Worldwide Engineering Magazine - October Issue

October Issue Fuzzy Logic raises millions to put robots in the hands of operators

3D Printing for low volume production: So what?

Mills CNC chooses laser triangulation sensor from Micro-Epsilon

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Pages 16-17

Pages 38-39

worldwide-engineering.com

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Delta Introduces Ultron HPH Gen. 20-40kVA UPS to the Market

Striatus Arched 3D Concrete Printing

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Fortress Technology: Made to order

Bunting Magnetic Separators for CRS Overseas

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Mills CNC chooses laser triangulation sensor

ABB helps make fashion industry more sustainable

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Real-world torque measurements enable electric car competition to go virtual

From the smallest housed camera with C-mount over 10GigE to AI

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MVTec launches MERLIC 5 and adds deep learning to easy-to-use software MVTec Software GmbH, a leading international provider of machine vision software, will release MERLIC 5, the new version of its allin-one machine vision software, on October 7, 2021.

The easy-to-use software enables complete machine vision applications to be created quickly and easily without having to write a single line of code. The highlights of the new MERLIC 5 release include modern deep learning features and improved camera handling. Along with the latest release, MVTec also offers a new licensing model for maximum flexibility.

It allows customers to choose whatever best meets their requirements from a range of different packages and price categories. “With MERLIC 5, we offer high-quality yet easy-to-use machine vision software for all conceivable applications and industrial sectors. It allows our customers to conveniently integrate a machine vision package into their process environment and access innovative deep learning technologies,” explains Christoph Wagner, Technical Product Manager for MERLIC at MVTec. Robust anomaly detection with deep learning MERLIC 5 contains new and optimized features that further increase usability, robustness, and the field of possible applications.

Among these features is included the improved camera handling using the Image Source Manager (ISM), which completely separates the image acquisition source from the image processing part. As a result, machine vision applications can be easily copied and run between different systems without adjusting the camera settings.

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The graphical user interface allows the image sources to be comfortably managed and configured.

In addition, the release of the new version means that MVTec’s latest deep learning functions are now also available in the MERLIC 5 all-inone machine vision software. It’s now easier than ever for users to exploit the benefits of this technology directly in their machine vision applications.

appearance, as in the case of natural products. The models can be trained using, among other things, the free Deep Learning Tool from MVTec and then imported into MERLIC 5.

The MERLIC 5 launch will be accompanied in its early phase by a campaign to generate curiosity about its deep learning features and also to help users understand them better.

More flexible use

Among other things, MERLIC 5 includes deep-learning-based anomaly detection, which provides important added value, particularly in applications where few or no “bad images” are available. Just a small number of “good images” is sufficient for training so that all types of defects can then be located reliably and precisely. The training process usually takes only a few seconds, meaning that users can perform many iterations to fine-tune their applications within a short period of time. The second deep learning feature integrated into MERLIC 5 is the “classify image” tool.

This tool can be used to assign images to trained classes based on deep learning algorithms. The technology is particularly suitable for classifying defects or objects with highly variable shapes and

Machine vision applications are now being used in a growing number of industries and sectors, resulting in an expansion of the fields of application and of the accompanying demands on the machine vision software. In concrete terms, this means that a wide range of image acquisition sources and technical features are required in practice.

MERLIC 5’s new package-based licensing model meets these very requirements. The packages are designed in such a way that users can choose the exact range of functions that they actually need for their application. “With our new licensing model, we are increasing MERLIC’s flexibility, which in turn expands its possible field of applications,” explains Christoph Wagner.

Anritsu announces 5G Standalone Network Service Assurance in the Public Cloud on AWS Anritsu is pleased to announce the deployment of its Mobile Network Service Assurance solutions on the public cloud with AWS. Following on from a recent press release where Anritsu announced two Tier-1 5G Standalone Service Assurance wins, Anritsu, in partnership with its Mobile Network customers and with AWS, introduces a solution to fully deploy the Service Assurance systems in the public cloud.

Perceptions of public cloud for telecoms networks have seen a significant shift over the last 12-18 months, with many operators assessing how to move network functions from a private cloud to a hybrid or public cloud, whilst also taking into consideration privacy, security, costs, and control.

Visibility via Service Assurance solutions is vital to assure the quality of network services and achieve a return on the significant investments in 5G Standalone.

Service Assurance needs to sit alongside those network functions in the same cloud, working to understand, monitor, assure and control the network functions and services. With the complexity and dynamicity of today’s and tomorrow’s networks, Service Assurance, Automation, AI and Analytics are pivotal to the rollout of new services, network slices, MEC (multi-access edge computing), and customer experience.

to support our customers, with 5G on the horizon at that time,” said Ralf Iding, CEO of Anritsu Service Assurance.

“The strategic investments in our business, starting in 2016 with virtualization, showed how we needed to adapt our solution

“This 5G Standalone technology is the most exciting moment in telecoms since the introduction of data services for mobile phones.

We’ve been waiting for 5G’s ultralow latency, hyper-density, superspeed cloudified networks for many years and 2021 is the year this anticipation becomes a reality,” said Nicolas Timothee, Director of Business Strategy at Anritsu Service Assurance.

“We have transformed our business to match our customers’ needs with agile development and delivery, and we have moved our Service Assurance portfolio to work in the cloud of our trusted partners and new customers. We continue to invest to innovate and help our customers realize their investments in 5G Standalone and continue to partner with them on this inspiring journey to the public cloud.”

“We have initiated the first deployments of 5G Standalone and are working closely with our customers and partners to make sure they are ready to assure their investment, services, and customers in the public, private and hybrid cloud. Deploying our Service Assurance solutions on AWS brings considerable flexibility, speed, scalability, and cost efficiency for operators as they consider their options on their 5G Standalone journey.”

Anritsu looks forward to working with its current customers, new customers, and partners to expand the Service Assurance possibilities of 5G Standalone, cloudification, and digital transformation.

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Fuzzy Logic raises €2.5 million to put robots in the hands of operators The Franco-American start-up Fuzzy Logic announces a €2.5 million seed round of financing from two European DeepTech funds: 42CAP, an industryspecialized German fund based in Munich, and Karista (via the Paris Region Venture Fund), an earlystage VC firm based in Paris.

Fuzzy Logic, which originated in the French start-up ecosystem (Agoranov and Wilco), is developing an “all- in-one” software platform that dramatically simplifies every step of robotization, from robotic cell design to daily reprogramming in the factory by operators. It reproduces a virtual environment in which the robot in the factory can be controlled “on the fly” and as simply as a video game.

Fuzzy StudioTM (desktop application) and Fuzzy RTOSTM

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(embedded software) are nocode platforms, allowing users to control any make of industrial robot, without the need for training or complex programming. Nonroboticist users can intuitively design robotic cells and production operators increase their scope of activity: a clearer and simpler software solution for interacting with robots and “crushing” their complexity. It’s the new standard for flexible automation.

Robotics in the service of operators The platform is attracting strong interest from large companies, especially for applications with many different part types to be programmed or which have demanding quality requirements.

But as well as current users of industrial robots, Fuzzy Logic intends to open up a market that is still in its

infancy, that of small and mediumsized industrial companies.

The platform removes the complexities of robotic integration and eliminates the need for robotics expertise throughout the service life, two obstacles that until now have often been prohibitive barriers for SMEs and SMBs. Ryan Lober and Antoine Hoarau, respectively CEO and CTO, co-founders of Fuzzy Logic, state: “We help SMEs to power up their competitiveness and autonomy, by making robots adapt to them - not the other way around. This round of fundraising will allow us to strengthen our R&D teams and deploy our vision of intuitive and flexible robotics among client ambassadors throughout Europe.”

“Fuzzy Logic will be one of the key enablers of the flexible production

paradigm changing the industry as we know it today. We were deeply impressed by Ryan Lober’s and Antoine Hoarau’s deep knowledge of the industrial robotics space, as well as the powerful solution they have built. They were able demonstrate everything we seek in entrepreneurs and bring their technology into the hands of industry leaders in real- world use cases. We are more than excited for what lies ahead and are proud to back the team on this journey.” declared Julian von Fischer from 42CAP. “Fuzzy Logic arrives on the market with a perfect timing given the mass-adoption of industrial robotics and underlying applications. Yet projects remain complex, pricy, and lengthy to implement. We immediately shared Ryan Lober and Antoine Hoarau ’s

vision: make robotics accessible for everyone, not only for experts, and revolutionize the way people interact and use industrial robotics.

In addition, we have identified a stellar team of entrepreneurs with impressive tech expertise around software and robotics. We are very proud to back them in this new phase” commented Benjamin Zerbib, Investment Director and Yvan-Michel Ehkirch, Managing Partner at Karista.

company has accumulated more than 600,000 euros in preseed financing. The current round of fundraising will help them strengthen the technical team in order to deploy to new customers, “Platform Ambassadors”, throughout Europe.

The Fuzzy Logic mission: unlock flexible production for any manufacturer, by making the robot a simple tool - accessible to any operator.

A scalable software platform www.flr.io Fuzzy StudioTM and Fuzzy RTOSTM are currently being deployed at customers in France and Germany, who were specifically chosen for their flexibility and precision requirements. Thanks to awards and support from the French public investment bank, Bpifrance, as well as the European Union, the

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Delta Introduces Ultron HPH Gen. 2 20-40kVA UPS to the Market Delta, a global leader in power and thermal management solutions, today announced the launch of its Ultron HPH series uninterruptible power supplies to the market. The HPH Series provides high AC-AC efficiency of over 96% with an ECO mode to 99% resulting in marked energy cost savings. Its slim design offers an extra compact footprint (40kW / 0.15m2) for added space savings. The user-friendly 5” color touch screen enables easy local UPS management to monitor UPS status at a glance. The Ultron HPH series is the ideal solution for various small and medium-sized data centers and critical power backups.

energy consumption and operating expenses so users can meet requirements for sustainability targets without compromising availability. In addition, the HPH Series provides a wider battery configuration choice (30-46pcs) to optimize on battery installation cost.

Easy Deployment and Maintenance with Compact Design Advanced technology and thermal treatment achieves the leading power density without sacrificing output power. It promises a unity output factor at 40 degrees, while offering the smallest footprint. The all manual protection device is built into a single cabinet.

Quicker ROI High Manageability and Flexibility The Ultron HPH Series provides a highly efficient UPS in its class with over 96% efficiency. It helps reduce

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The Ultron HPH Series comes with a user-friendly 5” color touch

screen that enables easy local UPS management. In addition, it provides a build-in 15A charger for a long backup solution without additional cost. It also provides a key component replacement warning countdown to remind users of component expiration dates. For customers that install the UPS in harsh environments, the HPH Series also provides an optional IP42 kit.

The Ultron HPH Gen 1 Series has won numerous industry awards worldwide since its release in 2013.

The Ultron HPH Gen 2 Series continues in this advanced design approach by providing improved energy efficiency of over 96%, and combining reliable protection and cost-effective power with a compact footprint and high performance.

Fluke Process Instruments debuts new Datapaq® furnace tracking systems for demanding heat treat applications Fluke Process Instruments, a global leader in infrared imaging and thermal profiling solutions for industrial applications, releases the latest Datapaq® Furnace Tracker System – complete with the TP6 data logger, thermal barriers and intuitive software.

The Datapaq Furnace Tracker System is designed to be used repeatedly, in-process in the most hostile manufacturing environments, providing accurate and reliable through-process temperature surveys. Each system can help users improve process performance, decrease downtime, reduce temperature uniformity survey (TUS) reporting times and more The first component of the system is the Datapaq® TP6 Data Logger, which can withstand the longest, most- demanding operating conditions. The Datapaq TP6 features a 316-grade, stainless-steel case and a IP67 rating, making it water resistant. This datalogger is available with either 10 or 20 thermocouple inputs and can be specified for use with base or noble metal thermocouples.

