machine building & automation - Industrial Technology Magazine

24-25October 2012Hall1 SilverstoneWing SilverstoneCircuit NorthamptonshireWednesday:9.30am-4.00pm&Thursday:9.30am-3.30pmDedicatedtosensingandmeasurementforcontrolandinstrumentationtheeventoffersengineersaneasyroutetoseeandlearnallaboutthelatestproductsintheirindustry.Theexhibitionwillenablevisitorstoevaluatecurrentindustrydevelopments,sourcenewproductsandservicesandupdateproductknowledgeatFREEworkshopspresentedbykeyindustryexperts.To exhibit call Gail Downham on 01822 614671email: gd@trident-exhibitions.co.uk or visit the websiteOfficial Media sponsors and supporters of Sensors + Systems for Control & InstrumentationInstitute ofMeasurement and Control

Driving sense into innovationWith Britain looking to rebuild its manufacturing sector, onestrategy is to look for emerging markets rather than trying tomuscle into existing ones against fierce competitors. And Ecotechnologies represent just that sort of opportunityElectric cars look like having a big future,and first generation vehicles are currentlybeing launched by many of the automotivemajors. All engineers will know that thesewill be redesigned and refined steadily over the next10-20 years until a mature version evolves. One ofthe technical issues developers are focusing on isthe power to weight ratio of the electric motor atthe heart of the vehicle. And a rapidly growingcompany spun out of Oxford University is makingthe running in this field.“It started when the University was asked todesign a motor for an electric sports car,” explainsTim Woolmer, founder and CTO of YASA Motors,now based in Abingdon. “I was just starting myDPhil was set a goal to make the smallest possiblemotor for use in the automotive sector.” After somemonths of research, Tim came up with the novelYASA motor architecture. Further innovations in thecooling, mechanical design and magnetics havemeant that the motor is now significantly smallerand lighter than competitor motors.YASA was set up in 2009 and is long sincepassed the £500,000 annual turnover mark. It justbeen named the UK’s Best Enterprise in the LloydsTSB/Telegraph Enterprise Awards. “Obviously,production will continue to climb as demand forthese motors grow. It is a process that we are goingto have to manage very carefully and we areplanning well ahead,” explains Tim.“The design cycle for a car is 4-5years, so we are expecting the firstspike in demand in 2016/17.“Importantly there will be furtherdemand from other industries.Construction vehicles designers for instance arekeen to overcome the inherent inefficiencies ofdriving the hydraulics from their main diesel engine.They are already working on hybrid designs withelectric motors powering the hydraulics. Its only asmall step from there into agricultural vehicles, thenmarine, aerospace etc.”Innovative test rigCurrently YASA is doing constant evaluation testsand, unsurprisingly, has developed a highlyinnovative test rig that makes mounting anddismounting the motor as simple, fast andergonomic as possible. At the core of this is aTorqSense non-contact speed and torque sensorfrom Sensor Technology. Tests often involve linkingmotors back-to-back, with one driving and the otheracting as a generator. TorqSense is non-contact andwireless so setting up before a test run isstraightforward. Based on surface acoustic wave(SAW) technology, the sensors comprise two thinmetal electrodes, which take the form ofinterlocking fingers on a piezoelectric substrate.When a radio signal of the correct frequency isapplied, surface acoustic waves are set up and itacts as a resonant circuit.The substrate can be attached to a motor shaftand deforms progressively when subject to torque;the resonant frequency changes accordingly,providing a measure of torque levels – withoutfiddly wires or slip rings. YASA uses a typeRWT321 sensor with integral electronics. Thiscombines high accuracy and resolution with a largeoverload capacity and the ability to operate bothclockwise and anti-clockwise. The sensor alsoprovides information about shaft speed, power andtemperature, with all of the data made available inreal time. The RWT321 incorporates a CANopeninterface, so directly compatible with the company’sdata acquisition and analysis systems.YASA Motors will be continually refining andimproving its designs for many years to come. Astandard range is being developed, and a customdesign and manufacturing service will provide avaluable second income stream.www.sensors.co.ukAutomation as a way of life to lift efficiencyIntegration of robots can decrease productiontime and cost, but can they successfully workalongside humans? At Rittal, automation is away of life here and lifts the company’sefficiencies and quality consistency as well as theoverall skill level of the workforce. Automation isone of the most powerful weapons in amanufacturer’s armoury when it comes tocompeting with manufacturers in low-wageeconomies, but when you are also makingcomponents for other automation companies it isalmost an obligation to use the latest robottechnology.Rittal UK is a leading manufacturer of enclosuresystems for mechanical and electrical applicationsin the industrial sector as well as racks andassociated products to the IT sector. Customersfrom around the world can see Rittal enclosuresbeing produced by robots controlled by state-of-theartlean and efficient manufacturing processes, withthe switchgear, drives and programmable logiccontrollers housed in Rittal products. The highestlevels of automation are utilised at Rittal’s UKfactory in Plymouth so it is not only an efficientworking production plant but also an ideal productshowcase and demonstration area. The productionline comprises 19 of the latest computer controlledrobots with the safe and reliable installation andintegration of automation and processinstrumentation inside Rittal’s own enclosuresystems to protect the expensive and sensitiveinfrastructure.Understanding customer needsDr Stephen Hobbs, managing director of thePlymouth factory, says the factory is a longestablishedleader in automation technology: “Wehave been highly automated for the past 20 yearsin order to provide solutions for our highlyautomated customers.” Dr Hobbs believes that theuse of automation in the factory has given Rittal UKa deep understanding of the needs of theircustomers in the automation sector. “From our ownproduction challenges, we know and have a betterunderstanding of the demanding needs of ourcustomers,” he says. “They want to take advantageof worldwide approvals and certifications, yet at thesame time require a high level of customisation tosuit their individual needs.”The extensive use of automation in thePlymouth plant has also enabled the company todevelop systems and software expertise that can beused to further help and add value to customerswhose core competence is not enclosure systems.“Rittal’s customers are often integrators, panelbuildersand contractors, who need support toensure that their solutions are designed swiftly,accurately and that they will perform correctlywhen completed,” Dr Hobbs explains. “To supportthis activity, Rittal and our sister company ePlanprovide software and design tools to facilitate andsimplify the engineers’ job.”www.rittal.co.uk12INDUSTRIAL TECHNOLOGY • April 2012

Profile Technology Conveyor Technology Linear Motion Factory EquipmentOUR PROCESSRELIABILITY ISYOUR ADVANTAGEmk Factory Equipment: thismeans modular arrangementswith a system. An extensiveprogram of compatible standardmodules allows theflexible and economicaldesign of workshops andworkplaces.mk Profile Systems Limiteda company of the mk Technology GroupUnit 2·Wolds Farm Business ParkKinoulton Lane·Kinoulton·Nottinghamshire, NG12 3EQPhone +44 (0)1949 823751·Fax +44 (0)1949 81270www.mkprofiles.co.uk·info@mkprofiles.co.uk13

What’s best for preserving wine:pressure or vacuum?Serious wine buffs have often asked themselves the question, ‘what’sbetter for preserving wine – pressure or a vacuum?’ However, DickBerresford, managing director of Ipswich-based Bermar, believes that,given the right technology, you can combine the best of both worldsPerhaps better known for its brand name, LeVerre de Vin, the market for Bermar’s UKmanufactured wine cabinets is found in hotels,restaurants and bars where wine is served bythe glass in 82 countries around the world. Every threestar Michelin restaurant in the UK uses Bermarequipment, as do over 800 Whitbread pubs.After opening, the wine remaining in a bottle initiallyhas a rapid oxygen consumption rate, which means thatmost chemical changes occur to the contents within thefirst couple of days. The process slows progressivelythereafter, but by then the damage is done; damage thatis irreversible and is simple to spot by smelling or tastingthe wine.The first chemical compound formed when oxygenreacts with the ethanol in a wine is acetaldehyde. At lowlevels it can make a wine taste ‘flat’ and vapid and it isalso responsible for the loss of a wine’s fresh fruity taste.Further exposure to oxygen converts the acetaldehydeinto Acetic Acid, the most common of all volatile acidsand one of the common, sour tasting carbonic acidswhich form the main constituent of vinegar. Thefinal chemical change takes place long after a wineshould have been discarded (usually within five toten days). The reaction between oxygen and thephenolics in the wine causes the wine to changecolour, moving to amber and finally to a brackishbrown.Pressure and vacuumTo help preserve the wine, Bermer’s managing directorDick Berresford turned to pressure and vacuumtechnology from PVL. “We buy switches from PVL for twopurposes: one is to create a sub-atmospheric pressure orvacuum in bottled still wine, and the other is to create asuper-atmospheric pressure or compression of carbondioxide inside Champagne or sparkling wine bottles,” heexplains. “We incorporate PVL switches into a range ofnine different preservation systems. The equipment isused for all wines including those at the lower end of themarket. If a restaurateur offers guests a choice of 20different wines by the glass, he doesn’t want tocompromise their quality. As long as he re-seals eachbottle after every glass sold, it will give him a 21-dayshelf life. Even if he is selling wines in the £3 to £8 aglass range, he can still get a significant profit boost inthe same way that the Michelin three star restaurantselling wine at £50 to £100 a glass would.”But wouldn’t it be better to compress an inert gas likecarbon dioxide into a still wine bottle instead of14INDUSTRIAL TECHNOLOGY • April 2012

