Drives&Controls; - Capsule-group.com

DRIVES & CONTROLS www.drives.co.uk MARCH 2010
Drives&Controls
THE LEADING MAGAZINE FOR AUTOMATION, POWER TRANSMISSION AND MOTION CONTROL
Drives&Controls
MARCH 2010
Two New
Arrivals ...
PipeDrive Servo Geared Motor
www.stober.co.uk
MOTORS:
A 15-page supplement on motors and their uses
BRAKES & COUPLINGS:
Torque-limiting bush cuts machine downtime
MACHINE BUILDING:
Winding and slitting films at 1.2km per minute
KL Helical Bevel Servo Gearbox
WE KEEP THINGS MOVING
www.drives.co.uk

PipeDrive Servo Geared Motor
with flange mount hollow bore.
Also available without integrated
gear unit.
KL Ultra Compact Helical
Bevel Geared Servo Motor
WELCOME TO THE FAMILY
Servo Geared Motors
Backlash from 1 Arc Min,
Torques upto 13,500 Nm
with or without Motors
Intelligent Power
Electronics
with STOBERS 5 th Generation
Digital Servo and AC Inverter
ranges we offer inbuilt drive
intelligence delivering flexible
and user friendly motion
platforms
AC Geared Motors
Motor Power 0,12 – 45 kW
Gear Motor Range 4 – 682
www.stober.co.uk
Phone +44 (0)1992 709710
YEARS
WE KEEP THINGS MOVING

DRIVES & CONTROLS
Editor
Tony Sacks, BA, BSc
t/f: 01732 465367
tony@drives.co.uk
Production Manager
Sarah Blake
t: 01233 770781
sarah@dfamedia.co.uk
Customer Liaison
Katherine Cairns
t: 01732 370340
katherine@dfamedia.co.uk
Financial
Clare Jackson
tel: 01732 370340
clare@dfamedia.co.uk
ADVERTISING
Sales Director
Doug Devlin
t: 01922 644766
f: 01922 633730
m: 07803 624471
doug@drives.co.uk
Display Sales Manager
London & South, & Recruitment
Simon Langston
t/f: 01353 863383
m: 07962 402454
simon@dfamedia.co.uk
Germany Victoria Hufmann
Meck Str. 3-5, D-90762 Furth, Germany
t: +49 (0) 911 939 764 42
f: +49 (0) 911 939 764 59
victoria@hufmann.info
Eastern US
Karen C Smith-Kernc
karenkcs@aol.com
t: +1 717 397 7100
f: +1 717 397 7800
Western US and Canada
Alan A Kernc
alankcs@aol.com
t: +1 717 397 7100
f: +1 717 397 7800
Publisher
Ian Atkinson
t: 01732 370340
ian@dfamedia.co.uk
Circulation
Andy Kirk
t: 0845 602 7390
f: 0845 604 2327
info@capsule-group.com
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DFA Media Ltd
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Tonbridge, Kent TN9 2BL
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Drives & Controls is a controlled circulation publication. If
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ISSN 0950 5490
Copyright DFA Media Ltd 2010
UPDATE
3 NEWS
A round-up of the latest business and industry developments from
around the world.
10 TECHNOLOGY
Cutting-edge innovations in motion, power transmission, controls and
related technologies.
IN DEPTH
18 Machine Safety
The delayed demise of EN 954-1 has created confusion in the world of
machine safety. An expert looks at the implications and how the safety market
may be affected.
21 Motors
In a special 15-page
supplement, we report
on the many and varied
ways in which electric
motors are being used,
and offer advice on how
to reduce noise levels in
stepper motor
installations.
36 Brakes and Couplings
How hydraulic brakes are playing a critical role in a novel subsea power
generation technology, and how torque-limiting bushes have cut downtime
on blow-moulding machinery.
41 Machine Building
A look at a machine that rolls and slits thin films at speeds of up to 1.2km per
minute, and a report on how a servo-controlled insertion machine has
speeded up the production of automotive parts.
REGULARS
9 Comment
45 ABB Back to Basics
46 Design Data
48 Multimedia
Software
50 Products
58 Workspace
59 Products & Services
64 Appointments
NEXT ISSUE
The April issue of Drives & Controls will
contain our annual supplement on
machine safety, plus reports on water industry applications
and what’s happening in the world of bearings, belts and chains.
IN THIS ISSUE March 2010 Vol 26 No 3
Drives&Controls
Two New
Arrivals ...
PipeDrive Servo Geared Motor
www.stober.co.uk
MARCH 2010
MOTORS:
A 15-page supplement on motors and their uses
BRAKES & COUPLINGS:
Torque-limiting bush cuts machine downtime
MACHINE BUILDING:
Winding and slitting films at 1.2km per minute
KL Helical Bevel Servo Gearbox
WE KEEP THINGS MOVING
6
THE LEADING MAGAZINE FOR AUTOMATION, POWER TRANSMISSION AND MOTION CONTROL
www.drives.co.uk
www.drives.co.uk
6
12
18
36
42
50
52
53
CONTENTS

automation
See us on
Stand D2336
Drives & Controls 2010
NEC, Birmingham
8-10 June 2010
PSS4000 –
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PSS4000. The new automation system from Pilz.
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Pilz Willow GmbH House, & Co. KG, Medlicott 73760 Ostfildern Close, Corby, Northants NN18 9NF
0711 Tel: 01536 3409-0, 460766, pilz.gmbh@pilz.de, pss4000@pilz.co.uk, www.pilz.de www.pilz.co.uk

Components such as MCCBs are tested in open-air
rigs that do not represent real conditions when
operating as part of an assembly
Controlgear
assemblies ‘could
pose a fire risk’
GAMBICA, the trade body that represents the UK’s control and
automation sector, is warning that a new series of IEC standards
covering low-voltage switchgear and controlgear assemblies will
not eliminate the need to exercise skill and caution when choosing
the ratings of components used in assemblies. If care is not taken,
it cautions, the assemblies could overheat, possibly causing injuries
or leading to fires.
Gambica’s Controlgear Group technical committee has
welcomed the long-awaited publication of IEC 61439 – soon to be
implemented in the UK as BS EN 61439. But it is worried that the
nominal current ratings of circuit-breakers and other components –
such as contactors, overload relays and even variable speed drives
– relate to tests carried out in “free air”. For these tests, the
component is mounted on an open framework with air all around
it, which helps to dissipate excess heat.
Unfortunately, the committee says, these test conditions are very
different from those in which the component will operate when
installed in a power switchgear or controlgear assembly (PSC). As a
result, substantial derating may be needed to ensure safe
operation and to comply with the temperature rise requirements of
the IEC 61439 standard.
If PSCs operate above their limiting temperatures, they can
suffer progressive insulation breakdown, leading ultimately to short
circuits. Users can suffer burns and the risk of the equipment
catching fire is increased significantly. Furthermore, the equipment
cannot be declared as compliant with IEC 61439.
Gambica’s committee warns that nominal component ratings
should be considered only as a starting point for making
sound engineering decisions relating to PSC design and
construction.
It points out that reputable PSC manufacturers are aware of
these issues and will undertake the testing needed to determine
ratings that are appropriate to the use of particular components in
their enclosures. Alternatively, the manufacturers may adopt
another approach permitted by IEC 61439, which relies on
calculations that incorporate generous safety margins.
Gambica stresses that specifiers and purchasers of PSCs must
insist on guarantees from their suppliers that issues relating to
component ratings have been addressed.
Gambica has published a free technical guide, called Current
Rating of Low-Voltage Electrical Switchgear Assemblies, which is
available as a download from www.gambica.org.uk
NEWS
Yaskawa chooses Drives & Controls show
to re-establish its UK presence
YASKAWA is the latest major supplier to
sign up to exhibit at the Drives & Controls
Show at the NEC in June. Following the
ending of its joint venture with Omron last
year, the Japanese motion engineering
giant is using the show as part of its
campaign to re-establish its presence in
the UK as an independent supplier.
“We are using the show to re-establish
Yaskawa in the UK with its own brand,”
says Paul Seale, the company’s key
account manager. “We think that the
Drives & Controls Show is great
opportunity to do that.”
Yaskawa will be showing a wide range
of its latest products, including inverters,
servo drives and linear motors. For
example, it will be demonstrating: the
energy savings possible with its IE3-rated
EcoIPM motors; the anti-vibration
performance of its Sigma-5 servo drives;
and the high levels of repeatability
possible with its linear motors. There will
also be new communications and safety
option modules for Sigma-5, as well as a
new IEC control platform.
Yaskawa is one of a stream of companies
that that have booked to attend the
exhibition in recent weeks. The show’s sales
director, Doug Devlin, says that the number
of companies signing up reflects a
widespread optimism about the future.
“There’s confidence in the marketplace,” he
says, pointing out that many exhibitors are
appearing at the show for the first time.
For example, IDEM Safety Switches, set
up in Leigh, near Manchester, in 2003, by
former employees of EJA Guardmaster, will
be showing items from its portfolio of light
curtains, interlocks, safety relays, rope
switches, and other safety-related products.
A highlight on the IDEM stand will be a
range of IP69K stainless-steel interlock
switches suitable for use in food, beverage
and pharmaceutical environments.
The show is also attracting first-time
exhibitors from
elsewhere in Europe,
Seale:
“a great
including the German
opportunity”
computer simulation
specialist, CST, and the
Italian power transmission
manufacturer, Chiaravalli.
Other recent signings include the
Warwickshire sensor specialist, Techni
Measure, the small motors manufacturer,
Dunkermotoren, and the electromechanical
components supplier, Stocko
(which will also be exhibiting items from
Wieland Electric’s portfolio).
Harting, which had already signed up to
exhibit at the Drives & Controls Show, has
recently taken a second stand at the show
taking its total floor area to 36m 2 .
If you would like to attend the show, you
can register online at www.drives2010.com.
If you are interested in exhibiting, please
contact Doug Devlin on 01922 644766 or
email him at doug@drives.co.uk
www.drives.co.uk March 2010 3

NEWS
IN BRIEF
A US report says that Emerson
Electric has been approached by an
unnamed potential buyer of its
Commercial and Industrial Motors
and Appliance Motors & Controls
operations. The businesses, which
employ around 6,000 people, are part
of Emerson’s Appliance and Tools
division. Last month, Emerson CEO
David Farr said he plans to divest
“non-core” businesses worth $1bn
over the next two to three years, and
$2bn within five years. He does not
regard Appliance and Tools as a
“cornerstone” division and says it will
contract. But Emerson has not decided
whether to sell the motor businesses.
Sales of manufacturing technology in
the US during 2009 totalled $1.77bn
– a drop of 60.4% from 2008. The
figures were compiled jointly by the
Association for Manufacturing
Technology and the American
Machine Tool Distributors’
Association. Although sales figures
for December 2009 were 22.9% up
on November, they were 5.7% lower
than in December 2008.
Oracle is the latest IT systems
supplier to join Mitsubishi Electric’s
e-F@ctory initiative which links
control hardware and networks with
IT systems from strategic partners
(already including IBM and
Microsoft). Mitsubishi is the first
hardware vendor with an approved
and tested connection to Oracle’s
Manufacturing Operations Center
software, which gives users real-time
information about plant production.
Birmingham-based Luso Electronics
has been appointed a distributor for
products from Warner Electric, TB
Woods and Boston Gear, which are
all part of the Altra Industrial
Motion Group. Contact Luso on
0121 321 2144 or at
yvonne.g@lusoelectronics.com
Caersys-based Olsen Engineering
has reported a record turnover for
the past year, which saw it expand
into new premises and employ two
new members of staff.
Rittal has launched a service to
modify its enclosures to UK users’
specifications, adding features such
as holes, cut-outs and engraving. The
service will offer delivery in five
working days.
Since the start of 2010, around 60
companies have booked to exhibit at
the MACH manufacturing
technologies exhibition, which will
run alongside the Drives & Controls
show at the NEC in June. The new
bookings add 1,200m 2 of stand
space to the show which is now
almost 90% full, according to its
organiser, the Manufacturing
Technologies Association.
Siemens’ drives and automation
divisions get new leaders
SIEMENS HAS announced two
key appointments at the top
of its Industry Automation &
Drives Technologies (IA&DT)
division in the UK. It has also
joined forces with several
industrial companies to form a
“drive train partnership”.
Andrew Peter has been
appointed director of the Drive
Technologies division, while
Brian Halliday is taking on a
similar role in the Industry
Automation division. They are
charged with leading the
future strategic direction and
operational delivery in their
businesses, and will report to
IA&DT managing director,
Juergen Maier.
“The UK IA&DT business is
going from strength to
strength,” says Maier. “The
individual merits of our
industry automation and drive
technologies solutions are
strong and well-proven, but
working more closely together
we can offer an enhanced and
powerful combination of
broad-based expertise,
technical solutions and
innovative thinking to provide
real and tangible answers for
industry.” The IA&DT
operation employs around
2,000 people in the UK.
In a separate move, Siemens
Drives Technology (DT) has
linked up with a number of
industry suppliers and
distributors to form a “drive
train partnership” aimed at
promoting the company’s
capability and delivering
ABB is buying the Swedish machine safety
specialist, Jokab Safety International, for an
undisclosed sum. Jokab, which was founded
in 1988, employs around 120 people in
Sweden, the US, Canada, Italy, France and the
UK. Its turnover in 2008 was worth around
€25 million.
Jokab will join ABB’s Swedish-based Cewe-
Control business in its Low Voltage Products
division.
“This investment is fully in line with our
strategy to diversify by offering value-creating
Taking charge: Siemens’ new divisional directors,
Brian Holliday and Andrew Peters
products and systems faster.
The companies involved are
Brammer, Hayley, Fraser &
Macdonald, Southern &
Redfern, Dorlec, Anstee Ware,
CPM and MR Engineering.
The products covered by the
partnership include variable
speed drives, induction
motors, geared motors and
gearboxes.
“This new partnership
enables Siemens to deliver its
DT products and services
through a strong national and
regional parts network to its
large and varied customer
base,” says Paul Dudley,
Siemens’ channel manager for
Drives Technology. “Customers
will see an immediate and longterm
benefit from this move.”
Siemens has also improved
its service operation and now
provides a 24-hour, seven-daya-week
call-out service for all
of its motors. It has also
increased and widened its UK
ABB adds Jokab Safety to its LV division
stock levels to meet the
additional demand it expects
the partnership to create. The
company can now supply Eff1
industrial motors up to 200kW
directly from its Bradford site,
while the new partners will be
able to supply motors up to
90kW from stock, as well as
offering other services such as
installation and motor repair
facilities.
• In Germany, Theo Maas has
succeeded Manfred Egelwisse
as head of Siemens’
mechanical drives business.
Egelwisse was with Flender for
more than 20 years before
Siemens acquired the business
in 2005. He managed the
integration of Flender into
Siemens which will be
completed with its imminent
legal absorption into Siemens.
Maas has been COO of
Siemens’ global industrial
gears business since 2008.
acquisitions,” says Tom Sjökvist, head of
ABB's Low Voltage division. “We are pleased
to have acquired one of the strongest product
portfolios in machine safety for
manufacturing.
“The acquisition strengthens both ABB and
Jokab Safety’s offering,” he adds. “Together,
we can better meet customers' growing
demands for low-voltage and machine
safety.”
The transaction is scheduled to be
completed by 10 March.
4 March 2010 www.drives.co.uk

get
all your
devices
on the same page.
Data Station Plus. Protocol conversion. Ethernet gateway. IT-ready data logging. It’s all here.
Red Lion’s Data Station Plus is the single-device solution for protocol conversion. One remarkable device bridges the
communication gap between serial only, fieldbus, and Ethernet devices—unlocking untold information from PLCs,
drives, motion controllers, and more. Red Lion’s free, robust Crimson ® software enables drag-and-drop register
mapping that lets a Siemens ® PLC to talk to an Allen Bradley ® drive in just seconds. The built-in Ethernet gateway
lets you network-enable serial or fieldbus machines onto a common communications backbone in minutes, and
convert your old PLC’s and drive’s proprietary protocol into a single modern and open standard.
But that’s just the beginning. Use the integrated web server to quickly set up secure,
real-time remote monitoring, operation, diagnostics and data acquisition from any web-enabled PC,
PDA or phone. Easily create a web based HMI depiction of your machine or process with the included
5000+ image graphics package. Receive alarms or event notification remotely via e-mail or SMS text.
Collect performance data, display it, store it for evaluation, or trigger PLC functions—live or remotely.
And seamlessly port logged “IT-ready” trending data to web pages, e-mail, ftp sites or other applications.
The no-risk asset and data management solution.
Data Station Plus is the evolutionary, non-invasive device and software platform that expands and unifies the
capabilities of your legacy processes into a modern, completely integrated control solution. And it does it for literally
tens-of-thousands less. See what Data Station Plus can mean to your process at www.redlion.net/DSP
Operator Interface Protocol Conversion Signal Conditioning Panel Meters Data Acquisition
Red Lion Controls Phone: +31 (0) 33-4723-225 Fax: +31 (0) 33-4893-793
europe@redlion.net Toll Free from UK and France: (00800 733 54667)
Trademarks used herein are property of their respective owners.

NEWS
£2m cash injection will fund
Deritend’s expansion plans
In the early days,
bearings were
assembled by hand
SKF notches up a
century in the UK
SKF IS CELEBRATING its 100th anniversary in the UK this year. The
company was founded in Sweden in 1907 by Sven Wingqvist, inventor
of the double-row, self-aligning ball bearing. Three years later, in 1910,
it opened a sales office in Lower Regent Street, London.
The following year, SKF inaugurated a production site in Luton.
Initially, the factory employed 150 people and produced around
180 bearings a day. By the end of the First World War, this figure
had risen to 24,000 bearings per month.
In 1936, a new factory was opened in Sundon, a few miles from
the first plant, where production continued until 1977 when all
operations were centralised at Sundon, now SKF’s UK headquarters.
The site makes spherical and toroidal roller bearings for heavy
industrial applications, as well as offering support services.
SKF has several other facilities in the UK including a plant in
Gloucestershire which manufactures high-performance bearings for
the aerospace sector.
Phil Burge, SKF’s UK marketing manager, says that the UK has
always played an important role in SKF. “Even during the recent
economic recession,” he adds, “we have still managed to maintain
a strong level of output, which we anticipate will grow in future
years as the pace of global recovery picks up. As a result, we
anticipate continued investment and development of our UK
manufacturing operations”.
• SKF is setting up a University Technology Centre on tribology in
Imperial College London's Department of Mechanical Engineering. The
initial contract is for five years and will focus on research into modelling
tribological systems with the aim of reducing friction and wear, and
thus extending the service lives and environmental performance of
products such as bearings. SKF’s first University Technology Centre was
established at the University of Cambridge last year.
DERITEND HAS secured a £2m
cash injection to fund the
expansion of its business. The
Wolverhampton-based
industrial maintenance, service
and repair group has received
the funding from the Capital
for Enterprise Fund (CfE), a
Government initiative to
attract capital for successful
UK businesses.
The investment will support
Deritend’s growth strategy,
which includes developing its
energy efficiency consultancy
services for industrial
customers.
Deritend Industries’ group
managing director, Richard
Hale, says the investment will
underpin the group’s growth
strategy. “It provides us with
the stability to further develop
our business close on the
heels of development of our
engineering centre of
excellence in West Bromwich,
and site services business in
Ashby,” he explains.
The funding is being
provided by Maven Capital
Partners, which jointly
manages the CfE fund.
Andrew Ferguson, a partner
at Maven, says that “Deritend
Industries has an impressive
record as a national business
introducing innovative valueadded
services to an
impressive blue chip client
base. The senior management
team have exciting plans for
the business and Maven is
delighted to be able to
provide this investment from
the CfE Fund at a critical time
in the company’s
development.”
Funding will help
Deritend to expand
Eff logo gets a stay of execution
Peter Still, industry
standards manager at
Schneider Electric, has been
appointed chairman of the
Cenelec TC44X committee
which is responsible for the
electrical safety of
machinery. Still, who has
been on the committee for
14 years, says a key role will
be to ensure that standards
can be harmonised under
the Machinery Directive.
CEMEP, the body that represents
European motor-makers, has
announced that motor
manufacturers will be allowed to
continue using the Eff motor
efficiency logo until the new
mandatory IEC efficiency classes
come into force from June 2011.
The Eff logo was originally
registered as a trademark by the
French electrical trade body
Gimélec, acting on behalf of
Cemep, on 10 February 2000.
Motor manufacturers wanting to
use the logo had to sign a
licencing agreement which expires
on 10 February, 2010.
Sign of things to come: an ABB motor
nameplate showing the new IE classification
Cemep has now decided to
offer a temporary licence to
registered motor manufacturers,
allowing them to continue using
the Eff logo until 15 June 2011. It
says it has done this because
many OEMs are still running
energy efficiency campaigns
based on Eff1 motors, while more
users are choosing Eff1 motors.
The extended licences will
expire the day before the new IEC
class IE2 efficiency motors (similar
to Eff1) become the mandatory
minimum for low-voltage threephase
motors sold in Europe.
Despite extending the Eff logo
licences, Cemep recommends that
motor manufacturers should now
be starting to use the new IEC
efficiency classes – as defined in IEC
60034-30, and using test methods
laid out in IEC 60034-2-1 (2007).
6 March 2010 www.drives.co.uk

www.crossmorse.com
Cross+Morse Shady Lane Great Barr Birmingham B44 9EU England
Tel +44 121 360 0155 Fax +44 121 325 1079 Email sales@crossmorse.com

