones, home appliances, automobiles, manufacturing plants, robots and more. For more, visit www.nidec.com

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New Generation of the All-in-One Engineering Tester Now Available in all applications. The product now also enables the remote access of test specimens. This can save a lot of time and money, especially in globally operating teams, as travel can be avoided and expensive test resources shared.

Following the successful launch at pilot customers, the new generation of the highperformance and use- caseoptimized Diagnostic Tool Set (Softing DTS 9) is now available.

New functionalities enable even faster and more cost-efficient diagnostic development – exactly what is needed for the growing complexity of E/E architectures and shorter product development cycles Softing DTS.monaco makes it possible for developers, engineers and technicians to create consistent diagnostic functions and sequences on the basis of international standards and to ensure that diagnostic communication works reliably over the entire value chain.

The highlights of the new product generation include, in particular, remote diagnostic support in the engineering network (remote diagnostics) and the display and recording of Ethernet communication (DoIP - Diagnostics over Internet Protocol). New functions in the area of OTX support, based on the latest standard, enable a perceptible increase in the speed of work thanks to automation and the ability to precisely solve individual problems with self-generated user interfaces. In addition, the integration of function-oriented diagnostics with the Smart Diagnostic Engine (Softing SDE)

has already made the leap to the next generation of diagnostic systems.

Proprietary user interfaces are created in OTX whenever the intuitively usable and flexibly configurable interface elements (SmartDiagnostic controls), available for all frequently used diagnostic functions, need to be extended. This means that entire release sequences, continuous operation controls and certifications can be safely incorporated into the Monaco workspaces to prevent operating errors.

DoIP continues to gain importance not only because of the high bandwidth required – especially in flash programming.

DTS is perfectly prepared for this

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Alongside system-specific licensing, the additional floating license mechanism ensures flexibility and saves customers both time and money. Furthermore, the new DTS 9 platform offers international users multilingual capability with the provision of a German, English and Japanese translation of the user interfaces. This not only reduces the amount of training required but also leads to increased acceptance of the whole system, particularly in globally operating teams.

Incidentally, today’s customers don’t need to worry about migrating to the new generation: Both existing DTS projects and OTX processes can be migrated and reused with the new software.

The Softing Diagnostic Tool Set 9 offers an all-in-one diagnostic solution for all use cases from ECU engineering and development to vehicle integration and SOP – futureoriented, efficient and safe.

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QNX RTOS chosen by ByteSnap to ensure high-reliability in new Vehicle-to-Grid charge post

Direct Insight, the UK-based, technical systems integrator and reseller of system-on-module (SoM) and other embedded systems, has announced that a new vehicle-charging system which embraces Vehicle-to-Grid (V2G) functionality is available based on QNX RTOS, enabling it to meet mission-critical availability goals and satisfy the needs of consumers reliably and safely.

Part of the UK Governmentbacked VIGIL program, the OCPP 2.0 compliant charge controller allows the chargepost to manage Electric Vehicle (EV) / building energy dispatch and ensures distribution network limits are not exceeded.

Based on NXP i.MX6 hardware, and designed by leading electronic design consultancy ByteSnap Design, the controller, named RAY, reduces latency and improves system robustness by allowing direct control via the building management system.

During the VIGIL project, it was successfully integrated into three V2G units at Aston University, and is already being used by commercial customers.

The QNX Neutrino RTOS, supplied by Direct Insight is a microkernel-based full-featured and robust OS that scales down to meet the constrained resource requirements of and real-time embedded systems.

Its modular architecture enables customers to create highly optimized and reliable systems with low total cost of ownership. QNX is often used as a commercially supported and licensed alternative to Linux in ARM-based embedded systems which are mission-critical, including those which require safety certification, particularly in automotive, medical or industrial fields.

“Early EVSE infrastructure has struggled with perceptions of poor reliability. Making this advanced controller available based on QNX means that customers can rely on the performance of the charge posts year-in, year-out,” commented Dunstan Power, ByteSnap Director.

Added David Pashley, Direct Insight’s MD: “ByteSnap is without doubt at the leading

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edge of embedded design and development, and are known for creating a quality product.

Therefore, its choice endorses QNX’s credentials in missioncritical applications.”

About Direct Insight The increasing complexity of electronics hardware and software has the potential to increase project timescales, yet at the same time most development teams are faced with ever more demanding time-to-market pressures.

Founded in 1992, UK-based technical systems integrator and reseller of system-onmodule (SoM) and other embedded systems, Direct Insight has helped hundreds of development teams to upgrade to the latest SoC, FPGA and OS technology by choosing the right off-theshelf hardware, software and tools, by providing the required support and services to fill the gaps, and by allowing customer development teams to focus on their differentiating core skills to deliver excellent products. Key partners include: OS supplier,

QNX; Ka-Ro Electronics, the German designer and manufacturer of embedded modules; and Taiwanese single board computer maker, DFI. About ByteSnap Design ByteSnap Design is a specialist in embedded systems development, encompassing hardware and software design, with an international client list. ISO 9001:2015 certified, ByteSnap Design is an NXP Gold Partner and an ARM Connected Community Partner. The team’s experience ranges from

electronic design through to BSP porting and mobile app development. ByteSnap won ELEKTRA 2019 Design Team of the Year and Consultancy of the Year - Highly Commended at the 2019 British Engineering Excellence Awards (BEEA).

ByteSnap was also named 2016 Design Team of the Year and Consultancy of the Year in 2013 at the BEEA, and was ‘Highly Commended’ developing electric vehicle charging posts for the London Olympic Games.

In addition, ByteSnap Design has previously won ‘European

Design Team of the Year’ at the ELEKTRA Awards.

The consultancy’s technical portfolio includes electronic circuit design, Linux and embedded software development, designing hardware products from wireless sensors to ruggedized tablets. ByteSnap has successfully delivered multiple software projects such as Android BSPs and video processing applications.

There’s more to discover about ByteSnap Design at www.bytesnap.com.

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Tips for replacing wheel hub bearings When it comes to vehicle repairs, NSK sets out to make processes faster, safer and more reliable for garage technicians and mechanics. For this reason, those purchasing NSK ProKIT solutions receive 100% genuine wheel bearings alongside all of the supporting components needed to perform a fast and high-quality wheel bearing replacement. Hub bearings are not the simplest of parts to install, which is why NSK is providing some extra tips to help avoid common mistakes.

The first tip is to compare the fitted bearing to the new one before mounting. Selecting the incorrect bearing is the most common mistake made by technicians. If the bearing is selected correctly, it can be re-checked quickly using the NSK online catalogue. Those requiring further help are invited to make direct contact with NSK.

