drives & controls - Industrial Technology Magazine

Together, we can put your ideas into motion.Whether you’re looking to improve productivity or process performance, Parker Hannifinis the first choice for a wide range of high performance AC and DC variable speed drives,servo and stepper systems, plus a comprehensive range of precision and industrialelectromechanical positioning solutions. With easy to use controls and designed to workon multiple control and communications platforms, Parker’s electromechanical anddrives products allow you to develop a complete motion solution with one supplier. Whenyou partner with the world’s leading diversified manufacturer of motion and controltechnologies, expect to see your ideas turned into reality.www.parker.com call: 00800 27 27 5374email: epic@parker.comMore details: Write in 30 on the free information card 3

COMMENT & ANALYSISIndustrial Technology ISSN 0967-5787 www.industrialtechnology.co.ukEDITORIALEditorMark Simms BSc Tel: 01732 773268ADVERTISINGAs a controlled circulation journal, Industrial Technology is sentfree of charge to individuals in the UK who meet the terms andconditions of the publishers. To apply for free regular copies,write to the Circulation Department. To those not meeting theterms and conditions, the magazine is available on UKsubscription at a cost of £60 per year (10 issues). Single copiesare £7. Overseas subscriptions (airmail) are as follows: Rest ofEurope including Eire £80 (single copies £9); USA $155 (single$18); Elsewhere £90 (single copies £10).Printing & production by Headley Brothers, Ashford, KentOrigination by Sarah & Marknew wavePUBLISHING LTDmark.simms@itmagazine.uk.comRegional Director (Home Counties & South East)Mark West Tel: 020 8467 3613mark.west@itmagazine.uk.comRegional Sales Manager (Midlands & South West)Helen Hardwick Tel: 01926 484648helen.hardwick@itmagazine.uk.comRegional Sales Manager (North of England & Scotland)Jan Anderson Tel: 01978 314730jan.anderson@itmagazine.uk.comDeutschland/Suisse/ÖsterreichEisenacher Medien Tel: +49 228-2499860info@eisenacher-medien.deOverseasGeorge Bennett MA Tel: + 44 161 374 5615PRODUCTIONit.marketing@itmagazine.uk.comProduction ManagerSarah Curl Tel: 0161 374 5615sarah.curl@itmagazine.uk.comMAILING ADDRESSESPress Releases: PO Box 342, Tonbridge TN10 4WDAdvertising Copy: 1st Floor, Hesketh House3 School Road, Sale, Cheshire M33 7XYCirculation Department: PO Box 85, Sale M33 2BBEmail: it.circulation@itmagazine.uk.comGENERAL ENQUIRIESEmail: it.info@itmagazine.uk.com Tel: 0161 374 5615Fax: 0161 374 6436AUDIT BUREAU OF CIRCULATIONSBUSINESS PRESSAre manufacturing andengineering out of balance?All the talk in industry in the UK right now seems to be centring on high valuemanufacturing. The Government has latched onto this in its updated manufacturingstrategy document, and bodies like the Technology Strategy Bureau (which is makinghuge investments in research, development, design and manufacturing across thecountry) are citing high value manufacturing as the only way forward for British industry. Butwhat exactly is high value manufacturing? Well, put simply, I would argue that it is arecognition that companies making run of the mill, me-too products can no longer competewith the low cost imports from the emerging economies. The focusinstead has to be on innovative products (with compelling functionalor feature-led advantages) made using innovative manufacturingprocesses (combining increased flexibility and increased productivitywith reduced operational costs).Successful UK enterprises will wonder if there is anythingsignificantly new here. Well, perhaps and perhaps not. But I reckonthe real benefit of the focus on the term ‘high value manufacturing’ isthat it has – maybe for the first time – really crystallised our thinkingon what it takes to survive as a high wage manufacturing economy.And this new focus is clearly paying dividends because manufacturingin the UK has been on the up for many months now. The economicgloom surrounding the banking and construction sectors that are threatening to drag othersectors down with them seem to be having very little impact on the manufacturing sector.Indeed, when The Times recently published a vulnerability rating for different industry areas,manufacturing was cited as the least vulnerable by quite some margin.So the future’s bright then? Well, we have a focus and a strategy, but I believe there’s aproblem brewing. Our manufacturing base is on the way up, but at the same time our coreengineering base is diminishing. If we can’t pull through the best people into careers inengineering, then who is going to design those high value products that the market is callingfor, and who is going to develop, maintain and continuously improve the innovativemanufacturing processes that will be needed to make them? Our manufacturing base and ourengineering base seem to be tipping dangerously out of balance.This won’t be news to any of you out there. I’ve seen first hand the problems you’re havingin recruiting good engineering staff to bolster your companies. The question is; what do we doabout it? The Government’s launch of diplomas in the likes of engineering and manufacturinghave attracted only a tiny fraction of the anticipated numbers of students, and I haven’t seenmuch in the way of roll out of the promised apprenticeship schemes. It would be interesting todevote a page in the magazine to this question of balance, built around your thoughts andcomments, because it’s an issue that we clearly need to address, and quickly. A high valuemanufacturing future can only be built on a sound engineering present.Mark SimmsEditormark.simms@itmagazine.uk.comFACT file...Think Automation and beyond...Innovation in Safety, from Japans marketleader in machine safetyPower + Signal + Display + Control + Switch + Safety = SolutionsWe are the obvious alternativeT. 01256 321000 E. marketing@uk.idec.com W. www.idec.com• Ergonomically designed “ON-OFF-ON” switch• 3 position switch for maximum operator safety• Compliant to:IEC 60204-1:1997ISO 12100-2:2003ANSI/RIA R15.06ANSI B11.19, 12.3.1.3• Various types and appearance; providing yourideal solutionMore details: Write in 50 on the free information card5

1020ContentsThis month in history: (1618) Sir Walter Raleighis executed for conspiracy against King James;(1963) The first Lamborghini, the 350GTV,debuts at the Turin Auto Show; (2003) Concordemakes its last commercial passenger flight548 INDUSTRY NEWS8 Government sets out manufacturing strategy10 Watertight at extreme depths12 Green collar skills gap will hit UK hard20 POWER TRANSMISSION Gears, Chains and Belt Drives20 Gear technology tuned up to get the noise levels down22 Gears, chains and belt drives: new products24 Out with the old and in with the new26 DRIVES & CONTROL SYSTEMS26 Industry’s drive for improved performance28 Energy saving: snake oil and disbelief30 Increasing the efficiency of industrial applications32 New drives update aging cold rolling mill34 Ten top tips for motion control system design36 Drives and controls: new products40 SENSORS & SYSTEMS Vision Sensors40 Bridging the divide between sensors and vision systems44 MECHANICAL JOINING Threaded Fasteners44 Threaded inserts meet the needs of critical applications46 DESIGN COMPONENTS Springs, Gas Springs and Dampers46 Gas springs provide a bird’s eye view of endangered eagles48 Wave springs deliver reliable performance in the toughest environments50 Tolerance rings – from concept to production52 FLUID POWER Hydraulics and Pneumatics52 Magnetic rotary sensors gain ground54 Commercial vehicle design: increased stability for fire fighting vehicles56 Hydraulics and pneumatics: new productsON THE COVERPutting ideas intomotion: innovative drivesfor stepper and servomotors from ElectroCraftSee page 36 for detailsENGINEERING LITERATUREEssential reading fordesign engineers p15COMPUTER AIDED DESIGNDealing with complex designsin the shortest time p16ENGINEERING DIARYJohn Richardson’s monthin viewp65EAR TO THE GROUNDBecky Silverton on the issuesaffecting manufacturing p66ALSO IN THIS ISSUE:FactfindersEvents calendarIndex to Advertisersp64p66p6658 MACHINE BUILDING & AUTOMATION Machinery Safety58 Power supplies take digital control to a new level60 A better way to build barriers62 Machinery safety: new productsNext month in Industrial Technology: Electric motors • Bearings, slides and lubricants • Enclosures, cabinets and fans• Fasteners and adhesives • Sensors and systems • Machine building and automation • Fasteners • Machinery safety6

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INDUSTRY NEWSwww.industrialtechnology.co.ukManufacturing strategysets out high value plansThe Government’s newly publishedmanufacturing strategy sets out aclear long term plan for how highvalue industry can contribute to amodern, balanced economyThe Government has revealed its new strategy for the UK’smanufacturing sector, which aims to provide UK firms withthe assistance and advice they need to take advantage of thechanging global trends in manufacturing. The strategy is setto bring nearly £150m of medium support for UK manufacturing,and relays the Government’s view of what the sector needs forsuccess in the long term. These include: developing low carbontechnology; supporting and promoting skills; realising overseasopportunities; improving technology networks; changing the UKperception of the manufacturing sector; and making the most ofintangiblesThe Government, despite the recent economic downturns,believes that the UK manufacturing sector has reason to beconfident. Citing open and flexible markets as the means for thesector to respond to the current challenging circumstances, thestrategy also reinforces the importance of manufacturing for the UKeconomy, and the support which Government is prepared to give toensure its survival.The aim of the strategy is to help more manufacturers move upthe value chain and to reap the benefits of high-skilled, knowledgeintensivemanufacturing operations. It recognises that the bestBritish manufacturers match the best in the world in new productdevelopment, innovative manufacturing processes, marketing andservices – all elements of the increasingly complex value chain. Nowthe goal is to ensure that far more companies match the success ofthe best.Commenting on the launch of the updated manufacturingstrategy, the CBI’s Chief Economic Adviser, Ian McCafferty, said:“Determining how UK manufacturing can best take advantage of thechallenges and opportunities of the 21st Century was a muchneeded exercise. The government’s new framework contains somefresh thinking – with a welcome emphasis on improvingmanufacturing skills, its public image, technology and the low carboneconomy. It must now deliver on its plans. To achieve success, thegovernment will also need to put in place a coherent procurementstrategy that enables industry to invest with confidence for the longterm.”EEF Chairman, Martin Temple, said: “The strategy sets out apositive and clear understanding of how manufacturing hasrestructured itself and the role that it can play as a high valuecontributor to a balanced economy. Government must take everyopportunity to drive home this message. “The next step as with allsuch announcements is to deliver and back the positive words withfirm actions of intent and support.However, Temple added that there remains an immediate shortterm need to help industry and the wider economy through thecurrent global economic turmoil. “This is a strategy for the long termand one we applaud. However, it does not detract from the need touse policy in the short term to help companies through the currentturmoil and ensure they are in a position to take advantage of theupturn.”EEF particularly welcomed a number of measures, with the firstbeing the positive view of how manufacturing has performed, how itis changing and what it contributes to the UK. EEF believes thatgovernment must continue to reinforce this message to keystakeholders and the public at every opportunity to promote a muchbetter understanding of the opportunities available in a thrivingindustry. Secondly, EEF welcomed the commitment to develop anindustrial strategy to realise the business opportunities associatedwith a low carbon economy and measures to ensure UK businessgets a significant chunk of any new business.EEF was also enthusiastic about the intention to address theimage of the sector through the ‘Manufacturing Insight Programme’,together with a ’Manufacturing the Future’ campaign in schools topromote a better understanding industry, its contribution to theeconomy and the careers available. Finally, EEF welcomed theexpansion of Apprenticeships by inviting bids from largemanufacturers to train additionalapprentices including for theirsupply chain. It also welcomed theefforts to simplify the skills system,though business will need to beconvinced that real progress isbeing made.Investment inskills will paybig returnsInvestment in engineeringand science skills can payback five fold – that wasthe message for Secretary ofState John Denham fromskills council Semta. DIUShas given the science,engineering andmanufacturing sector accessto £65million in a skillsfunding compact to improvecompetitiveness so theSecretary of State was keento hear what kind of returnon investment he couldexpect.Pilots in the WestMidlands region found thatwith government seedfunding of £18,000,companies achieved anaverage of £94,000 inprofit improvement in asingle year – a five foldpayback. Rolled out to just50 companies in eachEnglish region, thisapproach could reap a £42million sustainableimprovement in profit and2,400 B-IT trainedemployees. Moreover B-ITprogrammes managed bySemta’s new National SkillsAcademy for Manufacturinghave already producedaround £2.7 million insavings across eightcompanies.Denham commented:“Investment in skills paysdividends for individuals,companies and industries,and I congratulate Semtaon its admirable record ofworking with governmentand individual firms todeliver the world-classtraining the sector needs tosucceed. This Government,in partnership with Semta,will go further to make surecompanies get the trainingthey need, when they needit.”customised solutionsSpecialists in Brake MotorsFor stopping any applicationTo order a catalogue please contact us below.For the very latestproduct information,most up to date industrynews, plus companyprofile information, visitthe pages of IndustrialTechnology online atindustrialtechnology.co.ukTel. 01270 270022 Email. lafertuk@lafert.com www.lafert.com8More details: Write in 80 on the free information card

COMPANY NEWSRightsizingin actionWatertight atextreme depthCPE has won a contract to manufacturewatertight doors for Astute Class submarinesThe right drive technologyThe right choice of modelsThe right optionsThe right software toolsCorus Process Engineering(CPE) has been awarded acontract from BAE SystemsSubmarine Solutions tomanufacture a range of long leadtime equipment for use on the AstuteClass submarine Boat Number 5.The contract involves themanufacture of watertight doors,including: all associated locking andinterlocking mechanisms; tunnel doorand shielding plug arrangement;tunnel hatch; re-fuelling plugs; and avariety of other blanking plugs andinserts. The watertight doors, whichwill be manufactured at CPE’sWorkshops in Workington, will bedelivered in stages along with otherequipment, starting from January2009 through to February 2010.This contract follows similarcontracts for the supply of equipmentto Astute Class submarines, BoatNumbers 1 to 4. Equipment forBoats 1-3 has already beendelivered, with equipment for Boat 4currently progressing through CPE’sWorkshops. Vaughan Wilson,project manager at CPEcomments: “CPE hasalready carried out numerouscontracts for similar work on theAstute Class submarine, includingwatertight doors, torpedo tubes andre-fuelling plugs. The watertightdoors in themselves are very complexitems. Some of the items requirespecial materials, heat treatment orneed to be fabricated, so it allinvolves a lot of engineering skillsand technical know-how.”He adds: “There’s a lot ofcomplex welding required on theproject. Fortunately, CPE possessesthe necessary experience and skillsin welding to do this. We use a rangeof different welding techniques onthe doors, including MIG, TIG andflux-cored arc welding, eithermanually or automatic.CPE manufactures highspecification doors for use insubmarines, surface vessels andplatforms, ranging from watertightdoors and tunnel doors. All these aremachined and assembled fromcastings and forgings,working from drawingsprovided by thecustomer.Lenze drives & automationRightsizing for:smaller sizeslower costsfaster buildsmore performancewww.lenze.co.ukLenze10 More details: Write in 100 on the free information cardINDUSTRIAL TECHNOLOGY • October 2008

www.industrialtechnology.co.ukBeijing Wheel gets itsgiant spherical bearingsAfter 18 months, TheSchaeffler Group has nowcompleted the manufactureof two giant spherical rollerbearings for the world’s tallestobservation wheel, China’s newBeijing Wheel.In total, around 22 tonnes ofsteel has gone into producing thetwo hub bearings. Each bearing hasan outside diameter of 3,200mm, aninner ring bore of 2,600mm and aring width of 630mm. Each bearingincorporates 118 rollers, each ofthese weighing around 20kg.The hub bearings for the BeijingWheel will operate 108 metresabove the ground. The Beijing Wheelwill be 208m high and is designedto accommodate 1,920 passengers.One revolution of the wheel will take20 minutes to complete, but willenable guests to see stunning viewsof the city of Beijing.Schaeffler’s experience in thisarea includes the design andmanufacture of the hub bearings forLondon’s Millennium Wheel.Baldor’s powertrans acquisitionBaldor has announced that it hasacquired Poulies Maska ofSte-Claire, Quebec, Canada.Maska manufactures sheaves,bushings, couplings and relatedmechanical power transmissioncomponents. It has 180employees, primarily located inCanada, and a new facility inChina. Maska’s sales in 2007were approximately $33 million.Parvalux acquiresEMD Drive SystemsParvalux has acquired Halsteadbased geared motor maker EMDDrive Systems from RubiconPartners LLP, and is now in theprocess of aligning the twobusinesses to become the UK’slargest combined manufacturer ofsmall electric geared motors. Thecombined business is projectedto turnover £18.5m next year.Eriks buys SealsPackings & GasketsIn line with its strategy to take astrong market share in all regionswhere the group has its ownbranch operations, Eriks hasreached an agreement to acquireBarnsley based Seals Packings &Gaskets. SPG has annual sales of£7.0 million.Underwater gliderstudies AtlanticA team from the NationalOceanography Centre,Southampton, has launched anautonomous underwater glider inthe Eastern Atlantic. The aim isto understand better theinteraction between oceans andclimate. Using an average of just1.5 Watts, gliders have beendesigned for endurance. They aretypically able to ‘fly’ from thesurface to 1,000m depth andback to the surface, whiletravelling about 4km horizontally,in around 3 hours.Mitsubishi andCognex collaborateMitsubishi and Cognex havesigned an agreement to developand market vision productsjointly and to market them toMitsubishi’s customers aroundthe world. Cognex will work withMitsubishi to develop versions ofits vision systems designed tointegrate with Mitsubishi’sfactory automation products.October 2008 • INDUSTRIAL TECHNOLOGYMore details: Write in 110 on the free information card11

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QIndustrial Technology asksthe importantuestions...feedback@itmagazine.uk.comHow do we assure success even intoday’s adverse economic conditions?even be used for marketing before the real thing is actually made – imagesAmina West of Autodesk has the answercan be used for brochures or sales material without having to useexpensive photography or inaccurate artist’s impressions.There are two ways to deal with adverse economic conditions and When the model goes into engineering, the latest software functionalitythe steep rise in the cost of raw materials. The first is to keep enables the team not just to check for clashes and interferences, but alsoyour head down, dig your heels in and wait for things to improve. carry out stress analysis and other necessary testing. Engineers can alsoDon’t spend any more than is absolutely necessary, stick with the experiment with different design alternatives here too – this time tryingtried and tested, be cautious and remain safe. The second is to be bold, different materials including more economic alternatives to help keepthink strategically and continue to invest in innovation in order to get the prices low but still maintain realistic profit margins. And all this can bebest designed products to market as quickly and as cost-effectively as done before a physical prototype is created. Consequently, when a realpossible. This means protecting key assets such as the latest technology to prototype is made, it is likely to be a final check rather the first of many.ensure you can continue to deliver new products to your customers – even When a definitive digital model has been passed on to manufacturing,when others can’t because they have cut back too keenly on staff and and the design data carefully managed and stored, the design team canresources.use parts or the whole design to build new ideas and innovate further. AsThe decision on which path to take is particularly pivotal for UKhigh-tech consumer products as MP3 players and mobile phones show,manufacturers at the moment. On the whole, the industry seems to have product innovation doesn’t necessarily mean starting afresh every time –got itself into shape – at least prior to the most recent figures showing a the constant improvement of existing successful designs can also be a richdrop in output. It appears that an increasing number of businesses are source of revenue. Not only do digital prototypes enable design engineersfully equipped to deal with a downturn. Yet, on the whole the UK’s bornagainto work freely and creatively without huge overheads, they also acceleratemanufacturing industry has shunned the mass market, relyingthe entire process, ensuring products reach the market while demand isinstead on quality and innovation as its selling point. And there’s no doubt still keen and before competitors. A recent report by Aberdeen Groupthat the current global climate favours the second approach. International stated that best-in-class manufacturers typically build just half the numbermarkets are fickle, demanding a continuous stream of creative newof physical prototypes, and so halve development costs too. As a result,products and, after all, it seems that this is what the British do best. they get products to market 58 days faster.But, if innovation is at the very cornerstone of survival during aSo, it seems that if a firm is already using 3D design software,downturn, how can manufacturers cope without escalating costs? One of innovation does not necessarily mean huge new investment. Rather,the answers is to do as much work as possible on screen rather than on adopting best practices and optimising the use of existing products holdspaper or in the real world. The latest design technology enables users to the key – and being proactive by meeting the economic storms head-on.do this from the very beginning of the process – the ideas stage. Intuitiveand easy to use tools enable designers to capture ideas as they come into Amina West is manufacturing directortheir head without necessarily having the finished product in mind. Using for Autodesk in Northern Europe.parametric change technology they can hone and refine the design over asmany iterations as necessary without clocking up an excessive timeoverhead as they may well have done using 2D drawings. These imagescan be discussed and explained to colleagues and, especially, to the clientenabling immediate feedback and subsequent tailoring of the design.Multiple alternatives can be considered by the team and decisions made atan early stage. Sticking closely in this way to client needs and expectationsbrings fewer expensive changes further downstream. The digital model can“We can’t stand still in a downturn.Constant innovation is the only wayforward. But how do you cope withoutescalating costs? One answer is to do asmuch work as possible on screen ratherthan on paper or in the real world.”14INDUSTRIAL TECHNOLOGY • October 2008

