New Danfoss VLT® Decentral Drive E cient, reliable and powerful
New Danfoss VLT® Decentral Drive E cient, reliable and powerful
New Danfoss VLT® Decentral Drive E cient, reliable and powerful
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DRIVES & CONTROLS www.drives.co.uk NOVEMBER/DECEMBER 2010<br />
<strong>Drive</strong>s&Controls<br />
NOVEMBER/DECEMBER 2010<br />
THE LEADING MAGAZINE FOR AUTOMATION, POWER TRANSMISSION AND MOTION CONTROL<br />
<strong>New</strong> <strong>Danfoss</strong> VLT® <strong>Decentral</strong> <strong>Drive</strong><br />
Effi<strong>cient</strong>, <strong>reliable</strong> <strong>and</strong> <strong>powerful</strong><br />
Find out about the new dedicated <strong>Danfoss</strong> VLT® conveyor solution on the following pages!<br />
TCO<br />
Total Cost of Ownership<br />
Every aspect of the FCD 302<br />
contributes to the lowest TCO.<br />
Its unique design is intended to<br />
simplify ordering, installation,<br />
commissioning, operation <strong>and</strong><br />
maintenance.<br />
BEARINGS, BELTS AND CHAIN:<br />
A look at the vital role played by mechanical technologies<br />
PLCs <strong>and</strong> HMIs:<br />
Trends <strong>and</strong> applications from the world of controls<br />
LINEAR MOTION:<br />
Linear technologies at work from museums to industry<br />
One<br />
box concept<br />
Everything needed to<br />
control the motor is<br />
contained in the IP 66<br />
drive enclosure<br />
www.drives.co.uk
VLT® <strong>Decentral</strong> <strong>Drive</strong> FCD 302<br />
Putting the control closer<br />
to your motors<br />
– all you need is in one box<br />
It’s really that simple – everything needed to control the motor is contained within the IP 66 drive<br />
enclosure. Just loop the mains cable into the box, out to the next box, connect a cable to the motor <strong>and</strong><br />
you’re ready to run. Add a high speed fieldbus cable <strong>and</strong> your drives are an integral part of the whole<br />
drives control network. No need for an external 24 V DC power supply, no need for an external controller<br />
or motor switch – it’s all in the FCD 302.<br />
EHEDG<br />
Approval<br />
Compliance with the requirements for best<br />
cleaning <strong>and</strong> hygienic design according to<br />
EHEDG (European Hygienic Engineering &<br />
Design Group)<br />
www.danfoss.co.uk/vlt
VLT® <strong>Decentral</strong> <strong>Drive</strong> FCD 302 I VLT® OneGear<strong>Drive</strong> I VLT® Automation<strong>Drive</strong> FC 302<br />
Energy effi<strong>cient</strong>, flexible, <strong>reliable</strong><br />
– the new <strong>Danfoss</strong> conveyor solution<br />
offering total flexibility in your plant design<br />
The dem<strong>and</strong> for higher energy efficiency, different motor technologies <strong>and</strong> both centralised <strong>and</strong> decentralised<br />
plant designs has increased the number of solutions in use today for electrical drive components such as<br />
motors <strong>and</strong> frequency converters in many production plants. This leads to large stocks of spare parts, high<br />
training costs, dependence on a single manufacturer <strong>and</strong> a lack of flexibility. <strong>Danfoss</strong> expects the new flexible<br />
VLT® solution for conveyors to make sweeping changes in this area <strong>and</strong> significantly reduce effort <strong>and</strong> costs.<br />
The new <strong>Danfoss</strong> conveyor solution –<br />
consisting of the new VLT® <strong>Decentral</strong><br />
<strong>Drive</strong> FCD 302, VLT® OneGear<strong>Drive</strong><br />
<strong>and</strong> VLT® Automation<strong>Drive</strong> FC 302<br />
gives plant engineers <strong>and</strong> operators<br />
a very high degree of flexibility in<br />
the choice of components <strong>and</strong> plant<br />
structures. Regardless of whether the<br />
plant design is centralised or decentralised<br />
<strong>and</strong> whether the drives are<br />
used in dry, wet or aseptic areas, the<br />
flexible VLT® concept provides highly<br />
effi<strong>cient</strong> components for every<br />
conveying task. The concept aims to<br />
optimise costs in tailored drive systems<br />
as result of high flexibility, high<br />
efficiency, reduced version count <strong>and</strong><br />
an intelligent control concept.<br />
High flexibility<br />
Thanks to the open system architecture<br />
of the flexible VLT® concept,<br />
plant operators can easily <strong>and</strong> reliably<br />
combine components with existing<br />
solutions from other manufacturers,<br />
for example when exp<strong>and</strong>ing<br />
or refitting the plant, to achieve the<br />
required optimum configuration.<br />
Furthermore, the new VLT® concept<br />
is currently the only solution on the<br />
market offering EHEDG-certified<br />
components specifically designed<br />
for installation directly in plant areas<br />
where hygiene is critical. All components<br />
are coordinated with each<br />
other to ensure rapid commissioning<br />
<strong>and</strong> optimum efficiency of the<br />
overall solution.<br />
High efficiency<br />
Without exception, the <strong>Danfoss</strong><br />
components used in this solution,<br />
whether for new plants or for retrofitting<br />
or modernising existing plants,<br />
are highly effi<strong>cient</strong> <strong>and</strong> comply with<br />
the actual requirements of users <strong>and</strong><br />
the latest EU regulations on motors<br />
<strong>and</strong> motor efficiency.<br />
Simpler configuration<br />
The range of components reduces<br />
the overall number of variants in the<br />
plant by up to 70%. In many cases we<br />
are able to provide end-to-end solutions<br />
for conveyor applications with<br />
just a few variants, so spare parts<br />
stocks can be considerably smaller<br />
than is currently the case.<br />
Flexible <strong>and</strong> energy-effi<strong>cient</strong><br />
– VLT® frequency converters<br />
The new VLT® <strong>Decentral</strong> <strong>Drive</strong> FCD<br />
302 offers the same functionality in<br />
a decentralised converter as in the<br />
Up to70%<br />
reduction<br />
in overall number of variants in the plant<br />
by applying the components of the new<br />
VLT® conveyor solution
VLT® Automation<strong>Drive</strong> FC 302, which<br />
is designed for centralised plant<br />
configurations. Both have the same<br />
user interface concept in the form of<br />
a graphic message display, which can<br />
be connected to the FCD 302 on-thefly<br />
at any time.<br />
Both devices can drive st<strong>and</strong>ard<br />
motors with or without encoder<br />
feedback, as well as the compact,<br />
energy-effi<strong>cient</strong> PM motors in our<br />
VLT® OneGear<strong>Drive</strong> series.<br />
VLT® OneGear<strong>Drive</strong><br />
The efficiency of these motors<br />
exceeds even the premium IE3 class<br />
defined in the new EU regulation.<br />
With only two motor types <strong>and</strong><br />
three available gear ratios, the motor<br />
concept covers all typical versions<br />
for effective conveyor drives commonly<br />
used in e.g. the food <strong>and</strong><br />
beverage industry. The system as a<br />
whole, comprising motor, gear unit<br />
<strong>and</strong> frequency converter, achieves<br />
an efficiency up to 90%, yielding<br />
savings of up to 25% compared with<br />
conventional systems.<br />
Contact one of our competence centres<br />
<strong>and</strong> find out how you can save<br />
efforts <strong>and</strong> reduce inventory costs in<br />
your production plant.<br />
<strong>Danfoss</strong> VLT <strong>Drive</strong>s PartnerNET<br />
One place – one solution<br />
<strong>Danfoss</strong> VLT <strong>Drive</strong>s Competence Centres<br />
are fully equipped to satisfy the<br />
total needs of our valued <strong>Drive</strong>s customers;<br />
providing assistance in sales,<br />
installation, commissioning, technical<br />
support <strong>and</strong> service 24/7/365.<br />
For further information please<br />
contact <strong>Danfoss</strong> VLT <strong>Drive</strong>s on<br />
01895 617 100 or your Regional<br />
Competence Centre directly.<br />
Regional<br />
Competence Centres<br />
Scotl<strong>and</strong><br />
Tel: 01324 633 203<br />
WJ Electrical Supplies Limited<br />
Irel<strong>and</strong><br />
Tel: 0870 178 0056<br />
Greenville Industrial <strong>Drive</strong>s &<br />
Controls<br />
Northern Engl<strong>and</strong><br />
Tel: 01457 837 145<br />
P-n-P <strong>Drive</strong>s & Controls Ltd<br />
Southern Engl<strong>and</strong><br />
Tel: 01923 655955<br />
K2 <strong>Drive</strong>s <strong>and</strong> Controls Limited
DRIVES & CONTROLS<br />
Editor<br />
Tony Sacks, BA, BSc<br />
t/f: 01732 465367<br />
tony@drives.co.uk<br />
Production Manager<br />
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sarah@dfamedia.co.uk<br />
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clare@dfamedia.co.uk<br />
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doug@drives.co.uk<br />
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t/f: 01353 863383<br />
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karenkcs@aol.com<br />
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Western US <strong>and</strong> Canada<br />
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alankcs@aol.com<br />
t: +1 717 397 7100<br />
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http://www.drives.co.uk<br />
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Printing: Garnett Dickinson Print Ltd.<br />
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ISSN 0950 5490<br />
Copyright DFA Media Ltd 2010<br />
UPDATE<br />
3 NEWS<br />
A round-up of the latest business <strong>and</strong> industry developments from<br />
around the world.<br />
12 TECHNOLOGY<br />
Cutting-edge innovations in motion, power transmission, controls <strong>and</strong><br />
related technologies.<br />
IN DEPTH<br />
21 Cyber-security<br />
The recent widespread publicity given to the Stuxnet virus has brought home<br />
the real threat to industrial control systems posed by viruses <strong>and</strong> hackers. An<br />
expert examines the risks <strong>and</strong> how to minimise them.<br />
23 Linear Motion<br />
How a variety of linear motion technologies are being used in applications<br />
ranging from immersive 4D entertainment rides at museums, to tobacco<br />
processing machinery <strong>and</strong> controlling the flow of a Scottish river.<br />
29 Bearings, Belts <strong>and</strong> Chains<br />
Advice on how to tackle<br />
bearing currents <strong>and</strong> how<br />
to prolong the life of your<br />
chains, as well as<br />
examples of applications<br />
ranging from wind tunnels<br />
to solar power plants.<br />
39 PLCs <strong>and</strong> HMIs<br />
We examine some of the trends that are driving the development of control<br />
<strong>and</strong> display systems, <strong>and</strong> look at some examples of how these technologies<br />
are being applied in the real world.<br />
REGULARS<br />
11 Comment<br />
46 Gambica column<br />
47 ABB Energy Saving Award<br />
48 Dave’s <strong>Drive</strong>s Diary<br />
Design Data<br />
49 Software<br />
50 Multimedia<br />
51 Products<br />
60 Products & Services<br />
64 Appointments<br />
IN THIS ISSUE November/December 2010 Vol 26 No 10<br />
<strong>Drive</strong>s&Controls<br />
<strong>New</strong> <strong>Danfoss</strong> VLT® <strong>Decentral</strong> <strong>Drive</strong><br />
Effi<strong>cient</strong>, <strong>reliable</strong> <strong>and</strong> <strong>powerful</strong><br />
Find out abou the new dedicated <strong>Danfoss</strong> VLT® conveyor solution on the fo lowing pages!<br />
TCO<br />
Total Cost of Ownership<br />
Every aspect of the FCD 302<br />
contributes to the lowest TCO.<br />
Its unique design is intended to<br />
simplify ordering, insta lation,<br />
commissioning, operation <strong>and</strong><br />
maintenance.<br />
NOVEMBER/DECEMBER 2010<br />
BEARINGS, BELTS AND CHAIN:<br />
A look a the vital role played by mechanical technologies<br />
PLCs <strong>and</strong> HMIs:<br />
Trends <strong>and</strong> applications from the world of controls<br />
LINEAR MOTION:<br />
Linear technologies at work from museums to industry<br />
One<br />
NEXT ISSUE<br />
The January issue of <strong>Drive</strong>s & Controls will contain detailed reports from<br />
the SPS/IPC/<strong>Drive</strong>s show, as well as our annual variable speed drives<br />
supplement, <strong>and</strong> reports from the world of gears <strong>and</strong> gearboxes.<br />
box concept<br />
Everything needed to<br />
control the motor is<br />
contained in the IP 66<br />
drive enclosure<br />
23<br />
37<br />
THE LEADING MAGAZINE FOR AUTOMATION, POWER TRANSMISSION AND MOTION CONTROL<br />
www.drives.co.uk<br />
www.drives.co.uk<br />
24<br />
30<br />
43<br />
51<br />
52<br />
56<br />
58<br />
58<br />
CONTENTS
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High power den sity > 12 kVA/litre<br />
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AC connections at front or rear<br />
United Kingdom, Hertford +44 1992 584677 info.skuk@semikron.com www.semikron.co.uk
UK industry ‘is not managing<br />
its electric motors effectively’<br />
NEWS<br />
ABB IS WARNING that much of British industry is not<br />
managing its electric motors correctly <strong>and</strong> is<br />
rewinding too many old motors, rather than<br />
replacing them with more effi<strong>cient</strong> new models. This<br />
is costing it millions of pounds in terms of<br />
unnecessary downtime, repairs <strong>and</strong> energy usage.<br />
ABB says that the problem is highlighted by the fact<br />
that the motor repairs industry in the UK is now<br />
worth more than twice as much as the £70m market<br />
for new low-voltage industrial motors.<br />
While acknowledging that mechanical repairs, such<br />
as bearings <strong>and</strong> shafts, will always be needed, ABB<br />
argues that too many motors are being rewound<br />
automatically.<br />
Steve Ruddell, manager of ABB’s UK motors<br />
business, believes that the reason for so many<br />
rewinds <strong>and</strong> premature failures is a lack of awareness<br />
among end-users of the need to create motor<br />
management plans. “It appears much easier when a<br />
motor fails to have someone collect it, rewind it <strong>and</strong><br />
reinstall it,” he says. “But what if this is a critical,<br />
continuous-process application? Taking it offline<br />
could cost hundreds of pounds per hour.<br />
“Some industries are better than others,” he adds.<br />
“The pulp <strong>and</strong> paper sector, for example, tends to<br />
have a policy that if any motor is running for more<br />
than 4,000 hours per year, it will be replaced<br />
automatically by a high-efficiency motor at the point<br />
of electrical failure. Any motor below 75kW,<br />
irrespective of running hours, is automatically<br />
replaced at point of electrical failure.<br />
“No one should be making inferior motors today,”<br />
Ruddell continues. “The technology <strong>and</strong> materials<br />
used by today’s motors gives them an expected<br />
lifespan in excess of 20 years. They should be durable<br />
<strong>and</strong> highly <strong>reliable</strong>. Yet many repairers have motors<br />
Rudell: a few small steps can<br />
lead to significant leaps<br />
less than five years old on their<br />
benches for rewind, alongside older<br />
motors having had multiple rewinds.<br />
“It is analogous to the car industry,”<br />
he suggests. “Today you rarely see a<br />
rusty car <strong>and</strong> very rarely see cars<br />
breaking down. Technology has<br />
improved the reliability <strong>and</strong> lifespan of<br />
cars, <strong>and</strong> the same is true for lowvoltage<br />
motors.”<br />
To encourage better motor<br />
management practices, ABB has<br />
launched a scheme called<br />
MotorAdvantage, designed to reveal<br />
the true cost to a company of running<br />
its electric motors. The scheme<br />
includes a site visit by a motor<br />
engineer who assesses the installed<br />
motor base <strong>and</strong> identifies up to five<br />
motor-driven applications with the<br />
potential for further analysis.<br />
The scheme also assesses the user’s<br />
motor failure policy <strong>and</strong> its financial<br />
implications, identifies potential<br />
improvements to this policy <strong>and</strong><br />
stockholding, <strong>and</strong> determines the<br />
energy use of the current installation.<br />
According to Ruddell, a motor<br />
management plan can pay for itself<br />
within weeks, if not days, by<br />
preventing unplanned outages.<br />
“MotorAdvantage aims to elevate<br />
motors from being a hidden asset,<br />
with an out-of-sight, out-of-mind<br />
maintenance approach, to an asset<br />
that can earn you real financial<br />
rewards immediately,” he says. “Our<br />
job is to re-educate the market into<br />
the enormous savings that they could<br />
be making from this asset.<br />
“We want to show industry that a<br />
few small steps can lead to significant<br />
leaps in a plant or process<br />
profitability,” Ruddell continues.<br />
“Normally motor management plans<br />
are overly ambitious, trying to assess<br />
every single motor on a plant.<br />
“If it is more cost-effective to rewind<br />
a motor, we will advise of that action,”<br />
Ruddell emphasises. “Our role is no<br />
longer just about making motors – we<br />
need to help companies manage the<br />
ones they have in place more<br />
effectively.”<br />
www.abb.co.uk/energy<br />
Stuxnet virus targets Vacon inverters<br />
THE LATEST REVELATIONS about the<br />
Stuxnet virus suggest that it contains<br />
code that can alter the operation of<br />
frequency inverters from the Finnish<br />
drives-maker Vacon <strong>and</strong> from an Iranian<br />
supplier called Fararo Paya, thus varying<br />
the speeds of motors they are controlling.<br />
Eric Chien from the anti-virus specialist<br />
Symantec says that although his<br />
company had previously discovered that<br />
Stuxnet modifies PLC code in a potential<br />
act of sabotage, it had not been able to<br />
determine its exact purpose or target.<br />
However, its latest findings indicate<br />
that Stuxnet targets industrial control<br />
systems containing drives from at least<br />
one of the two vendors, as well as the<br />
previously identified Siemens S7-300<br />
CPUs <strong>and</strong> CP-342-5 Profibus modules.<br />
The virus requires the drives to be<br />
operating at the relatively high frequency<br />
of 807–1,210Hz. When Stuxnet finds the<br />
specified inverters operating at these<br />
speeds, it changes their output<br />
frequencies <strong>and</strong> thus the speed of the<br />
motors they control for short intervals<br />
spread over periods of months, thus<br />
disrupting the processes being controlled.<br />
Chien points out that drives with<br />
outputs above 600Hz are regulated for<br />
export by the US Nuclear Regulatory<br />
Commission because they can be used<br />
for uranium enrichment. Earlier reports<br />
have suggested that Stuxnet might be<br />
targeting centrifuges used by Iran as part<br />
of its nuclear programme.<br />
If the drives continue to run at high<br />
speeds for a period of time (about 13<br />
days), Stuxnet hijacks the PLC code <strong>and</strong><br />
begins modifying the drives’ behaviour.<br />
Over a period of months, it changes their<br />
output frequencies to 1,410Hz for short<br />
periods, <strong>and</strong> then to 2Hz <strong>and</strong> 1,064Hz.<br />
This “essentially sabotages the<br />
automation system from operating<br />
properly,” says Chien. Other parameters<br />
may also change, causing unexpected<br />
effects.<br />
Details of Symantec’s latest findings<br />
are contained in an updated version of its<br />
White Paper on Stuxnet. It has also<br />
created a YouTube video demonstrating<br />
how Stuxnet can hijack PLCs.<br />
http://goo.gl/YwTZC<br />
www.drives.co.uk November/December 2010 3
NEWS<br />
IN BRIEF<br />
Rockwell Automation has reported<br />
sales for the 2010 fiscal year worth<br />
$4,857m – a 12% increase on 2009.<br />
CEO Keith Nosbusch reports signs<br />
that spending on large capital<br />
projects is improving, although<br />
timings are still uncertain. He is<br />
predicting a revenue growth for 2011<br />
of 8–12%.<br />
RS Components is offering more<br />
than 30,000 own-br<strong>and</strong> products<br />
under the RS Essentials banner, with<br />
the claim that they are, on average,<br />
20% cheaper than br<strong>and</strong>ed<br />
manufacturers’ prices. The precise<br />
savings will vary, with some being<br />
above 20%. The products include<br />
bearings, tools, controls, power<br />
supplies <strong>and</strong> cables. All of the<br />
products are tested in-house by RS.<br />
The market analyst Frost & Sullivan<br />
predicts that the European Scada<br />
market, which as worth $1,325m in<br />
2009, will exp<strong>and</strong> to more than<br />
$1,900m by 2016. This growth will<br />
be driven by investments in Europe’s<br />
electricity <strong>and</strong> water sectors,<br />
supported by EU funding. Security<br />
regulations <strong>and</strong> compliance dem<strong>and</strong>s<br />
will also spur dem<strong>and</strong>, it adds.<br />
The Welsh Assembly is investing<br />
£26m in a project called Astute<br />
(Advanced SusTainable<br />
manUfacturing TEchnologies) aimed<br />
at boosting manufacturing industry<br />
by creating more than 130 skilled<br />
jobs <strong>and</strong> helping 350 enterprises <strong>and</strong><br />
40 collaborative r&d projects to get<br />
off the ground. The scheme, which is<br />
targeting the automotive <strong>and</strong><br />
aerospace sectors, is being led by<br />
Swansea University.<br />
Parker Hannifin <strong>and</strong> Brammer have<br />
signed a strategic pan-European<br />
partnership agreement, designed to<br />
extend the level of support <strong>and</strong><br />
product availability that both<br />
companies offer to customers in the<br />
fluid power sector. Initially covering<br />
15 countries, the agreement will<br />
provide guaranteed supply of Parker<br />
pneumatic, hydraulic, filtration <strong>and</strong><br />
instrumentation components <strong>and</strong><br />
systems to key accounts <strong>and</strong> endusers.<br />
David Harrow, managing director of<br />
Godiva Bearings, has been<br />
appointed president of the European<br />
Power Transmission Distributors<br />
Association for 2010/2011.<br />
Despite declining during 2009, the<br />
global market for gears, drives <strong>and</strong><br />
speed changers is expected to surge<br />
in the coming years. A recent report<br />
from Global Industry Analysts says<br />
that Europe remains the largest<br />
market, accounting for more than<br />
30% of global sales, but Asia-Pacific<br />
is the fastest-growing region with an<br />
annual growth rate predicted to be<br />
more than 5% for the next few years.<br />
Global drives sales<br />
‘will return to 2008<br />
levels next year’<br />
THE GLOBAL market for low-voltage AC <strong>and</strong> DC<br />
drives will return to double-digit growth this year<br />
with revenues reaching $10.5bn, <strong>and</strong> 16.4<br />
million drives being shipped. In a new report, the<br />
market analyst IMS Research predicts that drives<br />
sales will return to 2008 levels during 2011.<br />
Although the drives market did suffer as a<br />
result of the recession, it was not as severely<br />
affected as many other automation product<br />
markets. Total revenues in 2009 are estimated<br />
to have been $9.3bn – a 13% decline from<br />
2008, <strong>and</strong> just below 2007 levels. Around 13.9<br />
million drives were shipped during 2009 – an<br />
8% drop from 2008.<br />
Unit sales declined much less (in percentage<br />
terms) last year than revenues because of a shift<br />
in dem<strong>and</strong> from st<strong>and</strong>ard <strong>and</strong> premium drives<br />
to compact models. This shift resulted from<br />
customers’ increased price sensitivity due to the<br />
downturn, coupled with the increased<br />
capabilities of compact drives, allowing them to<br />
be used in a wider range of applications.<br />
“Companies across the board have reported<br />
Spectris pays $51m for<br />
industrial comms specialist<br />
THE BRITISH instrumentation<br />
<strong>and</strong> controls group Spectris<br />
has bought the US industrial<br />
networking specialist N-Tron,<br />
for $51m. The acquisition is<br />
in line with Spectris' strategy<br />
to exp<strong>and</strong> its key business<br />
segments.<br />
N-Tron, based in Mobile,<br />
Alabama, will become part<br />
UK owner:<br />
an N-Tron Ethernet switch<br />
of Spectris’ Industrial Controls segment <strong>and</strong> will co-operate<br />
with another US subsidiary Red Lion Controls, which supplies<br />
operator interface products. N-Tron, which employs around<br />
60 people, will keep its own br<strong>and</strong> <strong>and</strong> sales structure.<br />
N-Tron’s industrial communications products include<br />
managed <strong>and</strong> unmanaged Ethernet switches, media<br />
converters, power-over-Ethernet equipment, <strong>and</strong> wireless<br />
access devices.<br />
“The acceptance of Ethernet in the industrial market for<br />
integrating shop-floor information within the business IT<br />
infrastructure is rapidly increasing,” says Spectris CEO, John<br />
O'Higgins. “N-Tron's hardware capabilities will enable us to<br />
leverage Red Lion's communications technologies to meet this<br />
dem<strong>and</strong> <strong>and</strong> to build our position in the industrial controls<br />
market around the world.”<br />
Spectris, whose headquarters are in Egham, Surrey, employs<br />
around 5,800 worldwide <strong>and</strong> has offices in 29 countries.<br />
increased compact drives sales both during the<br />
downturn <strong>and</strong> in the recovery, causing large<br />
disparities between revenue <strong>and</strong> unit growth,”<br />
says IMS analyst, Sarah Sultan. “As the<br />
premium drives business begins to recover over<br />
the next several months, the disproportion<br />
between revenue <strong>and</strong> unit growth is expected<br />
to diminish.”<br />
IMS expects the Asia-Pacific region to<br />
overtake EMEA (Europe, the Middle East <strong>and</strong><br />
Africa) as the largest regional market for drive<br />
sales this year. The EMEA market is still<br />
struggling as a result of the financial crises in<br />
various European countries, <strong>and</strong> the weakness<br />
of the Euro.<br />
Nevertheless, IMS is forecasting a small<br />
positive growth in the EMEA region during<br />
2010, with a return to double-digit growth<br />
during 2011. By contrast, it predicts that the<br />
Asia-Pacific region will to grow by more than<br />
20% in 2010, after declining by only a few per<br />
cent during 2009.<br />
www.imsresearch.com<br />
Modified<br />
enclosures<br />
take 7 days<br />
RITTAL HAS announced a<br />
service called RittalXpress that<br />
will deliver custom-modified<br />
enclosures within seven<br />
working days of an order being<br />
placed online or by phone.<br />
The service has been created<br />
following market research <strong>and</strong><br />
discussions with customers<br />
which revealed a need for a<br />
turnkey service that delivers<br />
cost-effective, pre-configured<br />
enclosures quickly.<br />
Customers can order<br />
enclosures via a dedicated Web<br />
site, where they can search for<br />
products by application, size, IP<br />
rating, material or part number.<br />
Compatible accessories can<br />
then be added from a selection<br />
suitable for the chosen part.<br />
Modifications can be<br />
specified, including simple<br />
square or round holes, or more<br />
complex cut-outs such as holes<br />
for fans <strong>and</strong> filters, <strong>and</strong> baying<br />
kits. The modifications can be<br />
made to any enclosure face.<br />
www.rittal.co.uk<br />
4 November/December 2010 www.drives.co.uk
more than<br />
just a pretty<br />
interface.<br />
15"<br />
10"<br />
8"<br />
3" LCD<br />
only<br />
2 1 /2"<br />
deep<br />
The G3 Operator Interface Series.<br />
Connect. Convert. Acquire. Control. Anywhere.<br />
Red Lion’s G3 Series HMIs not only provide an intuitive interface for your connected<br />
devices, they give them a communications makeover. With the most on-board comms<br />
ports of any HMI available, you can monitor, control or acquire data from seven or more types<br />
of devices simultaneously—including PLCs, PCs, drives, PID controllers <strong>and</strong> more. Add even<br />
more connections with DeviceNet , CANopen <strong>and</strong> PROFIBUS, or with additional serial ports.<br />
G3 Series HMIs also feature integrated Ethernet, plus a built-in web server <strong>and</strong> gateway to webenable<br />
even your serial devices, allowing remote monitoring, operation<br />
<strong>and</strong> diagnostics. Pass-through communication capabilities let you use<br />
a G3 HMI as a conduit to your PLCs via industry-st<strong>and</strong>ard protocols,<br />
while a built-in protocol converter lets you share data between<br />
dissimilar devices. All G3s can log data in IT-ready CSV format<br />
that can be remotely accessed via the web server or automatically<br />
uploaded to an FTP site. And G3s can trigger an email or SMS<br />
message to your mobile device in response to an alarm condition.<br />
An attractive price too, made even more attractive by<br />
Red Lion’s free Crimson ® programming software. G3 models are<br />
available in a compact 3" LCD keypad panel, plus 6", 8", 10" <strong>and</strong> new 15"<br />
color touchscreens.<br />
See all the features at www.redlion.net/G3<br />
6"<br />
Operator Interface Protocol Conversion Signal Conditioning Panel Meters Data Acquisition<br />
Red Lion Controls Phone: +31 (0) 33-4723-225 Fax: +31 (0) 33-4893-793<br />
europe@redlion.net Toll Free from UK <strong>and</strong> France: (00800 733 54667)
NEWS<br />
Rare-earth crisis sparks quest for<br />
alternative motor technologies<br />
JAPANESE MOTOR manufacturers are<br />
scrambling for motor technologies that do<br />
not need rare earth metals, following a<br />
crisis in which China, which produces 95–<br />
97% of the world’s rare earths, cut off<br />
supplies to Japan <strong>and</strong> limited supplies to<br />
other countries. The materials – which<br />
include neodymium, dysprosium <strong>and</strong><br />