Datapaq InsightTM Software which transforms raw data into actionable analytics, clear user interface, context sensitive help screens and assistance options for infrequent users. Three software options are available and the complimentary Datapaq Insight for mobile is offered for free. This mobile application allows users to reset, download and analyze right on the factory floor and check thermocouple operation before a thermal profile run. The advanced TUS software also provides full temperature profiles and traceable reports for industry regulations like AMS2750 and CQi-9.

“The latest Datapaq Furnace Tracker System offers customers a robust solution that is designed for harsh environments like quenching and high temperatures,” says Rob Hornsblow, Product Manager at Fluke Process Instruments.

“Whether users are working with raw materials or finished products, measuring product and atmosphere temperatures

throughout the furnace is critical in ensuring both product quality and process efficiency. Datapaq continues to provide real-time, repeatable temperature data that can help improve performance and system accuracy, decrease downtime and much more.”

“We’ve really focused on what customers wanted in when engineering this new system and we are excited to introduce the patented quenchable thermal barriers, an IP67 rated data logger and the Insight for Mobile application that will allows users to check thermocouple operation before each run”.

The Datapaq Furnace Tracker System – including the new TP6 Data Logger and thermal barrier models – are now available. To learn more, or to speak with a specialist in your region, visit: www.lp.flukeprocessinstruments. com/datapaq-thermal-profilingsolutions/pr/

The latest thermal barrier models are ideal for high-temperature heat treat processes and have been designed to provide maximum thermal protection – including applications such as vacuum and controlled atmosphere, slab reheat and solution aging, among others.

The new patented quenchable thermal barriers eliminate the need for fiber blankets. Fluke Process Instruments also offers bespoke design services to create a solution that specifically fits a customer’s process.

To complete the system, Fluke Process Instruments offers the 9

Power transmission torque measurement: NCTE’s inline shaft mounted torque sensors are available from Ixthus The German manufacturer NCTE develops and manufactures inline shaft sensors that measure torque and other forces such as shear and bending moment.

Available with full support in the UK from Ixthus Instrumentation, these directly mounted sensors are especially practical for dynamic, high precision load measurement of power transmission and power take-off (PTO) shafts where realtime data acquisition provides not just the safe operation of connected machinery but also the ability to optimise efficiency and operation for the entire drive’s function.

NCTE sensors are designed to form part of the drive chain as a ‘plug and play’ component complete with integrated signal conditioning

and with no other components required. With several sized model options available torque measurement, from a zero reference, can range from 1 to 10,000 Nm. NCTE names its measurement technology ‘magnetostriction’ which is based on the magnetostrictive measurement principle. Simply put, this is a physical process where the length of a body changes under the influence of an external magnetic field. By reversing this principle NCTE’s sensors employ encoded magnetic fields and, as integral parts of the shaft, measure the miniscule dimensional changes directly induced on the driven shaft as torque or other physical forces.

This contactless, wear free

and low maintenance technology tracks these changes in real time with excellent stability over long periods of time. The sensors employ at least two opposed magnetic fields to allow error free use where external magnetic fields such as EMC interference are present – or where mechanical influences such as strong vibration and shock conditions cause shaft distortions.

With standard protection class options of IP50 and IP65, the sensors can operate in high humidity, water, oils, and aggressive liquids used, for instance, in washdown situations.

The sensors have a standard operating temperature range of -40 °C to +85 °C, a torque measurement accuracy in the region of +/- 0.5% and a shaft speeds range from 2,500 rpm for the larger sized models to 10,000 rpm for the smaller. Output frequency is 2,500 Hz with output options via a single electrical connector including 0 - 10 V, 4...20 mA, CANbus and USB; the USB interfaced models are supplied with free of charge PC software that enables direct data display via a GUI with the possibility to export data for detailed analysis. NCTE’s custom design service is offered across all model ranges to facilitate use in extreme environments.

NCTE applies its torque measurement technology across all areas of industry and research from controlling the power of e-bikes to preventative maintenance on wind turbines, and from precision torque measurement for motorsports to safety monitoring on robotic and automated medical equipment.

A particular area that demonstrates the technology and applied use of NCTE’s PTO torque sensors is that of mobile agricultural machinery where power and torque and/

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or bending moment and shear measurement can be optimised.

Easily integrated between the PTO shaft of tractor and connected machinery such as powered harrows, spreaders, bailing presses etc., the sensors help to maintain the highest process efficiency and provide the basis for safe operation, maximum reliability, and preventative maintenance to avoid costly failures and repairs. In this application area NCTE’s 7000 series torque sensors can measure bi-directional torque in the region of 3000 to 5000 Nm at speeds up to 3600 rpm. The 7000 series can be simply flange mounted or supplied with a wide choice of optional geared shaft and bush adapter that suit most common tractor, harvester and other farm machinery PTOs. Test bench mounts

are also available for research tasks. As a supplier from component level to complete instrumentation systems and with knowledgeable technical staff on hand to assist with measurement solutions, Ixthus Instrumentation offers a complete technical sales and support service for NCTE’s wide range of torque sensors and also has distribution partnerships with several global sensor technology leaders for force, torque and vibration measurement.

For further information please call +44 (0) 1327 353437, email info@ixthus.co.uk or visit www.ixthus.co.uk.

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Emerson marks 75 Years of innovation in precision cleaning and welding technologies Branson combines breadth of technologies and a problemsolving approach to deliver advanced solutions to automotive, medical, electronics industries worldwide Emerson: Emerson (NYSE: EMR) celebrates the 75th anniversary of its BransonTM brand, a name that has become synonymous with ultrasonic technologies for plastics and metal welding, and precision cleaning. The Branson portfolio has led the industry with expanded offerings beyond ultrasonics, developing nine other material joining technologies including laser, vibration and infrared welding.

Emerson marked the anniversary at its new $49 million global headquarters for welding and precision cleaning technologies that opened in January. The new facility bolsters Emerson’s continued innovation in advanced design, engineering and joining technologies that support such complex and fast-growing industries as medical devices, existing and new bio-based plastics packaging, electric cars and next-generation batteries.

“We are extremely proud of our history and how we revolutionized the use of ultrasonics in so many remarkable ways,” said Vernon Murray, president of Emerson’s assembly technologies business.

“Our goal has always been to deliver proven performance, unequaled expertise, and the broadest technology portfolio for material joining and precision cleaning applications. We look forward to continuing our stewardship in the field as we make advancements that benefit everyone.”

The Branson brand traces its history to Norman G. Branson, a research engineer who founded a company in Danbury, Connecticut, in 1946 12

to harness the power of highfrequency ultrasonic energy for cleaning and degreasing applications as well as non destructive testing and gauging.

But it was ultrasonic welding — developed in 1963 at Branson Sonics and Materials, which was acquired

by Emerson Electric Co. (Emerson) in 1984 — that represented the real breakthrough for the company and for manufacturing. It set in motion a monumental change in the way plastics, and later metals, were joined.

Since its beginning, Branson has been driven by the spirit of innovation, and today ultrasonics is just one of many cleaning and joining technologies offered by Emerson’s Branson portfolio.

Other welding methods include spin and vibration welding, staking and swaging, and a new patent-pending “dynamic mode” of ultrasonic welding that can automatically adjust itself to part-to-part variabilities and unique materials. “Clean welding” approaches, such as Contoured Laser Technology, Clean Vibration Technology and Contoured Infrared Technology, are being adopted with ever greater frequency.

Continuing the Commitment Given this depth of technical resources, Emerson application engineers are able to utilize a process-neutral approach to help manufacturers evaluate, select, implement, and optimize the right joining solution, regardless of the application or complexity.

This high level of customer support is enhanced by the technological capabilities available at the new 146,000-square-foot Branson headquarters. The facility includes an expanded research and development lab, increased manufacturing space, a dedicated training workspace for seminars, and training classes, technical services and other resources.

The 75th anniversary represents a milestone that Emerson will recognize throughout the next several months as the company continues its path of inventiveness, delivering advanced Branson products to solve critical industry challenges.

For more information about Emerson’s welding, assembly and cleaning solutions, visit: www.emerson.com

Ultrasonic Flow Meter Ideal for Ultra-Pure Water Applications Designed primarily for ultra-pure water dispensing applications requiring a high degree of cleanliness, clean bore flow measurement devices such as Titan Enterprises’ Metraflow® ultrasonic flowmeter, offer the ideal solution.

manufacturers use UPW in the manufacture of circuit boards and as a cleaning/etching agent. It is imperative to preserve the purity of process fluids as contaminants or particles can lodge on circuits and cause microchip failures.

Ultra-pure water - water that has been purified to very strict specifications – is an important component for industries across specialist markets where impurities can cause product contamination or impact process efficiency.

In the power industry, UPW is typically used as a source to make steam to drive turbine combustors and to steam boilers. The higher the boiler pressure, the higher the purity of water required.

Ultra-pure water (UPW) systems, typically used in production and cleaning processes within the pharmaceutical, medical, semiconductor and power industries, require a selection of technologies and equipment that preserve the purity of materials. It is crucial that any flow measurement device used in UPW systems can cope with low flow rates and are constructed from ultra-pure materials that cannot contaminate the liquids being measured.

Maintaining hygienic, sterile and sanitary conditions within these processes is critical.

Semiconductor and microelectronic device

Pharmaceutical and biotechnology facilities use UPW as a cleaning agent and a diluent for multipledose injections as well as an ingredient in products. Water free of endotoxins, microbes and viruses is essential in these applications and others such as inhalation therapy products, internal irrigation therapy products and bulk preparation of medicines.

Even in the food and beverage industries, water purity plays an important role in production, with some beverages, such as beer, requiring specific mineral compositions for the water used.

The Metraflow® uses Titan’s patented ultrasonic time of flight

technology to accurately measure liquid travelling through the clear, single, clean bore measurement flow tube constructed from high performance Perfluoroalkoxy Alkane (PFA) polymer.

Neil Hannay, Senior R&D Engineer with Titan Enterprises, says: “Ultrapure water can become easily contaminated by atmosphere passing through tiny leaks or diffusing through thin wall polymer tubing used for flow measurement.

PFA polymer was chosen specifically as an advanced tubing option for the Metraflow® as it offers excellent chemical inertness, is able to withstand damage by dangerous contaminants, prevents accumulation of particles and has an ultra-high grade of purity.”

Titan’s Metraflow® is non-intrusive with no internal moving parts, designed to precisely monitor process flows at temperatures from 10ºC to 60ºC (140ºF) and pressures up to 27 bar. In addition, this noninvasive single tube ultrasonic flow meter gives a wide operating flow range with an accuracy of +/-0.5% FSD and repeatability across flow ranges from 20 to 5000 ml/min.

Neil Hannay adds: “Whilst Metraflow® is the perfect pure water flow meter, the ultrasonic measuring device is also ideal for the flow measurement of challenging liquids and fluids, its wide flow range and PFA (FDA approved) tubing making it highly suited to aggressive chemical flow measurement.”

For further information on the Metraflow® ultrasonic flowmeter please visit www.metraflowmeter.com.

To discuss an optimised flow measurement device for your pure liquid dispensing application please contact Titan Enterprises on +44 (0)1935 812790 or email sales@flowmeters.co.uk.

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Fabric Group successfully commercializing micro additive manufactoring Fabrica Group (formerly Nanofabrica) has just returned from a highly successful time at the RAPID + TCT event in Chicago, IL, USA, where it was for the first time able to discuss its Micro AM technology with manufacturers face-to-face as COVID-19 travel restrictions are relaxed.