ELECTRICAL EQUIPMENTKeyboards & SwitchesDistinctive styling coupledwith essential functionalityWhat goes on inside your control panel is critical, but how it lookson the outside can be just as important. Idec now has both basescovered, with the introduction of the LW Silhouette SeriesWe’d all like sharp lines andstunning colours on ourmachines, helping to makea statement about style,especially in these highly competitive dayswhere distinctive styling can be one ofyour key advantages. But how often haveyou seen a switch product that offered youjust the attractive styling you wanted, onlyto find that the overall range was solimited that most of your control panelwould still have to be populated bytraditional switch products?Idec, though, has the ideal solution inthe form of its LW Silhouette Series whichcovers a full range of pushbuttons, pilotlights, key switches and selector switches.Perfect for industries requiring a hygienicfinish, they are flush mounted and projectjust 2mm from the front of the panel.Flush mounting eliminates the need foraccessories or additional parts,and the smooth design cuts downon surface area, preventing dust andother particles from accumulating on themachine. And the switches are sealed toIP65 for operation in challengingindustrial environments.The switches are availablewith PCB, solder tab or screw terminals,with gold or silver contacts, and withmetal or plastic bezels (including plasticwith guards). Colour options cover red,green, amber, yellow, blue and white.Illuminated key switchesParticularly novel in the range is theilluminated key switch offering, with theincorporation of a two-way splitillumination ring. While a two positionswitch would typically have the ringillumination off in one switch position,and either a solid blue or solid green inthe second position, the three positionswitch provides the option to split theleft and right halves of the illuminationring, to shine red in the left half in thesecond switch position and green in theright half in the third switch position.Across the range of pushbutton andkey switches, all the expected operatingfunctions are provided, with options forSPDT, DPDT and 3PDT contact blocks,and with the choice of momentary ormaintained switching actions in thepushbutton switches, and maintained orspring return actions in the key switchesand selector switches.Idec has over 60 years experience inindustrial switch design, so you’dexpect the highest levels ofreliability and quality. Reliabilityfor theLW SilhouetteSeries is assuredby a string of internationalapprovals from the likes of UL, CSA andTUV Rheinland, with the switchesthemselves tested well beyond thenumber of operation cycles required byinternational standards.Idec sees a host of applications forthe LW Silhouette Series, including foodprocessing, the semiconductor industry,medical equipment, chemical processplants, elevators, biomedical facilities,robotic cell work stations, yachts,transportation, audio/visual equipmentand many more.MORE INFORMATION:Enter J185 or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for furtherdetails from Idec18More details: Write in 180 on the free information cardINDUSTRIAL TECHNOLOGY • October 2008

Check out ournew ultra compactD700 inverterSorry! This card has already been usedMore details:Write in 190 on the Industrial Technology free information cardReturn reply card to win a1 Gb USB flash driveFor drives you can rely on, call 0870 516 8567 or visit www.mitsubishi-automation.co.uk19

POWER TRANSMISSIONGears, Chains & Belt DrivesGear technology tuned up toget the noise levels downNoiselessPlus from gear innovator Zeitlauf is a pioneering planetarygearhead that combines smoothness and extremely quiet operation withunbeatable reductions and the ability to handle high radial loadsIf you visited the Hanover Fair thisyear, then you may well have seenwhat Zeitlauf is describing as apioneering new gearhead. But youprobably won’t have heard it – thecompany says that this new design is oneof the smoothest running and quietestplanetary gearheads currently available onthe market. The breadth of applicationranges from almost silent industrial uses toa gearhead for a technologically complexgolf caddy made of titanium. With fourdifferent design sizes (32, 42, 52 and 63)and a multitude of possible combinationswith all standard EC and DC motors,NoiselessPlus planetary gears can copewith a wide range of different tasks.The low noise levels are one of themost striking characteristics of thegearhead. Sound level measurement in thecertified noise laboratory have confirmedextremely high values for smoothness andnoise reduction, and the noise levels areindependent of load, even underextreme operation conditions. Thesecharacteristics have been achievedthrough the combination of a modifiedtooth design and precisionmanufacturing of the gearheads.High radial loadsThanks to their ingenious design,NoiselessPlus planetary gearheads arealso able to handle extreme radialloads. The key to this is thearrangement of the two ball bearings onthe left and right of the planetary wheelcage and the large distance betweenthe bearings, allowing high radial loadseven at very high speeds.A further characteristic is the widerange of possible gear reduction ratios.NoiselessPlus planetary gearheadsmake reductions up to 21:1 possible inthe single-stage versions. Zeitlauf saysthis is considerably more thancomparable products can offer, quotingreductions of 10:1 asthe typical maximum.The two-stageversions of NoiselessPlus are still moreimpressive, and can even achievereductions of 231:1. Zeitlauf has thatcompares very favourably with the 70:1reduction ration that you might expectto achieve with an alternative two-stagetechnology. The reductions offered asstandard for NoiselessPlus areharmoniously graded from 3.44 to231:1, and the company says thatfurther reductions can be achieved forspecial applications.Optimised performanceNoiselessPlus gearheads are optimisedto cope with high speeds on the inputshaft and large torques on the outputshaft. Planetary wheels made of highgrade plastic guarantee optimum noisereduction during operation. The helicalteeth ensure even, flowing contact andthus enable especially high loadtransfer coupled with excellentsmoothness. The bores of the bearingsin the plastic planetary wheels havecross-grinding which ensuresoptimum embedding of thelubricant over the wholegearhead service life. Thecomplete gearhead is encased ina single-pieceplanetary20More details: Write in 200 on the free information cardINDUSTRIAL TECHNOLOGY • October 2008

Gears, Chains & Belt Drives POWER TRANSMISSIONhousing made of turned, solidaluminium. The teeth are slotted ratherthan cast, for maximum precision. Theresult is unique smoothness andminimum wear.Material combinationsModular design enables NoiselessPlusgearheads to be readily tailored to meetindividual requirements for smoothness,torque or power. Individual componentscan be replaced by modules in othermaterials. As standard, the sun wheel ismade in non-hardened steel, buthardened steel is an option. Theplanetary gear is plastic as standard, butcan be supplied in brass, non-hardenedsteel or hardened steel. The internal gearis aluminium as standard but couldequally be non-hardened steel, hardenedsteel or stainless steel. And the housingis aluminium as standard with stainlesssteel a possible alternative.Generally, NoiselessPlus drives aresupplied as complete units made up of(Clockwise from top left) The new gears providethe long service life and minimum noiserequirements for medical equipment • Acomfortable golf trolley drive built around theZeitlauf gearhead motors is neither seen norheard • Zeitlauf gearhead motors open andclose the doors or extend the footboards onpublic transport with reliability and smoothnessmotor and gearhead, since the teeth ofthe sun wheel of the first stage (pinion)are milled directly into the motor shaft.This makes a compact gearhead designpossible, as well as particularly low noiserotation. However, this does not precludethe use of other motors, which can beconnected to the gearhead using bondedor push-on pinions.Bonded pinionsIn the case of bonded pinions, fittingtakes place directly at Zeitlauf to ensurea permanent connection and optimumrotation properties. The push-on pinion isfixed on the motor shaft using a clampingring and connected with the motor via aconnecting flange.As standard, the NoiselessPlusgearheads transfer torque through outputshafts with feather key connection (DIN6885, Form A) or face. Thanks to theproduction of output shafts made ofspecial case-hardened steel, both featherkey groove and face are particularlywear-proof. The use of special outputshafts is also possible, for example withdouble faces, offsets, (thread) bore holeson the end and circumference, holes orserration. Zeitlauf can also react flexiblyto segment, centring and housing form.Setting new standardsThomas Horz, managing director ofZeitlauf in Germany says: “We areconscious of the fact that we arecontinually setting new standards in thefield with our new developments. On theone hand, this has made us into atechnological leader in the powertransmission segment. On the other, it isalso the ‘driving motor’ behind ouractivities, pushing us to ever higherlevels. NoiselessPlus is the perfectcombination of strength, precision,reliability and absolute smoothness.”MORE INFORMATION:Enter J205 or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for furtherdetails from ZeitlaufMore details: Write in 210 on the free information card21

POWER TRANSMISSIONGears, Chains & Belt DrivesChain attachment protector clipsSlip-free chain attachment protector clipsensure goods are conveyed without damageTransdev now offers a range ofchain attachment protector clipsfor use in chain-based conveyingand parts handling processes.These easy-to-install clip-on parts ensuredelicate goods are protected againstdamage by the chain system while alsoensuring a slip-free conveyance process.Manufactured from POM, a highperformance plastic polymer, thesedurable protector clips feature an overlayof TPU (thermo-plastic elastomer) on thetop surface, providing a high coefficientof friction between the clip and theconveyed goods – also making theseaccessories particularly useful whenmoving goods which slip easily. Thetop surface of these clips has beenspecifically designed to enlarge thecontact surface, significantlyincreasing the adhesion frictioncoefficient between the conveyeditem and the clip. Furthermore, toprevent any possible tilting or lifting ofthe carried load, the profile of the cliphas been shaped to ensure there are noedge lifting pressures at the transferpoints. As a result the clip guarantees aparticularly safe, slip-free conveyanceprocess. These parts are easy to install,highly durable and have a high loadcapacity, making them ideal for use in awide variety of applications.MORE INFORMATION:Enter J225 on the enquiry card, or visit ‘latest issuestories’ at www.industrialtechnology.co.uk forfurther details from TransdevPassivationcoating forprotectionRexnord’s zinc passivationand acid resistant coatingsnow have a new bluelustre. This new coating replacesthe former yellow chromate one tocomply with new legalrequirements introduced toeliminate carcinogenic coatings.As before, this new blue zinccoating is offered by Rexnord asan option on all its chains andassociated attachments.Zinc coatings are just one ofthe many options available forOvoid gearheadgets a redesignMclennan’s P5 series highprecision instrument gearheads,based upon the internationalovoid gearbox standard, have undergonesome design enhancements resulting inimproved delivery times and increasedapplication durability. In particular, thehousing material is now produced inZytel FR7025, a flame retardant plastic.The P5’s final output geararrangement maintains an identical toothform and diameter regardless of thereduction ratio – allowing final gear andshaft assemblies to be held in stock as‘blanks’ which are machined to suitstandard output shaft requirements andprovide the means for a fast turnaroundfor customised shafts.MORE INFORMATION:Enter J226 on the enquiry card, or visit ‘latest issuestories’ at www.industrialtechnology.co.uk forfurther details from MclennanBevel gearboxes arelightweight and compactRino Industries has introduced aseries of bevel gearboxes into itsproduct range, available in bothsingle and double shaft output versions.The simple construction housing is madefrom a plastic resin which has a superiorchemical and thermal resistance, andwhich results in gearboxes which areboth lightweight and compact.Suitable ambient workingtemperatures range from –10ºC to 40ºC,and humidity should be 80% or less. Awell ventilated atmosphere with dust-freeair, not including corrosive gas or steamin an indoor location, is the idealenvironment for these gearboxes. Theyare easy to use and install as the unithas through-holes and counter-boreholes allowing mounting in anyorientation. High grade grease is sealedin the casting before shipping ensuringmaintenance-free operation.The speed ratio available is 1:1.Overhang and thrust loads on the shaftsshould be avoided, by supporting bothends of the shaft on which a gear orsprocket is mounted by means of pillowblocks or bearings, customers caneliminate overhang loads. These unitsare not suitable for sudden reversals ofrotation or impact loads – KBX bevelboxes should be considered instead.MORE INFORMATION:Enter J224 on the enquiry card, or visit ‘latest issuestories’ at www.industrialtechnology.co.uk formore info from Rino IndustriesRexnord’s chains. As well as arange of different materials –including stainless steel, carbonsteel and plastic – there is a widechoice of lubricants to matchapplications from hygienic foodenvironments through to harshindustrial duties, plus low- andmaintenance-free characteristics.Zinc coatings are applied togive protection against rust andacid attack. They are applied byimmersing product in a solution ofchromatic acid and various otheradditives. During this process athin passivating chemical coatingis deposited.MORE INFORMATION:Enter J227 on the enquiry card, or visitwww.industrialtechnology.co.uk forfurther details from Rexnord®ReliancePrecision Mechatronics LLPLow Cost Brass Gears• Brass gears, an economical balance of accuracy andload capacity• Standard range available from stock• Starting under £3 each, visit our website atwww.rpmechatronics.co.uk or call our sales team formore informationCall our Sales Team on +44 (0) 1484 601002Visit us at www.rpmechatronics.co.ukUnique Solutions from Proven Concepts22More details: Write in 220 on the free information card

Designed tobe a part ofeverythingyou build.More details: Write in 230As a design or production engineer you're constantly looking for ways to simplify assembly.At the same time, of course, you want to reduce costs and improve performance. It’s a hardequation to balance. But it can be done – The Loctite range of engineering adhesives andsealants will help you do exactly that... and more. It’s the reason our products are usedand specified by manufacturers around the world. All Loctite products can be applieddirectly from the bottle or using Loctite Dispensing Equipment.To receive yourFREE sample, *log ontowww.loctitesolutions.com/ukFor further information contact one of our adhesive specialists.Call 01442 278100, email technicalservice.loctite@uk.henkel.com,or visit www.loctitesolutions.com/uk*Free sample restricted to the first 100 replies. Offer not open to distributors or stockists and ends in November.23

POWER TRANSMISSIONGears, Chains & Belt DrivesOut with the oldand in with the newReplacing rather than repairing old gearboxes onconveyor drives can help to cut energy bills andreduce other operating costs says Renold Gears’product manager Simon ChipchaseTo echo the slogan of a well-known supermarketchain, ‘every little helps’ in the drive to reduceenergy costs. Every effort should be made to findways of reducing energy consumption and operatingcosts if industry is to stay healthy and remain in profit.One area in which savings can be gained is in thedevelopment of more energy efficient drives for the bigconveyor systems that move material over huge distancesaround Britain’s quarries. Quite often these conveyors areseveral miles long, perhaps running heavy stone from aquarry face to a terminal where it may be loaded ontolorries, ships or trains for delivery to market.These big conveyor systems account for a large partof a quarry’s power consumption, so cutting costs herecan have a significant impact on the total energy bill forthe year. Motor manufacturers have rallied to the causewith a range of energy efficient products that are helpingto combat rising prices, but there’s another component inthe power transmission system that can make asignificant contribution too, and it is one that is oftenoverlooked: the gearbox.Rugged, reliable power transmissionIndustrial gearboxes have a reputation for being reliable,rugged components that will run for decades before theyneed to be replaced. When they do begin to wear outthere is often a temptation to have them repaired on anemergency basis to extend their life rather purchasing abrand new unit. A repair will cost less than a newgearbox, but the short-term saving is a false economy inthe longer term.It is worth remembering that an old gearbox comingto the end of its working life will almost certainly havebeen manufactured in an era before modern computeraided design and finite element analysis were in commonuse. It is easy to assume that power transmission is amature technology, and it is, but what has changed is theprecision with which gears are designed andmanufactured compared tosimilar products made decadesago. Modern gearboxes are alsomanufactured with advancedmaterials, improved bearings and betterlubricants than were previously available. An oldgearbox is inefficient at transmitting power compared toa modern one, and although a repair will extend an oldgearbox’s life the real cost will show up in the energy bill.The cost of gearbox inefficienciesConsider the typical running costs of a conveyor systemin a quarry with a 45kW motor running 16 hours a day,365 days a year. At current rates the bill to drive this onemotor alone will come to over £11,000 a year. And everypercent of efficiency loss in transmitting power from themotor to the conveyor will cost £110. Not too much youmight think, but when you consider the fact that oldergearboxes may be up to 30 percent inefficient then thingslook a little different. The old gearbox is now addingaround £3,300 a year to the quarry’s energy bill.Conversely, modern gearboxes are now so efficientthat only a few percent of motor power is lost,dramatically reducing running costs. When you calculatethe potential savings for all the gearboxes fitted on aquarry’s conveyor drives then the potential savings runinto serious figures. Additionally, because moderngearboxes are so efficient it is often possible to reduce thesize of the gearbox and motor to a size smaller than theones being replaced.When replacing an old gearbox and motor, rememberthat the original design of the motor will have taken intoaccount the high efficiency loss of the old gearbox. Forinstance, consider a drive with a 4,900Nm output torquerequirement at a speed of 30rpm. If the motor isconnected to a 70 percent efficient gearbox we cancalculate that a 22kW motor is required. Since mostreplacement drives are sized according to the installedmotor power, and theoriginal torque calculated bythe OEM machine builder isnot known, an oversizedmotor and gearbox would befitted.However, having establishedthe new gearboxefficiency from the gearboxsupplier, it is then possibleto calculate the outputtorque. If the drive isrecalculated with a 97percent efficient gearbox asmaller 18.5kWmotor can be selected totransmit the same torque, thusreducing the size and purchase cost of the motor. Thereare also other savings that can be made with a moderndrive system, over and above reduced energyconsumption and the reduced cost of purchasing asmaller gearbox and motor than the ones being replaced.For instance, many older power transmission systemswere commonly configured with a foot-mounted motorand gearbox on a sturdy metal base-plate. The motor andgearbox would have been connected with a flexiblecoupling, a component that requires regular maintenanceand more frequent replacement than either the gearboxor the motor it is connecting.Modern designs allow for flange mounting the electricmotor directly onto the drive shaft, eradicating the needfor the flexible coupling and the base-plate structure. Wehave therefore eliminated the initial purchase cost of thecoupling, the base-plate, the cost of couplingmaintenance, replacement couplings and the headacheof how to guard the whole arrangement.Even longer lasting designsEven though the age of old gearboxes still operating inBritish quarries is testament to the quality ofmanufacturing at the time, modern gearboxes will lasteven longer. Older gearboxes were fitted with lower loadcapacity bearings, based on older imperial ball racedesign technology, than their modern equivalents.Modern bearings have no effect on the efficiency of thegearbox but they do have a much longer operating life,which cuts maintenance costs and extends the life of thegearbox still further.Repairing old gearboxes to get a few years extra lifeout of them may seem tempting, but in today’s world ofrising energy costs it is worth considering replacementas an alternative in order to start benefiting from theenergy savings of an efficient drive system soonerrather than later.MORE INFORMATION:Enter J245 on the enquiry card, or visit ‘latest issue stories’www.industrialtechnology.co.uk for further details from Renold Gearsand more stories on gears, chains and belt drives24INDUSTRIAL TECHNOLOGY • October 2008