yttrium – are needed for a wide range of<br />
applications, from electric vehicles <strong>and</strong><br />
wind turbines, to computer hard drives <strong>and</strong><br />
mobile phones. They are a key component<br />
of high-power permanent magnets.<br />
In recent years, China has come to<br />
dominate the global market for rare earths<br />
by undercutting producers in other<br />
countries, thus forcing them out of the<br />
market. In recent months, however, it has<br />
raised the prices of some of its rare earth<br />
materials nine-fold.<br />
China has also cut back on its production<br />
of rare earths, citing environmental <strong>and</strong><br />
energy-saving reasons. At the same time, it<br />
is using more of them in domestic<br />
manufacturing, <strong>and</strong> is limiting exports.<br />
The rare earth problems hit the world’s<br />
headlines in September when China<br />
blocked supplies to Japan following a<br />
collision between ships from the two<br />
nations in disputed territorial waters.<br />
Japan relies on China for more than 90%<br />
of the 30,000 tonnes of rare earths it<br />
imports every year. Its dem<strong>and</strong> has been<br />
growing as it ramps up production of<br />
electric <strong>and</strong> hybrid vehicles, each of which<br />
typically needs 9–15kg of rare earths for<br />
motors, batteries <strong>and</strong> other equipment. A<br />
conventional car contains about 5kg of the<br />
materials.<br />
The crisis has accelerated Japan’s quest<br />
to reduce its dependence on rare earth<br />
materials, particularly from China. Its <strong>New</strong><br />
Energy <strong>and</strong> Industrial technology<br />
Development Organisation (Nedo)<br />
announced recently that, working with<br />
researchers from Hokkaido University, it<br />
has developed “the world’s first” rareearth-free,<br />
high-performance motor for<br />
hybrid vehicles. The 50kW motor is similar<br />
in performance to the motors currently<br />
used in Toyota’s Prius hybrid-electric car,<br />
which need 1kg of rare-earth materials.<br />
The Japanese motor-maker Nidec has<br />
revealed that it plans to start producing<br />
switched-reluctance motors, which do not<br />
need rare earths, in two years’ time. Nidec<br />
acquired the switched-reluctance<br />
technology when its bought Emerson<br />
Electric’s Motors <strong>and</strong> Appliance Controls<br />
businesses earlier this year. These<br />
businesses included the UK-based<br />
switched-reluctance specialist, SR <strong>Drive</strong>s.<br />
Nidec plans to start producing switchedreluctance<br />
motors for heavy machinery<br />
from 2012, followed by versions for<br />
tractors <strong>and</strong> other vehicles. At present,<br />
Piles of trouble:<br />
rare earth oxides<br />
(photo: US Department of Agriculture)<br />
Nidec produces synchronous motors for the<br />
electric vehicle market that rely on rareearth-based<br />
permanent magnets inside<br />
their rotor cores.<br />
Other motor developers with<br />
technologies that do not rely on rare-earth<br />
materials, are taking the opportunity to<br />
promote them. For example, Gibraltarbased<br />
Chorus Motors says that its<br />
multiphase Meshcon motor can produce<br />
five times the start-up torque of a similarsized<br />
conventional three-phase motor, <strong>and</strong><br />
more than a comparable permanent<br />
magnet motor, without using any rare<br />
earths or other exotic materials.<br />
The rare-earth supply problems could last<br />
for several years until new sources, now<br />
being developed, come on stream in<br />
countries including Vietnam, Australia,<br />
Kazakhstan, Turkey <strong>and</strong> India. In the US,<br />
rare earth production sites that were shut<br />
down because they could not compete<br />
with China, are being re-opened.<br />
Nidec targets GE <strong>and</strong> Bosch as it aims for the top<br />
THE ACQUISITIVE Japanese motor-maker Nidec has set its sights<br />
on becoming a global leader in the motors market, possibly by<br />
buying the motors activities of General Electric <strong>and</strong> Bosch. The<br />
company, which already claims to dominate the market for small<br />
precision motors for applications such as computer hard drives,<br />
is now exp<strong>and</strong>ing aggressively into the market for industrial <strong>and</strong><br />
appliance motors.<br />
Nidec, whose sales are expected to amount to around ¥700bn<br />
(£5.3bn) this year, is aiming to hit ¥1,000bn (£7.6bn) by 2012<br />
<strong>and</strong> ¥2,000bn (£15.2bn) by 2015. The company wants this<br />
income to be split evenly between four business “pillars”: small<br />
motors; industrial <strong>and</strong> appliance motors; automotive motors; <strong>and</strong><br />
other activities, including machinery <strong>and</strong> electronic components.<br />
Much of the growth in the industrial <strong>and</strong> automotive sectors<br />
will have to come through acquisitions. Even after Nidec’s recent<br />
acquisition of Emerson’s Motors <strong>and</strong> Controls business, its<br />
industrial <strong>and</strong> appliance motor activities account for less than<br />
¥100bn (£760m) of its income.<br />
Nidec’s chief executive Shigenobu Nagamori told the Financial<br />
Times recently that he is keen to buy the motor divisions of GE in<br />
the US <strong>and</strong> Bosch in Germany. In recent years, Nidec has had<br />
discussions with both companies, without reaching any<br />
agreement. But Nagamori is still keen to acquire both businesses<br />
which, he says, would fit well with Nidec’s existing operations.<br />
Nidec is also rumoured to be talking to Sanyo Electric about<br />
buying its motor activities.<br />
6 November/December 2010 www.drives.co.uk
Mechanical drives<br />
factory moves to Leeds<br />
Design<br />
Installation<br />
Take the complication out of designing, selecting<br />
<strong>and</strong> installing components <strong>and</strong> systems into your<br />
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Engineering Tools <strong>and</strong> support structure. From<br />
factory layout software through to CAD files,<br />
product configurators <strong>and</strong> documentation, Rexroth<br />
has the tools to simplify your project.<br />
www.boschrexroth.co.uk/etools<br />
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Support<br />
Simplify your system design,<br />
selection <strong>and</strong> installation<br />
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SIEMENS IS moving its mechanical<br />
drives (MD) factory from Bradford<br />
to a new purpose-built site in<br />
Leeds, with more space <strong>and</strong><br />
improved facilities.<br />
Since Siemens bought Flender’s<br />
gear <strong>and</strong> gear-motor business for<br />
€1.2bn in 2005, it has been<br />
investing in the operation. The<br />
new 4,645m 2 (50,000ft 2 ) factory<br />
Nadin: relentless commitment<br />
has 30% more production space,<br />
making it easier to optimise<br />
production cell layouts, as well as materials <strong>and</strong> h<strong>and</strong>ling flow. The<br />
site, in Stourton, will be used to assemble gears, geared motors,<br />
motors <strong>and</strong> couplings.<br />
The move has been overseen by Simon Nadin, who was<br />
appointed general manager of the MD division in July, replacing<br />
Nick Garthwaite, who has left the Siemens group. Nadin, who has<br />
been with Siemens since 1998, was previously based at the<br />
company’s drives factory in Congleton.<br />
“Siemens is committed to manufacturing in the UK <strong>and</strong> the<br />
mechanical gears aspect is a key element in the drive train,” he says.<br />
“This new facility will not only enhance our manufacturing capability;<br />
it will also be used to train apprentices <strong>and</strong> hold technical seminars.”<br />
Nadin believes that with the right strategy <strong>and</strong> investment, it is<br />
possible to be successful in the current economic climate. “A<br />
relentless commitment to process improvement is an essential part<br />
of our business DNA,” he states. “Without this focus, we open the<br />
door to competition.”<br />
The factory will be opened officially in early 2011.<br />
MV inverter is ‘world’s most effi<strong>cient</strong>’<br />
THE BRAZILIAN<br />
manufacturer WEG<br />
has produced a<br />
medium-voltage<br />
inverter which, it<br />
claims, is the world’s<br />
most effi<strong>cient</strong> <strong>and</strong><br />
<strong>reliable</strong>, with a 99% efficiency <strong>and</strong> a 22-year<br />
MTBF (mean time between failures). The 8,000hp (5,996kW),<br />
4.16kV system is also WEG’s largest-ever MV inverter.<br />
The 12-pulse inverter has been supplied to Weir Pumps,<br />
which is using it to drive a 7,500hp (5,593kW) WEG motor<br />
used to test mud drilling pumps at its laboratory in Dallas,<br />
Texas. These tests, which ensure that the pumps will support<br />
real loads during operation, have not been performed before,<br />
because of their complexity, risk <strong>and</strong> high costs.<br />
“In a single stroke, we have doubled the output of our MV<br />
inverter range to 8,000hp,” says Marek Lukaszczyk, WEG’s<br />
European marketing manager. “The 99% efficiency is an<br />
average 1% more effi<strong>cient</strong> than that delivered by any other MV<br />
inverter on the market – <strong>and</strong> this can mean an economy of up<br />
to $50,000 per year for this user.”<br />
The MVW voltage-source inverter drive has two layers of<br />
control, rather than the usual three or five layers. It is driving a<br />
four-pole 46Hz motor, rotating at 1,371 rpm.<br />
www.weg.net<br />
8 November/December 2010 www.drives.co.uk
Wow, why is this so easy?<br />
Because engineering has been redefined.<br />
Effi<strong>cient</strong>, intuitive, proven: engineering success has never been so easy. Siemens, the world’s leader in automation<br />
products, has developed a new generation of engineering software for industrial automation that redefines the entire<br />
engineering process. The key to success will be announced worldwide in November 2010. Then it’s your turn to benefit<br />
from outst<strong>and</strong>ing efficiency <strong>and</strong> usability for unrivalled profitability <strong>and</strong> sustainability.<br />
www.siemens.com/engineering-redefined<br />
Answers for industry.
Wow, why is this so easy?<br />
Because engineering has been redefined.<br />
Effi<strong>cient</strong>, intuitive, proven: engineering success has never been so easy. Siemens, the world’s leader in automation<br />
products, has developed a new generation of engineering software for industrial automation that redefines the entire<br />
engineering process. The key to success will be announced worldwide in November 2010. Then it’s your turn to benefit<br />
from outst<strong>and</strong>ing efficiency <strong>and</strong> usability for unrivalled profitability <strong>and</strong> sustainability.<br />
www.siemens.com/engineering-redefined<br />
Answers for industry.
COMMON SENSE<br />
ON RARE EARTHS<br />
COMMENT<br />
Totally<br />
transforming...<br />
The current rare-earth crisis has been looming for several years.<br />
Observers have long warned of the danger of China becoming the<br />
dominant supplier of these materials, which we rely on for products<br />
ranging from televisions <strong>and</strong> headphones, to batteries <strong>and</strong> glass –<br />
<strong>and</strong>, of course, for the high-power magnets used in many motors.<br />
Despite their name, rare earths are not uncommon. An estimated<br />
64% of the world’s reserves lie outside China, but the Chinese have<br />
cornered the market by undercutting other producers, <strong>and</strong> by<br />
showing little apparent concern for the environmental impacts of the<br />
dirty business of extracting <strong>and</strong> producing the materials. Until<br />
recently, that is.<br />
China is now cutting back on rare-earth production <strong>and</strong> exports, as<br />
well as hiking their prices, citing a new-found concern for the<br />
environment as one of its reasons. It is also diverting more of what it<br />
does produce to its own manufacturers, thus adding value to the<br />
minerals, while restricting supplies to foreign competitors.<br />
Another possible motivation for China’s restrictions is that at, at the<br />
previous rate of production, China’s rare-earth resources could start<br />
to run out within 15 years.<br />
Not surprisingly, China is now trying to buy into rare-earth production<br />
facilities in other parts of the world. For example, it has attempted to<br />
acquire controlling stakes in at least two Australian rare-earth<br />
producers. One of these bids was blocked by the Australian<br />
government on grounds of national security.<br />
Although Japanese manufacturers have been hit hardest by China’s<br />
rare-earth restrictions, the effects are being felt around the world. In<br />
Europe, for example, the trade body that represents around 3,000<br />
suppliers to the automotive sector, has called on the European<br />
Commission to ensure secure supplies of rare earths <strong>and</strong> to look at<br />
possible production within Europe. For its part, the EC says it is<br />
“monitoring the situation closely”.<br />
If rare earths become unavailable or too expensive, there could be<br />
far-reaching repercussions. For example, unless alternative motor<br />
technologies can be commercialised rapidly, we will need to turn to<br />
bigger, heavier motors which could affect the efficiencies <strong>and</strong><br />
economics of road vehicles – especially electric <strong>and</strong> hybrid vehicles.<br />
The current rare-earth problems could last until around 2015 when<br />
new sources of supply are due to come on stream in several<br />
countries around the world. But some of the materials – such as<br />
neodymium, which is used widely in high-power magnets – could<br />
remain in short supply.<br />
The rare-earth crisis emphasises how dependent we are on key raw<br />
materials <strong>and</strong> how vital it is to have alternative sources of supply. We<br />
need to act globally to ensure that no single country or company can<br />
dominate the supply of such crucial materials in future.<br />
...your old drives <strong>and</strong> motors to new<br />
The ABB swappage scheme replaces<br />
your old worn out drives <strong>and</strong> motors<br />
from any manufacturer for new,<br />
highly effi<strong>cient</strong> <strong>and</strong> compact<br />
equivalents from ABB. Not only will you get at least 17.5 % off the list<br />
price but with the help of the ABB <strong>Drive</strong>s Alliance, <strong>and</strong> for a small<br />
additional charge, your new drives <strong>and</strong> motors can be installed,<br />
started-up <strong>and</strong> the old equipment removed for recycling.<br />
To discover how easy it is to swap your old for new<br />
visit www.drives.co.uk <strong>and</strong> click on the “swappage<br />
scheme” banner. Or simply call us on 07000 DRIVES<br />
(that’s 07000 374837)<br />
Tony Sacks, Editor<br />
Sponsored by<br />
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TECHNOLOGY<br />
Motion system can cut moulding<br />
energy costs by 30%<br />
MOOG HAS unveiled a variable-speed<br />
hydraulic pump system for injection <strong>and</strong><br />
blow moulding machines which, it claims,<br />
can cut energy consumption by 30% or<br />
more.<br />
The speed-controlled pump system is<br />
based on three technologies: fixeddisplacement<br />
radial piston pumps;<br />
brushless servomotors; <strong>and</strong> modular, multiaxis<br />
servodrives. The drive controls the<br />
pump motor’s torque <strong>and</strong> speed,<br />
depending on pressure <strong>and</strong> flow dem<strong>and</strong>. It<br />
also stores the pump <strong>and</strong> servomotor<br />
characteristics, creating an “intelligent”<br />
system that can communicate with external<br />
systems via a fieldbus.<br />
Moulding machines experience different<br />
loads at different parts of their operating<br />
cycles. When a machine is in the pressureholding<br />
phase of the injection-moulding<br />
process, it needs low flow rates but high<br />
pressures, <strong>and</strong> the new system can cut<br />
energy consumption by 90% during this<br />
phase. Under full load, its performance is<br />
similar to that of a<br />
traditional system.<br />
“Our calculations<br />
<strong>and</strong> tests show that the<br />
total cost of ownership<br />
will be lower than<br />
traditional hydraulic<br />
technologies <strong>and</strong> the<br />
payback period for the<br />
initial investment is also<br />
shorter for operators due to<br />
the impressive energy savings,” says<br />
Sheriff El Henaoui, Moog’s marketing<br />
manager for Europe.<br />
As well as saving energy, the compact<br />
system allows the footprint of the machine<br />
to be reduced. It is also said to be quieter,<br />
with sound levels up to 9 dB(A) lower in<br />
partial-load conditions.<br />
The speed-controlled pump system not<br />
only has advantages over the traditional<br />
hydraulic systems, but is also said to cost<br />
less to install <strong>and</strong> maintain than all-electric<br />
systems. These systems usually need to be<br />
« Cost-cutter: Moog’s<br />
moulding control<br />
system<br />
built into the<br />
framework of the<br />
moulding machine<br />
<strong>and</strong> require complete disassembly<br />
<strong>and</strong> re-assembly for routine maintenance.<br />
The modular hydraulic system is said to be<br />
much easier <strong>and</strong> cheaper to maintain.<br />
If required, the motor <strong>and</strong> pump can be<br />
submerged inside a hydraulic tank, thus<br />
saving space <strong>and</strong> taking advantage of the<br />
heat-dissipating fluid in tank.<br />
www.moog.com<br />
High-res integrated stepper<br />
motor is ‘world’s shortest’<br />
THE DANISH integrated motor specialist JVL<br />
has launched an integrated<br />
stepper motor which, it claims,<br />
is the world’s shortest motor<br />
with a built-in controller. A 3Nm<br />
version of motor is just 95mm<br />
long, yet incorporates all of the<br />
stepper control electronics,<br />
including IP67-protected RS-485<br />
<strong>and</strong> CANopen interfaces <strong>and</strong> a<br />
programmable motion controller.<br />
The motors offer a resolution of 819,200<br />
steps per revolution, for smooth, quiet<br />
operation. They contain everything needed<br />
for st<strong>and</strong>-alone operation, or control from a<br />
PLC or PC. There are eight I/O points that<br />
can be configured individually as digital<br />
inputs or outputs, or analogue inputs. As<br />
well as the 95mm-long version, there is a<br />
126mm version that delivers 6.1Nm, <strong>and</strong> a<br />
156mm version that delivers 9Nm.<br />
The motors are said to offer a velocity<br />
precision of 0.01 rpm <strong>and</strong> an acceleration<br />
precision of 1 rpm/s. They operate from 12–<br />
80V DC supplies <strong>and</strong> can deliver high torque<br />
levels at high speeds.<br />
An ActiveX/OCX driver is available to<br />
simplify interfacing with LabView, Excel, VB<br />
or other Windows-based programs. Use of<br />
Shortest: JVL’s<br />
integrated stepper motor<br />
JVL’s MAC protocol allows MAC <strong>and</strong><br />
QuickStep motors <strong>and</strong> SMC85 controllers to<br />
be connected on the same RS-485 bus,<br />
supporting point-to-point or multi-axis<br />
operation of up to 254 axes.<br />
Options include: RS-422 <strong>and</strong> RS-485<br />
interfaces for encoder I/O <strong>and</strong> connection to<br />
external HMIs or PLCs; planetary gears; a<br />
pulse/direction mode for electronic gearing;<br />
<strong>and</strong> double-shaft <strong>and</strong> single- or multi-turn<br />
encoders. The motor can be supplied with<br />
wireless Bluetooth, ZigBee or WLAN<br />
functions, <strong>and</strong> is ready for future options<br />
such as Profibus, industrial Ethernet, <strong>and</strong><br />
absolute multi-turn encoders without<br />
external batteries.<br />
www.jvl.dk<br />
This image of a toggle clamp was<br />
produced using a digital technique<br />
that creates photorealistic images of<br />
products in software, without<br />
needing a camera or photographer.<br />
The technology is the result of a<br />
collaboration between the German<br />
company Cadenas, which produces<br />
electronic product catalogues, <strong>and</strong><br />
a Spanish company called Next Limit<br />
Technologies, which specialises in<br />
simulation technologies. A newly<br />
developed interface links Cadenas’<br />
eCatalogSolutions system to Next<br />
Limit’s Maxwell Render 3D rendering<br />
technology, which is based on the<br />
physical equations that govern the<br />
behaviour of light <strong>and</strong> is said to<br />
allow users to create convincing<br />
real-world images without resorting<br />
to the “tricks <strong>and</strong> approximations”<br />
used by other renderers.<br />
12 November/December www.drives.co.uk
0.75...250kW<br />
available<br />
from stock!<br />
<strong>New</strong> PowerFlex 753 AC <strong>Drive</strong><br />
PowerFlex 753 is the latest product from the family of Allen-Bradley<br />
PowerFlex 750-Series AC drives. This new drive provides a broad set of<br />
features <strong>and</strong> application specific functions that make it ideal for both<br />
st<strong>and</strong>ard <strong>and</strong> high performance applications.<br />
The PowerFlex 753 AC drive features simple network integration <strong>and</strong> with<br />
a comprehensive analogue <strong>and</strong> digital I/O built-in, it is a cost effective<br />
solution that helps reduce installation time.<br />
Embedded in the drive is DeviceLogix, a <strong>powerful</strong> control technology using<br />
function block programming that enables PLC style routines to be<br />
developed for local st<strong>and</strong> alone control of applications.<br />
Safety functionality is also available with Safe Torque-Off (CAT 3) <strong>and</strong> this<br />
can be extended by using the Safe Speed Monitor (CAT 4) to include<br />
advanced features such as Safe Limited Speed <strong>and</strong> Safe Maximum<br />
Acceleration.<br />
Features<br />
• Power range available from 0.75 to 250 kW at 400/480 V AC<br />
• Flexible slot architecture for options such as communications, safety,<br />
feedback, <strong>and</strong> additional I/O<br />
• DeviceLogix control with 225 function block capacity<br />
• Predictive diagnostics<br />
• Safe Torque-Off <strong>and</strong> Safe Speed Monitor options<br />
• Flux Vector Control with FORCE technology<br />
For more information or to order for<br />
immediate delivery, contact us on:<br />
Telephone 0370 607 1000<br />
Fax 0370 607 1001<br />
E-mail sales@routeco.co.uk<br />
Web www.routeco.com<br />
Routeco Limited, Davy Avenue, Knowlhill, Milton Keynes MK5 8HJ<br />
Routeco/PF753/2010/10
TECHNOLOGY<br />
Motor-mounting<br />
drives ‘offer widest<br />
power range’<br />
THE FINNISH drives manufacturer Vacon<br />
has announced a family of motor-mounting<br />
AC drives with ratings from 1.1kW to<br />
30kW – which, it claims, offer the widest<br />
power range in their class. The drives have<br />
been designed for use in harsh<br />
environments, <strong>and</strong> to cut space <strong>and</strong> costs<br />
by avoiding the need for extra enclosures.<br />
“The Vacon 100 Motor Mountable AC<br />
drives are our most robust AC drives,<br />
featuring a die-cast frame, <strong>and</strong> large <strong>and</strong><br />
open cooling ribs,” says Vacon’s executive<br />
<strong>Decentral</strong>ised<br />
debut:<br />
Vacon’s motormounting<br />
drive<br />
vice-president, Heikki Hiltunen. “The<br />
enclosure is rated up to IP66 <strong>and</strong> designed<br />
to withst<strong>and</strong> severe vibrations, so it's really<br />
made for a rough ride. These drives are not<br />
bound to a specific mounting location, so<br />
they open completely new ways of using<br />
AC drives.<br />
“Unlike most of the competition, these<br />
AC drives are intelligent <strong>and</strong> flexible,” he<br />
adds. “They have built-in PLC programming<br />
capability <strong>and</strong> the powers go up to 30kW,<br />
which is highest in this class. All these<br />
features give an edge, for instance, for<br />
machine-builders who want to offer their<br />
customers a complete, optimised solution<br />
with a minimised installation cost.”<br />
The new drives also mark Vacon’s entry<br />
into the decentralised drives market. They<br />
are designed to be located close to the<br />
motor, either mounting on the motor itself<br />
or on the machine it is driving. They allow<br />
engineers <strong>and</strong> machine-builders make the<br />
most of the space available in <strong>and</strong> around a<br />
machine, avoiding the need for separate<br />
electrical rooms, long shielded motor<br />
cables, <strong>and</strong> drive cabinets.<br />
The RoHS-compliant drives incorporate<br />
harmonic-filtering chokes <strong>and</strong> can be<br />
connected to electrical networks without<br />
extra precautions. The drives’<br />
components do not contain<br />
environmentally harmful substances.<br />
www.vacon.com<br />
<strong>Decentral</strong>ised<br />
drives support<br />
PM motors<br />
DANFOSS HAS launched a range of<br />
decentralised drives that can be<br />
mounted on or near motors for<br />
applications such as conveyors. The VLT<br />
<strong>Decentral</strong> <strong>Drive</strong> FCD 302, available in<br />
ratings from 0.37–3kW, offers similar<br />
functions to <strong>Danfoss</strong>’ Automation<strong>Drive</strong><br />
family, <strong>and</strong> can be used with highefficiency<br />
permanent-magnet motors<br />
as well as st<strong>and</strong>ard induction motors<br />
(with or without encoder feedback).<br />
The decentralised drives avoid the<br />
need for space-consuming control<br />
cabinets <strong>and</strong> for long runs of screened<br />
motor cables. They are also said to cut<br />
installation costs as well as reducing<br />
the risk of failures.<br />
The range includes versions certified<br />
by EHEDG (the European Hygienic<br />
Engineering & Design Group) for use in<br />
plants where hygiene is critical.<br />
The drives incorporate Safe Torque-<br />
Off capabilities <strong>and</strong> ten LEDs to indicate<br />
their status when an optional graphic<br />
display is not being used. Many options<br />
are built in, reducing the number of<br />
boxes that need to be mounted,<br />
connected <strong>and</strong> terminated.<br />
www.danfoss.com/drives
Power selector switch makes<br />
drive systems more versatile<br />
CONTROL TECHNIQUES has developed a<br />
device for multi-way switching of drive<br />
control cables via contactors which, it says,<br />
could cut capital costs, make operations<br />
more flexible, add redundancy at a low<br />
cost, <strong>and</strong> improve efficiency.<br />
The SPM power selector module is<br />
designed to be used with CT’s modular<br />
Unidrive SPM AC drives <strong>and</strong> allows<br />
automatic re-routing of connections<br />
between the control <strong>and</strong> power stages in<br />
parallel drive systems. It also provides<br />
automatic control of contactors.<br />
The switch was developed originally for<br />
the crane industry, with the aim of<br />
eliminating the need for separate hoist<br />
drives. CT says it can also make process<br />
equipment <strong>and</strong> test rigs more versatile,<br />
allowing operation over a wide power range,<br />
<strong>and</strong> providing continuous operation in<br />
the event of a fault, thus giving system<br />
redundancy for critical operations.<br />
For example, a gantry crane with dual<br />
long-travel motors <strong>and</strong> a main hoist can<br />
use just two drives instead of three – by<br />
switching the drives between travel <strong>and</strong><br />
hoist duty – thus delivering significant<br />
savings. Similarly, the power range can<br />
be exp<strong>and</strong>ed by using up to 10<br />
modules, again eliminating the need for<br />
a separate hoist drive.<br />
For test rigs operating over wide torque<br />
<strong>and</strong> power ranges, the SPM power modules<br />
can be switched out of circuit as the output<br />
power dem<strong>and</strong> is reduced <strong>and</strong>, conversely,<br />
re-connected as power dem<strong>and</strong> rises.<br />
Matching the drives to the motors makes the<br />
test rig more versatile, improves feedback<br />
Flexible: Control<br />
Techniques’ power<br />
selector module<br />
accuracy, <strong>and</strong> cuts losses, according to CT.<br />
One master can work with a string of<br />
modules which are switched in <strong>and</strong> out as<br />
required. This also offers the option of<br />
increasing the power at a later date by<br />
adding more modules.<br />
www.controltechniques.com<br />
TECHNOLOGY<br />
Actuator combines driving <strong>and</strong> guidance functions<br />
Two-in-one: Haydon<br />
Kerk’s motorised<br />
SplineRail<br />
THE US linear motion specialist Haydon<br />
Kerk has developed a linear actuator that<br />
combines the traditionally separate<br />
functions of driving <strong>and</strong> guidance in a<br />
single, coaxial component. The SplineRail<br />
actuator uses a precision-rolled leadscrew,<br />
supported by bearings <strong>and</strong> contained in a<br />
concentric aluminium spline, to drive a<br />
composite polymer nut/bushing.<br />
When mounted vertically, the SplineRail<br />
can be used to lift <strong>and</strong> rotate<br />
simultaneously. With one motor driving<br />
the screw <strong>and</strong> a second rotating the rail, a<br />
compact, self-supporting pick-<strong>and</strong>-place<br />
mechanism can be created.<br />
Typical applications are expected to<br />
include robotic assemblies, packaging <strong>and</strong><br />
assembly systems. The extruded aluminium<br />
spline is said to offer good torsional<br />
stability. Long, maintenance-free operating<br />
lives are promised.<br />
Screw leads will be available from 0.05–<br />
1.2 inches (1.27–30.5mm) per revolution,<br />
providing a wide range of performance<br />
profiles, including self-locking threads that<br />
can support a load without external power<br />
or breaks. The SplineRail is powered by<br />
single- or double-stack stepper motors.<br />
www.haydonkerk.com
TECHNOLOGY<br />
IN BRIEF<br />