COMMENT
HITTING THE
RIGHT TARGET?
According to a new poll conducted for the Carbon Trust, British
manufacturers are almost as worried by rising energy prices as
they are about the state of the economy. The survey of 700 UK
businesses with annual energy bills between £50,000 and £3m,
revealed that 53% of manufacturers are worried by energy
price hikes – only slightly behind the 57% whose biggest
concern is the economy. Just 19% of the manufacturers
surveyed were worried about environmental legislation, and
16% about a possible change of government.
The poll was conducted to promote a new Carbon Trust
campaign that offers free on-site energy surveys to companies
that spend £50,000–£3m a year on energy. The Trust says that
these surveys will typically identify potential savings of 20–30%
on a company’s energy costs. It hopes that the campaign,
called Best Advice*, will persuade British companies to stop
wasting more than £3bn worth of energy a year.
Businesses that spend less than £50,000 a year on energy will
have to make do with an online tutorial, including a video,
telling them how to calculate their potential savings and how to
develop a plan to achieve these savings.
But surely, it is the smaller businesses that would benefit most
from free on-site surveys? Although the larger businesses
could probably generate larger savings, they are more likely to
have the internal resources to conduct their own surveys. And
because they have such big energy bills, the large potential
savings give them the incentive to investigate where they could
make savings.
Smaller organisations are less likely to have the resources or
the time to organise their own energy surveys. And although
the amount that each company could save is probably less, on
average, than the larger organisations, there are many more
small companies in the UK and their combined savings could
outweigh those of the larger businesses.
The Carbon Trust reports that 13% of the manufacturers it
surveyed “admitted that no one within their organisation was
responsible for managing their energy consumption and
controlling costs”. But this suggests that 87% of companies do
have someone in this role. This is probably a much higher
figure than even a few years ago and shows that the vast
majority of organisations now realise that managing energy is a
vital aspect of their business.
In the past, the Carbon Trust has been criticised for placing too
much emphasis on publicity-grabbing initiatives such as its
campaigns to cut the energy wasted by domestic appliances
on standby. More recently, however, it has been more visibly
active in the industrial sector with high-profile initiatives such
its Big Business Refit scheme that gives interest-free loans to
replace inefficient, old equipment with newer technologies
such as variable speed drives and high-efficiency motors.
The Trust says that, since 2001, its initiatives have delivered
energy savings worth more than £1.4bn, and it hopes to
achieve a further £1bn of savings in the coming three years.
Let’s hope that industrial technologies play a significant role in
generating these savings.
Tony Sacks
Editor
* For more details, call 01865 885788 or visit
www.thebestadvice.co.uk

TECHNOLOGY
Powerful piezo actuator
‘could replace motors’
PARKER HANNIFIN has developed a
piezoelectric-based actuator which, it
claims, produces 50–100 times the
deflection and force of traditional piezo
stack devices. One possible application
for the Advanced Technology Actuator
would as a simple, direct-drive
replacement for less efficient electric
motors.
Parker says the technology will open
up applications that are unsuitable for
conventional piezo actuators, as well as
improving the performance of existing
applications.
The actuator consists of a proprietary
temperature-compensating frame, an
amplifier body, and a piezo ceramic
stack. It is said to be particularly
suitable for serial bus and batterypowered
applications.
Rich McDonnell, Parker’s product
manager, says that initial feedback on
THE SWITCHED reluctance drives specialist SR
Drives is part of a consortium which has won
a £15m award from the Technology Strategy
Board to help develop a lightweight, gasturbine-based
range extender for future
electric vehicles.
The consortium, which also includes
Jaguar Land Rover and Bladon Jets, aims to
produce the world’s first commercially viable,
« Parker Hannifin’s piezoelectric
actuator delivers more force
and moves further
the device from designers “has exceeded our
expectations. We're looking forward to choosing
several beta applications from among many
interested parties who wish to have early access to
the technology for use in their equipment and
devices.”
www.parker.com/pneumatics
Turbine-based EV generator will use SR technology
and environmentally friendly, gas turbine
generator specifically for automotive
applications.
The system will couple an axial-flow gas
turbine engine to a high-speed generator,
based on SR Drives’ proprietary switchedreluctance
technology.
Harrogate-based SR Drives is owned by
Emerson Electric.
Automation
giants back
integration
scheme
A GROUP of leading automation
organisations and suppliers has decided
to expand the scope of the EDDL Cooperation
Team to accelerate the
deployment of FDI (Field Device
Integration) technology. A new team
called FDI Co-operation will take over
the work of harmonising the EDDL and
FDT/DTM technologies, which began in
2007 and is now expected to result in a
final FDI specification by mid-2010.
The organisations backing the move
include the FDT Group, the Profibus
Users Association, the Fieldbus
Foundation and the OPC Foundation.
The companies involved include ABB,
Emerson, Honeywell, Invensys, Siemens
and Yokogawa.
The enlarged team, which will also
develop design and test tools, aims to
produce a system that will allow
devices to be integrated across all host
systems, devices and protocols that
users might need.
Anton Huber, chief executive of
Siemens’ automation division, sees the
development as “a milestone in
achieving an industry-wide
harmonisation of device integration as,
for the first time, a significant number
of vendors have cone together to agree
on such a standard”. He adds that
Siemens will support the FDI technology
in its products as soon as it is available.

Historian module keeps
an eye on machine
performance
ROCKWELL
AUTOMATION has
announced a
machine-level data
historian that helps
manufacturers to
reduce the risk of
machine downtime
and achieve
continuous process
improvements. The
FactoryTalk Historian
ME application is a
solid-state module,
hardened for onmachine
data
collection, which
has no moving parts
and a low risk of
data loss due to
network or other system interruptions.
The module fits into an Allen-Bradley
ControlLogix backplane. Its software
detects controllers automatically and
configures all relevant tags.
Communicating via the backplane
makes data collection quicker and
provides more detailed information
than is possible with traditional,
network-connected plant historians.
The application is part of a
distributed, tiered architecture that
allows employees in different locations
and at different levels to view and
« Rockwell’s Historian ME module can
be used to produce trend data
depicting factory operations
analyse historical data
tailored to their roles.
Operators, for
example, can view
data from the machine
they are using, while
plant-level supervisors
can view individual
machines or complete
lines to build real-time
comparisons.
Senior management
can use the technology
to develop executive
dashboards that
compare key
performance indicators
of production activity
across several
locations.
The software “improves
manufacturing intelligence by
providing a new level of visibility into
production operations,” says product
manager, Jan Pingel. “By integrating
data from a machine-level historian
with data from a plant-level historian,
operations can now locate and
correct sources of inefficiencies more
quickly to improve manufacturing
consistency, energy use and first-pass
quality.”
http://discover.rockwellautomation.com
/historian
Displacement sensors
promise long ranges
at a low cost
THE GERMAN sensor specialist Micro-Epsilon has
come up with a low-cost technology for
measuring displacement which, it claims, offers
high sensitivity and long operating ranges.
Unlike Hall Effect sensors, the patented
Magnetic Displacement Sensor (MDS) is based on
a linear relationship between the position of a
target magnet and the output signal. It uses
printed coils, thus avoiding the need for
semiconductor manufacturing processes and
making customer-specific adaptations easier.
The MDS uses much smaller magnets than Hall
sensors, cutting costs and simplifying installation.
It also supports considerably longer measuring
distances – currently up to 60mm.
Because the sensors are extremely sensitive,
simple, low-cost evaluation circuits can be used.
The output can be in the form of a PWM signal
which can be read by a microcontroller. Using an
eddy current sensor as the technological core,
fast, high-resolution versions are possible.
Micro-Epsilon developed the technology for use
in appliances such as washing machines where it
allows loads to be measured with a high
resolution, while monitoring spin cycles with high
dynamics. It could be applied anywhere needing
long measuring ranges and high resolution.
Micro-Epsilon’s patented sensing technology allows
long-distance measurements at a low cost
TECHNOLOGY

TECHNOLOGY
Monitor your
PLCs on a
BlackBerry
USERS OF Mitsubishi FX PLCs
can now monitor and adjust
their installations remotely from
a BlackBerry mobile phone. A
German company called Schad,
which specialises in Blackberrybased
automation software,
has joined Mitsubishi’s e-
F@ctory Alliance scheme, and is
offering support for the PLCs
via its Extend 7000 mobile
SCADA system.
The software allows
BlackBerry users to change
production schedules remotely,
and to diagnose and make
adjustments to their control
systems, based on alarms
triggered by preset parameters
or fault conditions.
The main innovation in the
Extend 7000 system is crossplatform
integration. A SCADA
layer hosted on a local server
connects to factory PLCs and
provides a secure connection
via the BlackBerry enterprise
server to the Internet and out
to a mobile network via a
stable, secure 256-bit encrypted
signal.
This allows real-time
interaction with PLC functions
using simple commands. The
system has already proved
popular with large production
sites and businesses such as
utilities where engineering and
maintenance teams need to
monitor and maintain remote
sites such as pumping stations.
Schad aims to become a
global leader in mobile systems
for operating and monitoring
machine and plant controls.
“We hope the Extend 7000
solution will be established as
the standard for mobile access
« Schad’s technology allows PLCs to be monitored and adjusted
remotely via secure BlackBerry connections
to Mitsubishi PLCs,” says
Christian Schad, the company’s
MD and the originator of its
technology. “We have been
able to convince users
[including Volkswagen and
Cologne-Bonn Airport] that the
system really does save time for
solving problems and improving
plant uptime, while freeing
operators to move around and
take care of other management
issues, without being shackled
to a PC and a hardwired
Ethernet link.”
The Schad system currently
works with any Mitsubishi FX
PLC connected to a network
with Internet access. There are
plans to extend the support to
other Mitsubishi products such
as its System Q, iQ Automation
Platform, inverters and servo
drives.
Chris Hazlewood, the
originator of Mitsubishi’s e-
F@ctory Alliance, believes that
the Schad system “offers our
end-users the opportunity to
make better use of personnel
and make improvements to
communications and
productivity.
“We are also looking for
future potential and believe this
platform has the potential to be
extended to include the
majority of Mitsubishi
automation products,” he adds.
www.schad-automation.de
www.mitsubishiautomation.co.uk
Cranfield
technology
will help to
manufacture
micro-scale
devices
≈ These piezoelectric micro-valve components on a 50mm
wafer, can change shape when an electrical signal is applied.
They are just 100µ thick – twice as thick as a human hair.
RESEARCHERS AT Cranfield University have
developed a technology that could slash the
cost of manufacturing complex micromechanical
and micro-optical devices. The
project, part of a €3.2m EU-supported research
consortium called Q2M (Quality to Micro), has
examined some of the key issues with existing
micro-fabrication processes, which are limited
by the conflicting requirements of different
materials.
“Standard micro-fabrication techniques are
often incompatible with high-quality transducer
materials, such as shape memory alloys and
functional ceramics,” explains Stephen Wilson,
a senior research fellow in microsystems
technology at Cranfield. “This is one of the
major bottlenecks for the development of novel
micro-scale systems.
“The new technology enables multi-material
devices to be made that do not conform to the
usual silicon MEMS stereotype,” he continues.
“It will bring down the cost of genuinely new
systems considerably.”
The new methods could be used to
manufacture items ranging in size from a few
hundred nanometres to a few millimetres.
Potential applications include: biomedical
devices that can diagnose disease and
administer drugs electronically; electronic noses
to sniff out explosives or dangerous chemicals;
and environmental control systems for personal
healthcare. The technology could also open up
new applications in communications because it
allows previously incompatible non-silicon
materials to be incorporated in radio-frequency
circuits.
The three-year Q2M project involved 12
academic partners and industrial companies, as
well as several end-users to ensure the work
addressed real industrial needs.
The Drives and Controls
Exhibition & Conference 2010
8-10 June 2010 - NEC - Birmingham
Contact us now for your FREE exhibition pack and become part of the
UK’s largest and most successful manufacturing event
www.drives2010.com
CONTACT:
Doug Devlin on
E: doug@drives.co.uk
+44(0)1922 644766 M: 07803 624471
Simon Langston on
E: simon@dfamedia.co.uk
+44(0)1353 863383 M: 07962 402454

TECHNOLOGY
Wavepower generator relies on
low-friction bearing materials
NOVEL BEARING and seal technologies are
playing a vital role in a new UK-developed
wave energy generator due to start testing
off Orkney later this year.
Engineers at Edinburgh-based Pelamis
Wave Power have been developing wave
power devices for more than a decade and
have overcome the challenge of continuous
operation in the punishing marine
environment. Building on their experience
of producing the world’s first offshore
wave energy converter, the team has now
developed a second-generation design
which is more efficient and cost-effective.
Crucial to the new design are the bearings
and seals. The P2 generator consists of a
series of floating, linked tubes with four
hydraulic rams at each main joint pivoting
on precision bearings to drive hydraulic
motors coupled to electric generators.
“Our biggest challenge has always been
how we manage the loads and motions
from such an active and constantly variable
environment, whilst at the same time
extracting as much power as possible,”
explains Mike Woods, Pelamis’ senior
engineer and bearings group leader. “The
working forces generated across each joint
can be several hundred tonnes, which can
present huge problems for the bearings as
they have to take up the reactive forces
coming back through the joints.”
Pelamis’ first wave energy converter (P1)
was a simpler design with separate hinged
joints. Although this arrangement allowed
useful working space between the axes, it
had to carry high transferred loads and was
unable to manage the combined motions
needed for the P2 configuration. Also, the
bearings themselves were relatively high
friction, affecting efficiency.
“Our engineering team had been trying
to work out a way of overcoming this
problem and eventually came up with the
idea of bringing the axes, or joints,
together,” Woods continues. “However,
this meant a completely new bearing
solution which was able to manage
combined angles in a single package.”
Pelamis turned to Schaeffler for help and
support. Key to the new joint is a low-friction
material developed by Schaeffler. The
modified PTFE fabric liner effectively
eliminates the “stick-slip” effect, allowing
the machine to perform better than standard
bearing materials would have done.
The Pelamis P2 wave power device, which builds on the experience
gained operating the first-generation P1 system (shown above),
relies on novel bearings for its connection structures (below)
“Now that we have been able to put all
the bearings in one place, we have taken a
major technological step forward,” says
Woods. “As well as being a much more
efficient bearing mechanism, the new
design is a self-contained, modular unit. It’s
a bit like being able to take an engine out
of a car in one go; it allows us to improve
our inspection procedures and reduce our
exposure to technological risk.”
The first P2 wave generator, ordered by
Eon, is now nearing completion. Its first
190-tonne tubes were launched in Leith
Docks last month. These will be linked to
form a 180m-long wave power station
capable of generating 750kW which is due
to be deployed at the European Marine
Energy Centre, Orkney, later this year.
Last month, Pelamis and Eon were
awarded £4.8m of funding from the UK
government’s Marine Renewable Proving
Fund, which will allow them to increase the
scope and pace of their trials.
Pelamis has also formed a joint venture
with the Swedish utility Vattenfall with the
aim of installing an array of up to 26 P2
generators off the coast of Shetland, to
generate up to 20MW.
Solid-state memory drives set to oust hard disks from industrial PCs
Solid-state memory drives
(SSDs) are likely to replace
traditional hard disk drives
(HDDs) in industrial PCs
within a decade, a new
forecast suggests. The
market analyst IMS Research
reports that the use of SSDs
in IPCs has already increased
substantially in the past two
years.
“SSDs now offer similar
levels of storage capacity to a
HDD, but without the
rotating parts that can
become vulnerable in
environments where vibration
is common,” points out IMS
senior analyst, Mark Watson.
“The higher level of reliability
offered by SSDs has made
them a popular choice for
critical applications.
“SSDs are currently more
expensive than HDDs,” he
adds, “but, whereas HDDs
have little room for prices to
fall further, SSD prices have
decreased significantly over
the past two years. A 16GB
SSD would have cost an IPC
manufacturer approximately
$200 in 2007. In 2009, the
same component would have
cost closer to $50.”
www.imsresearch.com
AIR-TECH 2010
8-10 June 2010 - NEC - Birmingham
Brochures available NOW!
www.airtech2010.com
In association with
CONTACT:
Ryan Fuller
E: ryan@dfamedia.co.uk
+44 (0)1732 370344
M: 07720 275097
Roberto Tondina
E: roberto@dfamedia.co.uk
+44 (0)1732 370348
M: 07886 119897

Market leading
Temperature and Position sensors!
Infra Red non-contact
Temperature sensors & imagers
Extensive 56 page catalogue describes sensors for almost all
applications and environments: -40 to +3300 °C; upto 250 °C
ambient without cooling; built in laser sighting;
from 1µm to 14 µm; wavelengths for specific materials,
including Metals, Glass, Plastics.
New: Inline fixed mount and handheld thermal imagers.
Market leading specifications at very competitive prices
LVDT, Inductive, Eddy current
and Draw wire sensors
Large range of over 250 different models available from stock!
No matter what your process – we have a sensor
to suit your requirement.
Measurement ranges from 0.5mm to 60m!
Extremely robust and stable in the
most demanding applications.
Call now to request your selection guide
Laser sensors
Using either Laser Triangulation or Time of Flight sensors
enable measurements from single microns to 3Km!
Compact and robust sensors with integrated controllers.
Low cost OEM and entry level models
to highest precision in class.
Select analogue, serial, BUS interfaces.
Largest selection of sensors worldwide.
Visit us: Maintec
2nd - 4th March 2010,
NEC. Stand C3
Call to speak to a sensor expert +44 (0) 151 355 6070
or visit
or visit www.micro-epsilon.co.uk

TECHNOLOGY
IN BRIEF
NSK has developed a new
stainless steel for use in highhumidity,
chemical or hygienic
environments where corrosion
can shorten the lives of rolling
bearings. The ES1 steel is said
to provide better corrosion
resistance and rolling contact
fatigue life than the AISI 440C
steel usually employed in wet
and aggressive environments.
This helps to cut maintenance,
downtime and replacement
bearing costs.
The German chip-maker iC-
Haus has designed a highresolution
sine-to-digital
converter chip with 13-bit realtime
interpolation that supports
the BiSS C protocol which
enables bidirectional data
exchange at the same time as
the cyclic output of
measurement data. The iC-NQC
chip can be used for
incremental or absolute
encoders as well as for
magnetic linear position
measuring systems and optical
linear scales. It offers binary
resolutions from 8–8,192 angle
steps, or decimal resolutions
from 25–25,000 angle steps.
The US motion control specialist
Magnetek has received an
initial production order worth
almost $1.5m for a new liquidcooled
inverter for wind
turbines. The inverters, which
transform the DC output of the
turbines’ generators into utilitygrade
AC power, are aimed at
sealed-structure applications
such as near-shore wind
turbines, or those operating in
corrosive environments or in
high ambient temperatures.
National Instruments is
collaborating with Denso
Robotics to integrate NI
measurement and vision
technology into Denso’s robotic
arms. NI partner ImagingLab
has produced a library of
graphical functions that
communicate with Denso’s
controllers to control robotic
arms via NI’s LabView software.
The library allows one software
environment to control and
integrate every aspect of a
machine, from part-handling to
measurements and vision.
Mobile link delivers field
service invoices ‘in hours’
A DUBLIN-based company which
specialises in vehicle tracking
systems, has branched into field
service management with a
system that automates service
call management, job dispatch,
signature capture and invoicing.
FleetMatics’ Field Service
Manager system allows service
departments to communicate
with their field engineers via
smartphones, PDAs or other
mobile devices.
The company says the
software can boost productivity,
cut overheads, ensure faster
receipt of payments, and make it
easier for field engineers to
complete forms. According to
sales director Derek Bryan, the
system can reduce invoicing
times from an average of six
weeks, “to a matter of hours”.
The software runs on any
handheld device using the
Windows Mobile 6 or Google
Android operating systems. It
connects to the service
department’s back-office system
via the GPRS network, and
appears as a dashboard accessed
via the Web.
From the dashboard, jobs can
be logged and issued to the
engineers. After finishing a job,
the engineer completes the
Metal-free air motor can
be used in MRI scanners
THE GERMAN air motor specialist Deprag has
developed a motor with no metallic
components for use in MRI (magnetic
resonance imaging) scanners where the
presence of metal can interfere with the
machine’s operation.
In response to a request, the company’s
development department has come up with
an air vane motor made entirely from ceramic
and synthetic materials. The 40mm-diameter,
78mm-long pneumatically-driven prototype
achieves an output of 150W at 14,000 rpm.
« FleetMatics’ software can generate a variety of reports on field service operations
relevant forms on their mobile
device and sends the
information back to the service
department for immediate
invoicing.
“Our product is unique,”
Bryan asserts, “as it allows
engineers to get on with the
job and complete the necessary
forms regardless of whether
they are online or not, unlike
most field service management
software solutions, which offer
Web-based forms. This is
critical when service engineers
are in basements or lift shafts,
or where network coverage is
patchy – it means job
processing does not stop even
when the mobile network is
down.” Once the device is back
online, the completed forms
are sent to the service
department.
Field Service Manager is
based on the “cloud
computing” concept, with
customers paying a monthly
subscription of around £70 per
engineer per month. It is
suitable for businesses of all
sizes. Free trials are available.
The industry analyst, Gartner,
predicts that the proportion of
technicians with wireless access
to field service management
systems will increase from 12%
to 40% over the coming two
years.
www.fieldservicemanager.com
Yaskawa’s North
American operation
has developed a free
application that runs
on Apple’s iPhone or
iPod Touch handheld
devices to estimate
the energy savings
that are possible
when using variable
speed drives to
control pumps or
fans. The $avings
Predictor calculates
the savings in five
steps. It is available
from Apple’s iTunes
app store.
IFPEX 2010
8-10 June 2010 - NEC - Birmingham
Brochures available NOW!
www.ifpex2010.com
In association with
CONTACT:
Ryan Fuller
E: ryan@dfamedia.co.uk
+44 (0)1732 370344
M: 07720 275097
Alistair McKay
E: alistair@dfamedia.co.uk
+44 (0)1732 370347
M: 07799 333961