Workholding formolecule-accuratemedical technologyAspecialist UK manufacturerof medical devices now hasmachining processes toproduce stainless steelcomponents used in meteringequipment so accurate it can measuredown to individual molecules. Due toa recent increase in demand, thecompany asked WDS to upgrade theexisting workholding solution toenable machine capacity toquadruple; allowing a two stagedrilling and reaming operation to becompleted four-up on a new 5-axisCNC machine.The components known as ‘ionblocks’ required many small holes tobe drilled and reamed into them. Thistype of complex component required aspecialised workholding solution toensure fast changeovers, repeatabilityand accuracy over the two stagemachining operation. WDS engineerswere able to design a cube fixturesolution which would allow four-upcomponents with precision chucks forthe first machining operation andbespoke fixture plates to locate andbolt the components for the final finishmilling operation.Nick Gautier, project and technicalsales engineer for WDS FixturingSystems, comments: “The challengewas to develop a way of mounting fourwork pieces in a very tight area on thenew 5-axis machine. WDS carried outa site visit to meet with the headengineer and measure the cutter pathsand spindle clearances of the newmachine to make sure our cube designwould work. The components need tobe extremely accurate and designedspecifically for the application.”WDS has been supplying both offthe-shelfand bespoke fixturing andworkholding systems for CNCmachining applications since the veryfirst CNCs were introduced. Thecompany offers a range of core workpiece support elements such asbaseplates 3000mm x 1800mm;cubes and double siders up to1000mm x 1.300mm and 3700mmx 2000mm jigs with boring capacity,all in cast iron or aluminium. They arean ideal fit for most machine centrepallet sizes and can easily be adaptedfor specialist applications such as this.Bespoke solutionsGautier concludes: “When you aremanufacturing medical equipment it isessential that components are held inplace accurately and without risk ofdamage. We specialise in bespokesolutions to very high tolerances in arange of materials. In this instance ourexperience, in-house manufacturingcapacity and site visits to inspect theCNC machine and discuss the solutionwith engineers on-site ensured wewere then able to provide an idealsolution.”A catalogue is available thatcontains all of the company’s standardWorkholding components as well asits Ball Lock quick release andlocation system. Microloc workholdingand fixture plates plus magnetic andhydraulic clamp systems are alsoavailable for grinding and millingapplications – all of which can beintegrated to meet individualapplication requirements. WDSFixturing Systems is a BS EN ISO9001, 2000 department running fullycompliant quality and design systems.www.wdsltd.co.uk17

FASTENERS & JOININGAdhesive BondingSpecial purpose bondingRather than being an afterthought, adhesivesare now first choice among numerous engineerswhen it comes to that unusual applicationLet’s face it, for most applications a standardadhesive product will often do the trick andcreate an effective bond. But for ‘special needs’applications, specific performance characteristicsare required. The original Loctite invention, developed in1953, solved a problem that had been faced by engineersfor many years – how to stop a screw vibrating loose. Itbecame a ‘special’ product for threadlocking all manner offasteners. But developments continued apace, and theanaerobic principle – that of taking a unique liquid resinthat hardened in absence of air and in presence of metalto produce a secure joint – soon embraced other forms ofbonding, such as retaining, sealing and gasketing.With these introductions, the need for many ‘special’mechanical fasteners disappeared. Since then, otheradhesive technologies have been introduced that havereplaced or augmented more traditional mechanical fixingmethods. Today, engineers turn to adhesives for costefficiency, automated production, lightweightcomponents, ease of assembly and joint reliability, even in‘special needs’ applications.Dirty bondingJust as ‘special’ mechanical fasteners may be called uponin specific circumstances, so adhesives have beendeveloped to meet equally extraordinary circumstances. Agood example is ‘dirty bonding’. Engineers know thatsurfaces to be bonded should be as clean as possible. Infact, adhesives manufacturers will often provide cleanersfor the very purpose of ensuring substrates are free fromcontamination. But, as engineers will also be aware, it isnot always possible to achieve that level of cleanliness. Insome instances bonding will be required on ‘as received’parts whose surfaces may be contaminated with engineoils, corrosion prevention oils,cutting fluids or other ‘dirty’materials.Oil tolerant adhesives – in theform of threadlockers and retainers –have been around for some time, butsome recent developments haveintroduced significant improvementsin the performance of these productsand enable them to be used in‘special’ circumstances. In fact,today’s oil tolerant threadlockers caneffectively reduce the need forspecial mechanical fasteners suchas spring washers, castle nuts and plastic inserts. Suchthreadlockers are available in medium and high strengthgrades, and alongside their oil tolerant qualities they canbe employed on high temperature applications, in somecases up to 180°C.Coping with chromeBut the benefits of these new threadlockers do not endthere. Recent industrial Health and Safety regulations meanthat Hexavalent chromates can no longer be used for manycoatings and, as a result, manufacturers are now switchingto Trivalent chrome. This move, however, presented achallenge for adhesives as the existing anaerobic grades donot adhere very well to the new coating.So, does that mean an end of bonding where suchcoatings are involved? Not at all. The formulation that wasneeded to ensure that adhesives cure not only on activesubstrates, such as iron, copper, brass and steel, but alsoon passive materials including stainless steel, zinc platedsurfaces, inorganic and organic coatings has beenincorporated into the new generation of threadlockers –making them more versatile than previously possible.All of this means that for ‘special’ situations whereinactive coatings and ‘as received’ parts are involved,there are adhesives that can provide the effective solution.Moving away from anaerobic adhesives, there havebeen some important developments in the area of silicones.Traditionally, standard single part silicones are slow to cure,have limited cure through volume and their optimumadhesion can be substrate dependant. In most cases, aprimer is needed. To overcome these limitations, a range ofnew two part products have been developed that provideunlimited cure through volume, and give good adhesion toa wide range of substrates without the need for a primer.And like all silicone products, they are extremely flexibleand can be utilised for bonding glass, metals, ceramics andmost plastics. In many cases, there is no need for surfacepreparation. The latest addition to this specialist range is ahigh temperature version that can withstand continuoustemperatures of 220°C – and peaks up to 300°C.However, the main benefit is the speed of cure. Thesenew two part products allow handling and subsequentuse in considerable shorter times than have previouslybeen possible. In some cases, handling strength isreached within minutes. Typical uses for the new productinclude the bonding and sealing of glass and ceramicstove tops to appliance frames, securing brackets to backof stove tops, bonding glass to microwave oven doors andthe sealing of washing machine drums.More two partsCyanoacrylate (CA) is another adhesive technology thathas been recently developed in two part form. Theseadhesives, previously available only as single componentproducts, have always provided an ‘instant’ answer tomany bonding situations. Their versatility and thecapability to automate dispensing operations have madethem a popular choice in a diversity of industries.All those benefits – including an initial bond withinseconds – are still available with the new two componentCA, but with the added advantage that any exposedadhesive remaining outside of the joint will harden withintwo to four minutes, removing the need for a postassemblyactivator.It will bond together close fitting parts in 20 seconds,and even where the gap is 3mm, bonding is achieved inless than 90 seconds. Indeed, the product can be usedwhere a more significant gap – up to 5mm – is involved.This adhesive, which can be used on substrates such asplastic, rubber, wood, stone or metal, is capable ofwithstanding a force of some 20N/mm 2 . Application isvery easy, with the adhesive available in a bi-packsyringe. The temperature range of this new two part CA isalso versatile: it can be used between –20°C and +80°C.For those special applications (especially in the area ofmaintenance) that demand an epoxy to be used, but wherea fast handling strength is required, a new product is nowavailable for general purpose repairs or the speedyassembly of small components. Called Loctite DoubleBubble it will bond to a wide variety of materials, and curesrapidly to give handling strength in approximately fiveminutes. This epoxy comes packed in a handy sachet,and is supplied complete with a mixing stick and pallet.www.loctite.co.ukThis article was prepared for Industrial Technology by Henkel18INDUSTRIAL TECHNOLOGY • April 2012

Smooth and sealedthin-metal assembliesPEM self-clinching concealedheadstuds and standoffsprovide strong, permanent,and reusable threads for matinghardware in thin-metal assemblyapplications. Their concealed-headfeature offers design and aestheticbenefits by allowing the side of thesheet opposite installation to remainsmooth and untouched. This featureadditionally serves as an idealsolution for applications where thehost metal sheet must remaincompletely sealed from air, liquid,dust, gases, or other potentialcontaminants.Concealed-head studs andstandoffs install permanently in steelor aluminum sheets as thin as1.6mm. Studs (aluminum orstainless steel) are available in threadsizes from M3 to M5 and in lengthsfrom 6mm to 25mm. Standoffs(stainless steel) are offered in threadsizes from M3 to M6 and in lengthsfrom 4mm to 25mm.Sheet preparation for theirinstallation requires only a blindmilled hole to the recommendedminimum depth. Using aPEMSERTER or other standard press,installation is quick and easy byplacing the fastener in the hole andapplying sufficient squeezing force.The fastener head then locks securely.www.pemnet.com19