Talking with Avi Cohen, Executive Vice President for Sales at Fabrica Group,

We have learnt that the company is at an exciting point in its development, and is now successfully selling its technology to companies that are responding to the growing demand for miniaturisation of parts and components — whether this has been driven by cost saving requirements, the need for increased functionality within smaller footprint products, or to help with such issues as lightweighting. Before the introduction of the Fabrica 2.0 Micro AM System, the inability of traditional AM processes to attain micron level tolerances repeatably meant that manufacturers had to rely on conventional production processes for miniature parts.

small, or medium volume runs are left with limited options but can now use the Fabrica 2.0 to manufacture smaller numbers of parts cost-effectively.

AM requires no tooling, and therefore provides an agile and attractive alternative to legacy production processes when it comes to lower volume runs. In addition, AM is agnostic to geometric complexity, which means that it stimulates innovation as it opens up the production of parts and components impossible via traditional manufacturing technologies.

Beyond direct manufacturing per se, Fabrica Group has devoted significant time and resource to the production of direct rapid soft tooling (DRST). 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. Fabrica Group’s AM process reaches micron-level resolution which means high surface finish, and the requirements of tooling can be achieved without the time-consuming and costly need to cut steel. Today, Fabrica Group is well positioned to lead the market in the production of DRST for micro injection.

The ability to now really think of volume production without the necessity to fabricate timely and expensive hard steel tools for injection molding is tantalising for many industry players. The creation of multiple, inexpensive, and rapid to create DRSTs means that true mass manufacturing is within grasp via Fabrica Group’s micro AM technology.

Avi Cohen, Executive Vice President for Sales at Fabrica Group also added that it is clear that the future roadmap for Fabrica Group and Micro AM is booming, and means the ability to create geometrically complex and innovative products with micron tolerances in a timely fashion and cost-effectively in volumes of 1 to 1 million plus. This is truly ground-breaking and disruptive for any companies that are manufacturing at the micro level.

Traditional micro molding is ideally suited to extremely high volume runs, due in no small part to the requirement for extremely costly and time-consuming micro tools.

The expense associated with micro tooling means that only when parts are mass produced in the millions will it be cost-effective. OEMs requiring prototype, 15

3D Printing for low volume production: So what?

The drivers behind process change in manufacturing

by Nick Allen, MD, 3DPRINTUK For anyone that works in engineering or manufacturing, there has probably been at least one time (probably more) when they have come across a headline about 3D printing, or maybe even seen a specific application that everyone is making a fuss about, and the first reaction is, ‘So what?

That is irrelevant to me.’

Let’s face it, the OEMs operating at the top of their respective supply chains tend to monopolise headlines with 3D printing for serial production applications. This tends to contribute to a pervasive assumption that industrial additive manufacturing (AM) technologies are some serious toys for the big

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boys, while desktop 3D printers can service product development activities across a broader spectrum of companies.

Is it time for a rethink? Almost certainly.

One of the key reasons for this article is to push back on this view somewhat, and consider the entire supply chain and how it can benefit from industrial 3D printing.

The OEMs are vital of course, but it is also important to understand that the supply chains for most sectors comprise a wide range of small and medium sized enterprises (SMEs) that collectively employ 3-4 times the number of OEM personnel. It goes without saying, then, that these organisations -

large, small and anywhere in between — are interdependent.

For this reason alone (although there are others) AM should not just be considered the preserve of the larger companies, rather, consider how SMEs can embrace AM to establish and/or maintain a competitive advantage in an ever-evolving and more distributed economy. Some are, but most aren’t. Yet. There is some evidence that the 3D printing / AM activities driven

by OEMs do filter down through supply chains, but for SMEs, new technology/process adoption is not easy or straightforward. Today, awareness of 3D printing has increased significantly as more developments and advances are

being made with the technologies, materials, and, most notably, the increasing number and type of applications. These advances, in combination, are driving the relevance of 3D printing for an increasing number of companies particularly with low volume production applications.

So, is it relevant for YOU? Typically, SMEs struggle when it comes to embracing — let alone adopting — 3D printing to actually make a difference. This largely comes down to resources, or a lack thereof. The biggest resource requirement is, at least initially, time, but the financial implications of new technology adoption are significant too. A dedicated investment of both is definitely required.

A reliable industrial 3D printing service provider with significant experience can help bridge this gap to realize the relevance and the real benefits of the technology.

Essentially, there are three primary business drivers for incorporating 3D printing into an organisation.

Simply put, these are: - To save time (get to market faster) - To reduce costs - To improve performance (of products / parts).

There is now a wealth of documented evidence that supports the benefits of 3D printing for product development processes and faster prototyping cycles, and there are many, many case studies that illustrate the advantages of rapid prototyping for new product development.

At the concept development stage of any new product, designers

understand the inherent value of holding a physical representation of their design in their hands. For consumer products, interacting with that product physically is essential and getting market feedback even more so. Similarly, with industrial products and components, the need to assess form, fit, and function is also vital.

Early prototypes help designers to quickly and more easily identify issues with a design, and correct them. The more iterations of a prototype through physical interaction, the more successful the design, and, significantly, the design for manufacturability (DfM).

This is also true when re-designing existing products with the benefits of new technology and tools. Moreover, the re-design can be optimised in numerous ways, most notably consolidating the number of parts involved and reducing assemblies.

Prototyping was the original application of 3D printing technologies and remains the dominant application across most vertical sectors today. However, there are increasing numbers of manufacturing applications of the technologies that add value to industrial businesses.

One of the most under-rated applications of 3D printing remains the manufacture of customized jigs and fixtures for holding specific parts during production.

The ability to design and print these items on-demand are dramatically improving existing manufacturing processes for many smaller manufacturing companies — saving them a lot of time and money. This is often overlooked, but can’t be over emphasised!

Another area where 3D printing often goes unnoticed is when 17

it is integrated into existing manufacturing workflows to improve tooling and vacuum casting operations. Again, it speeds up the overall process compared with conventional techniques and can reduce costs significantly.

Which brings us to end use parts.

The major gain in this respect is the elimination of the significant time and cost associated with tooling operations. This is why it is worth investigating the technology for your business to see if it is relevant to you. Identifying relevant applications is the key, also bearing in mind process type and the subsequent costs per part. This is where the homework comes in. You know your applications best — and you will have an existing status quo.

The question is, is that enough? Or can you do more, better, and at reduced costs?

If any or all of the points highlighted above resonate with your business goals, then the time really is now to investigate relevant applications of 3D printing and AM for your business while remaining open minded.

Start with a fact-finding mission.

The operative word here being “fact.” It is possible, maybe even likely, that you will have preconceived ideas about 3D printing and AM: impressions gleaned from media headlines and stories and/or perceptions based on the positive or negative experience of others. Considering this technology set within your business context may challenge these notions — and indeed, they should.

The emphasis here should be driven by your business: identifying application(s) and determining if integrating 3D printing into your workflow brings commercial benefits that improve the bottom line of the business.

If you do arrive at the conclusion that AM can provide a valuable solution for your business there is then a further decision to be made.

Do you outsource the capability 18

or bring the technology in house?

This needs to be addressed with the entire process in mind from concept generation / design (or redesign), through to the desired end result — whether for prototyping / tooling / manufacturing or production applications.

There are myriad options for both routes and both will be constrained by budgets. There is also an argument to consider both concurrently. A major consideration in this respect is the volumes of product involved. Building a relationship with an external supplier, with the skillset required, can be of benefit and eliminates the capital investment of bringing the technology in house and the time and expense involved in hiring someone with the necessary skills or upskilling someone in your workforce.

However, professional development is no bad thing; enhancing the skillset of a current member of staff who can undertake AM in-house can also be a great incentive. There are now training providers (vendors and independent) as well as national bodies that can provide a framework for apprenticeships and other qualifications with AM. For any company looking to engage with 3D printing within their business, the approach has to be holistic both in considering the business needs and how to integrate the technology.

Working with a trusted and experienced 3D printing service provider can present the best possible solution in terms of achieving business goals without the headaches of new infrastructure.

Striatus An arched 3D-concrete-printed masonry bridge

A project by the Block Research Group (BRG) at ETH Zurich and Zaha Hadid Architects Computation and Design Group (ZHACODE), in collaboration with incremental3D (in3D), made possible by Holcim

structural forces to create a “striated” compression-only funicular structure that requires no reinforcement.

Striatus is an arched, unreinforced masonry footbridge composed of 3D-printed concrete blocks assembled without mortar.

Exhibited at the Giardini della Marinaressa during the Venice Architecture Biennale until November 2021, the 16x12-metre footbridge is the first of its kind, combining traditional techniques of master builders with advanced computational design, engineering and robotic manufacturing technologies.

Proposing a new language for concrete that is structurally informed, fabrication aware, ecologically responsible and precisely placed to build more with less, Striatus optimises the interrelated properties of masonry structures, 3D concrete printing (3DCP) and contemporary design; presenting an alternative to traditional concrete construction.

The name “Striatus” reflects its structural logic and fabrication process. Concrete is printed in layers orthogonal to the main

A new language for concrete

Strength through geometry Striatus is an unreinforced concrete structure that achieves strength through geometry. Concrete can be considered an artificial stone that performs best in compression.

In arched and vaulted structures, material can be placed precisely so that forces can travel to the supports in pure compression.

Strength is created through geometry, rather than an inefficient accumulation of materials as in conventional concrete beams and flat floor slabs. This presents opportunities to significantly reduce the amount of material needed to span space as well as the possibility to build with lowerstrength, less-polluting alternatives.

Striatus’ bifurcating deck geometry responds to its site conditions. The funicular shape of its structural arches has been defined by limit analysis techniques and equilibrium methods, such as thrust network analysis, originally developed for the structural assessment of historic masonry vaults; its crescent profile encompasses the thrust lines that trace compressive forces through the structure for all loading cases.

Steel tension ties absorb the horizontal thrust of the arches.

Neoprene pads placed in between the dry-assembled blocks avoid stress concentrations and control the friction properties of the interfaces, echoing the use of lead sheets or soft mortar in historical masonry construction.

In plan, the boundaries of the structure form deep arches that transfer horizontal loads (for example, from visitors leaning against the balustrades) to the supports in pure compression.

Advanced discrete element modelling (DEM) was used to refine and optimise the blocks’ stereotomy and to check the stability of the entire assembly under extreme loading cases or differential settlements of the supports.

The bridge’s 53 3DCP voussoirs have been produced using non19

parallel print layers that are orthogonal to the dominant flow of forces. This avoids delamination between the print layers as they are held together in compression.

The additive manufacturing process ensures the structural depth of the components can be achieved without producing blocks with a solid section, hence reducing the amount of material needed compared to subtractive fabrication methods or casting.

Striatus follows masonry structural logic on two levels. As a whole, the bridge behaves as a series of leaning unreinforced voussoir arches, with discretisations orthogonal to the dominant flow of compressive forces, following the same structural principles as arched Roman bridges in stone. Locally, on the level of the voussoir, the 3DCP layers behave as traditional brick masonry evident in the inclined rows of bricks within Nubian or Mexican vaulting.

Sustainable digital concrete Circular by design, Striatus places material only where needed, significantly reducing its environmental footprint. Built without reinforcement and using dry assembly without binders, Striatus can be installed, dismantled, reassembled and repurposed repeatedly; demonstrating how the three R’s of sustainability (Reduce, Reuse, Recycle) can be applied to concrete structures.

Reduce: Lowering embodied emissions through structural geometry and additive manufacturing that minimises the consumption of resources and eliminates construction waste.

Placing concrete only there where needed, 3DCP minimises the amount of material required, while the low-stress, compression-only funicular geometry of Striatus proposes the further development of 3DCP that will enable the use of much lower-strength, less-polluting printable materials.