CORPORATE PROFILE
FACT FILE
Company Focus:
From Pioneer to Technical Leader
We keep things moving
For more than seven decades the name
STOBER has stood for innovation in
drive technology, particularly for system
solutions. To be right out in front with
technological leadership, multifaceted
excellence is required in the total drive
solution.
Along with the development of new
products, this statement refers also to
the ability to be able to exactly tailor
solutions to customers’ requirements.
STOBER supplies perfectly matched
components of digital servo drives and
frequency inverters, gear units, motors
and user software. These products are
available as complete assemblies or
separate components.
We work to provide best in class
products and solutions with full backup
of support, training and a worldwide
service network.
Our thinking and activities are always
focused on people – on the one hand
the customer with very individual
requirements and on the other the
employee who requires the competence
and technical knowledge.
This reflects another important corporate
strength of STOBER - a value system
which is consciously nurtured and passed
on from generation to generation.
This efficient company structure with its
close customer relationship and the
innovative products make it possible for
STOBER, as a family business with
approx. 620 employees, to be successful
in the global gearbox and drives market.
Energetically preserve traditions, actively
shape the future: Nothing is as constant at
STOBER as change – and that always with the
promise of using innovations to give
customers an advantage in their highly
competitive markets.
As a system supplier for digital drive
technology, STOBER keeps setting new
standards for integrated hardware and
software products in this market.
The decision to concentrate on three core
target sectors has been made consciously
to be able to operate in the market as a
specialist with a very clear know-how profile.
Company Profile:
Year founded: 1934
Employees: Approx 620 worldwide
Turnover: 80 million € / year
Target Markets::
Packaging
Automation & Robots
Machine Tool
Products:
Servo Motor with Drive Electronics
Frequency Inverters
Geared Motors with Servo/AC Motors
Planetary Gearboxes
Inline
Right Angle
Low Backlash
Shaft and Hollow Bore
Helical Inline and Bevel Gearboxes
Servo and AC Motor compatible
Torques up to 13,000 Nm
ATEX / Food Grades
Controller Software
STOBER DRIVES Ltd. – Essex UK
Martin Preece – Sales Director
www.stober.co.uk
A major accomplishment of STOBER is
that it made its vision a reality by
making the conscious decision not just
to be a leader in gearbox technology.
But couple this with being a leader in
servo motor technology – the
foundation for our success in geared
solutions.
STOBER – WE KEEP THINGS MOVING
Tel: 01992 709710
mail@stober.co.uk
martin.preece@stober.co.uk

MACHINE SAFETY
Three
standards,
one
objective
The delayed demise of EN 954-1 has created
confusion in the world of machine safety.
Dr Martin Payn, conformance officer at Parker
SSD Drives, tries to discern a few simple truths
that will define machine safety from now on.
Legislation and conformance have
mushroomed over the past decade or two,
and have reached a point where many larger
companies employ specialist engineers to keep
on top of things. But the trouble with this is that
these specialists can easily find themselves adrift
from the mainstream engineering issues that
concern their colleagues.
An example of this occurred towards the end
of 2009, when the European Union decided
suddenly to delay withdrawing the ageing EN
954-1 safety standard, even though its successor
had already been introduced. The reason for the
delay wasn’t entirely clear, but one factor was
that many companies had been focusing on the
economic situation and had not completed their
plans for the switchover. In fact, there are two
new standards, EN 13849 and 62061 – the
former for general machines, the latter for
electronic ones – in addition to EN 954-1.
On the face of it, this was a sensible decision
that would be welcomed by the general
engineering populace because it would give
them more time to get ready for the new regime.
However a major problem has arisen from the
delay in that some companies now want to stick
with the existing standard, others want to adopt
the new ones, while a third set don’t know what
to do! Many organisations that had invested
considerable amounts of time and money to
prepare for the changeover, now feel aggrieved.
EN 954 is nearly 20 years old and was due to
be discontinued at the end of 2009. Its
retirement has now been pushed back by two
years to 2011. During this period, engineers will
be able to choose whether to comply with the
old or the new standards.
(EN 62061 is appropriate for electrical and PLC
type applications, while EN 13849 is suitable for
all types of machinery, including pneumatic and
hydraulic. Based on Safety Integration Levels, or
SILs, this is attractive because it is an established
standard with which many engineers are already
familiar. But it should be recognised that while
EN 62061 is appropriate for some applications,
EN 13849 is suitable for all production machinery
work, particularly for those involving drive
systems and sub-systems.)
> Pragmatic approach
As the 2009 deadline approached, many companies
had not decided which route to follow. Instead they
were planning to go with the flow, watching other
companies and taking expert advice if necessary –
but never taking the initiative, in case they were
wrong. In truth, this is a pragmatic approach and
may be the best one for the many organisations
that do not have the resources to develop their own
strategies and to become leaders in the field.
The extension means that, in theory, engineers
can relax and carry on as before until December
2011. But the reality is that those companies that
weren’t ready in December, probably won’t be
ready in two years’ time either. They will wait it
out and hope to find a leader to follow.
Organisations that were ready in December are
pushing to make the changeover now.

The result will be confusion in the market,
with several standards vying for dominance.
This is messy, frustrating and expensive, and
could lead ultimately to lower safety levels
until a single new regime is established.
Before we examine the differences
between the standards, let us first look at
recent history for some guidance. There is
always a transition period before new
standards are introduced to give companies
time to get ready. But while some do
prepare, others are content to follow.
Directives relating to EMC
(electromagnetic compatibility) that were
introduced about 15 years ago, are a good
example. The problem had been around for
years and the legislation sought to
standardise strategies for dealing with it. But
the introduction was delayed for a year,
much as is happening now. Even then the
documentation was open to interpretation,
so initially several approaches emerged.
Over the next two to three years, a
consensus grew slowly, with optimum
solutions evolving and becoming accepted
across most of the industry.
The fact is that industry was only as ready
as it wanted to be, because most people
were waiting to see what others would do.
Thus the fact that there is currently little
enthusiasm for replacing EN 954-1 is to be
expected. There was no real reason for
delaying the matter. However, delayed it has
been, so we must live with that.
thinking uses a new concept, Mean Time
to Failure (Dangerous) – or MTTFd – for
the whole system.
The new EN 13849 concerns itself not
with individual parts or with design
details, but with overall system safety. It
defines the start and end points of
systems and subsystems, and requires
safety between the two.
For example, the start point of a system
may be the on/off button; the end point,
the final mechanism. Between the two,
there could be several components,
including drives, motors, contactors and
so on.It is the overall construct that is
certified under the new regime, not the
individual components.
Significantly, something like a
machine’s control system is defined under
EN 13849 as being a component part of
the machine. This means that the
machine-builder is responsible for its safe
functioning. If there is a problem, the
builder will be the first port of call.
They may be able to prove misuse by
the end-user or an out-of-spec
component. But passing the buck back to
a parts supplier will be much more
difficult, because the system design
should have been able to cope with an
internal malfunction.
EN 13849 defines Mean Time to Failure
(Dangerous) for systems. The critical point
is the word “dangerous”. MTTFd is not
necessarily the same as MTBF. Safe failure
is acceptable; dangerous isn’t. The
standard assumes a machine life of
typically 20 years, including service,
commissioning, repairs and
decommissioning.
Thus the machine-builder must involve
his suppliers from the earliest design
stages, and should choose a reputable
supplier who should be able to maintain
the machine for its proposed lifetime.
The procedure is for the machinebuilder
first to confirm with the end-user
the required Performance Level class for
the complete machine. It is then the
builder’s responsibility to ensure that the
design sticks to this brief, including work
by sub-contractors.
> Machine-builders’ responsibilities
The machine-builder must consider the
reliability of each component, and the
design architecture, accordingly. If
components are likely to fail, they must do
so in a safe manner – there should be
something in the architecture to control this.
In the control system, this is may mean
including failsafe and redundancy
subsystems, but it is possible that a failure
may be deemed non-dangerous.
New safety legislation almost inevitably
terrorises people who have to deal with it.
Fortunately help is at hand. Astute
MACHINE SAFETY
> Significantly different
EN 954 was introduced in 1992 and is now out
of date. It was written at a time when many
technologies and engineering practices were
significantly different from today. At the time,
output contactors were used to isolate motors
from machines so that if people were working
on a machine, it was stopped. An additional
parallel safety circuit allowed inching.
A key change since then is that it has
become far more common to start and stop
machines remotely. In the early 1990s, there
was nearly always a supervising manager
present, using his eyes as final check for
potential problems.
Another issue is that component reliability
has changed markedly.
But perhaps the biggest change has been
driven by EN 954 itself. New rigour has been
brought into calculating mean times
between potentially dangerous failures. This
can now be done so much more reliably, that
it is affecting the way machines are
designed.
In truth, EN 954 now looks dated and
crude. It concerned itself with the design of
circuits, developing architectures that implied
safety. It didn’t really look at component
quality. Products were generally good, but
there was a presumption that they would fail
eventually, so some sort of failsafe or
redundancy had to be built in. Current
The German-developed Sistema software simplifies safety design procedures
suppliers will be up to speed in advance
and, in this case, there is a wonderful
software tool available. Sistema – from
IFA, the German Institute for Occupational
Safety and Insurance – is probably the
designer’s best aid to the subject.
Sistema* will do all the calculations
automatically and simplify design
procedures no end. Significantly, it includes
a comprehensive library of safety-assessed
products and components. If you use these,
safety performance levels can be assured.
There are two conclusions to draw in
relation to the new Machine Safety
directive. Firstly, under EN 13849
responsibility for safety will not be
transferable or avoidable. Secondly,
delaying EN 954’s demise does not mean
people can forget it for a couple of years.
Instead, we have a period in which we
must be prepared to meet both the old
and the new requirements.
D&C
* Sistema can be downloaded from
www.dguv.de/ifa/en/pra/softwa/sistema/index.jsp.
www.drives.co.uk March 2010 19

SHOW NEWS
DRIVES AND CONTROLS EXHIBITION 2010
NEC, Birmingham 8-10 June 2010 www.drives2010.co.uk
Four Primary Sponsors of this year’s Drives & Controls show give a sneak preview of their
plans for the exhibition which takes place at the Birmingham NEC in June.
Micro-Epsilon
At the Drives & Controls Exhibition and
Conference 2010, precision sensor
supplier Micro-Epsilon (UK) Ltd will be
showcasing its complete range of displacement measurement
sensors and non-contact temperature measurement products.
Micro-Epsilon is a global manufacturer of sensors,
headquartered in Germany. The company is proud of its high
investment in R&D, which enables it to continuously develop
innovative, high performance sensor products. The company’s
range of sensors measure displacement, distance, position,
vibration, dimensions, thickness and temperature, using
contact and non-contact techniques, including 2D/3D laser
optical, confocal chromatic, eddy current, capacitive, inductive,
draw-wire/string pot, time-of-flight, non-contact infra-red
thermometers and pyrometers, as well as handheld thermal
imaging cameras.
Micro-Epsilon doesn’t just manufacture sensors. The
company has 35 years’ experience in the industry and so
understands the importance of providing complete solutions
and supporting its customers. Renowned for its expertise in
consulting, development and application of sensors to
complex, customer-specific solutions for measurement,
inspection and automation, Micro-Epsilon’s focus is always on
selling technical advantage to its clients.
Tel : +44 (0) 151 355 6070
www.micro-epsilon.com
Beckhoff
Beckhoff Automation GmbH now has a direct presence in
the UK market with the acquisition of Hayes Control Systems.
Now renamed Beckhoff Automation Ltd, the company has
chosen this year’s Drives & Controls Exhibition as the ideal
showcase to demonstrate the strength of its
product range and its commitment to
growing the UK market.
“Beckhoff is really going to make its
mark at this year’s show” says UK
Managing Director, Stephen Hayes, “We’re
showing the full product range on a scale
never before experienced in the UK”
Fuelled by sustained investment in PC
based automation technology Beckhoff is now the world’s fastest
growing automation company, with offices in 64 countries.
Beckhoff implements open automation systems based on PC
Control technology. The product range covers Industrial PCs,
I/O and Fieldbus Components, Drive Technology and
automation software. Beckhoff represents universal and open
control and automation solutions that are used worldwide in a
wide variety of different applications, ranging from CNCcontrolled
machine tools to intelligent building automation.
Tel : +44 (0) 1491 410539
www.beckhoff.com
HMK
YASKAWA
YASKAWA is a world leader in manufacturing inverter drives,
servo drives, machine controllers and industrial robots. For almost
100 years, the company philosophy has been based on the
principle of highest quality. This philosophy has helped YASKAWA
to become one of the top
global companies in the
field of electrical drive
technology. Its strong
focus on research and
development has yielded
innovations that have
contributed significantly to the success of many industries, among
them machine construction, mining, machine tooling, automotive
construction, packaging and semi-conductors. As supplier of
MOTOMAN branded industrial robots, market leader YASKAWA
is also the world’s biggest robot manufacturer.
www.yaskawa.eu.com
HMK brings three major partners to Drives & Controls 2010.
Partnering HMK on their stand this year are Siemens Energy &
Automation, Schaeffler (UK) and Parker EME. All these major
manufacturers have strong partnerships with HMK and will be
providing product, personnel and technical support to the 10m
x 10m stand.
“The focus this year is hands on product demonstrations”
comments HMK Managing Director Carl Krajewski. “ We can
all get a feel for product on the web, but our customers want
to live and breath the solutions, before investing in our
technology. We feel this is an ideal forum to demonstrate our
integrated product and solutions capabilities”.
Karen Preston of Schaeffler (UK ) adds "Schaeffler UK is
delighted to be joining HMK at this year's Drives & Controls
exhibition. We are fully committed to supporting HMK with
INA linear product solutions.”
European Sales Manager for Parker Electromechanical and
Drives, Nigel Steel says " The opportunity of presenting our
products in conjunction with HMK's expertise at an event such as
Drives and Controls serves to both cement our existing relationship
and provide real added value for our mutual customers."
Meeting Areas are being set aside and delegates and
attendees will be encouraged to make appointments prior to
the show to ensure they get the right amount of time with the
product and application experts.
Tel : +44 (0) 1260 279411
www.hmkdirect.com
20 March 2010 www.drives.co.uk

Drives&Controls
MARCH 2010
MOTORS SUPPLEMENT
Sponsored by
n Tackling stepper motor noise problems
n PM motors cut production costs by 33%
n Replacement motors give oil platforms a lift
n Direct-drive: the road to the future for EVs?
n Integrated drives help to put a cap on wine
n PM motor generates power in city centres

A stepper motor fitted with a
low-profile anti-vibration damper
Resonance, noise and vibration can be
important factors when designing
stepper motor systems. Simon Hunt of
Astrosyn International Technology
outlines the options available to
designers to minimise their effects.
MOTORS
Keep it quiet
Stepper motors are the motor of choice
for a wide variety of applications,
particularly in measurement and
control. They are low-cost, reliable, produce
high torque at low speeds, and have a
simple, rugged construction.
When designing systems using stepper
motors, there are many technical aspects
to take into account. One aspect is the
presence of resonance, noise or vibration,
which have the potential to cause
problems in numerous stepper motor
applications.
Audible noise is not a problem in most
cases, but can be unacceptable in some
applications such as in medical equipment
or theatre lighting systems. Noise
generated by stepper motors arises from
the pulsed driving technique that is
fundamental to their operation. The rotor
oscillation cycle from rest, though rapid
acceleration, deceleration, marginal
overshoot and so on, can generate
audible noise. At high speeds, this can be
accompanied by a high-pitched whine.
Vibration is inherent in all motor
systems and is the result of imbalances in
the moving mechanical parts. It is not
usually a serious problem, although it can
be crucial in, for example, panning
movements for CCTV cameras, or for
image-processing applications and sample
movements in scientific instruments.
In these circumstances, the answer may
be to use a three-phase stepper motor.
Unlike the more common two- or fourphase
motors, three-phase steppers are
inherently smoother and capable of
exceptionally quiet operation with a low
level of vibration. They also have the
advantage of having a smaller step
angles.
Options for minimising stepper motor resonance, noise and vibration
Technique
Choice of motor
Gearing and coupling
Damping
Driver
Options
Standard four-phase or smoother three- or five-phase.
Choice of step angle: 3.6, 1.8, 1.2 or 0.9 degrees.
Sizing to ensure adequate dynamic torque to match load.
Selection of speed / range / pulleys / gears.
Flexible or rigid couplings.
Anti-vibration mounts on front flanges.
Dampers connected to rear shafts.
Full-step, half-step or microstepping modes.
Sophisticated drivers can apply electronic
damping at natural resonant frequencies.
Low-speed torque ripple smoothing.
Command signal smoothing.
Optimisation of driver filtering frequencies and gain.
> Resonance
Resonance is a natural phenomenon
inherent in the torque-speed
characteristics of all stepper motors. In
some circumstances, it can cause a
sudden loss of torque with possible
skipped steps and loss of synchronisation.
It tends to occur mostly a low speeds,
especially in lightly-loaded motors, when
the rotor’s natural frequency oscillations
overlap with the driver stepping
frequency. At higher speeds, it is usually
masked by the drop-off in torque.
In most cases, the effects of resonance
can be eliminated or greatly reduced
using a variety of techniques. These range
from the initial selection of system
parameters such as operating voltage and
step resolution, to the control methods
and algorithms employed in the stepper
drive electronics. If it is not possible to
change the operating parameters enough
to improve performance without
jeopardising the overall design, it may be
possible to use a damper.
Dampers coupled between a motor
and its load will exert a damping torque
when the motor speed is changing, but
produce no drag torque when the motor
speed is steady. They normally consist of a
lightweight housing, which is fixed rigidly
to the motor shaft, and an inertia ring,
which can rotate relative to the housing.
The ring and the housing are isolated
mechanically by a viscous gel or by an
elastomer disc.
By selecting the appropriate damper,
dips in the torque-speed curve can be
eliminated. The only real drawback with
dampers is that they increase the effective
www.drives.co.uk March 2010 23

MOTORS
inertia of the system somewhat, reducing
the maximum acceleration.
Using a different approach, resonance,
as well as vibration and noise, can also be
reduced substantially by mounting the
stepper motor on an
elastomer damper.
Low-profile dampers are thin enough to
be used with standard shaft-length
motors.
> Driver algorithms
In recent years, some motor drivers have
started to incorporate high-level damping
algorithms in their firmware. These
calculate the system’s natural
frequency and apply damping to
the control algorithm. This
improves midrange
stability, allowing
higher speeds and
greater torque
utilisation and
improving settling
times.
Some stepper motor drivers
now incorporate damping
algorithms in their firmware
Other possible firmware functions
include microstep emulation, torque
ripple smoothing and command signal
smoothing. With microstep emulation,
low-resolution systems can still provide
smooth motion as the drive can modify
low-resolution step pulses and create
fine-resolution motion.
All stepper motors have an inherent
low-speed torque ripple that can affect
the motion profile of the motor. By
analysing this ripple, torque-ripple
smoothing can apply a negative harmonic
to negate this affect. This gives the motor
much smoother motion at low speed.
Command signal smoothing can soften
the effect of immediate changes in
velocity and direction, making the motion
of the motor less jerky. An added
advantage is that it can reduce the wear
on mechanical components.
D&C
Spanish submarines talk the torque
THE DORSET-BASED Underwater Systems business of the defence
manufacturer Qinetiq has developed an electrical drive for towed
array handling systems (TAHSs) used to deploy sonar arrays from
submarines.
The electric system offers many advantages over traditional hydraulic
drives in such applications. In particular, they improve reliability,
provide greater installation flexibility, and reduce lifecycle costs. The
TAHS has been designed to meet the needs of navies around the
world for robust systems that take up less space on submarines and
have minimal effect on other onboard systems.
A key to the new system is the use of thin-ring brushless servomotors
to drive large winches directly. The 700mm-diameter frameless torque
motors have separate rotors and stators and can deliver a continuous
stall torque of almost 7kNm and maximum torque approaching 24kNm.
The motors are customised versions of the Megaflex motors
developed by US-based Allied Motion, and supplied to Qintetiq by
Heason Technology. The space-saving motors are designed for directdrive
applications requiring smooth and precise control of large-inertia
or high-torque loads. They offer low cogging torque and a large
diameter-to-length ratio that allows the motor to be integrated with
the driven shaft, eliminating the problems of torsional resonance
Space-saving frameless
torque motors are being
used to drive winches
onboard submaries
associated with flexible couplings,
and backlash associated with gear-driven
systems.
The customisation for the TAHS application involved increasing the
stator and rotor length to 150mm to achieve an enhanced torque
density. The motor characteristics were also modified to maintain
voltage, torque and other critical mechanical and winding constants
that best matched the drive specification. The motor’s large throughhole
helped to maintain a compact design by accommodating
electrical cabling and other services, such as slip ring assemblies.
Qinetiq has sold four of the towed array systems to the Spanish Navy
for use in its S80 class of submarines, which are being built by
Navantia. The multi-million Euro contract was won against strong
international competition. Deliveries will stretch from 2010 to 2012.
The S80 programme could include up to eight submarines in two
batches, with the first submarine scheduled for commissioning in
2013. The second batch could begin by 2014.
24 March 2010 www.drives.co.uk