1

Avoid damage to the magnetic encoder Some hub bearings feature a magnetic encoder for the ABS signal, and thus demand even closer attention. The encoder seals contain many north (N) and south (S) poles which are read by the speed sensor (Image 1). If the N+S poles get damaged during installation it can lead to failure of the ABS system.

Garage technicians can identify if a hub bearing has an encoder by using an NSK test card. The same test card can also be used to establish whether a fitted bearing has pole damage (if the result does not look like Image 2), which in turn can help technicians identify ABS signal problems.

2

Keep the encoder from magnets and dirt A good tip is to avoid coming into contact or getting near the encoder with tools such as spanners and screwdrivers as they can change the N+S poles,

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again leading to issues with the ABS signal. With this thought in mind, only remove the bearing from its protective packaging immediately before fitting.

Ensure correct encoder orientation Encoders are only present on one side of Hub I generation wheel bearings – as identified by the test card – so it is vital to get the orientation correct when pressing into the knuckle. Before beginning this operation, always check that the encoder surface will be adjacent to the sensor after assembly.

Avoid pressure on the encoder surface For pressing, use a tool that only contacts the end face of the outer ring on Hub I generation bearings (Image 3). Never press on the encoder seal and never press on the inner ring as it will lead to bearing failure within a few kilometres of use. Once a suitable tool has been selected, keep the bearing aligned to the bore and press it vertically into the knuckle.

4

5

6 Further tips for correct bearing installation There are many general tips to keep in mind throughout the process, such as taking care of all suspension parts to avoid any unnecessary damage. Additionally, to ensure correct fitting of the bearing, it is especially important to control the hub and knuckle during assembly, while all surfaces which come into contact with the bearing should be cleaned beforehand (Images 4 and 5).

As a final point of note, for safe reassembly, technicians should only use only the recommended tightening torques recommended by the car manufacturers. In particular, it is known that applying excessive torque to the CVJ nut can lead to bearing damage (Image 6).

The correct fitting of Hub I generation wheel bearings with magnetic encoders is especially challenging, which is why NSK has produced a video on this subject that shows every step of the process. NSK also offers special training that focuses on wheel bearings. Those interested are requested to make direct contact. To find out more about NSK head over to www.nsk.com

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New Switch’Air™ Domes with Hole from Nicomatic enable integration of LEDs into electrical membrane switches and eliminate suction effect for faster, easier automatic assembly

Nicomatic, the leading manufacturer of high performance interconnect systems, has added new Switch’Air™ Domes with Hole to its successful Switch’Air 4-legged Domes range.

Switch’Air™ Domes feature patented technology with a cushion of air that prevents domes sticking to each other during automated pick & place manufacturing, resulting in faster, easier, more accurate assembly. With a life expectancy of up to five million actuations and guaranteed for one million actuation cycles, Switch’Air domes provide reliable, extended-life performance for demanding applications in the medical and industrial markets among others.

New Switch’Air Domes with Hole are specifically designed for membrane switches, sitting free in the spacer layer of the membrane. They have a superior tactile feel with a large sweet spot. The hole in the

dome enables an LED to be placed underneath and therefore under the top plastic membrane, not only saving space but also providing a more intuitive user experience, as the button itself lights up when activated. As membrane switches are sealed, they are ideal for medical applications and others where wiping down is necessary, either for hygiene reasons or due to use in dirty or dusty environments.

Manufactured from high quality stainless steel, they are contamination-free. Nicomatic also supply LEDs suitable for use in combination with these domes, available in a range of colours as well as bi-colour.

Switch’Air Domes with Hole are available in 280g, 340g and 400g trip force variants with 65g rebound force. Physical specifications are: diameter 10mm; footprint diameter 9.5mm; height 0.65mm; total travel 0.55mm. Operating temperature is -40degC to +105degC.

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Electrical specifications for Switch’Air domes include switching current of 5µA to 100mA DC, switching voltage of 0.1VDC to 100VDC, switching capacity 1W. Contact resistance is < 100 mΩ.

Qualified to ASTM F2592-16, RoHs compliant Switch’Air Domes with Hole are available in tube, on reel, in bulk or on array, with the shortest lead times in the industry. Customisation options are possible on request.

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Felix Printers becomes authorized OEM vendor to the US Goverment

FELIXprinters has successfully established itself as a leading supplier of industrial AM machines that are characterised by their accuracy, ease-of-use, reliability, and repeatability. The company’s culture of innovation and advancement ensures that not only are its AM platforms providing exceptional builds, but they are doing so at a cost that is sensitive to customer demand, opening up the industrial use of AM as a production technology to a huge section of industry previously under-served. The company is truly hitting the sweet spot between value and quality.

FELIXprinters is proud to announce that its products are officially on US Government contract Schedule 36 3D Products and Services Team One Contract #GS-03F-050GA and also now available on GSAadvantage.com for US government procurement.

Having Felix products on contract opens the US government to FELIXprinters’ technology product portfolio of 3D printing platforms and accessories. In addition to federal contract procurement state and local governments throughout the USA will now also gain access to FELIXprinters.

In the USA, FELIXprinters’ reseller network includes Team One based out of Suwanee, GA and Quincy, CA. TeamOne has significant interest in the 3D printing sector supplying 3D printers, filaments, scanners and accessories , and is also a General Services Administration (GSA) Multiple Award Schedules (MAS) contractor for the US government.

Wilgo Feliksdal, co-founder of FELIXprinters says, “We are delighted to be working with Team One in the States, and are extremely encouraged by our inclusion on this US government contract. This could help establish FELIXprinters as a prominent player in the US 3D printing sector, and it comes in a year when we have launched two new 3D printers, our

BIOprinter (also on federal contract) and an upcoming platform for high temperature printing. We continue to innovate, to listen to customer requirements, and then serve them with competitively priced 3D printing solutions which have at their core ease of use and above all else accuracy, reliability, and repeatability.”

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The Tera 250 Over the last 18 months Nanofabrica has moved out of stealth mode and into a fully commercial position, and the company has recently branded its successful micro additive manufacturing (AM) technology as the Tera 250.

Through the use of Nanofabrica’s technology, micro manufacturers can now realistically assess a shift to AM from conventional manufacturing processes. OEMs can therefore benefit from the inherent advantages that AM offers in terms of promoting part complexity with no increase in cost, eliminating the needs for expensive tooling, reducing part counts and the need for assembly, speeding product development time, easy revision of part design, mass customization, reduction in waste, and reduction in energy costs.