Giving youtotal flexibiltyDelivering superior product capabilityCage design and materials specially selected forindividual applications. Standard bearings withoptimised load distribution for better balanceand lower stress. Tougher technology for windturbines with 23% higher loads. They’re just apart of the full range of ball and roller bearingsthat gives NSK the flexibility to meet even themost challenging industrial gearbox application.An acknowledged leader in advanced motiontechnology, NSK invests over 60 millionannually to develop innovative products andsolutions that extend product lifetimes, increasereliability and lower maintenance. Our gearboxindustry experience is unmatched and backed byprofessional, knowledgeable and service-orientedauthorised distributors. From sophisticated failureanalysis to bearings selection, calculation andlubrication recommendation, our flexibility istotally geared around you.NSK EUROPEMore details: Write in 250 on the free information card 25

Laser sensorsfor displacement,position & thicknessDRIVES & CONTROLSVariable Speed DrivesIndustry’s drive forimproved performanceSilverteam’s StuartHarvey examines thestate-of-the-art invariable speed drivesNew sensors:- Series 2210 for large offsetdistances- Series 2220 for extremefast measurement:Measuring rate 20 kHz- Series 2200LL for metallic,shiny surfacesThe correct sensorfor your application:Measuring ranges 2 to 750 mmLinearity from 1 μmResolution from 0.03 μmMeasuring rate up to 37 kHzLargest selection worldwidewww.micro-epsilon.co.ukMicro-Epsilon UK Ltd.Call +44 (0) 151 355 6070info@micro-epsilon.co.ukBy any measure, the variablespeed drives market isenjoying an extended periodof tremendous growth.Research from various market analystsshowed that 2004 and 2005represented the strongest consecutiveyears of growth for the worldwide drivesmarket in over a decade, with themarket strong across all productcategories, all power ranges, and in allregions. In particular, 2005 sawdouble-digit growth, with only a slightslowing from this in 2006, andcontinued strength in 2007.There is no doubt that a significantslice of this growth is a response torising energy prices, with variable speeddrives being retrofitted to existing fixedspeed motor installations to deliverconsiderable energy savings. But behindthe headline grabbing energy statistics,there has been a raft of developments ininverter technology that are enablingrapid advances in machine design. Thishas proved significant for OEMs and endusers alike.Key trends in the developments invariable speed drives include improveddynamic performance, improvedelectrical characteristics, the ability tohandle higher power loads, easierprogramming of the desired controlresponse, increased ruggedness andreliability, and ever smaller size.The increased performance oftoday’s inverters is proving a majorboon for European OEMs as they striveto differentiate themselves from theincreased competition from the lowwage economies. The production ofindustrial machinery in Europe hasenjoyed consistent growth over the lastfew years, with market analysts IMSResearch forecasting total output to€345bn by 2010. IMS reported that2005 was a record year for industrialmachinery production in Europe, withtotal production of close to €294bn,with the biggest successes in theapplications where there is a benefit tobe reaped from more sophisticatedmanufacturing processes that combineincreased productivity with greaterflexibility, enabling end-users tomanufacture their products with vastlyincreased efficiency.The control performance of today’sinverter products is truly astonishing,with a raft of different controlalgorithms available to deliver superiormotor performance in any operatingmode. Modern drives continue to pushthe boundaries of control capability inboth open loop and closed loopoperation, with the best closed loopsystems even offering near servoperformance for demanding machinerycontrol applications.Required performanceHow this capability is delivered to theuser has become one of the key areaswhere the drives manufacturers candifferentiate themselves. Should everyoption be available in a given drive, withthe more complex functions hiddenunless they’re actually needed? Orshould different requirements each beserved by a wholly different invertermodel? Or should there be optionmodules to tailor generic drives tospecific applications? In truth, thespecific answer to these questions isperhaps less important than the goal:which is to be able to deliver a highlycost-effective solution that providesexactly the performance required in agiven application. And today’s productsare more than able to meet that need.Along with offering moresophisticated control algorithms andimproved performance, modern variablespeed drives are also a breeze to installand set-up. There was a time whentuning the drive to the motor meant thetedious job of entering all the variousmotor parameters. How our lives musthave changed when inverterdevelopments meant that all we neededto do was connect the drive and turn themotor, and the drive would do all of theconfiguration for us.Today, though, the state-of-the-artfor drive set-up has moved on, andoften there is no need to even touch themotor. The latest intelligent sensorlessflux vector drives provide fullyautomated tuning, setting up the drivewithin seconds for optimal performance.Much of this improvedperformance comes from developmentsin digital signal processors, with anumber of the dedicated DSP vendorsnow able to provide a completely, highlysophisticated drive on a single chip,embedding within the silicon a choice ofdifferent control algorithms. What thismeans for the user is a drive which ismore intelligent: it performs better, andis easier to program whilst giving theuser a far greater array of programmablefunctions. The result is a drive whichcan be enormously flexibleAnother significant development hasbeen the trend for more embeddedcontrol functionality within the driveitself. It doesn’t seem all that long agothat drives manufacturers took their firsttentative steps into the realms ofsequencing by embedding some simplelogic functionality within their products.Today, with advances in microprocessortechnology, PLC functionality iscommonplace on all but the simplest of26More details: Write in 260INDUSTRIAL TECHNOLOGY • October 2008

drive products. This often enablesusers to eliminate a complete level ofcontrol installation, thus simplifyingset-up and reducing cost. And having ahigher degree of intelligence on-boardthe inverter has been a primary driverin the move towards decentralised,‘drive-based control’.Embedded fieldbus commsA further enabler in this trend to ‘drivebasedcontrol’ has been theembedding of fieldbus interfaceswithin the inverter, simplifying theintegration and commissioning of thesystem, but also providing higherlevels of production data to bedelivered to higher level businesssystems. This is playing a key role inenabling manufacturers to optimisetheir production systems to best meettheir customers’ needs, and tomaximise efficiency through improveddiagnostics and trending analysis.Modern drives also address keyconcerns in industry – many of whichare now (or may soon be) governed byspecific European legislation. EMC is agood example, and EMC filters havebeen standard on drives for a numberof years. But whilst once they werehuge add-ons often as big as the driveitself, it is now not uncommon to seethe filter an inherent part of the inverterdesign. Similarly, modern drive designis addressing the issue of harmonics,ensuring that the minimum amount ofelectrical noise is fed back into thepower grid, and helping to optimise theefficiency of the drive itself.These developments and othersmake the modern variable speed drivemore powerful, more flexible and morecapable than it has ever been before.And there is much more to come. Asthe cost of silicon carbide transistorscomes down, we can look forward tohigh powers from even smallerinverters. At the same time, furtheradvances in DSP technology willdeliver even better control algorithms.Many of these developments will cometo market first in the high end drivesproducts, but, just as we see withcars, the technology will quickly filterdown to the general purpose end of themarket. We certainly won’t have longto wait to see where the future’sgoing to take us.MORE INFORMATION:Enter J265 or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for furtherdetails from SilverteamMore details: Write in 270 on the free information cardNurembergSPS/IPC/DRIVES/ElectricAutomationSystems and ComponentsExhibition & Conference25 – 27 Nov. 2008Experience electric automation at its best!Come and see it all!Control TechnologyIPCsDrive Systems and ComponentsHuman-Machine-Interface DevicesIndustrial CommunicationIndustrial SoftwareInterface TechnologyElectromechanical Components and Peripheral EquipmentSensor Technologywww.mesago.com/spsMesago Messemanagement GmbH, Postfach 10 32 61, 70028 Stuttgart, Germany, sps@mesago.com, phone +49 711 61946-828More details: Write in 271 on the free information card27

DRIVES & CONTROLSEnergy EfficiencySnake oil and disbeliefNo matter how you focus on energy issues, the use of inverterdrives makes real sense. They offer significant operational costand carbon savings and make control systems more responsiveto changing needs, says Jeff Whiting of Mitsubishi ElectricIn this current market, where energy costsare so volatile, it is vital to take whateveropportunities we can to reduce powerconsumption and therefore costs. Even inthe unlikely event that costs are not an issue,taking the situation from a green viewpoint, it isclear that we need to take carbon reductionseriously. This is high on the government agendaand it is clear that the carbon element of anyoperation will certainly begin to bite over the nextfew years.Manufacturers of variable speed drives orinverters claim that significant energy savingscan be realised in most fan and pumpapplications, simply by fitting their equipment tothe motors. In fact the high value of savings oftenpresented by manufacturers seems almost tocreate a credibility gap. As a ‘dyed in the wool’drives person, I have seen legitimate energysavings claims treated with suspicion rather likethe ‘snake oil’ solutions of the travelling WildWest shows.Dramatic energy reductionThe reality is that where inverters are usedappropriately, they deliver the projected savingsand very often exceed them dramatically.Manufacturers continue to stand by theirprojections and are often willing to put theirmoney where their mouth is by loaning drives toprove the projected claims. And it should be noted thatthe government has already recognised the importance ofinverter drives for energy saving and carbon reduction.Drives are included in the Carbon Trust Energy TechnologyList, and attract tax benefits where they are implemented.Let’s consider something as simple as an air handlingunit to understand the cost savings. Based on a typical110kW motor, the inclusion of an inverter drive andcontrols is likely to add about £9000 to the cost of theproject and would typically have a life expectancy inexcess of 10 years. A 110kW motor operating 24 hoursa day will have an annual energy cost of £70,000 attoday’s prices.Clearly, with this level of annual costs, saving energyshould be part of the long term strategy as even a smallsaving will make considerable impact on the lifetimecosts of the system. Given that a pump, fan or othermotor installation is likely to have a working life of at least10 years, the financial savings on the initial out lay canbe truly massive. And even in short-lived installations aninverter can be very cost effective, with the paybackperiod for installing an inverter often measured in months;indeed it rarely goes beyond a year. If energy prices rise,the payback period becomes shorter and shorter. Inreality, there are generally large savings to be achieveddue to the nature of the most installations and thecharacteristics of most fan and pump systems. Motors arefixed speed devices which run at a speed determined bythe supply frequency (50Hz in the UK), but fitting aninverter allows the speed to be adjusted, and the slowerthe motor goes the less energy it consumes.Quantifying the savingsThe amount of energy saved by slowing down a motor canbe quite considerable. For most fan and pumpapplications the consumed power falls in proportion tothe cube of the speed reduction which in real worldlanguage means that if you can run the fan or pump at90% of its rated speed then theoretically the powerconsumed would fall by 27%. The inverter itself wouldadd a few losses into the system, so a realistic savingwould be around 24% – a great saving, which based onour 110kW motor would equate to £16,800 per year incost reduction at today’s prices. Payback for fitting theinverter of about 7–8 months with an ongoing reductionin operating costs of at least £16800 for the life of theequipment. The question becomes, will the fan or pumpsystem operate effectively at the reduced speed to meetthe needs of the process? A review of actual installationsshows that most motors do run too fast, so there wouldappear to be room for energy savings. When systems aredesigned, they are generally sized for peak operationalloading, with an extra margin “to be on the safe side”.This is partly because motors only come in standard sizesand installing one that is too small results in poorperformance and high maintenance. Government figureshave identified that today most installed motor drivenfans and pumps are 25% oversized even for peakoperation.The oversized fan or pump does have ‘spare capacity’and traditionally operates with the excess air flow (orother output) being restricted or vented off throughmechanical restrictors such as baffles or valves. A verysmall degree of power reduction is experienced in thistype of system, but it pales into insignificance whenconsidering the savings which can be achieved usinginverters to adjust the motor speed and therefore therequired airflow.The inverter can be integrated into monitoring andcontrol systems to run at the optimum workingconditions, meeting operational requirements whilstmaking significant energy savings.Automatic motor optimisationModern inverters such as Mitsubishi’s FR Series invertershave further tricks up their sleeves as they are able totune themselves completely to the motor and dynamicallyreduce the power fed to the motor for the current loadconditions. This automatic motor optimisation cantypically save a further 3–10% of the power without anyloss of motor performance. It gives exceptional resultswhere systems have been oversized at it reduces heat andmagnetic losses in the motor itself.There are many motors installed throughout industrythat are contenders for being fitted with an inverter. Theexample quoted was based on one motor; but typically aninstallation – be it for a manufacturing plant, a processingfacility or a building’s environmental control – will includeseveral motors, each of which can be fitted with aninverter and gain significant energy savings.Indeed the situation is such that if you are starting anenergy reduction programme or just want to reduceoperational costs, a good first step would be to identify allmotors over 1.1kW and assume that they should all befitted with an inverter. You probably would not do theseall at once, but would do them in sequence, starting withthose that are either easiest or those that will provide thebest payback. With payback within a year, it would bepossible for the energy programme to become self-fundingafter the initial installations.Some people may always be concerned about ‘snakeoil’ where such large savings are claimed. As for me, I justhate paying energy companies and the taxman money Idon’t need to. Best of all, I know I am helping createa sustainable environment for us all.MORE INFORMATION:Enter J285 on the enquiry card, or visit ‘latest issue stories’www.industrialtechnology.co.uk for further details from Mitsubishiand more stories on drives and control systems28INDUSTRIAL TECHNOLOGY • October 2008

Visit us atSPS/IPC/ Drives 2008Hall 6; Stand Nr. 6-222Yourgatewayto AsiaCC-Link is the leading open fieldnetwork in Japan and Asia, andintegrating CC-Link technology intoyour product will open new doorsinto these markets.With over 5 million nodes installedworldwide, CC-Link provides high speed,deterministic communication, linking a widerange of automation devices, and now includesCC-Link IE, a new open Industrial Ethernet versionwhich runs at 1Gbps.If you would like to know how our European membercompanies are increasing their sales in Asia, visit:www.clpa-europe.com or email partners@clpa-europe.comfor a comprehensive information pack.PARTNER ASSOCIATIONCC-Link Partner Association - EuropeTel: +49 2102 486 1750 or +44 1707 278953email: partners@clpa-europe.com I www.clpa-europe.comMore details: Write in 290 on the free information card 29

DRIVES & CONTROLSEnergy EfficiencyIncreasing the efficiencyof industrial applicationsAndy Parker-Bates, John Hill and Andrew Delaney of ParkerHannifin discuss some of the latest technologies and processesavailable to help businesses cut energy consumption and costsFaced with spiralling fuel costs and growingenvironmental concern, today’s manufacturing andprocessing companies are under pressure tominimise their energy consumption, while at the sametime continuing to increase productivity and profitability.This is no easy task, but it is being made considerablyeasier with the latest engineering technology designed toincrease the efficiency of industrial applications.Whether electrically, pneumatically or hydraulicallycontrolled, almost all types of equipment can be mademore energy efficient by using greener components and abest practice approach to operation and maintenance.Energy efficient drivesIn comparison with fixed speed AC or DC drive systems,variable speed drives provide a more energy efficientmeans of controlling rotating shafts on motors, spindles,fans and pumps, as shaft speeds can be matched to thevarying requirements of the application. This providesinfinitely variable control over speed, acceleration,deceleration, torque and direction of load.For example, in an application where a pump needs tooperate when the fluid level in a tank reaches a certainpoint, the normal method of operation would have beento start the pump at a fixed speed as the critical level inthe tank is reached. In practice, this means that the pumpcycles on and off, producing frequent and high surges inthe power required to start the pump motor. It should benoted that when a motor is simply switched on in this wayit initially draws around 300% of its rated current whileproducing less than 50% of its rated torque, making itparticularly inefficient.By using a variable speed drive in place of a fixedspeed alternative, the motor can be started slowly,requiring only a low frequency and voltage, and then thespeed increased at a controlled rate to accelerate the loadwithout drawing excessive current. This method typicallyallows a motor to develop around 150% of its ratedtorque while drawing only 50% of its ratedcurrent. In addition to reducing energyconsumption, this results in minimalstress and wear on moving components,reducing costs further.It is also worth noting that with thedevelopments in AFE (Active Front End)technology, regenerative systems thatmight previously have seen excess energyconverted into heat via resistor loads arenow able to export power back onto the gridrather than wasting it, making further energy savingspossible. In order to minimise the energy consumption ofequipment, it is important to consider carefully thespecific needs of the application, in order to avoid overspecifyingthe final system. The best approach is toinvolve your preferred drives supplier as early in themachine design and specification process as possible, toenable them to understand the needs of the system andrecommend the most suitable technology.More efficient pneumaticsPneumatic systems have been estimated to consumebetween 10 and 15% of all the electrical energy used ina typical manufacturing plant, so increasing the efficiencyof equipment that uses compressed air can haveconsiderable energy saving and cost benefits. While thefocus of attention to date has generally been on reducingthe energy consumption of compressors, what isbecoming more widely recognised is that considerableenergy is often wasted downstream of the compressor. Byimproving the efficiency of FRL units, valves andcylinders, plant managers can increase the efficiency ofpneumatic systems simply and cost-effectively.The latest generation of in-line air filters offers anenergy efficient solution, enabling particulates and othermatter to be removed without a significant drop inpressure across the filter. Modular technology is nowavailable, such as Parker’s Moduflex system, to makebuilding and installing a bespoke air preparation solutionsimple and cost effective. These modular units provideoptimum performance and a tailored system to suit yourapplication can be assembled extremely quickly andsimply, with filters, regulators, lubricators, and dump andball valves available to form a completely integrated airpreparation solution.When specifying these filters, it is important to sizethem correctly to ensure that a higher degree of filtrationdoes not have an adverse affect on flow rate, pressuredrop and service intervals. Similarly, correct sizing ofvalves and cylinders is crucial to optimising the efficiencyof a pneumatics system and minimise energyconsumption and costs. It is important to determine theamount of thrust or clamping/holding force required; theair pressure available;and the operatingefficiency of the cylinder basedon its type or method of manufacture. Likewise, therequired flow rate, working pressure, and acceptablepressure drop across valves should also be carefullyconsidered.Saving energy with hydraulic accumulatorsWith as many as 80% of hydraulic pumps and the motorsthat drive them being over specified to eliminate the riskof insufficient system pressure, a considerable amount ofenergy is wasted. One far more efficient solution is to usea hydro-pneumatic accumulator to supplement pumpdelivery. Using an accumulator can enable the capacity ofmotors and pumps to be significantly reduced, cuttinginitial expenses and ongoing costs.Hydraulic accumulators are able to store andsubsequently release a quantity of fluid to maintain therequired rate of flow. This is typically achieved bycompressing an inert gas to a set 'pre-charge' pressure,typically around 90% of system pressure. Thepressurised gas is separated from the system fluid withina bladder or by a piston or diaphragm, depending on theaccumulator design. As the hydraulic fluid in the systemis introduced into the accumulator, the fluid is forcedunder pressure against the separator and is stored untilsystem pressure falls and fluid is returned to the system.By absorbing pressure spikes and shock loads,accumulators can increase system efficiency whileprotecting pumps and other components againstdamage.In summary, by using the latest generation of energyefficient industrial technology and following best practicesthroughout a plant, considerable reductions can be madein both costs and environmental impact. By working inclose partnership with a leading engineering specialistcapable of supplying and controlling all forms of electrical,pneumatic and fluid power, such as Parker, businessescan ensure they are able to operate in the mostprofitable and sustainable way.MORE INFORMATION:Enter J305 on the enquiry card, or visit ‘latest issue stories’www.industrialtechnology.co.uk for further details from ParkerHannifin and more stories on drives and control systems30INDUSTRIAL TECHNOLOGY • October 2008