MECHANICAL COMPONENTSBearings, Slides & ActuatorsMaximising motorsfor energy efficiencyHigh efficiency motors can bring significant savings but if budgetswon’t stretch to motor replacement, energy efficient bearingsoffer a powerful cost-saving alternative, says Phil BurgeIn the current economic climate, the pressure tomaintain a healthy operating margin is great butattempting to protect this margin by increasing pricesis risky. An alternative option is to look at your currentpractices and identify potential changes that could help toreduce your costs. The problem here is that it issometimes difficult to see how any cost reduction can beachieved, particularly when many raw material prices arerunning high and the demands of increasingenvironmental legislation continually add to the cost base.However, there are options that can help you cut a majorcost in any plant, and that cost is, of course, energy.The majority of commentators estimate that factoryenergy expenditure accounts for at least 50% of the totalrunning costs. Correspondingly, any savings made herecan make a marked effect on the balance sheet.One strong option that can have a positive, long-termeffect on the business is to replace older motors withmodern, high efficiency equivalents. However, this is notalways feasible; when budgets are tight, even proven,long-term cost-saving options such as the installation ofenergy efficient motors may be tricky and cash flowproblems may rule out the possibility altogether. So, if wehave had to rule out motor replacement, how do we effectan energy saving?Switching components offers a more affordable optionand a powerful one, too. Energy efficient bearings canmake a massive contribution to profitability, cutting energywastage by up to 50% and also extending the lifespan ofyour existingmotors.Today’s leading energy efficient bearingsenable components to rotate more easily withminimum friction and heat, dramaticallyreducing wear and enhancing performance.For example, E2, a range of energyefficient deep groove ball bearingsfrom SKF, features a host of technicalinnovations that reduce friction.The internal geometry of thebearings has been optimised viathe use of advanced modellingtools, which, in tandem with anew, fit-for-purpose polymer bearingcage, has brought a markedimprovement in operating efficiency.The very best of today’s energy efficientbearings offer the potential to minimise frictional losses tosuch a degree that operating temperatures can be loweredEnergy efficient bearings can make amassive contribution to profitability,cutting energy wastage by up to 50%and also extending the lifespan ofyour existing motorsby as much as 30°C, resulting in an improved lubricantviscosity that extends the operating life of moving parts. Inaddition, these innovative energy efficient bearings canlast twice as long as their conventional alternatives,cutting the cost of purchasing as well as running theequipment at your plant. Such developments as thesehave proved that energy efficiency can beachieved even without the expense ofreplacing plant motors, boostingperformance and productivity to thebenefit of operators while alsosatisfying environmental pressuresto consume less energy.Another positive point to bear inmind is that replacing your existingbearings with energy efficientalternatives does not requireadditional downtime; they can beexchanged during routinemaintenance. For example, SKF E2deep groove ball bearings aredimensionally interchangeable with standardequivalents and available in a range of sizes, enabling thechange to be made during planned downtime.Without generating the considerable cost of replacingmotors, energy efficient bearings can make a difference inall applications, and where energy savings are concerned,it’s not only a one-off benefit; any saving you make isbeing made day-by day and year on year. To give anexample of how this might be calculated in practice, takea typical electric motor, which can generally be fitted withenergy efficient bearings in sizes of up to 37kW. If the bestof the current crop of E2 bearings are used in a single37kW motor, running continuously at 3,000rpm, that willmake an energy saving of 270kW per year, and keep morethan 150kg of CO2 out of the atmosphere. The benefitsare even greater on a larger scale: SKF helped a leadingconsumer healthcare company to reduce frictional lossesby 46% by providing energy efficiency deep groove ballbearings in cold water pump motors (22kW) running atspeeds of 2,990 rpm. Ultimately, this translated to energysavings of 4,583kWh per year per motor.Energy is becoming an increasingly preciouscommodity, both financially and environmentally, andreducing consumption by plant and machinery across allsectors brings benefits to everyone. The development ofenergy-saving technologies is, thankfully, a growth areaand the recent innovations in energy efficient bearingsrepresent not only a positive step in the right direction butalso a significant opportunity for companies throughoutindustry to minimise the environmental impact of theiroperations and cut energy costs.www.skf.co.ukPhil Burge is communication manager for SKF20INDUSTRIAL TECHNOLOGY • April 2012

PARTNERSHIP BASED ON TRUST –AND TRUST BASED ON QUALITY.Total Quality by NSK: HPS TM spherical roller bearings.NSK’s compact HPS TM spherical roller bearings set new standardsfor precision and performance. This new generation of bearingsextends maintenance intervals considerably and reducesequipment downtime at high speeds and in extreme conditionswith wide temperature variations, wet and dusty environments.More about NSK at www.nskeurope.com or call us on +44 (0) 1636 605123NSK UK Ltd · Northern Road, Newark, Nottinghamshire, NG24 2JF · Telephone +44 (0) 1636 605123 · info-uk@nsk.com

MECHANICAL COMPONENTSBearings, Slides & AcuatorsNew bearing conceptsfor renewable energyBearings and simulation software will prove key to the futureof renewable energy systems, argues Dr Steve LaceyOne of the greatest engineering challenges thatwe face today is in meeting global energyrequirements while preserving the environment.Although solar energy will certainly play itspart, in the UK, wind, wave and tidal energy systems willbe the most likely future sources of renewable energy. Inthe UK wind energy sector, for example, experts predictthat by 2020, more than 6,000 wind turbines will needto be installed in the UK if the country’s future energytargets are to be met.Investment in renewable technologies requires asignificant financial commitment. Protecting thisinvestment by ensuring maximum availability of wind,wave and tidal turbines is therefore critical. As amanufacturer of high precision rolling bearings, Schaefflerwill continue to play an important role in improving thereliability and safety of wind, wave, tidal and solar energysystems.Rolling bearings are a core component of renewableenergy systems and are key to reducing operator costs.The design of low friction bearings for a wind turbine rotorshaft and gearbox, for example, are importantconsiderations, as well as the associated lubricationmethods for the bearings, mounting, maintenance and theuse of remote condition monitoring and diagnosistechniques to ensure that maintenance costs areminimised and service life is increased.In a typical wind turbine drive train, rolling bearingsare used to support the rotor, alternator and gearbox. Plainbearings are found in blade adjusters in pitch-controlledwind turbines and in geared motors that drive the towerslewing ring and pitch control. Over the next decade, thesignificance of rolling bearings will increase as new, larger,multi-Megawatt class windturbines are developed. Thistrend towards larger, multimegawattwind turbines willlead to more radical changes in the design of thebearings. And ‘single bearing’ designs willbecome increasingly important.With single bearings, the wind turbinerotor is supported only by a single, doublerow tapered roller bearing, typically in aback-to-back arrangement that supportsall forces and moments. This concept cantake many different forms, for example,with a shaft and gearbox and a high-speedgenerator, as a hybrid solution with shortened gearbox andmedium-speed generator, or as a direct drive without agearbox. Single bearings always result in more compactdesigns. For example, the wind turbine nacelle can be fullyThe trend towards larger, multimegawattwind turbines will lead tomore radical changes in the design ofthe bearings. Single bearing designswill become increasingly importantintegrated with the bearing-gearbox-generator unit. Thismeans that it is possible to eliminate drive traincomponents and reduce weight. This in turn reduces thehead weight of the wind turbine, allowing smallerfoundations to be used and simplifyinglogistics.Another advantage of the singlebearing design is that preloadedtapered roller bearings can beutilised, which prevent axialclearance and small axialmisalignments. This narrow, tightguidance of the rotorshaft means that lessmovements act onthe system, reducingthe negative effects onthe gearbox andgenerator.Spherical rollerbearings from Schaeffler are alreadyplaying an important part in several high profileEuropean wave and tidal energy systems, including thePelamis P2 wave energy converter. Key to the success ofthis development is a new joint concept that utilises a newlow friction material developed by Schaeffler. Thismodified PTFE fabric liner has low friction characteristicsthat effectively eliminate the problem of ‘stick-slip’. Thishas enabled the operating envelope of the P2 machine tobe extended beyond the capabilities allowed by standardbearing materials.Rolling bearing calculation software, Finite ElementAnalysis (FEA) and dynamic simulation tools will also playa critical part in developing next-generation renewableenergy systems. For this to succeed, collaborativedevelopment projects between multiple componentsuppliers will be necessary.Schaeffler is currently working closely with threecompanies – a gearbox manufacturer, a wind turbinemanufacturer and a software developer – to develop newsimulation software that is able to calculate thedynamic operating loads acting on windturbine powertrains. Used incombination with FEA tools, thiscomplex, multi-body simulation(MBS) model will enabledesign engineers to optimisethe design of individualpowertrain componentsand to establish howthese interact with othersystems across the entirepowertrain. Simulationtools such as these, whichcan be used at the initialwind turbine design stage, willprove invaluable in helping to makefuture wind turbine designs morereliable and cost effective under a widevariety of load conditions. New bearing designs can bedeveloped and tailored to specific wind turbinerequirements, including turbines for both onshore andoffshore wind farms.www.schaeffler.co.ukDr Steve Lacey is engineering manager at Schaeffler UK22INDUSTRIAL TECHNOLOGY • April 2012