Nanofabrica’s AM technology combines innovation in materials, software, and hardware to allow the repeatable mass manufacturing of micro parts and components with micron-scale features. Today it is a compelling option for manufacturers in the areas of optics, semi-conductors, electronics, MEMS, micro fluidics, injection molding, and life sciences, making products such as casings for microelectronics, micro springs, micro actuators and micro sensors, and numerous medical components such as micro valves, micro syringes, and micro implantable or surgical devices.

In recent months, the company has also made some crucial advancements in the manufacture of direct rapid soft tooling (DRST) on its platform and has begun to redefine the economics of volume production using AM produced tooling.

Jon Donner, Nanofabrica CEO explains, “Over all the months and years of developing our technology, we never really spent time thinking about giving it a name. For us it has always been our ‘micro-AM technology’, but the time finally came when we all sat down and decided we needed something that would brand the technology effectively. We came up with the Tera 250 as this conveys the most unique aspect of our technology, namely the fact that we manufacture the only commercially available AM platform that can produce micro products with micron resolutions. We have 250 tera voxels in the build volume of the printer, hence the Tera 250!”

250 tera voxels basically means 250 trillion (250 times ten to the power of twelve) voxels in the build area of the printer. There is no other machine with such a voxel capacity, and because of this Nanofabrica’s Tera 250 has the ability to apply so much data onto one part, which means highly precise and micron level accuracy can be achieved.

Tovit Neizer, VP Business Development continues, “Manufacturers have never been able to achieve such precision, accuracy, and resolution, through the use of AM before, and so the technology is truly a game changer. It is the voxel capacity of the Tera 250 that facilitates this, and such capacity is only really required when you are looking at miniaturisation and micro manufacturing. Our voxel capacity means that we can fit a large number of end-use parts in one build volume. For example we can manufacture over 10,000 1 mm x 1 mm x 1 mm parts in a single build. You can see how we are looking at mass manufacture using AM very quickly.”

“For manufacturers this is the goal when looking at AM as a production technology. The ability to mass produce AM parts without the need for time consuming and costly hard tooling, and with all the advantages AM brings in terms of agility and geometric complexity impossible using traditional production techniques is a large step forward for industry,” Donner concludes.

Nanofabrica combines the highest quality components together with its patented technology to provide a precision additive manufacturing platform that achieves extremely high resolution with unprecedented repeatability. The machine delivers micron precision digital innovation in every part produced.

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Efficiency at a new level IE5+ motors and LogiDrive

The new IE5+ motor generation from NORD DRIVESYSTEMS offers a constant high efficiency over the entire adjustment range in a hygienic design that raises the LogiDrive concept for intralogistics to a new level with regard to energy efficiency and reduction of variants. The total cost of ownership (TCO) can be considerably reduced.

The energy-efficient latest generation permanent magnet synchronous motor has considerably lower losses than the current IE4 series. The unventilated smooth motor achieves its high efficiency that, at times, is significantly above efficiency class IE5 via a wide torque range – and is optimally suitable for the operation in the partial load range. The compact IE5+ motor offers a high power density with less installation space and will be initially launched in a size for power ranges from 0.35 to 1.1 kW with a continuous torque from 1.6 to 4.8 Nm and speeds from 0 to 2,100 min-1. Direct motor attachment as well as NEMA and IEC motor attachments are available. The motor concept will be gradually extended with more sizes and powers. It is ideal for use in hygiene-sensitive and harsh environments because it is easy to clean, corrosionresistant and wash-down capable. nsd tupH surface

treatment and IP69K protection class are optionally available, as well as an integrated mechanical brake. An integrated encoder is part of the standard equipment. With the new generation of IE5+ motors, NORD DRIVESYSTEMS takes the first step towards a new product system landscape with focus on ultimate energy efficiency paired with compact design.

LogiDrive with high efficiency up to IE5+ The new IE5+ synchronous motor can be combined with all NORD gear units and drive electronics as a modular system and supplements the successful LogiDrive concept.

The standardised geared motor variants – consisting of an energy-saving synchronous motor, a 2-stage helical bevel gear unit and a NORDAC LINK frequency inverter – have been specially developed for use in intralogistics, parcel logistics and airport technology, and represent an optimal compromise between energy efficiency and a reduction of variants. The new IE5+ motor can further increase these benefits.

Utilising the high overload capacity of the motors and the system’s wide adjustment range, the solution is individually tailored to each customer and specificallydesigned for the system’s individual load range.

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The decentralised LogiDrive systems are highly efficient and extremely easy to service thanks to plug & play technology. The entire system has a modular design, so that all components of the drive technology can be individually serviced. This minimises maintenance and repair costs. The compact design saves space and is light in weight thanks to the aluminium housing. Thanks to the special design of the IE5+ motor and its operation with the frequency inverter, the same motor variant can be universally used worldwide. This means that the same motor type can be used independent of the respective mains voltage or local energy efficiency regulations.

The IE5+ synchronous motor and the respective LogiDrive systems are available from the second quarter of 2020.

With more than 4,000 employees, Nord Drivesystems has developed, produced and sold drive technology for over 50 years, and is one of the leading global full-service providers in the industry. In addition to standard drives, NORD delivers applicationspecific concepts and solutions for special requirements such as energy-saving drives or explosion-protected systems. In the 2018 financial year, annual sales amounted to € 700 million NORD now has subsidiaries and sales partners in 98 countries worldwide. The extensive sales and service network guarantees optimal availability, enabling short delivery times and customer- oriented service.

NORD produces a very diverse range of drives for torques from 10 Nm up to over 250 kNm, supplies electric motors in the power range of 0.12 kW to 1,000 kW, and supplies the required power electronics with frequency inverters of up to 160 kW. Inverter solutions are available for conventional control cabinet installations as well as for decentralised, fullyintegrated drive units. www.nord.com

Sharp images even with varying object distances

IDS extends selection of automatically focusable boardlevel cameras. Thanks to their practical autofocus function, uEye LE AF industrial cameras deliver perfectly focused images even with frequently changing object distances.

IDS Imaging Development Systems GmbH now offers additional camera variants with 2.1 and 3.1 MP Sony sensors which provide more flexibility in terms of application design and camera integration. For the first time, the company also offers models with upright USB Type-C alignment in this product family.