Easypeasy...More details: Write in 310 on the free information cardDRIVESANDROLLERSTHE HEART OF CONVEYOR TECHNOLOGYW W W .IN TERROLL.COMINTERROLLCORPORATEART●• Motorised Drums 80mm - 215mm Dia.• Drives for all makes of modular belts• Zone Controlled Roller Drives• Gravity Rollers• Fixed & Friction Drive Rollers• Tapered Rollers• Conveyor Wheels• Omniwheels • Ball Transfer Units• Roller Tracks • Pallet Drives / RollersInterroll Ltd., Brunel Road, Earlstrees Industrial EstateCorby, Northants, NN17 4UXTel: +44(0) 1536 200 322 • Fax: +44(0) 1536 748 515gb-sales@interroll.com • www.interroll.com… lightweight, low-price EasyChains ® : simplypush the cables in place by hand, filling fromthe inside or outside. Short installation time!Now even more sizes and versions available:inner height from 5 to 45 mm, inner width from5 to 140 mm, with multi-chamber system forseparate cable tracking.igus ® (UK) Limited51A Caswell RoadBrackmills Ind. EstateNorthampton NN4 7PW/en/easychainEnergy Chains Systems ® within 3-10 days 3D-CAD onlinePhone 01604-677240Fax 01604-677242sales_uk@igus.co.ukplastics for longer life ®More details: Write in 311 on the free information card More details: Write in 312 on the free information card 31

DRIVES & CONTROLSAC Drive TechnologyNew drives updateCopper rolling first requires the copper to undergo temperaturesranging from 600°C to 1,000°C during hot rolling, at the same timereducing the copper’s thickness to 10-15mm. It then undergoes thecold rolling and annealing process, which hardens the metal. Thesecomplex and delicate processes produce copper which is thenprimarily used in the electrical and electronics industries, such assubmarine cables and transformersaging cold rolling millUpgrading an old copper rolling mill with new inverters andservos has given the mill new life – and saved a lot of moneyA50 year old rolling mill was showing its age.Whilst the mechanics of this Robertsonmachine were still sound, the DC drivetechnology was causing problems withbreakdowns and costly downtime. The mill is used as aspecialist machine tool to form narrow strips of copperalloy and a replacement machine had been quoted at acost over £1million and a leadtime approaching twoyears. Therefore the chosen solution was to refurbish themachine and replacement of the drives at a fraction ofthat cost, with installation done by SEAR EngineeringServices and equipment and software provided by Lenze.SEAR Engineering Services is a small company basedin Derby providing an individual maintenance service fora number of large and small manufacturing companies inthe Midlands. It offers strong engineering support with anemphasis on minimising downtime and lost production.SEAR has a background inhydraulics and mechanicaldrive systems, so for thisproject it turned to Lenze,which was able toprovide the electricaldrive and automationskills necessary.The Robertson millconsisted of a pair of largeforming rollers driven by a250HP DC motor. Thehard but malleable copperalloy strips are manuallyfed into the rollers from theoven. Two further screwdown drives are positioned ateach end of the top roller. These adjust the roll separationin a range between 1 and 32mm. The customerrequirement was to replace the large and increasinglyunreliable DC drives. Improved safety was neededtogether with an accuracy and repeatability of the rolledsection down to 0.01mm. Important was a need tosimplify machine operation and get away from thesituation where the only person with the skills andknowledge to operate the mill was an employee pastretirement age.Modern drives solutionLenze was able to supply SEAR with both the inverterand servo technology needed. The main roller drive runsat a constant speed but needs adjustment according tothe type of strip to be formed. A Lenze inverter wasselected with a rating of 250kW, 475A, and with a150% overload available for 60 seconds. This drives asquare frame through-blown motor rated at 235kW. Thesquare frame option was chosen for its small size, butmainly because the through-blown ventilation can beducted out of the machine area – a customer requirementnot easily met with more conventional motors.The DC screwdown drives were replaced by servotechnology to achieve the 0.01mm accuracy required.As the existing gearboxes were in good condition, newsynchronous servo motors were fitted to them. TheseLenze MCS motors are compact and can be run down tovery low speeds without cogging torques. Control is setso that they always drive forward to the target position,so taking out the effect of gearbox backlash. Connectionbetween the gearbox and the motors was made usingLenze torsionally rigid metal disc couplings. These wereselected with locking bushes instead of keywayconnection to the shafts so that no further backlash wasintroduced. The synchronous servo motors are poweredby Lenze 9325 Servo PLC drives which act as a mastercontroller and slave for the whole machine. Theintegrated and powerful PLC means that no othermachine controller is needed.All three drives are fitted in a panel supplied byLenze and installed by an Engineering Partner. Systemcommunication is through the Lenze CAN system buswhich is integrated as standard, and features in not onlythe drives but also the extensive I/O used for machinemonitoring. Customised software written by Lenzeapplication engineers gives five pre-programmed menusfor roll spacing to suit different products. This isaccessible to the operator through a Lenze touchscreenHMI, with the alternative of control by a pendant remotestation with push buttons.Bringing a modern drive solution to solve problems ona 50 year old machine tool illustrates good teamworkbetween SEAR Engineering Services and Lenze. Theresulting solution is economical and close liaisonbetween SEAR, Lenze and the customer allowed theinstallation to be made in a short time window,minimising lost production. The new high power inverterexceeds the capacity of the old DC drive system and thecomplete solution with servo drives and panel hasresulted in easier operator control and increasedproductivity.MORE INFORMATION:Enter J325 on the enquiry card, or visit ‘latest issue stories’www.industrialtechnology.co.uk for further details from Lenze andmore stories on drives and control systems32INDUSTRIAL TECHNOLOGY • October 2008

More details: Write in 330 on the free information cardNEWMulti Axis SolutionsFrom light high speed componentplacing to heavy lifting and handling,HepcoMotion’s multi axis solutionswill allow increased productivity andimproved efficiency with reliableround-the-clock working.Our linear driving elements come from ourstandard range of proven products with orwithout the necessary motor/control packagefrom our systems partners; SmartDrives.• Custom engineered solutions fromyour specification• Standard driven elements used,good availability• Range of gearboxes, motors andother mechanical parts to suit• Frame building usingHepcoMotion MCS system• Rack, screw or belt drivenoptions. Supplied in assembledformat or as a kit of parts• Extensive before and aftersales serviceHepcoMotion ®Tel: +44 (0)1884 257000 E-mail: sales@hepcomotion.comTiverton Way, Tiverton, Devon EX16 6TG Fax: +44 (0)1884 243500More details: Write in 331 on the free information card 33

DRIVES & CONTROLSMotion ControlTen top tips formotion control systemsProblems with implementing motion control systems? GerardBush of servo system specialist Inmoco gives his top ten tipsWhen asked to name the single biggest barrier toimplementing motion control systems, manyindustry experts cite the difficulty thatnumerous engineers have in keeping up with all thetechnical advances in this fast-moving field. So how doesan engineer go about designing a system that is easy toimplement and maintain? Try these ten tips:1. Use open standards for developing applicationprograms for motion and I/O control. For example,PLCopen motion control function blocks provide a richfeature set and reduce the learning curve betweenvendors’ products.2. Select digitally networked drives to simplifycommissioning and reduce cabling costs. Networkeddrives also typically have superior diagnostic capabilitiesover analogue drives.3. Create and maintain a library of reusable functionblocks that perform tasks specific to your machines,product, or industry, such as flying shear, cut-to-length,winding, etc. Many motion control vendors can supplyyou with these, or with examples that are easilymodified.4. Buy an integrated package of drives, motors, andcables in order to reduce design and commissioning time.5. Make sure your commissioning software haspowerful, intuitive tools to simplify tuning. A built-indigital scope with frequency analysis makes configuring anotch filter trivial.6. Build error handling into your application from thebeginning. Fault recovery is critical to most applications,and can be relatively painless if designed in from thestart.7. Select the proper feedback device. Consider speedrequirements, ambient temperature, machine vibration,and resolution. If it is an electronic gearing application,consider the relative resolutions between master andslave axes to reduce the amount of gearing up.8. Size your motors and drives properly for theapplication. Your vendor can assist you with this process– or provide you with software tools to simplify doing ityourself.9. Choose a motion controller with a rich feature set ofapplication-specific function blocks or built-incapabilities, such as high-speed registration, tensioncontrol, and others. In selecting the most appropriateproduct, match your application requirements to thefeature set of the motion controller.10. Select a motion controller with IEC-61131-3programming and I/O support to eliminate the PLC. Anintegrated package reduces development costs andincreases performance by eliminating communicationsprogramming and overhead between the two devices.MORE INFORMATION:Enter J345 on the enquiry card, or visit ‘latest issue stories’www.industrialtechnology.co.uk for further details from Inmoco andmore stories on drives and control systemsIncrease productivity and reduce costsEthernet PowerLink motion bus network brings keyperformance benefits for motion control systemsParker Hannifin has enhanced its ACR9000 familyof motion controllers with the addition of two newmodels featuring Ethernet PowerLinkcommunication. The new controllers are designed toincrease system productivity while decreasingoverall costs and installation time,through the use of inexpensive and readilyavailable Ethernet cabling for theinterface between servo drive and motioncontroller.The compact ACR9040 is capable ofcontrolling 16 axes of servo drive via theEthernet PowerLink network, withinterpolation of up to eight axes in anycombination. The ACR9030 offers theaddition of up to eight axes ofconventional command interfacing, forthe control of traditional servo andstepper drive axes. Both models generateposition set-points which are sent tothe servo drives via the EthernetPowerLink network, providing tightlysynchronised and co-ordinatedmulti-axis control that maximisessystem productivity.The ACR9000 platform featuresadvanced motion controlfunctionality including high-speedregistration, segmented cams,electronic gearing and a wide range ofinterpolation modes including linear, circular, sinusoidal,helical, elliptical, spline/NURBS and 3D arcs. Capable ofmulti-tasking up to 24 simultaneous programs, thesenew controllers can act both as an Ethernet PowerLinkMaster and as an Ethernet gateway for maximumflexibility. Onboard CANopen ports enhance thecapability of these controllers further, permittingintegration with HMI panels and remote I/O expansionmodules, while ACR-View front-end software provideseasy to use tuning, configuration and diagnostic toolsfor fast and simple set up.Ethernet PowerLink is a high-speed digitalmotion-bus network, which enables the easyinterconnection of PLCs, motion controllers, drivesand I/O products from a variety of automationvendors. Utilising standard, well proven industrialEthernet network hardware, Ethernet PowerLinkcombines a mix of polling and time-slicingmechanisms to provide a real-time, deterministiccommunications channel via a reliable, low cost andeasy to install hardware platform.Parker Hannifin is a member of the EthernetPowerLink Standardisation Group. This multi-vendorsupport for the standard ensures that a wide range ofautomation products are available for integration intoEthernet PowerLink-based automation systems.MORE INFORMATION:Enter J346 on the enquiry card, or visit ‘latest issue stories’www.industrialtechnology.co.uk for further details from ParkerHannifin and more stories on drives and control systems34INDUSTRIAL TECHNOLOGY • October 2008

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DRIVES & CONTROLSNew ProductsPutting ideasinto motionAt the heart of thousands of everydayessential machines and vastmanufacturing facilities are motors.As design engineers contemplate each “nextbig idea,” one of the first critical steps in thedesign process is to decide how to powertheir inventions. ElectroCraft’s latestinnovation has been to develop a new line ofmotion control drive products calledCompletePower which drive anentire range of PMDC,brushless DC and steppermotors.The company says theCompletePower drives are idealfor OEM design engineerslooking for a compact, easy tointegrate motion controlsolution, providing proof of howmodern state-of-the art devicescan help users make immediatesavings across many areas ofmachine equipment and plantconstruction. Not only areinvestment costs reduced, but soare the costs of secondary tasksassociated with installation,commissioning and maintaining.So what makes up these new drives?Key characteristics of the high performancefamily include robust design, compactfootprint, and ultimate ease of use.Equipment with a switched output designedfor two and four quadrant operation ishoused in robust aluminium covers. Theyare just 120mm high, 85mm deep and27mm wide. PWM technology means theamplifiers operate with an efficiency of atleast 95%, and additional cooling methodsare often not necessary at lowerperformance levels. The four quadrantPMDC amplifier with linear output is evenmore compact at 105 mm high, 65 mmdeep and the same width of 27.5 mm,however it does have a higher power loss.Power plugs can be attached without usingtools. Shielded RJ45-CAT5 connectors aresupplied for drive inputs and outputsmaking signal level cabling simple andstraightforward.The amplifiers can be commissionedquickly using the basic settings shown inthe manual. The desired mode of operationis easy to set using simple DIP switches.The versatile range of equipment opens upa wide spectrum of applications, since theamplifiers can be configured for verydifferent situations or applications.With most inventions, the fundamentalquestion of all design engineers is: How doI get this to work at a given price point andwith these given inputs? The solutionElectroCraft found was in the simplicity ofits motor and servo amplifier paired offering.With a quick-and-easy setup, designengineers can tweak their prototypes intoworking condition then have somethingready for full-scale production. Nowthat’s innovation.MORE INFORMATION:Enter J365 on the enquiry card, or visitwww.industrialtechnology.co.uk for further detailsfrom ElectroCraftCompact drive for stepper motor controlComplex CNC applications, according to B&RAutomation, are increasingly implementingstepper motor technology. In addition, more andmore pneumatic systems are being replaced by electricaldrives. ACOPOSmicro – an extremely compact drive foroperating stepper and servo motors in the lowerperformance range – provides an innovative solution.At only 63 mm wide, it saves cabinet space. An 80VDC model is available in order to achieve higher torqueat high speeds. The performance ranges between 50Wand 1kW. Powerlink and the X2X remote backplane areonboard as fieldbus interfaces. A clever cooling designmakes side and back wall mounting possible. Cold platemounting with oil or water cooling is available in additionto wall and feed-through mounting. This cooling designreduces costs by eliminating the need to carry outadditional work for climate-control and the relatedservice tasks.Using standardised PLCopen motion control functionblocks and CNC robotics libraries, all motor typessupported by ACOPOSmicro can be controlled via B&RAutomation Studio software without problems. Thecompany says ACOPOSmicro provides an ideal solutionfor use in the semiconductor, packaging, textile andprinting industries.MORE INFORMATION:Enter J366 on the enquiry card, or visit ‘latest issue stories’www.industrialtechnology.co.uk for further details fromB&R Automation and more stories on drives and control systems36INDUSTRIAL TECHNOLOGY • October 2008

When it comes to flexible couplings, the answer is “yes”. Now, what’s the question?CENTAPowerTransmissionSolutionsTechnologyLeading by Innovation | Advertisement | October 2008Can Centa flexible couplings,gears, gearboxes and brakes beintegrated into existing machineryor new solutions?Yes, Centa is increasingly being asked to provide completepower transmission solutions to manufacturers and suppliers ofall size, type and in all industries.Integrated solutions can be provided on a bespoke basis to anoriginal brief or as a maintenance, repair or refurbishmentproject for existing plant and equipment. There are over twentyflexible coupling models which can be specified individually oradapted and integrated into any situation. These arecomplemented by Centa’s range of gears, gearboxes, speedreducers for precision motion control and other drives. Inaddition, Centa supplies a range of heavy duty brakes and brakesystems that are ideal for large scale braking situations, forexample, on dock cranes, conveyors and all types of plant andautomated machinery.Over 11 million Centa mechanical power transmission couplingsare in service worldwide in industrial plant, generators, pumps,compressors, rail traction and construction plant, both mobileand static.Whatever your power transmission problems,Centa will provide the answer.Can you improve on a market-leadingflexible coupling?Yes, the new CENTAMAX-HTC for diesel engines is a highlyinnovative and unique development of its CENTAMAX flexiblecoupling that dissipates heat far more rapidly than the previousversion. The unique design of this new high thermal capacitycoupling enables end-users to specify a rubber flexible couplingon modern diesel engines that are highly torsionally active,without the damaging heat concentration previously found inthe centre of the coupling element.High Power/High Output diesel engines often cause morevibration and consequently, heat build up is vastly increased.Therefore, there is a need to increase the capacity of heatdissipation and the new CENTAMAX-HTC meets this need.The CENTAMAX-HTC is effectively two flexible couplings in asingle element. This means that each part of the dual rubberelement is narrower and therefore, with increased airflowthrough the coupling, cooling capacity increases and heatdissipates far more quickly than would be the case in aconventional single element.The CENTAMAX coupling is specifically designed forgenerators, marine propulsion, locomotives, splitter gearboxes,screw compressors and rotary pumps and was originallydeveloped by Centa over 25 years ago. These couplings areeminently suitable for axial plug-in and therefore perfect forconnection to flywheels in diesel engine flange housings.The new CENTAMAX-HTC high thermal capacitycoupling from Centa“Modern diesel engines now benefit from higher power densityand improved gas exhaustion values and therefore are more“torsionally active”. This places greater demand on the flexiblecouplings and consequentially, an increase in operatingtemperatures that now can be overcome with the new HTCcoupling”, said a Centa spokesperson.The new CENTAMAX-HTC considerably reduces the internaloperating temperature of the coupling, increases coupling lifeand in many cases, Centa can demonstrate that it is possible tospecify a smaller, less stiff coupling with a higher heat capacity.This eliminates the necessity for an expensive, complex andspace-consuming coupling, making the CENTAMAX-HTC asignificantly more cost-efficient drive solution.The CENTAMAX-HTC is developed initially as an 18,000Nmcoupling. Extensive testing confirms the improvement inefficiency and heat reduction performance. It is durable andreliable, as it follows the design criteria of the well-provenCENTAMAX coupling range, now established for over 30 years.Can specific power transmissionproducts be adapted acrossdiverse markets?Yes, the innovative design team at Centa prides itself on theability to develop products into all types of new applications.A perfect example of Centa’s creativity in action is theCENTADISC-C, an ultra lightweight, composite carbon fibreshaft, designed to reduce bearing loads and defeat noise andvibration caused by misalignment, particularly in spans of up to10 meters, or longer if required!Having been used successfully in numerous marine applicationsto provide single-shaft drives that are free of intermediatesupport bearings along the entire length, the CENTADISC-C hasbeen employed in the water industry in water wells. Its longreach capability enables the pump and the drive to be isolatedat distance and as no supports are required along its length, itis consequently simple to fit and inexpensive to maintain.It has also been successfully deployed in providing a reliablelong reach drive connection in wind turbines, where itintegrates with Centa’s high precision gearboxes for highlyefficient power delivery.Will CENTAFLEX couplings withstandthe rigours of construction vehiclesand plant?Yes, Centa’s highly successful CENTAFLEX-K and KE seriescoupling has been modified to make it even stronger. Speciallydeveloped to meet the demands of excavators, vibratoryrollers, loaders and other plant, it combines the uniquecombination of high torsional stiffness and simultaneous radialflexibility to optimise hydrostatic diesel drives in the low ormedium power range.CENTAFLEX-K/KE - now even strongerUntil recently, diesel powered construction vehicles with flangeconnected hydraulic pumps have predominantly been coupledwith a torsionally stiff coupling but performance suffered as aconsequence of high radial stiffness and consequential wear tothe driveshaft and bearings.The highly flexible CENTAFLEX-K/KE coupling overcomes theseproblems, increasing the lifespan of both the coupling and driveand reducing maintenance costs.FOR MORE ANSWERSCALL CENTA NOWCenta Transmissions LimitedTel: 01274 531034 Fax: 01274 531159post@centa-uk.co.ukwww.centatechnology.co.ukMore details: Write in 370 on the free information card 37