MECHANICAL COMPONENTSBearings, Slides & ActuatorsWelding guns rely on ballscrewsSwitching from roller screws to ballscrews has provided a 40% costreduction for a welding gun manufacturer, improving competitivenessAwelding gun manufacturer has achieved amassive reduction in costs by replacing anexisting actuation mechanism using planetaryroller screws with high quality, silent runningNSK ballscrews. The new units offer maximisedefficiency and load carrying as a result of integrating agreater number of load carrying balls.NSK was called in as part of a cost reductionstrategy introduced by the welding gun manufacturer,and tasked with providing a lower cost alternative to theplanetary roller screws currently used. However, thealternative had to meet stringent operating demands: itmust not reduce performance, nor increase energyconsumption or levels of maintenance. In the actualmechanics of providing an alternative, NSK had to takeinto account the fact that, in welding guns an extremelyhigh load is applied in a very short time and always inthe same point of the stroke. Therefore, to ensurereliable operation requires the maximum number of loadcarrying balls at equal load distribution.Reduced operating frictionNSK, with its wide experience in high load ballscrewapplications proposed a SFD3605-12 unit that offeredthe key benefits of conforming to the same dimensionsas the existing design, plus reductions in operatingfriction and temperature, as a result of changing fromrollers to balls. Moreover, these benefits have beenachieved with a ballscrew that shows a 40% costsaving, greatly improving competitiveness for thewelding equipment manufacturer.Key to the all-round improved performance of theNSK ballscrew is a new ball recirculation technique. Thisemploys a deflector at each end of the ballnut to ensurethat the load carrying balls are picked up tangentially,thus eliminating the direct ball-to-ball contact thatcauses noise and vibration. In addition, the improveddesign also provides smoother and more stable runningat low speeds, qualities that are extremely important inensuring high levels of reliability and accuracy inmachine tool applications and other precisionequipment applications.www.nskeurope.comTHE PERFECT BOND BETWEEN BEARINGS AND PLASTICJESA combines ball bearings with plastics technology and manufactures fi nished ball bearings units. In order to ensure reliable bonding of bearingand plastic throughout the product’s life cycle, the process must be perfect. Thanks to Swiss quality, precision and innovation JESA is a worldleader in the fi eld of ball bearing assemblies and plastic rollers, customised ball bearing solutions and standard ball bearings. www.jesa.chspinning solutions24INDUSTRIAL TECHNOLOGY • April 2012

Bearings save space,weight and powerFranke wire-race bearings are65% lighter than comparablesteel bearings, so they reducethe overall weight of your design andsave valuable operating power.Thanks to the Franke principle ofinlaid steel raceways, you getcomplete freedom with regard to thematerial and shape of your matingstructure. In contrast to conventionalbearings, the rolling process does notoccur directly between the rollingelements and mating structure, butinstead smoothly on four open racerings. The raceways are matched tothe ball diameter using a specialgrinding process.This special construction principleproduces an extremely compactbearing, which also suits use in verysmall spaces. The designer also hasthe freedom to choose the individualshape and material of the bearingassembly. This enables designers toemploy materials such asaluminium, bronze, magnesium orplastic for the mating structure,without losing on load capacity,precision or service life.The Franke anti-friction bearingsproduct range includes bearingelements ready to be inserted itoexisting applications, slim bearingsmade to international standards,ready-to-use bearing assemblies withfree centre space, and motorisedsystems with measuring and controlunits.www.frankebearings.co.ukAEROSPACEMEDICALDENTALNUCLEARCANNINGVACUUM PUMPSDEFENCEprecisionwithThe Barden Corporation is a world leader in the design andmanufacture of super precision ball bearings. We offer thousandsof bearing variations plus a free design service. Download ourspecialist catalogue at www.bardenbearings.co.ukThe Barden Corporation (UK) LtdTel: 01752 735555 Fax: 01752 733481Email: bardenbearings@schaeffler.com25

POWER TRANSMISSIONGears & Geared MotorsSophisticated separationmachine designReliable drives for the food industry are proving key in anapplication to separate sinews and cartilage from meatHow to best puree fruit containing stones, or toseparate fish mince from fishbone? And howto remove sinew and gristle from meat withoutwasting material? Every amateur chef who hasalready spent hours pressing fruit through a sieve with aspoon or preparing chicken soup knows these questions.In the food industry, these methods have an automatedequivalent that makes time-consuming manual labourunnecessary: so-called soft separators are used to gentlyseparate the solid and soft components of a wide range ofbasic products. Robust, reliable drive technologycomponents that are suitable for the requirements of thefood industry are a key prerequisite for a consistently highproduct quality.The Baader group, a leading manufacturer ofmachinery and processing plant for the food industry,developed suitable technology for the clean separation ofmeat and sinews or cartilage more than 40 years ago.Over time, the product range was extended, and nowincludes soft separators with varying performances thatcan be used to remove sinew from meat and poultry, torecover meat from fish, to extract pulp from fruit andvegetables, and to unpack food products. In Baader softseparators, a toothed chain powered by a geared motor isused to move a squeezing belt. The squeezing belttransports the product to a perforated drum and squeezesthe soft components through the perforation, while thesolid particles remain outside of the drum. An adjustablecylinder allows users to adjust the yield/quality ratio. Thismethod ensures maximum product quality andminimal temperatureincrease.Thus, the cellstructure of the source product is notdestroyed, since the squeezing belt systemoffers sufficient flexibility. At the sametime, unwanted solid componentsare kept out of the end productduring meat processing. Last but notleast, the method results inconsiderable time savings and astandardised final product comparedto manual product separation.Baader’s soft separators weredeveloped in the 1960s and havebeen constantly optimised sincethen, for example with regard to thecleaning options. They comply with internationallyrecognised hygiene standards. In several models, helicalbevel geared motors from Nord Drivesystems serve asdrive units. One example is the Baader 605 type, whichreaches a maximum performance of approximately3,000kg per hour depending on the hole size in theThe separation technology results inconsiderable time savings comparedto manual product separation,without destroying the cell structureof the source productperforated drum, the feeding type, the product, thefeeding temperature and the selected pressure – therebyqualifying for continuous large volume processing. Userscan choose a hole diameter of 1.3, 2, 3, 5 or 8mm in theperforated drum, with other diameters availableon request.Nord provides robust helical bevel gearmotors for the soft separators – Baader uses theSK 9016.1, SK 9022.1 and SK 9042.1 gearunit types. These drives owe their long lifeendurance partly to the Unicase design of Nord’sgeared motors: the housing, which is made from asingle-piece casting with integrated bearing seats,eliminates all sealing surfaces that could deflectunder the effect of torque or radial forces. The highefficiencygear units with durable, wear-free gearteeth also contribute to high reliability duringoperation. Nord’s consultation services for customersand users was another factor in the choice of a supplier.Nord has, for instance, also advised Baader during thepreparation of switching over to IE2 motors, helped byextensive experience in the development of efficientdrive technology and application-specific energy savingsconcepts. “In Nord, we have found a reliable, competentpartner who supplies us with customised drivesolutions,” explains Martin Schaarschmidt, sales managerfor separator technology at Baader. “Consultation throughNord experts in particular is a great relief, and allows usto focus completely on our own products.”Since June 2011, electric motors must fulfill thestricter energy efficiency requirements of the IE2efficiency class. Nord has been supplying IE2 motors forsome time. The company has implemented a three-pointconcept: compliance with the IE2 efficiency class isachieved firstly by the use of more active material,secondly by choosing higher quality sheet metal with lesslosses, and thirdly with increased copper filling incombination with a simultaneous reduction in the size ofthe windings. Nord IE2 motors offer various advantagesover previous models, including improved efficiency,higher start-up and breakdown torques, decreased slip,and less waste heat with better thermal performance.Compared to their direct predecessor models, IE2-typemotors thus offer an increased service life and help saveoperating costs. If required, the operating range, whichhas been shifted upwards towards a better efficiency, canbe used to continuously operate the new motors at a150% performance factor. Alternatively, users can nowchoose a smaller motor type for many applications.Nord also develops IE3 motors. These solutions mustensure an efficiency increase of at least 10% comparedwith the IE2 class. In many cases, this goal can beachieved through the three-point concept. For some IE3systems, Nord will also make use of different materials.Replacing aluminium with copper as the conductormaterial for the squirrel cage considerably reduces rotorlosses in IE3 systems. In addition to that, some furthermeasures can be useful in IE3 solutions, such as the useof sheet lamination material with lower specific corelosses, larger conductor cross-sections in the windings,flux-optimised windings, and smaller windings. Furtherincreases in efficiency can also be achieved withpermanent magnet motors and with frequency inverteroperation (synchronous motor principle).www.nord.com26INDUSTRIAL TECHNOLOGY • April 2012

POWER TRANSMISSIONGears & Geared MotorsMaximum precision, dynamics,durability and efficiencyWittenstein’s vast range of rack-and-pinion drive systems combinesignificant performance benefits with efficiencies of up to 97%Regardless of whether you are aiming to speedup the 25 ton gantry of a machine tool,position a laser cutting head at 400m/min orexecute welding operations with a toleranceof just 0.1mm using a jointed-arm robot, Wittensteinsays its rack-and-pinion drives guarantee maximumprecision, dynamics and running time, combined withoptimal efficiency.Owing to their operating principle, there is norestriction on the length of these drives, which is whythey are perfect for applications with long traveldistances. The fact that the racks can be sortedassures consistently high precision irrespective of theaxle length.Compared to linear drives – the traditional rivaltechnology – rack-and-pinion drives provide clearlysuperior energy efficiency. Whereas in practical dutyballscrew drives and linear motors only rarely exceedthe 90% efficiency mark, Wittenstein’s rack-and-pinionsystem achieves up to 97%. The resulting energysavings are considerable, especially inapplications with high duty cycles.Wittenstein’s rack and pinion drivesoffer maximum travel speeds of 440m/minand a maximum feed force of 47kN with a single drive.Maximum precision is 5µm using a direct measuringsystem, and the maximum input torque is 3654Nm.Racks are available with 2mm to 6mm module, inlengths up to 2000mm. Total pitch deviation is up to12µm/min. The rack and pinion drives are availablewith servo planetary and worm gearheads, as well asright-angle and coaxial gearhead configurations.Torsional backlash is guaranteed less than 1 arcminute, and the innovative pinion connection ensuresvery high rigidity. In view of the wide range of rackclasses, gearhead types and pinion connections, it ispossible to configure the ideal system for almost anyapplication. Wittenstein has an extensive portfolio ofgearheads, racks and pinions, and combines this withvast sizing expertise (amassed over more than aquarter of a century) plus the latest simulation andanalysis tools.Wittenstein products are used in some of the mostdemanding applications: they fly into space, winFormula 1 races, and find their way into the latestmedical technology.www.wittenstein.co.uk28