The OPC Foundation <strong>and</strong> the<br />
MTConnect Institute are cooperating<br />
to develop a set of<br />
st<strong>and</strong>ards – called MTConnectOpcUa –<br />
that will ensure interoperability <strong>and</strong><br />
consistency between MTConnect<br />
specifications <strong>and</strong> OPC specifications,<br />
as well as manufacturing equipment,<br />
software <strong>and</strong> other products that<br />
implement these st<strong>and</strong>ards. OPC<br />
Foundation president Tom Burke says<br />
the collaboration will provide the<br />
infrastructure to revolutionise<br />
interoperability for all manufacturing<br />
technologies.<br />
TT Electronics has won a contract to<br />
develop micro-inverter <strong>and</strong> power<br />
electronics modules for use in inwheel<br />
motors being developed for<br />
hybrid <strong>and</strong> electric vehicles by UKbased<br />
Protean Electric. The rugged<br />
modules, to be built by TT in Austria,<br />
are designed to withst<strong>and</strong> water, dirt,<br />
shocks <strong>and</strong> vibration.<br />
FDT Technology – which allows any<br />
fieldbus, device or sub-system<br />
software tool to be integrated in<br />
lifecycle management tools – looks<br />
likely to be adopted in st<strong>and</strong>ards being<br />
issued by the ISA (the International<br />
Society of Instrumentation) <strong>and</strong> ANSI<br />
(the American National St<strong>and</strong>ards<br />
Institute). Last year, it was approved as<br />
an international st<strong>and</strong>ard (IEC 62453).<br />
US–based membrane switch specialist<br />
Pannam Imaging has developed a<br />
patented circular switch technology<br />
that mimics the light actuation<br />
behaviour of capacitive switches, but<br />
can be operated using gloves. The<br />
SimScroll switches are said to be<br />
cheaper than capacitive switches.<br />
The Austrian semiconductor specialist<br />
SensorDynamics has developed a<br />
failsafe inertial measurement system<br />
that detects angular rates <strong>and</strong><br />
acceleration in three axes <strong>and</strong><br />
transmits the data wirelessly to a<br />
receiver up to 150m away. The system<br />
can be used to detect motion<br />
wirelessly or to avoid connectors <strong>and</strong><br />
cabling.<br />
ON Semiconductor has announced a<br />
combined stepper motor driver <strong>and</strong><br />
CAN transceiver device which can<br />
control multiple similar motors on one<br />
bus. The space-saving 1Mb/s ANIS-<br />
30523 device offers seven step modes<br />
from full-step to 32 micro-steps <strong>and</strong><br />
can provide programmable peak<br />
currents up to 1.6A.<br />
Performance Motion Devices has<br />
produced a motion control chip which<br />
can capture real-time variables such as<br />
encoder position, motor comm<strong>and</strong>s<br />
<strong>and</strong> position errors <strong>and</strong> store them in<br />
on-board buffers for later retrieval <strong>and</strong><br />
analysis. The 58000 series Magellan<br />
Motion chip can monitor up to 64<br />
variables <strong>and</strong> send the data via RS-<br />
232/485, CANbus or parallel ports.<br />
‘Virtual engineer’<br />
warns when machines<br />
need maintenance<br />
RESEARCHERS AT THE University of<br />
Portsmouth have created a “virtual engineer”<br />
which uses artificial intelligence to predict<br />
when machines need maintenance. The<br />
technology learns how a machine works <strong>and</strong><br />
uses this to make accurate predictions about<br />
when it needs maintenance, thus avoiding the<br />
need for regular maintenance shutdowns or<br />
waiting for a machine to fail before calling an<br />
engineer.<br />
Sensors are placed on vulnerable parts of<br />
the machine, such as the bearings. Predictive<br />
software monitors <strong>and</strong> analyses the signals,<br />
alerting technicians when it detects that a part<br />
is not working properly or needs replacing.<br />
“The machines in many processing plants<br />
<strong>and</strong> factories are running day <strong>and</strong> night <strong>and</strong><br />
an unscheduled stoppage can cause havoc<br />
<strong>and</strong> can result in huge costs,” explains Dr<br />
David Brown, head of the University's Institute<br />
of Industrial Research (IIR). “This new<br />
diagnostic system prevents potential<br />
mechanical failure by identifying the faulty or<br />
worn-out part before it causes a problem.<br />
“It's the first time this kind of technology<br />
has been used on this scale in the processing<br />
industry,” he adds. “The traditional approach<br />
to machine maintenance is being blown out<br />
of the water by real-time diagnostics.”<br />
According to Brown, the clever part is that<br />
the system is adaptive. “During the process of<br />
monitoring the machine, the software learns<br />
more about how it works, which parts are<br />
becoming worn, <strong>and</strong> anything else that could<br />
potentially cause mechanical failure,” he<br />
explains.<br />
This is particularly important for custombuilt<br />
machines. The IIR diagnostic system can<br />
learn the particular behaviour of each<br />
machine.<br />
The diagnostic software can direct an<br />
engineer to a specific fault which might<br />
otherwise take days to identify. “Human<br />
beings are highly intelligent <strong>and</strong> a good<br />
engineer might sometimes spot if something<br />
is about to break, but this system will help<br />
speed up the time it takes to fix,” says Brown.<br />
He predicts significant costs savings to<br />
industry, because keeping a specialist engineer<br />
on call around-the-clock is expensive. “The<br />
entire process becomes very much easier if the<br />
company knows when to schedule machine<br />
repairs <strong>and</strong> maintenance in advance,” he<br />
points out.<br />
IIR has been working with Stork Food &<br />
Dairy Systems (SFDS) to test the new system at<br />
some of its plants. SFDS develops <strong>and</strong> supplies<br />
processing equipment for the dairy, juice, food<br />
Brown: blowing<br />
traditional<br />
maintenance<br />
out of the<br />
water<br />
<strong>and</strong> pharmaceutical industries. Its customers,<br />
which include milk suppliers, run their<br />
machines around the clock <strong>and</strong> need their<br />
machines to be mechanically <strong>reliable</strong>.<br />
“An unplanned stoppage on a production<br />
line can be a total disaster,” explains SFDS’<br />
general manager, Luke Axel-Berg. “It can spell<br />
chaos for a processing plant, especially a dairy<br />
plant where milk is arriving every single day.<br />
The cows don’t stop producing milk because a<br />
machine has broken. Instead the milk must be<br />
sent to an alternative location, putting<br />
unexpected pressure on another plant.<br />
“In the event of a major breakdown lasting<br />
several days, we could even risk losing a<br />
customer,” he adds “How do you put a price<br />
on that?”<br />
Planned downtime, on the other h<strong>and</strong>, is<br />
less disruptive because users can build supply<br />
<strong>and</strong> delivery around it <strong>and</strong> arrange in advance<br />
for other plants to take over production. “It's<br />
an entirely new way of looking at downtime,”<br />
says Axel-Berg.<br />
“Our customers are already calling for a<br />
zero fault levels on their machines,” he<br />
continues. “Until now, it's been impossible to<br />
guarantee that level of customer service, but<br />
this new diagnostic system looks set to<br />
change all that by taking away the risk. It will<br />
benefit any business which relies on machines<br />
to keep its operation turning over – especially<br />
if they want to minimise costs <strong>and</strong> guarantee<br />
customer satisfaction.”<br />
The IIR is collaborating with Stork as part of<br />
a Knowledge Transfer Partnership (KTP), a<br />
government scheme which helps businesses<br />
to improve their competitiveness <strong>and</strong><br />
productivity by partnering with academic<br />
institutions.<br />
www.port.ac.uk/research/iir<br />
16 November/December 2010 www.drives.co.uk
Confocal measurement system<br />
Laser profile sensors<br />
- Measuring ranges from 0.12 to 24mm<br />
- Nanometre resolution<br />
- Tiny, constant measuring spot 7µm<br />
- Measure any target diffuse, specular<br />
<strong>and</strong> liquid<br />
Typical applications:<br />
Measuring of glass <strong>and</strong> mirrored surfaces<br />
Measurements inside bores <strong>and</strong> holes<br />
One-sided thickness measurement of<br />
transparent materials (e.g. glass)<br />
NEW<br />
optoNCDT 2402<br />
The world’s first miniature sensor with<br />
just a 4mm outside diameter<br />
- Measuring ranges from 25 to 245mm<br />
- Lightweight <strong>and</strong> compact sensors<br />
- Very high measuring rate of 256kHz<br />
- 3D view of the target<br />
- Micrometre resolution<br />
Typical applications:<br />
Position <strong>and</strong> contour measurement, edge<br />
detection, web width, groove width / depth,<br />
welding seam inspection, welding robot control<br />
NEW<br />
scanCONTROL 2700<br />
Most compact design with integral controller<br />
Laser triangulation sensors<br />
Compact infrared temperature sensors<br />
- Measuring ranges from 2 to 1000mm<br />
- Models with integrated controller<br />
- From low-cost entry level models up to<br />
highest precision in class<br />
- Analogue <strong>and</strong> digital interface<br />
- In built synchronisation for thickness<br />
measurement<br />
Typical applications:<br />
High precision measurements in automation,<br />
positioning<strong>and</strong> in-process quality control<br />
NEW<br />
optoNCDT 1302 / 1402<br />
Very compact sensors with integrated controller<br />
- Temperature range: -50 to 3300°C<br />
- Spot sizes as low as 0.45mm<br />
- CTlaser with built in laser alignment<br />
- CThot withst<strong>and</strong>s ambient temperatures of<br />
250°C without cooling<br />
- Exposure time from 1ms<br />
- Analogue <strong>and</strong> digital outputs incl. Profibus DP<br />
- Specific models for glass, metals, ceramics<br />
NEW<br />
thermoIMAGER TIM<br />
Thermal imager for inline applications<br />
Temperature ranges: -20°C to 900°C<br />
optoNCDT 2220<br />
Extremely fast measurement with 20kHz measuring rate<br />
optoNCDT 2200LL<br />
Small laser line for metallic, shiny surfaces<br />
Eddy-current displacement sensors<br />
More Precision: www.micro-epsilon.co.uk<br />
- Measuring ranges from 0.4 to 80mm<br />
- More than 300 sensor models<br />
- Nanometer resolution<br />
- Intelligent controller<br />
- Robust sensor - IP67<br />
- Pressure-resistant sensors<br />
up to 2000 bar<br />
- Ideal for Machine builders & OEMs<br />
World leading sensors <strong>and</strong> systems.<br />
displacement · distance · length · position · profile · thickness · temperature<br />
Typical applications:<br />
Harsh industrial environments (resistant to oil,<br />
dirt, dust, moisture, interference fields, etc.)<br />
eddyNCDT 3300<br />
Nano-precision for industrial applications<br />
Call the experts now!+44 (0) 151 355 6070
Simple servodrive can<br />
be tailored to dem<strong>and</strong><br />
Simple servo:<br />
Rockwell’s Kinetix 3<br />
Rockwell Automation has announced a<br />
component servodrive that, it claims, avoids<br />
the complexity of traditional servos. The<br />
Allen-Bradley Kinetix 3, available in ratings<br />
from 50W–1.5kW <strong>and</strong> capable of delivering<br />
up to 12.55Nm of instantaneous torque,<br />
allows axes to be tailored to a machine’s<br />
actual power requirements, thus minimising<br />
system size <strong>and</strong> costs.<br />
“Manufacturers are challenged by<br />
tougher economic conditions. There is less<br />
capital available for new equipment<br />
purchases <strong>and</strong> users expect solutions that<br />
A pioneering technique for detecting<br />
fingerprints on bullet casings has been<br />
adapted to measure corrosion on<br />
machine parts by the s<strong>cient</strong>ist who<br />
developed the technique, Dr John Bond<br />
of Leicester University.<br />
Dr Bond’s technique for identifying<br />
fingerprints on brass bullet-casings, even<br />
after they have been wiped clean, is<br />
based on the minuscule amounts of<br />
corrosion which can be caused by sweat.<br />
Now, working with s<strong>cient</strong>ists in the<br />
University’s Department of Chemistry, Dr<br />
Bond has used the same technique to<br />
produce a simple, h<strong>and</strong>held device which<br />
can measure corrosion on machine parts.<br />
“This is a new, quick, cheap <strong>and</strong> easy<br />
way of measuring the extent of corrosion<br />
on copper <strong>and</strong> copper-based alloys, such<br />
as brass,” explains Dr Bond, who is an<br />
honorary research fellow in the<br />
University’s Forensic Research Centre.<br />
“It works by exploiting the discovery<br />
we made during the fingerprint research<br />
– that the corrosion on brass forms<br />
are easier to use <strong>and</strong> also yield greater<br />
uptime <strong>and</strong> return on investment,” says<br />
Rockwell product manager, Oliver Haya.<br />
“When combining the new Kinetix 3 servo<br />
drive with Allen-Bradley MicroLogix<br />
controllers, machine-builders can deliver a<br />
cost-effective motion control solution for<br />
low-axis count applications, that is simple to<br />
use <strong>and</strong> maintain.”<br />
The drive is configured using the free<br />
Allen-Bradley UltraWare software.<br />
Configuration can be simplified further<br />
using the automatic motor recognition<br />
facilities in some Allen-Bradley rotary <strong>and</strong><br />
linear servomotors. Additional features<br />
include online vibration suppression,<br />
advanced auto-tuning, <strong>and</strong> rapid settling<br />
times. The drive can index up to 64 points<br />
via Modbus or through its digital inputs.<br />
Rockwell’s Connected Component<br />
Building Blocks technology can be used to<br />
provide CAD drawings, electrical layouts,<br />
bills of materials, sample code <strong>and</strong> operator<br />
interface screens for the drive. Indexing<br />
operations for three axes can be performed<br />
over the Modbus network using Rockwell’s<br />
MicroLogix 1400 controller, PanelView<br />
component operator interfaces, <strong>and</strong> TL-<br />
Series motors.<br />
www.rockwellautomation.co.uk<br />
Fingerprinting breakthrough<br />
spawns corrosion detector<br />
something called a Schottky barrier. We<br />
use this to see how much the metal has<br />
corroded. Such measurements can be<br />
made already, but this is quick, cheap <strong>and</strong><br />
easy, <strong>and</strong> can be performed in the field as<br />
it works off a 9V battery.<br />
“Measuring the corrosion of metals<br />
such as brass is important to ensure that<br />
machinery does not operate outside its<br />
safe limits,” Bond points out. “This could<br />
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“Also, rather than simply saying that<br />
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to be determined – for example, copper<br />
oxide or zinc oxide corrosion.” This gives<br />
clues about how severe the corrosion is.<br />
The system works by touching the<br />
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says Bond, who is now looking for a<br />
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SECURITY<br />
Are you safe from<br />
cyber-attack?<br />
The recent widespread publicity given to the Stuxnet virus, has brought home the real threats to industrial control<br />
systems posed by viruses <strong>and</strong> hackers. Dr Richard Piggin* examines the risks – <strong>and</strong> how to minimise them.<br />
In his first-ever public speech, GCHQ director<br />
Ian Lobban recently highlighted the “real<br />
<strong>and</strong> credible” threat facing the UK’s critical<br />
infrastructure from terrorists, organised<br />
criminals <strong>and</strong> hostile foreign governments. He<br />
dem<strong>and</strong>ed a swift response to match the<br />
speed with which “cyber events” can occur,<br />
<strong>and</strong> warned that the country's future<br />
economic prosperity rested on ensuring a<br />
defence against such assaults.<br />
So, which systems are under threat? The<br />
critical national infrastructure comprises<br />
facilities, sites <strong>and</strong> networks that deliver the<br />
essential services on which daily life depends.<br />
This spans nine sectors: communications;<br />
emergency services; energy; finance; food;<br />
government; health; transport; <strong>and</strong> water. The<br />
UK’s Centre for the Protection of National<br />
Infrastructure (CPNI) works with the providers<br />
of these services <strong>and</strong> government departments<br />
to identify the critical elements <strong>and</strong> to help<br />
protect them against national security threats.<br />
Cyber-threats to control systems extend far<br />
beyond energy <strong>and</strong> telecommunications<br />
facilities. For example, activities such as food<br />
distribution <strong>and</strong> logistics could be hit, resulting<br />
in a loss of consumer confidence, <strong>and</strong><br />
potential health risks.<br />
All are potentially<br />
The UK’s Centre for the Protection of National<br />
Infrastructure recommends adopting the protection<br />
principle known as defence in depth to avoid single<br />
points of weakness<br />
vulnerable to targeted or accidental cyberevents<br />
<strong>and</strong> to the actions of disgruntled<br />
former employees.<br />
One often-cited example is the “drive-by”<br />
wireless hacking by an ex-employee of an<br />
Australian sewage treatment plant. He used<br />
his knowledge of the plant’s control system to<br />
hack into it 46 times <strong>and</strong> to release millions of<br />
litres of waste into public waterways. Cyberthreats<br />
to industrial control systems are<br />
growing, as attackers seek new targets <strong>and</strong><br />
sources of revenue.<br />
> Extortion dem<strong>and</strong>s<br />
The US Central Intelligence Agency has<br />
confirmed that a cyber-attack caused power<br />
outages in several cities in 2008, including<br />
<strong>New</strong> Orleans. The agency has also revealed<br />
that there have been intrusions into utilities<br />
that have been followed by extortion<br />
dem<strong>and</strong>s.<br />
The US government has been taking the<br />
potential reconnaissance of its power<br />
infrastructure by Russia <strong>and</strong><br />
China seriously, as well as<br />
responding to the potential for<br />
terrorist attacks. This year, it<br />
formed the United States<br />
Cyber Comm<strong>and</strong> – a unit of<br />
the armed forces responsible<br />
for directing operations,<br />
defending Department of Defense networks,<br />
<strong>and</strong> conducting military cyberspace operations.<br />
According to the US National Institute of<br />
St<strong>and</strong>ards <strong>and</strong> Technology’s (NIST) Guide to<br />
Industrial Control Systems (ICS) Security,<br />
potential incidents may include:<br />
• blocking or delaying the flow of information<br />
through ICS networks, thus disrupting their<br />
operation;<br />
• making unauthorised changes to<br />
instructions, comm<strong>and</strong>s, or alarm thresholds,<br />
which could damage, disable, or shut down<br />
equipment, have environmental impacts,<br />
<strong>and</strong>/or endanger human life;<br />
• sending inaccurate information to system<br />
operators, either to disguise unauthorised<br />
changes, or to cause operators to initiate<br />
inappropriate actions, which could have<br />
various negative effects;<br />
• modifying ICS software or configuration<br />
settings, or infecting ICS software with<br />
malware, which could have various negative<br />
effects; <strong>and</strong><br />
• interfering with the operation of safety<br />
systems, which could endanger human life.<br />
NIST’s recommendations include:<br />
• restricting physical access to ICS networks<br />
<strong>and</strong> devices;<br />
• protecting individual ICS components from<br />
exploitation, using measures such as:<br />
deploying security patches as soon as possible<br />
after testing; disabling unused ports <strong>and</strong><br />
services; restricting ICS user privileges to those<br />
that are essential; tracking <strong>and</strong> monitoring<br />
audit trails; <strong>and</strong> using security controls such as<br />
anti-virus software <strong>and</strong> file integrity-checking<br />
software to prevent, deter, detect, <strong>and</strong><br />
mitigate malware;<br />
• maintaining functionality during adverse<br />
conditions – this involves designing the ICS so<br />
that each critical component has a redundant<br />
counterpart <strong>and</strong>, ensuring that if a<br />
component fails, it does so in a manner that<br />
does not generate unnecessary traffic on the<br />
ICS or other networks or cause other<br />
problems (such as cascading events)
elsewhere; <strong>and</strong><br />
• restoring systems after an incident –<br />
such incidents are inevitable <strong>and</strong> response<br />
plans are essential.<br />
There has been a mistaken belief in<br />
“security through obscurity” – the use of<br />
specialised systems, protocols <strong>and</strong><br />
proprietary interfaces. However,<br />
information on protocols is now widely<br />
available <strong>and</strong> some systems have already<br />
been specifically targeted. Examples<br />
include the Modbus protocol <strong>and</strong>, most<br />
recently, Siemens’ WinCC Scada <strong>and</strong> Step<br />
7 PLCs which have been targeted by the<br />
Stuxnet trojan/virus (see box, right).<br />
Industrial control systems have long<br />
operating lives – 10–20 year lifecycles are<br />
not uncommon. Older systems were<br />
designed with little or no regard for<br />
cyber-security, <strong>and</strong> are interconnected<br />
<strong>and</strong> used in ways that was never<br />
envisaged originally. Add to this<br />
increasing system complexity, the<br />
proliferation of access points, <strong>and</strong> the<br />
growing use of wireless technologies <strong>and</strong><br />
the Internet. It is underst<strong>and</strong>able why<br />
governments are promoting cybersecurity<br />
<strong>and</strong> producing general <strong>and</strong><br />
sector-specific guidance.<br />
> Securing industrial controls<br />
In the UK, the CPNI is offering Scadaspecific<br />
advice in a series of process<br />
control <strong>and</strong> Scada security good practice<br />
guidelines. These are founded on three<br />
guiding principles:<br />
• Protect, detect <strong>and</strong> respond It is<br />
important to be able to detect possible<br />
attacks <strong>and</strong> respond in an appropriate<br />
manner to minimise the impacts.<br />
More information<br />
A still from a YouTube video showing a<br />
simulated attack on a generator Scada<br />
system, staged by the Idaho National<br />
Laboratory in the US<br />
• Defence in depth No single<br />
security measure is foolproof<br />
because vulnerabilities <strong>and</strong><br />
weaknesses can be identified at<br />
any time. To reduce these risks,<br />
implementing multiple<br />
protection measures in series<br />
avoids single points of failure.<br />
• Technical, procedural <strong>and</strong><br />
managerial protection measures<br />
Technology is insuffi<strong>cient</strong> on its own to<br />
provide robust protection.<br />
The CPNI also refers to further forms of<br />
guidance – many of them resulting from<br />
work sponsored by the US Department of<br />
Homel<strong>and</strong> Security. These include road<br />
maps to secure the water, electricity <strong>and</strong><br />
chemical sectors. These follow a similar<br />
ten-year programme to assess risks, <strong>and</strong><br />
to develop <strong>and</strong> implement measures to<br />
mitigate these risks. There is an emphasis<br />
on cost-effective security for legacy<br />
systems <strong>and</strong> on new architecture designs<br />
<strong>and</strong> secure communications.<br />
Cyber-security st<strong>and</strong>ards are<br />
blossoming, including work being done<br />
by the US-based International Society of<br />
Automation (ISA), which has published<br />
ISA99 Parts 1 <strong>and</strong> 2 which deal with the<br />
security of industrial automation <strong>and</strong><br />
control systems. Part 1 is the foundation<br />
for all subsequent st<strong>and</strong>ards in the ISA99<br />
series. At the same time, the IEC is also<br />
working on ICS st<strong>and</strong>ards <strong>and</strong> is<br />
considering the work done in ISA.<br />
The challenge is to develop a sustainable<br />
approach <strong>and</strong> to continue a process of<br />
assessment, adjustment <strong>and</strong> review in the<br />
light of emerging vulnerabilities, threats,<br />
consequences, while implementing<br />
appropriate measures.<br />
D&C<br />
* Dr Piggin is a network <strong>and</strong> security consultant with<br />
an engineering doctorate in industrial control systems<br />
networking. He is a UK expert to IEC Network &<br />
System Security <strong>and</strong> Cyber Security Working Groups<br />
involved in producing IEC 62443 Security for Process<br />
Measurement <strong>and</strong> Control – Network <strong>and</strong> System<br />
Security.<br />
UK Centre for the Protection of National Infrastructure: www.cpni.gov.uk<br />
Practical Scada Security blog (Byres Security): http://goo.gl/GH0e<br />
NIST Guide to Industrial Control Systems (ICS) Security: http://goo.gl/T50V<br />
Siemens information page on Stuxnet virus: http://goo.gl/vwvY<br />
ISA99, Industrial Automation <strong>and</strong> Control System Security: http://goo.gl/Qi2l4<br />
YouTube video of simulated attack on generator Scada system: http://goo.gl/UkGP<br />
Stuxnet – the first<br />
worm known to target<br />
industrial controls<br />
The threat posed by Stuxnet has been portrayed as a<br />
once-in-a-decade event which goes beyond anything<br />
seen before. The worm is designed to sabotage plants<br />
by reprogramming PLCs, <strong>and</strong> to hide the changes from<br />
programmers or users.<br />
Research released by Symantec in mid-September showed<br />
that almost 60% of the approximately 100,000 hosts<br />
infected by Stuxnet have been in Iran, with high infection<br />
rates also seen in India <strong>and</strong> Indonesia. This has led to<br />
speculation that Stuxnet’s goal was to disrupt Iran's nuclear<br />
activities.<br />
Symantec says that Stuxnet is one of the most complex<br />
threats it has ever analysed. Its elements include:<br />
• four “zero-day” exploits (which were previously<br />
unknown, undisclosed to the software vendor, or for<br />
which no security fix is available – a rarity for any virus<br />
which would be considered wasteful by most hackers);<br />
• a Windows rootkit – software that allows privileged<br />
access to a computer, while hiding its presence;<br />
• the first-ever “PLC rootkit” for infecting PLC programs<br />
<strong>and</strong> remaining undetectable;<br />
• anti-virus evasion measures;<br />
• two stolen digital signatures;<br />
• complex process injection <strong>and</strong> hooking code (to<br />
prevent programmers from seeing the infected code);<br />
• network infection routines;<br />
• privilege escalation measures;<br />
• peer-to-peer updates; <strong>and</strong><br />
• remote comm<strong>and</strong> <strong>and</strong> control.<br />
Because PCs used to program control systems are not<br />
normally connected to the Internet, Stuxnet replicates<br />
via removable USB memory drives, exploiting a<br />
vulnerability that allows auto-execution. It then spreads<br />
across a LAN via vulnerabilities in a Windows print<br />
spooler <strong>and</strong> Windows Server remote procedure calls. It<br />
copies <strong>and</strong> executes itself on remote computers via<br />
network sharing <strong>and</strong> Siemens WinCC database servers.<br />
Stuxnet also copies itself into Siemens Step 7 PLC program<br />
projects <strong>and</strong> executes when a project is loaded. It updates<br />
versions via peer-to-peer communications across a LAN. It<br />
communicates with two comm<strong>and</strong> <strong>and</strong> control servers,<br />
originally located in Denmark <strong>and</strong> Malaysia, to enable code<br />
to be downloaded <strong>and</strong> executed, including updating<br />
versions, <strong>and</strong> can change comm<strong>and</strong> <strong>and</strong> control servers –<br />
although this has not been observed yet.<br />
Stuxnet fingerprints specific PLC configurations that use<br />
Profibus for distributed I/O. These configurations were<br />
gleaned using earlier versions of Stuxnet. If the<br />
fingerprint does not match the target configuration,<br />
Stuxnet remains benign. If the fingerprint matches, the<br />
code on the Siemens PLCs is modified with the infected<br />
Step 7 programming software, <strong>and</strong> the changes are<br />
hidden. The modified code prevents the original code<br />
from running as intended <strong>and</strong> causes the plant<br />
equipment to operate incorrectly, potentially sabotaging<br />
the system under control. This is achieved by<br />
interrupting the processing of code blocks, injecting<br />
network traffic onto the Profibus network, <strong>and</strong> modifying<br />
output bits of PLC I/O. How this affects each plant will<br />
depend on how the control system is connected to the<br />
PLC <strong>and</strong> the distributed network I/O via Profibus.<br />
Stuxnet creates is a blueprint for future attacks on realworld<br />
infrastructure, providing generic methods to reprogram<br />
industrial control systems. However, Stuxnet’s<br />
sophistication <strong>and</strong> complexity make it unlikely that similar<br />
threats will develop overnight.<br />
SAFETY<br />
SECURITY<br />
www.drives.co.uk November/December 2010 21
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Engineering excellence - by design
LINEAR MOTION<br />
Museum’s 4D ride<br />
has added muscle<br />
Visitors to Manchester Museum of<br />
Science <strong>and</strong> Industry can now<br />
experience a “four-dimensional”<br />
immersive ride, during which their seats<br />
are moved by a novel form of pneumatic<br />
linear actuator. The 4D Theatre’s seats<br />
subject their occupants to a variety of<br />
movements, synchronised to the film<br />