In addition to the previously available uEye LE AF cameras with 6.4 MP (IMX178, 58 fps) and 18.1 MP (AR1820HS, 20 fps) sensors, customers can now also purchase models with 2.1 (IMX290, 120 fps) or 3.1 MP (IMX265, 80 fps). All cameras feature a USB 3.1 Gen 1 interface, USB Power Delivery â&#x20AC;&#x201C; which can be used, for example, to power an LED light source or a

photoelectric sensor â&#x20AC;&#x201C; and allow the use and control of liquid lenses.

The autofocus function ensures sharp images in the blink of an eye, even if the lens is not physically accessible or if the distance between the lens and the object changes frequently.

The board-level cameras are therefore particularly wellsuited for applications in fields such as logistics (e.g. for parcel acceptance and sorting) or traffic monitoring.

Due to their compact design with dimensions of only 36 x 36 x 20 mm they also prove their strengths in embedded vision systems. This means that they are also interesting for integration into small medical or industrial devices.

About IDS Imaging Development Systems GmbH: The industrial camera manufacturer IDS Imaging Development Systems GmbH

develops high-performance, easy-to-use USB, GigE and 3D cameras with a wide spectrum of sensors and variants.

The almost unlimited range of applications covers multiple non-industrial and industrial sectors in the field of equipment, plant and mechanical engineering. In addition to the successful CMOS cameras, the company expands its portfolio with vision app-based, intelligent cameras.

The novel image processing platform IDS NXT is freely programmable and extremely versatile.

Since its foundation in 1997 as a two-man company, IDS has developed into an independent, ISO-certified family business with more than 300 employees.

The headquarters in Obersulm, Germany, is both a development and production site. With branches in the USA, Japan, South Korea and UK as well as other offices, IDS is represented internationally.

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Altair Named Ducati Corse Technical Partner for Legendary Official Team in MotoGP

Altair (Nasdaq: ALTR), a global technology company providing solutions in product development, high-performance computing (HPC), and data analytics, today announced a multi-year technical partnership agreement with Ducati Corse, the racing division of the legendary Italian motorcycle manufacturer.

Ducati will expand its use of Altair’s computer-aided engineering (CAE) software for product development, providing Ducati Corse engineers with a vital competitive edge in their 200mph-plus pursuit of racetrack success. Altair will sponsor the team in the MotoGP World Championship, which began in Spain on July 17, 2020.

Ducati Corse is a long-standing user of Altair design and simulation tools, and the new agreement will expand this relationship in critical areas including aerodynamics, fluid dynamics, weight optimization, structural optimization, vehicle dynamics, and advanced powertrain technology. In a sport where the difference between success and failure is

often measured in milliseconds, Altair’s software will help Ducati engineers explore, optimize, and implement innovative ideas more quickly and efficiently than ever.

“We are delighted to welcome Altair as a Ducati Corse technical partner for the start of the 2020 MotoGP season. Strengthening the team’s partnership with an industry leader in advanced CAE and simulation will help extend our technology leadership in the fastest, most demanding motorcycle racing environment on the planet,” said Luigi Dall’Igna, Ducati Corse general manager.

“Altair is all about empowering talented and visionary engineers to deliver innovation and excellence. In this respect, the synergy with Ducati Corse is perfect,” said James Scapa, Altair’s chief executive officer and founder. “This new agreement means we can forge an even closer relationship through our software and consultancy to support the Ducati Corse engineering team as it transforms bold concepts into race-winning performances.”

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Established in 1999, Ducati Corse is recognized as a pioneer in racing motorcycle design and development. Over the years, many of its racebred innovations fueled by advanced technology have been incorporated in Ducati’s range of stylish, high performance, and high-quality road bikes.

About Altair (Nasdaq: ALTR) Altair is a global technology company that provides software and cloud solutions in the areas of product development, high performance computing (HPC) and data analytics. Altair enables organizations across broad industry segments to compete more effectively in a connected world while creating a more sustainable future. To learn more, please visit www.altair.com.

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Dafo Vehicle introducing Li-IonFireTM increasing the safety of electric and hybrid electric vehicle operations

As there is a global transition to renewable fuels, there is an increasing demand for electric or hybrid vehicles (EV and HEV). However, knowledge is limited about the new fire risks associated with vehicles having these new energy carriers.

Consequences connected to risks of Li-ion batteries, in case of a malfunction, can be serious, for example, they can result in toxic gas emissions or explosion. In collaboration with the coordinator, Dafo Vehicle Fire Protection, an EU initiative has built a fire protection system that addresses and mitigates these risks effectively and safely.

Fire suppression systems for vehicles have been on the market for decades, and are widely used and regulated across a wide variety of

industries. However, these systems are tested to be effective on vehicles with combustion engines, and all test standards are designed with this in mind.

The growth of the electric and hybrid electric vehicle industry has accelerated the demand for new fire suppression technologies.

“With the rapid introduction of electric and hybrid electric vehicles in public transport, there are new challenges because they present totally different risk scenarios,” says Anders Gulliksson of Dafo Vehicle, coordinator of the EUfunded Li-IonFire (Automated e-vehicle Lithium Ion Battery Early Warning and Fire Suppression System) project.

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“When the commonly used Li-ion batteries fail through short circuiting, overcharging, high temperatures, mechanical damage and overheating, this might cause thermal runaway and the release of a flammable electrolyte, which makes fire extinguishing very difficult.

In addition to the dramatic fire scenario with the rapid increase in heat, there are a lot of potentially toxic gases being emitted”.

A comprehensive solution for fire mitigation The project partners, including Dafo Vehicle Fire Protection and RISE Research Institutes of Sweden, explored different techniques to detect potential battery failure, as early as possible, and take immediate action to stop, or delay, a potentially hazardous situation.

The partners studied the various fire risks related to battery spaces, including specific risks when charging, and procedures for handling electric vehicles and batteries after a crash.

They also investigated to what extent fixed and integrated fire suppression systems, which are widely used to protect engine compartments on heavy vehicles, can be applied to vehicles powered by Li-ion batteries, and how they should be designed.

Through extensive testing, the Li-IonFire team better understood how a breakdown occurs within the battery and how it can be detected. “If a system is activated at this early stage, the battery can be ‘brought back’ to a safe state, without the fire developing further,” explains Gulliksson.

“The tests have also shown that even with a late deployment of the fire suppression system, there’s a possibility of delaying the battery reaching a critical

state, meaning that the chance of safe evacuation is very high.”

With proper detection and system activation, the hazardous scenario can be reversed and potentially even stopped entirely.

An integrated solution for early fire detection, system cooling and fire suppression The project team successfully validated and demonstrated a highly innovative fire protection system for electric and hybrid electric vehicles.