STRONG BRANDS
ONE GROUP
www.brookcrompton.com

MOTORS
PM upgrade cuts textile
production costs by 33%
A Brazilian textile-maker has cut its costs and raised its productivity by
replacing two-speed motors with permanent-magnet machines.
For more than a century, the
Brazilian company Buettner
has been producing textiles.
It now manufactures more than
two million bath towels every
month at its Santa Catarina
plant for export to more than 40
countries around the world.
Buettner uses ring-spinning
machines to transform raw
cotton into threads of the
required thickness for each
application, and to wind the
threads onto spools. This
equipment uses a catch to
determine what gauge of
thread will be produced. For
each thread thickness, there is
a different diameter catch.
The machines were
previously driven by two-speed
12.7/18.6kW motors –
operating at 1,180 or 1,765
rpm. They had to be stopped
each time the gears need to be
changed, and each new ring
took up to two hours to be
“softened” before spinning
Wafer ovens are on a roll
« Part of
Buettner’s
spinning plant,
showing one of
the inverters
used to control
the new
permanent
magnet motors
could start, resulting in
substantial time losses.
In 2008, Buettner replaced the
two-speed motors on three of its
45 ring-spinning machines by
permanent magnet (PM) motors
supplied by the Brazilian motormaker,
WEG. The invertercontrolled
motors can be varied
with constant torque over a
speed range of 0–1,800 rpm.
The advantages of the
motors soon became evident.
Utilisation of the equipment
increased by 80% while the
process also showed a 33%
reduction in power
consumption and production
costs. The new motors’ softstart
capabilities reduced
machine wear and increased
the reliability of the machines.
Maintenance costs were
reduced to almost zero.
“Our personnel no longer
need to stop the machine to
change gears,” reports Aires
Fantoni, Buettner’s
electrical maintenance
supervisor. “The
operator himself
programs this.”
The
company is
now planning
to install more
of the PM
motors. “In the first
package, we acquired
three WMagnet motors,” says
Fantoni. “Now we’re going to
buy three more. The goal is to
replace all of them within three
years.” D&C
IN 1945, TWO German brothers, Ewald and Wilhelm Steinhoff, started a mechanical engineering
company which soon started to specialise in building ovens for baking flat and round wafer biscuits.
By 1956, they had developed the first automatic oven for baking wafer cornets, and the Duisburgbased
business now supplies customers around the world.
A few years ago, the company decided to redesign the ovens’ drive system to boost its productivity.
The previous vertical shaft drive was replaced by a modern seven-axis servo system.
Six of the axes use compact right-angle servo geared motors supplied by Stober. The digitally
controlled SMS KS motors have a special, space-saving right-angle design. The high-torque, lowbacklash
motors achieve a positive connection by outputting via a shrink disk. A helical geared motor
is used for the oven’s metering pump.
The axes are controlled by Stober’s Posidrive MDS 5000 servo inverters, synchronised via a SSI bus. The
inverters are linked to the main machine controller via Profibus DP. The axes are co-ordinated precisely
using dedicated application software which provides graphic programming of individual applications.
The new drive system allows Steinhoff’s XR70 automatic
wafer oven to bake up to 20,000 wafer rolls per hour –
a considerable increase over its conventionally-driven
predecessor. The new system is also easier to clean,
and offers more flexibility when changing recipes.
≈ The right-angle geared servomotors are helping Steinhoff to
bake up to 20,000 wafer rolls (right) every hour
26 March 2010 www.drives.co.uk

MOTORS
Direct-drive: the road
to the future for EVs?
Driving electric vehicle wheels
directly using internally mounted
permanent magnet motors can
overcome many EV limitations,
argues Dr Sab Safi of SDT Drive
Technology. By eliminating
mechanical transmission
components, this configuration
raises efficiency and reduces
complexity.
Electric vehicles are a fast-growing
niche in the global automotive
market in both the consumer and
commercial sectors. Demand for hybrid
electric vehicles (HEVs) is growing by
around 20% annually, while interest in
zero-emission battery electric vehicles
(EVs) is also rising, but is presently an
under-served market.
The main barriers in the EV market are
cost, performance and availability. One
way of overcoming these limitations is to
use proven, efficient permanent-magnet
(PM) direct-drive technologies. These
gearless systems offer low
implementation and maintenance costs
and could overcome the barriers
currently impeding mass-market EV
adoption. They offer high torque and
power densities in an advanced form
factor, and are ideal for applications that
need high torque at low speeds.
Most current vehicles rely on gearboxes
and other mechanical transmission
systems. Direct-drive motors mounted
inside a vehicle’s wheels can eliminate
the need for gears or mechanical
differentials and their associated energy
losses. These wheel-motors eliminate the
weight and manufacturing complexity of
the engine, transmission, coupling (clutch
or torque converter), drive shaft, and
differential. The net result is lower
vehicle production costs and increased
reliability because there are fewer
complex parts.
Various topologies are available for
direct-drive brushless PM motors – for
example, radial, axial and transversal flux
designs. Radial-flux machines are
particularly suitable for direct-drive
applications because of their high torque
and relatively low speed. They have been
also considered for other transport and
renewable energy applications. Axial-flux
machines have also been used in the both
low-speed direct-drive and high-speed
flywheel applications.
The performance of direct-drive
brushless PM machines depends greatly
on their design and control. Factors that
need to be optimised include the amount
of magnetic material, back-emf shape,
compactness, torque and efficiency.
Traditional EV powertrains consist of
batteries, electric motors with drives, and
transmission gears to the wheels. Each
subsystem converts chemical, electrical or
mechanical energy into different forms,
thus dissipating energy through windage
and friction.
ROTOR TUBE
MAGNET
STATOR
MOUNTING
BEARING
SHAFT
HOUSING
Fig. 1: Direct-drive
wheel-motors transmit
torque directly to the
wheel without any
mechanical couplings
Despite the attractions of direct drives
for EV applications, they suffer from two
major drawbacks – high costs (largely
because of their use of permanent
magnet materials) and small constantpower
regions.
Detailed analysis can accomplish a
thorough understanding of the design
and manufacturing considerations of
vehicle drive systems. Two types of plan
are needed: one to design the electrical
machine; the other to develop the drive
process.
Under the machine design plan, it is
critical to identify and quantify specific
requirements such as cost, noise,
vibration, efficiency, torque per amp,
Advantages of direct-drive PM machines
• Radial/axial flux PM motors and alternators offer exceptional
power densities and efficiencies in a pancake form factors.
• Brushless PM motors increase efficiency, safety and reliability.
• High stall torques allow high performance and rapid acceleration
that is complemented by optimal operation at both low and high speeds.
• Segmented bar winding designs (one or two layers) yield high filling
factors, short end-windings, low leakage inductances, and good cooling.
• Scalable architectures are easily configurable for a wide range
of applications.
• Hall effect commutation allows high torque at low speeds,
or sensorless control of high-speed systems.
Fig. 2: How the various elements in SDT’s
direct-drive system interact
28 March 2010 www.drives.co.uk

continuous and peak power outputs, back-emf, torque ripple,
reliability and robustness. This plan also needs to identify and
define power densities, thermal and electromagnetic designs, and
voltage and current supplies. And, of course, it needs to explore
different machine types (PM, induction, switched reluctance,
synchronous reluctance, and so on).
The drive process development plan needs to define requirements
for rotor and stator manufacturing, and for materials.
Once the product design and process development plans have
been devised, one can then create a matrix that will aid in
matching the machine type to specific requirements.
Figure 1 shows the basic construction of a direct-drive wheelmotor.
The torque is transmitted directly to the wheel without
needing reduction gears or flexible couplings. It therefore
represents a simple drive system that solves problems such as
transmission losses, noise, maintenance, and the mass and volume
of mechanical power transmission systems.
The rotor of the wheel-motor contains the permanent magnets
and is fixed to the rim of the wheel. To reduce the size and mass
of the direct-drive brushless motor and to boost its efficiency,
high-performance Nd-Fe-B rare-earth permanent magnets are
typically used.
The stator is inside the rotor and is fastened to the wheel’s halfshaft.
A pair of ball bearings allows the rim to rotate with respect
to the fixed half-shaft. The motor is fed by a DC/AC converter,
operating at high switching frequencies and connected to the
vehicle battery.
The short lengths and wide magnetic teeth flux paths of directdrive
brushless PM motors contribute to their good performance.
The concentrated winding arrangement, combined with the
shape of the stator teeth, gives a high torque density. The
supporting teeth between each phase have a beneficial effect on
the flux in the stator core, and a cooling effect on the winding
components close to it.
Safi Drive Technology (SDT)* is working on direct-drive PM drive
systems for electric vehicles (see Fig 2). It is focusing its efforts on
the technologies that are critical to making direct-drive machines
competitive with conventional machines in terms of cost,
performance, and reliability.
Direct drive is coming of age. It encompasses the entire spectrum
of drive powers and sizes. High performance is now possible at a
substantially lower cost than conventional gear-motor drive systems.
Direct-drive machines reduce assembly, tuning and maintenance
D&C
operations, as well as reducing operating costs.
* More information is available from
www.sdt-safidrivetechnology.co.uk
Totally
transforming...
...the way you buy motors
At ABB, we bring you products and services to
help you do things in a different way. For
instance, you can now buy ABB industrial
performance motors and a range of matching
drives via the Drives&Controls website. The ABB motors offer long,
reliable service life. The ABB drives are packed with features to help you
control machinery more efficiently. Telephone support is available to
help you make the right selection.
ABB motors and drives are now available
via the Marketplace at www.drives.co.uk
Or simply call us on 07000 MOTORS (that’s 07000 668677)
Power and productivity
for a better world TM

Z
Zone 1 Electric Motors Ltd
Suppliers of Atex motors
Agents for euromotori s.r.l
Manufacturers of the following Atex motors:-
Zone 1 EXD 11 2G Gas groups 11b & 11c also 2GD
Single phase, 3 phase, 3 phase 2 speed and brake motors
Zone 2 ExnA 11 T3 IP65 11 3G, 3 phase motors
Zone 21 ExtD A21 IP65 135°c 11 2D 3 phase motors
Zone 22 ExtD A22 IP55 155°c 11 3D 3 phase motors
All on short delivery times!
Brochures available on request
Picture shows a single phase EXD
flameproof motor with capacitors
encased on the body of the motor
For more details contact Pat Richardson on:-
T: 01656 722395 M: 07501721827 F: 05603111885
E: zone1electricmotors@btconnect.com
euromotori website: www.euromotori.it
www.zone1electricmotors.com

Cutting the cap
to fit the bottle
MOTORS
To most people, the foil caps on wine bottles that prevent the corks from being
damaged, are a mere irritation. But as Paul Williams, senior UK sales engineer with
maxon motor explains, the caps take a complex level of technology to create.
Making a wine bottle cap – the shrink-wrapped sheath that
covers the cork of a new bottle – seems like a relatively
straightforward task. What is simple once, however,
becomes complicated when it needs to be done millions of times,
as rapidly as possible.
The process involves several stages – each of which contains
many sub-processes. In many factories, the film is shrunk over the
bottleneck and cap. An optical reader then detects a mark on a
reel-fed band which initiates a relative position move. A digital
signal then activates a pair of scissors, which cut the band. All of
this occurs at a rate of at least three working cycles a second.
This is easier said than done. In particular, the job of cutting the
shrink-wrapped caps to the right size while still on the bottle
involves a host of different processes, each of which requires
precision. These include controlling local inputs and outputs,
selecting programs, signalling starts and stops, operating light
barriers, controlling the scissors, and flagging up errors.
As with most industrial technologies, it is important that the
mechanisms that drive these processes are as reliable as possible. A
breakdown doesn’t just cost money for a new part – the far
greater cost is in lost time, and therefore production.
One innovative way of achieving this is to implement a compact
drive system combining a motor, controller and encoder in one
low-maintenance box. Localising intelligence and power keeps
things simple, while having fewer moving parts means fewer
breakable pieces.
However, this can only be effective if
component sizes are small enough. Extra
machinery clogs workspaces, and results in
inefficient operations and expensive wear
and tear. Until recently, even “compact”
drive systems have been too cumbersome to
be practical.
Now, however, maxon’s MCD EPOS
compact drive has opened new possibilities
by working in a space not much larger than
the bottle caps themselves. It combines a
motor, controller and encoder in a smaller
volume than a controller alone would have
occupied in the past. A few years ago this
combination of parts would have been bulky and
inefficient, but the integrated drive can now replace the controller
that once commanded the movements of the manufacturing line
The drive is powered by a 60W brushless DC motor combined
with a ceramic gearhead (with a reduction ratio of 18:1). The drive
fits below the feeding roll and a toothed belt transmits the torque
from the gearhead to the roll with an additional reduction of 2:1.
The IP54-protected drive is housed in tough aluminium casing
and all internal wiring is vibration-proof, to survive operation on
the factory floor. A modular design means that as upgrades
become available in future, it will be easy to take any component
out of the compact drive and plug in a newer one.
D&C
The compact integrated drive controls the
bottle-capping process from a box not
much bigger than the caps themselves.
www.drives.co.uk March 2010 31

New additions to the
FAMILY
Teco Flameproof Motor
TECO’S NEW RANGE of FLAMEPROOF
motors have been certified by Baseefa in the
UK to ATEX/IECEx
The new Exd IIB T4 series offer rugged motors
that are reliable, cost efficient and have the following
impressive benefits:
• EFF1 and EFF2 both available
• IP55 enclosure with non-contact seal
• All Cast Iron frame
• Exd IIB T4
• Exde IIC T4
• Class F insulation with Class B rise
• Oversize terminal box with metric threads
• Ambient temperature range –20°C to +50°C
• Tested according to EN 60079-0 EN 60079-1
EN60079-7 IEC 60079-0 IEC 60079-1 IEC 6009-7
• Stainless Steel nameplate
• PTC150 thermistors fitted in all frame sizes
For detailed information on our products
please contact our sales office
MV Softstarters IP65 Inverters Inverters with built in PLC LV motors to 500kW HV motors up to 13.8kV
TECO ELECTRIC EUROPE LIMITED
T + 44 (0)161 877 8025
F +44 (0)161 877 8030
E enquiries@teco.co.uk
www.teco.co.uk

PM motor generates interest in novel wind turbine
A PERMANENT MAGNET motor is being used to
generate power in an innovative wind turbine
that is designed to capture energy in built-up
areas that are unsuitable for conventional
turbines. The vertical-axis turbine, developed
by London-based Quietrevolution, operates
effectively in areas where wind speeds are
low and where the wind direction changes
frequently.
MOTORS
At 5m high and 3m in diameter, the helicalshaped
turbine is compact and easy to mount
on buildings to generate some of their power
and to reduce their consumption from the
grid. It is designed to cope with turbulent
winds and is claimed to produce minimal
noise and vibration. With just one moving
part, maintenance can be limited to an annual
inspection.
The turbine rotates an ABB permanent magnet
(PM) motor linked to an industrial drive acting
in a regenerative mode that converts the
energy and exports it to the local grid.
Quietrevolution’s vertical-axis wind turbines rely on permanent magnet motors acting as generators
The synchronous PM motors are designed to
drive low-speed applications directly, without
a gearbox. They have to be used with
frequency converters, and ABB has
developed special software that allows its
drives to control the motors.
In the turbine application, the software allows
the motor to change speed rapidly – during
wind gusts, for example – for improved
efficiency.
“The sensorless control of the permanent
magnet generators is a key benefit to the
turbine application because of its simplicity
and low cost,” explains Quietrevolution’s
founder and chief technical officer, Richard
Cochrane. “The drive allows us to switch
seamlessly from regeneration to drawing
power, as well as giving accurate speed
control. This produces the maximum amount
of energy from gusty and turbulent winds
which are prevalent in urban environments.”
The turbine’s drives incorporate ABB’s DTC
(direct torque control) technology. “DTC is
crucial to the operation of the turbine as it
allows us to effectively vary the rotor speed
to optimise performance at any given wind
speed,” says Cochrane. “Another useful
feature of the ABB drive is the simple
communications protocols, which are a costeffective
way to control and report on the
performance of the system via our Web
interface.”
The Hillhead 2010 website is now part
of Agg-Net.com – The Aggregates &
Recycling Information Network.

CORPORATE PROFILE
FACT FILE
Customised
motors
LAFERT ELECTRIC MOTORS, a member of the
Lafert Group, offers engineered solutions that
enable OEM’s to build machines with superior
performance in their particular market to give them
a competitive advantage or even make it possible
to manufacture them at all.
The Lafert Group focuses on those applications
where off-the-shelf product is not the ideal
solution. This is underlined by the fact that of
Lafert’s total motor output of €90 million around
70% is of a non-standard design.
Customised motors are based upon the flexibility
of the company’s multi-mount standard range. This
includes a comprehensive range of single phase, three
phase and Brake motors. All in various application
configurations spanning frame sizes 56-315 and
power ratings 0.09kW - 200kW. Also available are
IE2 high efficiency, Brushless servo motors; and CSA
and UL approved motors.
More recently Lafert have pioneered the
development of the High Performance (HP) motor.
This hybrid version of the permanent magnet and
standard induction motor gives extremely high
efficiencies and can give weight and space savings
by offering reduced frame sizes. Suitable for the
volume OEM market Lafert can also offer tailor made
mechanical designs as well as options for the drive
from Lafert Drives.
Lafert has five manufacturing centres and its
products are supported worldwide by Group
companies in North America, Europe, Far East and
Australasia.
Main Areas of Activity:
Lafert Electric Motors’ principal
objective is to provide the specific
motor solution for each of our
customers’ needs.
Product ranges:
Single and 3-phase AC motors with
various pole options in frame sizes
from 56-315 and powers from 0.09-
200kW; Brake motors; IE2 high
efficiency motors; Smoke extraction;
Progressive motors; Brushless AC servo
motors; Stainless steel motors;
Aluminium 3-phase motors; Cast iron
3-phase motors and Stainless motors:
Lift motors
Parent company:
Lafert S.pA., Venice, Italy
Group turnover: €90million
Founded: 1962
Lafert Electric Motors Ltd
Electra House, Electra Way,
Crewe. CW1 6GL
T: 01270 270022
E: lafertuk@lafert.com
www.lafert.com
See us on
Stand D3706
Drives & Controls 2010
NEC, Birmingham
8-10 June 2010
The HP series, a radical change
in motor drive technology
• Increased control
• Increased efficiency
• Reduced size and weight
Lafert Electric Motors Ltd Tel: +44 (0)1270 270 022
Email: lafertuk@lafert.com www.lafert.com

Replacement motors
give oil platforms a lift
MANY OIL PLATFORMS in service around
the world were built more than a quarter
of a century ago and are still raised and
lowered using their original
electromechanical jacking systems with
integrated brake motors. These platforms
are typically equipped with 72 jacking
motors – 24 on each of their three
By replacing old jacking motors on its
platforms, Maersk Drilling is saving money
and avoiding maintenance problems
elevating and lowering legs.
In the severe environments in which oil
platforms have to operate, considerable
maintenance is needed over the working
lives of the brake motors. But insurance
companies only permit a maximum of
two of the 72 motors to be out of service
during jacking operations.
The oil industry faces a problem when it
comes to repairing or replacing worn-out
jacking motors – the original jacking
motors are often no longer produced, and
it is difficult to obtain spare parts for them
(and even if they can be found, the parts
are expensive). These difficulties can result
in unstable jacking and this wastes money.
One of the global leaders in drilling
operations, Maersk Drilling was looking
for a sustainable, future-proof answer to
the problems it was experiencing with its
old jacking systems. It got in touch with a
Danish electromechanical service
contractor, Olesen & Jensen, which
specialises in servicing the offshore
industry.
Esbjerg–based Olesen & Jensen is
ATEX-certified to perform work on
electric equipment where there is a
danger of explosion, such as in the oil
and petrol gas industry.
Working with Leroy-Somer Denmark,
Olesen & Jensen developed an
interchangeable motor which matches
the original jacking motors in terms of
their mechanical and electrical design.
The new motors conform accurately to
the oil platforms’ original jacking
construction, allowing fast and effective
replacement.
To date, these motors have replaced
ageing jacking motors on at least five
platforms and the jacking systems seem
to be working well with the replacement
motors. The contractors recommend
replacing all 24 of the jacking motors on
each elevating/lowering leg at the same
time. This ensures that they all run at the
same speed and avoids possible
overloading of the motors.
Leroy-Somer Denmark has identified
444 older oil platforms in use around the
world that might need to have their
jacking motors replaced.
MOTORS
R
®
Reliance
Precision Mechatronics LLP
Quality Range of Precision Couplings
Alongside high performance Reli-a-Flex ®
couplings, Reliance nowoffers a range
of Spiral Beam, Flexible Disc and Curved
Jawcouplings at very competitive prices.
Selected couplings available for
next day delivery.
Call our Sales Team on+44 (0) 1484 601002
Visit us at www.rpmechatronics.co.uk
Unique Solutions from Proven Concepts
www.drives.co.uk March 2010 35