DRIVES & CONTROLSMOTIONcontrolComponents, systems and support.● Linear slides● Rotary tables● Elevator tables● Single & Multi-axis● Manual & Motorised● Standard & Custom● Linear bearings● Drives & MotorsMotion products andsystems for scientific,industrial and defenceorganisations.LG SeriesUniSlideBiSlideAgile SystemsSchneebergerEngineering excellence - by designLG Motion LimitedTel: +44 (0)1256 365600Fax: +44 (0)1256 365645info@lg-motion.co.ukwww.lg-motion.co.ukPowered rollers arebig on versatilityThe newest development inInterroll’s RollerDrive seriesis the EC200, bringingpeace and quiet back to theworld of unit load handling withzero-pressure accumulation.The 24V DC-powered 50mm roller meets the fullrange of requirements interms of safety,throughput and conveyor speeds. Akey feature of this next-generation isthat it combines space-saving designwith ultra-smooth running and hightorqueperformance – the perfectchoice for powered bends, lifts aswell as supply and discharge lines.Designed for applications with themost demanding throughputrequirements and container weights,this Hercules of a drive can achieveup to 30 start/stops per minute andtransport loads of up to 100kg persection. Even in wet conditions, theRollerDrive EC200 will deliver asterling performance thanks to itsIP66 protection classification. TheRollerDrive EC200 is supplied withall the necessary commutation andcontrol electronics integrated in theroller housing.If speed is of the essence,operators need look no further thanSmooth positioning stagefor sub nano resolutionAerotech’s new ALS130H serieslinear motor driven positioningstages have been designed forultra high precision scanning andpositioning applications where subnanometrelevel resolution needs tobe combined with exceptionalsmoothness, high traversingspeeds and fastaccelerationover travelranges up to150 mm. Theclassic two-partstage design is said tooutperform leadscrew drivenalternatives with their inherentfriction related stick-slip problemsand offers a higher load accelerationforce than piezo based positioners.The ‘H’ stage design bringstogether the latest technologiesavailable from Aerotech, buildingupon and improving the performanceInterroll’s newEC110 RollerDrives.Brushless, with 24 V DC motorpoweredrollers and a noise emissionof less than 55 dB(A) duringoperation, they are said by thecompany to be around 12% moreefficient than conventional products.Even with varying loads, a constantspeed is guaranteed. In conjunctionwith the new DriveControl HC-EC110, Interroll can supply an all-inonesolution.Conveyor rollers, drive electronics,cables and power supply unitscomplete the drive kit for InterrollRollerDrives, which the companysays provides the exact solution plantdesigners, system manufacturers andengineers are looking for.MORE INFORMATION:Enter J385 or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for furtherdetails from Interrollof the highly successful ALS130series to combine a centre drivenzero-cogging brushless linear motor,anti-cage creep cross roller bearingsand a 4.0 micron glass scale linearencoder with 40MHz encoderprocessing when used withAerotech’s motioncontrols. Theresult is acompact andultra-stiffmechanical systemfor high performancetest, measurement andinspection applications, capable ofdelivering exceptionally smooth lowspeed performance with vibrationfree, ultra-fine resolution.MORE INFORMATION:Enter J387 or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for furtherdetails from Aerotech38More details: Write in 380 on the free information cardINDUSTRIAL TECHNOLOGY • October 2008

New ProductsStepper drive providessoftware control optionAstrosyn reckons its MSST5-Sstepper motor driver will reallyshake up the stepper market.This brand new unit is similar inprice to traditional 5A step-anddirectionmicrostepping drives, butoffers three modes of control: stepand-direction;internal oscillatorspeed control; and full-blown PC orPLC software control.Software control allows it to beset up for running pre-coded routinesrepeatably, but it can also be usefulto use this PC control to carry out onlineoptimisation of parameters suchas acceleration/deceleration rates,speeds and wait times.Even used in ‘dumb’ mode as astraight replacement for a traditionaldrive it has the advantages of highcurrent capacity in a compact sizewithout requiring additional cooling,and very comprehensive protectionssuch as over/under-voltage, overcurrent,over-temperature, andopen/short circuit. The 256 microstepMSST5-S also incorporates featuressuch as automatic system statusmonitoring and display, andcommand signal smoothing.MORE INFORMATION:Enter J395 or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for furtherdetails from Astrosyn InternationalCANopen intelligent driveNew from Technosoft is a 3kWintelligent servo drive thatembeds motion controller,drive and PLC functionalities in thesame unit. Based on the MotionChiptechnology, IDM3000 is speciallydesigned for servo applicationsrequiring high peak torque, dynamicresponse and flexible integrationfeatures. It can be used to controlUL registered brakingresistor for large drivesREO has added a high voltageunit to its range of brakingresistors. It is ideal fordynamic braking applicationsinvolving large frequency converters oras a charging resistor for railapplications.The NTT606 units are compact,just 345x640mm by 250mm tall,and easy to install with excellentcorrosion protection. They also havegood vibration and shock resistancemaking them especially suitable foruse in traction or shipboardapplications.There are four models in REO’sNTT606 high voltage braking resistorrange which covers from 600 to2700W continuous power ratings, allwith up to x20 maximum ratingbrushless, induction, and DC motorsup to 3kW. IDM3000 drives 10Acontinuous and 30A peak currents, ata supply voltage ranging from 160 to325V.MORE INFORMATION:Enter J396 or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for furtherdetails from Technosoftoverload capability. Resistance valuesare from 1.20 to 52Ω and all modelshave been tested to 9.5kV.MORE INFORMATION:Enter J397 or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for furtherdetails from REOmotion andmechatronicsPermanent magnet and hybrid steppermotorsLow inertia dc motorsSynchronous and brushless motorsOptional tachos, encoders and brakesPrecision spur instrument gearheadsIndustrial and ultra low backlash planetarygearheadsHigh resolution industrial linear and rotaryincremental and absolute encoders.Stepper, DC servo and AC Brushless servodrive and control modulesCustomised motion control andmechatronics systemsContract EMC FacilitiesMclennan Servo Supplies Ltd.Unit 1, The Royston CentreLynchford RoadAsh ValeSurreyGU12 5PQUK Tel:+44 (0) 8707 700700Email:sales@mclennan.co.ukwww.mclennan.co.ukOctober 2008 • INDUSTRIAL TECHNOLOGYMore details: Write in 390 on the free information card39

SENSORS & SYSTEMSVision SensorsWhere visionmeets sensingSensors and vision systems have traditionallybeen at opposite ends of the complexity andcapability spectrum. But here we find outfrom Balluff how all that is changingDesign it yourselfDavall Stock Gears introduce a rangeof modular, adaptableWORM GEARBOXES for all industries.ATEX certified available.dsg@davall.co.uk | www.davall.co.ukCatalogueNowOnlineTel: 01707 283 131 Fax: 01707 283 132Afew years ago, the focus onquality rested on the PLC, buttoday the quality focus rests onsensors and vision basedsolutions to make sure products meetquality requirements. The next step inquality improvement is the merger betweensensors and vision systems.Traditionally there have beensignificant differences between sensorbasedand vision-based inspectionsystems. Most discrete sensor-drivenquality monitoring works best when amanufactured part can be automaticallypositioned for inspection exactly thesame way each time, so that sensorscan be used to verify a specific aspect ofthe product. This calls for sensorsstationed at the critical locationsnecessary to make their individualinspections a vital part of themanufacturing process.Vision based inspection calls formore expensive equipment to executein-line or final inspection. Visionmethodology has the advantages ofbeing able to inspect parts in variousattitudes relative to the camera andinspect more than one attributesimultaneously. Attributes can include:appearance, presence or absence,dimensional attributes, and positioning.And because vision technology can domore in the long run, it will actually bevery cost effective. Several discretesensors are needed to error proof acarton of cans, while one optical sensorcan handle the same task.Polar oppositesDiscrete sensors and vision tend to be atpolar opposites in complexity andcapability. In the past, sensor driven errorproofing of a manufacturing line has beenlimited to discrete functionality based onspecific technology. This includes(Top) Several discrete sensors are needed toerror proof a carton of cans, while one opticalsensor can handle the same task.(Lower) When using multiple discrete sensors,box corners need to consistently appear in thesame location in order to error proof labels;one optical sensor can do the same job, plusmany other tasks, while boxes are not inexactly the same position. (Left) All qualityaspects of this clamp – two drilled holes, boltsin position, overall configuration – can easilybe handled with an optical sensor.photoelectric sensing, proximity sensing,or laser based sensing. This process worksvery well in the discrete manufacturingarena, providing relatively inexpensivesolutions based on application expertise.On the opposite side of the spectrum,vision systems typically provide morecomplex multi-tasking sensing. Thesemethods can perform error proofingoperations similar to discrete sensors, butwith the addition of complex sensing thatrequires interconnection between sensingmethods.Sensor suppliers are now providingmore sophisticated sensors andapplication techniques advancing up thecurve towards vision solutions.Meanwhile, vision providers are trying toexpand down the curve towards thediscrete sensor world. But instead of acrash of technologies, there is evolving anew layer of technology that combinesthe best from each. With the combinationof both technologies and the simplified‘sensor like’ approach to configurationand usage, the user can apply higher levelsensing at a lower cost. This allows thesenew optical sensors to be applied morereadily in a true error proofing or packagedefect scheme.New vision based optical sensorssuch as Balluff’s BVS range bridge thegap between the two technologies. Theyprovide a simple, practical, and costeffective way to error proof production bysimultaneously checking several aspectsof the product with a single device. Thesedevices use a simple configurationinterface that can be learned and usedquickly by plant technicians. New optical40More details: Write in 400INDUSTRIAL TECHNOLOGY • October 2008

sensors also have multipleinspection and measurementalgorithms to drive multiplesensing options, that can store multipleconfigurations for quick part changeover.They provide more information than asingle function ‘smart camera’ or astandard discrete sensor. At the sametime, optical sensors avoid the traps ofcomplex vision systems in cost,complexity, and needed expertise forachieving reliable error proofing.Benefits for the userThis new type of optical sensorcombines aspects from bothtechnologies to provide a number ofbenefits to the end user. First iscomparative simplicity, with simpleconfigurations and interface, but withmultiple sensing functions within asingle device. Then there is faster setup, part changeover, and operationwith the solid reliability of discretesensing methodology. And then there isthe lowest overall cost to implementand maintain these sensors comparedto vision systems at the high end ormultiple sensor arrays (including singlepurpose smart sensors) at the low end.This new type of vision basedsensor is used more like a smart sensorthan a vision system. Just like a sensor,it is configured to look for certainattributes of a package or product tomake sure specific aspects are present,everything is configured correctly, andpositioning is verified. But unlike adiscrete sensor, the optical sensor doesnot need the product to be presentedexactly the same way for eachinspection, thus reducing fixturingcosts. And unlike a discrete sensor, itcan check for multiple characteristicsat the same time, thus justifying itscost sooner with a higher ROI.This is accomplished by taking theplace of several sensors, each of whichcan only check one attribute at a time.As opposed to using a more traditionalsensingarray, theseoptical sensors can significantly reducethe complexity and cost of errorproofing and product checking whileimproving the overall reliability of thepackaging process.This opens up a whole new world oferror proofing that was not availablebefore to reduce both unplanned andplanned down time, makingchangeovers easier, better, and moreflexible. The optical sensor is a wellplaced solution specifically forapplications that have multiple pointsof discrete inspection but do not havetight fixturing. This type of sensor isalso good when different products arerun on the same line and require lineconfiguration changes that wouldseriously hamper sensor arrays. Opticalsensors do not require significantchangeover or planned down time toallow for changes in sensor placement.However, an optical sensor would notbe as useful where a single discretesensor or two could also solve theapplication. It would also not be asuseful in applications where complexinspection algorithms or complexinternal logic would be necessary. Inthese cases, a vision system would stillbe the better choice.Thus, in most cases, the field is leftwide open for optical sensors to beused during the manufacturing processto check for specification and qualityadherence at each step of theproduction process. Optical sensorsprovide the missing piece that beforehad caused many users to force theuse of more complex vision systemsfor these types of applicationsto accommodate the neededfunctionality.MORE INFORMATION:Enter J405 or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for furtherdetails from BalluffMore details: Write in 410 on the free information cardOctober 2008 • INDUSTRIAL TECHNOLOGYMore details: Write in 411 on the free information card41

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FASTENERS & ADHESIVESThreaded FastenersNext generation threaded insertsfor critical applicationsTappex has taken threaded inserts to the next level with thelaunch of the Trisert-3. Suitable for use in plastic and metalalloys, it is designed to withstand harsh environments andcorrosive atmospheres, making it ideal for critical applicationsThe Tappex name has been synonymous withthreaded inserts for over 50 years, with thecompany building its name on designing,developing and manufacturing inserts to meet the everchangingdemands of the plastics industry. The widerange of self-tapping inserts under the Trisert brandwere developed specifically to solve the requirements ofboth the established thermoset market and theincreasing high-strength thermoplastic applications,where installation time and reliability are of primeimportance.The standard Trisert range has for many yearsincluded three primary designs, with double ended,reduced headed and regular headed variants. Thesesolve most application problems in thermoset andthermoplastic grades, including the latest engineeringplastics. The concept of the Trisert design is to providea reliable and efficient post-mould process, where theinstallation torque can be controlled and monitored forgreater reliability. As the internal thread is used toinstall the Trisert, every insert is therefore automaticallychecked in the moulding for the existence of a goodthread.Now Tappex has expanded its range with theintroduction of the Trisert-3, developed to expand theTrisert range into more critical applications. Trisert-3has three cutting features to provide more balancedcutting forces and therefore reduced installation torquewhen compared to the many cross-slot designsavailable that only have two cutting features. Thedesign combines three cutting facets with three shallowflutes offering balanced cutting and enhanced back outperformance. The internal thread is not interrupted bycutting features and therefore will guarantee a freerunning internal thread without the risk of swarfjamming the screw.The Trisert-3 design maintains the completecylinder design that provides a stronger body, size-forsize,than the slotted design and also allows it to beused in pull-through applications, without anyproblems due to increased assembly torque associatedwith slotted inserts.Trisert-3 is available in two lengths – regular andlong – and is based upon the Trisert reduced headeddesign. This provides an increased bearing surface thatnot only allows higher tightening torques to be applied,but also provides more support to softer matingcomponents. The head diameter is designed to exactlyfit the counter bore in the prepared hole, and thuspresents a neat flush fit finish, where required.In most applications into plastic, the standard brassTrisert offers a satisfactory and economic solution withgood wear resistance and strength. Also it willwithstand corrosion in most environments without anysecond operation surface treatment. But to meet therequirements of a wider range of host materials andharsher applications, the selection of the material forthe Trisert-3 was very important. Thus the Trisert-3 isoffered in two grades of Stainless Steel (303 and 316)and also in case hardened steel with a zinc nickel,trivalent passivated finish.A key feature of the Trisert-3 is its ability towithstand critical environmental conditions, such asmarine and chemical/food processing, while stillretaining good wear resistance and strength.MORE INFORMATION:Enter J445 on the enquiry card, or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for further details from Tappexand more stories on mechanical fastenersFor more information on automationequipment, and other machinebuilding technologies, visitwww.industrialtechnology.co.uk44More details: Write in 440 on the free information card

Unifast Fastening Systems Ltd . +44 (0)1420 563333 . info@unifast.co.uk . www.unifast.co.ukFastenersorFastening Solutions?Unifast has the answerFAST TurnThe quick acting panel fixingfastener system used bymanufacturers throughoutthe automotive, aerospaceand other industries.KAPti-nutA high strength, captive threaded fasteningsystem for sheet metal, ideallysuited to multiple and automatedinsertion into thin gauge steel, aluminiumand pre-finished materials.Unifast Fastening Systems Ltd . Woodlea Park . Four Marks . Alton . Hants . GU34 5AZMore details: Write in 450 on the free information cardMore details: Write in 452 on the free information cardTRISERT-3THE NEW STAINLESS STEEL INSERTFROM TAPPEX• For plastic andmetal alloyapplications incritical environments• Stainless Steel 303and 316 plus casehardened steel witha zinc nickel, trivalentpassivated finishnew extensivetechnical literaturenow available+44 (0) 1789 20 66 00sales@tappex.co.ukwww.tappex.co.ukLeading Insert TechnologyMore details: Write in 451 on the free information cardMore details: Write in 453 on the free information card 45

MECHANICAL COMPONENTSSprings, Gas Springs & DampersGas springsflying highJet Press’s gas springs give watchers abird’s eye view of endangered eaglesThey are usually employed to hold open car boots orprop up heavy covers allowing access toindustrial machinery, but gas springs haveproved they can have a softer side by allowingenthusiasts to get closer to one of the country’srarest birds. Six Camloc gas springs have beenpurchased by the Forestry Commission Scotland andfitted to a bird hide which will allow dozens of watchersan unobstructed view of magnificent white-tailed seaeagles in their natural habitat.The hide, operated under the Mull Eagle Watchpartnership, is the only organised hide in the world tooffer a view of a white-tailed sea eagle nest, and issituated on the banks of Loch Frisa in a remote area of theIsle of Mull. It has canvas interpretation panels and twoTV screens featuring live footage of the eagles, the UK’slargest and most endangered birds of prey, which isbeamed into the hide from CCTV cameras placed close tothe nest. However, earlier this year, the Commission got intouch with industrial components suppliers Jet Press,based in Huthwaite, Nottinghamshire, with a challenge.At the front of the hide are three wide windows, whicheach weigh 6kg and are hinged so that they can beopened to allow watchers to rest their elbows on thewindow frame and look through their binoculars.However, weather in Mull is changeable. The Commissionwanted a mechanism whereby not only could thewindows be held open securely on windy days so thatthey would not shut or twist, they also had to be closedeasily, safely and quickly by rangers at the hide, which isa walk and a minibus ride away from where the visitorspark their cars. The task to find a suitable solution fell toForestry Commission buildingsurveyor Steve Wassall, whodecided that what was needed wasa set-up similar to an open car boot.He realised that he needed two gas springs for eachwindow, but was unsure of what specification they wouldhave to be. He approached Jet Press and outlined theproblem to its technical manager, Martin Belcher who,given the remoteness of the site, would have to doeverything over the phone.Jet Press stocks gas springs manufactured byArvinMeritor in Leicester and its range reflects the vastversatility the motion control components offer in size,performance capabilities and their applications. “Gassprings are used for an incredible number of differentapplications, but this was certainly a new one to us,” saysBelcher. “They are, however, perfect for the job, althoughthe application required some communication betweenSteve and myself to establish the type of strut and themounting point positions to achieve the required action.”After getting Wassall to weigh and measure thewindows, Belcher worked out what was needed. “Therange of gas springs we stock can handle lid weights from5kg up to 250kg, and we can normally calculate the gasspring force required to suit the application,” he says.“But small changes in the centre of gravity,temperature or the mounting position canradically alter the handling characteristics of thegas strut. Add to this the changeable weatherconditions in the Mull, and calculating the optimum gaspressure for the strut soon becomes analmost impossible task.” In the end, Belcherdecided that the task would be best servedby using a Varilift gas strut in the 8-18range. The Varilift has a gas release valvewhich would allow the fitters to release smallamounts of gas from the strut until thecorrect ‘feel’ of the gas strut is achieved.“Another consideration was the need to openthe windows safely,” Belcher continues.“After all, we did not want the window tospring open as soon as the catch was released, as thiscould cause injury to anyone stood nearby.”This involved accurately working out the static anddynamic mounting points so that the window had a slightself closing action over the final 5 to 10 degrees ofmovement, whilst still keeping them in an achievableposition for the frame and window constraints. Thissolved one problem. Next, Belcher had to consider thepossibility that the weather could cause the window toslam shut in a gust of wind. “Also, the sensitive nature ofthe birds means that there is always a ranger present, butat the end of the day, they are often alone, so one personneeds to be able to close the windows,” says Wassall.“Because of the size of the windows, it would beimpossible for them to reach and activate the lockingmechanism on the gas struts on both sides of the windowat the same time as closing the window.”Belcher comments: “These problems forced us toconsider the Econoloc range, which has a locking shroudwhich springs into place once the gas strut has reachedits full extension. It acts like a mechanical lock, preventingclosure of the window without manually releasing thelocking shroud.” After a flurry of telephone calls andpaperwork between Nottinghamshire and Scotland, theproblem was solved. The hide has one Econoloc strutfitted on one side of the window and a Varilift Swift andSure on the other, which allows one ranger to operate thelocking mechanism with one hand and close the windowwith the other.The springs were sent to Mull in February, allowingWassall to fit them well in time for when the eggshatched – allowing the watchers to enjoy natureunfolding before them. All of this went unnoticed to theeagles themselves, but has made a significant differenceto the enthusiasts watching the birds. “We are delightedto have solved the problem,” says Wassall, “especiallysince we were not able to see the hide at first hand. Wehope that the gas springs add, if only in a small way, toeverybody’s enjoyment of watching the sea eagles intheir natural habitat.”MORE INFORMATION:Enter J465 on the enquiry card, or visit ‘latest issue stories’www.industrialtechnology.co.uk for further details from Jet Press andmore stories on springs, gas springs and dampers46INDUSTRIAL TECHNOLOGY • October 2008