The new system provides an early fire warning system, and spot cooling to prevent thermal runaway while localising and suppressing fire.

now: a system that can offer real protection against battery fires, using a new suppression agent, Forrex EVTM, which is specifically developed for these applications,” concludes Gulliksson.

“Li-IonFire will significantly boost the safety of operators and the protection of valuable assets.”

Li-IonFire will be available from 01st September 2020.

For more information contact James Mountain by emailing jamesm@fireshieldsystemsltd. co.uk or calling 07779 637 896.

Alternatively, you can visit www.dafo.co.uk or www.fireshieldsystemsltd.co.uk.

The system was officially unveiled at in 2019, and has generated tremendous interest from both end users and vehicle manufacturers.

“Li-IonFire delivers to the market a product that didn’t exist until

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How can holding open doors prevent the spread of COVID-19?

Reducing the spread of germs and bacteria has never been more essential in the current climate. Holding open internal doors provides an easy and effective method of infection control within your building, but it is important that this does not impact your fire safety.

Reducing door handle contact A study by the New England Medical Journal, which researched the survival of coronavirus on a number of surfaces, identified that the virus was still detectable on hard surfaces such as plastic and stainless steel 72 hours later. While regular cleaning can help combat transmission, the inevitable use of door handles means that they can quickly become a hotspot for the spread of germs.

Improving visibility and aiding social distancing While lock down restrictions remain uncertain, social distancing measures are expected to stay for some time.

Holding open internal doors facilitates social distancing by allowing improved vision when entering or leaving a room, or when travelling through a corridor. Not to mention the post-COVID etiquette of whether or not you should hold the door open for the person behind you!

Increasing ventilation Workplace guidance published on 11th May 2020 identified ways employers and employees can work safely during the pandemic. One of the recommendations included the requirement for increased ventilation which can be achieved by opening windows and doors.

The Health and Safety Executive (HSE), said: “Good ventilation can help to minimise the risk of spreading coronavirus, so focus on improving general ventilation. Where possible, consider ways to increase the supply of fresh air, for example, by opening windows and doors”

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The solution Geofire’s Agrippa door holder allows a door to be hygienically held open in a fixed position, preventing the need to touch the door handle. The Agrippa door closer’s free-swing feature allows a door to be held open at any angle. Using ‘listen and learn’ technology, the Agrippa suite of products will automatically release the door on the sound of the building’s fire alarm.

Wedges or homemade devices should never be used to hold open a fire door and is illegal should a fire occur.

Building operators have a legal responsibility to ensure fire doors are not illegally wedged open to ensure that they can prevent the spread of smoke and flames. The Agrippa wirefree fire door holder and closer are fully compliant to the requirements of BS 7273-4 for standard actuation of fire doors, and third party tested and approved to EN1154 and EN1155.

Andy Collinson, CEO at Geofire said: “Wedging open a fire door removes its ability to stop the spread of fire, putting lives at risk. There are legally compliant solutions readily available if ease of movement around a building or increased ventilation is required.

“From new builds to listed buildings, we have products to suit every installation; conventional hard wired, radio wire free and the Agrippa fire door holder and closer allow ‘dual mode’ installation, meaning you can install straight from the box and programme our innovative ‘listen and learn’ patent technology at a more convenient time”.

To learn more about Agrippa and how it can help infection control within your building, visit www.geofire.co.uk/agrippa-covid19-solution/. Geofire, home of Agrippa and Salamander, began life in 1972 and has, since then, been designing and manufacturing a wide range of electromagnetic activation devices, including fire door holders and closers. The Agrippa wire-free, fire door holders and closers offer an alternative, battery-powered solution. The devices ‘listen and learn’ the sound of the fire alarm, closing the door upon hearing the pre-recorded sound of the alarm.

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HeavyDuty rotary encoders - The high precision heavyweight champions conditions. And secondly that these heavyweights work as precisely as “small” rotary encoders for an extended period of time. HeavyDuty rotary encoders from Baumer Hübner accomplish this through four characteristics:

HeavyDuty rotary encoders from Baumer Hübner are the “original”. More than half a century ago, Baumer Hübner developed this type of particularly reliable and robust rotary encoders. Since then they have been used in all situations where the going is tough and where failure is not an option.

What distinguishes a HeavyDuty rotary encoder exactly and what options do they offer users?

The sophisticated HeavyDuty impermeability concept from Baumer conforms to protection classes IP 66 and IP 67 within a broad temperature range of up to +95 degrees Celsius. Thanks to an ingenious combination of labyrinth and shaft seals, Baumer HeavyDuty rotary encoders are permanently optimally protected against all types of solids, moisture, and contamination by adherence.

Dockside cranes that unload thousands of tons of shipped goods daily. Conveyor systems that carry thousands of tons of mined ore from mining plants across many kilometers.

Elevators that carry thousands of people daily. Automated production lines on which automobiles in various assembly stages are transported. Lifting bridges with a total weight of 1000s of tons that can carry several trains at once and that are lifted many times per day

to allow ships to pass. These and many other application scenarios constitute the world of HeavyDuty rotary encoders – anytime difficult tasks must be reliably carried out under difficult conditions and over the long term.

The term has been linked to Hübner Berlin since the 1950s, when the company established the supreme rotary encoder class. Since that time, Hübner Berlin, which today belongs to sensor specialist Baumer, has continuously improved its products and is still considered the expert provider of HeavyDuty rotary encoders.

But what do we mean when we talk about HeavyDuty products?

After all, the term is not legally protected or regulated by a standard. “Heavy duty” as such simply means hard-wearing.

A possible reason why some people think that HeavyDuty rotary encoders are simply encoders with thick housing walls and rust protection. In reality, the term denotes much much more.

What makes a rotary encoder “HeavyDuty”?

To Baumer Hübner, “HeavyDuty” is an all-encompassing performance promise. First of all, this means that such a rotary encoder never lets its user down, even under the most difficult

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Precision: A rotary encoder must deliver reliable signalsto allow users to precisely control and regulate drives and generators. Plant control systems utilize these signals for speed monitoring of drives or for position feedback of machine parts. To controllers, this information is the only way to get informed and intervene, for example, if a drive exceeds or falls below a defined speed limit. Since the machines and systems are usually very big – dock cranes, bucket-wheel excavators, rolling mills, garbage shredders – they could give the above-mentioned impression that precision does not matter much. That is a mistake.

Particularly because heavy loads are moved with great force, small measuring errors could have extensive consequences, for example, when setting down a container weighing several tons.