BRAKES & COUPLINGS
Going with the flow
Compact oil-immersed hydraulic brakes are playing a key role
in a novel UK-developed renewable energy device which
will sit on the seabed capturing energy from tidal flows.
ABritish company is
developing a power
generator that will sit on the seabed
extracting energy from tidal streams in a
predictable and economic way, without having
the visual impact of other renewable energy
technologies, such as wind turbines. The
Rotech Tidal Turbine is being developed by
Aberdeen-based Rotech Engineering, and
marketed by Glasgow-based Lunar Energy,
which has an exclusive global license to
commercialise the technology.
The 20m-high RTT is designed to operate
completely submerged and to be
connected to an on-shore electrical
substation via subsea cable. A 1MW
prototype, reaching the final stages of
construction, will produce enough
electricity to power around 800 homes. The
1MW system contains an 11.5m-diameter
turbine and has a ballasted weight of more
than 2,500 tonnes. Lunar is negotiating with
several energy companies about large
projects based on the RTT.
For example, it has an agreement with
Korean Midland Power to create a 300-
turbine field off the South Korean coast to
provide 300MW of renewable energy to the
utility by December 2015. The tidal turbines
will be built and installed by Hyundai Samho
Heavy Industries, with Rotech providing
design optimisation and specialist
components.
The RTT is a gravity-based system with a
central “cassette” that contains a generator,
hydraulic pump, brake and motors. The
cassette is removable for operational and
maintenance purposes. It uses the venturi
effect to capture the energy from tidal flows
so efficiently so that its performance is
competitive with wind turbines and
considerably less controversial in visual terms.
The impellers are mounted on a central
shaft within the cassette that incorporates an
in-line, fixed-displacement hydraulic pump
and an oil-immersed hydraulic brake, all
within a sealed pod. To maximise the flow
efficiency through the turbine, the generator
is mounted outside of the flow tube. The
T: +44 (0) 121 321 2144
F: +44 (0) 121 355 5045
E: yvonne.g@lusoelectronics.com
W: www.lusoelectronics.com
Just appointed
new distributor of
Warner
Electric
An Altra Industrial Motion Company
• Electro Magnetic Clutches & Brakes
• Tensioning Systems
• Sensors & Switches
• Safety Products
• Overrunning, Indexing
& Backstopping Clutches
• Wrap Spring Clutches
& Clutch/Brakes
T: +44 (0) 121 321 2144 F: +44 (0) 121 355 5045 W: www.lusoelectronics.com

hydraulic pump drives the generator via two
hydraulic swash motors in an efficient
closed-loop system.
The brake is crucial to the design, allowing
the cassette to be manufactured, handled and
installed safely while remaining separate from
the surrounding tube and seabed mounting.
The brake provides a full-stop mechanism to
prevent the central shaft and impellers from
turning during construction, installation and
maintenance. Mounting the brake inline with
the shaft meant that it had to fit within a
diameter dictated by the hydraulic pump
motor. This, in turn, meant that it had to
provide an extremely high braking force from
an extremely compact envelope.
The brake also provides an emergencystop
function and has to be powerful
enough to stop the turbine within seconds
when it is working at full-speed – and to do
this repeatedly. The brake remains on when
hydraulic power is not being supplied.
Rotech’s engineers worked closely with
Wichita Clutch (part of Altra Industrial
Motion) to create the brake for the RTT. “The
challenge we faced was to source a braking
device that would withstand the unique
rigours of spending its entire operating life
undersea,” explains Martin Graham, the
engineer in charge of the project.
The brake was not an off-the-shelf
product, although it was based on an
existing Wichita technology – a compact,
oil-immersed brake that could be mounted
inline with the shaft without restricting flow
through the turbine, thus maximising its
generating efficiency.
Cellulosic linings, combined with a large
volume of cooling oil within the housing,
result in a brake capable of dealing with
about 13 Megajoules of stopping energy. It
can provide a braking torque of more than a
million Newton-metres. Rotech developed
an innovative sealing system to balance the
oil pressure within the brake and to work
with the cassette design that has just one
dynamic seal on the whole shaft, including
the bearing system.
The 1MW prototype RTT has been
developed with the assistance of phased
funding from the DTI. The control system and
hydraulics are being assembled and tested,
and the generator synchronised with a
simulated power grid. D&C
BRAKES & COUPLINGS
Arrays of Rotech’s tidal turbines will be mounted on the seabed. For ease
of construction and maintenance, the generator, hydraulic pump, brake and
motors, will be contained in a “cassette” that is inserted into the main frame
T: +44 (0) 121 321 2144
F: +44 (0) 121 355 5045
E: yvonne.g@lusoelectronics.com
W: www.lusoelectronics.com
Just appointed
new distributor of
W
TB Wood’s
Incorporated
An Altra Industrial Motion Company
Wide range of couplings:-
• Duraflex
• Sureflex
• Grid Couplings
• Gear Coulings
T: +44 (0) 121 321 2144 F: +44 (0) 121 355 5045 W: www.lusoelectronics.com

BRAKES & COUPLINGS
Torque-limiting bush reduces
blow-moulding downtime
PET (polyethylene terephtalate) is increasingly used for beverage
containers because it is light, unbreakable, stable and taste-free.
It is also recyclable, and thus environmentally friendly.
PET bottles are produced on blow-moulding machines that
start with a “preform” that is pre-heated to achieve elasticity. The
preforms are then transported using conveyors and feed wheels
into the blow moulds. Depending on the type of machine, there
can be between four and 36 of these blow moulds on a rotating
assembly. The materials used are mainly aluminium to reduce
inertia and to achieve higher speeds – it is possible to produce up
to 72,000 bottles per hour.
The individual blow moulds are opened and closed by lever
arms. Traditionally, one of the leading global manufacturers of
PET blow-moulding machines has clamped the lever arms
mechanically to their actuators using a locking bush with seven
screws, which had to be torque-tightened in sequence. As well as
being time-consuming, this technique risked damaging the
machine.
This company has now replaced the mechanical clamping
elements by novel, hydraulic-based bushes that connect the lever
arms to the actuator. These bushes allow the shaft to slip if there
is a stuck preform or bottle. This avoids damage to the machine
and reduces downtime. Resetting is quick and simple
compared to the previous
R
mechanical clamping system.
Under normal operation, the
new bush acts as a backlash-free
connection. But if there is a jam
from a misfeed, the bush slips at a
«
The hydraulically-operated bushes (on the right, above, and in
close-up in the image on the left) have cut downtime and reduced
the risk of damage to the bottle-moulding machines
predetermined torque without damaging the actuator shaft.
Once the machine operators have cleared the jam, it takes a few
seconds to reposition the mould by loosening the bush’s single
screw. As well as minimising costly downtime, the low and even
surface pressures of the new system avoid shaft damage and help
to achieve a consistent slip torque.
The bush being used in the PET application is the selfcontained
ETP-Express system that connects shafts to hubs
without keyways. A single radial fixing screw pressurises an
internal hydraulic chamber and expands the walls, gripping the
hub and shaft. Accurate positioning both radially and axially is
easy as the screw is tightened. Once the screw reaches a travel
stop, the bush is set and full torque is transmitted by friction
evenly over the surfaces. The bushes, made by Swedish-based
ETP Transmission, are available in the UK from Techdrives.
Intelligent Solutions In Power Transmission
An increasing range of quality industrial disc brakes
Excellent technical support
3D Solid models available
Most models X-Stock
40 years experience
RINGSPANN (U.K.) Ltd.
Telephone: 01234 342511
Telefax: 01234 217322
info@ringspann.co.uk
www.ringspann.com
Industrial Disc Brakes Torque Limiters Couplings Shaft-Hub-Connections Freewheels Force Limiters Irreversible Locks
38 March 2010 www.drives.co.uk

See us on
Stand D3911
Drives & Controls 2010
“Hidden Protection!”
NEC, Birmingham
8-10 June 2010
Benefits
• Easy Installation
• Standard IEC / NEMA Flanges
• Load Bearing Capability
• Accurate Torque Sensing
• Integrated Limit Switch
• UK Based Stocks
EAS ® -HTL ®
Housed Torque Limiter
Applications
The Mayr HTL can be
installed into almost any
Motor / Gearbox drive
system offering accurate
and reliable overload
protection.
www.mayr.co.uk
Mayr Transmissions Ltd.
Valley Road Business Park,
Keighley, West Yorkshire, BD21 4LZ
T: 01535 663900 F: 01535 663261
E: sales@mayr.co.uk
ATEX
approved
CENTAFLEX-A
SERIES
Lightweight,
compact design
Eliminates 4-way
misalignment
High performance, high
speed power transmission
couplings from Centa
Highly versatile and
flexible couplings for
every application
Easy to fit and
maintenance free
Fits almost all diesel
and electric drives
Quiet and
vibration free
LEADING BY INNOVATION
Overcomes torsional,
radial, angular and
axial misalignment
Centa Transmissions Limited
Thackley Court
Thackley Old Road, Shipley
Bradford BD18 1BW
T: +44 (0) 1274 531034
E: post@centa-uk.co.uk
V ISIT
WWW.CENTADRIVES.CO.UK

ADVERTORIAL
KTR Couplings Ltd
Since 1959, KTR Kupplungstechnik GmbH
has gone from being a relatively small
manufacturer in Germany, to having 20 wellestablished
subsidiaries around the world,
making it one of the only coupling
manufacturers with its own global sales and
service network, research and development
facilities and in house engineering expertise.
K KTR Couplings Ltd, the UK subsidiary
based in Sheffield, opened to provide a
better service and more local contact to its
existing and future customer base in the UK
and Ireland.
KTR are now one of the largest suppliers
of mechanical couplings in the world, and
saw this 50 year milestone as the perfect
opportunity to modernise their corporate
image in the hope that customers around
the world will easily identify the KTR brand
and realise just how established the
company is.
Two new products will be launched at this
year’s Drives and Controls Exhibition which
were first seen at Hannover 2009; the
revolutionary all-steel gear coupling
GEAREX ® and the OAC/OPC range of oil/air
coolers which completes the KTR product
line of heat exchangers.
GEAREX ® is an all-steel AGMA standard
flanged gear coupling with a compact design
ensuring a long service life and high degree
of operating safety. Its crowned gear splines
along with permanent grease lubrication are
key design features resulting in minimal wear
of the coupling when dealing with axial,
radial and angular shaft displacements.
With 16 sizes available, GEAREX ® covers a
torque range from 930 Nm to 720,000 Nm
allowing for a very high power density with
compact dimensions making it an ideal
choice for a wide range of applications such
as pump drives, compressors, steel mills and
many more.
Other areas of expertise include hydraulic
components – including bellhousings,
damping elements, oil coolers and tank
heaters; steel tanks – either standard or
bespoke design; torque limiters, torque
measurement and clamping elements.
KTR Couplings Ltd
Robert House, Unit 7
Acorn Business Park
Woodseats Close
Sheffield S8 S8 0TB 0TB
T Tel: +44 (0)114 258 7757
Fax: +44 (0)114 258 7740
Email: ktr-uk@ktr.com
Web: www.ktr.com
See us on
Stand D3406
Drives & Controls 2010
NEC, Birmingham
8-10 June 2010

Ipswich-based Ashe Converting
Equipment has set a new standard for
film-slitting machinery with the launch
of its Jade series, which incorporates
numerous innovative design features to
address problems associated with
conventional machines.
Ashe, founded in 1976, specialises in
designing, developing and building
slitting and rewinding machinery for use
in the film, paper and web industries.
With full in-house engineering and
manufacturing expertise, and a strong
background in control systems, the
company works hard to develop
products that are at the cutting edge of
technology.
The development of the Jade series
was typical of this ethos. “During the
design phase of the machine, we
approached as many different user
companies as we could and asked them
to identify the main problems of existing
types of machinery,” reports chief
engineer Keith Fordham. “The results
were, commonly: set-up times; the
reliability of different parts of the
machine; and initial costs. We set about
addressing all of these issues, and the
Ashe’s Jade slitter/rewinder machines are
claimed to eliminate creasing and wrinkling,
even on the most sensitive of materials
High-speed slitting
is no wind-up
An Ipswich winding equipment
specialist has developed a machine for
slitting and rewinding thin films that
operates reliably at speeds of up to 1.2km
per minute. This performance has been
achieved using novel design concepts including
rewind stations that move on precision linear slides.
result is the Jade series. The machine is
easy to use, requires lower capital outlay,
and guarantees production of highquality
rewind rolls.”
The structure, web path, tension
control and rewind process are designed
around the slitting process and Ashe
describes the machine as acting
effectively like a giant knife-holder. The
tension control affects the slitting, the
rewind quality, and the web tracking
through the machine. When the machine
accelerates to its top speed of 20m/s, all
of the rollers affect the tension and have
to be able to accelerate several hundred
kg precisely up to 1,000 rpm. Control is
equally vital during the slowing-down
process which involves rewinding the
materials at low tension while
maintaining edge profiles accurate to
tens of microns.
The Jade machine has been designed to
use several different winding methods,
making it extremely versatile. The three
main methods are: centre winding;
surface winding; and combined centre
and surface winding. This flexibility is
achieved using an unconventional rewind
arm that replicates the winding functions
of conventional machines but without the
cumbersome lay-on rollers. A vacuum
drive roller isolates the unwind tension,
while twin, individually driven, surface
drive rollers transport the tensioncontrolled
web directly to the rewind
stations. Perfect tension isolation is said to
eliminate creasing and wrinkling, even on
the most sensitive of materials.
As the rewind roll increases in
diameter, the rewind stations – mounted
on precision roller slides supplied by
Matara – move independently and
horizontally away from the lay-on/surface
rollers. Contact is maintained through
the diameter build-up, which ensures
excellent finished roll quality.
Tension isolation is controlled through a
vacuum pull roller, rather than the nip
rollers and S-wraps that might
conventionally be used. The
precision linear tracking of
these rewind stations
ensures perfect roll quality.
The linear tracking of the
arm, designed for rewind
diameters of up to 1.2m,
means that different
diameters can be wound on
the same rewind beam.
With the conventional lay-on
rollers eliminated, the machine
uses two common surface rollers. Both
are driven at line speed and operate as
centre winders. If needed, the speed of
these rollers can be trimmed accurately
so that the machine can also induce
surface tension. Lay-on pressure is
profiled through the arm, and controlled
via Matara pneumatic cylinders. Pressure
is adjusted via the machine’s HMI.
Because there is no changing of lay-on
rollers, downtime is reduced significantly
when changing a slit pattern.
The machine’s design eliminates the
need for hydraulics, and makes use of
pneumatics in areas such as adjusting and
maintaining surface tension. Careful
design has eliminated multiple pneumatic
connection lines and trailing electrical
cables, minimising the risk of these being
trodden on, pulled out or otherwise
disconnected. The result is a reliable
machine with a compact footprint.
Finished reel unloading is operated
electrically. Once the arms have been
retracted to the unload position, Matara
precision screwjacks rotate the beam
through 90 degrees.
Ashe’s Jade series has brought new
slitting and winding principles to the
plastic film industry. The slitter/rewinders
offer the benefits of optimised finish roll
quality, along with high speeds and
D&C
minimal downtime.
MACHINE BUIDLING
www.drives.co.uk March 2010 41

MACHINE BUIDLING
The Nottingham-based automation
specialist TQC has developed an
innovative machine for pressing preformed
metal inserts into the plastic bodies
of automotive throttle mouldings. The
machine automates the entire process –
including checking the insert depth – and
uses closed-loop position and torque servocontrol
to ensure consistent accuracy and
quality. A novel dual-channel architecture
allows two throttle mouldings to be
processed simultaneously to achieve a
throughput of one moulding every 35
seconds.
TQC developed the machine for the
Telford-based automotive component
manufacturer, Mahle Filter Systems UK. It
handles the cold insertion of three steel
compression limiters and the hot insertion
of six threaded brass inserts, in each of the
two throttle body mouldings.
“We were up against considerable
competition from companies in Asia for
this particular machine contract,” recalls
TQC sales engineer, Mike Gordon. “But
whereas our competitors proposed using
individual, physically separate insertion
mechanisms for each phase of the process,
we developed an innovative four-axis
The novel dual-channel architecture allows two throttle mouldings to be processed
simultaneously for a throughput of one moulding every 35 seconds
Pressing home
the advantage
A UK automotive parts supplier is using a servo-controlled
insertion machine to speed up the production of throttle
assemblies. A sophisticated closed-loop control system
ensures that the hot insertion process operates precisely.
servo-controlled manipulator that enables
all 12 hot insertion operations to be
performed, two at a time, consecutively
into a pair of static throttle body
mouldings.
“This approach provides several key
competitive advantages,” he adds. “It limits
the amount of workpiece movement that is
needed and thereby helps to minimise
machine process time, and has enabled us
to create a very compact machine that
takes up little space on the factory floor.”
The freestanding machine operates
autonomously. The operator first loads
components onto fixtures at
the front of the machine,
and then initiates the
insertion process.
Poka-yoke sensing
of component
features ensures
that the operator
is alerted
immediately if
there are any
missing or
misoriented
components. Provided
that all of the parts are
The machine-builder
TQC uses a 3D SolidWorks CAD
system for mechanical design work.
The image shows one of the throttle
assemblies, highlighting its inserts.
present, the machine cycle begins.
First, a twin-headed press system pushes
home three steel compression limiters per
part and verifies their presence and correct
position. The fixture is then retracted along
a pair of linear guides into the hot insertion
station. The threaded inserts are fed from a
twin-track vibratory bowl feeder to two
temperature-controlled heater blocks,
where they are heated to around 350°C
and queued, ready for use.
The hot inserts are transferred in pairs
from the heater blocks to the throttle
mouldings by an overhead twin Z-axis pickand-place
system, using Festo DGE
actuators for X-Y positioning. The gripper
fingers are driven by Festo’s HGPP
pneumatic parallel grippers which
incorporate sensors for position feedback.
The vertical Z-axis movement of the
gripper fingers is controlled by a Festo
DNCE servomotor-driven electric cylinder,
paired with a CMMP motor controller. The
controller uses a combination of torque and
position control modes, enabling the
downward speed and the force of the
gripper fingers to be varied to match the
melt rate of the plastic, as the heated insert
is pressed into the throttle moulding.
Three inserts are pressed successively into
the top face of each throttle moulding. The
support fixture is then rotated through 180
degrees by a pneumatically-powered Festo
DSM-B swivel module, so that three more
inserts can be pressed into the moulding's
bottom face.
Once all of the brass inserts have been
pressed into the throttle mouldings, they
are checked automatically for correct
insertion depth, with a tolerance range
from flush to 0.2mm proud. The fixture is
then returned to the operator who fits a
seal manually to each moulding. The
machine verifies the position of the seals
and, providing that everything is correct,
stamps a pass mark on each completed
throttle assembly.
The machine is controlled by a Mitsubishi
PLC which communicates with the various
servo controllers and drives via Profibus-DP.
All of the operator commands and
feedback are handled by a front-panel
Mitsubishi colour touchscreen. The
machine is EN 954-1 safety
compliant, and uses light
guarding and autoshutdown
procedures to
protect the operator
from exposure to
moving parts.
TQC used
SolidWorks 3D for the
mechanical design work
and used CAD models of
the linear and rotary
actuators, supplied
by Festo.
D&C
42 March 2010 www.drives.co.uk

Extrasensory
The LSIS 400i heralds the arrival of a smarter
‘Smart’ camera from Leuze electronic ‘the sensor people’
Extremely bright and homogeneous illumination.
Motorized focus adjustment in an IP65 housing.
Easy setup using inbuilt WebConfig via an i nternet
browser. No extra software or hardware required.
Superb object detection and discrimin ation using
multifaceted specialised blob analysis.
Have a look at the best range of
optical detection, identifi c ation
and protection solutions.
For more information call 01480 408 500 or go to www.Leuze.co.uk
Koyo has been a world leader in bearing technology since 1921.
In this world of global competition it is comforting to know that UK
investment and manufacturing is still an integral part of our global strategy.
In all types of environment Koyo has proven its expertise and ability to
understand and deliver bearing technology to the highest possible
standards. As part of the Toyota group of companies we only accept the
highest quality, reliability and performance from our products.
UK manufacturers can rely on Koyo; there is no longer the need to choose
between quality and competitive pricing - with Koyo you always get both!
KOYO MANUFACTURE OVER 100,000 VARIATIONS
OF BALL AND ROLLER BEARINGS
UK SALES & DISTRIBUTION (MILTON KEYNES)
UK MANUFACTURING FACILITIES (BARNSLEY)
...setting the world in motion
Whitehall Avenue, Kingston,
Milton Keynes MK10 0AX
t: 01908 289 319 f: 01908 289 322
www.koyo.co.uk/bearings

MACHINE BUIDLING
Low-heat motor starters meet the knead
Kneading dough is an essential part of the
bread-making process, as it helps to separate
the flour particles so that they can adsorb
water more easily. This shortens the proving
time, and has a major effect on the quality of
the bread. However, because kneading is
essentially a rubbing process, frictional heating
raises the temperature of the dough, typically
by around 1ºC for every minute of kneading.
Ideally, the dough should not be heated at
this stage, so it is desirable for kneading to
be carried out as quickly as possible. This is
exactly what the kneading machines
produced by Diosna Dierks & Sohne of
Osnabrück in Germany are designed to
achieve. Although the company has been
making machines for almost a century, it
prides itself on making the best use of
modern technology.
Diosna’s machines vary considerably in size
and specification, with some versions having
control systems integrated into the main body
of the machine, and others having separate
control cabinets. In either case, space is at a
premium so compact control devices are
essential.
Most of the machines use two-speed stardelta
starters for the main drive, because
these can deliver the high torque needed to
start the kneaders moving through the viscous
dough. Four contactors are needed to
implement this arrangement. The machines
also have two further drives for the tub and
hydraulic pumps. For these, direct-on-line
starting is usually used.
On its latest machines, Diosna is using Eaton
Moeller’s PKZ motor protection circuit
Diosna’s dough-kneading
machines use contactors
that can be packed
tightly together in the
control panel (left).
breakers and DILM xStart contactors for all of
the motor starting functions. The contactors
are not only compact but also have a low
sealing power requirement so they dissipate
less heat when energised than normal
contactors, and so can be packed tightly
together without the risk of overheating.
Diosna has also replaced the bulky wiring
usually needed between contactors and
motor protection devices by plug-in modules
that can be fitted without tools. As well as
reducing wiring time, this system also
minimises the possibility of wiring errors and
saves even more space in the control
enclosures.