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MECHANICAL COMPONENTSSprings, Gas Springs & DampersPerformance in tough environmentsBrian Goode, technical director at TFC Europe,describes how the Smalley wave spring couplessimple reliability with engineering excellenceIt would be difficult to imagine anapplication much more demanding fora spring than the Mars Lander project– the first mission to touch andexamine water on Mars. The fact thatNASA’s space exploration team selectedSmalley’s Crest to Crest (CTC) wave springis testament to its ability to function inharsh environments and to endure therigours of the alien terrain.CTC springs are able to function intemperatures in excess of 250 degreesCelsius and perform reliably at depths ofup to three miles below the Earth’ssurface, and their size and strengthdemonstrate further potency. As they aremanufactured from a continuous coil ofsingle filament pre-tempered, round edgedflat wire, the springs have a uniqueadvantage over round wire springs in theform of assembly space. They canmaintain the same force and loadspecifications, yet occupy 50% or less ofthe axial space. As a result, they allowlower operating heights, free heights andsolid heights when being used to replacecoil springs.In effect, the design and manufactureof CTC springs grant a lighter and higherperforming product. Pre-stacked in series,the springs have a decreased spring rateproportionally to the number of turns,which eradicates the need to keep thewave crests aligned. Furthermore, thewave peaks are able to hold theirconfiguration because the spring isformed from a single piece of wire. Assuch, there is no need to use a keylocating device, or to insert a shimbetween individual springs.The CTC springs’ attributes andabilities to challenge the imperfectionsof traditional coil springs have enabledtheir application in a huge spectrum ofindustries. If their operationwithin the protectivebackshell of thePhoenix Mars Landerillustrates a complexuse, the application ofCTC springs in aircraftperhaps demonstrates asimpler one. Theirimplementation in thedesign of an LED lightingcomponent which fits intothe arm mechanism of lightunits on British Airways and VirginAtlantic planes has stirred other aircraftmanufacturers to approach TFC aboutits springs. The interest lies in CTCsprings and retaining ring componentsfor use in aircraft passenger serviceunits, which allow passengers to controllocal environment and entertainmentsystems.The CTC springs’ multitude of usesdoes not stop at the aeronauticalindustry. Employed in multiple in dualpath injection annulus safety valves,they have a proven track record in theoil industry. CTC springs have beenimplemented for the injection valvecomponent, packer and liner tie backseal assembly and in the liner hangerpacker. Each spring operates over afixed working range, providing aguaranteed force. In order to maintain afaultless operation, exact pressureagainst the sealing surface is essentialto avoid excessive wear and to providea good seal.The CTC springs have also beenused in packer setting devices deployedin the oil industry. The springs’functionality is crucial to the successfuloperation, which allows full bore accessthrough the device to the surface whenopened. What’s more,the CTC springs arewidely used in asignificant selection ofother industries,including military andautomotive.The recentintroduction of a newrange of metric sizedCTC springs bring anew dimension of uses toindustry that allow them tooperate in applications that requirereduced bores and shafts. With sizesdesigned to operate in bores of 6mm,these springs offer a multifaceted andmulti-functional component essential tomodern technology.Springs have always been vitalwithin industry and TFC prides itself onit technical knowledge, distribution andlogistical expertise. With continualevolvement and the spring’s ability toadapt, this unassuming part willcontinue to play an important rolefor many years to come.MORE INFORMATION:Enter J485 or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for furtherdetails from TFC EuropeImage courtesy of NASA/JPL48More details: Write in 480 on the free information cardINDUSTRIAL TECHNOLOGY • October 2008

Wire FormsANY SIZE OR SHAPE OF SPRINGESTABLISHED 1790Over 200 years of excellence with unsurpassedexperience of supplying all types of spring expertlyand economically.CUSTOM-MADEIn any quantity. In any degree of complexity.At high speed assisted by some of the most sophisticatedcomputer-controlled spring technology in the world.WORLD-CLASSOur springs are used on satellites and submarines,motor cars and telephones, meeting the stringentdemands of world-class customers.Approvals include ISO 9002 and many others.JUST IN TIMEWe offer a complete service package to provide maximumflexibility and meet the exact needs of our customers fromdesign to manufacture, stocking and delivery.Line-side service available.SPRINGSESTABLISHED 1790WILLIAM HUGHESLIMITEDStation Road, Stalbridge, Dorset DT10 2RZ. UKTel: +44 (0)1963 363377 Fax: +44 (0)1963 363640Email: sales@wmhughes.co.ukWebsite: www.wmhughes.co.ukMore details: Write in 490 on the free information cardMore details: Write in 491 on the free information cardwhatspringstomind?Stock springs?We’ve 15,500 differenttypes and sizes of springs.New for 2008Constant force springsREDUX wave springsMillions in stockand custom options.Call us on 0118 978 1800 or visit www.leespring.co.ukLee Spring Limited, Latimer Road, Wokingham, Berkshire, RG41 2WATelephone: 0118 978 1800 Fax: 0118 977 4832 Email: info@leespring.co.ukMore details: Write in 492 on the free information card 49

MECHANICAL COMPONENTSSprings, Gas Springs & DampersFrom conceptto productionWhen tackling a fixing issue between two mating parts, itcan prove beneficial to consider integrating an innovativeradial spring fastener. Stuart Kelly, appliance productmanager at Saint-Gobain Performance Plastics Rencol,looks into the many possibilities of using tolerance ringsDesign essentially is an exercise in problem solving;whether the engineer is starting from designconcept or re-designing an existing product, it isessential problems are solved early on in the process. Thisis true particularly where the fastening of two annularcomponents is being considered. In the final assembly,typical fixing issues can include excessive noise andvibration, resonance frequencies and thermal expansion.There may also be a requirement for predictable andrepeatable slip or torque overload protection. In many ofthese circumstances, the use of a tolerance ring can dealwith, or even eradicate, these issues completely.The idea behind tolerance rings is very straightforward– they’re simply radially sprung steel rings that aredesigned to be press fitted between two matingcomponents, such as a motor shaft and a take-off pulley.They are, in other words, a special form of frictionalfastener. Typically manufactured from high quality springsteel, stainless steel or specialist spring materials,tolerance rings are invariably custom designed to suit aparticular application. All types, however, have oneessential characteristic in common – a series ofprotrusions or ‘waves’ around their circumference. Each ofthese waves acts as an individual radial spring which,when the tolerance ring is in situ, transfers forces betweenthe mating components.This arrangement means that tolerance rings arecapable of handling direct torque transfer, torque slip,axial retention, controlled collapse and radial loadingbetween the mating components. Providing exactly theright combination of properties needed for a particularapplication involves deciding on the number ofwaves on the ring, the optimum wave design,and the best combination of material fromwhich to manufacture the ring.Tolerance rings are normally purposedesignedfor each application with engineersat Saint-Gobain Performance Plastics Rencolworking closely with designers from the earlystages of development. Once the need forusing a tolerance ring is identified, feasibilitystudies are carried out to check whether thefastener can be physically developed anddesigned. At the concept stage, initial samples of the ringare produced and delivered for testing in the finalassembly. This is the point at which the true benefits ofusing tolerance ring can be observed first hand, such as:reductions in noise and vibration; avoidance of resonancefrequencies; provision for predictable and repeatable slip;overload protection; and combating the effects of thermalexpansion. In bearing applications, for example, tolerancerings are able to compensate for differential thermalexpansion between components, allowing use ofcomponents with wide tolerances.Proving the production processDuring pre-production, a production representativequantity is manufactured using production tooling. This isused to prove the production processes and controlsystems. If successful, the tolerance ring moves intoproduction status after the first full run, and the drawingand system status are updated to reflect this. Tolerancerings are currently used in a wide rangeof appliance applications, mostcommonly in electric motors. Forexample, in vacuum cleaner motorsthey are used to securely retainbearings under all operating conditions.Other applications include: retainingbearings in washing machine drums;mounting bearings and componentsonto rollers in photocopiers, printersand other paper handling machines;fixing clutch assemblies into plastichousings; and mounting transmissioncomponent bearings in plastic housingson floor cleaners. Tolerance rings arewell suited to bearing retentionapplications in as-cast, as-pressed oras-moulded housings, eliminating theclose tolerance machining of the bearing bore. Tolerancerings can also be implemented to compensate fordifferential thermal expansion in dissimilar materials, forexample in alloy or plastic housings, and can also toleratehigh levels of vibration. Operational speeds in excess of20,000rpm and temperatures up to 150°C can be readilyaccommodated with no loss of bearing retention.However, tolerance rings can be used in otherapplications besides bearing retention. Power tools, suchas drills, saws and hedge trimmers, need to integratesome sort of torque overload protection to prevent themotor from stalling when an overload condition or jamoccurs. This safeguard also helps eliminate the possibilityof the motor burning out and prevent damage to the drillbit, if it’s a power drill, and drive gears. Here the speciallydesigned tolerance ring is inserted between the gear andthe hub to create an interference fit.Since the parts are rigidly connected through the ring,a zero backlash system is achieved. At a pre-determinedtorque level, when the load reaches a point at whichdamage would otherwise occur, the tolerance ring will flexand slip. As soon as the overload condition is removed,the interference fit is re-established allowing the powertool to continue normal operation. Key to this particulardesign is that overload can occur many times – up to1000, 360-degree slips can be accommodated – withoutadversely affecting operation.Tolerance rings are convenient, versatile andinexpensive, yet they solve a whole range of designproblems and deliver valuable benefits. Many appliancemanufacturers are already enjoying these benefits;perhaps it’s time for you to join them.MORE INFORMATION:Enter J505 on the enquiry card, or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for further details fromSaint-Gobain Performance Plastics Rencol50INDUSTRIAL TECHNOLOGY • October 2008

SPRINGS...all types and all sizesand... all in stockHigh-performance ranges available®BARNESGROUP INCSee our NEW web site for Gas Strutswww.gasspringstruts.co.ukwww.associatedspring.co.ukFOR EXPERT ADVICEMore details: Write in 510 on the free information cardMore details: Write in 512 on the free information cardMore details: Write in 511 on the free information cardMore details: Write in 513 on the free information card 51

FLUID POWERHydraulics & PneumaticsNew control valves fit commonmotor port patternIntegrated Hydraulics has introduced a new range of controlvalves that fit common motor port patterns, increasing systemdesign options and enabling system performance to be optimisedMounting hydraulic control valves directly tothe ports of a hydraulic motor saves space,simplifies installation and places the valve inthe best position to provide protectionand/or control. Using cartridge valves located in a motormounted body enables the designer to select from aremarkable range of variants to obtain the optimumperformance from the system as a whole.These valves, designed for the most common portpatterns, bolt directly onto the motor eliminating the needfor steel pipe or hose between valve and motor, thusreducing installation time, removing the cost ofconnectors and pipework and minimising the overall sizeof the motor and valve package.Cartridge valves are used in theblock and because an extensiverange of overcentre cartridgesusing the same cavity isavailable, the most appropriatedesign – standard, partbalanced, balanced orcounterbalanced – pressurerange and pilot ratio can beselected to give the bestpossible performance andstability from the system.Overcentre valves givestatic and dynamic controlof loads by regulatingthe flow into andout of the hydraulicmotor. They will stoprunaway (even in theevent of a hose burst)and if open centredirectional control valves areused, will give thermal expansion reliefof the hydraulic fluid.The integral check section allows free flow into themotor, then holds and locks the load against movement.The pilot assisted relief valve section will give controlledmovement when pilot pressure is applied. The reliefsection is normally set to open at a pressure at least 1.3times the maximum load induced pressure, the pressurerequired to open the valve and allow movement dependson the pilot ratio, for optimisation of load control andenergy usage a choice of pilot ratios is available.For use on smaller motors, Integrated Hydraulics’1CE*30 cartridge is used. It is suitable for flows up to30 l/min and is available in four versions. The standardversion has two pressure ranges, one to 210 bar the otherto 350 bar. Both pressure ranges have 2.5:1, 5:1 and10:1 pilot ratio options. The part balanced version, inwhich the poppet is partially balanced from the effects ofpressure in the valve line, has one pressure range up to350 bar and 2.5:1 and 4:1 pilot ratio options. Valve linepressure has no effect on the poppet in the fully balancedversion, which again has one pressure range, to 350barand one pilot ratio, 5:1. The counterbalanced model hasthree standard pressure ranges, 220, 280 and 350bar:the primary pilot ratio is 4.3:1 and the secondary 0.4:1.The counterbalanced valve will maintain a back pressurein the motor until the pressure in the inlet line acting onthe secondary pilot area is sufficient to overcome theforce of the spring.For larger motors the 1CE*90 cartridge with flows to90 l/min is employed. The standard, part balanced andfully balanced valves have two pressure ranges, up to225 bar and 350 bar, and two pilot ratio options, 4:1 and8:1. The counterbalanced option again has two pressureranges, up to 350bar and 380bar, but has a primary pilotratio of 5.6:1 and secondary pilot ratio of 0.7:1. Blocksare available with a built-in brake release shuttle that willdisengage a static brake regardless of which line is underpressure. Incorporating this function into the block savesinstallation time, cost and complexity and eliminatesmore potential leak paths.Integrated Hydraulics’ motor mounted overcentrevalve blocks offer exceptional flexibility not only becauseof the range of cartridgesavailable but alsothrough the use ofcavity plugs thatcan be used tochange a blockfrom a dual to asingle overcentre withcontrol in either line ‘A’ or ‘B’.Single valves arenormally usedwhen the load isunidirectional, forexample on awinch and dualversions for controllingloads in both directions, forinstance on drive systems. For most applicationsthe standard, high strength aluminium body issuitable, but for pressures over 210bar or arduousconditions a steel body may be preferable.Integrated Hydraulics also manufactures motormounted cross line relief valves. These are designedto protect both lines in a circuit from overpressurisation by relieving oil from the high to the lowpressure line. The company’s cross line relief valves use asingle, differential area, poppet type cartridge whichoffers reliable, fast acting performance.In operation, pressure acts over one of two equaldifferential areas, either will force the poppet back againstthe spring allowing relief flow from the high to lowpressure port. Pressure is adjustable from 114 to 350barand as the differential areas are equal it will be the samein either direction. Maximum flow through the valve is150 L/min and, being of the poppet type, internalleakage is minimal at 5 millilitres/min.MORE INFORMATION:Enter J525 on the enquiry card, or visit ‘latest issue stories’www.industrialtechnology.co.uk for further details from IntegratedHydraulics and more stories on hydraulics and pneumatics52INDUSTRIAL TECHNOLOGY • October 2008

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FLUID POWERCommercial Vehicle DesignFire fighting vehicles boost stabilitywith hydraulically controlled feetAccess platform fire fightersneed to be able to park theirvehicles safely and accurately.Get it wrong and either theplatform won’t reach or, if theplatform has to extend too far,the vehicle could topple overdue to lever effectsWhen a system was needed to control thestabiliser feet on fire fighting vehicles and tocontrol the extension of the platform, Sensor-Technik had the solution. The system had to deliverincreased safety, in situations where every secondcounts.Sensor-Technik built its solution around an ESXCANbus controller and Opus HMI unit to control thehydraulics for the stabiliser feet, applying more pressurewhere needed to adapt the balance as the platform isrotated. The system also controls the extension of theplatform, with fail-safes for overload conditions. Thesystem interfaces with the existing engine CANbussystem to speed up or slow down the hydraulic pump.The biggest issue in the implementation was to set upthe HMI to show the operator the exact position of theplatform, indicating at the same time how much moreextension was possible before any overload, so that anearly decision could be made about whether to move thevehicle. Safety considerations included using the CANbussystem to first test the ground under the vehicle to ensurethat the surface is sound enough to support the vehicle.With this new system, fire engines can now bepositioned and used within minutes of arriving on thescene, allowing fires to be tackled more quickly andwith a higher degree of safety.MORE INFORMATION:Enter J545 on the enquiry card, or visit ‘latest issue stories’www.industrialtechnology.co.uk for further details fromSensor-Technik and more stories on CANbus control systemsA greener approach to climate controlA novel solenoid valve design is making life much more comfortable for truck and bus driversArecently introduced industrial climate controlsolution offers an on/off valve with terminationsthat plug into the auxiliary equipment of heavydutytrucks and buses to regulate heating and coolingsystems. The valve was developed by Parker FluidControl Division, manufacturer of the Skinner and GoldRing lines of solenoid valves and the Sinclair Collins lineof process control valves.The industrial climate control solution acts as acomponent of the vehicle’s auxiliary equipment. Whenplugged into the system, it helps extend the life of theengine by eliminating the need for idling – a primarysource of emissions.The product comes at a time when a number ofcountries are looking at tightening their anti-idlingregulations. Now this fluid control system can beincorporated into the vehicle’s design to regulate heatingand cooling, as required.The two-way normally closed or normally open valveis available with an orifice diameter of 12.7mm or largerand a process connection of 0.5in NPT. It operates witha Cv factor of 4.0 or better and features bubble-tightinternal and external leakage. Constructed of brass, it isassembled with FKM and fluorocarbon seal material.Electrical specifications include a continuous-duty, ClassH moulded coil enclosure with an open-frame yoke andelectrical leads. The valve’s electrical capabilities allowfor 12V DC and 11-16W of power consumption,depending on the valve type. Electrical connectors areavailable on request.The valve can withstand a maximum pressuredifferential of 1.7bar or more and a maximum ambienttemperature of 65°C. Additionally, the valve offersconnectors on leads, barb fittings in ports and amounting bracket, on request.MORE INFORMATION:Enter J546 on the enquiry card, or visit ‘latest issue stories’www.industrialtechnology.co.uk for further details from ParkerHannifin and more stories on fluid control systems54INDUSTRIAL TECHNOLOGY • October 2008

mobilized STEELcold rolled open sections andtubes for transportWelser Sections (UK) Ltd.Sovereign House, Stockport RoadCheadle, Cheshire • SK8 2EA / Great BritainTel (+44 161) 491 52 10 • uk@welser.comwww.welser.comMore details: Write in 550 on the free information cardMore details: Write in 551 on the free information cardMore details: Write in 552 on the free information card 55