Gearheads offer moremounting optionsNabtesco Precision Europe hasintroduced the RD2 series ofgearhead series suitable forvery demanding reduction tasks,delivered ready for installation. Thenew series features expandedmounting options – RD2 gears arealso suitable for belt-drive operationor can be installed at right angles.The reduction gearheads combinethe advantages of RV trochoidalgears with easy mounting. Thegearhead is closed and filled withgrease, so it is completely ready forinstallation. To further simplifyinstallation, an adapter plate and amotor shaft coupling are included.Nabtesco offers gear variants withand without a hollow shaft.The new series is based on thesuccessful RD series, but offers evengreater flexibility. As in the earlierseries, the gearheads are ready formounting. “We have furtheroptimised the design, so that the newgears are even more lightweight andcompact,” Marcus Löw, Nabtescosales manager, explains. “Switchingfrom the old series to the new RD2series is easy, since the mountingdimensions and boring patterns areidentical.”The RD2 gearheads are availablefor ordering now, with the entire lineupof all sizes included in the originalRD series.www.nabtesco-precision.de % "*"&% *& !" ! '(")"&% +* () #"% #)& &()'(")"&% (&+% () (&$ $&+# % &$'*"*", (% & ()) )'+( () % '"%"&%)() (% (&$ $&+# *& $&+##* () ,"## &( %-* . #",(. www.andantex.co.uke: sales@andantex.co.uk t: 024 7630 772229

COMPETITIVE ADVANTAGE:Customised process solutions for yourentire value chainSEW-Eurodrive’s process portfolio for drivetechnology is innovative and transparentDriveBenefits from SEW-Eurodrive offer avariety of practice-oriented possibilities toaccelerate processes in every value creationphase, to simplify these processes, and tohandle them in a cost-optimised manner. Selecting thesuitable components and combining them to form anoverall concept will give you sustainable benefitsincluding measurable cost savings, reduced expenditureof time, increased process safety, increased efficiencyand enhanced process automationThe project planning tools and the DriveConfiguratorfrom SEW-Eurodrive bring you support before placing yourorder. Simply choose the components from thecomprehensive range of products offered by the company,combine them, and use them effectively. In this way SEW-Eurodrive enables planners and design engineers toconveniently plan their systems by offering them a wideselection of CAD models in 2D or 3D. All this is easilyaccessible and available at any time.Order and procurement logistics: Electronic datainterchange is the fastest and most efficient way for you totransmit order, delivery and invoice data. SEW-Eurodrivewill happily advise you on how to benefit from automatedorder processing. Combined with SEW-Eurodrive’scustomised procurement logistics, you will save precioustime, avoid mistakes in order processing and increase theefficiency.Material flow and startup: All deliveries and theirinternal further processing can be controlled efficiently usingDriveTag. In this way, the effort in your own incoming goodsdepartment is reduced and the internal material flow gainsin dynamics. The new documentation search offered bySEW-Eurodrive lets you create customised documentationpackages for your customer documentation.Operation and spare parts procurement: SEW-Eurodrive’s process solutions go far beyond the delivery ofthe company’s products. For example, you can optimiseyour spare parts management using the DriveGate onlineplatform, your portal for a variety of process solutions. Hereyou can directly inquire and order the parts you need.Processing is carried out directly by the responsible salesemployee who is available if you have any questions.Engineering and selectionSEW Workbench: The SEW Workbench is a planning andconfiguration tool for specifying SEW-Eurodrive products.The SEW Workbench includes a complete electronicproduct catalogue, all required documentation, and anoption for creating individual CAD files. In this way you caneasily and quickly create complex configurations andvirtually check their functions.DriveCAD: CAD data on all SEW-Eurodrive products areavailable on our DriveGate customer portal. You can eitherdownload CAD data in one of the various formats, or youcan integrate the data directly in your CAD environment bythe click of a button. You neither need the SEW Workbenchnor other software installations to directly access therequired drawings. The registration required for accessingDriveGate is free of charge.EPLAN macros: For efficient electric design, SEW-Eurodrive offers product data within EPLAN Electric P8.Apart from the typical macro drawings, this product dataalso comprises the complete technical data and productinformation. The product data can be directly downloadedfrom the EPLAN data portal to a P8 wiring diagram project.This saves you a lot of time for creating wiring diagrams asthere is no need for creating your own drawings and nocomplex data has to be prepared.DriveConfigurator: This innovative DriveGateapplication lets you configure your drive online and you willdirectly obtain all the information on the required product.The guided selection will navigate you through all availabledrive options in a user-friendly manner. All the requireddocuments (operating instructions, parts lists) as well asCAD models and dimension sheets will be available afterthe download. In this case as well, you can convenientlytransfer CAD models to your CAD environment by the clickof a button. You can also directly initiate a request forquotation. A template management lets you save driveconfigurations so you can use them for other order inquiries.The DriveConfigurator is also available as offline version inthe event that you do not have access to the internet.Order and procurement logisticsElectronic data interchange: SEW-Eurodrive offersvarious templates for electronic data interchange (order,order confirmation, invoice, etc.) and formats that enabledirect connection to SEW-Eurodrive. In this way, the entireorder management can be handled directly andelectronically. Doing so will increase process safety and letsyou save costs. Connection to external order platforms isalso supported.Customised procurement logistics: SEW-Eurodrive’sinnovative procurement logistics lets you combine severalcomponents to form a standardised solution. You can assignany name to this package so you can easily order it againand again. The identification is fixed so that the order canbe easily processed and automatically identified in yourcompany. This is also how the order can be easily assignedto the individual assembly stations. The result is reducedcosts, and your intralogistics becomes easier.Electronic invoicing: Electronic invoices from SEW-Eurodrive make invoice receipt processing easier andfacilitate your administrative processes. Direct connectionvia electronic data interchange (EDI) is not required. If youwant to have your invoices sent electronically, just contactSEW-Eurodrive to agree on the required modalities.Material flow and startupOrder tracking: The order tracking function in DriveGatelets you trace the status of your order. Simply log in, selectthe required order and query any available informationquickly and easily. All you need is internet access andDriveGate registration (free of charge).Order-specific documentation: DriveGate gives youaccess to a variety of product-specific documents. A newfunction lets you view a list of any documentation relevantfor your order by simply entering your order number. Youcan easily collect the required documents in the languageyou need and download them. Or you can order thedocuments on a data CD.Intelligent material flow – DriveTag: SEW-Eurodrive’sDriveBenefits module allows you to automate yourincoming goods process and optimise the flow of goods.SEW-Eurodrive equips your drives and packaging units withDriveTag on request. DriveTags are labels with data youhave defined which make it possible to identify the driveelectronically. Various standard variants with fixed optionsare available for this purpose, which can be fitted withdifferent types of barcodes depending on your scanner.SEW-Eurodrivewww.sew-eurodrive.co.uk30INDUSTRIAL TECHNOLOGY • April 2012

DRIVES, MOTORS & CONTROLSThe cost ofdowntime is asimple equationWhen a Hull port started experiencing problems with obsoletedrives, AC motors and resistors in two of its aging cranes, thesituation needed addressing immediately. Peter Scott explainshow the problem was solvedThe UK's leading ports group, AssociatedBritish Ports (ABP) owns and operates 21ports around the UK and handlesapproximately a quarter of the country'sseaborne trade. So it’s no wonder that in such abuzzing environment, downtime is never an option.With two cranes in need of urgent maintenance, theport’s management was expecting a substantial bill forresolving the issue.The equation looked like this: a new drive for thecrane, priced at over £20,000, plus a new motor, anadditional £20,000, plus installation and engineeringworth up to £60,000 and the additional cost of threeweeks downtime. Were this not enough to furrow thebrow of even the most resilient finance director, thetotal bill of £100,000 would be doubled, as therewere two cranes on site in need of maintenance.Unfortunately, as the cranes were over 20 yearsold, many of the parts needed had become obsoleteand were extremely hard to source. This is when ABPHull asked maintenance specialist CP Automation tocome up with a viable solution to their troublesomeequation, one that would not disrupt activity and keepmaintenance expenditures down.Permanent solution“We knew that the hoist drives on the two older craneswere coming to the end of their life,” explains KeithPayne, electrical supervisor at ABP Hull. “In the lastfew years we’ve tried to repair and update them to thebest of our capabilities, so that we could keep themgoing. But despite all of our predictive maintenance,there came a point when we encountered too manytechnical problems so we had to find a permanentsolution.”Having previously worked on a similarimplementation abroad, the CP Automation fieldmaintenance team took on the challenge of fixing theHull cranes. The solution to the product obsolescenceproblem came in the form of motor controllers for slipring motors from Sprint Electric. Sprint Electric’s JL/Xrange of slip ring motor controllers covers outputcurrents from 100 to 1850A in either two or fourquadrant mode.A slip ring motor is a type of induction motor witha wound rotor connected to external rotor resistors viaa slip ring. The motor’s speed/torque characteristic ismodified by resistors connected to the rotor slip ringscontrolled by JL/X relay output drivers. Out of the fourresistor control outputs provided, only one or twowould be used for applications such as slew, yaw orX/Y travel. Hoist applications however might use threeor four of these outputs. For hoist applications,lowering at speeds above synchronous speed isdetected and, as a result, rotor resistance is minimisedfor maximum regeneration into the supply. Anadditional digital output is provided for this purpose.Provision is made for selection of analogue orprogressive joystick switch speed demand, with tworaising and two lowering speeds. Analogue outputsrepresenting speed, torque and power are supplied inthe standard configuration.With the Sprint drives fitted, the cranes were givena new lease of life. CP Automation’s solutions used anew controller and retained the existing motor, whichled to a significant saving on the overall project costs.For the first crane, the total costs were significantlyless than the initial budget price of changing both driveand motor, a saving of more than 60%. The secondcrane costs were further reduced due to theprogramming and design engineering done for the firstcrane was implemented on the second crane refit. Thetotal bill for both cranes came in at a fraction of ABP’santicipated price.The crane refit in Hull is a perfect example ofmaintenance expertise combined with speedy andcommitted customer service. What’s more, the CPAutomation team simplified an otherwise financiallydaunting equation: two cranes functioning at optimumperformance, additional spares and support and only afew days of downtimewww.cpaltd.netPeter Scott is service manager at CP Automation32INDUSTRIAL TECHNOLOGY • April 2012