Compared to embedded reinforcement in concrete, Striatus 20

uses external ties to absorb the thrust of its arched shape and dramatically reduce the amount of steel required. A high carbon-intense material, steel reinforcement (100% recycled) per unit mass is more than ten times that of standard concrete.

Reuse: Improving circularity and longevity. Unlike conventional reinforced concrete structures, Striatus is designed to be dry assembled without any binder or glue, enabling the bridge to be dismantled and reused in other locations. Its funicular design ensures the 3DCP blocks experience low stresses throughout their use, resulting in no loss of structural integrity. Striatus separates components in compression and tension, ensuring external ties can be easily accessed and maintained, resulting in a longer lifespan for the entire structure.

Recycle: By ensuring different materials are separated and separable, each component of Striatus can easily be recycled with minimal energy and cost.

3D printing also avoids the waste and costs associated with single-use moulds. Additionally, the component materials within Striatus remain separate and separable with the use of mechanical connections such as simple dry contacts between the voussoirs rather than chemical glues or binders, ensuring a simple, low-energy recycling process at the end of the elements’ life, potentially after multiple cycles of reuse.

Robotic 3D concrete printing Unlike typical extrusion 3D printing in simple horizontal layers, Striatus uses a two-component (2K) concrete ink with corresponding printing head and pumping arrangement to precisely print nonuniform and non-parallel layers via a 6-axis, multi-DOF robotic arm. This new generation of 3D concrete printing in combination with the arched masonry design allows the resulting components to be used structurally without any reinforcement or post-tensioning.

To prevent misalignment between the direction of structural forces and the orientation of material layers that arises from typical shape-agnostic slicing of explicitly modelled geometry, a customdeveloped design pipeline was formulated for Striatus to ensure that its printed layers are wholly aligned with the direction of compression forces throughout the entire bridge and also locally through each 3D-printed block. To address issues and challenges that could prevent in-between stability during printing, the coherence and feasibility of the gradually evolving print paths have been modelled using a Functional Representation (FRep) process.

This process encodes and continuously checks rules of minimum overlap, maximum cantilever between print layers and print length, print speed and the volume of wet concrete extruded.

These measures, typically used in horizontally layered 3DCP, have been advanced and refined to work on an inclined-plane setting: The angular differences between start and end planes of all 53 printed blocks have been simultaneously adjusted to meet multiple criteria such as an appropriate structural contact and angle between adjacent blocks, and maximum print inclination.

The careful design and iterative refinement of the hollow crosssections and infill triangulation have ensured that material is placed corresponding to the precisely analysed, local structural performance of each block. This design and optimisation have been applied to each individual layer of every block (with 500 print layers on average per block), ensuring that all blocks are as hollow and light as possible, and consequently use the least amount of material possible while maintaining structural integrity under all loading conditions.

The resulting intricate crosssectional design has been processed into a single, continuous print path meeting various

criteria that include appropriate print speed and turning radii, structurally required material width and thickness, and controlled expression of naturally occurring printing artefacts.

A nuanced aspect of robotic 3DCP masonry is the re-introduction of intelligence and highly skilled labour into the manufacturing and construction industry. The digitisation of fabrication and digital augmentation of skilled assembly and construction techniques makes historicallyaccrued knowledge accessible to younger generations and enables its systematic upgrade towards industrialised construction through the use of computational and robotic technologies. In stark contrast to a brute force, and often materially wasteful economy biased towards automation and assembly line production, 3DCP masonry introduces possibilities of a symbiotic human-machine economy. This promises an environmentally, socio-culturally and economically sustainable alternative to its 20th-century predecessor.

with the same structural principles and a similar fully-integrated computational design-tofabrication approach that form the basis of the vaulted, rib-stiffened, unreinforced concrete floors being developed by the Block Research Group in partnership with Holcim, Striatus proposes an alternative to the standard inefficient floor slabs within any building.

Compared to typical reinforced concrete flat floor slabs, this new floor system uses only 30% of the volume of concrete and just 10% of the amount of steel. The very low stresses within the funicular structure also enable the use of low-embodied-carbon concrete

that incorporates high percentages of recycled construction waste.

Prefabricated and dry-assembled, and therefore fully demountable and reusable, this floor system is easily and cleanly recyclable at end-of-life.

With an estimated 300 billion square metres of floor area to be constructed worldwide over the next 30 years, and floors comprising more than 40% of the weight of most high-rise buildings (10+ storeys), introducing the principles demonstrated by Striatus would truly disrupt the construction industry — transforming how we design and construct our built environment to address the defining challenges of our era.

Computational design-toconstruction integration Integrating design, engineering, fabrication and construction, Striatus redefines conventional interdisciplinary relations. The precise manufacturing of the blocks was enabled by well-defined data exchange between the various domain-specific software toolchains involved in the process.

This co-development approach was facilitated through the use of COMPAS, an open-source computational framework for collaboration and research in the AEC industry, which enabled the fluent interaction among the key players of the project, working together in five different countries, under a very tight schedule and budget, at a time in which travelling was not possible.

Disruptive outlook Striatus offers a blueprint for building more with less. Created 21

3D Concrete Printing: Korodur and CyBe’s innovative construction methods create impressive projects all over the world Multiple applications: from residential construction to the artificial reef - again and again, new application possibilities for specialized building material from Bavaria In Germany, 3D printing applied to houses still only plays a marginal role – worldwide, however, more and more projects are being carried out using this innovative method. Korodur, the specialized building materials manufacturer based at Amberg and the CyBe Construction technology specialists from Oss in the Netherlands are reaping the benefits of it now, not only in residential construction, but by constantly developing new applications for 3D concrete printing – from outdoor furniture to environmental protection projects based on artificial ocean reefs.

Since 2012, this medium-sized Bavarian company and the Dutch civil engineering experts have been running their joint-venture, and have already completed a variety of quite sensational residential buildings. “We implemented our first joint project, a residential construction in Dubai, in the desert under the most difficult conditions.

Since then, even more exciting properties have been added to this, for example in India, Japan, Indonesia and Saudi Arabia. After putting in years of lab work on the task of perfecting our 3D printing method, this combination of robotics and intelligent mortar has been refined even further. In the process, we have not only gained new insights into the most efficient methods of construction, but have also explored completely new possibilities for applications”, says

Frank Sander, Technical Manager at Korodur International GmbH. Efficient, fast and inexpensive The CyBe MORTAR, a mortar designed specially for 3D printing, is applied layer by layer in this process by means of robots, in a short time forming a wall or column with a high load-bearing capacity.

CyBe’s 3D printers reach a speed of up to 500 mm/s. Thanks to the CyBe MORTAR building material developed by Korodur, units can be manufactured in one complete piece. Via the integration of an additive, the concrete can solidify very quickly, thus reducing the printing time significantly.

The particular advantages of this method are, on the one hand, a considerably shortened construction time and the cost savings involved. On the other hand, it offers architects and planners completely new design options that go beyond those of conventional construction.

The buildings created in this way can be replicated any number of times with identical floor plans or simply adjusted as appropriate to cater for varying circumstances and requirements. The 3D printing robots can be used, as required, on the actual construction site or for the prefabrication of components in an arbitrarily located workshop.

In addition, there are mixed forms in which a robot close to the actual construction site produces various tailor-made components.

Sustainable, versatile and variable “The possibilities for application are practically endless! Accuratelyfitting service shafts are produced and installed on site in the shortest possible time lags using this

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innovative technology, for example, allowing damaged conduit access assemblies and connections to be replaced quickly. In addition, we have already created seating areas as well as combinations of tables and benches for outdoor use. Their exceptional design plus high degree of durability and stability all carry conviction. In any case, sustainability has always been a labour of love for us. A quite spectacular application in this context is the use of the product for the construction of artificial reefs. Thus, at critical locations we would like to help to revive the marine environment and assist the animals, plants and, in particular, corals in developing new habitats”, Frank Sander explains.

There are other ways, too, in which the Korodur/CyBe process contributes to climate and environmental protection – namely, in terms of its CO2 footprint: the quantity of carbon dioxide obtained during the production of the solely mineral CyBe MORTAR “made in Germany” is at least 20 per cent lower than that produced by conventional Portland cement.

Nikola Heckmann, Korodur’s CEO, says emphatically: “This is an essential part of our corporate philosophy. We consider the careful use of resources and the reduction of emissions to be fundamental to our future viability. For the same reason we are committed to the development of new technologies and processes.

This also includes our 3D concrete printing process, with which we have positioned ourselves not only in Europe but throughout the world as an innovative and reliable partner to the construction industry”.

Up-to-date information on CyBe MORTAR procedures and applications is presented for architects, planners, developers and other companies from the real estate sector on the site www.3dconcrete-printing.com.

Further information: www.3d-concrete-printing.com; 23

NAFSA Electromagnets explained…

To the average person, the term ‘Electromagnet’ is usually linked to a big lump on the end of a crane, picking metal or old cars up and transferring them into the next stage of processing plants.

In our world here at OEM Automatic, an electromagnet is somewhat smaller but no less impressive. Whether holding a product down during fabrication or operating a lock or part of a machine build - there are many possible applications that NAFSA electromagnets can be used for.

Two basic designs are available: Permanent Magnet or Coil Wound Permanent magnet The permanent magnet is exactly what it sounds like. A permanent magnet within the electromagnet will keep hold of the work piece without voltage. This design is ideal for passive locking systems and designs that call for a hold to be in place for a long time, with no residual current being drawn. The magnetic force is broken when a voltage is applied to a coil within

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the electromagnet, breaking the magnetic force and releasing the work piece.

diameter with a force of up to 8000N (roughly 800Kg) per metre.

Typical applications

Coil wound Coil wound electromagnets work in reverse to the permanent magnet unit. The electromagnet offers no magnetic attraction until voltage is applied to the coil, at which point it attracts the workpiece and holds whilst under voltage. Removing the voltage releases the work piece.

Both permanent magnet and coil-wound electromagnets offer various physical sizes, with holding forces up to 7000+ Newtons (roughly 700Kg) for held pieces featuring a flat smooth surface.

Locking systems – doors, panels, frames Holding devices – machining jigs, assembly stages, mould workpieces Brakes & lifting devices - these require analysis into every application for health and safety reasons NAFSA With electromagnets designed and built at NAFSAs’ facility in Spain, a full technical team are available to assist with sizing, technical calculations and support.

The smooth surface ensures maximum contact area between the electromagnet and the object being held, thus allowing the greatest holding force to be achieved.

As a partner to NAFSA in many countries, including the UK, we at OEM Automatic are happy to help with any application requirements for electromagnets!

Using a purposely designed electromagnet, it is possible to hold round bars from 120 to 250mm

To find out more about NAFSA electromagnets, email us at motors@oem.co.uk.

Developing the Powder Metallurgy Future

Regist ration End U Now O sers A pen ttend Exhib ition F ree Euro PM2021 International Powder Metallurgy Congress & Exhibition

18 – 22 October 2021 ONLINE EVENT

europm2021.com

Intelligent power with Crouzet SQ75 BLDC motors Brushless DC motors are often the best solution for applications where precise speed, torque and position control is required. By communicating with PLCs, other motors and various types of sensors in the application, they create a fully autonomous motion control system.

The Crouzet DCmind brushless motor family features integrated controllers that provide the functionality of a traditional servo motor. The built-in encoder with angular accuracy of 0.1° (4096ppr) guarantees high precision positional control. Today, Crouzet has expanded its range with the new, intelligent SQ75 brushless motors.