being shown, along with special effects<br />
including water sprays <strong>and</strong> air blasts.<br />
The ride has been developed by<br />
Simworx, a specialist developer of 4D<br />
effects theatres <strong>and</strong> simulation attractions,<br />
based in Kingswinford, West Midl<strong>and</strong>s.<br />
The company is a world leader in<br />
designing <strong>and</strong> manufacturing stationary<br />
<strong>and</strong> mobile 4D effects theatres <strong>and</strong><br />
simulation attractions, with more than 600<br />
installations worldwide at sites including<br />
aeronautical <strong>and</strong> science museums in the<br />
UK <strong>and</strong> US, <strong>and</strong> theme parks in Europe.<br />
The seats for Simworx' latest<br />
Dimensions theatres are based on a<br />
modular design, with all of the motion<br />
actuators incorporated in a shallow, floorst<strong>and</strong>ing<br />
plinth that supports four seats.<br />
The most sophisticated models offer<br />
forwards/backwards <strong>and</strong> left/right tilting<br />
movements, as well as vertical drops. The<br />
headrest of each seat can be fitted with<br />
optional water sprays <strong>and</strong> air blasts, <strong>and</strong><br />
the pedestal can be fitted with a<br />
pneumatically-powered leg tickler.<br />
Over the years, Simworx has used<br />
various actuators from different suppliers<br />
to achieve its dynamic effects. Most have<br />
been pneumatic, because this is a safe,<br />
cost-effective technology which offers a<br />
higher power density than electric<br />
actuators, making it easier to integrate<br />
into the body of the seat.<br />
While developing its latest seats,<br />
Simworx became aware of Festo's “fluidic<br />
muscle” technology – a unique form of<br />
tensile pneumatic actuator which mimics<br />
biological muscles by contracting when<br />
fed with compressed air. These actuators<br />
are capable of fast, smooth operation, as<br />
well as slow, jolt-free movements, <strong>and</strong> can<br />
generate an initial force about ten times<br />
higher than a conventional pneumatic<br />
actuator of a similar diameter.<br />
According to Simworx director, Andy<br />
Roberts, when he first saw fluidic muscles<br />
being demonstrated, “it was immediately<br />
apparent that the muscles are considerably<br />
better than conventional pneumatic<br />
actuators for simulator-type applications<br />
like ours. They provide excellent dynamic<br />
performance, <strong>and</strong> have a much higher<br />
power density.”<br />
Simworx is using the most <strong>powerful</strong>,<br />
40mm-diameter versions of Festo's latest<br />
DMSP series fluidic muscles for its new<br />
seats. The muscles use press-fit<br />
connections to minimise size <strong>and</strong> weight.<br />
Each four-seat plinth module contains four<br />
fluidic muscles – one in each corner –<br />
together with four manifold-mounted<br />
Festo VPPM proportional pressure<br />
regulators, <strong>and</strong> a controller. The cascaded<br />
dual-stage regulators provide an easy,<br />
precise means of varying flow rates to the<br />
actuators. To minimise noise interference,<br />
the compressed air supply is generated<br />
outside the theatre <strong>and</strong> is distributed to<br />
each seat module via a “pneumatic ring<br />
main”. The exhausted air is released<br />
locally, via silencers.<br />
The controller in each seat module<br />
communicates with a host control PC via a<br />
fieldbus system. Special event triggers in<br />
the film being shown instruct the central<br />
controller to issue appropriate signals to all<br />
of the seat modules in the theatre<br />
simultaneously, resulting in the entire<br />
audience experiencing exactly the same<br />
effect – be it pitch, rock, vibrate or a<br />
The theatre’s seats incorporate<br />
<strong>powerful</strong> “fluidic muscles”<br />
in a shallow floor-st<strong>and</strong>ing plinth<br />
sudden drop – at the same time.<br />
Following the Manchester museum<br />
installation, Simworx is supplying a<br />
Dimensions system for an indoor theme<br />
park on Weston-super-Mare's newly<br />
rebuilt Gr<strong>and</strong> Pier. “I envisage we'll be<br />
making increasing use of this technology<br />
in the future,” says Roberts. D&C<br />
www.drives.co.uk November/December 2010 23
LINEAR MOTION<br />
Electric axes<br />
show a<br />
clean pair<br />
of heels<br />
LPW makes wide use of<br />
electric actuators in its hightech<br />
cleaning machines<br />
A German machine-builder is using electric linear axes to transport <strong>and</strong> feed parts into<br />
cleaning <strong>and</strong> drying chambers, ensuring high positional accuracy, reliability <strong>and</strong> speed<br />
under often harsh operating conditions.<br />
The German company LPW<br />
Reinigungssysteme specialises in<br />
designing <strong>and</strong> manufacturing<br />
advanced aqueous cleaning systems. It<br />
produces a variety of spray degreasing <strong>and</strong><br />
cleaning systems, using technologies such as<br />
high-pressure <strong>and</strong> ultrasound cleaning,<br />
coupled with advanced drying processes<br />
using filtered air. These systems are used in<br />
the automotive, mechanical engineering <strong>and</strong><br />
aerospace sectors.<br />
An essential element of these systems is a<br />
<strong>reliable</strong>, easy-to-use method for transporting,<br />
transferring, separating <strong>and</strong> feeding the<br />
products <strong>and</strong> components – which can range<br />
from small parts to bulky objects such as<br />
gearbox or engine assemblies, often<br />
weighing as much as 400kg.<br />
To integrate its cleaning systems with up<strong>and</strong><br />
down-stream production equipment<br />
<strong>and</strong> to deliver optimum performance <strong>and</strong><br />
productivity, LPW has developed customised<br />
transport mechanisms, typically based on<br />
pneumatic <strong>and</strong> electromechanical<br />
technologies, with advanced inductive<br />
sensing <strong>and</strong> control systems.<br />
For example, its modular PowerJet series<br />
provides high-pressure flooding at up to<br />
18bar <strong>and</strong> incorporates up to five cleaning<br />
stages. Components to be cleaned are<br />
transported in special cages that are moved<br />
manually or automatically on heavy-duty<br />
accumulating roller conveyors that<br />
compensate for fluctuations in feed flow <strong>and</strong><br />
cycle rates. Pneumatic piston rod cylinders<br />
mounted between the conveyor rollers<br />
separate the cages <strong>and</strong> queue others until a<br />
cleaning station is free. Once separated, each<br />
cage is lifted from the main conveyor <strong>and</strong><br />
fed to the entrance of the cleaning chamber.<br />
At this stage, LPW uses high-performance<br />
electric linear drives with integrated heavyduty<br />
guides <strong>and</strong> stroke lengths of 2m to<br />
feed heavy or large components (such as<br />
engine blocks <strong>and</strong> gearbox housings) safely,<br />
gently <strong>and</strong> accurately into each cleaning<br />
chamber. For this application, it has chosen<br />
Parker Origa’s OSP-E BHD drives which can<br />
withst<strong>and</strong> high loads <strong>and</strong> moments, even<br />
when positioning products accurately <strong>and</strong> at<br />
different speeds.<br />
The linear drives also allow the rate <strong>and</strong><br />
speed of the feed process to be adjusted to<br />
match the weight, size <strong>and</strong> cleaning<br />
requirements of each batch of components.<br />
In addition, the compact devices can be<br />
driven indirectly, allowing their motors to be<br />
isolated beneath the roller conveyor.<br />
Once the cleaning <strong>and</strong> rinsing processes<br />
are complete, the chamber door opens <strong>and</strong><br />
the linear drive moves back into the chamber<br />
to raise the component cage before drawing<br />
it out on smooth-running rollers. When the<br />
component has been lowered back onto the<br />
main roller conveyor, it continues on to<br />
further cleaning chambers (if required),<br />
before being moved to the drying chamber.<br />
Similar linear drives are used at each stage.<br />
The system allows cleaning <strong>and</strong> drying<br />
stages to be carried out concurrently, to<br />
maximise throughput in high-volume<br />
applications.<br />
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Unique Solutions from Proven Concepts<br />
24 November/December 2010 www.drives.co.uk
Application<br />
Door closer mechanism<br />
for underground train<br />
Solution<br />
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systems from Schaeffler UK offer first<br />
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E-mail: info.uk@schaeffler.com<br />
Web: www.schaeffler.co.uk<br />
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Cantilever axis assists<br />
tobacco-cutting skates<br />
WINCHESTER-BASED<br />
Garbuio Dickinson makes<br />
tobacco-cutting machines<br />
with a near-vertical action that<br />
minimises compression of the<br />
tobacco.<br />
The machines are fed by<br />
vibrating tray feeds that<br />
need to be removed for<br />
cleaning. The 1,800kg<br />
feeds are usually moved<br />
manually on air skates.<br />
“One customer however, wanted to take things a stage further<br />
<strong>and</strong> asked if we could devise something which would actually pull<br />
the feeder accurately into the machine,” says Garbuio Dickinson’s<br />
senior design engineer, Peter Todd. With only a 5mm clearance<br />
between the feed tray <strong>and</strong> the cutting machine sidewalls, he<br />
needed to find a linear motion system that would avoid contact<br />
between the two, <strong>and</strong> tolerate contamination by tobacco dust.<br />
Garbuio Dickinson chose HepcoMotion’s DLS3C linear actuator,<br />
which uses an aluminium beam to provide rigid support for<br />
cantilevered loads with minimal inertia. The actuator’s drive is<br />
mounted on the carriage <strong>and</strong> not connected to the end-plate, so<br />
the motor, carriage <strong>and</strong> cables remain stationary while the beam<br />
moves. For added safety, an overload clutch on the motorised<br />
gearbox limits the push/pull forces.<br />
The tray actuator that Todd designed consists of two linear<br />
systems, linked by a common shaft to ensure it moves in <strong>and</strong> out in<br />
parallel. The moving tray is supported by a pivoting mount that<br />
allows the connecting end of the tray to rise <strong>and</strong> fall as the feeder<br />
is lifted by its air skates.<br />
“In the event, with the air skates activated, the system wasn’t that<br />
dependant on being powered,” says Todd, “but the design of the guidance<br />
system has proved a major factor in the success of our product.”<br />
Screwjack goes with the flow<br />
A screwjack system is helping<br />
to control the flow of one of<br />
Britain’s shortest rivers – the<br />
River Morar which links Loch<br />
Morar to the sea, a few<br />
hundred metres away, on<br />
Scotl<strong>and</strong>’s west coast. The jack<br />
raises or lowers a sluice gate<br />
at a weir near a hydroelectric<br />
dam <strong>and</strong> fish ladder at the<br />
west end of the Loch.<br />
The 100kN rotating screwjack<br />
in a ram-style linear actuator<br />
design, is used, with a motor<br />
<strong>and</strong> reduction gearbox, to<br />
raise or lower the gate to<br />
control local water flows.<br />
Garbuio Dickinson’s feed tray movement<br />
system relies on a pair of linear actuators<br />
(under the tray) linked by a shaft<br />
A screwjack controls the level<br />
of Scotl<strong>and</strong>’s River Morar<br />
The screwjack operates over a<br />
stroke of 2,350mm, pivoting on its integral trunnions located midway<br />
on the ram's outer tube. At the end of the ram, a clevis end with<br />
spherical bearing connects the jack to the weir gate.<br />
When the jack was first installed in 2001, it was driven by a 2.2kW<br />
geared motor with position feedback coming from end-of-stroke<br />
limit switches <strong>and</strong> an absolute encoder that links back to the control<br />
system. Since then, it has been upgraded by replacing the motor<br />
with an alternative with an integrated h<strong>and</strong>wheel. The screwjack was<br />
supplied by Power Jacks, the Scottish linear actuation specialist.<br />
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www.drives.co.uk November/December 2010 27
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Bearing up to<br />
electrical erosion<br />
Variable speed drives can make life tough for motor bearings. SKF’s<br />
communications manager Phil Burge explains that preventing the damage caused<br />
by stray currents needs careful motor installation, bearing selection <strong>and</strong> diagnosis.<br />
BEARINGS, BELTS & CHIAINS<br />
Stray currents inside motors can<br />
be caused by a variety of<br />
sources, including rotor<br />
eccentricities <strong>and</strong> asymmetries,<br />
uneven air gaps, unbalanced<br />
windings or even poor electrical<br />
steel homogeneity. However, the<br />
increasingly widespread use of<br />
variable speed drives has introduced<br />
an important new source of these<br />
currents. Common-mode voltage –<br />
resulting from the inability of PWM<br />
(pulse width modulation)<br />
techniques used by drives to<br />
produce a perfectly smooth<br />
sinusoidal output – creates a rapidly<br />
changing potential difference<br />
between the motor windings <strong>and</strong><br />
earth. In many motor installations,<br />
the bearings provide the path of<br />
least resistance for these currents,<br />
but following that path can take a<br />
severe toll on the bearings.<br />
To high-frequency currents, the<br />
lubricant film in a rolling element<br />
bearing acts as a capacitor. A<br />
voltage difference builds up<br />
between the bearing casing <strong>and</strong> the<br />
rolling elements until it becomes<br />
large enough to overcome the<br />
insulation provided by the lubricant.<br />
At that point, a discharge occurs.<br />
Heat generated by the discharge<br />
can cause local melting of the<br />
bearing’s metal surface. Craters are<br />
formed <strong>and</strong> particles of molten<br />
material are transferred <strong>and</strong> partly<br />
break loose. The crater material rehardens,<br />
becoming much more brittle<br />
than the original material. Below the rehardened<br />
layer there is a layer of<br />
annealed material, which is softer than<br />
the surrounding material.<br />
While the substantial electrical<br />
discharges typically seen in DC motor<br />
installations can cause craters up to 1mm<br />
in diameter <strong>and</strong> are clearly visible to the<br />
A pattern of lines across bearing raceways can indicate that<br />
current has passed through the bearing. This effect, known as<br />
fluting, is secondary damage that becomes visible over time.<br />
Electric discharges can cause the base oil in a bearing lubricant to<br />
burn <strong>and</strong> harden, resulting in poor lubrication<br />
AC currents passing through bearings can produce tiny surface<br />
craters, a few microns in diameter, which give the rolling<br />
elements a dull appearance (left).<br />
naked eye, AC applications typically result<br />
in the formation of “micro” craters just a<br />
few μm in diameter. Over time, however,<br />
mechanical vibrations caused by elements<br />
rolling over these tiny craters will cause<br />
secondary damage, manifesting itself as a<br />
series of parallel grey segments along the<br />
raceways, known as fluting. The<br />
temperature peaks around the discharge<br />
area can also cause the lubricant<br />
inside the bearing to decompose<br />
<strong>and</strong> degrade, <strong>and</strong> to become<br />
blackened over time. Together,<br />
these damage mechanisms lead to<br />
premature bearing failure, <strong>and</strong> to<br />
costly downtime.<br />
>Difficult diagnosis<br />
Bearing currents cause problems in<br />
a small minority of VSD installations.<br />
It is desirable, however, to find<br />
methods of diagnosis that do not<br />
rely on inspecting a failed bearing.<br />
The complexity <strong>and</strong> unpredictability<br />
of stray currents within motors can<br />
make such diagnosis difficult, <strong>and</strong><br />
the occurrence of problems in an<br />
installation can depend on the asmanufactured<br />
characteristics of the<br />
motor, the details of its installation,<br />
<strong>and</strong> its mode of use.<br />
Because electrical erosion typically<br />
manifests itself within a few months<br />
of a system being commissioned,<br />
frequent basic condition monitoring<br />
can be an effective way to identify<br />
early bearing damage.<br />
Detecting stray currents<br />
traditionally requires considerable<br />
skill <strong>and</strong> specialist equipment,<br />
including high-speed oscilloscopes<br />
<strong>and</strong> special sensors that can be<br />
installed on rotating shafts. When<br />
correctly set up, the oscilloscope will<br />
show peaks on the screen<br />
corresponding to each electrical<br />
discharge in the bearing.<br />
A useful recent innovation in the battle<br />
against electrical erosion has been the<br />
development of specialised electrical<br />
discharge detection devices. These<br />
h<strong>and</strong>held instruments are tuned to<br />
monitor changes in the magnetic field<br />
around a motor shaft at the specific<br />
frequencies associated with electrical<br />
erosion, allowing rapid, robust<br />
www.drives.co.uk November/December 2010 29
BEARINGS, BELTS & CHIAINS<br />
identification of potential<br />
problems.<br />
> Remedial action<br />
The most effective<br />
preventative or remedial<br />
action in the event of<br />
electrical erosion in bearings<br />
will depend on the<br />
characteristics of the<br />
equipment <strong>and</strong> on the<br />
interventions available to the<br />
engineer. In new installations,<br />
risks can be minimised by<br />
using symmetrical multi-core<br />
motor cables in which the<br />
earth conductor is either<br />
arranged as a concentric<br />
shield around the phase leads<br />
or as three separate leads<br />
positioned between them.<br />
Shielded motor cables can<br />
also provide a short, lowimpedance<br />
path for commonmode<br />
current to return to the<br />
inverter. Likewise, a<br />
grounding brush on the<br />
motor shaft can offer an<br />
easier path to earth than that<br />
provided by the motor<br />
bearings. Effective grounding<br />
between other motor<br />
components can also be<br />
important.<br />
The high-frequency<br />
switching that can be a major<br />
cause of electrical erosion can<br />
sometimes be minimised by<br />
changing the characteristics<br />
of the drive control program,<br />
or by installing dedicated<br />
filters in the drive circuit.<br />
The use of bearings with<br />
insulating housings can<br />
eliminate the electrical<br />
pathway through the motor<br />
bearings, thus preventing<br />
erosion. Insulated bearings are<br />
readily available, but different<br />
coatings <strong>and</strong> bearing designs<br />
have different characteristics<br />
when exposed to highfrequency<br />
AC currents.<br />
Bearing manufacturers have<br />
tested their proprietary<br />
designs under a wide range of<br />
operating conditions <strong>and</strong> can<br />
offer advice on the most<br />
suitable bearings for particular<br />
applications. In some cases,<br />
bearings with ceramic rolling<br />
elements can be particularly<br />
useful, providing perfect<br />
electrical insulation between a<br />
motor’s stator <strong>and</strong> rotor. D&C<br />
Solar plant uses plain<br />
bearings to track the sun<br />
More than 1,000 precision plain bearing<br />
rod ends are playing a key role in the<br />
world’s largest parabolic trough solar<br />
power station – the 50MW Andasol 1 plant in<br />
southern Spain<br />
The €300m plant, which went on line in mid-<br />
2009, is expected to generate about 180GWh a<br />
year – supporting the power needs of more than<br />
200,000 people, <strong>and</strong> saving around 150,000<br />
tonnes of carbon dioxide. It is the first of three<br />
similar plants being built at the site in Andalusia.<br />
The plant consists of three main parts, the<br />
largest being an array of solar troughs with a<br />
collector area of more than 510,000m 2 –<br />
equivalent to around 70 soccer pitches. There is<br />
also a power plant area <strong>and</strong> a heat accumulator,<br />
which allows the station to continue generating<br />
electricity even in cloudy weather or after sunset.<br />
The solar field consists of parallel rows of<br />
parabolic collectors arranged on a north-south<br />
axis to follow the path of the sun from east to<br />
west. To track the sun, each collector is fitted<br />
with a hydraulic drive.<br />
The trough-shaped parabolic mirrors focus<br />
the solar radiation onto an absorber pipe,<br />
positioned along the collector’s focal line. A<br />
closed-circuit pipe system uses synthetic oil to<br />
transfer heat at up to 400°C. The heated oil is<br />
pumped to a power block where it flows<br />
through a heat exchanger. The next stage is<br />
similar to the steam cycle in a conventional<br />
power plant – the steam generated in the heat<br />
exchanger drives a turbine connected to a<br />
generator. The steam then condenses back into<br />
water, which is recirculated.<br />
A total of 1,248 Elges hydraulic rod end<br />
bearings supplied by Schaeffler support the<br />
solar troughs, positioning them with millimetre<br />
precision to follow the sun.<br />
“High-precision bearings are required so that<br />
the power plant can operate at maximum<br />
efficiency,” explains Dr Arndt Schweigert, head<br />
of Schaeffler’s power generation sector.<br />
“Moreover, the bearings also have to withst<strong>and</strong><br />
loads that should not be underestimated.”<br />
The plain bearings have been optimised for<br />
the slow, precise swivel motion. It is critical that<br />
these movements are smooth, without any<br />
stick-slip effects or jolting on start-up.<br />
At the same time, the hydraulic rod ends<br />
need to support high forces <strong>and</strong> to h<strong>and</strong>le<br />
alternating loads. This allows the 150m-long<br />
chains of collectors to be adjusted to within a<br />
tenth of a millimetre.<br />
The rod ends are fitted with manganese<br />
phosphate-coated radial spherical plain bearings<br />
with steel-to-steel sliding contact surfaces. The<br />
Parabolic reflectors focus the<br />
sun’s energy on a pipe carrying oil<br />
which is heated to 400°C<br />
surface treatment improves the running-in<br />
characteristics <strong>and</strong> reduces friction. The inner<br />
ring of the spherical plain bearing is 70mm wide<br />
<strong>and</strong> has a 110mm cylindrical bore diameter, as<br />
well as a spherical outer slideway. The 160mmdiameter<br />
outer ring has a cylindrical outer<br />
surface <strong>and</strong> a concave inner slideway with a<br />
diameter of 140mm.<br />
Schaeffler has also provided 7,488 lead-free<br />
plain bearing strips for the Andasol plant. These<br />
are mounted in the supports between the<br />
individual segments of the 150m-long collector<br />
chains, ensuring smooth slewing movements<br />
while tracking the sun.<br />
30 November/December 2010 www.drives.co.uk
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NSK UK Ltd · Northern Road, <strong>New</strong>ark, Nottinghamshire, NG24 2JF · Telephone +44 (0) 1636 605123 · info-uk@nsk.com
2<br />
BEARINGS, BELTS & CHIAINS<br />
Tests helped to make World Cup stadia vuvuzela-resistant<br />
Long before the first kick-off at the recent football World<br />
Cup in South Africa, engineers working for Wacker<br />
Ingenieure Wind Engineering in Germany had tested<br />
scale models of the stadia to determine how they would<br />
h<strong>and</strong>le storms, vibrations <strong>and</strong> other disturbances.<br />
Using the three wind tunnels at their facility in<br />
Birkenfeld, the engineers were able to test how the<br />
stadia would withst<strong>and</strong> wind loads – <strong>and</strong> whether they<br />
would start to vibrate when 80,000 fans celebrated<br />
by making a deafening noise with their vuvuzelas.<br />
The wind tunnels can generate wind speeds<br />
of more than 100km/h to simulate the<br />
conditions encountered during a hurricane.<br />
The equipment uses scale models to<br />
analyse structures such as skyscrapers,<br />
airports or bridges, years before the<br />
foundation stone is laid. The engineers<br />
evaluate the test data using software<br />
developed in-house. There is only one other<br />
company in the world that offers similar "wind<br />
engineering" services.<br />
To obtain exact measurements, absolute precision is<br />
required in the wind tunnels. For example, a rotary table<br />
at the end of one of the tunnels carries scale models of<br />
the building being tested, which can be turned through<br />
360 degrees in 4,000 precise steps.<br />
This table is rotated using a 3.2m-long, 30mm-wide belt<br />
with protuberances known as nubs. The belt is attached<br />
to a free-running steel rim, with the nubs facing<br />
outwards <strong>and</strong> connecting with a drive wheel containing<br />
matching indentations.<br />
Bernd Reinhard of Wacker Aerodynamics (right) with René Pressler<br />
from Hilger <strong>and</strong> Kern Antriebstechnik at the rotating table mounted<br />
in front of the wind tunnel (background). The inset (left) shows a<br />
close-up of the nubbed belt drive system. Photos: Wacker Ingenieure<br />
“When combined with the nubbed wheel, the belt allows us to test aerodynamics in<br />
precisely defined steps to obtain exact measurements,” explains Wacker’s<br />
aerodynamics specialist, Bernd Reinhard. “The nubs on the nubbed wheel roll on a<br />
precise circle. The constant belt tension <strong>and</strong> high performance are guaranteed by<br />
wear-resistant, durable polyurethane with steel cord reinforcements.”<br />
Wacker’s engineers developed the drive system in co-operation with Mulco partner<br />
Hilger <strong>and</strong> Kern Antriebstechnik. The Synchrodrive N10 nubbed belt was supplied by<br />
ContiTech’s Power Transmission Group.<br />
The Wacker engineers are now using their wind tunnel equipment to test the stadia for<br />
the 2012 European Cup in Pol<strong>and</strong>.<br />
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32 November/December 2010 www.drives.co.uk<br />
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BEARINGS, BELTS & CHIAINS<br />
Converting to<br />
synchronous<br />
belts cuts<br />
HVAC costs<br />
by $34,000<br />
US-BASED Reichhold Corporation is a<br />
global supplier to the composites <strong>and</strong><br />
coatings industries, with 18 manufacturing<br />
facilities in 11 countries. During the hot<br />
summer months, the energy to run beltdriven<br />
HVAC systems at its site in Durham,<br />
North Carolina, was costing it about<br />
$80,000 a month.<br />
The site’s maintenance technician called<br />
in a representative from the belt-maker<br />
Gates to survey the plant for potential<br />
energy savings on its V-belt driven systems,<br />
which included 21 HVAC systems powered<br />
by 30hp (22.4kW) motors, 44 fume hood<br />
exhaust fans powered by 5–10hp (3.7–<br />
7.4kW) motors, <strong>and</strong> four cooling tower<br />
fans powered by 50hp (37kW) motors.<br />
The HVAC drives were being driven by<br />
four-str<strong>and</strong> V-belts which needed frequent<br />
retensioning, <strong>and</strong> had to be changed every<br />
three months. Gates replaced them with<br />
Before <strong>and</strong> after: a cooling tower fan with a five-str<strong>and</strong> V-belt drive (left)<br />
<strong>and</strong> the same fan with a synchronous belt drive (right)<br />
14mm Poly Chain GT Carbon synchronous<br />
belt drives, <strong>and</strong> monitored them.<br />
The current being drawn per belt fell<br />
from 12.5A to 10.4A, <strong>and</strong> the annual KWh<br />
usage dropped to 10,103–10,557kWh,<br />
representing annual energy savings of<br />
$505–527. Converting all 21 belts<br />
represents an energy cost saving of at least<br />
$10,608. In addition, the synchronous belt<br />
drives should run for years without needing<br />
to be retensioned or replaced, avoiding<br />
extra downtime <strong>and</strong> maintenance costs.<br />
The Reichhold facility also includes two<br />
1,200-tonne chillers <strong>and</strong> cooling towers.<br />
Each cooling tower had two fan drives<br />
fitted with V-belts. When one drive was<br />
converted to a 14mm synchronous belt<br />
drive, the savings were substantial. The<br />
estimated annual saving of converting all<br />
four fans is $12,595, including reduced<br />
downtime <strong>and</strong> maintenance costs.<br />
Although the 44 fume hood exhaust fans<br />
on the roof of the Reichhold facility are<br />
covered, they are subject to extreme<br />
variations in temperature. Previously they<br />
were driven by two-str<strong>and</strong> V-belts which<br />
had to be replaced every three months <strong>and</strong><br />
were each costing $250 a year to maintain.<br />
By changing to 8mm synchronous belt<br />
drives, energy consumption fell by 12.9%.<br />
Converting all 44 drives is cutting<br />
maintenance costs by $11,000/year, in<br />
addition to the energy cost savings.<br />
In total, the maintenance <strong>and</strong> energy<br />
cost savings achieved by converting the<br />
various V-belt drives at Reichhold site to<br />
synchronous belt drives is amounting to<br />
more than $34,000 a year.<br />
34 November/December 2010 www.drives.co.uk
Falcon HTC<br />
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Falcon HTC<br />
For more information about Falcon HTC, please contact Veyance Technologies Europe, Unit 2, Zone 4, Burntwood Business Park,<br />
Burntwood, Staffordshire WS7 3XD, phone: +44 1543 672511, email: uksales@veyance.com<br />
The GOODYEAR (<strong>and</strong> Winged Foot Design) trademark is used by Veyance Technologies, Inc. under license from The Goodyear Tire & Rubber Company. Goodyear Engineered Products<br />
are manufactured <strong>and</strong> sourced exclusively by Veyance Technologies, Inc. or its affiliates. ©2008 Veyance Technologies, Inc. All Rights Reserved.