Mechanical robustness: a HeavyDuty rotary encoder must be so resilient that it can withstand hard shocks, vibration, and forces on the rotary encoder shaft for many years. Exchanging rotary encoders is expensive, not because of pricing but because of installation in places difficult to access and the system being down for the time of exchange. HeavyDuty rotary encoders are distinguished by several characteristics: Double-sided bearing setup with generously dimensioned, largely spaced bearings at both shaft ends to compensate axial and radial load, robust and thick-walled housings, and durable protection of the inside components against shocks and vibration.

Tightness: HeavyDuty rotary encoders are usually deployed in dusty, soiled, and damp environments. For this reason, the HeavyDuty encoder housing must be well sealed, especially at critical, neuralgic points - the shaft and electrical connections. Further, in terms of potential contact to chemicals or salt water, a good corrosion protection through appropriate housing materials and coatings is mandatory.

Electrical robustness: HeavyDuty rotary encoders must be immune against electromagnetic fields.

These are generated by live, unshielded cables routed nearby, which is a quite common situation in many applications. Without adequate shielding, the electronics in the rotary encoder might be destroyed or provide erroneous measuring signals. Another point are shaft currents caused by potential differences.

They may burn the bearing lubrication, which results in bearing destruction. For all these reasons, the inside electronics of HeavyDuty rotary encoders must be electrically isolated from the ambiance of operation.

Whether absolute or incremental – above the standard As described above, there are diverse application areas for HeavyDuty rotary encoders.

Therefore, the HeavyDuty portfolio of Baumer Hübner is just as diverse with many variations of incremental or absolute rotary encoders. The HOG 10 / POG 10 is the reference device among incremental rotary encoders. The rotary encoder HOG10 provides even more features only offered by Baumer that can enormously increase the fitting accuracy, as shown by the following two examples: HeavyDuty rotary encoders are usually deployed in harsh environments with exposure to

dust, moisture, and chemicals and therefore require powerful protective seals. But not all seals are equal. This is why HOG 10 is available with several sealing concepts for optimum protection in oily, damp, or dusty environments, for use in tropical and offshore climates, in cement works or other demanding environments. There are, for example, reliable and absolutely wear-free seals that endure impacts by coarse and finegrained solids and whose sealing components function with absolute wear and tear durability. In addition, sealing free from friction prevents any performance loss. Such a sealing concept is most efficient and less energy-consuming at high speed.

Since HeavyDuty rotary encoders are generally deployed in giant installations, signal transmission must often cover a distance of 100 meters or more.

For this reason Baumer attaches great importance to excellent signal quality and high-power outputs using short-circuit proof power transistors. There are even product variants that are capable of a distance up to 550 meters. Where this is not sufficient, fiber optic cables ensure noise-immune signal transmission over a distance of 1.5 kilometers.

Similarly, absolute rotary encoders such as the HMG 10 / PMG 10 also have special features beyond those of standard encoders: for example, providing precise position outputs via PROFINET. Frequently, incremental signals are also required for speed feedback in absolute rotary encoders, which is why absolute HeavyDuty encoders deliver speed signals in addition to the absolute position, for example as HTL or TTL, via serial digital interfaces such as SSI or fieldbus. Some product variants even integrate a speed switch for limit speed information via switching output.

application: There are various mounting options, whether as hollow shaft designs (through or non-through), cone shaft, or solid shaft with optional EURO flange B10 connection.

If required, HeavyDuty rotary encoders, speed switches, and tacho generators can be combined in one single robust, space-saving unit to provide varied types of output signals measured at a single drive shaft all at once. Large encoders such as HOG 16 / 22 /28 from Baumer are used for maximum speed limit monitoring of large drive shafts under the most difficult conditions, such as in coal dust, corrosive air, or in the burning heat of steel mills.

Due to the many available options, interested buyers should best check first together with our experts which HeavyDuty rotary encoder is appropriate for the intended application. No matter what product you opt for in the end – above-average precision and durability are always part of the package of HeavyDuty rotary encoders from Baumer Hübner.

The revolutionary concept of absolute HeavyDuty rotary encoders of the HMG 10 / PMG 10 series from Baumer Hübner combines the well tried and tested double-sided bearing setup with magnetic precision sensing and the patented Energy Harvesting microgenerator in a revolutionary concept.

HeavyDuty rotary encoders from Baumer Hübner excel through a robust design with bearings at both shaft ends. Thanks to unmatched resistance to axial and radial load, this doublesided bearing setup ensures maximum mechanical reserve capacity and unrivalled long service life.

Flexible solutions for every

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Pickering Electronics’ miniature HV reed relay at the heart of IC test system for On Semiconductor

Pickering Electronics, the reed relay company which has pioneered miniaturization and high performance for over 50 years, has announced that it has developed a miniature high voltage relay for use in a new test rig, designed by globallyrenowned chip maker, ON Semiconductor.

In switching systems for test and measurement applications, reed relays are often the best solution thanks to their small size, high isolation resistance, hermetically sealed contacts, fast operate time and long-life expectancy.

When developing a new test rig, ON Semiconductor – a longstanding customer of Pickering - identified the need for a reed relay with a stand-off voltage of at least 400VDC, which was also small enough to meet its demanding high switching density requirements.

The internal clearance constraints required by the uprated specs would not fit within the package dimensionsof other miniature relays in Pickering’s broad

portfolio. However, in just seven weeks, Pickering was able to send first prototypes of a device housed in the mini-SIP package with a footprint of 12.5mm x 3.7mm and a height of 6.6mm able to deliver a minimum stand-off of 1500V. Comments Keith Moore, Pickering’s CEO: “Because Pickering has all elements of relay design and manufacture in house we are able to respond quickly and effectively to custom requests such as this. In this instance, as so many previously, a special design leads to a new standard product, and so we now offer Series131 devices – industry’s smallest high voltage reed relays.”

Featuring a choice of 3, 5 or 12 volt coils, with optional internal diode, Series 131 reed relays are available in the 1 Form A (energize to make) SPST N.O. configuration, and can switch up to 0.7 amps, 10 watts. Devices are ideal for cable testers, mixed signal/ semiconductor testers, backplane testers, high voltage instrumentation, in-circuit

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test equipment and other HV applications. Pickering Electronics also manufactures various other miniature high voltage SIL/SIP reed relays.

Series 119 types deliver a standoff voltage performance of up to 3kV on a footprint of 15.1 x 3.7mm (1 Form A) and a profile of 6.6mm, while Series 104s offer the same high voltage performance but with a higher switching power of up to 25W and a higher coil resistance of up to 3000Ω in a package measuring 24.1 x 6.3 x 8.2mm (1 Form A).