SQ75 - Range of BLDC motors up to 600W with integrated electronics Thanks to the SQ75s’ built-in intelligence, security features and communication capabilities, the SQ75 can be used in a wide variety of applications. Manufactured in France, this new member of the DCmind brushless motor family is available in three versions: 310W

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(24V DC), 400W (32V DC) and 600W (48V DC).

High performance with integration: A winning combination Crouzet set themselves the goal of achieving technical excellence by developing the SQ75 series BLDC motors. The starting point is the high torque values, especially in the 310W version, which provides a nominal torque of 1Nm (2.5Nm at peak; up to 6.0Nm in the 600W version), with an extended speed range, up to 5,000rpm.

Michel Nuicol, business engineer at Crouzet says the following: “The SQ75 is therefore capable of working in applications requiring high acceleration and braking, even those with high inertial loads, thanks to its energy management module. This functionality is extremely useful, for example, during the braking phase of AGV mobile robots used widely in intralogistics” So, what is unique to the market?

The standard BLDC motors of the SQ75 series are waterproof and

dustproof (excluding the output shaft and the front plate) including the version with a built-in 4.5Nm brake. SQ75 series motors can withstand short-term immersion in water up to a depth of 1 metre and washing with high pressure water. With two levels of protection: IP67 and IP69, these motors can be safely used even in the harshest environments.

The widest range of power supply options available on the market In combination with a wide range of supply voltage from 9V to 75V, the SQ75 series motors can be used in applications where we are dealing with power from batteries with a voltage of 12V, such as autonomous vehicles used in warehouses or agriculture.

The wide ranging power supply input is also one of the protective elements, ensuring uninterrupted operation of the motor despite a sudden increase in the supply voltage, for example, in the event of disconnection of one of the motors operating in the application.

The last, but equally important, benefit of a wide voltage range is the protection of the motor against overheating, for example in winch applications or autonomous vehicles. The issue of ensuring proper protection against the motor overheating is particularly important in applications where we deal with highly dynamic movements - fast acceleration and braking. SQ75 series brushless motors allows you to connect an external resistor to dissipate excess energy through a load bank, if required.

A safe, smart and truly communicative motor The SQ75 is fully safe, thanks to two STO inputs (safe torque off) which enables an emergency stop of the motor, regardless of the microprocessor operation.

In the event of a failure, these inputs cut off the power supply from the motor windings. The STO function is activated even in spite of a damaged microcontroller and ensures a high level of security of the safety of the application.

Thanks to the built-in CANopen interface, the SQ75 can be controlled over the network via the standard CAN bus. Galvanic isolation protects against mains interference. The SQ75 can also work completely independently. it’s intelligent functions (speed, position and torque control profiles, and pre-installed test applications) can be configured via USB using the free DCmind Soft + CANopen software.

By collecting information about alarms and monitoring motor operating parameters, the user can plan service activities and even predict the occurrence of a potential device failure.

Highlights of the SQ75 - Supply voltage: 9 to 75V DC - Nominal power: from 300 to 600W - Nominal torque: from 1,000 to 1,900mNm - Speed range from 1 to 5,000rpm

- IP67 and IP69 - Integrated 4096ppr encoder - CANopen - 75mm faceplate Easy to install, operate and maintain Crouzet attaches great importance to the proper integration of its products in customer environments, considering both application and user requirements. This is done during the installation, use and maintenance phases.

This is reflected, for example, in the built-in protection against reverse polarity which protects the motor against damage in the event of improper connection of the power cables. In addition, there is the possibility of configuring the motor via a computer and USB cable, the preinstalled applications, or fine tuning of parameters through the DCmind Soft + CANopen software (chart recorder, measurement performance, control loop adjustment and error code information). The user can also carry out diagnostics via the USB port without interrupting the motor operation in the CANopen network and check the communication status with the LED on the front panel.

The 14mm diameter shaft is compatible with many types of gearboxes available on the market, this facilitates straightforward adaptation to the existing application environment. The SQ75 can be supplied with the PM72 and P81 planetary gears or the RAD20 worm gear option.

The front panel is equipped with standard industrial connectors: power, I/O (supporting four digital inputs, two analogue/PWM inputs and two STO type) CAN network cable connection and USB port, as well as the status indicator LED. High efficiency, space saving, built-in intelligence and ease of use make the SQ75 series motors fit perfectly with the trend of the increasingly popular use of all-in-one devices, which is visible on the market today.

Please email motors@oem.co.uk to find out more 27

Rethinking customised food safety commissions In our daily lives as consumers, we have become accustomed to a high degree of customisation. In fact, we’ve grown to expect it, with much of the success of companies like Netflix and Amazon stemming from their ability to create tailored offerings. However, in the world of food production, the concept of customisation can still feel like an extravagance. In particular, smaller companies may fear that ordering a bespoke metal detection with a custom-built conveying system will be an expensive and complicated process, fraught with delays.

Thankfully, that couldn’t be further from the truth. Jodie Curry, Commercial Manager at Fortress Technology and Sparc Systems, highlights several situations when bespoke can be better.

European food manufacturers rightly demand extremely high levels of performance from their inspection equipment.

From a safety and brand integrity perspective products must reach consumers free from contamination. However, inspection machines like metal detectors are highly sensitive.

Performance can be affected by various environmental factors.

These should be considered and addressed during the design phase of any system. Noise immunity technology can reduce many

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of these challenges and is built into Fortress metal detectors as standard.

Factoring in the conveying and reject system is equally important to guarantee reliable operation and avoid false readings. For example, when the footprint is tight, a customised solution may be the only way to ensure that metal detector performance is not compromised.

Aperture size is also critical to optimal operation. A metal detector’s performance becomes more limited as the aperture size increases in relation to the product being inspected.

Yet, too small and there’s a risk that product won’t pass through.

At times, customising the aperture around the product to be inspected is one way to ensure the metal detector will perform to its full capability.

Rather than being over-engineered or complicated, these factors are essential design elements of any successful food inspection system.

Purchasing a customised machine with an integrated conveyor system, fully assembled and quality checked by a reputable food inspection manufacturer, is a stellar way to achieve functionality, productivity and the best performance.

It’s not unusual Demand for customised solutions is far more common than people realise, accounting for around 20% of Fortress conveyor orders.

Even Vector conveyors are somewhat customised to specific manufacturers’ needs.

Often, our engineers are tasked with configuring a new inspection machine with legacy upstream or downstream equipment. This can limit the options. There are also design limitations. For instance, the dimensions of a standard Vector conveyor won’t work within the footprint. Trying to shoehorn it in may even invade the detectors’ metalfree zone and cause false reading.

Due to line speed, belt width or product profile, a particular reject mechanism may be required, for instance sweep arm or retractable band rejects.

Recently, our North American colleagues installed a customised twin-lane inspection/conveyor system for a pizza crust manufacturer.

Although the line speed wasn’t particularly fast, and the product wasn’t especially difficult to handle, this project still required a customised approach. Mainly because the detection system needed to precisely align with existing upstream and downstream legacy equipment.

In this instance, the only viable option was a customised S-curve conveyor. The reject mechanism also proved challenging. Air blast wasn’t suitable because of the belt width. A kicker proved incompatible because of the low profile of pizza.

Lastly, there was insufficient space to accommodate a flap style reject. Instead, we engineered an innovative retracting reject mechanism.

featuring user-friendly controls, automated single-pass learning, and speedy calibration to deliver accurate system set-up within seconds. In general, our customers aren’t concerned with how many megabytes per second the processor inside is capable of handling – they want a detection system that will consistently run as intended, accurately rejecting contaminated product without incurring high levels of false rejects.

Staying on task When it comes to business continuity, reliability, agility and productivity are key. Contrary to popular belief, custom-designed inspection systems are only marginally more expensive than standard designs. It has long been our philosophy to support the optimal operation of all inspection systems. If poorly designed or installed, the risk of a contaminated product entering the food chain greatly increases. As well as the impact to human health, the long-term cost implications for a food business dealing with a contamination scandal are stratospheric.

The average cost of a recall according to a joint industry study by the Food Marketing Institute and the Grocery Manufacturers Association is $10m in direct costs, in addition to brand damage and lost sales. Cutting corners here can be a false economy.

If clients require simple additions, such as buzzers and alarms, or want to equip systems with the latest smart digital technology, almost anything is possible. Our standard data capture and reporting technologies – Contact and Contact Manager – provide traceable and auditable QA information, ensuring compliance with food safety standards.

For even more sophisticated operations, Fortress offers Industry 4.0-ready options, including OPC-UA Adapter and Ethernet/ IP Adaptor. These facilitate smart information exchange between systems on a line. Yet also offer a seamless, automated method of collecting traceable and auditable QA information as well as realtime process and performance improvement data.

Lead time for a bespoke system is only marginally longer – four weeks at most. This is largely due

to the extra design work required to deliver an on-spec machine that meets the exact application requirements. Getting the right solution for the customer is what matters most – while this may take a few weeks longer, the end result is a reliable, longer lasting food inspection system.

As a result of Fortress and Sparc’s innovative and stable technology platforms, customised systems can be retrofitted to incorporate smart solutions. A robust build quality coupled with a modular approach and the use of interchangeable parts provides additional future proofing value.

Jodie sums up: “For any customised project, collaboration is critical.

Having worked together for close to two decades, Fortress and Sparc have engineered dozens of bespoke inspection systems, including the world’s first ever five lane multi-aperture ferrous metal detector and checkweighing system. Our latest innovation, the Raptor series, is testament to what can be accomplished in the innovation space to advance manufacturing due diligence when engineering competence is pooled.

“Because both our companies are masters in our respective fields, when we partner together customers benefit from a higher specification combination system with synergy in test methods and product development,” ends Jodie.

One of our fundamental principles is to design machines that are easy to use but employ advanced processing power – simple on the surface but sophisticated under the hood. For example, a number of our metal detectors, including our Interceptor and Stealth ranges, use an advanced algorithm and powerful ARM processor which allow for multi-channel digital signal processing to collate realtime data from transmission and reception in both inspection fields.

Yet as digitally ‘smart’ as they are, all our systems – including customised machines –remain extremely simple to operate, 29

Collaboration in the Ecosystem: What Matters Today’s ecosystem of industrial automation is characterised by many media disruptions during the processing and transfer of documentation.

It is essential to resolve these issues within the development process for machines and plant systems – via targeted collaboration among all stakeholders and systems.

Data created in the engineering process must be shared with everyone involved in the process.

The ideal goal: machine builders and system integrators, control cabinet manufacturers, component manufacturers and also the machine or plant system operator all work networked together.

Operators of production facilities, machine builders and system integrators, control cabinet manufacturers and component manufacturers all have one thing in common: they all work together along the value chain, from the

planning through to operating a finished machine or plant system – and continuously exchange information in the process.

The ecosystem of industrial automation What does this process – the collaboration among the various process participants – look like today?

In the planning phase, the characteristics of the desired machine or plant system are described. If the company has particular supplier specifications, these are also detailed and then passed on to the operator, who takes the specifications into account when designing the machine or system. The planning phase is followed by the pre-planning process.

Additional information such as devices, release lists from Excel, specifications in Word or preplanning tools such as Eplan

Pre-planning are taken into account and, in turn, are used by the basic engineering designers to prepare a quote, for instance. In the case of more complex production lines, this is traditionally taken care of by a system integrator, who is also responsible for the detailed engineering and for generating electrical and fluid-power schematics.

Data is enriched in the Eplan Project The project created with systems of the Eplan Platform – Eplan Electric P8 or Eplan Fluid, for example – is now transferred to the control cabinet manufacturer. This manufacturer creates the virtual prototype of the switchgear system in the form of a 3D assembly of the control cabinet using Eplan Pro Panel. The control cabinet is then built, approved and commissioned by the operator. With the delivery of the switchgear system, the control cabinet manufacturer processes are complete. The company hands over the Eplan Project, which has been enriched with data, back to the machine builder or system integrator, who then commissions the machine or plant system based on the final project data.