POLY CHAIN ® GT CARBON BELT<br />
TECHNOLOGY DRIVES<br />
PRODUCTIVITY SOLUTIONS<br />
Lightweight • Clean • Maintenance free • Environmentally friendly • Energy <strong>and</strong> cost saving<br />
Nothing tougher<br />
If you thought that the limit in power ratings was<br />
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excellent alternative to roller chain drives <strong>and</strong> gear.<br />
For more info go to www.gates.com/europe/PTI<br />
or mail to inforequest@gates.com
Extend your chain<br />
lives at no extra cost<br />
Simply by looking for signs of early wear <strong>and</strong> eliminating the cause,<br />
engineers can prolong the lives of conveyor <strong>and</strong> transmission chain without<br />
incurring any extra costs, says Renold Chain’s marketing communications<br />
manager, David Turner, in the first article in a series.<br />
BEARINGS, BELTS & CHIAINS<br />
St<strong>and</strong>ard roller chain is<br />
designed to last at least<br />
15,000 hours. Certain<br />
unavoidable factors may shorten a<br />
chain’s life, but if chain is routinely<br />
needing to be replaced before this,<br />
then it is worth checking to see if<br />
anything can be done to extend its<br />
working life. Often it can.<br />
If it were possible to get just<br />
10% more life out of every str<strong>and</strong><br />
of chain on every production line<br />
<strong>and</strong> machine in a factory, the<br />
savings would be enormous when<br />
extrapolated over a year – not just<br />
in terms of reduced chain<br />
replacement costs, but also<br />
through reduced downtime.<br />
Every year, our engineers come<br />
across dozens of cases where chain<br />
has worn prematurely due to<br />
relatively minor problems that could<br />
have been put right quite easily.<br />
When you consider that some<br />
production lines are running<br />
hundreds – possibly thous<strong>and</strong>s –<br />
of metres of chain, it’s not difficult<br />
to work out that if each str<strong>and</strong><br />
could be made to last longer, then<br />
real savings could be made across<br />
the whole factory. Even small<br />
operations can benefit from<br />
extended chain lives, especially<br />
when all that may be needed is a<br />
little time to investigate operating<br />
conditions <strong>and</strong> to consider<br />
maintenance routines.<br />
To find out where the tweaks<br />
<strong>and</strong> adjustments might be needed,<br />
first undertake a thorough visual<br />
inspection of the chain while it is<br />
not running. Just as a forensic<br />
pathologist can look at a dead<br />
body <strong>and</strong> determine the cause of<br />
death, if a chain is suffering from<br />
premature wear, there will be visual<br />
signs that can be spotted easily.<br />
Although failure to lubricate chain<br />
correctly might seem an obvious cause of<br />
early wear, it is still the most common<br />
Fig. 1: Fretting corrosion can result from poor lubrication<br />
Fig. 2: Misalignments can result in side-plate wear<br />
reason for premature failure. Checking your<br />
lubrication regime should be a top priority.<br />
Check that each chain is being lubricated<br />
regularly with the correct lubricant,<br />
referring to the manufacturer’s<br />
lubrication guides.<br />
Fig. 1 shows an example of<br />
conveyor chain where scoring <strong>and</strong><br />
heavy red deposits are a clear sign<br />
of fretting corrosion. This is<br />
caused by marginal lubrication<br />
where there is not enough<br />
lubricant present to prevent the<br />
asperities on the chain’s<br />
components rubbing together. In<br />
such a case, lubricate the chain<br />
thoroughly to wash out some of<br />
the oxide, <strong>and</strong> monitor it<br />
regularly. The chain should then<br />
be lubricated regularly <strong>and</strong><br />
correctly to prevent the problem<br />
from recurring.<br />
The transmission chain in Fig. 2<br />
is showing signs of wear on the<br />
face <strong>and</strong> the end of the sideplates.<br />
The reason for this type of<br />
wear is misalignment, which<br />
causes abrasion with a fixed point<br />
on the circuit. From the wear<br />
pattern, it looks as if the chain<br />
may have worn its guides too, so it<br />
should be easy to spot the point of<br />
contact. The remedy is to realign<br />
the chain before the damage<br />
becomes any more serious <strong>and</strong> the<br />
chain needs to be replaced.<br />
Renold has produced a free<br />
troubleshooter guide, available as<br />
a downloadable PDF from its Web<br />
site (www.renold.com). The guide<br />
documents dozens of examples of<br />
the sort of conditions that will<br />
cause premature failures, <strong>and</strong><br />
provides fix-it advice on rectifying<br />
the problems. Doing this can<br />
increase the chain’s working life<br />
significantly, postpone<br />
replacement costs <strong>and</strong> cut<br />
downtime.<br />
D&C<br />
When chain does eventually need replacing<br />
there are more opportunities for improving<br />
performance. This will be examined in the<br />
next article in this series.<br />
www.drives.co.uk November/December 2010 37
Time to<br />
put HMIs<br />
in control?<br />
PLCs AND HMIs<br />
The boundary between HMIs <strong>and</strong> Scada systems is breaking down,<br />
with modern CE-based HMIs offering many of the functions previously<br />
restricted to PC-based systems. Graham Isherwood (left), sales manager<br />
for ABB Open Control Systems, examines this trend <strong>and</strong><br />
considers what it means for the automation market.<br />
The distinction between HMI <strong>and</strong><br />
Scada is becoming increasingly<br />
blurred. Traditionally, an HMI was a<br />
simple interface to a PLC <strong>and</strong> was in the<br />
domain of the machine-builder. Scada, by<br />
contrast, was the “line controller” which<br />
ran on a PC <strong>and</strong> had better functions for<br />
visualisation, trending <strong>and</strong> alarm reporting<br />
– but was usually not cost-effective at the<br />
machine level.<br />
Both technologies have evolved. Scada<br />
vendors now offer Windows CE-based<br />
products that run on HMI hardware, while<br />
HMI vendors are adding features to boost<br />
functionality.<br />
Does this mean that there is now a<br />
simple choice between “large” <strong>and</strong><br />
“small” Scada, or is there an application<br />
niche for high-performance HMI panels,<br />
that are both feature-rich <strong>and</strong> costeffective?<br />
The automation industry has no<br />
accurate definitions for HMI or Scada. The<br />
two terms are often freely<br />
interchangeable – or are simply seen as<br />
being different names for the same thing.<br />
You therefore need to set up a framework<br />
to allow comparisons to be made.<br />
In general, there are two generic<br />
approaches to providing an operator<br />
display – those based on Microsoft’s<br />
Windows CE, <strong>and</strong> those based on fullscale<br />
PCs. Windows CE displays are<br />
probably less obvious to users because<br />
vendors implement their own flash<br />
screens on boot-up.<br />
Microsoft’s CE developments (driven<br />
largely by the requirements of the mobile<br />
phone market <strong>and</strong> by CPU developments)<br />
have resulted in CE becoming a <strong>powerful</strong><br />
platform for HMI applications.<br />
On the PC-based side, you find Scada<br />
<strong>and</strong> DCS. Scada vendors often add (<strong>and</strong><br />
sometimes remove) functions to provide a<br />
CE-based offer, usually offering the same<br />
development tools as for their PC-based<br />
systems. DCS vendors tend to use CEbased<br />
panels for peripheral operator<br />
stations rather than for those found in<br />
control rooms. The boundaries in the<br />
operator display market are therefore<br />
blurred, but this perhaps ignores other<br />
important attributes in the hardware.<br />
What’s missing?<br />
CE devices tend to be more robust than<br />
PCs, <strong>and</strong> thus more <strong>reliable</strong> in the field,<br />
needing no mains power supply (they<br />
operate from 24V DC supplies), no hard<br />
drive (they use flash memory) <strong>and</strong> no fans.<br />
These factors make CE-based HMIs<br />
functionally attractive – even more so<br />
when relative prices are considered, along<br />
with easier installation <strong>and</strong> swap-out.<br />
Another attraction is that the<br />
combination of a CE panel <strong>and</strong> its<br />
associated software is cheaper than the<br />
PC-based Scada alternative. This has a<br />
direct bearing when a system needs<br />
multiple operator stations, <strong>and</strong> the budget<br />
is a maximum of £1,000 per station.<br />
But you might wonder what is<br />
“missing” in a CE-based HMI that you<br />
might regret later on. If the price per<br />
station is lower, then what are you doing<br />
without?<br />
In the past, CE-based systems posed<br />
some development problems, with an<br />
over-dependence on processor types <strong>and</strong><br />
other limitations. In addition, the software<br />
was clumsy <strong>and</strong> required a knowledge of<br />
electronics as well as of automation.<br />
Thankfully this is over. There are now<br />
two sub-divisions within the CE operator<br />
station market – those from vendors that<br />
supply both hardware <strong>and</strong> software, <strong>and</strong><br />
those that supply these elements<br />
separately.<br />
Both approaches have attractions in<br />
terms of squeezing more out of the CE<br />
format. Holistic hardware with software<br />
combinations offer ease-of-use <strong>and</strong><br />
extended, dedicated functions.<br />
If a CE-based panel is going to be costeffective,<br />
it has to offer more for your<br />
money than an equivalent PC-based<br />
system (bearing in mind the software<br />
licencing cost). The front has to look good<br />
(offering a choice of a touchscreen or<br />
function keys), but the detail is at the rear.<br />
Turning an HMI panel around shows its<br />
connections <strong>and</strong> how thoughtfully <strong>and</strong><br />
practically it has been designed. For<br />
example, can you see an RJ-45 Ethernet<br />
connector, a USB socket, a memory card<br />
slot, an old-style D-Sub serial port, a<br />
printer port, a 24V DC terminal, <strong>and</strong> so<br />
on? You should also check the mounting<br />
www.drives.co.uk November/December 2010 39
PLCs AND HMIs<br />
method <strong>and</strong> the sealing arrangements<br />
for dust <strong>and</strong> fluids.<br />
From this you can gauge the likely<br />
functionality. A quick check of the<br />
headline software features does the rest.<br />
For example, does it offer scalable<br />
graphics (you don’t want to have to<br />
develop separately for each size of<br />
panel)? Also, how does the alarm<br />
h<strong>and</strong>ling interface with external systems,<br />
<strong>and</strong> can the panel generate SMS alerts<br />
directly without needing another<br />
program (as would be the case for a PCbased<br />
alternative)? Is the HMI program<br />
backed-up to non-volatile memory <strong>and</strong><br />
can the memory be exp<strong>and</strong>ed via<br />
memory card slots? The ability to use<br />
one HMI panel to display another’s<br />
content can also be an advantage. The<br />
list goes on, but attractive <strong>and</strong> functional<br />
features are exposed in this way.<br />
The remaining item on the checklist is<br />
connectivity to controllers. Extensive<br />
connections are needed for a st<strong>and</strong>ard<br />
hardware <strong>and</strong> software HMI system that<br />
can be deployed across a whole site <strong>and</strong><br />
for machine-builders who may have<br />
different controllers on different<br />
machines, but want to benefit from a<br />
st<strong>and</strong>ard operator display.<br />
Compact Flash-slot<br />
Can – or should – you ab<strong>and</strong>on PCbased<br />
Scada <strong>and</strong> move to CE-based<br />
HMI? Well, you would save a lot of<br />
money but, as ever, you need to take a<br />
balanced view. Modern CE-based HMIs<br />
do not have the same compromises <strong>and</strong><br />
difficulties that you might remember<br />
from earlier generations. Combined<br />
hardware <strong>and</strong> software systems will<br />
probably offer useful extra functions<br />
(such as SMS alerting) compared to<br />
RS422/485 Expansion port Internal Compact Flash-slot<br />
USB Host<br />
Ethernet<br />
A peek around the back of an HMI panel reveals its connections <strong>and</strong> other design features<br />
RS232<br />
piecemeal supplies.<br />
The control room <strong>and</strong> the line<br />
controller are the domains of Scada <strong>and</strong><br />
DCS solutions. But “out there” <strong>and</strong><br />
“down there” you need the functions,<br />
robustness <strong>and</strong> attractive pricing of an<br />
all-in-one CE-based HMI panel. This<br />
could be the right time for you to reevaluate<br />
your view of CE-based HMIs –<br />
there is much to be gained, <strong>and</strong> nothing<br />
D&C<br />
to be lost.<br />
Dual PLCs ensure a smooth lift for aircraft passengers<br />
An Italian company called Oxley specialises in manufacturing aerial<br />
platform systems, including vehicles used to transfer people with<br />
restricted mobility to <strong>and</strong> from passenger aircraft.<br />
Traditionally these vehicles have been based on diesel-engined trucks<br />
which have been costly to buy <strong>and</strong> maintain. Since 2005, Oxley has<br />
been working on an alternative electrically-powered design which is<br />
smaller <strong>and</strong> cheaper to operate <strong>and</strong> has been designed to comply with<br />
new European airport <strong>and</strong> environmental regulations.<br />
A key requirement was the ability to operate the lifting system both<br />
from the ground <strong>and</strong> from the platform in the raised position, <strong>and</strong> to<br />
provide the operator with full information on this process.<br />
Initially, Oxley produced a platform using relay-based electronics but<br />
the authorities rejected this approach, saying that it did not comply<br />
with stringent airport st<strong>and</strong>ards. Oxley therefore decided to fit the<br />
mechanical components, fully tested, to the vehicle <strong>and</strong> to adopt<br />
programmable industrial controls.<br />
The latest vehicle – known as the <strong>New</strong>Ox906Air – is controlled by two<br />
Rockwell Automation Micrologix 1100 PLCs. One PLC is installed on the<br />
platform which carries the passenger <strong>and</strong> operator. The second is<br />
located within the electric motor bay in the lower section of the<br />
vehicle. The PLCs communicate with each other using the DH485<br />
protocol, allowing communication via three coiled cables which avoid<br />
problems of cable movement <strong>and</strong> wear.<br />
The use of two PLCs guarantees redundancy of the control systems<br />
responsible for maintaining the platform in the correct horizontal<br />
attitude, <strong>and</strong> prevents any unexpected movement <strong>and</strong> the risk of<br />
collision or crushing when docking with the aircraft. Operators can<br />
check the operating parameters via a Rockwell PanelView C300 control<br />
panel which also provides first-level diagnostics for detecting faults.<br />
Maintenance personnel can monitor the control system remotely via<br />
Uplifting: Oxley’s air passenger transport vehicle uses a pair of PLCs to<br />
provide redundant control <strong>and</strong> to allow operation from two locations<br />
Ethernet, thus reducing maintenance times <strong>and</strong> costs in the event of<br />
any problems.<br />
The electrically-propelled platform is said to be quick <strong>and</strong> simple to<br />
operate. It is fitted with all of the safety systems needed to embark <strong>and</strong><br />
disembark passengers without risk to their safety or damage to the<br />
aircraft.<br />
40 November/December 2010 www.drives.co.uk
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Superior Systems’<br />
test rig puts car<br />
hinges through<br />
their paces<br />
Tests hinge on<br />
precision control<br />
Miniature <strong>Drive</strong> Specialists<br />
COVENTRY-BASED industrial controls<br />
expert Superior Systems has developed<br />
a rig for testing a new generation of<br />
car door hinges for a leading<br />
automotive components supplier. The<br />
rig had to be <strong>reliable</strong>, easy to operate<br />
<strong>and</strong> able to transfer the test results to<br />
a mainframe computer.<br />
Essentially, the rig consists of an arm<br />
that is attached to the hinge being<br />
tested, which engages with a platen<br />
that runs around a 1m-radius curved<br />
track. Weights can be added to the<br />
arm to simulate the loads that a car<br />
door would impose on the hinge.<br />
This arrangement allows the arm to<br />
be moved through any angle (up to a<br />
maximum dictated by the design) <strong>and</strong><br />
for the speed of the movement to be<br />
controlled accurately between 1m/min<br />
<strong>and</strong> 1m/s. A second, similarlyequipped<br />
platen boosts the rig’s<br />
versatility.<br />
To control the servomotors used on<br />
the platens, Superior chose Mitsubishi<br />
MR-J3 servo drives, while overall<br />
control of the rig is provided by a<br />
Mitsubishi Qn PLC. A Mitsubishi E1070<br />
colour HMI, with a built-in keypad, is<br />
used to set up <strong>and</strong> operate the<br />
machine.<br />
A typical test sequence begins by<br />
pre-exercising the hinge for several<br />
cycles at a relatively high speed. It is<br />
then operated through one cycle at a<br />
lower speed while detailed<br />
measurements are made of its<br />
performance.<br />
Using the HMI terminal, all that the<br />
machine operators need to do to set<br />
up a test is to enter the speed <strong>and</strong><br />
angle of travel for the exercise cycles<br />
<strong>and</strong> the number of cycles required,<br />
together with the speed <strong>and</strong> angle of<br />
travel for the measurement cycle. The<br />
test is then initiated at the touch of a<br />
button, with the results collected<br />
automatically by the PLC <strong>and</strong><br />
transferred to a mainframe system via<br />
Mitsubishi’s MX Sheet software.<br />
The HMI keypad is also used to<br />
access ancillary functions, such as<br />
facilities for manual jogging as an aid<br />
to mechanical set-up. While the tests<br />
are in progress, the HMI screen<br />
displays a graphical representation of<br />
the results in real time.<br />
According to Superior’s proprietor,<br />
John Ferris, two of the main attractions<br />
of the Mitsubishi PLC for this<br />
application were its support for<br />
Ethernet <strong>and</strong> its ability to run the MX<br />
Sheet software. This Excel<br />
communications support tool, he<br />
explains, “made it easy for us to collect<br />
the data produced by the test rig <strong>and</strong><br />
to format it for use by the end-user’s<br />
mainframe systems, while the Ethernet<br />
connectivity provided us with the<br />
means to transfer the data to those<br />
systems. Its data formatting <strong>and</strong><br />
transfer were very straightforward to<br />
set up – no complicated programming<br />
was needed.”<br />
PRECISE STEPS FOR<br />
SAFE OPERATION<br />
PRECISION MINIATURE<br />
STEPPER MOTORS<br />
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EMS<br />
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DC Micromotors<br />
Brushless DC motors<br />
Gearmotors<br />
Low Profile Motors<br />
Stepper Motors<br />
<strong>Drive</strong> Electronics<br />
Linear Actuators<br />
Custom Solutions
PLCs AND HMIs<br />
What can HMIs learn<br />
from the iPhone?<br />
What are latest trends in HMIs <strong>and</strong> what should you look<br />
for when choosing one? Dirk Hartmann, marketing<br />
manager for Beijer Electronics, outlines some key trends.<br />
HMIs are in a state of flux. Industrial<br />
user interfaces are taking inspiration<br />
from consumer products such as<br />
mobile phones <strong>and</strong> MP3 players, with<br />
advanced 3D-style graphics <strong>and</strong> icon-based<br />
navigation <strong>and</strong> controls, resulting in friendly<br />
<strong>and</strong> intuitive user interfaces. Leading-edge<br />
HMIs support this with embedded graphics<br />
<strong>and</strong> functions, providing intuitive user<br />
interfaces based on modern software<br />
technologies <strong>and</strong> open architectures.<br />
Trend 1: Enhancing the user experience<br />
The significance of user interfaces has<br />
become increasingly clear in recent years.<br />
For example, Apple’s iPod <strong>and</strong> iPhone are<br />
iconic examples of how appealing <strong>and</strong><br />
intuitive user interfaces have changed the<br />
perception of some types of product. The<br />
success of these products <strong>and</strong> other<br />
consumer-oriented merch<strong>and</strong>ise shows that<br />
a common look-<strong>and</strong>-feel among the<br />
products, graphics <strong>and</strong> environments<br />
contributes to br<strong>and</strong> distinction <strong>and</strong> to<br />
consistent customer experiences.<br />
Many industrial corporations have<br />
reached the same conclusion <strong>and</strong> are<br />
focussing increasingly on their products’<br />
user interfaces. In many ways, the HMI is<br />
the front of a machine or process. The<br />
higher the level of functionality <strong>and</strong><br />
interaction embedded in an HMI, the more<br />
the user interface reflects the essential<br />
experience of a machine or process.<br />
Tomorrow’s HMIs will elevate the HMI from<br />
being a functional add-on, to becoming an<br />
integral part of a user experience.<br />
Design features will include the use of<br />
WPF (Windows Presentation Foundation)<br />
objects, scalable to any size without losing<br />
picture quality, <strong>and</strong> the use of Microsoft<br />
.Net objects found or bought on the<br />
Internet. The use of templates <strong>and</strong> object<br />
styles will facilitate effi<strong>cient</strong> ways to ensure<br />
consistent, re-usable designs. Embedding<br />
functional objects, including Windows<br />
media objects, in the screen design will<br />
further enhance the user experience.<br />
In addition to the competitive advantages<br />
for machine-builders, there are solid<br />
arguments for end-users to justify investing<br />
in well-designed, intuitive user interfaces.<br />
The added value of tomorrow’s HMIs will<br />
be reflected in ease of use, higher efficiency<br />
<strong>and</strong> productivity, reduced time to complete<br />
tasks, improved user satisfaction, trust in<br />
the systems, <strong>and</strong> fewer user errors.<br />
Trend 2: Innovation based on modern<br />
software technologies<br />
The evolution of HMIs is being driven by<br />
continuous software development, backed<br />
by robust, high-performance hardware.<br />
Today, the panel is considered as a vehicle<br />
for the HMI software platform, allowing<br />
OEM design engineers to add value to their<br />
products with various functions <strong>and</strong> design<br />
options. The software platform is therefore<br />
a crucial element.<br />
HMI software development is costly <strong>and</strong><br />
complex. Innovative HMI manufacturers<br />
need to base their software platforms on<br />
widely-used modern technologies to access<br />
a broad variety of tools <strong>and</strong> functions.<br />
For example, the resources behind the<br />
.Net technology are enormous, <strong>and</strong> this will<br />
be reflected in the continuous development<br />
of new HMI functions. Dependence on<br />
proprietary technologies or technologies<br />
from smaller vendors is a risky strategy.<br />
HMIs based on .Net or similar<br />
technologies are likely to deliver innovative,<br />
future-proof tools with continuous updates<br />
<strong>and</strong> service support, appreciated by OEMs<br />
with long-term strategies for their own<br />
products <strong>and</strong> external suppliers.<br />
Trend 3: Open platform architectures<br />
Essentially, HMIs integrate the operation of<br />
a machine or a process with feedback to or<br />
from the operator. A key aspect is the<br />
openness of the HMI system. How easy is it<br />
to exchange essential information with<br />
different systems or controllers? Is the<br />
application code locked for customisation<br />
of functions or objects? Will runtime<br />
software be able to operate on different<br />
hardware platforms? Increasingly, HMI<br />
vendors are discussing these issues with<br />
their customers.<br />
The open platform architecture of<br />
tomorrow’s HMIs will offer opportunities<br />
for OEMs to enhance the look, functions<br />
<strong>and</strong> connectivity of applications to produce<br />
unique products. HMIs, from compact<br />
operator panels to industrial PCs, will<br />
become less proprietary <strong>and</strong> will offer<br />
increased freedom of choice.<br />
It will be possible to create a scalable<br />
master project, which can be applied to<br />
different controller br<strong>and</strong>s <strong>and</strong> panel<br />
resolutions, thus needing to maintain only<br />
one project. Engineers will dem<strong>and</strong><br />
opportunities to use scripting tools, such as<br />
C++ script, to customise the look or<br />
functions of objects. Design tools will offer<br />
the possibility of importing third-party<br />
objects <strong>and</strong> .Net controls.<br />
Freedom in terms of connections <strong>and</strong><br />
communications is the hallmark of truly<br />
open HMIs <strong>and</strong> covers options from simple<br />
real-time exchange of data between<br />
controllers, up to SQL <strong>and</strong> OPC<br />
communications with other equipment <strong>and</strong><br />
IT systems.<br />
User interfaces do not need advanced<br />
graphics. Simplicity <strong>and</strong> consistency often<br />
beat complexity <strong>and</strong> overly artistic systems.<br />
However, the design process often benefits<br />
from co-operation between graphic<br />
designers <strong>and</strong> application engineers.<br />
D&C<br />
44 November/December 2010 www.drives.co.uk
Package deal links<br />
new HMIs to old PLCs<br />
CANNOCK-BASED Nicholl Food Packaging<br />
is one of the UK’s largest food packaging<br />
companies, <strong>and</strong> specialises in<br />
manufacturing aluminium foil containers<br />
<strong>and</strong> catering disposables for the food<br />
industry. Its 10-acre site houses one of<br />
Europe’s most advanced production<br />
facilities <strong>and</strong> includes many electronically<br />
controlled presses.<br />
Some of the site’s HMIs had been<br />
installed several years ago <strong>and</strong> were<br />
becoming un<strong>reliable</strong>. “We were<br />
experiencing ongoing problems with failure<br />
of our existing HMIs, some apparently<br />
caused by machine vibration,” explains<br />
engineering manager, Joe Taylor. “We<br />
spent a long time trying to rectify the<br />
problem, but were eventually left with no<br />
alternative but to look for replacements.<br />
A key consideration in this search was to<br />
ensure open connectivity so that the<br />
replacements would be compatible with<br />
the plant’s existing PLCs. Nicholl chose<br />
HMIs from Schneider Electric’s Magelis<br />
range. One attraction was the HMIs’<br />
flexible programming which provided a<br />
seamless transition between the old<br />