Motors specially developedfor lifts and elevatorsAnew gearless brushless synchronousmotor range engineered specifically forthe lift/elevator market has beenintroduced by Lafert Motors. Complete with afactory fitted brake and traction sheave themotor is a compact, fully integrated motivepower solution for this application.The motors employ the latest permanentmagnet motor technology and enable lift/elevatormanufacturers to offer customers compactenergy efficient ‘machine roomless’ designs. Themotors also permit end users to upgrade existinginstallations to achieve significant savings onboth energy and maintenance costs. Because Lafert’snew motors use permanent magnet technology theyare very efficient, experiencing zero losses in the rotor,whilst also being very quiet and compact.The energy efficiency of the permanent magnettechnology is complemented by the elimination oflosses arising from the use of gears – typically wormgears that can have efficiencies as low as 50% areemployed for this application. The exclusion of gearsalso results in reduced noise and space enveloperequirement, and cuts any maintenance requirementssignificantly by eliminating such operation as oil topups/renewals. The motors, which are Directive95/16/EC EN 81-1 compliant and TÜV verified, offertorques up to 660Nm at low speeds, and payloadcapabilities ranging from 240kg to 1275kg (from 3 to17 people). The range is available as single and threephase units, has plant speeds of 0.6, 1.0 and 1.6metres/second with motor speeds of 90 to 300rpm(roping 2:1) and 45 to 150rpm (roping 1:1). Powerranges are from 1.4kW to 17.6kW.www.lafert.comAntivibration mounts for motorsNoise or vibration generated by small motorscan be a problem in applications as varied asmedical equipment, analytical instruments,security camera control and engraving machines. Aswell as careful selection of system parameters, aneffective way to minimise vibration is to insert adamper between the motor and its mount.A range of suitable antivibration dampers for smallflange-mounted industrial motors is available fromAstrosyn International Technology. These energyabsorbingrubber mounts with a metal mounting faceare available in NEMA motor frame sizes 16, 17, 22and 23. Their low profiles of only 6mm for thesmaller sizes and 10mm for the larger ones meanthey can be retrofitted to existing motors withstandard shaft lengths.Central access holes 22mm in diameter for thesmaller sizes and 40mm for the larger models arelarge enough to accommodate a spigot and gear orpulley. Lightweight but robust, the dampers can bebolted directly onto the motor flange. Threadedmounting holes are provided on the damper'smounting face.www.astrosyn.comMaximum precision from spindle drivesFaulhaber high precision ball screws can now beintegrated directly with its range of DC-micromotors, brushless DC-motors or stepper motors.The series BS22-1.5 enables precise linearmovements with minimum travel variations of just5µm over the total travel. In combination with theirhighly efficient ironless rotor motor technology, highresolutionencoders and integrated motion controllers,maximum precision is guaranteed.Mechanical interface to the motors is achievedwith a backlash-free coupling integrated into the ballHIGHLIGHTThis month’sfeaturedproductscrew. Theall stainlesssteelconstructionof the seriesBS22-1.5offers intermittent axial forces up to 500N and speedsup to 125mm/s with a maximum efficiency of 89%.Countless modifications including screw length,modified ball nuts or special lubricants are available.www.ems-limited.co.uk33

COMPETITIVE ADVANTAGE:All change for motor controlas more engineers outsourcePrecision motor giant reports “sea change”in attitudes to building controllersThe market leader in high-precision DC drives,maxon motor, has noticed a sudden surge inthe number of design engineers specifyingmatching controllers for their DC brushed andbrushless motors. Traditionally, the world-classengineers who have relied upon maxon products downthe years – in fields as challenging as space exploration,surgical instruments, advanced robotics and Formula 1racing – would place such intense demands upon theircontrollers that it often made sense to build them inhouse.Now, however, advances in off-the-shelfcontroller technology have reversed the situation – withan increasing number of engineers viewing homemakingmotion control electronics as a waste of time,money and effort… not to mention an unnecessary risk.maxon senior sales engineer Paul Williams explains:“With the quality available in controllers now, we’resuddenly seeing a lot of engineers compare that cost tothe time and money they’d spend developingin-house… and the savings are simply huge.“These days you have immense functionality,with all kinds of hardware and connections – andenergy efficiencies ashigh as 95% –on somethingaffordablethat’s notmuch biggerthan a stamp! It’sa no-brainer, really.“It is easy to overlookthe work and investment thathas gone into their developmentnot just in engineering, componentsand technical design, but also thecertification of the unit; CE, EMC,communication standards, electrical safety andso on. When developing a controller from scratch, thecost and time involved in these things alone are oftenmuch higher than you’d think. What’s more, buying acontroller that’s completelyoptimised for your motor –with in-built protectionagainst overcurrent, excesstemperature, under andover-voltage, transients andshort-circuits – cuts out awhole lot of risk.“I used to see a lot ofexpensive motors burnedout at the prototype stagebecause of simple errorswiring the in-housecontroller. Thankfully, that’snow increasingly a thing ofthe past.”Good things, small packagesAmong the new generation of miniaturised, highperformancecontrollers that has changed the motioncontrol landscape so dramatically ismaxon’s highly popular 36/2ESCON DC servo motorcontroller. The maxonengineers’ initialclaims that thetiny 55 x 40mmcontroller representeda “breakthrough” havecertainly been supported byits performance in the market,with design engineers flockingto take advantage ofits dynamic, 4-quadrantcontrol capabilities forbrushed DC motors up to72W. A variety of operatingmodes, including open and closedloop speed control, current control andbonus functions like speed-ramping, make the ESCONa versatile performer at speeds up to 150,000 rpm.Nonetheless, Paul Williams believes it is thecontroller’s widespread compatibility and ease ofuse which – along with its tiny dimensions – havebeen the biggest difference to engineers designingnew technology. “It’s absolute child’s-play toconfigure,” he enthuses. “Just plug it into your PC’sUSB port and away you go. You don’t need anyexternal hardware, and we can even supply preassembledstartup cables if you like. The thing is,it’s such a neat little package so it’s really easy totuck it away in your device and hook it up to yourexisting design. Job done.” A sister controller,ESCON 50/5, will be launched in the coming days –extending the same level of functionality andconvenience to both brushed and now brushlessmotors up to 250 watts.Ready-made, bespoke… or both?Although off-the-shelf controllers are becoming eversmaller and more sophisticated, many applications stillrequire something unique – be it a particular shape andsize, unusual wiring, protective shielding againstextreme conditions or even bespoke software. Maxonbridges this gap by offering a full customisation servicefor all its control products – a move so successful thatmore than half its UK controller orders are now customspecified.Paul Williams continues: “Controllers like theESCON 36/2 are naturally exceptional in their ownright, but often a new application needs somethingextra special. We’re all engineers, so there’s nothing welike more than a challenge – whether it’s to fit a certainspace, survive temperature and vibration or simply tointegrate seamlessly with existing firmware. It’s not justfor big customers, either – we offer all kinds ofcustomisation to companies ordering barely a handfulof controllers each year.“It’s always great to get a call about a demandingnew application – helping design engineers achievethe impossible is what we do every day.”maxon motor ukmaxon house, Hogwood laneFinchampstead RG40 4QWTel: 0118 9733337Email: salesuk@maxonmotor.comwww.maxonmotor.co.uk34INDUSTRIAL TECHNOLOGY • April 2012