FLUID POWERHydraulics & PneumaticsControl two circuits from justone hydraulic sourceA new range of diverter valves can switch betweentwo independent operations, offering users the benefitof considerable cost savings in hydraulic systems designBritish valve manufacturer Hy-Pro has introduced a new rangeof diverter valves that allow twoseparate circuits to becontrolled from a single hydraulic source,saving considerable cost on additionalvalves and hoses. The DDV valves areG1/2, six-port valves available in bothmanual and direct acting solenoidversions, offering a simpler and morecost-effective alternative to conventionalsolenoid or proportional valves.The DDV diverter valves build on thecapabilities of earlier generations in theHy-Pro range, but have been uprated tooffer improved efficiencies. Both offerflows up to 60 l/min, with the manualversion (DDVd) rated at 250 bar and thesolenoid operated version rated at 210bar in standard form, or 300 bar with aseparate drain fitted. High precisionmachined components and matchedspools and bodies give lower leakagerates (less than 10 cc/min at 210 bar)and higher pressure/flow characteristicsthan alternative products on the market.The valves allow two double-actingcylinders or reversible hydraulic motors tobe controlled separately from a single,four-way valve. The ability to switchbetween two independent operations cansignificantly increase system capabilitywithout incurring the significant extra costof traditional solutions.Best-fit approachThe DDV range delivers this function socost-effectively because the design onlyallows one operation to be carried out ata time – a solution that actually providesa best-fit approach in a wide range ofapplications. These include tractors(lifting and then opening the bucket),recovery vehicles (tilting the bed and thenoperating the winch),road sweepers (driving the brush andraising/lowering it), and many othersacross a broad spread of industries.Both valves are manufactured from aniron casting with a hardened and groundsteel alloy spool, offering exceptional loadholding capability. The spool is totallyenclosed by the hand lever in the manualversion, and by the compact solenoid inthe electric version, offering a high degreeof environmental protection as standard.A fully marine-rated version of themanual valve is also available. Forprotection against accidental operation, apilot check valve can be directly mountedonto the service ports.MORE INFORMATION:Enter J565 on the enquiry card, or visit ‘latest issuestories’ at www.industrialtechnology.co.uk forfurther details from Hy-ProEnd capsprotect andisolateLegris’ new female blankingplugs are ideal fortemporarily isolating parts ofa pneumatic installation duringoperation, for protectingcompressed air networks fromdamage and dust ingress duringshipment and for protectingpneumatic tools in storage.The new range of end capcomponents are an extension toLegris’ LF3000 pneumatic push-infittings concept.MORE INFORMATION:Enter J567 on the enquiry card, or visitwww.industrialtechnology.co.uk forfurther details from LegrisValve islandsare compactDesigned to meet industrydemands, the new 676COMPACT 8 and 677COMPACT 13 valve islands from OEMAutomatic are fast becoming the firstchoice for designers and machinebuilders alike.Manufactured by Asco, they featureflow rates of 900 l/min (series 677)and 300 l/min (series 676). Theflexible valve configuration includes3/2 N/O – N/C, 5/2 and 5/3 options.The design includes IP65 electricalconnections, and is fieldbuscompatible with up to 21 stations.MORE INFORMATION:Enter J566 on the card, or visit ‘latest issuestories’ at www.industrialtechnology.co.uk forfurther details from OEM AutomaticPneumatic rodless cylinders handlepayloads from grams to a tonneFesto has upped the ante in terms ofpayload, flexibility and performance withtwo new pneumatic rodless cylindersFesto has launched two highperformance pneumatic linearactuators, extending the loadbearingcapabilities of its popular DGCfamily to unprecedented levels. The newDGC-50 and 63 actuators featureinternal piston diameters of 50mm and63mm respectively, providingsignificantly more force and higherpayload capacities than other actuatorsin the same series. The top-of-the-rangeversion of the DGC-63, for example, canaccommodate payloads in excess of onetonne – approximately 50% more thanthe previous largest model.Festo’s DGC family of pneumaticrodless actuators now spans eightcylinder sizes, ranging from a tiny 8mmto 63mm. Standard models within thisseries offer velocities up to 3m/s, forcesas high as 1870N and up to 5m strokelengths as standard. DGC actuatorsemploy a unique angledsealing mechanism betweenthe carriage drive and theactuator body, whichunusually for rodlessactuators ensures virtuallyzero air leakage andfacilitates the manufacture of extralong actuators for special applications.Festo has supplied DGC actuators withstrokes of up to 9m to special order.Carriage guide optionsDGC series actuators offer a choice ofthree types of carriage guide, to bestsuit the application and the load. Thebasic guide features a plain polymerbearing suitable for light loads; themedium load guide also uses plainpolymer bearings running on a guide railcompactly integrated as part of theactuator extrusion, and is factoryadjustedfor optimum performance; andthe high-performance guide usesstainless steel caged and sealedrecirculating ball bearings. The lattertype can handle very smooth and highspeed movements, has zero backlash,and is capable of accommodating loadsthat apply a high moment of torque tothe carriage, such as cantilever andoffset loads.MORE INFORMATION:Enter J564 on the card, or visit ‘latest issuestories’ at www.industrialtechnology.co.uk formore info from Festo56INDUSTRIAL TECHNOLOGY • October 2008

Monitor cylinderdisplacement withincreased accuracyThe new Gefran RK Seriesposition transducer uses acontactlessmagnetostrictive linear sensorfor accurate and reliabledisplacement measurement inhydraulic applications. The RKSeries is designed for OEM usewithin the hydraulic cylinder,typically for monitoring andcontrol in mobile applications,such as earth moving, agriculturaland mining equipment.Suitable for cylinderstroke lengths from 50mmto 4000mm, the compactsensor has a 10mm diameter probe,with a compact, versatile headarrangement smaller than any othersolution currently available on themarket. External connection to thehead is via an IP67 rated cableconnection, up to 50m long, providinga straightforward analogue output ofdisplacement, with an industryleading linearity and accuracy ofbetter than 0.02% of Full Scale.The robust and durable transducerrelies on the interaction between amagnet on the moving piston and themagnetostrictive transducer rodelement. This enables a non-contact,solid state position measurement, thatis not subject to mechanical wear,tolerates working temperatures up to90°C, with 20g vibration and 100gshock, and is sealed against thehydraulic environment for workingpressuresup to 700bar.The RK Seriestransducer provides adirect analogue voltage output(0-10V) proportional to position,using a standard 18-30V DC powersupply: optionally available, a 12Vpowered unit provides an analogue0-5V output. The magnetostrictivetiming pulses from the transducer canalso be monitored by the Gefran EKSeries remote electronics module.This module offers CANopen andother digital interfaces, transmittingdigital position and speed ofmovement measurement information(up to 10m/sec) to the equipmentcontrol system. The EK Seriesmodules are also capable ofmonitoring the position of two ormore magnets operating on the samemagnetostrictive transducer rodelement, if required.MORE INFORMATION:Enter J575 on the enquiry card, or visitwww.industrialtechnology.co.uk for furtherdetails from GefranFor more information, contact Lee ProductsInnovation in Miniature Tel: 01753 886664Fax: 01753 889588www.industrial-microhydraulics.co.uke-mail: sales@leeproducts.co.ukLee Products Limited, 3 High Street, Chalfont St Peter, Bucks SL9 9QEMore details: Write in 570 on the free information cardRugged safety screenshandle twice the pressureArange of high pressure flangemount etched safety screenswith burst/collapse pressureswhich are on average more thandouble that of the existing stainlesssteel 304L type safety screens hasbeen introduced by miniaturecomponent specialist Lee Products.Thanks to their rugged construction,using 17-7PH CRES material, thesescreens provide burst/collapsepressures (depending on the hole size)from 1250/100 psid for the 656flange mount option, and up to7000/4550 psid for the 130 flangemount option. A pleated screen bendfeature maximises the open area forgreater dirt holding capacity.MORE INFORMATION:Enter J576 on the enquiry card, or visitwww.industrialtechnology.co.uk for furtherdetails from Lee ProductsOctober 2008 • INDUSTRIAL TECHNOLOGYMore details: Write in 571 on the free information card57

MACHINE BUILDING & AUTOMATIONPower SuppliesThe power andthe gloryTDK-Lambda says its UK team has made abreakthrough in power supply design, withrevolutionary core intellectual property thattakes digital control to a new levelTDK-Lambda says its revolutionary EFE Series ofembedded frontend power supplies deliversindustry leading power density, high efficiencyand enhanced reliability. The first products in therange are the 300W EFE-300 and the 400W EFE-400single output supplies that deliver 133% peak powercapability for ten seconds and offer a class leadingefficiency of up to 90%.The EFE Series employs an 8-bit microcontroller forfull digital control of the output and to handlehousekeeping routines This brings a 25% parts countreduction to achieve a 45% smaller and up to 56% lighterdesign when compared to similar recently announcedcompetitive products, says the company. Power densitiesof up to 22W/in 3 are achieved under peak load conditionsand 16.6W/in 3 under continuous loading.TDK-Lambda’s European marketing director MartinSoutham comments: ‘’This is the breakthrough thatmarks a new inflexion point in the power supply industry.Our UK design team have created revolutionary core IPthat will spread rapidly across our product roadmap.”Compact dimensions and a 1U profile (the EFE-300 isonly 127mm by 76mm by 34mm and the EFE-400 isonly 152mm by 76mm by 34mm) allow the EFE Seriesto be incorporated in designs where space is limited, soend equipment can be smaller, cooler and more featurerich. Typical markets include broadcast, instrumentationand industrial, and other applications, such as ATE,automation, routers, servers and security networks.Innovative design featuresThe new digitally controlled power supplies incorporatemany innovative design features including an integratedmagnetics transformer that increases efficiency by up to1%. The digital control allows the power supply’sperformance, such as current limit and start-upcharacteristics, to be optimised. A low cost primary sidecontrol topology is used, supervised by themicrocontroller. This results in fewer parts and higherefficiency without sacrificing load regulation performance.Furthermore, the need for an opto-isolator is eliminated –a device which is undesirable for long life power supplydesigns.TDK-Lambda UK’s advanced development manager,Andrew Skinner comments: ‘’Many of the design featuresof the EFE Series directly enhance reliability. For example,having precise control of abnormal situations throughproprietary algorithms prevents device overstress. Inaddition, better circuit noise immunity is achievedcompared to analogue designs, and the substantial partscount reduction allows for more optimised componentspacing leading to improved thermal performance.”The EFE-300 delivers 300W continuous power(400W peak for ten seconds) with nominal outputs of12V/25A or 24V/12.5A, and the EFE-400 delivers 400Wcontinuous power (530W peak for ten seconds) withnominal outputs of 12V/33.3A or 24V/16.7A. All modelscan be precisely factory programmed to accommodatenon-standard system voltages. An additional 12V/0.25Afan supply is also available and all models operate from90-264V AC input with dual fusing as standard. Activepower factor correction ensures EN61000-3-2compliance. Other EMC improving design features, suchas the use of SiC diodes, ensure curve B EMCperformance with a significant margin.As well the impressive technical performance, the EFESeries meets TDK-Lambda’s design brief forenvironmentally responsible products by consuming lessenergy in manufacture and use, having fewer parts,weighing less and having a long life expectancy.The EFE Series is available in a variety of caseoptions, either open frame or enclosed. The use of lowprofile output connectors allows maximum airflow foroptimised cooling efficiency.All products in TDK-Lambda’s EFE Series areapproved to IEC/EN/UL/CSA 60950-1 for general purposeapplications and IEC/EN 61010-1 for laboratory andprocess control applications. In addition, the units carrythe CE mark according to the LV Directive and comewith a three-year warranty.MORE INFORMATION:Enter J585 on the enquiry card, or visit ‘latest issue stories’www.industrialtechnology.co.uk for further details from TDK-Lambdaand more news on power supplies58INDUSTRIAL TECHNOLOGY • October 2008

More details: Write in 590 on the free information card 59

MACHINE BUILDING & AUTOMATIONMachinery SafetyA better way to build barriersUnprotected hazardous zones in work and transport areas posea serious threat to personnel. In the past, however, the designand installation of effective protective barriers have been costly,inconvenient and time-consuming processes. Now there’s abetter way, says Mark Dash of Bosch RexrothTraditionally, protective barriers have been customfabricated from steel. Provided that the designand fabrication work is carried out properly andto the relevant standards, the result is effective inachieving the required levels of safety but, in terms ofconvenience, cost and ease of modification, steel barriersleave a lot to be desired. An attractive alternative is,however, now available in the form of modular aluminiumbarrier systems, and it’s instructive to see how thesecompare with their traditional counterparts.Let’s start with the design process. With a steelbarrier, ensuring that the relevant safety standards –usually some combination of EN292, EN294 and EN811– are met is entirely in the hands of the designers. Theymust ensure, for example, that the spaces between theelements making up the barrier are sufficiently small toprevent the entry of upper or lower body limbs, or evenfingers, as required by the application. There may also berequirements to contain projectiles – items that areejected, usually under fault conditions, by the equipmentaround which the barrier is being constructed.With prefabricated barrier systems, the design processis much faster, easier and more certain. Simply pickingsuitable elements from the manufacturer’s catalogue willensure that, provided the simple assembly guidelines arecorrectly followed, safety requirements are metautomatically. In addition, the wide range of elementsavailable, which invariably include such items as doors inslide and swing formats, means that there is virtually nolimit of the types of barrier that can be configured. As afurther aid to the design process, the best modularguarding systems are complemented by dedicated CADsoftware that makes the processes of configuringcomplete assemblies and generating parts lists fast andeasy. But if modular systems simplify and speed thedesign process, they do even more for the fabricationstage – in fact, they eliminate it entirely.The aluminium barrier elements are manufactured bythe supplier under controlled conditions that ensurequality and uniformity. Because these are standardelements held in stock, deliveries are fast, in markedcontrast to the delays inevitably associated with thecustom fabrication of steel barriers. With modularaluminium barriers, the only work that has to be done onsite is installation. Once again, this is straightforward fastand convenient. Usually, the only requirement is to drillfoundation holes for the barrier supporting posts and erectthem, and then add the barrier elements to complete thesystem. As the barriers are developed from standardaluminium profile sections, only hand tools are needed formounting and assembly.Fast and inexpensive installationUnlike their steel counterparts, modular aluminiumbarriers require no cutting, welding and painting on site.In addition, because installation is so straightforward, itcan be successfully carried out by personnel withrelatively low levels of skill. Installation is also fast andtherefore inexpensive. Other major benefits of modularaluminium barriers include the light weight and their highresistance to corrosion.The lightweight but strong construction is a great aidduring installation and means that, in many cases, thework can be carried out by just one person. In contrast,the sections of a fabricated steel barrier, which size-forsizetypically weigh three times as much, invariablyrequired the efforts of several people to manoeuvre theminto position. Aluminium is, of course, inherently resistantto corrosion. In almost every case, however, steel needs tobe painted, which adds to costs. Further, if a steel barrieris scratched or otherwise damaged, corrosion rapidly setsin unless remedial action is taken, whereas scratching analuminium barrier has no effect whatsoever. Interestingly,aluminium barriers can be painted, if required. It issometimes desirable, for example, to paint them yellow sothat they are easy to see, or black so that it is easier tosee through them and observe the equipment that theyare surrounding.An area where aluminium modular barriers reallyscore over steel is ease of modification. If changes areneeded to an aluminium system, the work is limited toadding, removing and reconfiguring sections, using onlysimple hand tools. The most difficult requirement that willbe encountered is adding or re-positioning a support post.With steel systems, modifications are, in contrast, costlyand inconvenient. Cutting, welding and repainting on siteare almost sure to be needed, along with detailed designwork to ensure that the new configuration continues tomeet the appropriate safety requirements.Last but not least, aluminium barriers have a pleasingmodern appearance that complements the latestmachinery. That perhaps doesn’t seem important, buteveryone benefits from an attractive working environment,and those accountants and managers who controlbudgets are surprisingly often influenced by appearances.Modular aluminium barrier systems, such as EcoSafefrom Bosch Rexroth, are versatile, dependable and,particularly when their low design and installation costsare taken into account, they are offer significant costsavings compared with conventional steel barriers. Withso much in favour of the aluminium solution, whatpossible reason could there be for specifying any othertype of protective barrier?MORE INFORMATION:Enter J606 on the enquiry card, or visit ‘latest issue stories’www.industrialtechnology.co.uk for further details from Bosch Rexrothand more news on machinery safety60INDUSTRIAL TECHNOLOGY • October 2008

GEInspection TechnologiesSee us on Stand G24 at the PPMA ExhibitionHardness testing withineasy reach of your pocketDynaPOCKET is one of our range of portable hardness testersfrom GE to bring you compact, accurate, easy-to-useand affordable instrumentsfor measuring in any plane,even where access is limited.Digital display of test resultsin Vickers, Rockwell orBrinell in seconds.To discover how we canmeasure up to yourquality control standards,contact us today or visitwww.ge.com/inspectiontechnologiesGE imagination at workGE Inspection Technologies • Coventry CV4 8AF • tel: 0845 6015771More details: Write in 610 on the free information cardMore details: Write in 611 on the free information cardMore details: Write in 612 on the free information card 61

MACHINE BUILDING & AUTOMATIONMachinery SafetySafety switching goes modularPSR-based modular safety relaycombinations take up less space in thecontrol cabinet, minimise wiring costs, andextend contacts with maximum safetyPhoenix Contact’s PSR modularsystem is built around auniversal master, which isresponsible for monitoringsafety-oriented signals. Subject torequirements, up to four secure off-delayor instantaneous contacts can beconnected via the T-bus rail busconnection to extend each module.The power supply, a safe switchedpotential, and the feedback loop arecontrolled via the T-bus. Each function,for example an emergency cut-out,safety door or light barrier, canconsequently switch to up to tenexpansion modules without crosswiringfaults.Pluggable connection terminals areavailable as standard with screw orspring-cage technology. The new springcageconnection terminals can be openedat the front with the use of a screwdriver,which opens two clamps. As a result, thewires can be conveniently released andre-wired. Flexible wires with ferrules canbe plugged directly into the clampswithout the use of tools.MORE INFORMATION:Enter J625 on the enquiry card, or visit ‘latest issuestories’ at www.industrialtechnology.co.uk forfurther details from Phoenix ContactLow cost pressureswitches ATEX certifiedConnectionsmade saferwith I/O boxBürkert’s new Power I/O Boxtype 8643 is designed toconnect binary signals toFoundation Fieldbus H1 orProfibus PA in process systems,easily, cost effectively and safely.ATEX approved for operation inZones 1 and 21, the Type 8643meets all explosion-protectionrequirements, as well as offeringusers maximum flexibilityregarding intrinsically safeactuator and sensor technology.The Power I/O Box Type 8643replaces conventional discretecabling with a modularmultiplexed system, saving space,cabling costs, and time duringverification and documentation ofsafety procedures. The device issuitable for use in areas subject toFibre opticE-stop easesintegrationThe Pico-Guard E-Stop button fromTurck Banner works in conjunctionwith the Pico-Guard controller andother optical elements in personnel safetyand equipment protection applications.Used with Banner’s plastic fibre opticcable, it offers a simple, quick means ofconnecting and disconnecting the fibre.When paired with the Pico-Guardcontroller, the E-Stop button meetsSafety Category 4 applications (per ISO13849-1) and is certified for use inharsh and potentially explosiveenvironments. It is rated to IP65 andcomplies with IEC 60204-1 emergencystop requirements.Pico-Guard safety systems eliminatethe hassles and hazards of electricalwires commonly used in safeguardingequipment, providing simple operationand integration of safety devices.Arange of compact, low costpressure switches are nowavailable that are ATEX-certifiedfor use in Zone 0, Zone 1 and Zone 2gaseous atmospheres. The new 901range of ATEX-certified pressure switchesfrom Impress Sensors, are ideal formonitoring overpressure, vacuum ordifferential pressure of both liquid andgaseous substances, including aggressivemedia, in hazardous environments. Theswitches can be used to monitor fluidlevels and filters, as well as excessive orinadequate pressure and pressuredifferentials in closed systems.The explosion-proof pressureswitches are ideal for a range ofexplosive atmosphere environments,including nuclear, oil and gas, chemicals,pharmaceuticals, sewerage and foodprocessing. The switches are available ina factory-set version, in which thepressure setting and switchingdifferential are set by the manufacturer,or an adjustable version, the 901Prescal, where the customer uses ascaled adjustment knobto alter the trip andreset pressure,without having to use a screwdriver. Awide range of switch options areavailable, including pressure connectionsin various materials, shapes and sizes.Customers can also select from a diverserange of materials for seals anddiaphragms. All switches are intrinsicallysafe and have been categorised asTemperature Class T4 and ExplosionGroup IIB or IIC.Sam Drury, sales director at Impresscomments: “Some of our customers needto monitor pressures in potentiallyexplosive atmospheres. In the chemicalssector, for example, air mixtures andignitable gases are commonplace andcan cause explosions if a source ofignition is present. Therefore, industrialinstrumentation devices such as pressureswitches need to be protectedaccordingly. We are delighted to be ableto offer these ATEX-certified sensors.”MORE INFORMATION:Enter J624 on the enquiry card, or visit ‘latest issuestories’ at www.industrialtechnology.co.uk formore info from Impress Sensorsexplosion hazards, such as inpetrochemicals, oil and gas, thepharmaceutical industry, watertreatment and fine chemistry. Foruse in these sectors, the device isavailable either in an aluminiumor polyester casing with IP65protection, or as an electronicmodule with IP20/IP30 protectionfor installation in Ex-e enclosuresor control cabinets. In addition,the 8643 has reliable galvanicisolation between its powersupply, bus port and inputs andoutputs, making it safe and easyto install.The design of the Type 8643integrates 4 intrinsically safedigital outputs, making possiblethe control of a wide range ofintrinsically safe actuators such assolenoid valves (4 maximum),relays or indicator lights. Theseoutputs are complemented byintrinsically safe digital inputs,which allow the connection of upto 8 Namur proximity switches.MORE INFORMATION:MORE INFORMATION:Enter J626 on the enquiry card, or visit ‘latest issuestories’ at www.industrialtechnology.co.uk forfurther details from Turck BannerEnter J627 on the enquiry card, or visitwww.industrialtechnology.co.uk forfurther details from Bürkert62INDUSTRIAL TECHNOLOGY • October 2008