interfaces <strong>and</strong> the new ones.<br />
“Our previous HMIs had physical<br />
function buttons, whereas the Schneider<br />
Electric products have touchscreens,” Taylor<br />
explains. “However, we were able to<br />
configure the screen to match exactly the<br />
layout that our operatives were familiar<br />
with, which meant that we did not have<br />
the time or inconvenience of re-training to<br />
the new models. That made it a very<br />
smooth transition for us.”<br />
Production at the Nicholl site is organised<br />
into three shifts with operations running<br />
continuously from 10pm on Sundays to<br />
10pm on Fridays. Using the new HMIs’<br />
Web-gate feature, Taylor can log onto the<br />
production system remotely from anywhere<br />
with an Internet connection, to monitor<br />
operations <strong>and</strong> to check for faults.<br />
The compact, robust HMIs have cut<br />
downtime significantly. To date, some 18<br />
Magelis XBT GT4330 HMIs have been<br />
installed, including one that has been built<br />
into a machine made at Cannock for the<br />
company’s site in France. Taylor is planning<br />
« The new HMIs at Nicholl’s Cannock plant have<br />
been linked to the site’s existing PLCs<br />
to exp<strong>and</strong> the replacement programme to<br />
cover all 46 of the pressing lines in<br />
Cannock.<br />
He says that the HMIs “have the scope<br />
to do a lot more with them. When we have<br />
completed the replacement programme,<br />
we will have more opportunities to add<br />
new functions to our systems.”<br />
Control all your sites...<br />
from any site!<br />
PLCs AND HMIs<br />
MONITOR, MODIFY, MAINTAIN...JMOBILE<br />
For more information see www.scatts.co.uk<br />
or to arrange a demonstration, please contact: exor@scatts.co.uk | Tel: 0113 243 0203
GAMBICA VIEWPOINT<br />
Taking the open road<br />
In the third of Gambica’s exclusive columns for<br />
<strong>Drive</strong>s & Controls, the organisation looks at how open<br />
communications are giving manufacturers the flexibility to<br />
deal with today’s challenges.<br />
Businesses across a broad spectrum of industries are looking to<br />
deploy integrated, cost-effective automation solutions that link the<br />
plant floor to the rest of the enterprise. As well as providing control,<br />
this trend is being driven by the need to access plant floor process<br />
<strong>and</strong> equipment remotely for process status <strong>and</strong> diagnosis reports,<br />
asset management, <strong>and</strong> quality control – <strong>and</strong> to improve overall<br />
operational efficiency.<br />
Added to this is the need to provide clear migration paths from<br />
installed legacy systems, while at the same time ensuring futureproof<br />
architectures that support the broadest range of best-in-class<br />
products with easy interoperability to solve dem<strong>and</strong>ing control<br />
applications <strong>and</strong>, most importantly, are not restricted to proprietary<br />
or vendor-specific solutions.<br />
As we approach the end of the first decade of the new<br />
millennium, the explosion of the Internet <strong>and</strong> the development of<br />
Internet Protocol (IP) based services in our daily lives, as well as the<br />
arrival of a new generation of decision-makers familiar with these<br />
high-tech solutions, has resulted in a growing acceptance <strong>and</strong><br />
expectation that these new technologies will be applied to enhance<br />
<strong>and</strong> improve industrial <strong>and</strong> process applications.<br />
As a result, the combination of open Ethernet technology <strong>and</strong><br />
Web services, along with other open industry st<strong>and</strong>ards for software<br />
<strong>and</strong> device integration – such as FDT/DTM technology – is changing<br />
the face of industrial <strong>and</strong> process control.<br />
FDT (Field Device Tool) technology st<strong>and</strong>ardises the<br />
communication <strong>and</strong> configuration interface between field devices<br />
<strong>and</strong> host systems. It provides a common environment for accessing<br />
a device’s features, so they can be configured, operated, <strong>and</strong><br />
maintained via a st<strong>and</strong>ardised user interface, regardless of the<br />
device type or supplier, or the communication protocol.<br />
FDT closes the fieldbus gap by providing a st<strong>and</strong>ard way for<br />
device vendors to create user interfaces for advanced device<br />
management. It allows device manufacturers to install a single DTM<br />
(Device Type Manager) driver to use a device with multiple<br />
Windows-based software products, such as asset management, PLC<br />
programming, <strong>and</strong> device configuration <strong>and</strong> parameterisation<br />
programs. FDT provides a workspace environment for the DTMs to<br />
be configured, <strong>and</strong> a method for communicating between PCs <strong>and</strong><br />
field devices.<br />
In the not-too-distant past – <strong>and</strong>, in many cases, still today – the<br />
way to integrate control equipment with enterprise systems would<br />
involve a combination of multiple proprietary technologies. Control,<br />
I/O <strong>and</strong> device networks would exist separately <strong>and</strong> use different<br />
network <strong>and</strong> fieldbus technologies, while sensor <strong>and</strong> actuator<br />
connections still relied heavily on hard wiring, with its cabling <strong>and</strong><br />
installation costs. To read data from low-level devices required the<br />
data to be “transformed” at each layer – from bits to bytes, bytes to<br />
data, <strong>and</strong> then data to information. This traditional approach puts a<br />
heavy burden on the automation controller <strong>and</strong> on Scada<br />
applications.<br />
Simple, open technology st<strong>and</strong>ards are the best way to foster the<br />
emergence of new, more effective applications. Collaboration with<br />
international st<strong>and</strong>ards organisations, such as the IEC <strong>and</strong> ISO, plus<br />
groups such as the Zigbee Alliance, FDT Group, OPC Foundation<br />
<strong>and</strong> ODVA, are essential for this to happen.<br />
The great advantage of using open st<strong>and</strong>ards – <strong>and</strong>, in particular,<br />
Ethernet-based networks using the Internet Protocol (IP) suite – is<br />
that they are essentially neutral to higher-level protocols. This means<br />
that they can be a part of a platform to connect diverse systems via<br />
modern methods such as service-oriented architectures (SOAs).<br />
Simple, open technology<br />
st<strong>and</strong>ards are the best way<br />
to foster the emergence of new,<br />
more effective applications.<br />
Although normally associated with the business processing<br />
environment, SOAs are fundamental to Microsoft’s .Net framework<br />
<strong>and</strong> provide a unified programming model for rapidly building<br />
service-oriented applications that communicate across the Web <strong>and</strong><br />
the enterprise. Other major software developers, such as IBM, BEA,<br />
Sun, HP, Oracle <strong>and</strong> SAP, are moving in a similar direction.<br />
The challenges faced by today’s manufacturing <strong>and</strong> process<br />
industries have been compounded by the volatile state of the<br />
global economy. In this environment, the dem<strong>and</strong>s on the control<br />
system go beyond functional <strong>and</strong> regulatory performance. It<br />
becomes a tool to not only to manage the plant, but also to reduce<br />
energy consumption, to cut costs <strong>and</strong> emissions, <strong>and</strong> to provide<br />
quick <strong>and</strong> precise information from the field to the enterprise,<br />
supporting both production <strong>and</strong> business decisions.<br />
Today’s challenges require control systems that are not only easy<br />
to engineer <strong>and</strong> maintain, but that also deliver a clear picture about<br />
what is happening in the process, regardless of the application.<br />
Control systems must be flexible enough to be tailored to meet the<br />
needs of all types of process including discrete, batch, continuous<br />
<strong>and</strong> safety (or any combination of these) <strong>and</strong> be capable of<br />
integrating easily with energy management <strong>and</strong> third-party devices.
& <strong>Drive</strong>s&Controls Energy Award<br />
Bank’s investment<br />
pays off with<br />
70% saving<br />
The energy consumed by<br />
HVAC fans at the London<br />
offices of the European Bank<br />
for Reconstruction <strong>and</strong><br />
Development (EBRD) has<br />
been slashed by around 70%<br />
by retrofitting variable<br />
speed drives to the fan<br />
motors.<br />
The project to reduce the energy<br />
consumed by HVAC fans at the<br />
London headquarters of the EBRD<br />
involved upgrading 23 VAV<br />
(variable air volume) fans ranging in<br />
size from 30–60kW, as well as four<br />
30kW cooling tower fans. The<br />
variable-pitch axial fans had not<br />
been performing to their original<br />
specifications, due to factors such<br />
as age <strong>and</strong> a higher requirement for<br />
process cooling. The fan-maker<br />
Fläkt Woods identified a way of<br />
improving the fans’ efficiency by<br />
fixing the pitch of their blades, <strong>and</strong><br />
controlling their speed using<br />
frequency inverters.<br />
As an initial trial, the fan blade<br />
pitch of one of the 30kW axial fans<br />
was fixed <strong>and</strong> its speed varied.<br />
Monitoring of this arrangement<br />
showed that the annual savings in<br />
terms of electricity costs would be<br />
£4,266, <strong>and</strong> that annual CO 2<br />
emissions would be reduced by 30<br />
tonnes.<br />
The remaining fans were<br />
upgraded over weekends over the<br />
course of about four months,<br />
without disrupting normal office<br />
operations. The work included<br />
dynamic balancing, where<br />
required.<br />
Part of the project was to<br />
integrate the new ABB drives with<br />
the existing Trend building<br />
management system. Fläkt Woods<br />
worked with Trend engineers to<br />
ensure that the change from<br />
variable pitch to 0–10V control via<br />
the BMS was seamless.<br />
Before the work started, Fläkt<br />
Woods commissioned an energy<br />
audit using an energy profiler<br />
located in an LV panel remote from<br />
the fan, to gather energy<br />
consumption data with minimal<br />
disruption. This data – including<br />
values such as kW consumed,<br />
phase voltages <strong>and</strong> current, power<br />
factor <strong>and</strong> kVAr – was captured<br />
around the clock for seven weeks.<br />
After the upgrade, a similar<br />
exercise was conducted. The 30kW<br />
fan which had previously been<br />
averaging a consumption of around<br />
22kW, was now averaging a<br />
consumption of 7kW – a 68%<br />
decrease, or the equivalent of<br />
56.37MWh a year, based on 252<br />
working days. For the project as a<br />
whole, the annual savings are<br />
estimated to be 1.3GWh or 690<br />
tonnes of carbon.<br />
000<br />
0 <br />
00 <br />
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www.<strong>and</strong>antex.co.uk<br />
e: sales@<strong>and</strong>antex.co.uk t: 024 7630 7722
Sponsored column<br />
No. 3 November/December 2010<br />
DESIGN DATA<br />
Dave’s DIARY<br />
DRIVES<br />
In this regular feature, Dave Baston, UK General Manager<br />
for Control Techniques, looks at how modern drive <strong>and</strong><br />
motor technologies can improve your business. In this issue,<br />
Dave insists that a proposed rating system for variable speed<br />
drives (VSDs) must take a system-level view<br />
For as long as I can remember, I’ve advocated the use of variable<br />
speed drives (VSDs) to raise motor efficiency. They cost more upfront,<br />
but ongoing energy savings will dwarf the initial investment.<br />
Their benefits in pump <strong>and</strong> fan drives are already well known, <strong>and</strong><br />
the EC Energy Using Products (or Ecodesign) Directive has identified<br />
VSDs as a desirable technology. The biggest potential for energy<br />
being applications that move air or fluids at an adjustable rate, i.e.<br />
fans <strong>and</strong> pumps.<br />
An obvious next step is to introduce an efficiency grading scheme<br />
for VSDs, as is already done for electric motors. The EC has issued a<br />
m<strong>and</strong>ate to CENELEC to develop a suitable technical st<strong>and</strong>ard.<br />
Developing it will be a technical challenge, because it’s difficult to get<br />
an accurate measure of VSD efficiency: mostly because it’s already so<br />
high (97-98%), measuring the ratio between input <strong>and</strong> output power<br />
stretches current instrumentation to the limit. And that’s before we’ve<br />
addressed more general questions: which operating conditions should<br />
be covered? And how should results be weighted?<br />
The key problem is that the quality of the drives output waveform<br />
significantly impacts on the losses within the motor. The loss in a<br />
VSD is 2-3% of rated throughput. The loss in the motor is 5-20%,<br />
depending on the rating. A simple drive only efficiency rating would<br />
be meaningless because it would ignore these system-level effects.<br />
Any new st<strong>and</strong>ard for VSD efficiency must address this dilemma –<br />
perhaps by defining an efficiency test between power source <strong>and</strong><br />
shaft, using a hypothetical ‘st<strong>and</strong>ard motor’. I can already hear the<br />
arguments, but they’re worth overcoming if we’re to avoid a<br />
simplistic st<strong>and</strong>ard for VSDs that ignores their effect on the motor.<br />
Jargon Buster - The Ecodesign Directive<br />
The Ecodesign Directive (http://ec.europa.eu/enterprise/policies/<br />
sustainable-business/documents/eco-design/framework-directive/<br />
index_en.htm) provides consistent EU-wide rules for improving the<br />
environmental performance of energy related products (ERPs) through<br />
ecodesign - a way of thinking about design which takes into account the<br />
environmental impact of a product or packaging across its entire<br />
existence, including Raw Materials, Manufacture, Retail, Use & End of<br />
Life. This approach is known as life cycle thinking <strong>and</strong> can be used to<br />
reduce environmental impacts as well as costs for businesses.<br />
Do you agree? Tell us what you think:<br />
Visit www.controltechniques.com/viewpoint<br />
Rockwell Automation has published a White Paper<br />
explaining how intelligent motor control centres<br />
(MCCs) – which integrate communications,<br />
hardware <strong>and</strong> software – can help to minimise<br />
downtime. The eight-page publication outlines the<br />
evolution of MCCs, configuration methods,<br />
networking advantages, <strong>and</strong> real-world<br />
application examples. It describes the underlying technologies,<br />
including advanced monitoring <strong>and</strong> sensing devices, <strong>and</strong> network<br />
connections. Intelligent MCCs can cost less to install than<br />
traditional MCCs <strong>and</strong> offer protective, monitoring <strong>and</strong><br />
troubleshooting advantages. They also allow manufacturers to<br />
capture <strong>and</strong> use equipment <strong>and</strong> process data to improve<br />
productivity.<br />
http://goo.gl/prgn<br />
US-based Abhisam Software has announced the publication of a<br />
downloadable eBook called The Quick Guide to AC Variable<br />
Frequency <strong>Drive</strong>s, which explains how drives work, <strong>and</strong> how to<br />
select, use <strong>and</strong> install them in common applications. The<br />
“vendor-neutral” guide contains six chapters covering all aspects<br />
of VSDs from basic concepts related to AC induction motors <strong>and</strong><br />
their control, to an explanation of functions such as vector<br />
control, torque control, anti-windmill control, <strong>and</strong> dynamic<br />
braking. The eBook is available at an introductory price of $27,<br />
<strong>and</strong> a free trial can be downloaded from Abhisam’s Web site.<br />
www.abhisam.com<br />
PI (Physik Instrumente) has published a 400-page<br />
catalogue covering its piezomechanical<br />
components <strong>and</strong> motion systems, from simple,<br />
direct actuators, to long-travel ceramic linear<br />
motors <strong>and</strong> complex multi-axis flexure guided<br />
nanopositioning stages. A separate section lists<br />
control electronics. The catalogue includes a<br />
tutorial on piezo design for positioning applications. It can be<br />
downloaded as a PDF.<br />
www.piezo.ws/pdf/Piezo_Mechanism_Cat10.pdf<br />
Thomson has produced a guide to using electric<br />
linear actuators to replace hydraulic <strong>and</strong><br />
pneumatic cylinders in off-road machinery <strong>and</strong><br />
vehicles. Potential applications include controlling<br />
engine speed, operating safety locks remotely,<br />
lifting access panels, <strong>and</strong> controlling spool valves.<br />
The publication compares electric actuators with<br />
fluid power drives <strong>and</strong> outlines their advantages<br />
including low development costs, easy installation, user-friendly<br />
control functions, low energy costs, high adjustment accuracy,<br />
low maintenance, <strong>and</strong> environmental acceptability. The brochure<br />
is available as a downloadable PDF.<br />
http://goo.gl/JJquQ<br />
Leuze electronic has issued a 12-page brochure<br />
describing its machine safety inspection service,<br />
as well as its machine safety devices <strong>and</strong> support<br />
services. It explains the company’s UK-based<br />
technical support service, its 24-hour telephone<br />
helpline, its parts return process, its machine<br />
stop-time measurement service, <strong>and</strong> its machine<br />
safety training. The publication also covers the free-to-download<br />
ePlan macros for Leuze’s machine safety components<br />
01480 408 500 mail@leuze.co.uk<br />
http://bit.ly/LeuzeMachineSafetyInspections<br />
48 November/December 2010 www.drives.co.uk
M<br />
SOFTWARE<br />
AutoCAD<br />
returns to<br />
the Mac<br />
after 16 years<br />
Autodesk has<br />
announced that it is producing a version of its AutoCAD<br />
design software for Apple Mac computers for the first time<br />
since it stopped supporting the Mac in 1994. The software<br />
has an intuitive interface that will be familiar to Mac users <strong>and</strong><br />
takes advantage of the latest Mac OS X operating system,<br />
including its graphical browsing of design files <strong>and</strong> its use of<br />
multi-touch gestures for panning <strong>and</strong> zooming on Mac<br />
notebooks, mice <strong>and</strong> trackpads. More than 5,000 customers<br />
helped to develop the Mac version in a beta programme.<br />
Autodesk has also announced a free app called AutoCAD<br />
WS mobile which extends AutoCAD to Apple’s iOS operating<br />
system for portable devices, allowing users to edit <strong>and</strong> share<br />
AutoCAD files on iPads, iPhones <strong>and</strong> iPod touch devices. The<br />
app supports real-time collaboration, even while users are on<br />
the move.<br />
The Mac software allows native creation <strong>and</strong> editing of files<br />
in AutoCAD’s DWG file format <strong>and</strong> supports collaboration<br />
with suppliers, customers <strong>and</strong> partners, regardless of the<br />
platform being used. It integrates with AutoCAD WS,<br />
allowing users to upload <strong>and</strong> manage designs in online<br />
workspaces, <strong>and</strong> to edit <strong>and</strong> share those designs via a Web<br />
browser or Apple iOS devices. AutoCAD for Mac is available<br />
as a free 30-day trial download. In addition, free educational<br />
licenses are available for personal use by students <strong>and</strong><br />
educators, subject to certain conditions.<br />
Autodesk 01252 456600<br />
www.autodesk.com/autocadformac<br />
Module produces 3D panel<br />
mounting layouts<br />
Eplan is offering a<br />
software module that can<br />
be used to produce<br />
mounting <strong>and</strong> production<br />
drawings, <strong>and</strong> associated<br />
model views, quickly <strong>and</strong><br />
easily. The Pro Panel<br />
module can be used to<br />
populate panels or to<br />
define fluid power<br />
devices <strong>and</strong> valve blocks,<br />
based on Eplan’s Electric P8 or Fluid software.<br />
The module offers 3D functions to define electrical <strong>and</strong><br />
fluid engineering mounting layouts, based on Eplan’s new 3D<br />
technology <strong>and</strong> facilitates design across various disciplines by<br />
using a common database. It also shows correct views of<br />
hidden edges. Users can plan a mounting panel first, <strong>and</strong><br />
design the schematic later. The module can be used to check<br />
the position of devices, wire ducts <strong>and</strong> mounting rails. When<br />
placing elements, it verifies whether they are on the correct<br />
mounting panel. Online access is provided to all of the devices<br />
in the design, <strong>and</strong> to Eplan’s parts management <strong>and</strong> data<br />
portal.<br />
Eplan Competence Centre 01709-704 100<br />
www.eplan.co.ukww.elutions.com<br />
moti on <strong>and</strong><br />
mechatronics<br />
brushless DC motors<br />
brushed DC motors<br />
ac & dc servo motors<br />
synchronous motors<br />
stepper motors<br />
spur gearboxes<br />
planetary gearboxes<br />
rotary encoders<br />
linear encoders<br />
stepper <strong>and</strong> servo<br />
drives<br />
motion controls<br />
custom engineered<br />
motion <strong>and</strong><br />
mechatronic systems<br />
www.mclennan.co.uk<br />
Tel:+44 (0) 8707 700700<br />
Email:sales@mclennan.co.uk<br />
Mclennan Servo Supplies Ltd<br />
Unit 1, The Royston Centre, Lynchford<br />
Lane Ash Vale, Surrey, GU12 5PQ
MULTIMEDIA<br />
Blogging site aims<br />
to connect<br />
Molex has launched an interactive blog<br />
site to provide connector industry news,<br />
trends <strong>and</strong> opinions. Called The<br />
Connector.com, the blog will also carry comments from<br />
Molex experts on issues <strong>and</strong> challenges relevant to design<br />
engineers. There will also be links to social media sites,<br />
newsfeeds <strong>and</strong> videos illustrating interconnect products <strong>and</strong><br />
technologies. Initial articles cover general connector topics as<br />
well as high-power delivery <strong>and</strong> sustainable systems.<br />
www.connector.com<br />
Site spotlights laser<br />
measurement systems<br />
Polytec, which specialises in noncontact,<br />
laser-based vibration <strong>and</strong><br />
velocity measurement systems, has<br />
unveiled a new Web site which<br />
includes product news, technology videos, application<br />
examples <strong>and</strong> information on the company’s educational<br />
services. Products covered include vibration sensors,<br />
microsystems, MEMS analysers, speed <strong>and</strong> length sensors,<br />
<strong>and</strong> dynamic stress <strong>and</strong> strain measurement systems.<br />
www.polytec-ltd.co.uk<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
Controls comparisons<br />
are simplified<br />
Following a major review of its UK Web<br />
site, Schneider Electric has made a<br />
“significant” investment in new<br />
features, including an intelligent reference database that<br />
makes it easier to compare products from its wide portfolio.<br />
Visitors can compare the features of part numbers within a<br />
range <strong>and</strong> underst<strong>and</strong> differences such as colour, voltage<br />
ratings, dimensions <strong>and</strong> settings, making it easier to pinpoint<br />
products that meet their needs. The database is supported by<br />
datasheets which can be downloaded for use in project plans<br />
<strong>and</strong> quotes. The first products covered by the enhanced service<br />
are in the automation <strong>and</strong> control section. Others will be<br />
added progressively.<br />
www.schneider-electric.co.uk<br />
Twitter stream gives<br />
links to weekly videos<br />
The plastic bearings <strong>and</strong> energy chains<br />
specialist igus is producing weekly videos<br />
highlighting aspects of its products <strong>and</strong><br />
their applications. Recent videos have<br />
covered: a bespoke guide trough<br />
designed to meet the needs of a large<br />
rotating energy chain system; a self-guiding<br />
energy chain system which avoids the need for troughs; <strong>and</strong><br />
the speedigus service for rapid production of customdesigned<br />
parts. Links to the videos are given in igus’s<br />
Twitter stream.<br />
http://twitter.com/igusUK<br />
50 November/December 2010 www.drives.co.uk
TEST AND MEASUREMENT<br />
Clampmeters’ jaws reach more places<br />
Clip-on monitor shows<br />
when hearing<br />
protection is needed<br />
3M has introduced a compact clip-on<br />
device that offers a quick <strong>and</strong> easy guide to<br />
potential noise hazard levels, helping to<br />
identify areas where hearing protection<br />
may need to be worn. The 3M Noise<br />
Indicator NI-100EU incorporates a LED<br />
which flashes green when exposed to<br />
ambient noise levels below 85db(A) <strong>and</strong><br />
red for levels above 85dB(A) – the point<br />
above which hearing protective equipment<br />
must legally be worn.<br />
The noise indicator is designed to be<br />
clipped onto a shirt or jacket. Its<br />
rechargeable battery operates for up to 200<br />
hours between charges <strong>and</strong> the device<br />
incorporates an automatic turn-off system.<br />
3M 0870 80 800 60 www.3M.co.uk/ohes<br />
Fluke has introduced<br />
a family of<br />
clampmeters with<br />
thinner, smaller jaws<br />
(for easy use in<br />
crowded cabinets),<br />
large backlit<br />
displays, true-rms<br />
readings, increased<br />
resistance ranges,<br />
<strong>and</strong> overmoulded<br />
cases for easier<br />
h<strong>and</strong>ling <strong>and</strong> improved survival if dropped. Most of the new models are<br />
compatible with a new range of flexible current probes that exp<strong>and</strong> their<br />
measurement range to 2.5kA AC.<br />
The basic Fluke 373 true-rms AC clampmeter is aimed at users needing only<br />
AC current <strong>and</strong> voltage measurements up to 600A AC <strong>and</strong> 600V AC or DC. The<br />
374 <strong>and</strong> 375 models add min/max, average <strong>and</strong> inrush recording, with the 375<br />
incorporating a low-pass noise filter <strong>and</strong> the ability to measure frequencies to<br />
500Hz, as well as mV DC. The 376 model can measure currents up to 2.5kA AC<br />
<strong>and</strong> 1kA DC <strong>and</strong> can troubleshoot noisy motors <strong>and</strong> drives. It includes the new<br />
iFlex high-current current probe which has a big coil suitable for large or<br />
awkward conductors, <strong>and</strong> a 7.5mm-deep profile for reaching between tightlypacked<br />
cables. The Fluke 381 clampmeter has a detachable wireless display,<br />
allowing one technician to do jobs that previously needed two. The clamp section<br />
can be shut in a cabinet <strong>and</strong> the measurements read across a room while the<br />
controls are being operated.<br />
Fluke (UK) 0207 942 0700 www.fluke.co.uk<br />
Modular power monitor can be exp<strong>and</strong>ed<br />
Products 4 Automation has launched a<br />
low-cost, modular power monitoring<br />