The project is then made available to the operator, who can access the current documentation, for instance using Eplan eView, in the event that servicing or maintenance becomes necessary, and who can digitally document any changes using the redlining function as needed.

This process describes the daily work in this ecosystem of industrial automation. The challenge, however, is that all the data for an automation project is created and added at various stations along the value chain. Often, all the project participants are working with partially inconsistent data,

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which ends up making the process even more time consuming and error prone. For instance, the drive power of a motor is changed at some later point in a project, but this change isn’t taken into account when the machine or plant system is commissioned. As a result, the documentation is not up to date.

A “data container” as the central source of information This is where Eplan comes in: the systems of the upcoming Eplan Platform 2022, in combination with the new Eplan eManage cloud service, network together machine builders and system integrators, control cabinet manufacturers, component manufacturers and the operators of machines or plant systems. Eplan CEO Sebastian Seitz explains: “We connect companies with their clients and suppliers via the cloud, for easy and secure data sharing.

The Eplan Project as the central, digital model of an automation solution supplies all processes with the necessary data. What we’re talking about is a sort of ‘data container’ that is fed from the systems of the Eplan Platform.

This generates added value in the digitised collaboration of all participants – through secure data transfer and central access to the Eplan Project.” A new feature includes the connection to the cloud via Eplan ePulse, which also significantly facilitates mobile working in design and engineering.

them to the Eplan Platform for further processing. This is accomplished without the timeconsuming sending of project data via email or using an FTP server. And the centralised, clear availability in the cloud also enables all project participants to search quickly for specific content. With Eplan eView, all the changes in a project are centrally available. The advantages are obvious: project documentation is always up to date – along the entire product life cycle and into operation and service scenarios.

An important component of this method of working is device data, which is provided on the Eplan Data Portal. Seitz says, “What matters here is the quality and depth of the data, something we are intensively advancing with the Data Standard.” Comprehensive, integrated and end-to-end digital data serves as a project accelerator. And don’t forget, the data are consistent and the data transfer is secure.

Box: High-quality digital device data is a key factor in: - Processing orders in shop floor management and deriving production orders.

- Controlling automated machine fleets (Rittal Automation Systems).

- Providing information to partially automated workstations (for instance, simplifying wiring processes with Eplan Smart Wiring).

Seitz continues: “With these optimised processes and increased efficiency, companies can optimise their machine and plant system design processes and sustainably increase the availability of their machines and plant systems.

Collaboration among all participants ultimately increases the quality of the data and thus the added value.”

Find out more at: www.eplansoftware.com/inyourhands

Cross-project collaboration via the cloud Using the new Eplan eManage, projects can easily be uploaded to the cloud and managed and shared from there. More specifically, this brings together the worlds of on-premises software and the cloud. Clear access rights via role management ensure data security and provide flexibility for accessing projects. Users of Eplan Electric P8 and Eplan Pro Panel can conveniently upload their projects to the cloud and transfer 31

Rohde & Schwarz introduces R&S VSESIMVSS that combines EDA simulation with hardware testing T&M expert Rohde & Schwarz and Cadence have collaborated on a solution aimed at simplifying the engineering process from RF design to implementation and enhancing accuracy by using realistic signals for both simulation and testing.

The new R&S VSESIM-VSS signal creation and analysis tool speeds up the development process for RF components. It is particularly useful for customers in the wireless, automotive, and aerospace and defense industries as well as for manufacturers of active components and systems.

New wireless and satellite technologies offer ever wider frequency ranges and involve increasingly demanding requirements. Realistic signal simulation at the early stages in RF system design is more important than ever. Using the same signal creation methods and analysis algorithms as for subsequent hardware testing enables direct result correlation from the early design stages to implementation verification, allowing conclusive and consistent analysis of widely used key performance indicators such as error vector magnitude (EVM).

To this end, Rohde & Schwarz has collaborated with Cadence Design Systems, Inc. to develop the R&S VSESIM-VSS signal creation and analysis tool, which supports all major standards such as 5G, the latest Wi-Fi evolutions and many more. The joint solution combines signal generation, design simulation and signal analysis, building on the strengths of either company’s popular and proven solutions. As a result, developers and design engineers benefit from an optimized tool that allows them to address design

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challenges earlier than before in the development process.

The R&S VSESIM-VSS signal creation and analysis tool functions as an addition to the Cadence® Visual System SimulatorTM (VSS) software, a well-established solution for system simulation and modeling, particularly for RF components and RF assemblies used in wireless communications and radar design.

R&S VSESIM-VSS from Rohde & Schwarz is designed to expand the capabilities of the VSS software by adding realistic signals to the workflow, increasing simulation accuracy and simplifying the design process. R&S VSESIM-VSS benefits from two established software tools from Rohde & Schwarz for testing operative circuits, modules and devices – the signal generation capabilities of the R&S WinIQSIM2 simulation software and the signal analysis capabilities of the R&S VSE vector signal explorer software.

R&S VSESIM-VSS combines these functions and adds plug-ins for Cadence electronic design automation (EDA) tools.

The data sink plug-in from Rohde & Schwarz provides access to the signal at any point in the design process. The signal can be transferred to a vector signal generator and applied to available hardware, enabling system level analysis of hybrid hardware/ simulated implementations. An important feature of R&S VSESIMVSS is support of direct digital predistortion (DPD) techniques to verify the effects of linearization already in the simulation phase of power amplifier development.

An added benefit of combining the solutions is increased compatibility between Rohde & Schwarz and

Cadence tools. Signal generation and analysis provided by the Rohde & Schwarz solutions can also be used in other connected Cadence products such as the Cadence Microwave Office® circuit design software or the Cadence Virtuoso® RF Solution for radiofrequency integrated circuits (RFIC) and RF modules.

Christina Gessner, Vice President Spectrum & Network Analyzers, EMC and Antenna Test at Rohde & Schwarz says: “Connecting EDA design simulation and test and measurement helps our customers achieve first-pass design success and shorter times to market. Using realistic signals, deriving common figures of merit such as EVM and understanding linearization capabilities even before tape-out means a competitive advantage for our customers. We look forward to bringing the results of our cooperation with Cadence to the market.”

Vinod Kariat, corporate vice president of R&D in the Custom IC & PCB Group at Cadence adds: “Customers developing RF frontend communication ICs and systems require access to the latest communications standards. The joint solution from our companies enables our mutual customers to accurately analyze standard compliant signals throughout the design phase, including final test validation.”

R&S VSESIM-VSS is available from Rohde & Schwarz. For more information visit the website: www.rohde-schwarz.com/ applications/from-electronicdesign-automation-eda-tohardware-implement ationapplication-card_56279-1114370.html

Industry News

Bunting magnetic separators for CRS overseas recycling project Bunting-Redditch has completed the manufacture and supply of three (3) magnetic separators and one (1) eddy current separator to recover metals in an overseas recycling plant designed and installed by CRS NI Ltd. 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.

CRS NI (Complete Recycling Systems) is a leading player in the UK waste processing market, designing and manufacturing bespoke Material Recycling Facilities (MRF) to suit any size operation, from in-line trommel plants to full co-mingled waste plants as well as original plant extensions and “add-ons”.

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After an extensive review of recycling equipment suppliers at the end of 2020, CRS selected Bunting-Redditch to supply the metal separators. The configuration of the waste processing plant led to the selection of three (3) ElectroMax Overband Magnets and one Eddy Current Separator with vibratory feeder.

The Model EMAX150 ElectroMax Overband Magnets recover steel cans and other ferrous metals from the conveyed waste. One is suspended inline with a conveyor, over a non-magnetic head pulley, with the remaining two positioned across the conveyors.

All the ElectroMax models feature compact, air-cooled, high-powered electromagnets with heavy-duty self-cleaning rubber belts. In operation, the waste passes under the electromagnet on a conveyor where any ferrous metal attracts up and out of the burden.

The self-cleaning belt transfers captured ferrous metal out of the magnetic field, discarding into a collection area. Each EMAX150 weighs 2.8 tonnes and is 2750mm long, 460mm high and 1590mm wide.

In this project, two of the conveyors are 1200mm wide for the cross-belt installation, with the third being 1500mm for the in-line position.

There are three size fractions: <50mm, 50-150mm and 150-400mm with the burden depth on all three conveyors averaging around 300mm.

The 1500mm wide Eddy Current Separator, with integrated vibratory feeder, is located later in the process and recovers non-ferrous metals such as aluminium cans.

The HIC Model (high-intensity concentric) features a 300mm diameter magnetic rotor. The vibratory feeder regulates an even and controlled feed of waste material onto the faster running

Eddy Current Separator conveyor belt, which then transports the waste into the alternating magnetic field of the rotor.

An Eddy Current Separator is a dual pulley conveyor system, where the non-metallic rotor cover houses an independently rotating highspeed magnetic rotor. Separation occurs when a non-ferrous metal particle (e.g., aluminium, copper or zinc) is conveyed into the magnetic zone. The non-ferrous metal particle is exposed to rapidly changing magnetic polarity. This induces ‘eddy currents’ into the particle generating an electrical current (Fleming’s left-hand rule) that subsequently creates its own magnetic field.

The two magnetic fields oppose each other (i.e., North vs North pole repulsion), causing the repulsion of the non-ferrous metal particle and change in trajectory.

The measured positioning of a splitter enables the separation of non-ferrous metals from nonmetallic material due to the altered and unaltered material trajectories.

The 1500mm wide Eddy Current Separator and vibratory feeder combined system weighs 3.9 tonnes and is 5.8 metres long, 2.6 metres wide and 2.3 metres high. 15 tonnes per hour of mixed waste with a maximum particle size of 50mm feeds through the separator.

The waste contains approximately 1% non-ferrous metals, which are dominantly aluminium beverage cans.

United Kingdom,” said Adrian Coleman, the General Manager of Bunting-Redditch. “CRS is one of the leading designers and suppliers of recycling plants and we [Bunting-Redditch] were thrilled to be selected as the suppliers of the metal separators. Effectively managing waste is a global challenge and we are proud to see UK designed and built plant being used in overseas recycling projects.”

For further information, please contact us on press@buntingmagnetics.com or visit our website: www.bunting-redditch.com

The combination of the ElectroMax Overband Magnets and Eddy Current Separator ensures the maximum recovery of metal from the waste stream.

“This is another manufacturing export success story for the

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SG Transmission develops first of its kind hybrid permanent magnet and spring applied brake SG Transmission has successfully designed and manufactured a permanent magnet and spring applied hybrid brake, in what is thought to be the world’s first of its kind The hybrid solution has been designed for a range of next generation small, multi-axis surgical robots manufactured by a leading European robotic innovator.

Due to the critical nature of the application, a pre-assembled solution was designed with both spring applied and permanent magnet technology to offer double redundant capability in the event of a failure.

The hybrid solution offers the benefits from both technologies, combining the high torque and back-lash free capability of a permanent magnet brake, with the extended temperature range of a spring applied brake.

When quick and accurate holding is required, spring applied and permanent magnet brakes are known for their reliable, fail-safe braking capability. Unlike other electromagnetic brakes, they are designed to engage when electrical supply is removed (power-off brake engagement). Spring applied brakes transmit torque through pressure generated by built-in springs, while

the holding force in a permanent magnet brake is created by multiple permanent magnets attracting a single face armature.

Paul Short, Technical Manager at SG Transmission, explained: “While a hybrid permanent magnet and spring applied brake provides significant benefits, the design complexity and unpredictability of the two interacting magnetic fields have prevented this concept from previously being explored.