Machinery Safety MACHINE BUILDING & AUTOMATIONMagneticlock withindicationMagne from Jokab Safetyis a magnetic lock that issuitable for industrialapplications and that canwithstand demanding conditions.It can electrically keep a doorclosed against a force of up to1500N. When the current isswitched off, no magnetic materialremains sticking to the magneticsurface. Moreover, there is nocurrent surge when engaging.Magne has no moving partsand is prepared for use with Edennon-contact safety sensors toprotect against dangerousmachine movements. Using M12connectors, it is easy to connectseveral Magne units and Edensensors in series.MORE INFORMATION:Enter J638 on the enquiry card, or visitwww.industrialtechnology.co.uk forfurther details from Jokab SafetyGetting to grips withsafety integrity levelsIFM Electronic has introduced a newgeneration of fail-safe inductive sensorsSafety is paramount. The word oneverybody’s lips these days is SIL.A Safety Integrity Level, whether itis to EN61508, EN62061 or a similarstandard, is what everyone is aiming for.To make matters easier, IFM Electronichas recently launched more inductivesensors which achieve SIL2 or SIL3.Available in M12 (SIL2) or M18,M30 and cube styles (SIL3) these newinductive proximity sensors show, thecompany says, that it is listening to itscustomers. Designed with two OSSDs(output signal switching devices) built in,the new fail-safe series will work withconventional safety relays, and will ofcourse still work with safety PLCs.No special demands such asshielding, twisted wires or separatelaying are placed on the industrialstandard M12 connection. The sensor issimply connected to existing evaluationunits, safety controllers and safe bussystems using a common unscreened4-core cable.Functional safety is assured with theIFM Electronic fail-safe inductive system;coil damage, component health, crossmonitoring,short-circuit protection – allaspects are continuously checked withinthe device itself. Any fault, at any time isinstantly signalled.All fail-safe inductive switches fromIFM electronic are constructed with fullredundant and diverse internal circuits,certified by the TÜV Rhineland, butotherwise has all the advantages of aninductive sensor: with no moving parts,IP67, standard M12 connector etc. Nowyou may think an inductive sensor whichneeds no special target would be easy todefeat – but of course that would defeatthe object of safety. The target may benothing special, but its position in theright place at the right time is whatcounts. When the target is present, anyother piece of metal between the switchand the target will cause the output toswitch off. Setting the unit is not difficulteither, because the LED helps inadjustment, while incorporating a delayto befuddle the fiddlers.MORE INFORMATION:Enter J635 on the enquiry card, or visitwww.industrialtechnology.co.uk for furtherdetails from IFM Electronic6-7, Faraday Road | AylesburyBuckinghamshire HP19 8TXTel 01296 398865 | Fax 01296 398866e-Mail: rkgb@phoenix-mecano.co.ukwww.rk-online.co.ukMore details: Write in 630 on the free information card63

product and service factfindersASTROSYN INTERNATIONALTECHNOLOGY LtdThe Old Courthouse, New Road Avenue, Chatham, Kent ME4 6BEe-mail: astrosyn@btinternet.com www.astrosyn.comHybrid Stepper Motors –The Affordable Range• Unbeatable price/performance ratio• Frame sizes from NEMA 11 to 34• Best torque performance at desired speed• Smooth, low noise operation with high precision• Choice of windings to match custom applications• Full range of shaft and connection optionsMore details: Write in 640 on the free information cardROTAFLOW FV LtdRotec House, Bingswood Trading EstateWhaley Bridge, High Peak SK23 7LYe-mail: sales@rotaflow.com www.rotaflow.comRobust and Durable SwivelJointsRotaflow FV Limited manufacture a range of robust anddurable Swivel Joints which provide 360° movementthrough a clear bore to transfer fluid under pressurewithout leakage from a static position to a moving point –ideal for loading arms or removing the twist in hoses.Single-flow, and multiport swivel joints available in carbonsteel and 316 SS. Sizes 1 ⁄4” to 24” nominal bore, with a choice of seals for maximumcompatibility.More details: Write in 644 on the free information cardCOTEL MOULDINGSJG Coates (Burnley) Ltd, Trafalgar Street, Burnley, Lancashire BB11 1THe-mail: sales@cotel.co.uk www.cotelmouldings.comNew Products 2008from Cotel MouldingsPlease request the new Cotel Mouldings catalogue featuring thelatest additions to our comprehensive range of industrialproducts:• New Design Bridge Handles & Wing Knobs• Rubber Dampers • Cam Locks & Latches• Nylon Bushes & Insulation Sleeves • Industrial CastorsFor fast, reliable service please contact us today, and please also visitwww.cotel.safetychannel.com for over 23,000 safety signs and related products.More details: Write in 641 on the free information cardSANDVIK MATERIALS TECHNOLOGY UKManor Way, Halesowen, West Midlands B62 8QZe-mail: sales.smtuk@sandvik.com www.smt.sandvik.com/ukSandvik Stainless Steel Tube,Pipe, Fittings and FlangesSandvik have a new information sheet on their stainless steeltube, pipe, complementary fittings and flanges and extensivepackage building capabilities. The information sheet emphasisesSandvik’s supply of worldwide products, locally from the UKdistribution centre in Halesowen, which is backed by a centralwarehouse in Holland and the manufacturing plant in Sweden.Complete the information card for your copy of the Sandvikinformation sheet.More details: Write in 645 on the free information cardigus51 Caswell Road, Brackmills Industrial Estate, Northampton NN4 7PWe-mail: sales_uk@igus.co.uk www.igus.co.ukNew Cable CatalogueThe Chainflex cable catalogue is now available from igus.igus has manufactured its own cables since 1989.The high-flex cables withstand the stress of tight bendingradii in moving applications and have been tested overmillions of cycles. They include control cables, robot cables,motor cables, data cables and servo cables.Request yours today.More details: Write in 642 on the free information cardSCHAEFFLER (UK) LtdForge Lane, Minworth, Sutton Coldfield, West Midlands B76 1AFe-mail: info.uk@schaeffler.com www.schaeffler.co.ukNew Boxed Set – UltimateLinear Reference LibraryThree brand new hardbacks, supplied as a BOXED set. Over750 pages. Tabulated sections. Clear illustrations.Book 1: Track Roller Guidance SystemsBook 2: Shaft Guidance SystemsBook 3: Monorail Guidance SystemsIncludes: Track roller guidance systems, bolts, guideways and accessories. Linear bearingsand housing units. Solid shafts, hollow shafts. Support rail units. Shaft support blocks.Linear recirculating roller or ball bearings and guideway assemblies.More details: Write in 646 on the free information cardMACHINE BUILDING SYSTEMS LtdHeage Road Industrial Estate, Ripley, Derbyshire DE5 3GHe-mail: sales@mbsitem.co.uk www.mbsitem.co.ukMachine ConstructionSystemThe item MB System is a modular aluminium extrusionbasedsystem for machine construction.The item range encompasses machine frames, machineguarding, linear slides, work benches, conveyors, jigs andfixtures. Machine Building Systems is the sole distributorin the UK and Ireland for the item MB System.With an online catalogue, CAD downloads and regularnew-product updates, the website is well worth a visit.More details: Write in 643 on the free information cardJAMES WALKERGlobal Support Centre, 1 Millennium Gate, Westmere Drive, Crewe CW1 6AY, UKe-mail: csc@jameswalker.biz www.jameswalker.bizNew Guide To Global SealingOperationsThe worldwide fluid sealing and materials expertise ofJames Walker Sealing Products & Services is covered in thisnew guide.As well as R&D and new technology, it describes the value ofpartnering contracts, e-commerce systems and thehighly-developed logistics networks that give customers thesurety of supply they need.More details: Write in 647 on the free information card64INDUSTRIAL TECHNOLOGY • October 2008

John Richardson’s ENGINEERING DIARYTravelling up and down the country as I do, visitingmany manufacturers and their suppliers, I haveseen many companies implementing leanstrategies to help boost their competitiveadvantage. Lean is the term used to describe the productionsystem developed by the Toyota company in the post World WarII years, with the name coming from the ability to achieve morewith less resource, by the continuous elimination of waste.Indeed the practice considers that any expenditure of resourcesfor any means other than the creation of value for the customerto be wasteful, and thus a target for elimination.Toyota identified seven areas of waste: transportation(movement of products that is not actually required to performprocessing); inventory (all components, work-in-progress andfinished product not being processed); motion (people orequipment moving or walking more than is required to performthe processing); waiting (such as waiting for the next productionstep); overproduction (production ahead of demand); overprocessing (due to poor tool or product design creating activity);and defects (covering the effort involved in inspecting for andrectifying defects). Some of these may seem a little idealistic,and many might think to dismiss lean as just another buzzwordcoming out of Japan. But given that Toyota has to be the largestcar manufacturer in the world, we shouldn’t treat it lightly.Helping to compress timeOf course, lean has been refined over the years. Today leanthinking encourages us to specify what creates value from thecustomer’s perspective, identify all the steps across the wholevalue stream, make those actions which create value flow, onlymake what is pulled by the customer just-in-time, and strive forperfection by continually removing successive layers of waste. Interms of manufacturing, though, lean manufacturing essentiallyaims to compress time. Typically, if you quarter your leadtime,you will double productivity and take 20% off your costs –popularly summed up as the quarter-two-twenty rule. Thegenerally expected results are that you will halve your leadtimes(with a doubling of stock turns), reduce floor space requirementsby 30-50%, increase overall equipment effectiveness (OEE) by20-40%, achieve labour productivity gains in the order of 20-25%, and reduce your administration and co-ordinationoverhead.The concept of lean in manufacturing, though, is notrestricted solely to the pure manufacturing aspects, and appliesto the whole enterprise, including the supply chain, the newproduct development process and the provision of service. Butnow new research says UK manufacturers could gain a furtherprofit advantage by adopting lean accounting. A survey of 101UK manufacturers across the automotive, electrical/electronic,aerospace and defence, food and beverage, and petrochemicaland pharmaceutical sectors showed that only 14% of UKmanufacturing companies have adopted the principles of leanaccounting. Tom Lawton, head of manufacturing at BDO StoyHayward which carried out the research, says: “UKmanufacturing continues to make great strides in adopting ideasaround lean manufacturing, and we believe that this has beenone of the reasons that the sector has been so successful inrecent years. However, lean accounting, which provides strongsupport to the lean manufacturing process, has not been widelyadopted, meaning that manufacturers are not using the rightfinancial metrics in measuring and monitoring theirimprovements under lean manufacturing. As a result, it could bereducing the benefits available under continuous improvementprocesses.”He continues: “The survey shows that the principles of leanaccounting are not well understood by most UK manufacturersand this may be the reason for the low take up. But at its heartlean accounting is about establishing a financial reportingsystem that supports, complements and enhances leanmanufacturing – and therefore helps improve a company’sprofitability and working capital management. In the currentdifficult times this focus on profit and working capitalmanagement – particularly the reduction of inventories – isfundamental to the well managed manufacturing business.”The biggest barriers to implementation were a lack ofunderstanding of the approach (60%) and a lack ofunderstanding of the benefits (51%). However, a surprisinglyhigh percentage of respondents (42%) said that companyculture was a barrier in preventing lean accounting. On a morepositive note, a quarter (24%) of manufacturers planned onintroducing lean accounting into their businesses within the nexttwo years and 42% said they would consider it in the long term.“Lean accounting provides measures that are far more suited totoday’s lean manufacturing methods than the more establishedmethods based around standard/absorption costing. It can alsohelp drive profitability and cash flow. Therefore it is pleasingthat the survey shows that the use of lean accounting bymanufacturers is expected to increase considerably in the nextcouple of years. Hopefully, this wider usage will help UKmanufacturing as it seeks to maintain its competitive edge in theglobal market,” concludes Lawton.feedback@itmagazine.uk.comOctober 2008 • INDUSTRIAL TECHNOLOGY65

EAR TO THE GROUND • Becky Silvertonbecky@itmagazine.uk.comPatents, IP and good oldfashioned commercialisationIdon’t know whether this is a wise thing to ownup to, but there’s only so long you can keepthese little secrets to yourself before yousuccumb to the need to get it all out in theopen. I can’t really believe it’s happened, because itcertainly wasn’t planned, expected, or evenanticipated. But somehow I’ve found myselfaddicted to Dragon’s Den, the BBC2 programmewhere hapless inventors and would-beentrepreneurs try to wrest tens of thousands ofpounds of investment from the UK’s leading venturecapitalists, who are willing toinvest their own money inexchange for equity.One of the big questions thefive Dragons always ask theirpotential partners is how wellprotected their intellectualproperty is, particularly withregard to international patents onnew ideas. More often than not,the entrepreneurs pitching forinvestment either have no patents at all, or at besthave patents pending – with no real guarantee thatthe patent will ever be granted.This is always a turn-off for the Dragons, andyou can hear the collective sharp intake of breath,which is only very slightly quieter than on the HarryEnfield and Paul Whitehouse pastiche of the show.Now, moving from the Shepherd’s Bush to SouthAfrica, just before Perth-based British FemaleInventor of the Year Tanya Ewing stood up toaddress 1500 women inventors and innovators inAfrica, she received a text message from her patentattorneys telling her that her US design patentapplication had just been granted. Even before thatpatent had been granted, her company had beenvalued at several million pounds, despite havinggenerated very few sales at that stage. Thevaluation was based purely on the strength of thecompany’s intellectual property rights, including itsEuropean patent, trade mark and registered design.Does anyone else find any of this slightlyworrying? In all the focus on venture capital andvaluations and patents, we seem to have lost sightof the product itself and bringing it to market.Getting a product patented can cost a heck of a lotof money and can tie you up in paperwork formonths, if not years. In the meantime, theimplication is that you market your product at yourperil lest someone should try to copy it. But if youdon’t go ahead and market your product as soon asyou’re able, aren’t you just opening the door forsomeone with a similar (or even a less wellspecified or less capable) product to come in andsteal market share from under your feet?I found myself flitting around the Dragon’s Denhomepage, and out of interest clicked on a link tothe European Patent Office. And guess what I foundin large type at the very top of the page? The line“There’s more to commercialising an invention thanjust filing a patent.” Doesn’t that say it all?Sealing, Adhesive, ElastomerOctober 21-23, 2008Nuremberg, Germanywww.mesago.deMesago Messe Frankfurt(+49 711 61946-0)Fastening & AssemblyOctober 23, 2008National Motorcycle Museum, Birminghamwww.fastening-solutions-exhibition.co.ukNewbyCom (01844 202279)SPS/IPC/DrivesNovember 25-27, 2008Nuremberg, Germanywww.mesago.deMesago Messemanagement(+49 711 61946-0)Manufacture 2008December 8-9, 20086th annual manufacturing conferenceSaint-Etienne, Francewww.manufacture2008.euCTIM (+33 344 67 47 41)Southern ManufacturingFebruary 11-12, 2009Farnborough, Hantswww.industry.co.ukETES (01784 880890)Machine Building(including Drives & Automation)March 25-26, 2009NEC, Birminghamwww.devicelink.comCanon Communications (01622 661363)MTECMarch 25-26, 2009NEC, Birminghamwww.devicelink.comCanon Communications (01622 661363)Index to Advertisers October 2008Alliance Plastic Parts Centre ........................... 53Alwayse Engineering ..................................... 17Asco Numatics ............................................. 55Associated Spring ......................................... 51Astrosyn International .................................... 64Autodesk ...................................................... 17Baldor .......................................................... 59Bosch Rexroth .............................................. 11Brevini ......................................................... 31Centa Transmissions ...................................... 37CLPA Europe ................................................ 29JG Coates .................................................... 64Davall Gears ................................................. 40E2S ............................................................. 61Elesa (UK) ................................................... 44George Emmott ............................................. 47Euro Bearings ................................................. 4Expert Tooling & Automation .......................... 33GE Inspection Technologies ............................ 61Henkel Loctite Adhesives ............................... 23HepcoMotion ................................................ 33Huco Engineering Industries ........................... 20William Hughes ............................................ 49Idec ............................................................... 5Igus ............................................................. 31Igus ............................................................. 64Industrial Gas Springs ................................... 51Interpower Components ................................... 7Interpower Components ................................... 9Interroll ........................................................ 31Albert Jagger ................................................ 51JBJ Techniques ............................................ IBCJokab Safety ................................................. 61Kingston Engineering ..................................... 27Kobold Instruments ....................................... 57Lafert Electric Motors ...................................... 8Lee Products ................................................ 57Lee Spring ................................................... 49Lenze .......................................................... 10LG Motion .................................................... 38Machine Building Systems ............................... 4Machine Building Systems ............................. 64Maxon Motor ................................................ 15Mclennan ..................................................... 39Micro-Epsilon ............................................... 26Mitsubishi .................................................... 19Moog Controls .............................................. 13Murrelektronik ............................................ OBCNSK Europe .................................................. 25Parker SSD Drives ........................................ 2-3PVL ............................................................. 41Reliance Precision Mechatronics LLP .............. 22Renold Chain ................................................. 4Rino Industries ............................................. 49RK Rose & Krieger ........................................ 63Rotaflow FV ................................................. 64Sandvik Materials Technology ......................... 64Schaeffler ..................................................... 64Sensopart ............................................... 42-43SEW-Eurodrive ............................................. 35Sherborne Sensors ........................................ 41SKF.............................................................. 17Spirol Industries ............................................ 45Spirol Industries ............................................ 48Spirol Industries ............................................ 51Springmasters ............................................... 45SPS/IPC/Drives ............................................. 27Tapeswitch ................................................... 18Tappex ......................................................... 45THK ............................................................ 21Unifast ........................................................ 45James Walker ............................................... 21Welser Sections ............................................ 55The West Group ............................................ 6466INDUSTRIAL TECHNOLOGY • October 2008

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