system that can be programmed to collect<br />
data from external devices <strong>and</strong> to provide<br />
centralised monitoring of energy use. The<br />
system is based on P4A’s Monitouch<br />
programmable HMIs <strong>and</strong> can depict all<br />
aspects of power usage.<br />
It can monitor data from up to 31<br />
distributed nodes measuring variables such<br />
as power, voltage, current, <strong>and</strong> power<br />
factor. These values can be logged at userdefined<br />
intervals <strong>and</strong> saved in the CSV<br />
format <strong>and</strong>, if required, exported to an<br />
Excel spreadsheet. The simplest form of<br />
monitoring shows graphs of expected<br />
dem<strong>and</strong> based on current values, <strong>and</strong><br />
displays accumulated power values. A<br />
second level depicts measured values from<br />
multiple power monitors at a glance. A<br />
third level displays accumulated monthly<br />
power data as bargraphs. Installations can<br />
start with just a few nodes <strong>and</strong> be<br />
exp<strong>and</strong>ed as needed.<br />
Products4Automation 0845 077 3858<br />
www.products4automation.com<br />
<br />
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www.drives.co.uk November/December 2010 51
SENSORS<br />
Cable extension<br />
sensors have<br />
selectable outputs<br />
Variohm is offering a rugged cable<br />
extension sensor with a plastichybrid<br />
potentiometer <strong>and</strong> winding<br />
drum that can be configured for 4–<br />
20mA or 0–10V DC outputs by<br />
connecting the appropriate signal<br />
wires during installation. The<br />
Celesco SP3 String Pot sensor<br />
provides absolute linear position<br />
measurements in four ranges from<br />
120–1,270mm, with an accuracy of<br />
0.25–1% of full-scale, depending<br />
on the stroke length.<br />
The sensor needs no critical cable<br />
alignment, making it suitable for<br />
awkward applications where there is<br />
insuffi<strong>cient</strong> space for traditional<br />
measurement devices, or where the<br />
moving components may be<br />
submerged or obscured by other<br />
equipment. The 120mm-travel<br />
version has a rated life of more than<br />
2.5 million cycles, <strong>and</strong> repeatability is<br />
said to be better than 0.05% FS. The<br />
supply voltage is 8–40V DC for the<br />
current output version, <strong>and</strong> 12–32V<br />
DC for the voltage version.<br />
Variohm EuroSensor<br />
01327 351004<br />
www.variohm.com<br />
Scanning array detects web positions<br />
Sick has announced a scanning optoelectronic sensor for web-positioning <strong>and</strong> edgedetection<br />
applications. The Ax20 array sensor offers repeatable automated object<br />
detection with a resolution down to 50 microns, allowing precise control of web<br />
positions, even at high speeds.<br />
The device operates from one side of the web <strong>and</strong> has a measuring range of up to<br />
30mm. A visible light spot makes accurate alignment easy, without needing a teach-in<br />
procedure. The sensor is said to be more versatile <strong>and</strong> <strong>reliable</strong> than fork sensors, <strong>and</strong><br />
easier to set up. It needs no reflector, making it simple to mount. It is unaffected by<br />
ambient light <strong>and</strong> reflective or transparent materials. Applications include measuring the<br />
thickness of, <strong>and</strong> detecting the edges of, sheet-fed materials such as paper, even in<br />
stacks. It can also count small parts, determine widths, <strong>and</strong> track glue beads.<br />
Sick (UK) 01727 831121 www.sick.co.uk<br />
High-power LEDs boost sensor performance<br />
Pepperl+Fuchs has released a range of<br />
miniature photoelectric sensors for<br />
applications requiring long ranges <strong>and</strong><br />
high reliability. The ML100 sensors use<br />
<strong>powerful</strong> lenses <strong>and</strong> PowerBeam LEDs,<br />
said to guarantee good visibility of the<br />
red light spot <strong>and</strong> easy alignment.<br />
The high power density <strong>and</strong> quality of<br />
the light spot improve the sensors’<br />
reliability <strong>and</strong> service lives. The IP67-<br />
protected sensors have low power<br />
consumption, are insensitive to ambient<br />
lighting, <strong>and</strong> are protected against<br />
ifm has introduced inductive ring <strong>and</strong><br />
tube sensors for detecting the passage of<br />
small metal items such as screws, rivets<br />
<strong>and</strong> springs. The high-resolution sensors<br />
have a 0.2ms response time. They can<br />
detect 0.6mm-diameter steel balls<br />
moving at up to 35m/s.<br />
For the ring sensors, the tube is guided<br />
through the ring. Because the sensing<br />
crosstalk. Indicator LEDs show the<br />
operating <strong>and</strong> switching status.<br />
There are two versions that optimise<br />
the light spot for different applications.<br />
The ML 100-8-H diffuse-mode sensors<br />
with background suppression are suitable<br />
for short ranges, providing a bright, sharp<br />
spot for simple setup <strong>and</strong> <strong>reliable</strong><br />
detection of dark objects. The ML100-55<br />
sensors provide a larger spot for easy<br />
alignment <strong>and</strong> longer detection ranges.<br />
Pepperl+Fuchs GB<br />
0161 6336431 www.pepperl-fuchs.com<br />
Inductive rings <strong>and</strong> tubes detect small parts<br />
field lies inside the ring, external<br />
disturbances are minimised. The tube<br />
versions can be installed quickly <strong>and</strong> one<br />
type of sensor can be used with different<br />
diameter tubes. Pulse stretching <strong>and</strong><br />
sensitivity are adjustable, <strong>and</strong> users can<br />
select normally open or closed operation.<br />
ifm electronic<br />
020 8213 0000 www.ifm.com/uk
Safety you know & trust<br />
Leuze electronic’s people are proud of their safety products<br />
<strong>and</strong> some say they have ‘a safe head’ on their shoulders.<br />
By providing the best machine safety products <strong>and</strong> services<br />
they help make the workplace safer.<br />
Welcome to the specialists for industrial safety systems –<br />
welcome to the sensor people<br />
Safety light guards, safety laser scanners,<br />
safety relays <strong>and</strong> gate interlocks, you can<br />
rely on.<br />
Leuze electronic’s expertise <strong>and</strong> quality is<br />
recognised <strong>and</strong> relied upon in many<br />
industries <strong>and</strong> applications around the UK.<br />
For more information call 01480 408 500 or go to www.Leuze.co.uk<br />
20 th Anniversary competition<br />
Win 1 of 3 iPods<br />
for Christmas<br />
Check www.leuze.co.uk to enter<br />
Solutions for high precision positioning <strong>and</strong> machine control from Aerotech<br />
Increase Throughput with Advanced Controls<br />
Comm<strong>and</strong> Shaping Harmonic Cancellation Interative Learning Control<br />
Decrease Settle Time<br />
Increase In-Position Stability<br />
Increase Rate Stability<br />
Reject System <strong>and</strong><br />
Environmental Disturbances<br />
Trigger laser more accurately<br />
Automation Control Solutions<br />
provides comprehensive information on<br />
Aerotech’s advanced controls, drives,<br />
GUI, Motors I/O <strong>and</strong> software.<br />
Call for your copy today or downlaod<br />
from www.aerotech.co.uk<br />
Position Synchronized<br />
Output (PSO)<br />
Enhanced Throughput<br />
Module (ETM)<br />
Friction Compensation<br />
Dedicated to the<br />
Science of Motion<br />
Direction Gain Scheduling<br />
Aerotech Ltd, Jupiter House, Calleva Park, Aldermaston, Berkshire RG7 8NN - UK<br />
Tel: +44 (0)118 940 9400 - Email: sales@aerotech.co.uk<br />
www.aerotech.com<br />
A e r o t e c h W o r l d w i d e<br />
United States • Germany • United Kingdom • Japan • China<br />
AH1010LTD_-AdvancedControls
CONTROL<br />
CNC offers a choice of drives<br />
Mitsubishi has<br />
announced a CNC<br />
range based on RISC<br />
CPUs <strong>and</strong> high-speed<br />
graphics chips. The<br />
M70V CNCs provide<br />
multi-channel support<br />
<strong>and</strong> high-speed, high-accuracy functions, resulting in faster<br />
processing times <strong>and</strong> higher precision of machined parts,<br />
with cutting speeds of up to 1m/min.<br />
There is a choice of two drive systems: high-speed MDS-<br />
D/DH servo/spindle drives; <strong>and</strong> the lower-priced MDS-<br />
SVJ3/SPJ3 series. Interpolation gives 1nm resolution. A new<br />
interface provides user-friendly operation, programming<br />
<strong>and</strong> configuration. Machine setups are performed using a<br />
PC-based servo-tuning tool which links to the M70V via<br />
Ethernet. This tool can automatically optimise parameters<br />
such as speed <strong>and</strong> position loop gains, <strong>and</strong> time constants.<br />
Mitsubishi Electric<br />
01707 276100 www.mitsubishielectric.co.uk<br />
Controller closes loops in 62µs<br />
Galil has introduced a motion controller that accepts encoder<br />
inputs up to 15MHz <strong>and</strong> can close loops in 62µs. The DMC-<br />
41x3 controller is faster than its predecessor (the DMC-21x3)<br />
<strong>and</strong> incorporates Ethernet 100Base-T <strong>and</strong> USB 2.0 ports, as<br />
well as analogue inputs <strong>and</strong> optically isolated I/O. It also offers<br />
twice as much memory for user programs <strong>and</strong> arrays.<br />
The controller is available for up to eight axes <strong>and</strong> each<br />
axis can be configured for stepper or servo motor<br />
operation. It can be connected to external drives of any<br />
power range or to Galil’s multi-axis (500W per axis) servo<br />
drives or 60V, 3A microstepping drives. It can operate by<br />
itself or with a PC. St<strong>and</strong>ard I/O includes 16 optically<br />
isolated I/Os for 1–4 axis models, <strong>and</strong> 32 I/O for 5–8 axis<br />
models. Eight analogue inputs are provided. Motion modes<br />
include point-to-point positioning, jogging, linear <strong>and</strong><br />
circular interpolation, contouring, <strong>and</strong> electronic gearing<br />
<strong>and</strong> camming. Galil’s UK distributor is MotionLink.<br />
Galil Motion Control 01488 638488<br />
www.galilmc.com www.motionlink.co.uk<br />
PCs use multi-core processors<br />
Beckhoff has announced a new generation of industrial PCs<br />
based on 3½-inch motherboards that support multi-core<br />
processors which can distribute PLC, NC, robotic,<br />
measurement or HMI functions to dedicated cores<br />
The PCs can be equipped with various processors, such as<br />
the Intel’s Core Duo or Core2 Quad, as well as low-cost<br />
dual-core Celeron processors. On-board interfaces include<br />
SATA, COM <strong>and</strong> USB ports. A mini-PCI card slot can be<br />
used to integrate fieldbus interfaces, while a DVI interface<br />
allows two separate displays to be connected for enhanced<br />
visualisation. The motherboard has a PCI-Express extension,<br />
which can be used for further interfaces inside <strong>and</strong> outside<br />
the PC. An integrated UPS <strong>and</strong> an on-board RAID controller<br />
are said to improve availability.<br />
Beckhoff Automation 01491 410539 www.beckhoff.co.uk<br />
DRIVES AND MOTORS<br />
Servodrive operates from<br />
high-voltage supplies<br />
Inmoco has announced a digital servodrive that can operate<br />
from a 400V or 750V DC power sources without a<br />
transformer. The Elmo ExtrIQ Panther drive can be mounted<br />
onto a motor or PCB <strong>and</strong> deliver up to 7kW of continuous<br />
power for single- or multi-axis applications.<br />
The MIL-st<strong>and</strong>ard drive can operate at extremes of<br />
temperature (–40°C to +70°C), humidity <strong>and</strong> altitude, <strong>and</strong><br />
endure high levels of vibration (more than 15g) <strong>and</strong><br />
mechanical shock. It can be used with sinusoidal, trapezoidal<br />
<strong>and</strong> DC motors, <strong>and</strong> is available in 80–400V or 200–750V<br />
DC bus versions with built-in “smart” supplies for controlling<br />
the back-up capabilities. It can also operate with a 24V DC<br />
auxiliary power supply. The drives, which support CANopen<br />
communications, measure 110 x 75 x 30mm.<br />
Inmoco 01327 307600 www.inmoco.co.uk<br />
Stepper drives detect<br />
mechanical blocking<br />
Micromech is offering a range of<br />
stepper motor drives for bipolar<br />
two-phase stepper motors,<br />
which can operate with motor<br />
coil currents from 0.7–7A RMS<br />
(9.8A peak) <strong>and</strong> at voltages from 15–75V. The Trinamic<br />
TMCM-078 drives incorporate a patented sensorless load<br />
measurement technology to detect mechanical blocking.<br />
To prevent the motor from heating up unnecessarily, <strong>and</strong><br />
to save energy, the motor current is reduced automatically<br />
to an adjustable level during st<strong>and</strong>stills. All settings are<br />
made using DIP switches, avoiding the need for a PC.<br />
Accuracies of up to 256 microsteps are possible. The drives<br />
allow two-phase stepper motors to be used in high-torque<br />
<strong>and</strong> high-velocity drives without needing separate cooling.<br />
The inputs for step, direction <strong>and</strong> enable signals are<br />
optically isolated. The compact modules in aluminium<br />
housings measure 145 x 96 x 33mm.<br />
Micromech 01376 333333 www.micromech.co.uk<br />
Miniature brushless DC motors<br />
produce little noise<br />
Rotalink has announced a range of miniature brushless motors<br />
with nominal output torques that extend above 250mNm at<br />
maximum efficiency, <strong>and</strong> with maximum power ratings of<br />
270W. The BL brushless motors are available in 12V <strong>and</strong> 24V<br />
DC versions with three-phase Hall effect commutation for<br />
smooth, precise speed <strong>and</strong>/or position control.<br />
The effi<strong>cient</strong> brushless design produces little electrical<br />
noise <strong>and</strong>, unlike brushed DC motors, is not prone to<br />
commutation sparking, making the motors suitable for use<br />
in EMC-sensitive environments. The range includes five<br />
frame sizes with nominal diameters from 29–65mm. The<br />
brushless motors can be used with the brushless version of<br />
Rotalink's recent drag-<strong>and</strong>-drop/flowchart programmed Red<br />
<strong>Drive</strong> motor driver <strong>and</strong> controller. Matching gearboxes,<br />
motor feedback devices <strong>and</strong> motion controls are available.<br />
01460 72000 www.rotalink.com<br />
54 November/December 2010 www.drives.co.uk
ELECTRICAL<br />
Multi-pump soft-starter<br />
h<strong>and</strong>les pumps from 1–15kW<br />
Ralspeed has announced a<br />
multi-pump soft-starter for<br />
controlling <strong>and</strong> protecting<br />
pumps from 1–15kW, thus<br />
avoiding the need to use<br />
different soft-starters for each<br />
size of pump. The system is<br />
based on an overload protection<br />
relay that can be set to match the pump in use via a rotary<br />
switch calibrated in kW – no other settings are needed.<br />
A digital display shows the kW rating selected, the<br />
instantaneous running current <strong>and</strong> the status of the softstarter.<br />
It can also show data from the last eight trips,<br />
enabling problems to be diagnosed rapidly. The soft-starters<br />
are equipped with a load-break isolator, a h<strong>and</strong>/auto<br />
selector switch, a door-mounted e-stop pushbutton, <strong>and</strong> an<br />
analogue output proportional to the motor current. The<br />
overload relay provides earth leakage protection <strong>and</strong> can be<br />
used with thermistors to monitor motor temperatures.<br />
Ralspeed 01254 582345 www.ralspeed.com<br />
Light curtains have 14ms response<br />
Panasonic has introduced a slim safety light curtain which it<br />
describes as one of the smallest on the market. The IP67-<br />
protected SUNX SF4B Type 4 light curtain offers 10, 20 or<br />
40mm beam pitches <strong>and</strong> comes in three versions – for<br />
finger, h<strong>and</strong> <strong>and</strong> arm, or foot protection. All types can be<br />
wired to provide NPN or PNP transistor outputs.<br />
The curtains offer a 14ms response time, regardless of the<br />
number of channels, the beam axis pitch, or the number of<br />
curtains connected in series. The rapid response time,<br />
coupled with the small beam pitch of the finger protection<br />
version, allows the light curtain to be installed closer to<br />
danger points than conventional models. The body <strong>and</strong> the<br />
cylindrical inner casing that protect the electronics ensure<br />
that the curtains conform to IP65 <strong>and</strong> IP67. An easy-to-read<br />
digital error indicator makes troubleshooting easy.<br />
Panasonic Electric Works UK<br />
01908 231555 www.panasonic-electric-works.co.uk<br />
Solid-state relays are ‘smallest’<br />
Carlo Gavazzi claims to be offering the first UL-certified<br />
solid-state relay <strong>and</strong> contactor combinations in a 17.5mmwide<br />
format. The RG series SSRs include panel-mounting<br />
versions rated up to 600V AC <strong>and</strong> 90A AC, <strong>and</strong> versions<br />
with integrated heatsinks that can h<strong>and</strong>le 20A AC in<br />
17.5mm widths <strong>and</strong> 30A AC in 22.5mm widths.<br />
With a 100kA short-circuit capability, the relays are<br />
suitable for silent switching of motors <strong>and</strong> will resist up to<br />
5g of vibration. DC versions can be controlled by 4–32V<br />
DC, while AC versions can be controlled by 20–275V AC or<br />
24–190V DC. There is a choice of zero-crossing or instanton<br />
(r<strong>and</strong>om) mains voltage switching. Over-voltage<br />
protection is provided across the output. A removable IP20<br />
cover allows power terminals to accept ferrule, ring <strong>and</strong><br />
fork type terminations. Control status is indicated by LEDs.<br />
Carlo Gavazzi UK 01252 339600 www.carlogavazzi.co.uk<br />
FLUID POWER<br />
Stainless-steel cylinders<br />
resist washdowns<br />
SMC has developed <strong>and</strong><br />
improved several<br />
stainless-steel pneumatic<br />
products for wet <strong>and</strong><br />
washdown applications.<br />
For example, its<br />
portfolio now includes<br />
the CJ5-S <strong>and</strong> CG5-S airoperated<br />
cylinders for<br />
food-processing<br />
machinery where<br />
corrosion <strong>and</strong> heat<br />
resistance are often essential. The cylinders, in bore sizes<br />
from 10–100mm, have an all-stainless steel external<br />
construction <strong>and</strong> are fitted with a scraper to prevent water<br />
from entering the cylinder.<br />
There are also two improved stainless-steel fittings ranges –<br />
KQG2 <strong>and</strong> KFG2. The KQG2 one-touch fittings, based on the<br />
earlier KQG series, are about 30% smaller <strong>and</strong> more than<br />
60% lighter than conventional models <strong>and</strong> come in 17<br />
versions designed to operate with fluids from -5ºC to 150ºC.<br />
The insert fitting type series KFG2, which operates with fluid<br />
temperature from -65ºC to 260ºC, is more than 40% smaller<br />
<strong>and</strong> nearly 40% lighter than conventional models.<br />
SMC is also offering a stainless-steel speed controller<br />
(series ASG) with one-touch fittings for ambient operating<br />
fluids from -5ºC to 60ºC, <strong>and</strong> operating pressures from 0.1–<br />
1MPa.<br />
SMC Pneumatics (UK)<br />
01908 555017 www.smcpneumatics.co.uk<br />
Linear drives combine power,<br />
accuracy <strong>and</strong> flexibility<br />
Parker Hannifin’s Parker-<br />
Origa division has<br />
launched a range of<br />
magnetically-coupled<br />
pneumatic rodless<br />
cylinders with a single<br />
rod <strong>and</strong> rotating carriage,<br />
or with integrated anti-rotating guides. The P1Z linear drives,<br />
which consist of a stainless-steel pneumatic cylinder body fixed<br />
between two end-plates, can be used at low speeds from<br />
0.05m/s <strong>and</strong> can deliver thrust forces up to 942N.<br />
A hard anodised aluminium carriage is fitted to the<br />
outside of the cylinder body, with the carriage <strong>and</strong> the<br />
cylinder piston coupled magnetically using annular<br />
magnets. In the unguided version, the carriage can rotate<br />
through 360 degrees around the cylinder, with adjustable<br />
pneumatic end-of-stroke cushioning <strong>and</strong> air ports at both<br />
stroke ends. The guided version uses two rigid chromeplated<br />
steel guide rails, with optional magnetic sensors for<br />
precise positioning. They can be fitted with elastomeric<br />
bumpers for light loads or hydraulic shock absorbers for<br />
heavier loads. Both versions can be mounted horizontally or<br />
vertically <strong>and</strong> are available in bore sizes from 16–40mm <strong>and</strong><br />
in stroke lengths up to 2m.<br />
Parker Hannifin 00800 27 27 5374<br />
56 November/December 2010 www.drives.co.uk
DRIVES AND CONTROLS<br />
EXHIBITION 2010<br />
8-10 June 2010<br />
NEC, Birmingham<br />
www.drives-expo.com<br />
‘<br />
." "& ( ,(#&' +& ( +( ( %) (- "<br />
%)"((- # ' '$ - &#! ) $ #!$"' ' "<br />
( *'(#&' ! &#! &#'' ( #& ")'(& '(#&'<br />
" !#& !$#&("( - +( * $&#(' " ##" (# $ <br />
#&&' '!"& $&#&!! $&#* - $#$) & +(<br />
'#! '''#"' #*& #+" "(# ( ' ' "*'(!"( -<br />
,(#&' " '(" '" #( " '$ #" - " '<br />
'! * ( +# *"( & - ## (#& #)<br />
" *+ #!!"(' #" ( ,(#" *# - *'("<br />
+++&*',$##! &*' " #"(&# ' + <br />
#" ( ( $& ( ( &!"!0<br />
Doug Devlin, Exhibition Director<br />
"*A;* '**3 ;*7> .257*88*) "* -&) 8*9 & 9&7,*9 +47 9-* 3:2'*7 4+<br />
*36:.7.*8 4+ ! '&8*) 1*&)8 ).7*(9*) &3) &<br />
5:7548* 94 9-*2?'4:9 4+ 9-* 1*&)8 &7* 574/*(98 47 9-48*<br />
1440.3, 94 2.,7&9*?#4: ,*9 9-* +449+&11 &9 7.;*8 &3) 4397418<br />
/ Mike Loughran, Rockwell Automation<br />
For further information <strong>and</strong> exhibiting contact<br />
Doug Devlin on T: 01922 644766 M: 07803 624471<br />
E: doug@drives.co.uk<br />
M ULTIFUNCTIONAL GATE BOX<br />
All possible functions in one housing. Due to<br />
transponder technology this system meets the<br />
highest safety levels. The set is suitable for hinged<br />
<strong>and</strong> sliding doors.<br />
Three semiconductor outputs provide the status:<br />
door closed (1), bolt detected (2), safely locked (3).<br />
In addition two safe pulsed semiconductor outputs<br />
are activated after a safe condition is achieved.<br />
<br />
<br />
<br />
<br />
<br />
Curious?<br />
Check the videos on the news page on the website<br />
Versatile<br />
door switch<br />
w w w . e u c h n e r . c o . u k<br />
E U C H N E R ( U K ) L t d . - U n i t 2 , Pe t r e D r i v e - S h e f f i e l d , S 4 7 P Z - P h o n e 0 1 1 4 2 5 6 0 1 2 3 - Fa x 0 1 1 4 2 4 2 5 3 3 3 - s a l e s @ e u c h n e r. c o . u k
MECHANICAL AND LINEAR<br />
Magnetic clutches boost slip<br />
torque to 12Nm<br />
Mayr has exp<strong>and</strong>ed its Robacontitorque<br />
range of permanent<br />
magnet hysteresis clutch/brakes<br />
with a size 5 version that<br />
increases the slip torque range<br />
to 0.1–12Nm. The devices offer<br />
<strong>reliable</strong>, wear-free torque<br />
limitation in continuous slip applications. Unlike frictionbased<br />
devices, torque is transmitted without contact via<br />
magnetic forces, extending service lives <strong>and</strong> ensuring<br />
accurate, repeatable slip torque values.<br />
The compact, maintenance-free clutch/brakes can be<br />
used for load-holding, tensioning or torque-limiting<br />
applications. Their low weight <strong>and</strong> mass moment of inertia<br />
allow easy integration into a variety of applications.<br />
Optional sealed <strong>and</strong> corrosion-protected versions are<br />
available for use in almost any environment.<br />
Mayr Transmissions 01535 663900 www.mayr.co.uk<br />
Spur gears target everyday uses<br />
Ondrives has introduced a series of<br />
“competitively priced” spur gears for<br />
everyday uses. The gears are available<br />
with or without a boss, with various<br />
numbers of teeth <strong>and</strong> bore sizes,<br />
keyways, <strong>and</strong> tapped <strong>and</strong> pin holes.<br />
Sizes range from 0.5–6 Mod as<br />
st<strong>and</strong>ard with others available on<br />
request. St<strong>and</strong>ard materials are steel<br />
<strong>and</strong> white Delrin. Most parts are<br />
available off-the-shelf with short turnaround times for parts<br />
not in stock. Modifications to st<strong>and</strong>ard parts <strong>and</strong> specials to<br />
customer drawings are available with short lead times.<br />
Ondrives 01246 455500 www.ondrives.com<br />
Large-bore SRBs<br />
last twice as long<br />
NSK has exp<strong>and</strong>ed its HPS range<br />
of spherical roller bearings up to<br />
260mm bore. The bearings,<br />
known as the CAM series, are<br />
said to offer twice the lifespan<br />
<strong>and</strong> a 20% higher limiting speed<br />
than conventional spherical roller bearings (SRBs), resulting<br />
in cost <strong>and</strong> energy savings, <strong>and</strong> reduced maintenance.<br />
The improved wear resistance of the larger bearings<br />
under high speeds <strong>and</strong> mechanical loads enables them to<br />
cope with dem<strong>and</strong>ing applications. The bearings differ in<br />
design from the existing HPS-EA SRBs (up to 130mm bore)<br />
<strong>and</strong> have a guide ring for precise roller guiding, <strong>and</strong><br />
optimised solid brass retainers which carry higher loads <strong>and</strong><br />
offer high wear resistance. As well as increasing the lifespan<br />
<strong>and</strong> the wear resistance of the bearings, the design changes<br />
also increase their dynamic load rating by up to 25%. This<br />
can allow downsizing in high-loaded drive assemblies,<br />
cutting space <strong>and</strong> costs.<br />
NSK UK 0500 2327464 www.nskeurope.com<br />
COMMUNICATIONS<br />
Converters connect serial<br />
devices to Ethernet<br />
Brainboxes has introduced a range of Ethernet-to-serial<br />
converters that provide fast, <strong>reliable</strong> connections between<br />
Ethernet ports on a network <strong>and</strong> asynchronous serial<br />
interfaces. The one- or two-port RS-232 <strong>and</strong> RS-422/485<br />
device servers support data transfer rates up to 230.4 kbd.<br />
The autonomous converters allow devices at the edge of<br />
a network to be managed from any connected location<br />
with the same control as if working locally. They come with<br />
drivers for Windows 7 <strong>and</strong> XP 32-bit <strong>and</strong> 64-bit versions.<br />
Brainboxes is packaging them with its Boost.net driver,<br />
keeping existing software applications on the network <strong>and</strong><br />
allowing high reliability connections over long distances.<br />
The converters, which consume less than 1W, are housed in<br />
rugged metal enclosures.<br />
Brainboxes 0151 2202500 www.brainboxes.com<br />
IP67 box provides<br />
serial-EtherCat links<br />
Beckhoff has announced an IP67-<br />
protected module that can connect<br />
devices with serial interfaces, such as<br />
barcode or RFID readers, to EtherCat<br />
networks without needing a control<br />
cabinet. Using selectable RS-232 or<br />
RS-422/485 interfaces, the compact,<br />
two-channel EP6002 module<br />
integrates the serial devices into<br />
EtherCat networks.<br />
The module transmits the data in a<br />
transparent way to higher-level<br />
EtherCat controllers. The serial<br />
communication channels operate in full-duplex mode at up<br />