& Drives&Controls
BACK TO BASICS
Get ready
for the new
efficiency
standard
The new IEC standard for motor
efficiency will make it easier to
get an accurate picture of
machine efficiencies, as ABB’s
Geoff Brown explains.
No more
corkscrews
A new international efficiency
standard for electric motors is in
the process of being introduced.
The efficiency classes that were
introduced in Europe in 1999 –
Eff1, Eff2 and Eff3 – will
disappear, to be superseded by
the new IE3, IE2 and IE1
efficiency classes. In the future,
we may even see a new class of
super-efficient motors, called IE4.
Note that a higher number
now means a higher efficiency
class – in the old system, a
lower number was better, with
Eff1 being the highest
efficiency class.
The main problem with the
old standard was that it did not
offer an adequate system for
showing a true comparison
between motors. Motors with
large differences in energy
performance ended up in the
same efficiency class and
appeared to be equally efficient.
In addition, the measurement
method used to determine
efficiency was not sufficiently
accurate. Losses due to stray
magnetic flux, created during
operation, are difficult to
measure, so these losses were
arbitrarily assumed to be 0.5%.
New testing methods have now
been developed that allow more
accurate measurement.
The efficiency resulting from
measurements performed to the
new standard will be a lower
figure. A motor with a 97%
efficiency figure under the old
system may be 96% efficient
under the new system. This
does not mean that the motor’s
energy performance has
changed; only that its efficiency
is now being measured more
accurately. It does, however,
mean that efficiency figures
from the old and new systems
cannot be mixed and used
together. During the transition
period, this will be a potential
source of confusion.
Another reason for phasing
out the old system was that it
was based on a voluntary
agreement between the
European Commission and
Europe’s motor manufacturers.
Over time, this turned out to be
far less effective at increasing
the penetration of highefficiency
motors into the
marketplace than the mandatory
systems used in markets such as
the US and Australia.
The European Energy Using
Products directive sets out
mandatory minimum standards
for motors that can be placed
on the market. From June 2011,
motors in the lowest efficiency
class, IE1, can no longer be sold.
From January 2015, only IE3
motors or IE2 motors equipped
with a variable speed drive can
be sold. However, from an
energy-efficiency point-of-view,
it will make more sense to put
the VSD on an IE3 motor – the
gap between a highly efficient
motor and a less efficient one
becomes even greater under
variable speed control.
New: Chainflex ® CFBRAID.
Braided control cable. Corkscrews are now finally a
thing of the past, thanks to the way we braid our cables.
Available as 4-core or 8-core. Shielded and unshielded.
Also the very latest:
Chainflex ® CFLG.T: Now 21% thinner
Chainflex ® CFBUS: Now with UL/CSA
Chainflex ® CF98: Now 4xd
igus ® (UK) Limited 51A Caswell Road Brackmills Ind. Estate Northampton NN4 7PW
Phone 01604-677240 Fax 01604-677242 sales_uk@igus.co.uk
www.drives.co.uk March 2010 45

Drive technology that
reduces your costs
DESIGN DATA
Brammer has launched the 2010 edition of its
maintenance products catalogue with the claim that
it is the most comprehensive maintenance
engineering catalogue ever produced in the UK. The
1,800-page publication covers more than 50,000
maintenance, engineering and health and safety
products – including many new products and brands
– making it 10% larger than the 2009 edition.
08447 363616 marketing.uk@brammer.biz
SMC Pneumatics has issued a 218-page catalogue of its pneumatic
piping equipment. The publication is split into product sections
including the KQ2 one-touch fittings which come in 50 body shapes
and allow quick and easy insertion and release of tubing with
diameters from 2–16mm without needing tools.
0845 121 5122
Huco Dynatork has published a 30-page brochure
covering its range of low-noise air motors that
provide controllable speed and torque, as well as
instant stop/start. The motors, which consume less
energy than vane motors, have been redesigned,
streamlining their gearbox assembles.
01992 501900 www.huco.com
Lenze Rightsizing software reduces
your costs and saves energy
Expertise and Lenze DSD dimensioning
software make your machine run more
efficiently. And there is an Energy
Certificate to prove it.
www.lenze.co.uk/Rightsizing
Lenze
Newey & Eyre has launched its “biggest and best” catalogue to
date of its Newlec products that cover areas such as cable
management, tools, HVAC and security, and fasteners.
The new products section includes a quick-connect range of
industrial plugs and sockets, as well as a new range of wire basket
cable trays and accessories. The catalogue, produced in A4 or A5
formats, is available in printed versions or in a downloadable
electronic version.
0845 123 6539 www.neweysonline.co.uk
TDK-Lambda has compiled a downloadable brochure
covering its customised power supplies, which range
from fully bespoke designs, to modified standard
designs and “brick on board” products covering
voltages from 0.6–50kV and power ratings from
1W–50kW, in AC-DC or DC-DC versions.
http://uk.tdk-lambda.com/custom
The US actuator manufacturer Tolomatic has published a white
paper comparing pneumatic, traditional electric and integrated
electric linear actuators. According to the author, pneumatic
cylinders and traditional electric actuators still have a role, but
integrated electric systems offer advantages in terms of cost and
ease of operation. These systems integrate servomotors, drives,
controllers and linear actuators in all-in-one packages that
deliver 100% duty-cycle performance at about half the cost of
traditional actuators.
00 1 763 478 8000 www.tolomatic.com
A 300-page catalogue containing technical and
application details of more than 4,000 products is
available from Verotec which manufactures, from
the original tooling, the Vero Electronics families of
metal enclosures, system components, power
supplies, backplanes and configured hardware
systems. As well as the hard-copy version, each of
the 14 individual sections can be downloaded as PDFs
from the company’s Web site.
02380 246900 www.verotec.co.uk

6 DRIVES IN 1
V/F, Vector, & PM Motors
Open or Closed Loop,
Light or Heavy Duty
Application Specific Algorithms Included As Standard
LCD Plain English Keypad
c/w Programming Knob
Integral EMC Filter
(200V Drives up to 5.5kw)
(400V Drives up to 15kw)
Integral Braking Chopper
(up to 22kw)
Programmable I/O
7 Sink/Source Digital Inputs
3 Analogue Inputs*
2 Relay Outputs
3 Transistor Outputs
2 Analogue Outputs*
(*Selectable 0-10V / 4-20mA)
Supplied As Standard
Sizes Available:
200-230V 0.7 to 90kw
380-480V 0.7 to 475kw
The New Meiden Advanced AC Drives
VT240S
Universal
Built in PLC
PID Control
Multipump
Brake Control
Traverse
Spinning Frame
Quality, Reliability, Functionality,
Inverter Drives,
Designed & Manufactured by Meiden (Meidensha)
have been in use in Britain for over 25 Years.
Sold under our distributors brands such as NEI & Contraves,
Many of these drives are
Still There, & Still working,
hidden away in the bottom of a control panel,
long forgotten because they have given no trouble.
Pumping, Blowing, Printing, Winding,
Grinding, Turning, Carrying & Lifting.
Day after Day, Year After Year, without missing a beat.
The Thyfrec Family
VT83, VT86, VT87, VT110, VT200, VT210, VT230
And Now:
VT240
VT240EL
Lifts & Elevators
Induction & Permanent Magnet Motors
Open or Closed Loop
Application Specific Algorithms Included As Standard
Dedicated Parameter Set for Lifts & Elevators
S-Shape Speed Commands
Load Compensation with/without Load Sensor
Torque Feed-Forward Accel and Jerk Control)
Operation on 1-ph 400/200V UPS on power failure
External Brake Control
Motor Contactor Control Output
Stationary auto-tune for PM & Induction Motors
Control of Up to 48 Pole Motors and Down to 50 rpm
Sizes Available:
200-230V 2.2 to 50kw
380-480V 2.2 to 45kw
25
Motors
For Over 25 Years
Meiden Europe Ltd
Milton Keynes
Tel : 01908 276000
Fax: 01908 276010
Also Available From:
Agut Control Gear Ltd
Blackburn
Tel : 01254 683714
Fax: 01254 663630
www.agut.co.uk
MLH Services
Peterborough
Tel : 01733 348395
Fax: 01733 349136
www.mlhservices.co.uk
A
MotionControlSolutions
Tel: 01162 325161
Fax: 01162 325162
sales.uk@aucotec.com

SOFTWARE
Monitor energy use across a site
Schneider Electric has introduced a
power and energy monitoring
package that works with its meters
and PowerLogic EGX100 gateway
to track real-time power conditions
and to monitor electrical equipment
and installations across a business.
The PowerView package allows users to measure the energy
consumption of specific applications or circuits by the day or
the hour, analyse and compare total harmonic distortion,
produce reports and plot trends.
The software can read up to 32 meters, transferring data
from their RS-485 ports to the Ethernet port on which the
PowerLogic gateway operates, allowing data to be viewed on
a PC. The software is compatible with Schneider’s Compact
NSX MCCBs that also monitor energy and power.
Schneider Electric
0870 608 8 608 www.schneider-electric.co.uk
Package turns plant
data into intelligence
Wonderware has announced an enterprise manufacturing
intelligence (EMI) system that allows users to contextualise,
aggregate and report historical and operational data using
“dashboards” that present key indicators and real-time
operating data for monitoring, tuning and optimising
operations and supply chains. Wonderware Intelligence
Software 1.0 acquires data not only from Wonderware
products, but also from external systems such as ERP, LIMS,
PDM and even other execution systems and historians, to
provide plant, multi-plant and corporate views of
operations and performance.
The software transforms the data into business
intelligence by aggregating it in real time and adding
contextual elements, such as equipment, product, work
orders, material and personnel. This gives insights into the
root causes of problems and relationships between events.
The information is saved and optimised for fast reporting
and analysis, allowing users to create dashboards.
Wonderware UK www.wonderware.co.uk
HMI/SCADA software
gets animated
Copa-Data has announced a new
version of its zenon HMI/SCADA
package, giving new options for
creating projects with bespoke designs. The 6.50 version
includes graphical enhancements – including, for the first
time, animated objects – and a customisable user interface.
Enhanced project and driver simulation capabilities allow
projects to be simulated without needing to use hardware or
test laboratories. The simulation mode can also be used for
training. New programming tools provide developers with
more than 10,000 classes, allowing them to develop entirely
object-orientated applications. The software also includes
features for specific sectors, such as automotive production
(including Simatic S7 graphs), process control and energy.
Copa-Data UK 0845 862 0146 www.copadata.co.uk
MULTIMEDIA
Two-minute videos solve
motion problems
Galil Motion Control has released a
library of two-minute videos which
offer solutions to common motion and
I/O control problems, such as achieving
smooth multi-axis motion through arbitrary points, and
controlling liquid temperatures precisely. The videos are
intended to help engineers get a quick start on their motion
projects. Galil plans to add more videos to build a library
showing how to solve specific motion problems, as well as
providing how-to explanations, and demonstrating its
products including PLCs and motion controllers.
www.galilmc.com/learning/two-minute-videos.php
Measurement site hits the Web
Ixthus Instrumentation, the specialist in non-contact
position and force measurement owned by Variohm, has
launched a Web site showcasing its range of sensors,
transducers, weighing controllers, and vibration monitoring
and calibration equipment. As well as PDF downloads of
many individual products, there are also direct links to
Ixthus’ distribution partner Web sites where complete
product and technical specifications are available. There is
also a section on customised applications for the company’s
products.
www.ixthus.co.uk
Air product benefits
captured on video
Boge has added a video section to its
Web site where visitors can see the
company’s experts discussing and
demonstrating its products. The Boge-TV section is designed
to provide a quick overview of its products that can be
accessed and viewed at anytime and anywhere via the
Internet. As the facility is developed over the next few
months, visitors will be able to select videos from a library on
key products to gain an insight into their features and
benefits. The new section is found on the company’s Web
site by choosing News and Boge-TV.
www.boge.co.uk
Revamped machine
tool site gets a forum
Machine Tool Direct has launched a
revamped Web site, including a forum
where engineers can find or list unwanted
machinery and tools, post CVs, find staff,
or keep up to date with the latest news and gossip. Machine
Tool Direct was set up in 2006, initially to create a platform for
used CNC machine dealers to advertise their stock. It now
includes directories of new machines and tooling, as well as a
news section, case studies and an on-line finance calculator.
Suppliers have their own control panel “cockpits” that allow
them to add listings and send email marketing campaigns.
www.machinetooldirect.co.uk
48 March 2010 www.drives.co.uk

Design solutions
for design engineers
DIN Rail Power Supplies
Low profile
Short circuit protection
10 to 480W, 5/12/24/48V
outputs available
UL/CE Approved to EN60950 &
EN61000-6-3
2 Year warranty
Machine Safety
Control units up to
SIL 3/PLe/Cat. 4
Non contacting sensors for
machine guard monitoring
Hygiene and ATEX
sensors available
Approvals EN61508,
ISO13849-1, EN954-1
Joysticks
Hall effect technology
eliminates degradation of
output signal with wear
Output options: current,
voltage, ratiometric
voltage, switching points, CAN
EMC standard DIN40849 or
IEC801-3
IP67 protection class for
output modules
RFI Filters
Single phase 1, 2 or 3 stage,
1 to 36A, 250V AC
Three phase 1 or 2 stage, 4 to
250A, 275/440/480/520/550 VAC
Standards EN133 200,
IEC60939, UL1283
Operating temperature range:
-25 to +100ºC
Web: www.relec.co.uk Tel: +44 (0) 1929 555700
Email: sales@relec.co.uk Fax: +44 (0) 1929 555701
www.andantex.co.uk
e: sales@andantex.co.uk t: 024 7630 7722

TEST & MEASUREMENT
Dual signal interface delivers
higher encoder accuracy
Renishaw has announced a dual signal interface for its Tonic
incremental optical encoders, bringing higher accuracy to
rotary axis measurements. The DSi interface also gives a
selectable reference mark position at the press of a button
using Renishaw’s propoZ technology, whose output
position is angularly repeatable, regardless of bearing
wander or power cycling.
Using two readheads on an angle encoder
improves motion system
accuracy and repeatability by
eliminating eccentricity, bearing
wander and “odd” error
harmonics. When used with
Renishaw’s REXM ring encoders, an accuracy of better than
±1 arc-second is possible. The combined Tonic-DSi system
makes adding a second readhead easy by taking care of the
combination of incremental channels and reference mark
processing. The system can be used with RESM encoder
rings with standard diameters from 52–550mm (and other
sizes on request), or with super-accurate REXM rings.
Renishaw 01453 524524 www.renishaw.com
Three-phase module reveals
energy consumption data
Wago has announced a three-phase power measurement
module that allows detailed measurement of parameters in
three-phase power networks. The modules can be used
with Wago’s 750 Series I/O system to enable the detailed
measurement of electrical quantities in supply networks.
The module records the current and voltage values from six
analogue and/or digital converters in all three phases within a
16µs time frame. It calculates the effective power and the
energy consumption from these values, which can be used to
derive other values such as apparent power and phase-shift
angles. Extra measuring devices are unnecessary, because
analyses can be performed using Wago’s I/O system .
Wago 01788 568008 www.wago.com
Dynamometer operates in
confined locations
Kistler has announced a threecomponent
dynamometer for
measuring forces in machining
operations, as well for general,
multicomponent force measurements
in confined spaces. The 32mm-high
Type 9129AA dynamometer has a
±10kN measuring range.
The dynamometer uses four
piezoelectric force sensors which provide the three
components of the force vector and the three components
of the resultant moment vector. Forces are measured with
almost no displacement. The four sensors are isolated to
avoid earth loop problems. The dynamometer is resistant to
cutting fluid corrosion, and is sealed to IP67 when used
with a matching cable.
Kistler Instruments 01256 741550 www.kistler.com
CONTROL
‘Mobile HMIs’ provide factory
data anywhere at any time
Exor International has introduced a mobile HMI platform for
remote real-time monitoring and control of equipment such
as drives, PLCs, and sensors. The jMobile platform, available
in the UK from Scattergood & Johnson, is a software suite
that provides a HMI system with a client-server architecture.
Its server can interface with databases and more than 100
device protocols. The data is available via Web browsers,
mobile phones and most devices with Ethernet connections.
The suite includes commissioning tools for easy
configuration and maintenance of multiple remote devices,
as well as desktop and runtime engineering software for
developing applications. There are no network configuration
issues or management problems with firewalls or proxies,
and there are no data representation problems between
connected systems. The jMobile runtime system is available
integrated in eight HMIs ranging in size from 4.3–15 inches.
Scattergood & Johnson 0113 2430203
www.jmobileproject.com www.scatts.co.uk
Combined HMI-PLCs support
multi-axis stepper control
Alldrives is offering a range of combined
PLCs and HMIs from the Israeli supplier,
Unitronics. The Vision series includes a
model (V350-35-TR34) with four highspeed
outputs, allowing users to
implement up to four independent pulse
train output instruction sets at a time for
accurate multi-axis step-motor control.
The Vision130 and Vision350 TR controllers can handle
digital inputs up to 200kHz for high-speed counters and
encoders, and frequency modulated pulse train outputs up
to 200kHz for control duties. The TR models offer more
flexibility with high-speed I/O connections offering benefits
where speed, position or closed-loop control are needed.
Alldrives & Controls
01543 27 18 99 www.alldrivesandcontrols.co.uk
Microcontrollers can store up
to 260 function blocks
GE Intelligent Platforms has launched a
range of low-cost microcontrollers with
built-in displays and I/O for
applications such as conveyor control
and motor monitoring. The Durus Plus
controllers offer facilities such as PID,
Modbus master/slave communications, high-current outputs,
analogue outputs, and expansion slots.
The controllers have 12-line displays with 16 characters per
line. They can store 300 lines of ladder code and 260 blocks
of function block diagram programming. Programming
functions include add/subtract, multiply/divide, data
multiplexing and data moves. They controllers can be
programmed either via the built-in display and keypad or
using free programming software. Expansion modules can be
fitted using slide-and-snap mechanical interlocks.
GE Intelligent Platforms 01327 322821 www.ge-ip.com/plc
50 March 2010 www.drives.co.uk

MAKING MODERN LIVING POSSIBLE
The Art of Running
Speedy delivery of VLT® Drives now available in power sizes up to 1.4MW
All the qualities experienced since Danfoss put the first mass-produced drives
on the market in 1968 are found in our entire VLT® product range
A host of advanced easy-to-use features and options are built in and tested at factory level
to meet any specification your applications require
• User-friendly commissioning and operation
• Save time – intuitive user interface including our award-winning control panel (GLCP)
• Save space – compact design makes them easy to fit in small spaces.
• Built-in filters, options and accessories facilitate installation
• Built in DC Coils can eliminate the need for external AC coils for harmonic suppression
• Low Harmonic Drives NOW available
• High efficiency – up to 98%
Danfoss VLT® Drives, Capswood, Oxford Road, Denham, Bucks UB9 4LH, Tel. 0870 241 7100
Ireland freephone: 1 800 946332 • e-mail: drivesuk@danfoss.com • www.danfoss.co. uk