MACHINE BUILDING & AUTOMATIONPower & Data CablesA critical decision: cablesfor dynamic applicationsIn today’s sophisticated machines, the need for moving power anddata supply is increasingly common. But, if safe and reliable operationis to be achieved, choosing the correct cable for these applications isa critical decision. Justin Leonard looks at the factors that must beconsidered and explains why standard cables are unsuitableIn a dynamic application – that is, anapplication where a cable is used toconnect moving parts of a machine –cables may have to move backwardsand forwards, in a rolling loop or even witha twisting motion. In today’s highperformance machines, these movementstypically take place at high speed and it iscommon for them to be repeatedthousands or even millions of times in ashort timescale.Standard cables are totally unsuited tothis type of application. They have a verysimple construction where each of theircopper cores is made up of a small numberof relatively large conductor strands. Whencables of this type are subjected to repeatedbending at a small bend radius, the copperstrands making up each core ‘work harden’,become increasingly brittle and then break.The same process can easily bedemonstrated by bending an ordinary paperclip back and forth. Initially, it is flexible andbends easily, but after a short time it ‘workhardens’ and breaks. The breaking ofconductor cores because of work hardeningis a very common failure mode, usuallyleading to intermittent signals and data orshorting. There are other modes of failurewhen an unsuitable type of cable is used ina dynamic application.In multicore cables, the cores arealways twisted together in layers and instandard cables this twist has a long pitch.This means that when the cable bends, theinner cores are compressed while the outercores are stretched. After a time, thisprocess forces the cable to take up acorkscrew shape which, in effect, shortensit, and often pulls the cores out of theirterminations or connectors. The deformedcable may also form loops that get trappedin the carrier or in machine parts, damagingthe outer jacket and exposing the coreconductors.A third failure mode occurs when thecores untwist under the outer jacket of thecable, due to the forces described above. Ona standard cable, this outer jacket is a simpletubular extrusion. This is beneficial whenterminating the cable, because the jacketdoes not grip the cores tightly and is,therefore, easy to strip back. In dynamicapplications, however, the jacket has theimportant role of stopping the cores fromuntwisting, and even with dummy filler coresor strings (a common trick used to pack outthe inner construction on a standard cable) asimple tubular jacket is not effective in doingthis. The result is that the cores untwist withinthe jacket, and this can be seen as bulgesalong the length of the cable. Ultimately, theouter jacket will burst under the strain.With shielded cables, there’s yetanother problem. The braiding angle of theshield is usually steep, but this means thatthe braid has a tendency to open up andcreate gaps in the shielding when the cableis flexed; this leads to a worse quality ofEMC protection. Also because of the steepangle, the braid will be extended andcompressed under bending leading to workharden and fracture. This leaves sharp endsthat can pierce the insulation of the innercores leading to earth faults, or cut into theouter jacket starting a split.So much for the shortcomings ofstandard cables in dynamic applications, buthow do cables specifically designed for theapplications – ‘dynamic’ cables – overcomeThe dominant factor is theminimum bend radius thatthe cable with have toadopt, matching the bendradius of the energy chainthese problems? First of all, the copper coresare more finely stranded. However, it is acommon misconception that the finer thestrand the better; the strand size mustactually be optimised for maximum flexibilityThis type of construction reduces the risk ofwork hardening and core fractures, and canbe used to give even large core high-currentmotor cables the flexibility needed forreliable operation in dynamic applications.Next, in a dynamic cable, the cores aretwisted with a much shorter pitch and, inmulticore cables, the cores are braided andbundled wherever possible. This means thatthe path of the core takes it from the outsideof the cable to the inside and back again overa very short distance. Because this distance(Below) Standard cables are totally unsuited to dynamic applications(Left) Jacket ruptured due to broken shielding element(Above) General dynamic cable layup view (Top) Standard nondynamiccable layup (Above right) General machine with e-chainand Igus Chainflex cables installedis so short, the compression and tensionstresses experienced by the core, when thecable is flexed, cancel each other out to alarge extent, which means that the overalllevel of stress on the cores is greatly reduced.Dynamic cables still rely on the outerjacket to prevent the cores from untwisting,but instead of a plain extruded jacket, a gooddynamic cable will have a pressure-filledjacket. This fills all of the space around thecores (meaning dummy cores or strings arenot needed) and ensures that they cannotuntwist.In good quality dynamic cables whereEMC shielding is required, this will be of thebraided type rather than wound foil, and itwill have a shallow braid angle to preventgaps opening up as the cable flexes, whichwould reduce the effectiveness of theshielding. The shallow angle reduces stresson the strands, whose sizes will also havebeen chosen to maximise flexibility, whileminimising the risk of work hardening.Because of their special construction,dynamic cables often feel stiffer than theirstandard counterparts. This shows that themyth suggesting that the cables mostsuitable for dynamic applications are themost flexible is not only wrong but alsomisleading. A rough and ready test todetermine whether or not a cable is properlyconstructed for dynamic applications is tobend it tightly. A good dynamic cable willreturn immediately to its original shapewhen released, but other cables will tend toretain a kink.We have already seen why it is essentialto use dynamic cables in dynamicapplications if safety and reliability are to beassured, but it is also necessary to choose36INDUSTRIAL TECHNOLOGY • April 2012

ESX ® -3XLESX ® -RangeMobile Control SolutionsESX ® -TC3ESX ® -IOXESX ®the right dynamic cable for the task inhand. The information needed to makethis choice falls into three areas –electrical, mechanical and environmental.The electrical information needed isprincipally the number of cores requiredand their cross section, and whether or notshielding is needed. The cross section willdepend on the current the cable isrequired to carry and, particularly forlonger cables, the maximum permissiblevoltage drop. If the cables are being usedfor data rather than power, it will also benecessary to take into account the type ofcommunications protocol being used.The dominant factor is the minimumbend radius that the cable will have toadopt, which will typically match the bendradius of the energy chain or otherarticulated cable support.The minimum bend radius for aspecific cable is usually expressed as factorthat is a multiple of the cable diameter. Forexample, a 25mm diameter cable with adynamic radius factor of 10 can withstandbending at a minimum radius of 250mm.It is very important when working withthese figures to be absolutely certain thatthe factor used is applicable for repeateddynamic use – the factor for static bendingis likely to be much lower and, if it used indynamic applications, early cable failure islikely to occur.The dynamic bend radius factor for agood dynamic cable should always beaccompanied by the guaranteed minimumlife of the cable, expressed in millions ofcycles, when that factor is used. IgusChainflex cables are, for example, designedfor 10 million cycles at the factors quotedby the company. For most types ofdynamic cable, the dynamic bend factor istypically around 10, but it is worth notingthat newer cables with dynamic bendfactors as low as 4 are now beingintroduced for some applications. Amongthe other mechanical considerations arethe travel length, speed and acceleration.The higher these are, the more strain willbe placed on the cable.Environmental questions that need tobe answered include, for example, is thecable exposed to direct sunlight or other UVsources? Is it subject to caustic washdownor exposure to oils, solvents and dirt? Whatis the required operating temperaturerange? The answers to these questions willprincipally determine the type of materialused for the cable outer jacket.The last step in getting the best fromdynamic cables is ensuring that they areinstalled correctly. Almost always, theywill require some form of support andarticulated carriers, for example those inthe igus energy chain range provide aversatile and convenient option. Thecables must, of course, be fitted properlywithin the chain with particular attentiongiven to the provision of strain relief. Thisis usually achieved by the use of saddleclamps, but the clamps chosen must,once again, be suitable for dynamicapplications where the forces they have towithstand are many times higher thanthose experienced in static cable systems.Copper cables provide a versatile andconvenient solution for providing powerand data connections to moving parts ofmachines. Provided that genuine dynamiccables are used and that they are selectedand installed correctly, solutions of thistype are safe, reliable and cost effective.However, as this article has made clear,any attempt to cut corners or trim budgetsby using standard cables is doomed tofailure, and will without doubt lead toinconvenience and ultimately higher costs.The conclusion is, therefore, simple.For dynamic applications, use goodquality dynamic cables from a reputablesupplier that can provide dependableadvice and guidance on getting thebest from them.www.igus.co.ukJustin Leonard is with Igus UK• Freely Programmable (C/ / IEC61131-3)• Wide range of digital and analogue I/O• Designed to operate in the toughest environments• CAN, RS232 & Ethernet communicationsSensor-Technik UK Ltd.Unit 21M, Bedford Heights Business CentreManton Lane, Bedford, MK41 7PH, UKTel. +44 (0) 1234-270770sensor-technikApril 2012 • INDUSTRIAL TECHNOLOGY37