Pickering Electronics was formed over 50 years ago to design and manufacture high quality reed relays, intended principally for use in Instrumentation and Test equipment. Today, Pickering’s Single-in-Line (SIL/SIP) range is by far the most developed in the relay industry with devices 25% the size of many competitors.

These small SIL/SIP reed relays are sold in high volumes to large ATE and Semiconductor companies throughout the world.

Power Integrations Releases Highly Integrated InnoSwitch3 Flyback Switcher IC for Automotive BEV and PHEV Applications

Power Integrations (Nasdaq: POWI), the leader in highvoltage integrated circuits for energy-efficient power conversion, today announced the production release of the InnoSwitch™3-AQ, an AECQ100-qualified flyback switcher with integrated 750 V MOSFET and secondary-side sensing.

The newly qualified device family targets automotive EV applications, such as traction inverter, OBC (onboard charger), EMS (energy management DC/DC bus converters) and BMS (battery management systems).

The InnoSwitch3-AQ uses Power Integrations’ high-speed FluxLink™ coupling to achieve ±3% accuracy for combined line and load regulation while eliminating both dedicated isolated transformer sensewindings and optocouplers.

FluxLink technology maintains output voltage regulation even under the transient stress test, which is particularly challenging for PSR-based implementations.

The integrated 750 V MOSFET meets stringent automotive de-

rating requirements, and an on-chip synchronous rectifier controller delivers above 90% efficiency at the nominal 400 VDC input voltage. Optimized InnoSwitch3-AQ designs achieve less than 10 mW no-load energy usage across the input voltage range. The InnoSwitch3-AQ family ICs are packaged in a surface-mount InSOP with 11 mm primary to secondary creepage, which exceeds the stringent requirements for high altitude (> 5000 m) isolation.

The DER-840Q reference design incorporating the newly released IC demonstrates startup, shutdown and efficient operation from 30 VDC to 550 VDC input, as well as fast transient response and a variety of safety and protection features.

Comments Power Integrations’ product marketing manager, Edward Ong: “The InnoSwitch3AQ represents the highest level of integration for a flyback controller, resulting in automotive power supplies with the lowest component count and smallest PCB area. The high

efficiency of the device across a wide load range means that it easily meets the automotive industry’s demanding thermal requirements.” Ong continued “FluxLink technology enables accurate performance and is highly reliable.”

InnoSwitch3-AQ ICs are available in the InSOP-24D package.

Devices are available now with prices starting at $2.75 in 10,000-piece quantities.

Power Integrations, Inc. is a leading innovator in semiconductor technologies for high-voltage power conversion.

The company’s products are key building blocks in the cleanpower ecosystem, enabling the generation of renewable energy as well as the efficient transmission and consumption of power in applications ranging from milliwatts to megawatts.

For more information please visit www.power.com.

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Drive controllers and filters minimise power losses in high speed machine tool spindles and turbo blowers

New drive controllers and motor filters for high frequency (HF) applications from KEB Automation are helping customers develop highly efficient machine concepts for turbo blowers and CNC machine tool spindles. The objective is to increase performance and protect the motor windings at output frequencies up to 2,000 Hz. “For industrial high speed applications, we have developed particularly powerful drive controllers, which our customers are using to operate all common high frequency spindles and high speed motor types,” explains Fabian Fischer, Team Leader Application Sales at KEB Automation.

The associated motor filter technology is an important part of the drive package. HF motor chokes, input/output filters and sinusoidal filters based on the latest core materials, ensure the

long operating life of CNC main spindles and high speed compressors.

The two main features are based on the winding protection and the stabilisation of the thermal balance of the HF motors. As Fischer states: “By using a specially designed HF motor choke, both the voltage level in the winding and the rate of voltage rise [dU/dt] can be reduced to below 500 V/µs.” Both are main factors that affect the lifetime of the insulation.

In addition, there is a noticeable reduction in the high frequency spectrum and therefore an improvement in the power loss balance in the motor. For very thermally-sensitive systems such as air bearing spindles or the electromagnetic bearing of the rotor in blower motors – both the current and the phase voltage must be reduced to the torque-forming fundamental frequency.

This requires the use of a sine filter.

Comparison – Switching frequency and Filter technique vs power losses

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By using a motor filter, the physical properties and therefore the equivalent circuit diagram of the motor is significantly changed due to the filter’s own inductance. As Fischer says: “In order to adjust the components in the system in such a way that control dynamics, torque and shaft power on the motor side are not significantly reduced, we start at two points: firstly, through our own filter development, production and EMC test environment, and secondly, through additional control routines in the drive controllers.”

Asynchronous motor – without and with different types of motor choke

Resonance-free operation For correct operation of the sine filter, the output circuit can be checked for the natural frequency and the filter-internal components can be dimensioned for resonance-free operation. For large series, it is possible to tune an applicationspecific sine filter to the operating point of the customer’s machine.

“Here, the power loss balance can be optimised in a way that would not be possible with any currently known modulation method and none

of the common power stage topologies on the inverter side,” explains Fischer.

In addition, the motor / sinusoidal filter output network can be adjusted in such a way that the power loss balance is improved by increasing the voltage at the motor terminals, respectively an increase in power at the motor shaft is achieved.

The COMBIVERT F6 and S6 drive controllers from KEB feature software notch filters that generate resonance-free modulation for all speedcontrolled operating modes, whether with or without an encoder.

Synchronous motor – with/without sine filter.

For more information on drive controllers and motor filter technologies from KEB, please visit www.keb.co.uk

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Thermal imaging to screen for elevated skin temperature

A thermal imaging camera can be an effective screening device for detecting individuals with an elevated skin temperature. This type of monitoring can provide useful information when used as a screening tool in high-traffic areas to help identify people with an elevated temperature compared to the general population. That individual can then be further screened using other body temperature measuring tools.

Although thermal imaging cameras are primarily designed for industrial and night vision uses, public health organizations have used FLIR cameras around the world at airports, seaports, office buildings and other mass gathering areas to provide rapid, efficient screening in high-traffic areas. FLIR thermal cameras are particularly well suited to this because they can provide a temperature reading of a person’s face in a matter of seconds.

The FLIR Systems product line-up includes a wide variety of thermal imaging cameras that can be used for detecting people with elevated skin temperature. FLIR A320 Tempscreen, however, was especially developed for thermal screening in high-traffic applications.

How thermal imaging works A thermal imaging camera produces infrared images or heat pictures that display small temperature differences. This allows thermal cameras to create and continually update a visual heat map of skin temperatures. In addition, FLIR thermal imaging cameras are sensitive devices capable of measuring small temperature differences.