“In addition to the innovative design, the customer required a ‘plug and play’ solution which presented an additional challenge due to its small, compact design and limited axial length. So far, we have successfully supplied three versions of the brake in various sizes.”

The internal design team at SG Transmission worked closely with the customer throughout the project, using video conferencing and 3D data transfer to enable the collaboration of the team’s electromagnetic knowledge with the requirements of the application.

Andy Collinson, Chief Executive Officer at SG Transmission, said: “We were delighted to be approached with this unusual request. We are committed to our position in the industry as the expert in bespoke electromagnetic solutions, and this project has provided the opportunity to add yet another pioneering design to our catalogue”.

For more information please visit: www.sgtransmission.com

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NSK triple lip seal provides ultimate bearing protection Bearings that operate in conditions with a high degree of contamination must offer many attributes. A highly efficient sealing arrangement is priority number one. However, these bearings must also be costeffective and provide easy, quick and convenient fitting and removal, including the capability to counter any misalignment during assembly.

To help meet all of these demands, an increasing number of OEMs and manufacturing plants are finding the optimum solution in NSK’s Self-Lube® bearing units with triple lip seal.

Self-Lube® bearing units help users to combat extreme condition challenges through a broad portfolio of reliable inserts and housings.

Notably, these cost-effective units provide a simple and fast solution for mounting bearings without the need for complex housings or special shaft arrangements. Self-Lube® units provide all the features necessary to easily attach a bearing to a frame and a shaft.

Premier among the advantages is the specially developed triple lip

seal, a one-piece moulded nitrile seal with three sealing lips. Bonded to a protective outer steel pressing (secured in the outer ring), the triple lip seal makes for a highly efficient sealing design that protects the bearing in severe conditions involving dust, sand, water or slurry.

The solution produced a significant lifetime extension to more than 7 months (at least 133% improvement).

As a result, the manufacturer of barrel washers is saving €56,600 in bearing replacement and maintenance costs over every sixmonth period of operations.

Among a growing number turning to Self-Lube® bearing units with triple lip seal is a manufacturer of barrel washers for cleaning vegetables prior to processing or packaging. The barrel washer’s bearings submerge in water with every rotation of the drum. Due to water washout and corrosion it was proving necessary to replace the bearings every three months. To avoid this costly exercise, the company invited NSK’s expert team of engineers to investigate the problem.

Self-Lube® bearing units comprise an insert and a housing. The inserts are deep-groove ball bearings made to the popular 6200 series configuration, with integral design features that make them more functional and versatile than standard ball bearings. Self-Lube® inserts not only suit the wide range of RHP housings available from NSK, but applications where the user’s own housing is preferred.

After a full application review and bearing failure analysis, NSK recommended its Self- Lube® bearing units with triple lip seal, which are perfect for applications where bearings face exposure to water contamination.

NSK offers a large size range along with various shaft locking arrangements – including set screw, eccentric collar and taper sleeve locking options. Moreover, extended re-lubrication intervals greatly reduce maintenance costs and increase the productivity of machines.

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Mills CNC chooses laser triangulation sensor from Micro-Epsilon Mills CNC, a machine tool supplier based in Leamington Spa, has chosen to use a laser triangulation sensor from Micro-Epsilon in one of its bespoke machine tool automation cells (SYNERGi) with a primary focus on inspecting large, hot rolled steel railway fishplates.

The triangulation sensor, which is mounted on a Fanuc robot end effector, intricately measures the contours – the ‘bend’ and ‘twist’ – of the fishplates to ensure they are within the required manufacturing tolerances. The automation cell then places the fishplates into a Mynx 5400 to be machined.

One of the fastest growing machine tool companies in the UK, Mills CNC is the sole provider of Doosan Machine Tools within the nation and has machines to suit all the manufacturing sectors including aerospace and defence, power generation, motorsport, oil and gas, medical, automotive and general precision component manufacture.

The company’s reputation is

built on the quality, reliability and performance of the Doosan machine tools it sells.

Established in 2018, Mills CNC Automation was created to project Mills CNC and its customers businesses forward. Mills CNC saw automation as key to increasing manufacturing productivity and output for all customers, both old and new. The division, which is located at Mills CNC’s Technology Campus facility in Leamington Spa, has two principal specialisms, Industrial Robots and Collaborative Robots.

Chris Ingham, Controls & Systems Engineer at Mills CNC Automation comments: “At the Technology Campus, we’ve developed a number of automation systems and machine tool demonstrations for our customers to view.

We are currently testing and commissioning an automation system for a customer who needs to inspect railway fishplates manufactured by a hot rolling mill.

The project began in late 2020 and the inspection system uses a laser triangulation sensor from MicroEpsilon.”

Fishplates are metal bars that are bolted to the end of two rails to join them together in a railway track. The hot rolling mill produces the high ductile steel fishplates in four different product groups that vary in length from 0.5m up to 1.0m. Mills CNC Automation has custom designed, and built, a fully automated machine tool pick-andplace system for inspecting the fishplates.

Easy integration was key The optoNCDT 1750 laser triangulation sensor from MicroEpsilon is mounted on a robot end effector in between two magnetic grippers. The laser sensor measures the fishplate in eight different positions (on average) and outputs this data via the Micro-Epsilon IF2030 EtherNet I/P module into the Fanuc robot controller.

This data is then utilised by Mills CNC’s own custom analysis software with the results displayed on the machine tool HMI. The data is used to verify that the fishplates are within tolerance in all three planes, including whether ‘bend’ and ‘twist’ tolerances have been exceeded.

As Chris Ingham explains: “If the measurement data shows that a fishplate is out of tolerance, the part is rejected before machining and returned to the rolling mill.

The fishplates need to be within a tolerance of 2mm over a length of one metre, but we needed a sensor that was reliable and capable of communicating with our Ethernet I/P network. These factors, as well as a favourable price-performance ratio, were critical for us when searching for a suitable sensor solution.”

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The optoNCDT 1750 is a laser triangulation sensor with integrated controller that is perfect for mounting on a robot end effector.

It is also suitable for high speed distance, displacement and position measurements in a wide range of applications, including automation, machine building, electronics production, packaging, automotive and process manufacturing. Mills CNC is using a sensor with a measuring range of 750mm.

to carry out ourselves was to build a custom enclosure for the sensor that provides additional protection from machine tool coolant mist,” says Chris Ingham.

He concludes: “The sensor is performing well and is providing reliable measurement data.

During the machine test and commissioning phase, the customer has been sending us different groups of parts to inspect and so we’ve really been able to put the

sensor through its paces. We’ve been very impressed with the sensor and technical support when we’ve required it. We look forward to working with Micro-Epsilon again in the future.”

For more information on the optoNCDT 1750 series of laser triangulation sensors, please visit www.micro-epsilon.co.uk or call the Micro-Epsilon sales department on +44 (0)151 355 6070 or email info@micro-epsilon.co.uk

The optoNCDT 1750 series is also available in measuring ranges from 2mm up to 750mm. The sensor’s measuring rate is continuously adjustable up to 7.5kHz and can be individually adapted to suit each measurement task. Data output is via analogue or digital RS422 interface. Due to the Advanced Real Time Surface Compensation (A-RTSC) feature, the sensor operates almost regardless of the target material and colour. The exposure time or amount of light produced by the laser sensor is optimally matched to the reflection characteristics of the target surface, which enables reliable measurements even of difficult, changing surfaces.

The IF2030 module from MicroEpsilon converts the sensor’s RS422 output for integration to industrial networks and is available for Profinet or Ethernet/IP. The IF2030 EtherNet I/P interface module is a single channel system that is compatible with Micro-Epsilon sensors that output data via their RS422 or RS485 interface. The interface module supports data rates up to 4 MBaud and can be installed in switching cabinets via a DIN rail.

“When I first contacted MicroEpsilon, their application know-how and experience was evident. Once I had fully explained our application to Micro-Epsilon, they advised me on which type of measurement technique would be most suitable, in this case laser triangulation. From there, they advised me on which sensor product would best meet our needs. The only aspect of the sensor solution that we decided 39

ABB helps make fashion industry more sustainable with innovative technology ABB will deliver automation, electrification, quality control systems, motors and drives for Renewcell’s new industrial textile recycling production line in Sundsvall, Sweden. Renewcell is a fast-growing Swedish sustaintech company specializing in textile-to-textile recycling.

With ABB technology, a former SCA paper mill will be transformed into the world’s first commercial-scale recycling plant for cellulosic textiles – created by dissolving natural materials such as cellulose which is then regenerated to create a wide range of fabrics. Renewcell is already working with several fashion manufacturers, and in 2020, the company and H&M Group entered a multi-year partnership to replace virgin fibers with recycled textiles in clothing.

The contract between ABB and Renewcell marks an important milestone for the fashion industry, as it has a major impact on the environment due to the production of raw materials that are made into clothing. According to Renewcell’s preliminary calculations, textile

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fibers made from its recycled raw material use approximately 50 liters of fresh water per kg in production, compared to around 1,600 liters for cotton and 90 liters for non-cotton cellulosic material viscose. With a maximum production capacity of 60,000 tons per year Renewcell’s innovative approach could help to preserve around 90 billion liters of fresh water, the equivalent of 36,000 Olympic-sized swimming pools.

The process also lowers waste, plastic pollution and both CO and chemical emissions. The use of recycled fabric can help brands deliver on their promises to reduce their negative impact.

“The ABB team proved their unique ability to deliver a complete automation and electrification solution based on their products

and services,” said Patrik Lundström, CEO at Renewcell.

“They have the knowledge, presence and experience that we need to keep this project on track, both in terms of budget and schedule. We also share a joint vision when it comes to resource efficiency, circular economy and sustainability so are pleased to be working closely with them on this exciting project.”

“As a technology company, we at ABB believe that electrification and automation technologies can play a key role in transforming industries and reducing their environmental footprint,” said Theodor Swedjemark, ABB’s Chief Communications and Sustainability Officer. “We are honored to support Renewcell

in their exciting journey towards increased circularity of the fashion industry – an ambition that is fully aligned with our own efforts to systematically improve circularity across ABB’s supply chain as part of our 2030 sustainability strategy.”

Joachim Braun, Division President, Process Industries, ABB said: “This contract allows us to apply our deep pulp and paper expertise and project experience to help Renewcell reduce its emissions and preserve resources, and ultimately change fashion for the better. Until now, less than one percent of textiles were recycled because the technology to recycle and create new textiles did not exist. This is a significant development for the industry and we’re proud to apply our quality control processes to the sustainable fashion movement.”

The process for clothing recycling is similar to pulp drying, breaking down cellulose in cotton and viscose textiles to recycle into new raw materials.

This similarity enables Renewcell to use the existing infrastructure, including buildings and the supply and processing of raw water, waste water, compressed air and electricity at the SCA mill. This will be coupled with ABB’s paper and automation expertise, to manufacture recycled textiles that might otherwise have gone to landfill or incineration.

ABB brings its domain expertise from the pulp and paper industry, for example with specific technology to control the pulp dryer – a piece of equipment that was previously in use to dry raw wood pulp for paper and packaging – and quality control knowledge specific to the process.

The customer requested weight and moisture measurement based on testing on a pilot machine.

Among the ABB technology that will be installed in the new plant is the market-leading process control system ABB Ability™ System 800xA that will provide operators with wide visibility and precise control from a central command center to ensure that production is as resource efficient as possible, with less material consumption and reduced waste. In addition, ABB’s PMC800 drive systems will reduce the cost of ownership over the automation lifecycle and improve energy efficiency during production.