to 115.2 kbd. Serial devices are connected via rugged M12<br />
connectors. When used with suitable software, the module<br />
can also be used without a controller as a COM interface in<br />
Windows-based systems. It measures 126 x 30 x 26.5mm.<br />
Beckhoff Automation 01491 410539 www.beckhoff.co.uk<br />
Gateway delivers wireless<br />
ZigBee-serial connections<br />
IDC has launched a gateway that acts as a ZigBee-to-serial<br />
interface connection, <strong>and</strong> can convert RS-232/422/485<br />
serial devices, such as intelligent sensors <strong>and</strong> barcode<br />
readers, into wireless devices. The ZB103 gateway is<br />
designed for applications such as remote control <strong>and</strong><br />
monitoring of machinery where cables are difficult to install,<br />
or for transferring data to <strong>and</strong> from mobile plant.<br />
The device can operate as a gateway for a network of<br />
ZigBee devices in factory automation, warehouse<br />
management <strong>and</strong> production monitoring systems, linking to<br />
a PLC via a serial port using Modbus or other protocols. The<br />
gateway complies with IEEE 802.15.4, providing two-way<br />
communications on the licence-free 2.4GHz b<strong>and</strong>. It can<br />
connect hundreds of devices in a mesh network using<br />
gateways, routers <strong>and</strong> end devices (usually batterypowered).<br />
It is housed in a robust IP45 enclosure.<br />
IDC 01332 604030 www.zig-bee.co.uk<br />
58 November/December 2010 www.drives.co.uk
1<br />
HPMG Hangzhou Permanent Magnet Group Co. Ltd<br />
Hangzhou Permanent Magnet Group<br />
Co. Ltd. is one of the leading<br />
manufacturers of permanent magnets<br />
in China, enjoying an enviable<br />
reputation in the field of Automotive,<br />
Communications, Health Care,<br />
Aerospace, Industrial etc.<br />
Established in 1980, with a staff of<br />
1000 <strong>and</strong> a turnover of $US80 Million,<br />
HPMG consists of 6 subsidiary divisions<br />
<strong>and</strong> a number of departments assuring<br />
our sales <strong>and</strong> supply activities.<br />
To keep fully abreast of the constant<br />
evolution in our fields of activities<br />
we have a R & D Department, our<br />
Laboratory <strong>and</strong> a system which<br />
allows us to apply the latest<br />
“state-of–the-art” technology to our<br />
production.<br />
As an ISO9001, ISO/TS 16949 <strong>and</strong> ISO<br />
14000 certified manufacturer HPMG<br />
offers a complete range of permanent<br />
magnets <strong>and</strong> magnetic assemblies <strong>and</strong><br />
solutions including the following:<br />
• Cast <strong>and</strong> Sintered Alnico, 1800<br />
Tonnes annually, accounting for<br />
around 35% of the world’s<br />
Alnico production<br />
• Sintered & Bonded NdFeB,<br />
2000 tonnes annually<br />
• SmCo 5<br />
/ Sm 2<br />
Co 17<br />
Sintered &<br />
Bonded, 200 tonnes annually<br />
• Die Cast magnetic assemblies,<br />
25 million sets annually<br />
• Magnetic assemblies & Motors,<br />
7 million annually<br />
• A variety of magnetic devices such<br />
as Magnetic Chucks, Magnetic<br />
Separators <strong>and</strong> Magnetic h<strong>and</strong>ling<br />
devices also Reducers, Shafts <strong>and</strong><br />
Gears<br />
We are able to discuss with you<br />
<strong>and</strong> find the magnetic solution<br />
best adapted to your own specific<br />
needs using our in-house experience<br />
on Die Casting, Plastic Injection/<br />
compression moulding <strong>and</strong> design.<br />
FACT FILE<br />
Main Areas<br />
of Activity:<br />
Automotive, Communications,<br />
Health Care, Aerospace,<br />
Industrial etc.<br />
Size of operation:<br />
160,000m 2 , 60,000m 2 working<br />
area, 1000 employees,<br />
$US80 million Turnover.<br />
Contact details:<br />
HPMG<br />
The South Beach of 2nd<br />
Qianjiang Bridge,<br />
311231 Xiaoshan,<br />
Hangzhou,<br />
China 311231<br />
T: +86 571 82696116<br />
F: +86 571 82696043<br />
E: hpmg@xs.hz.zj.cn<br />
UK Sales T: +44 (0) 1332 515565<br />
www.chinahpmg.com<br />
Rare Earth Magnets: HPMG are<br />
very aware of the growing<br />
importance of Rare Earth magnets<br />
both NdFeB <strong>and</strong> SmCo 5 /Sm 2 Co 17 .<br />
Our range has been developed<br />
with the assistance of the<br />
National Institute of Materials<br />
(NIM) in China since our<br />
production first began in 1994.<br />
Alnico Magnets: The name<br />
HPMG has been synomomous<br />
with Alnico for many years. We<br />
have been making Alnico since<br />
1980 <strong>and</strong> currently supply<br />
around 35% of the world’s<br />
total production.<br />
Magnetic Systems: We offer<br />
you a complete range of<br />
precision magnetic assemblies<br />
using all the magnetic<br />
materials in our range<br />
including rotor & stator<br />
assemblies, sensor devices<br />
etc etc.<br />
A1000 Inverter:<br />
One class better… The A1000 AC high performance<br />
inverter from YASKAWA.<br />
Available from stock.<br />
Power Ratings from 0.4 – 630 kW<br />
allowing one drive to cover all your needs<br />
Voltage options 3 phase 400 V <strong>and</strong> 200 V<br />
Application specific parameter<br />
presets such as Crane, Conveyor, Pump &<br />
Fan, Compressor, Hoist for quick drive setup<br />
Inbuilt Safety (STO) to meet the latest<br />
st<strong>and</strong>ards<br />
Connectivity to all major bus networks<br />
including DeviceNet, Profibus-DP, CANopen,<br />
CC-Link, MECHATROLINK, MEMOBUS<br />
Designed for 10 years maintenance free<br />
operation<br />
A1000<br />
More information at<br />
www.yaskawa.eu.com<br />
CONTACT<br />
Inverter <strong>Drive</strong>s<br />
Linear-Technology<br />
Servo <strong>Drive</strong>s<br />
Industrial Robots<br />
Machine Controller<br />
YASKAWA UK<br />
01908 565874
PRODUCTS & SERVICES DIRECTORY<br />
AUTOMATION<br />
BEARINGS<br />
BELTS & POWER TRANSMISSION<br />
The Total Power Transmission....<br />
Solution for<br />
To advertise contact Simon Langston<br />
t/f: 01353 863383 e: simon@dfamedia.co.uk<br />
CIRCUIT PROTECTION<br />
TA35<br />
Circuit Breaker<br />
for safe <strong>and</strong><br />
easy operation<br />
- thermal circuit breaker 1-, 2- or 3-pole<br />
- current ratings up to 20A, 3-pole up to 12A<br />
- safe <strong>and</strong> easy operation with gloves<br />
- conforms to IEC, UL <strong>and</strong> CSA st<strong>and</strong>ards<br />
BEACONS & SOUNDERS<br />
D<br />
BEARINGS & FASTENERS<br />
www.pixeuro.com<br />
PIX Europe Limited<br />
Unit<br />
24 Farthing Road Industrial Estate,<br />
Sproughton,<br />
Ipswich,<br />
Suffolk,<br />
IP1 5AP<br />
Tel:<br />
01473 7446124<br />
| Fax:<br />
01473 744613<br />
email: info@pixeuro.com<br />
CAD SOFTWARE<br />
www.schurter.com/cbe_news<br />
COOLERS<br />
Stainless Steel<br />
Bearings <strong>and</strong><br />
Fasteners<br />
Wide Range Includes<br />
Captive, Ventilation <strong>and</strong><br />
Wire Locking Screws<br />
High Precision<br />
Small Orders Available<br />
BEARINGS<br />
Japan’s Leading<br />
Bearing Manufacturer<br />
Tel: 01908 289300<br />
Email: info@koyo.co.uk<br />
Web: www.koyo.co.uk<br />
Reliance ®<br />
Precision Mechatronics LLP<br />
Tel: +44 (0) 1484 601060<br />
www.rpmechatronics.co.uk<br />
BELTS<br />
MEGADYNE<br />
Manufacturers of RUBBER<br />
power transmission belts<br />
WORLD’S LARGEST<br />
manufacturers of POLYURETHANE<br />
power transmission belts<br />
CHAINS<br />
PROCESS<br />
CHILLERS<br />
1-350kW<br />
Market leading<br />
Build Quality<br />
24 Hour parts<br />
& Service<br />
Global Service<br />
in 80 countries<br />
Tel: 01709 704000<br />
email<br />
information@rittal.co.uk<br />
R<br />
Keeping<br />
UK Industry<br />
on the Move<br />
Gildersome Spur, Gildersome,<br />
Leeds LS27 7JS<br />
Tel: 0113 2382910 Fax: 0113 2383870<br />
Email: sales@megadyne.co.uk<br />
www.megadyne.co.uk<br />
www.drives.co.uk
To advertise contact Simon Langston<br />
t/f: 01353 863383 e: simon@dfamedia.co.uk<br />
DC/AC DRIVES CONTROLS<br />
AND AUTOMATION<br />
DC MOTORS & GENERATORS<br />
<br />
PRODUCTS & SERVICES DIRECTORY<br />
DRIVES SERVICES<br />
WARNING! WARNING!<br />
<strong>Drive</strong> breakdown!<br />
ENCODERS<br />
The leading UK<br />
manufacturer of<br />
<br />
DC Motors & Generators<br />
<br />
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DC Motors 0.5––150kW<br />
DC generators <strong>and</strong> dynamometers <br />
DC Traction Motors<br />
<br />
<br />
<br />
<br />
ATEX certified EEXd motors<br />
<br />
services 24/7 if required.<br />
<br />
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<br />
T: +44 (0) 1384 567755<br />
F: +44 (0) 1384 567710<br />
<br />
E: ken.evans@sts-international.co.uk<br />
<br />
www.sts-motors.com<br />
DRIVES<br />
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Tel | 0116 2796891<br />
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Independent Control Systems Ltd<br />
The Driving Force in fully<br />
Integrated Electrical<br />
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Capabilities:<br />
Turnkey Systems<br />
Hardware / Software Design<br />
System Build & Test<br />
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Product Expertise:<br />
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PLC SYSTEMS & DRIVES<br />
PLC PROGRAM TRANSLATION<br />
BACKUP & DOCUMENTATION<br />
SPARES & REPAIRS TO ALL<br />
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To order your FREE<br />
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Email : info@iconsys.co.uk<br />
Website : www.iconsys.co.uk<br />
Approved solution partners:<br />
ISO 9001:2008 registered<br />
FM23783<br />
BTJ DRIVES & CONTROLS LTD<br />
STOKE on TRENT ST10 4PG<br />
t: 01889505315 f: 01889505604<br />
www.btjdrives.co.uk<br />
DRIVES SERVICES<br />
ELECTRICAL ENGINEERING<br />
T. 01490 413550<br />
F. 01490 413014<br />
E. info.uk@globalencoder.com<br />
W. www.globalencoder.com<br />
ENCLOSURES<br />
IMPORTANT NOTICE<br />
For users <strong>and</strong> purchasers<br />
oflow voltage switchgear<br />
<strong>and</strong> controls<br />
EDM Ltd specialises in electrical<br />
engineering. We can supply<br />
all types of bespoke electrical<br />
panels to your requirements<br />
at competitive prices<br />
For more<br />
news stories,<br />
the latest informaton<br />
<strong>and</strong> more detailed<br />
coverage, log onto:<br />
www.drives.co.uk<br />
Contact us for a quotation<br />
Tel/Fax: 01279 433500<br />
Mobile: 07855 753749<br />
E: enquiries@edmlimited.co.uk
PRODUCTS & SERVICES DIRECTORY<br />
ENCLOSURES<br />
D<br />
GEARS<br />
MOTORS/GENERATORS<br />
To advertise contact Simon Langston<br />
t/f: 01353 863383 e: simon@dfamedia.co.uk<br />
POWER QUALITY<br />
<strong>New</strong> Extended<br />
Gear Range<br />
Available Ex-stock<br />
Brass Gears<br />
Fine Pitch Ground Gears<br />
Bespoke Precision Gears<br />
to Order<br />
Reliance ®<br />
Precision Mechatronics LLP<br />
Tel: +44 (0) 1484 601060<br />
www.rpmechatronics.co.uk<br />
• Full range of EFF 1 energy effi<strong>cient</strong> motors<br />
• Asynchronous Motors 0.12kW to 2800kW,<br />
2/12 poles LV<br />
• Asynchronous Motors 110kW to 2000kW,<br />
2/12 poles MV<br />
• Hazardous Area Motors 0.12kW to 560kW,<br />
2/12 poles LV<br />
• Hazardous Area Motors 10kW to 500kW,<br />
2/12 poles MV<br />
• Single Phase Motors 0.18kW to 3kW, 2/4 poles<br />
• Synchronous/Asynchronous Generators 10 to<br />
5000kVA, 2/16 poles LV<br />
• Synchronous/Asynchronous Generators 200 to<br />
5000kVA, 4/16 poles MV<br />
Marelli UK Ltd, Loughborough, Leics<br />
T 01509 615518<br />
E john.attenborough@marellimotoriuk.com<br />
GEARBOXES<br />
LINEAR ACUTATORS<br />
PLC AND SCADA SYSTEMS<br />
POWER TRANSMISSION<br />
Olsen Engineering UK Ltd<br />
Unit 17, Parc Haford, Tregynon, <strong>New</strong>town SY16 3EQ<br />
t: 01686 651151<br />
email: info@consultolsen.com<br />
web: www.consultolsen.com<br />
“When push comes to shove,<br />
Olsen has the answer”<br />
Independent Control Systems Ltd<br />
Leading the way in<br />
Industrial Automation<br />
& Control Systems<br />
Capabilities:<br />
Turnkey Systems<br />
Hardware / Software Design<br />
System Build & Test<br />
Installation & Commissioning<br />
Site Service & Training<br />
24 Hour Support<br />
Product Expertise:<br />
AC, DC & Servo <strong>Drive</strong> Systems<br />
PLC, HMI & SCADA Industrial IT<br />
Email : info@iconsys.co.uk<br />
Website : www.iconsys.co.uk<br />
Approved solution partners:<br />
ISO 9001:2008 registered<br />
POWER TRANSMISSION DIVISION<br />
General Purchasing Office in the UK for<br />
Industrial Power Transmission Equipment,<br />
Electrical <strong>and</strong> Engineering Components<br />
Sourcing service throughout the<br />
UK, Europe, America <strong>and</strong> the Far East<br />
Luso offers:<br />
• Boston Gear/Warner Distributor<br />
• Specialised service for American parts<br />
• Ship to stock programme; kanban<br />
• Fast response to all enquires<br />
• Prompt despatch of stock orders<br />
• Only original parts supplied<br />
• ISO9001 (2000 revision) ISO1400/18001<br />
• 24 hour service<br />
The name LUSO is your guarantee<br />
of quality <strong>and</strong> service.<br />
Make LUSO your major supplier<br />
E: yvonne.g@lusoelectronics.com<br />
T: 0121 321 2144<br />
F: 0121 355 5045<br />
www.lusoelectronics.com<br />
INDEXING TABLES<br />
WEISS UK Ltd<br />
• Up to 5M dial capacity<br />
• No need for clutch unit<br />
• Unbeatable reliability<br />
• Short delivery times<br />
• NC programmable variant<br />
• Optional:<br />
Control Cards<br />
Precision m/c'ed Dials<br />
Machine Bases<br />
Tel: 01952 728112<br />
Fax: 01952 728337<br />
Email: info@weiss.uk.com<br />
Internet: www.weiss.uk.com<br />
MOTOR INVERTERS<br />
Smartdrive<br />
Motor inverter<br />
Features:<br />
Single <strong>and</strong> three phase versions<br />
Vector control<br />
Output speed range at constant<br />
torque rpm : 36 ÷ 2450<br />
Force ventilation options for<br />
wider constant torque range<br />
0.18 to 3kw<br />
On-board control or remote control,<br />
by keypad <strong>and</strong> potentiometer<br />
Protection degree IP54, IP55, IP56,<br />
IP65, IP66<br />
Optional boards I/O, RS485, CANBus<br />
www.motovario-group.com<br />
POWER ELECTRONICS<br />
H rep<br />
<br />
<br />
<br />
Tel: 01249 767701<br />
www.h-rep.net<br />
sales@h-rep.net<br />
REPAIRS<br />
<br />
<br />
Specialists in AC/DC industrial<br />
<br />
electronic repairs<br />
Fast turnaround<br />
<br />
No fixed repair costs, quote on<br />
each repair<br />
Site support<br />
IXYS<br />
Return to base 6 month warranty<br />
WESTCODE<br />
Service exchange<br />
PCB board repairs down to<br />
component level<br />
Experts in Industrial<br />
Electronics Repairs<br />
ElectroAid Service Engineering Ltd<br />
Unit 15 Horton Court,<br />
Hortonwood 50, Telford, TF1 7GY<br />
Tel: 01952 677555<br />
Fax: 01952 676083<br />
www.electroaid.co.uk
To advertise contact Simon Langston<br />
t/f: 01353 863383 e: simon@dfamedia.co.uk<br />
SENSORS<br />
PRODUCTS & SERVICES DIRECTORY<br />
SERVO MOTOR & DRIVE REPAIRS<br />
VIBRATORY MOTORS<br />
Industrial & Technical Services<br />
SERVO MOTOR<br />
REPAIR CENTRE<br />
FANUC SIEMENS INDRAMAT ELAU<br />
MITSUBISHI PANASONIC SEM BOSCH<br />
& Many More<br />
Unbalanced<br />
Vibratory Motors<br />
ROSTA Screen<br />
Suspensions<br />
SERVO MOTOR & DRIVE REPAIRS<br />
For All Your Product<br />
Repair Needs<br />
Tel +44 (0) 1270 508822<br />
Fax +44 (0) 1270 251240<br />
emeasales@electrocraft.com<br />
visit us at www.electrocraft.com<br />
STEPPER MOTORS<br />
HYBRID<br />
STEPPER<br />
MOTORS<br />
UNRIVALLED<br />
CHOICE<br />
CALL:<br />
0116 276 8686<br />
Alpha Electrics Ltd<br />
Unit 11, 158 Tithe Street,<br />
Leicester. LE5 4BN Engl<strong>and</strong> U.K.<br />
info@alphaelectrics.com<br />
www.alphaelectrics.com<br />
n Widest range of NEMA frames<br />
from 16 to 42<br />
n Rare earth high torque models<br />
n Single or double shafted<br />
n Protection options up to IP68<br />
n Customisation <strong>and</strong> full accessory range<br />
n Large range available ex-stock<br />
ASTROSYN INTERNATIONAL<br />
TECHNOLOGY Ltd<br />
Tel: 01634 815175<br />
Fax: 01634 826552<br />
email: astrosyn@btinternet.com<br />
web: www.astrosyn.com<br />
Two Great<br />
Products<br />
One Supplier<br />
..<br />
KOBO (UK) Ltd<br />
Tel: 01625 529514<br />
e-mail info@kobo.co.uk<br />
www.kobo.co.uk<br />
IF YOU’RE<br />
READING THIS,<br />
THEN SO ARE<br />
60,000+<br />
ENGINEERS<br />
IMAGINE THE<br />
IMPACT YOUR<br />
ADVERTISEMENT<br />
COULD HAVE<br />
Contact us at<br />
<strong>Drive</strong>s & Controls<br />
T: 01922 644766<br />
e: doug@drives.co.uk<br />
T: 01353 863383<br />
e: simon@dfamedia.co.uk<br />
www.drives.co.uk<br />
MAKING MODERN LIVING POSSIBLE<br />
<strong>Drive</strong>s PartnerNET<br />
<strong>Danfoss</strong> <strong>Drive</strong>s Competence Centres<br />
are fully equipped to satisfy the total<br />
needs of our valued <strong>Drive</strong>s customers;<br />
providing assistance in sales, installation,<br />
commissioning, technical support <strong>and</strong><br />
service 24/7/365.<br />
For further information please<br />
contact <strong>Danfoss</strong> <strong>Drive</strong>s on<br />
01895 617 100 or your<br />
Regional Competence Centre<br />
directly.<br />
one place - one solution<br />
Regional Competence Centres<br />
Scotl<strong>and</strong> Tel: 01324 633 203<br />
WJ Electrical Supplies Limited<br />
Irel<strong>and</strong> Tel: 02890 645 060<br />
Greenville Industrial <strong>Drive</strong>s & Controls<br />
Northern Engl<strong>and</strong> Tel: 01457 837 145<br />
P-n-P <strong>Drive</strong>s & Controls Ltd<br />
Southern Engl<strong>and</strong> Tel: 01923 333 375<br />
K2 <strong>Drive</strong>s <strong>and</strong> Controls Limited
APPOINTMENTS<br />
Career opportunities<br />
Routeco is the market leading industrial control,<br />
automation <strong>and</strong> process products supplier<br />
in the UK employing over 230 staff nationwide.<br />
The company has continued to grow by<br />
providing both technical <strong>and</strong> business solutions<br />
through professional collaboration <strong>and</strong> service<br />
excellence, becoming a partner of choice to our<br />
customer <strong>and</strong> suppliers.<br />
We have a number of exciting opportunities<br />
based around the UK within both our Product<br />
Sales Specialist <strong>and</strong> Business Development<br />
teams which reflects the ongoing positive<br />
growth in the business.<br />
System Control Solutions was formed in<br />
1984, as the senior staff move towards retirement,<br />
we are seeking a Business Development<br />
Partner, either an individual or a organisation<br />
for purposes of working with or on behalf of the<br />
company to secure <strong>and</strong> increase new business,<br />
help bring onboard younger staff <strong>and</strong> develop<br />
the company with the eventual objective of taking<br />
over <strong>and</strong> running the business.<br />
I believe the ideal c<strong>and</strong>idate will be aged 35-45,<br />
already have a strong presence in the drives &<br />
controls industry <strong>and</strong> be in a position to navigate<br />
new business almost immediately, either by<br />
being part of an existing young organisation or<br />
as successfull sales engineer.<br />
If this opportunity is of interest <strong>and</strong> you<br />
wish further discussion, please email some<br />
basic details of yourself or organisation to<br />
tim@scslow.co.uk <strong>and</strong> I will contact you in<br />
due course.<br />
www.scslow.co.uk<br />
• Safety <strong>and</strong> Sensor Product<br />
Sales Specialists<br />
• Industrial Control Gear Product<br />
Sales Specialists<br />
• ATEX Product Sales Specialists<br />
• Process Sales Specialists<br />
• Business Development<br />
Engineers<br />
Looking for a new<br />
career opportunity?<br />
Visit www.drives.co.uk/jobs.asp<br />
The simplest route to your next job<br />
Routeco strives to be an employer of choice;<br />
offering an infrastructure that enables you to<br />
develop your career with us through continuous<br />
development, professional challenges, an<br />
environment that is open <strong>and</strong> flexible <strong>and</strong><br />
a culture that recognises <strong>and</strong> rewards success.<br />
For further information about the above<br />
positions <strong>and</strong> to apply online, please visit our<br />
careers page at www.routeco.com/careers<br />
Please be sure to provide a covering letter<br />
outlining your interest in the role <strong>and</strong> stating<br />
your current salary details <strong>and</strong> expectations.<br />
www.routeco.com
To advertise contact Simon Langston<br />
t/f: 01353 863383 e: simon@dfamedia.co.uk<br />
<br />
APPOINTMENTS<br />
MAKING MODERN LIVING POSSIBLE<br />
<strong>New</strong> career opportunities with global market leader<br />
<strong>Danfoss</strong> <strong>Drive</strong>s is renowned worldwide as the foremost specialist in ac variable speed drives, as the global markets continue to<br />
grow for us we see an excellent opportunity to build on our recent success <strong>and</strong> increase our market share by strengthening our<br />
dedicated Strategic Business Area Teams. As part of our local commitment to the S.B.A’s we are looking to appoint new members<br />
to the Sales Team.<br />
Sales Manager for the Water & Waste Water Business in<br />
Scotl<strong>and</strong> & Irel<strong>and</strong> to provide front end consultancy on<br />
sales of ac drives to the UK water authorities, OEMs,<br />
consultant engineers, panel builders <strong>and</strong> the main<br />
contractor who operate in this area throughout the UK.<br />
The successful applicant will report to the UK<br />
Country Manager.<br />
Business Development Manager for the Food &<br />
Beverage Industry across Northern Europe to target &<br />
develop potential new key accounts by gaining<br />
specification at End Users, OEM’s <strong>and</strong> system builders<br />
throughout the Region.<br />
The successful applicant will report to the Northern<br />
European Director.<br />
C<strong>and</strong>idates would ideally come from either a drives or the Strategic Business Area environment with an electrical engineering<br />
background, preferably qualified to HNC st<strong>and</strong>ard or equivalent. In-depth drives or systems knowledge is a prerequisite <strong>and</strong> at<br />
least two years sales experience in the appropriate sector is essential. Computer literacy, commercial awareness, good<br />
communications skills with self motivation <strong>and</strong> the ability to form effective partnerships with clients are all essential to success.<br />
The company offers a competitive salary commensurate with the importance of these critical appointments <strong>and</strong> a personal/team<br />
performance related bonus. A pension scheme, private healthcare (BUPA) <strong>and</strong> company car policy are all part of the generous package.<br />
Interested parties should forward their CV in the first instance to:-<br />
John Martin, Sales Director, <strong>Danfoss</strong> <strong>Drive</strong>s, Capswood, Oxford Road, Denham, Bucks, UB9 4LH<br />
or by e-mail to john.martin@danfoss.com<br />
INDEX OF ADVERTISERS<br />
A&S Fersa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28<br />
ABB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11<br />
Aerotech . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53<br />
All <strong>Drive</strong>s & Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38<br />
Andantex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47<br />
B&R Automation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10<br />
Baldor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55<br />
Balluff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52<br />
Beckhoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17<br />
Bosch Rexroth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8<br />
Control Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7,48<br />
<strong>Danfoss</strong> . . . . . . . . . . . . . . . . . . . . . . . . . .Front Cover Gatefold<br />
Diamond Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34<br />
Dold Industries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41<br />
<strong>Drive</strong>s <strong>and</strong> Controls Show . . . . . . . . . . . . . . . . . . . . . . . . . . .57<br />
EMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43<br />
Euchner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57<br />
Gates Power Transmission Europe . . . . . . . . . . . . . . . . . . . .36<br />
Goodyear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35<br />
Heidenhain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41<br />
HPMG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59<br />
igus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27<br />
Koyo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28<br />
Lafert Electric Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42<br />
Lenze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50<br />
Leuze electronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53<br />
LG Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22<br />
Linak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22<br />
maxon motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33<br />
Mclennan Servo Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . .49<br />
Medway Power Transmission . . . . . . . . . . . . . . . . . . . . . . . .33<br />
Meiden . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41<br />
Micro-Epsilon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18<br />
NSK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31<br />
Ondrives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28<br />
Parker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26<br />
Red Lion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5<br />
Reliance Precision Mechatronics . . . . . . . . . . . . . . . . . . . . .24<br />
Renold Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32<br />
Rittal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-15<br />
Routeco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13<br />
Scattergood & Johnson . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45<br />
Schaeffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25<br />
Schurter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51<br />
Semikron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2<br />
Siemens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9, OBC<br />
Softstart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19<br />
Yaskawa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59<br />
www.drives.co.uk November/December 2010 65
SITOP compact power supply<br />
Extremely effi<strong>cient</strong> in saving space<br />
<strong>and</strong> energy<br />
Space<br />
savings of<br />
up to 33%<br />
Energy<br />
savings of<br />
up to 35%<br />
SITOP PSU100C<br />
Due to the extremely space-saving slim design, the new power supply series for the lower performance range is especially<br />
suited to distributed applications in control boxes or in small control cabinets. The power supplies are characterised by<br />
their low power loss over the entire load range. Power loss is extremely low even during no-load operation, which is why<br />
they are ideal, for example, for supplying machinery <strong>and</strong> equipment that are often in st<strong>and</strong>-by mode.<br />
The SITOP PSU100C switched-mode power supplies have a wide-range input for AC <strong>and</strong> DC networks, with plug-in<br />
terminals allowing a simple electrical connection.<br />
Contact us: 08457 70 50 70 Email: marketing.ad.uk@siemens.com<br />
Answers for industry.