Many of the FLIR thermal cameras that are appropriate for measuring skin temperatures also offer built-in functions like visual and sound alarms that can be set to go off when a certain temperature threshold is exceeded. The operator can then instantly decide whether the subject needs to be referred for further screening with additional temperature measurement tools.

As the thermal imaging camera produces images in nearrealtime, the total evaluation process takes mere moments, making thermal imaging technology very useful for rapidly screening large numbers of people.

Measuring the temperature of the human body It’s true that a person’s general

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skin temperature is typically not equal to the person’s core temperature. That doesn’t detract from the use of thermal cameras to detect elevated skin temperatures, however.

Thermal cameras are useful in this role because the goal is not to measure absolute skin temperature, but to differentiate people who have an elevated skin temperature compared to others while also considering the environmental conditions of the location.

Some FLIR camera models offer an elevated skin temperature screening mode that is helpful in comparing the person being screened against the temperature of other people previously screened. When in Screening mode, the operator can save ten thermal images of faces that the camera automatically averages as a reference.

Sound and color alarms All areas on the subject’s face that are hotter than a predefined temperature value can be displayed as a designated color on the thermal image. This built-in alarm allows users to make an immediate decision regarding whether the subject may need further screening with additional screening tools. In addition, some FLIR cameras are equipped with an audible alarm that can be activated to sound if the detected temperature exceeds a predefined value.

A small investment to enable high-traffic screening Airports all over the world are using FLIR cameras and have applied this methodology to screen people entering and leaving the country. It is a quick, non-contact method that is safe for both the camera operator and the people being screened.

To Learn More visit: www.flir.com/ebt

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ExpoPharma’s PAT analytical sensor evaluation platform includes Mclennan supplied motion and machine control sub-system

When ExpoPharma designed a new Process Analytical Technology (PAT) powderstream conditioning chute – a full-scale development platform for characterising analytical sensors for use in continuous pharma or similar manufacturing processes – they turned to Mclennan for a standalone Ethernet-based three-axis micropositioning subsystem, complete with planetary gear units, pre-programmed HMI and a temperature controller.

ExpoPharma’s Spectrum Multi-Probe Chute allows multiple PAT technologies to be simultaneously evaluated as a means to economise API software related use and speed production development by providing optimum interfacing for several sensor types that economically gather highquality data in sequence during the same process stream. The various sensors used provide precise information from the powder stream including chemical structure, identity, particle size, contamination etc.

The three positioning axes, supplied from Mclennan’s distribution partner JVL, are MIS232 series integrated microstepping motors – the novel motion control solution that combines motor, drive, controller and comms in a single package. Fitted with Mclennan’s own range of IP57-M01, 10:1 ratio planetary gear units to provide high resolution angular positioning, each drive micropositions special ‘wheels or flipper-shaped’ end-effectors that are designed to collect sample material from the powder stream and present it to the sensor being assessed through a probe window. These sensors are typically particle image analysers, Raman spectroscopy probes and a near infrared (NIR) spectrometers.

For these diverse and complex analytical sensor types, the characterisation process necessitates its corresponding and different shaped endeffector to manage the sample collection (and for some a PAT probe cleaning regime) with quite different positioning sequences in terms of angular

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travel, speed, acceleration and deceleration.

Mclennan worked engineerto-engineer with ExpoPharma from the early stages of product development. Through its system integration capability and experience the ‘distributed’ integrated stepper motor solution was recommended to provide cost and functional advantages, and to maintain the maximum portability requirements specified for the Multi-Probe Chute. The compact and easily installed stand-alone solution reduced ExpoPharma’s product development burden and also required much less installation effort through less cabling which furthermore simplified commissioning.

And most importantly, JVL’s integrated motor technology is proven to be inherently better protected against electrical noise, which can be a significant problem with traditional ‘centralised’ panel-mounted motion systems where power, signal and communications cabling is typically longer and noise-prone - an especially

important requirement for the sensitive sensor equipment under evaluation on the platform.

Electrical installation for the JVL integrated microstepping motors, which are also available as servomotor variants, was simply achieved through onboard M12 connectors for drive power and the daisy-chained Ethernet connection to the HMI. Whilst an ‘open-loop’ microstepping motor solution was used, to boost positional accuracy and to ensure that axis position is always known on power-up (with no homing procedure required), optional absolute encoders were included and conveniently wired directly to the HMI from another M12 connector on the integrated motor. Mclennan also provided the wiring for the temperature controller – each end effector includes a heater and temperature sensor that is used to reduce the possibility of powder material sticking as well as aid the cleaning of PAT probe windows.

Mclennan’s scope of supply covered the programming and commissioning of the complete sub- system for the Multi-Probe Chute with the three motor axes part of a Modbus TCP protocol network segment which also

included an MT400 series HMI from Kinco and an EMKO PIDQuadro temperature controller. The three motion axes, pre-programmed for comms interfacing and configuration, are slaved to the HMI which is assigned as the sub-network master. Using Kinco’s HMIware configuration software, Mclennan programmed a series of graphical screens that display or assign values for the positioning axes. There is also provision for manually positioning each axis with jogging and other functions to help develop specific motion sequences used during sensor evaluation. Also slaved to the HMI through the Modbus TCP network segment are the temperature controller’s display, level setting and alarm functions for each of the three end-effector mechanisms. Thus, through the HMI, each axis with its different positional and dynamic motion requirements, and corresponding end-effector temperature settings, are all easily selected, interrogated or diagnosed. As part of its system commissioning service, Mclennan supplied a complete installation and programming manual and also carried out site visits for system evaluation and acceptance testing. With the evaluation of the various analytical sensor probes

managed by ExpoPharma as a further Ethernet network segment, the complete machine combines positioning and machine control capability from Mclennan with ExpoPharma’s considerable expertise as a leading manufacturer of equipment interfaces for process based analytical sensors.

ExpoPharma are the pharmaceutical manufacturing division of expo Technologies – a global leader in engineered solutions for electrical protection by purge and pressurisation.

Product information on the Spectrum Multi-Probe Chute can be found here.

Mclennan combines its own design and production capability with major motion control equipment supplier distribution partnerships where individual components or complete servo motor and/or stepper motor based motion systems including positioning mechanics and machine controls or automation software can be supplied and fully supported.

For further information on Mclennan’s comprehensive range of motion control products and system integration capability, visit www.mclennan.co.uk, email sales@mclennan.co.uk or call +44 (0) 1252 531444.

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