ABB will also supply ACS880 variable speed drives (VSDs) and IE4 super premium efficient motors, an efficiency level above the IE3 standard mandated by EU Ecodesign regulations. Combining high-efficiency motors with VSDs can typically reduce energy consumption in flow-controlled pulp and paper applications by 30 percent or more.

ABB is committed to helping its customers reduce their emissions and preserve resources. Last year, ABB released its Sustainability Strategy 2030 which focuses on the areas where the company can make the biggest impact – reducing carbon emissions, preserving resources and promoting social progress.

ABB (ABBN: SIX Swiss Ex) is a leading global technology company that energizes the transformation of society and industry to achieve a more productive, sustainable future. By connecting software to its electrification, robotics, automation and motion portfolio, ABB pushes the boundaries of technology to drive performance to new levels. With a history of excellence stretching back more than 130 years, ABB’s success is driven by about 105,000 talented employees in over 100 countries. www.abb.com

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Titan explains the factors that determine Flow Meter performance Titan Enterprises has published a new technical article focusing on flow meter performance. The article discusses the factors involved in determining the overall performance of pulse output turbine flow meters and how each factor influences the accuracy of flow measurement.

Flowmeters have become essential measuring devices used in a vast array of different industries. From commercial applications measuring the fuel feeding industrial boilers, for flow monitoring of lubricant supply lines for wind turbines, to dosing chemicals for agricultural sprays. Domestically, flow meters are installed to manage the dispensing of beer or coffee and built into washing machines and dishwashers to meter efficient water usage.

Turbine flow meters are invaluable measurement tools, and their repeatability and linearity are the key elements that determine the

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flowmeter’s performance and overall accuracy. Both the mechanical properties of the flow meter and the physical properties of the fluid combine to influence the general performance of the flow measurement device.

Terms synonymous with calibrating flow meters – the K-Factor, calibration uncertainty, repeatability, accuracy and linearity – are explained. The technical article discusses the relationship between all these flow factors and how they each influence the overall performance of a flow meter.

Whereas turbine flow meters, such as Titan’s Beverage flow meter and 800 series, offer the high level of repeatability and reliability required for accurate batch delivery systems, Titan’s Atrato® and Metraflow® ultrasonic flow sensors and the larger oval gear flow meters, are highly accurate over wider flow ranges, especially with viscous liquids such as oils.

Neil Hannay, Senior R&D Engineer with Titan Enterprises, suggests: “When customers are deciding on appropriate flow meters to suit their application, they need to be aware of the difference between FSD linearity and ‘of reading’ linearity accuracy, as often suppliers do not specify which accuracy is being quoted for.” The technical article from Titan illustrates how the linearity reading has a significant impact on the performance of the flowmeter, particularly at the low end of its flow range.

To read the technical article in full please visit: www.flowmeters. co.uk/titan-explains-the-factorsthat-determine-flow-meterperformance/ For further information on flow measurement devices to suit specific applications, please contact Titan Enterprises on +44 (0)1935 812790 or sales@flowmeters.co.uk.

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Real-world torque measurements enable electric car competition to go virtual Student engineers are using a newly launched torque sensor for predicting the energy efficiency of a competition-grade electric car.

Young technologists from the University of Sheffield alleviated their disappointment at the Covidcancellation of Shell Eco Challenge Rally by instead developing a computer simulation tool for predicting electric cars’ energy efficiency.

The university has a long association with the Shell Eco Challenge, in which student teams from around Europe compete to see whose car electric will cover the greatest distance on a single charge. So, when Covid shut down the event, rather than abandon their efforts Team Sheffield shifted their focus and set about a related project.

“We have been developing our own computer simulation tools for predicting our electric vehicle’s (EV’s) energy efficiency,” says student Lucy Edwards.

“This has let us calculate our vehicle’s competition score for the 40 minute/15km competition run.”

To put the competition into context, Shell Eco EVs achieve upwards of 800 km/kWh, whereas the EVs on the road today may achieve only 15 km/kWh (at the same 25 kph).

The competition EV are of course ultra lightweight, very aerodynamic single seaters and the drivers chosen by weight, whereas their road-going counterparts are better adapted for say a family day out. However, the competition demonstrates the potential of electric propulsion and, over the years, has undoubtedly helped development of the technology.

Sheffield’s involvement is extracurricular but provides a great opportunity for the students to

apply what they have learnt in lectures in a practical context.

To build the simulation tool, the students used their knowledge of engineering theory to create a mathematical representation of all the energy losses present in the car. A key piece of data was the motor efficiency curves, which were derives using a dual-purpose powertrain test rig and motor dynamometer.

This was developed in-house and based around a TorqSense SGR521, the latest product from from Sensor Technology Ltd, Banbury based specialists focused on developing torque and load measuring technologies.

In fact, Sensor Technology is a regular supporter of Shell Eco Challengers; over the years it has supported several teams from mainland Europe and now one from the UK. “The student teams basically need to run lots of tests on their drive motors and map out the results,” explains Mark Ingham of the company. “As such they are really no different from motor test engineers the world over.

“We are far and away the most active supplier of torque measuring technology and expertise to the Eco Challenge. It is very gratifying to know we give young engineers at the start of their careers a solid grounding in such an important subject, which they will be calling on for decades to come.”

Like their professional counterparts, the young engineers tend to want to develop a test rig that is accurate and easy to use. Usually,

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they also have space and time constraints, so want a compact design which is quick and easy to set up for each test.

“Our new SGR510/520 range fulfils all these requirements,” says Mark.

“It’s only been on the market for a couple of months but is already proving itself to be a favourite in EV test labs around the world – and that is a rapidly growing market at the moment.”

For the Shell Eco Challenge, teams across Europe have to design and build their own electric cars and motor controllers in-house. Typically, powertrains are based on either a brushless DC, or PMSM motor - and complex control algorithms are needed for precision control.

This requires custom electronics, typically based on MOSFETs and other carefully chosen low power loss components.

In fact, the rules of the Challenge are such that the controller is included in the motor testing that is done on each teams’ entry. In effect, the capabilities of each piece of hardware are quantified so that the teams can see how they compare with each other.

Lucy sums up the team’s year: “With the tools and hardware we have developed we have posted competitive competition scores. Of course, we are all hoping that soon Covid restrictions allow us to meet our competitors face to face and compete car against car. That will be real world engineering at its best.”

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From the smallest housed camera with C-mount over 10GigE to AI Preview: Product innovations from IDS on display at VISION 2021 From precise monitoring to picking and automation, there are countless applications that benefit from reliable image information. However, what can be done when there is only a tight budget for the realisation of such an application? With the introduction of uEye XCP, uEye XLE and Ensenso S, camera specialist IDS proves that industrial-grade image processing technology does not have to be expensive.

For users who need a camera for particularly fast data transfer and also require high-resolution sensors, there will be the uEye Warp10 in future.

The company also has big plans for IDS NXT. The next software update will follow in October, making the embedded vision system even more user-friendly and the AI behind it easier to understand. All innovations will be presented at VISION on the IDS booth 8C60 with the help of demo systems.

IDS invites all those who cannot visit the trade fair to take a virtual tour of the booth. On the IDS Vision Channel (www.ids-visionchannel.tech), users can discover the new products at the same time as regular VISION visitors. uEye XCP: Smallest industrial camera with housing and C-mount The new uEye XCP camera family from IDS shows that costeffective industrial cameras with C-mount can also be offered in the industry’s smallest standard format. Initially, the USB3 camera will be launched with the 2.3 MP AR0234 global shutter sensor and the 5 MP AR0521 rolling shutter sensor from ON Semiconductor.

Their cost-optimised

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design makes them ideal for high-volume and price-sensitive projects. The cameras feature a fully enclosed die-cast zinc housing measuring just 29 x 29 x 17 mm. Their C-mount adapter allows the use of common lens sizes and ensures a favourable system price. uEye XLE: Versatile and consistently cost-optimised For anyone looking for cameras specifically designed for highvolume and price-sensitive projects, the uEye XLE camera family is also worth considering.

Thanks to different housing and lens holder variants, extremely compact dimensions and USB3 interface, the cameras can be easily integrated into any image processing system.

Customers can choose between models with plastic housing and C/CS mount or S-mount and board-level version with or without C/CS mount or S-mount lens holder.

Available with the 2.3 MP sensor ON Semiconductor AR0234 and the light-sensitive 5 MP sensor ON Semiconductor AR0521, other sensors will follow. uEye Warp10: 10GigE high-speed for image data For users with particularly high demands on resolution, image quality and transmission speed, IDS will launch industrial cameras with a 10GigE high-speed interface and various sensors under the name uEye Warp10.

They are capable of precisely capturing even high-speed processes and forwarding the image information in the network without delay. They excel in sports

analysis as well as in highprecision surveying and inspection tasks. The company plans to implement large-format sensors up to 45 MP. Ensenso S: Compact and budgetfriendly 3D camera Ensenso S has been specially designed for 3D applications that require budget-friendly, easy-tointegrate and industrial-grade camera technology. Especially price-sensitive projects in logistics, automation or agriculture can now benefit from industrialgrade 3D imaging. The models are equipped with an ultra- compact zinc die-cast housing (IP 65/67), a 1.6 MP Sony sensor and an infrared LED laser and provide robust 3D information even in low ambient light.

IDS NXT ocean: Embedded vision system with AI becomes even more user-friendly Artificial intelligence running directly on cameras and enormous flexibility through vision apps – this makes tasks possible where conventional image processing reaches its limits. IDS provides users with all the necessary and perfectly coordinated tools and workflows to realise their own AI vision applications without prior knowledge. The next free software update will be released in October.

It will focus on user-friendliness – e.g., new features will be integrated into the IDS NXT cockpit – as well as on making artificial intelligence comprehensible. New helpful tools, such as attention maps, illustrate how the camera AI works and makes decisions.

Learn more: https://en.ids-imaging.com/ vision-2021.html

Mclennan and MOONS’ sign partnership for hybrid stepper motor distribution MOONS’, the Shanghai stock exchange listed designer and manufacturer of high-performance motion control components has production, research and sales facilities that extend internationally. For Mclennan, a long-established distribution partnership with Applied Motion Products (AMP) – a MOONS’ USA subsidiary - brings stepper and servo drives and controls that perfectly complement its motion system design and integration capability. Now, widening its ties with MOONS’, Mclennan has signed a UK and Ireland distribution agreement directly with the parent company for the sale and support of MOONS’ extensive range of hybrid stepper motors.

MOONS’ position as a global Top 3 hybrid stepper motor manufacturer is demonstrated by its annual shipment rate of over 10 million

motors and a strong reputation for creative solutions and high-quality products. Economies of scale in advanced automated production maintain highly competitive pricing whilst flexible manufacturing systems allow economic customisation for complete application matching.

The extensive range covers frame sizes from NEMA 8 through NEMA 42, available in a wide choice of stack lengths with 2 or 3 phase unipolar and bipolar windings.

These precision quality 200 and 400 step/rev motors offer innumerable advantages in throughput and performance for OEMs and end users alike. MOONS’ design refinements include standard highfill motor windings for increased torque over competitive size-forsize motors as well as low inertia rotors for higher acceleration. Other advantageous features include

increased efficiency models for lower power consumption, motors with low loss stators for higher speed performance and low detent torque motors for reduced resonance and quieter operation.

With its own design and production capability, Mclennan works closely with its distribution partners and customers to bring motion control and automation solutions that, as part of the enabling technology of a machine or process, bring distinct benefits in performance whilst competitively maintaining high quality and reliability.

Mclennan’s engineers can assist with motor sizing, drive technology, and motion controls for MOONS’ complete range of hybrid stepper motors.

For further information please visit www.mclennan.co.uk, email sales@ mclennan.co.uk, or call +44 (0) 1252 531444.

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