COMMUNICATIONS
Ethernet extender can reach 15km
Westermo has announced its
first industrial Ethernet line
extender to use the WeOS
operating system, which
provides advanced switching
and routing functions for
managing complex industrial
networks. The DDW-225
extenders are designed to
establish reliable, high-speed, long-distance, remote
connections between Ethernet networks using existing
twisted-pair copper cables.
The extenders support two SHDSL interfaces and have a
built-in four-port managed Ethernet switch, enabling users to
build complete Ethernet networks with daisy-chain and ring
topologies. The devices, suitable for use in harsh industrial
environments, can transfer data at 5.7 Mbit/s in both
directions over distances of up to 15km, depending on the
cable quality.
Westermo Data Communications
01489 580585 www.westermo.co.uk
Ethernet cables offer a choice
of more than 30 designs
Belden has introduced a range of copper cables specifically
for industrial Ethernet and associated communication
networks. The cables include more than 30 different
designs and are available in a choice of jacket grades. They
can be tailored to customer specifications.
There are two families: the first, for Profinet installations,
conforms to the standard managed by PI International; the
second is for other industrial Ethernet standards such as
EtherNet/IP and Profinet. The Profinet cables have a star quad
conductor design and offer Cat 5e transmission
performance. The general-purpose cables are available in
solid and stranded conductor versions, in two- and four-pair
formats. They offer Cat 5e or Cat 7 performance, and are
available in permanent, flexible, and trailing-torsion variants.
Belden www.belden-emea.com
Ethernet starter kits come
with an introductory discount
Harting has introduced a pair of low-cost entry-level
industrial Ethernet switch starter kits and patch cables. The
Basic and Basic+ Ethernet kits and the Cat 6 patch cables will
be available at discounted prices until 26th March.
The Basic switch kit contains everything needed for a
simple industrial Ethernet implementation, including a fiveport
unmanaged switch, ten tool-less assembly RJ-45
connectors, and 20m of Cat 5 Type B Ethernet cable. The
Basic+ kit adds a 24V DC/1.4A power supply and a cablestripping
tool. The RJ-45 connectors have a two-part boot
design said to offer robust handling and bending
protection. The flame-retardant, halogen-free Cat 6 patch
cables can handle Ethernet speeds up to 1Gb/s. They can be
used at temperatures from –20 to +80°C.
Harting 01604 827500 www.harting.co.uk

Single-axis stages have
‘smallest dead zone’
MECHANICAL & LINEAR
Micromech is offering range of high-thrust, highspeed
linear stages, powered by maintenance-free
linear motors. The low-profile Nippon Pulse SLP stages are claimed to have the
smallest dead zone and the highest force-to-volume ratio of any stage on the market.
The maintenance-free, non-contact drives result in low noise and no dust.
There are three models, all with built-in 1µm encoders. The SLP15 delivers
continuous forces up to 17N and peak forces of 90N. Its top velocity is 3m/s, its
maximum horizontal load is 5kg, and its repeatability is 0.0005mm. It is available in
single-forcer versions with stroke lengths from 100–1,300mm and double-forcer
versions with strokes from 100–1,200mm. The SLP25 model delivers continuous forces
of 80N and peak forces of 340N. It can handle horizontal loads up to 30kg and offers
stroke lengths up to 1,200mm. The third model (SLP35) delivers a continuous force of
185N and a peak force of 970N, and can handle horizontal loads up to 60kg.
Micromech 01376 333333 www.micromech.co.uk
Actuators are delivered within 24 hours
Festo has launched a range of compact precision electric actuators that can be
ordered on-line and delivered within 24 hours. The ballscrew-driven EGSK and
EGSP series actuators offer ±10 micron repeatability, a choice of two performance
categories, stroke lengths from 25–800mm, and three classes of precision (with
repetition accuracies of ±3, ±5 or ±10µ).
The rigid actuators have one-piece steel housings which also serve as guide rails.
They are said to be ideal for applications demanding short, precise moves,
especially where space is limited. Their low profile makes them suitable for small
pick-and-place systems and X-Y tables. The standard-performance EGSK range
comprises five models, with profile heights from 15–46mm. The high-performance
EGSP actuators use caged recirculating ball bearings between the carriage and the
guide. There are four models with profile heights from 20–46mm.
The actuators can be used in any mounting position and can accommodate a
wide range of load conditions. They are compatible with Festo’s stepper and servo
motors and controllers, and can also be used with third-party motors. A
downloadable PC-based software tool helps to choose the optimum components
for high-efficiency positioning systems by calculating the ideal combination of
linear axes, motors, gears, controllers and software
Festo 01252 775000 www.festo.co.uk
Universal joints are
more accommodating
Techdrives is offering a range of universal
joints that allow much higher angular
misalignments than flexible couplings.
The joints, for shafts from 6–50mm, can
accommodate misalignments of up to 45
degrees compared to a typical 1–3
degrees for couplings.
The joints are available in single,
double and telescopic versions, in both
plain and needle roller versions. Single
universal joints can run with angles up to
45 degrees, but their output speed varies
cyclically four times per revolution.
Double universal joints can transmit
torque through up to 90 degrees.
Telescopic joints are suitable for machines
where modules are set statically – for
example, packaging machinery guides.
At low speeds, low-cost plain bearings
are the best option because they offer
good resistance to peak loads. However,
they tend to shed their lubricant and
often need grease-filled rubber gaiters.
At higher speeds (1,000–3,000 rpm),
sealed needle rollers are recommended.
Techdrives
01234 321320 www.techdrives.co.uk
M i n i a t u r e D r i v e S p e c i a l i s t s
PRECISE STEPS FOR
SAFE OPERATION
PRECISION MINIATURE
STEPPER MOTORS
satisfy the most demanding medical applications.
Faulhaber Precistep stepper motors are 2-phase
multi-polar motors with rare
earth permanent
magnets providing exceptionally
high power
to
volume
ratio.
The
large
magnet
volume
delivers high torque
density and the rare earth
characteristics allow
for consistent stable
performance across a
very wide temperature
range. Compatible with Faulhaber
encoders and
gearheads these stepper motors start at just 6mm
diameter and are also available with integrated
lead screws.
EMS
www.ems-limited.co.uk
0118 9817391
DC Micromotors
Brushless DC motors
Gearmotors
Low Profile Motors
Stepper Motors
Drive Electronics
Linear Actuators
Custom Solutions

FLUID POWER
Auditing system
analyses up to 12
compressors
Boge has introduced a
compressed air auditing system
which can analyse up to 12
compressors simultaneously and
identify where savings can be made. As well as monitoring
compressors, the AIReport system also measures associated
equipment, such as air dryers.
The logged data can be viewed graphically, providing reports
on pressure dew point, flow rates, net pressure profile and so
on. The data accumulates into reports highlighting the current
cost of any system in-efficiencies, such as idling times. Wastage
can be identified and actions can be taken to eliminate
unnecessary costs which, in most cases, start with low- and nocost
methods such as repairing air leaks.
Boge Compressors 0800 318104 www.boge.co.uk
Compact valve
manifolds squeeze
a lot in
SMC has developed a compact valve
manifold for use with air-operated
three-port solenoid valves. The
Series VV061 manifold integrates
the valves, circuit board and fittings in one compact device.
The manifold, designed for use with SMC’s 6mm-wide
V060 valves, is 38.6mm wide and 31.5mm deep. It is
available either in 26mm-high four-valve versions weighing
47g, or 38mm-high eight-valve versions, weighing 75g. The
manifolds are suitable for either panel or bracket mounting.
They can be detached from the piping plate and electrical
connector cable for maintenance. There is a choice between
standard 0.5W or power-saving 0.23W models, which are
useful for continuous applications
SMC Pneumatics 0845 121 5122 www.smcpneumatics.co.uk
Double 3/2 valves make their debut
Rexroth has announced double 3/2 versions of its TC single
valves and valve terminal systems, increasing the performance
and flexibility of the products. The double versions offer flow
rates of 600 l/min for the TC08 line, and 1,100 l/min for the
TC15 line. Each 3/2 function enables the full nominal flow on
all valves, even during simultaneous operation.
The double 3/2 functions increase performance density,
while maintaining a 16.8mm width for the TC08 and 21mm
for the TC15. This enables simple, flexible assembly in
applications where space is limited. In the single-valve
version, the control valve can be brought closer to the load,
shortening hose lengths, saving energy and cutting cycle
times. The integration of two independent 3/2 functions in
one valve reduces assembly efforts and installation costs.
Bosch Rexroth 1285 863000 www.boschrexroth.co.uk
)% #'$#%!"$ +++'#* (&$
54 March 2010 www.drives.co.uk

SENSORS
Linear encoders
give high resolution
at high speeds
Heidenhain has announced a range
of exposed linear encoders that
combine properties previously
considered to be mutually exclusive:
high resolution at high speeds, over
measuring lengths of up to 3m. The
LIP 200 series encoders are said to
provide significantly better stability in
terms of speed and position than
earlier devices.
The improved performance has
been achieved by a combination of
enhanced electronics in the scanning
head, and the Optodur measuring
standard, whose graduated structure
reflects light efficiently. The
encoders, which can be installed
quickly and easily, can traverse at
speeds of up to 3m/s. The generated
signals can be interpolated to
produce resolutions of better than
one nanometer. Using an EnDat
interface, measuring steps down to
31.25 picometers are possible at the
maximum traversing speed. Variants
with TTL and 1V pp outputs are
available.
Heidenhain (GB) 01444 247711
www.heidenhain.co.uk
Enclosed encoders offer
the best of both worlds
Electronica has launched a range of enclosed magnetic
linear encoders said to combine the easy mounting of optical
encoders with the robustness of magnetic measuring systems. The
MG232 non-contact encoders have no bearings or springs, thus ensuring high reliability.
The low-profile encoders are as easy to mount as traditional optical linear encoders and
have a similar footprint. They can achieve traverse speeds of 2m/s at 0.001mm resolution,
or up to 10m/s at 0.005mm resolution. Users can choose between two levels of accuracy
(0.005 or 0.010mm) and resolution (0.001 or 0.005mm). Measuring lengths range from
120–2,040mm, with reference marks every 50mm. The encoders are available in IP67-
rated versions which can be used in harsh environments without suffering ingress from
oil, dust or coolant. They can even run submerged. A scale cover is included.
Electronica Mechatronic Systems 0116 279 6891 www.electronicaems.co.uk
Light switches offer a
choice of sources
SensoPart has launched a range of
proximity switches and light barriers with a
choice of red-light LED or laser sources.
The F55 series sensors are said to combine
good performance with robust housings.
Background suppression versions have
a scanning range of up to 1.2m, while
through-beam versions have a 25m
BEI has developed an incremental encoder
whose resolution can be set from 1 to
10,000 counts/rev, reducing stock levels
for OEMs which use several different
fixed-resolution encoders. The Omnicoder
encoder, available in the UK from Variohm
EuroSensor, is programmed by connecting
it to a PC using a special USB cable.
The Omnicoder uses a patented control
algorithm that ensures that the duty cycle
and phase relationship is unaffected at the
range. Good optical performance allows
the sensors to be mounted at long, safe
distances from a process, and makes
them easy to commission. The light spot
is visible from a long distance and in
broad daylight, and can be aligned and
adjusted by one person. The sensors are
available in either glass-fibre-reinforced
plastic housings, or IP69K-rated
impermeable stainless-steel enclosures.
SensoPart 0121 772 5104
wwww.sensopart.com
Programmable encoder helps to cut stocks
maximum resolution. The resolution
information is stored in non-volatile
memory, making it as reliable as a fixeddisc
encoder. The encoder has a die-cast
aluminium housing, a stainless-steel shaft
and heavy-duty bearings. The encoders
can be used in labelling and packaging
applications where resolutions need to be
modified when products are changed.
Variohm Eurosensor
01327 351004 www.variohm.com

DRIVES & MOTORS
ELECTRICAL
Inset doors
reduce enclosure
footprints
Schneider Electric has introduced a
range of floor-standing enclosures that offer a combination of
space saving, flexibility and ease of installation. The Spacial
SF/SM enclosures, have inset doors that reduce their footprints.
The SM versions, available in 45 sizes, are formed from
two parts – a body and a welded back – and can withstand
loads up to 600kg. The SF versions, available in 65 sizes, are
claimed to have the highest inertia profile on the market
and can handle loads up to 1,000kg. An additional kit
allows more than 600 configurations to be created.
The IP55-rated enclosures can be coupled in any direction.
With eight captive screws per panel, installation time is
minimised and doors and panels can be mounted by one
person. The enclosures are offered in RAL7035 as standard
and have been tested to the new IEC 62208 standard.
Schneider Electric
0870 608 8 608 www.schneider-electric.co.uk
Non-safety light curtains can
monitor or measure
Omron has announced ranges of area-monitoring and
measuring light curtains that, it says, are easy to install with
minimal wiring. The non-safety devices use the same light
aluminium housings and mounting arrangements as Omron’s
safety light curtains.
The F3ET area-measuring curtains operate as multi-beam
sensors and can detect targets that are irregularly shaped,
have variable sizes, or contain holes. Reliable results are
difficult to achieve with such targets using single-beam
photoelectric sensors. The curtains have a maximum
operating range of 3m or 15m and are available in versions
with vertical detection capabilities from 15cm–2.1m. They
have transistor outputs that can be set as light-on or dark-on.
The F3EM measuring light curtains are available either as
analogue output models for measuring object heights, or as
serial output versions that measure the target profile using a
single beam. They are available with 3m or 15m ranges, and
can measure target heights and profiles up to 2.1m.
Omron Electronics 0870 752 0861 www.industrial.omron.co.uk
40A supply is ‘world’s smallest’
Puls UK claims that a new 40A, three-phase power supply
that weighs 1.5kg, is the world’s smallest. The DIN-railmounting
QT 40 supply, which measures 1110 x 124 x
127mm, is available in 40A, 24V or 20A, 48V versions,
both delivering 960W and operating with an efficiency
of 95.3%.
The supplies use three microcontrollers to optimise
efficiency at all loads. Several supplies can be mounted sideby-side
on a rail without needing fan cooling. Current
inrush at switch-on is said to be close to zero and the
supplies can provide 150% of their nominal current for up
to 4s to help start demanding loads. They can operate in
temperatures down to –25°C.
Puls UK 0330 999 9988 www.puls.co.uk
DC motor packs in the power
Maxon has unveiled a 200W two-pole DC motor which, it
says, is one of the most powerful and robust of its type. The
50mm-diameter, 108mm-long RE 50 motor delivers up to
0.38Nm of torque and has an efficiency of more than 90%.
The motor incorporates neodymium permanent magnets,
combined with four different versions of maxon’s patented
winding technology. An ironless, low-inertia rotor provides
smooth running. The motor, which operates from 24–70V
DC supplies, is compatible with maxon’s gearhead, encoder
and control systems. Pre-loaded bearings reduce vibration,
and offer quiet running and long service lives. A heavy-duty,
IP54-protected version with an extra brake is planned.
maxon motor uk 01189 733337 www.maxonmotor.co.uk
Integrated stepper drives
rival servomotors
A US-developed motion
control technology that
prevents stepper motors from
losing synchronisation due to
transients, overloads, extreme
acceleration or deceleration,
or excessive slew speeds, is now available from Motion
Control Products. The IMS MDrive AccuStep (see Drives &
Controls, May 2009) allows motors to operate safely at
their maximum torque curve, thus avoiding the need to size
them with a 25–50% torque margin. In some applications,
smaller frames or shorter stack-length motors can be used.
The technology allows a system to ride through transient
overloads. It can reduce motor heating and energy use by
enabling variable current control. There are two versions:
one combines a stepper motor, a microstepping drive and
an internal encoder, to provide step, torque and speed
operating modes; the other adds a programmable motion
controller for full motion control. The packages offer a lowcost
brushless alternative to servomotors for applications
such as positioning, conveyor control, and camming.
Motion Control Products
01202 599922 www.motioncontrolproducts.com
OEM micro-drives
reach a wider public
The Vacon 10 micro-drive, launched in 2007 for
OEMs, is now available in an enhanced range
for all customers. The drives are designed to
eliminate unnecessary complexity, while offering
the features needed for standard applications such as
controlling pumps, fans and simple conveyors.
The drives – available in single-phase ratings from 0.25–
2.2kW and three-phase versions from 0.37–5.5kW – can be
mounted using screws or DIN rails. They offer PI control and
macros for common applications. All but the smallest
versions have built-in brake choppers, and they can be
supplied with optional internal EMC filters. The drives have
programmable I/O, with three digital inputs, one analogue
input and one relay output as standard. Versions with more
I/O are available. An RS-485/Modbus interface is standard.
Vacon 01455 611515 www.vacon.com
56 March 2010 www.drives.co.uk

GEAR DESIGN SOLUTIONS
Gear Design and Development
Analysis and Optimisation
(Stress, NVH, Efficiency)
Failure Investigation
Software Tools
Training and Support
Tel – 01661 833828 Fax – 01661 523614
info@dontyne.com
www.dontyne.com
Stepper motor with integral leadscrew
11 to 34 frame stepper motors with integral lead screws
Forces up to 2600N thrust
Up to 190mm/sec linear speed
DC brush motor versions available
Low cost, high reliability
Medical, packing, labelling and general industrial uses
SERVO COMPONENTS & SYSTEMS LTD
Email: sales@servocomponents.co.uk
www.servocomponents.co.uk
Tel: 01 202 666 636
Fax: 01 202 666 500
5 th International Conference on Power Electronics, Machines and Drives
19 - 21 April 2010. Thistle Hotel, Brighton, UK
Conference highlights
hear over 200 presentations on the latest developments in electrical drives, machines and power electronic systems
take part in tutorials examining Reliability of power electronics in harsh environments and
Thermal analysis of electrical machines
meet AMS Technologies, Cobham Technical Services, Converteam, Doble, Heidenhain (GB) Ltd, Infolytica Ltd,
John G Peck Ltd, MDL Technologies, Motor Design Ltd and PPM Power at the exhibition
Keynote speakers
Dr Gourab Majumdar, Senior Chief Engineer, Power Device Works
MITSUBISHI ELECTRIC CORPORATION, JAPAN
Professor Frede Blaabjerg
AALBORG UNIVERSITY, DENMARK
Drinks Reception
Sponsor
Sponsors
Supported by
Media partners
Register your place online at www.theiet.org/pemd

WORKSPACE
Survey shows more boards are discussing health and safety
Manufacturers an increasingly discussing health
and safety issues in their boardrooms
Hannover Fair
19–23 April, 2010
Hannover, Germany
The spotlight at the industrial megashow
will be on industrial
automation, energy, technology,
industrial subcontracting and
cutting-edge technologies. The
official partner country will be Italy.
www.hannovermesse.de
EVENTS 2010
Manufacturers are urging government to
resist pressure to impose new legal duties on
directors after a survey concluded that,
despite the recession, company boards are
spending more time on health and safety.
The Health and Safety Executive (HSE) Board
is under pressure to recommend a new duty
on directors, however the survey of nearly 400
companies, conducted by EEF, the
manufacturers’ organisation, reveals there
boards have become more involved in
managing health and safety risks over the past
three years. According to EEF, the survey
proves that the proposed new laws are
unnecessary and could be counter-productive.
The survey found that:
• 81% of boards discuss health and safety
regularly, compared to 58% in 2006;
• 73% of boards set and monitor targets for
health and safety, compared to 53% in 2006;
• 91% identify the health and safety
responsibilities of senior managers in their
health and safety policy, compared to 77%
in 2006; and that
• 80% of companies are spending more
time on health and safety than they were in
2006.
The most common requests for further
advice and support were: assistance with
benchmarking performance (54%); help
with setting and monitoring meaningful
targets (45%); and health and safety training
for senior managers (41%).
“Leadership of health and safety is
extremely important,” says Steve Pointer, the
EEF’s head of health and safety policy. “Our
survey confirms that there has been a sea
APPOINTMENTS
Schneider Electric has
appointed Richard
Beighton as national
commercial manager,
industry. Beighton, an
automation and control expert
with almost 30 years of
experience with several of the
sector’s leading players (including
a decade at Schneider), will
manage and reinforce Schneider’s
70-strong sales team. He will also
be responsible for increasing the
services the company offers, and
informing industry of those it
already offers.
Terry Scuoler, managing director
of Ferranti Technologies, has been
appointed chief executive of EEF,
the manufacturers’ organisation.
Scuoler has been at Ferranti since
1999 and has helped to turn the
company from years of decline
and making losses, into a
profitable and expanding
business. Manufacturing, he says,
remains central to our future as a
high-value, high-skill employer and
“we now have an ideal
opportunity to ensure this is
widely recognised”. Scouler takes
up his new post on 15 March.
change in director involvement – active
leadership is now very definitely the norm,
not the exception.
“Recent legal changes, insurance
considerations and a campaign by HSE and
other organisations have all played a part in
that improvement,” Pointer adds. “With the
effect of those legal changes still feeding
through the system, it makes no sense to
introduce a new law now. We urge HSE to
stick with the current approach and are keen
to continue lending our active support.”
Pointer fears that further statutory duties
would simply lead to a “box ticking”
mentality aimed at protecting board
members rather than protecting employees.
The survey shows that promotion,
encouragement and support, coupled with
robust enforcement of the existing duty on
directors, is more likely to bring further
improvements.
The survey further reveals that confidence in
the regulators has dropped, albeit from a high
baseline. This could be a result of the recession,
but EEF believes HSE must look closely at this
to ensure it does not become a trend.
The greatest area of concern for employers
continues to be unnecessary bureaucracy
and there is a noticeable increase in concern
about the effect of requirements on small
companies.
“In recent years, HSE has made significant
efforts to reduce regulatory burdens,” says
Pointer. “Our survey shows that further work
is needed to reduce burdens from existing
legislation and to resist new legislation, most
of which now emanates from EU directives.”
Steve Riley has been
appointed general
manager of the
compressed air
specialist, Beko
Technologies. Riley has more
than 30 years experience of
the compressed air industry,
most recently as UK sales
director of Parker Hannifin’s
Domnick Hunter division.
His responsibilities at Beko
will include launching products,
developing the sales force
and managing marketing
activities.
Machine Building and Automation
27–28 April, 2010
NEC, Birmingham
The annual show has changed to
new dates, about a month later than
originally announced. It will run
alongside other shows including
MTEC, Green Manufacturing and
Vision Technology.
www.devicelink.com/expo
MACH 2010
7–11 June, 2010
NEC, Birmingham
The manufacturing technologies
event will include three new
specialist zones: Grinding Solutions;
Preferred Suppliers (showcasing the
subcontracting sector); and Solutions
for Business (where business advisory
services will offer assistance on all
aspects of commerce and industry).
www.mach2010.com
Drives & Controls Show 2010
8–10 June, 2010
NEC, Birmingham
The now-biennial show for motion
engineering, power transmission and
industrial engineering, will again
form part of the UK’s most
important event for industrial
engineering, alongside other shows
including MACH, the AirTech
compressed air show, the Plant &
Works Exhibition, and the Subcon
sub-contracting event.
www.drives2010.com
Hillhead Quarry Exhibition
22–24 June, 2010
Hillhead Quarry, Buxton, Derbyshire
Hillhead is the world’s largest working
exhibition of plant and equipment for
the extractive and heavy construction
industries. Exhibits from around 400
manufacturers will be on display, both
outdoors and in covered pavilions.
www.hillhead.com
Profibus and Profinet User
Conference
29–30 June, 2010
Stratford Manor, Stratford-upon-
Avon, Warwickshire
The seventh annual conference will
include application-oriented technical
presentations and hands-on workshop
sessions. The event is designed to lead
new users from the basic technologies
to their use in real-world industrial and
process applications.
www.profi-bus.co.uk
58 March 2010 www.drives.co.uk

To advertise contact Simon Langston
t/f: 01353 863383 e: simon@dfamedia.co.uk
PRODUCTS & SERVICES DIRECTORY
ACS Drives & Control
Systems Ltd
Ireland
+353 (0)44 934 0242
www.abbdrivesalliance.com
Advantage Control
Northern Ireland
02844 613 782
www.abbdrivesalliance.com
APDS Ltd
South West
0117 982 2049
www.abbdrivesalliance.com
Central Electrical Ltd
Merseyside
0151 546 6000
www.abbdrivesalliance.com
EDC (Scotland) Ltd
Scotland
0141 812 3222
www.abbdrivesalliance.com
Gibbons Drive
Systems Ltd
East Anglia
01621 868 138
www.abbdrivesalliance.com
Halcyon Drives Ltd
Yorkshire & Greater
Manchester
0113 236 1509
www.abbdrivesalliance.com
Inverter Drives
Southern Ltd
South
01483 766 555
www.abbdrivesalliance.com
Inverter Drive
Systems Ltd
East Midlands
0115 981 3893
www.abbdrivesalliance.com
MKE Drive Systems
South East
01795 438 436
www.abbdrivesalliance.com
Quantum
Controls Ltd
North East
01661 835 566
www.abbdrivesalliance.com
Sentridge Ltd
Midlands
024 7655 3303
www.abbdrivesalliance.com

S
PRODUCTS & SERVICES DIRECTORY
AUTOMATION
BEARINGS
CAD SOFTWARE
To advertise contact Simon Langston
t/f: 01353 863383 e: simon@dfamedia.co.uk
COOLERS
RENU
ELECTRONICS
PVT. LTD
HI05
1
⁄16 Din HMI with PLC
(from) £199
• 1.25” GraphicalHMI
• 8 Function Keys
• Full Function PLC
• Ladder Logic Programming
• RTC, HSC, PID
• Option 1. 8DI, 8DO
• Option 2. 6DI, 6DO, 1AI, 1AO
Japan’s Leading
Bearing Manufacturer
Tel: 01908 289300
Email: info@koyo.co.uk
Web: www.koyo.co.uk
T: 01527 578376
E: sales@siamcontrol.co.uk
www.siamcontrol.co.uk
Keeping
UK Industry
on the Move
CHAINS
01732 865 635
www.seifertmtmsystems.com
AxisControls
CONTROL PANELS & PLC AUTOMATION SYSTEMS
• Control Panels
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PROCESS
CHILLERS
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in 80 countries
Tel: 01709 704000
email
information@rittal.co.uk
R
Tel. 01704 560 777
www.axiscontrols.co.uk
sales@axiscontrols.co.uk
www.drives.co.uk
BELTS
BEACONS & SOUNDERS
CONNECTOR SYSTEMS
CURRENT SENSORS
MEGADYNE
Manufacturers of RUBBER
power transmission belts
WORLD’S LARGEST
manufacturers of POLYURETHANE
power transmission belts
Gildersome Spur, Gildersome,
Leeds LS27 7JS
Tel: 0113 2382910 Fax: 0113 2383870
Email: sales@megadyne.co.uk
www.megadyne.co.uk

To advertise contact Simon Langston
t/f: 01353 863383 e: simon@dfamedia.co.uk
DC/AC DRIVES CONTROLS
AND AUTOMATION
DISTRIBUTION
PRODUCTS & SERVICES DIRECTORY
DRIVES SERVICES
ENCODERS
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TYPES OF INDUSTRIAL
ELECTRONIC CONTROLS
THERMAL IMAGING SURVEYS
FRIENDLY ATTENTATIVE SERVICE
FM23783
BTJ DRIVES & CONTROLS LTD
STOKE on TRENT ST10 4PG
t: 01889505315 f: 01889505604
www.btjdrives.co.uk
24/7 Engineer Availability
Emergency Contact
07811 459820
Quantum Controls Ltd
(Formerly Slater Drive Systems Ltd)
Tel: 01661 835566
Fax: 01661 833868
www.quantum-controls.co.uk
T. 01490 413550
F. 01490 413014
E. info.uk@globalencoder.com
W. www.globalencoder.com
DC MOTORS & GENERATORS
DRIVES SERVICES
ELECTRICAL ENGINEERING
ENCLOSURES
IMPORTANT NOTICE
The leading UK
manufacturer of
DC Motors & Generators
DC Motors 0.5––150kW
DC generators and dynamometers
DC Traction Motors
ATEX certified EEXd motors
For users and purchasers
oflow voltage switchgear
and controls
EDM Ltd specialises in electrical
engineering. We can supply
all types of bespoke electrical
panels to your requirements
at competitive prices
T: +44 (0) 1384 567755
F: +44 (0) 1384 567710
E: ken.evans@sts-international.co.uk
www.sts-motors.com
Contact us for a quotation
Tel/Fax: 01279 433500
Mobile: 07855 753749
E: enquiries@edmlimited.co.uk

PRODUCTS & SERVICES DIRECTORY
ENCLOSURES
LINEAR ACUTATORS
PLC AND SCADA SYSTEMS
To advertise contact Simon Langston
t/f: 01353 863383 e: simon@dfamedia.co.uk
REPAIRS
Independent Control Systems Ltd
Leading the way in
Industrial Automation
& Control Systems
Capabilities:
Turnkey Systems
Hardware / Software Design
System Build & Test
Installation & Commissioning
Site Service & Training
24 Hour Support
Product Expertise:
AC, DC & Servo Drive Systems
PLC, HMI & SCADA Industrial IT
Olsen Engineering UK Ltd
Unit 17, Parc Haford, Tregynon, Newtown SY16 3EQ
t: 01686 651151
email: info@consultolsen.com
web: www.consultolsen.com
“When push comes to shove,
Olsen has the answer”
Email : info@iconsys.co.uk
Website : www.iconsys.co.uk
Approved solution partners:
ISO 9001:2008 registered
GEARBOXES
M
MOTORS/GENERATORS
POWER QUALITY
INDEXING TABLES
• Full range of EFF 1 energy efficient motors
• Asynchronous Motors 0.12kW to 2800kW,
2/12 poles LV
• Asynchronous Motors 110kW to 2000kW,
2/12 poles MV
• Hazardous Area Motors 0.12kW to 560kW,
2/12 poles LV
• Hazardous Area Motors 10kW to 500kW,
2/12 poles MV
• Single Phase Motors 0.18kW to 3kW, 2/4 poles
• Synchronous/Asynchronous Generators 10 to
5000kVA, 2/16 poles LV
• Synchronous/Asynchronous Generators 200 to
5000kVA, 4/16 poles MV
Marelli UK Ltd, Loughborough, Leics
T 01509 615518
E john.attenborough@marellimotoriuk.com
INTELLIGENT MOTION CONTROL
POWER TRANSMISSION
Specialists in AC/DC industrial
electronic repairs
Fast turnaround
No fixed repair costs, quote on
each repair
Site support
Return to base 6 month warranty
Service exchange
PCB board repairs down to
component level
Experts in Industrial
Electronics Repairs
ElectroAid Service Engineering Ltd
Unit 15 Horton Court,
Hortonwood 50, Telford, TF1 7GY
Tel: 01952 677555
Fax: 01952 676083
www.electroaid.co.uk
SENSORS
Integrated Servo
Motion Control
Package
POWER TRANSMISSION DIVISION
WEISS UK Ltd
• Up to 5M dial capacity
• No need for clutch unit
• Unbeatable reliability
• Short delivery times
• NC programmable variant
• Optional:
Control Cards
Precision m/c'ed Dials
Machine Bases
Tel: 01952 240953
Fax: 01952 244442
Email: info@weiss.uk.com
Internet: www.weiss.uk.com
NEMA size 11, 17 & 23
Integrated Memory &
Logic Banks
Onboard Power Managament
Networking Ability
Reliance ®
Precision Mechatronics LLP
Tel: +44 (0) 1484 601060
www.rpmechatronics.co.uk
General Purchasing Office in the UK for
Industrial Power Transmission Equipment,
Electrical and Engineering Components
Sourcing service throughout the
UK, Europe, America and the Far East
Luso offers:
• Boston Gear/Warner Distributor
• Specialised service for American parts
• Ship to stock programme; kanban
• Fast response to all enquires
• Prompt despatch of stock orders
• Only original parts supplied
• ISO9001 (2000 revision) ISO1400/18001
• 24 hour service
The name LUSO is your guarantee
of quality and service.
Make LUSO your major supplier
E: yvonne.g@lusoelectronics.com
T: 0121 321 2144
F: 0121 355 5045
www.lusoelectronics.com

To advertise contact Simon Langston
t/f: 01353 863383 e: simon@dfamedia.co.uk
SENSORS
PRODUCTS & SERVICES DIRECTORY
SERVO MOTOR & DRIVE REPAIRS
STEPPER MOTOR
MOTION CONTROL
Stepper Motor
Motion Control
4 Axis-Simultaneous, upto
16 Axis-Independent
SERVO MOTOR & DRIVE REPAIRS
For All Your Product
Repair Needs
Tel +44 (0) 1270 508822
Fax +44 (0) 1270 251240
emeasales@electrocraft.com
visit us at www.electrocraft.com
ALPHA ELECTRICS LTD
Tel: +44 (0) 116 276 8686
www.alphaelectrics.com
STEPPER MOTORS
HYBRID
STEPPER
MOTORS
UNRIVALLED
CHOICE
n Widest range of NEMA frames
from 16 to 42
n Rare earth high torque models
n Single or double shafted
n Protection options up to IP68
n Customisation and full accessory range
n Large range available ex-stock
ASTROSYN INTERNATIONAL
TECHNOLOGY Ltd
Tel: 01634 815175
Fax: 01634 826552
email: astrosyn@btinternet.com
web: www.astrosyn.com
Interface with
USB, I2C, RS232
High & Low Power
Stepper Drives with
Microstepping
Integrated
Basic Scripting
Low Cost - Made in the UK
Custom Design Available
JAF Graphics Ltd
Tel. 01260 275127
Email: info@jafmotion.co.uk
www.jafmotion.co.uk
VIBRATORY MOTORS
Unbalanced
Vibratory Motors
ROSTA Screen
Suspensions
Two Great
Products
One Supplier
..
KOBO (UK) Ltd
Tel: 01625 529514
e-mail info@kobo.co.uk
www.kobo.co.uk
MAKING MODERN LIVING POSSIBLE
Drives PartnerNET
Danfoss Drives Competence Centres
are fully equipped to satisfy the total
needs of our valued Drives customers;
providing assistance in sales, installation,
commissioning, technical support and
service 24/7/365.
For further information please
contact Danfoss Drives on
01895 617 100 or your
Regional Competence Centre
directly.
one place - one solution
Regional Competence Centres
Scotland Tel: 01324 633 203
WJ Electrical Supplies Limited
Ireland Tel: 02890 645 060
Greenville Industrial Drives & Controls
Northern England Tel: 01457 837 145
P-n-P Drives & Controls Ltd
Southern England Tel: 01923 333 375
K2 Drives and Controls Limited

APPOINTMENTS
To advertise contact Simon Langston
t/f: 01353 863383 m: 07962 402454 e: simon@dfamedia.co.uk
Beckhoff $. /# 2*-'6. !./ ./ "-*2$)" 0/*(/$*) *(+)4 ) $. )*2 $) /# 2)/ /* # - !-*( -$''$)/
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INDEX OF ADVERTISERS
Field Sales Engineers – Automation Products
Mitsubishi Electric is one of the world’s leading automation equipment manufacturers, with
an excellent reputation for innovation, reliability and value. In the UK, the Mitsubishi brand
has established itself as leading supplier in many industries with a strong portfolio of
automation products including PLCs, HMIs, drives, servos, and software solutions.
Mitsubishi’s extensive growth and development programme has created opportunities for
5 new automation sales people to work directly for our channel partners BPX and
LC Automation.
Automation sales professionals are required to cover the following areas:- West
Midlands, East Anglia, North and South West England and Home Counties.
The Role
To introduce and represent Mitsubishi products, along other key automation products, to
system builders, OEM manufacturers and end users. A major part of the role will be to
identify and develop new business opportunities including the specification and selection of
suitable equipment for automation projects. A further aspect of the role includes managing
existing accounts.
Qualifications
Sales experience in industrial automation or a related business sector would be an
advantage. However, recent graduates or engineers who consider themselves suitable for a
technical sales role are also invited to apply. As this role has a strong emphasis on face to
face contact with clients within the defined territory, it is important to have an appropriate
driving license.
Applications
To apply in confidence, please send a copy of your current CV and covering letter by
post to:
Channel Resource Manager
Automation Systems Division
Mitsubishi Electric Europe BV
Travellers Lane, Hatfield
Herts. AL10 8XB
Agencies submitting CVs or representing applicants will not be accepted
ABB . . . . . . . . . . . . . . . . . . . . . . . . . .29
Air-Tech 2010 . . . . . . . . . . . . . . . . . .14
Andantex . . . . . . . . . . . . . . . . . . . . .49
Aucotec . . . . . . . . . . . . . . . . . . . . . .47
B&R Automation . . . . . . . . . . . . . . . .13
Baldor . . . . . . . . . . . . . . . . . . . . .21,22
Balluff . . . . . . . . . . . . . . . . . . . . . . . .55
Beckoff . . . . . . . . . . . . . . . . . . . . . . . .7
Brook Crompton . . . . . . . . . . . . . . . .25
Cantoni . . . . . . . . . . . . . . . . . . . . . . .30
Centa Transmissions . . . . . . . . . . . .39
CRD Devices . . . . . . . . . . . . . . . . . .39
Cross+Morse . . . . . . . . . . . . . . . . . . .8
Danfoss . . . . . . . . . . . . . . . . . . . . . .51
Dontyne . . . . . . . . . . . . . . . . . . . . . .57
Drives & Controls 2010 . . .12,20,54,IBC
EMS . . . . . . . . . . . . . . . . . . . . . . . . .53
Heason . . . . . . . . . . . . . . . . . . . . . . .47
Hillhead . . . . . . . . . . . . . . . . . . . . . .33
IET PEMB 2010 . . . . . . . . . . . . . . . .57
IFPEX 2010 . . . . . . . . . . . . . . . . . . . .16
igus . . . . . . . . . . . . . . . . . . . . . . . . . .45
Koyo . . . . . . . . . . . . . . . . . . . . . . . . .43
KTR . . . . . . . . . . . . . . . . . . . . . . . . . .40
Lafert Electric Motors . . . . . . . . . . . .34
Lenze . . . . . . . . . . . . . . . . . . . . . . . .46
Leuze electronic . . . . . . . . . . . . . . . .43
LUSO . . . . . . . . . . . . . . . . . . . . .36, 37
Marelli . . . . . . . . . . . . . . . . . . . . . . . .27
Matara . . . . . . . . . . . . . . . . . . . . . . . . .9
Mayr Transmissions . . . . . . . . . . . . .39
Meiden . . . . . . . . . . . . . . . . . . . . . . .47
Micro-Epsilon . . . . . . . . . . . . . . . . . .15
Pilz Automation Technology . . . . . . . .2
Red Lion . . . . . . . . . . . . . . . . . . . . . . .5
Relec . . . . . . . . . . . . . . . . . . . . . . . .49
Reliance Precision Mechatronics . . .35
Renold Coupling . . . . . . . . . . . . . . .44
Ringspann . . . . . . . . . . . . . . . . . . . . .38
Rittal . . . . . . . . . . . . . . . . . . . . . .10,11
Rotalink . . . . . . . . . . . . . . . . . . . . . . .52
Servo Components & Systems . . . . .57
SKF . . . . . . . . . . . . . . . . . . . . . . . .OBC
Stober . . . . . . . . . . . . . . . .OFC, IFC, 17
TECO . . . . . . . . . . . . . . . . . . . . . . . .32
Zone 1 . . . . . . . . . . . . . . . . . . . . . . .30
64 March 2010 www.drives.co.uk

2010
BROCHURE
AVAILABLE
NOW!
Don’t
miss out
“Tuesday and Wednesday were
both very busy days with a good
calibre of enquiries and a good
response. We had 12 people
manning the stand and they
were all very busy.”
Patrick O’Neill – WEG
“Initial indicators on the decision
to go back to Drives and Controls
were well founded. Quality leads
from a busy 3 days.”
Bradley McEwan –
Rockwell Automation
The Drives and
Controls Exhibition
& Conference 2010
8-10 June 2010 NEC, Birmingham
Contact us now for your
FREE exhibition pack and become
part of the UK’s largest and most
successful manufacturing event
“The Drives and Controls
exhibition has resulted on 40%
increase enquiries taken over the
three days from the 2006
exhibition.”
Tony Pickering – Danfoss
“Wow! As a first time exhibitor
we will certainly be back in
2010.”
Mark Cooper – Wittenstein
( formerly Alpha Gearheads)
“We are very pleased with the
show, it is one of the best shows
we have ever exhibited at.”
David Higham – Habasit Rossi
“Excellent visitor numbers each
day including blue chip
companies.”
Nick Cadby –
Ideas in Automation
“The show looked great and the
support facilities were second to
none. The quantity and quality of
visitor was excellent.”
John Attenborough – Marelli
“The leads we had surpassed our
expectations and we need to talk
about booking a larger stand for
the 2010 event.”
Nigel Evenett – Lafert
“We think Drives and Controls is
now firmly established as the UK’s
number one exhibition for
automation and drives.”
Dave Baston – Control Techniques
www.drives2010.com
For further information and your FREE exhibition pack contact:
Doug Devlin | T: 01922 644766 | M:07803 624471 | E: doug@drives.co.uk
Simon Langston | T: 01353 863383 | M: 07962 402454 | E: simon@dfamedia.co.uk
DFA Media Ltd | Cape House | 60a Priory Road | Tonbridge | Kent TN9 2BL | Tel: 01732 370340 | Fax: 01732 360034
“Drives and Controls is the best
show that we have exhibited at for
8 years. We had more enquiries on
the first day than ever before.”
Carl Krajewski –
HMK Technical Services
“Compared to 2006 we’ve seen a
noticeable increase in visitors. The
co-location with the other shows
makes it a must see event for
engineers.”
John Wilkins – Rittal Ltd
“A superb show. By the end of the
Tuesday we already knew that we
would be back in 2010.”
Dave Proud – KTR

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