MACHINE BUILDING & AUTOMATIONMachine Control PLCsMaking the most ofmachine control PLCsToday’s PLCs can bring a raft of benefits to boththe machine designer and end user. We spoke tothe leading vendors, and asked their opinions onwhat can be achieved today, and what we canexpect from machine control in the futureBack in the early 1970s whenPLCs first became accepted asthe way to automate a machineor process, very few users wouldhave considered the cost of developingthe ‘logic control’ software as part of theoverall machine cost. In fact, it isestimated that in 1970, the cost of theman hours to write the machine controlcode accounted for just 1-2% of theoverall cost.As the capabilities of traditional PLCshave expanded to meet the demands ofthe OEM machine builders and their endusercustomers, such as the inclusion ofcomplex motion control, integrated safetyand vision inspection, and data storageand manipulation, so the cost of softwaredeveloped has also increasedproportionally. Even just a decade ago, upto 40% of the cost of any machine wasattributable to the cost of its controlsoftware development. Today, that figure islikely to be even higher.Of course, it is not just the complexityof machines that has changed over theyears, as Omron’s Karl Walker explains:“Flexibility and re-configurability havebecome top priorities for OEMs. Theevidence of this is the ever-increasingnumber of servo axes per machine,automating traditional, manual ‘changeparts’ processes, reducing productchangeover times and increasingthroughput speeds.”PLC evolutionSo how have machine control PLCs haveevolved over the last ten years or so tomeet these needs? Idec’s Sean Knellercomments: “With the increasing need forrobust but compact systems in machinecontrol applications, PLCs have had toreduce in size but increase in intelligenceand control. The processing power interms of speed and memory of the modernday PLC has increased dramatically, withPLCs processing logic in nanoseconds. Theease with which you can upgrade thesystem, by adding I/O cards andcommunication cards has become easier,with literally only a few minutes ofdowntime to expand or adapt your systemto your needs.“In addition, the need formultiple communications platformshas developed over theyears,” he continues, “with mostPLCs being able to interface notonly with competitor hard ware,but also with machine controllers,robots and drives via a directconnection.”Rockwell Automation’s Steve Pethickadds: “PLCs have become ProgrammableAutomation Controllers (PAC) – with keyattributes such as Motion Control beingtightly integrated into the controller,expanding the control potential.Specialised networking has been overtakenby the use of standard EtherNet for the keyFlexible machines arethose that can beconfigured easily to handledifferent products withlittle or no manualinterventionfunctions of machine control, safety andmotion control. Solutions have alsobecome more scalable, with two-axiscontrol now available in a ‘low end’,inexpensive controller. We have also seen atrend towards safety integration withincontrollers to assist with safetylegislation.”Rockwell Automation offers a widerange of PLCs for machine builders, withthe larger products in the Logix platformproviding solutions that fit the mostdemanding application needs. They offermodular architectures and a range of I/Oand network options. Thesepowerful control solutions deliver worldclasscapabilities for all disciplines, fromprocess to safety to motion. Designed fordistributed or supervisory controlapplications, the large programmableautomation controllers (PACs) andprogrammable logic controllers (PLC)provide exceptional reliability andperformance.Further down the range and ideallysuited to complex machine designs, theCompactLogix control systems provide theperfect solution for mid-rangeapplications, offering the features andflexibility you need without the overheadof larger systems. Users can choose fromstandard and safety-certified controllers inchassis-based, packaged and modulardesigns.For simpler machine designs, theMicroLogix PLCs provide economicalsolutions that meet the needs ofapplications such as conveyorautomation.For machine builders, key featureswithin the Logix range include integratedmotion that is simple to configure andwhich reduces engineering effort. Inaddition, information-enabled controllersshare useful information with the rightpeople in a timely fashion, allowing betterreal-time decision making in theproduction environment. Integrating safety(Above) Idec’s configuration softwaremakes it easy to create projects whichcan easily be adapted for each machinebuild, keeping the PLC, HMI andconfiguration software all in one filein standard controllers eliminates the needfor an additional safety PLC or safetycontroller.Increased flexibilityGiven this ongoing evolution of the PLCinto today’s powerful platforms, how dothe latest generations of products helpmachine builders to design machines thatare more flexible and offer reduceddowntime and increased productivity?Pethick says: “Flexible machines arethose that can be configured easily tohandle different products with little or nomanual intervention. The use of linearmotors and actuators coupled with theability to reconfigure motion profiles ‘onthe fly’ contributes to making this possible.Integrating“Overall Equipment Effectiveness(OEE) into your machine helps reducedowntime, while integrating OEE softwarewith your controller provides a simple viewinto the cause of machine downtime andtherefore faster resolution. Using smartsensors and instrumentation connectedover Ethernet can provide predictivediagnostic information so that machine38INDUSTRIAL TECHNOLOGY • April 2012

Perfect machine DNAThe evolution of machine control(Above) The latest release of RockwellSoftware RSLogix 5000 software fromRockwell Automation delivers the highperformance of an integrated controlsystem for machine builders requiringa smaller control systemdowntime can be prevented by takingearly remedial action.”The modularity of the modernPLC also helps, as Idec’sKneller explains: “Thisallows the machinebuilder to design a systemwhich is easily maintainedand can be upgraded withlittle or no downtime. ThePLCs are also being usedto monitor the systemsand generate emails or textmessages to maintenancestaff if the machine requiresattention, again increasing the responsetime for failures which in turn reducesdowntime.Integration with other products isalso key. Festo’s Hanbury comments:“Traditional binary or analogueinterfaces between intelligent terminalsand complex sensors and actuators arebeing replaced to enable robust and fastdata transfer. Intelligent point to pointconnection systems such as IO-Link arestarting to impact upon the field level.IO-link promises a big reduction ofinstallation and maintenance time andcosts as far less on-site interaction isrequired. Festo is about to release anew compact PLC (CECC) for machinecontrol offering direct integration withthis type of interface.”Reduced development timeAs well as boosting the functionality,performance and flexibility of machines,modern PLCs also help machinebuilders to develop new designs morequickly, and here software is key.Hitachi’s Arnold Rupperath, whose PLCproducts are distributed by SoftstartUK, comments: “Modern andstandardised programming softwarewith advanced features drives increasedefficiency, while library functions makeit possible to re-use existing engineeringknowhow.”Rockwell Automation’s Pethickadds: “The increasing trend towardsmodular code generation, standardcontrol blocks (add-on instructions) andtechniques such as power programming(based on the S88 state model) can allhelp machine builders developapplications more quickly. In addition,the tight integration between the logiccontrol and motion functions can alsodrastically reduce development time.”To minimise the cost of softwaredevelopment and, indeed, the timetaken to create the working solution,reusability of existing code is key, alongwith the ability for several engineers towork on the same piece of code withoutthe risk of conflict. Omron’s Walkercomments: “It must also be structuredThe trend towardsmodular code andstandard control blockshelp machine buildersdevelop applicationsmore quicklyin such a way that it is understandablefor everyone, including those who willhave to maintain the system in thefuture.“Traditional programming methodsof one continuous, often uncommented,ladder logic program using meaninglessphysical I/O addresses are now givingway to symbol-based programming,often using Sequential Flow Chart (SFC)structures to provide a clear picture ofhow the machine or process operates(understandable by everyone, even nonprogrammers)and helping to breakdownthe code into individual tasks andrequisite disciplines (mechanicalhandling, process control, etc). Thisfacilitates the ideal of severaldevelopers working on the controlsoftware at the same time.”IEC standards (IEC61131-3) havehelped to provide some commonality inSysmac Automation PlatformNJ-Series Machine ControllerVision,Logic,Motion,I/O....IntegratedTel: +44 (0)1908 258258Email: uk@eu.omron.comWeb: www.industrial.omron.co.ukApril 2012 • INDUSTRIAL TECHNOLOGY39

Machine Control PLCs MACHINE BUILDING & AUTOMATIONNew breed of PLC is small on size,large on performanceMeeting the needs of OEMs, the new Lseries PLC from Mitsubishi Electric hasbeen designed to provide all theperformance, functions and capabilitiesnecessary for today’s demanding machine automationrequirements in a compact, modular, rack-freepackage. Bridging the gap between the FX compactPLC and the iQ platform high performance PAC, thenew modular controller combines much of the powerof a Q series CPU, with the ease of expansion anduser-centric design inspired by the FX. This greatlyincreases the range of functionality traditionallyassociated with mid-range PLCs.All the features and functions needed for the mostsophisticated of automated machines are built into theCPU as standard, minimising hardware, saving panelspace and engineering costs and ensuring the highestlevels of flexibility. Every L series CPU provides asstandard; 24 points of on board I/O, a 2-channel highspeed counter, 2-axes of positioning, pulse catch andinterrupt functions, Ethernet connectivity and built-indata logging. The built-in positioning function has astart time of just 30µs, with a maximum high-speedoutput of 200k pulses per second, and features such asS-curve acceleration and deceleration, meeting theneeds of complex machine positioning applications.The unique built-in data logging function provides asimple means of collating OEE (overall equipmentefficiency) data, energy monitoring, sequencing andproduction traceability, with the facility to store this datato SD memory card using the integral memory card slot.The same memory card slot also makes it easy to backup or load the CPU programs and parameters. The builtinEthernet communications port provides a simpleinterface to the enterprise level, seamless peer to peercommunications and direct connectivity to other devicessuch as HMIs. Logged data can also be retrievedvia this port using FTP commands. All of theseinnovative and sophisticated features are includedat no extra cost and offer many benefits to themachine builder.The CPU has a basic operation processingspeed of better than 9.5ns per instruction and thismakes it ideally suited to high speed machineapplications. This high level of performance comeshand in hand with ease of use. The base CPU forexample, can incorporate a 16-character by 4-linedisplay, providing convenient monitoring and easyaccess to diagnostic information both for the CPU andany connected I/O modules, without the need toconnect a PC or software.Reducing machine downtimeUsers can check the system status and make settingchanges directly from the display. Error status is clearlyidentified and error investigation can be readilyperformed from the detailed historic information,reducing downtime and speeding up diagnosis ofmachine problems.A key feature of the L series is its easyexpandability. The integrated backplane means thatexpansion modules can simply snap-on to the CPUwithout the need for a base unit, with the assemblymounting on a standard DIN rail. The system can beexpanded up to a total of 40 expansion modules. Theexpansion options include motion control modules,analogue I/O modules and temperature control modules.To meet the needs of advanced motion controlapplications, Mitsubishi Electric has developed a newmotion module for the L Series that provides highspeed,high precision control of up to sixteen axes permodule over Mitsubishi’s SSCNET III servo controllernetwork. The CPU can accommodate multiple motionmodules and can consequently provide many axes ofcontrol, with capabilities including a cam function,phase compensation, mark detection and 600 points ofuser-defined positioning data.The high-speed analogue modules have beendesigned to provide a conversion speed of just 20µs perchannel, with a precision of ±0.1%. Temperaturecontrol modules provide highly stable regulationperformance, with functions including heating/coolingcontrol, peak current suppression, self-tuning,simultaneous temperature rise, selectable samplingcycle and a temperature input mode.Providing seamless communication through alllevels of a network hierarchy, the L series combinesenterprise, control and sensor level networks asstandard through on-board Ethernet and interfaces toCC-Link IE Field, CC-Link and Modbus, allowing easyaccess to information no matter where it resides on thenetwork. CC-Link IE Field is an Ethernet-based gigabitnetwork designed to provide cost-effective, reliableconnectivity to field devices.Combining the L Series with other Mitsubishiproducts such as the GOT HMIs and Inverter Drives,offers the machine builder a sophisticated, costeffective, integrated control platform.www.mitsubishi-automation.comreliability and stability, being the OS ofchoice in many aerospace, industrial anddefence system applications. Such anopen control platform demands opennetworks to ensure the trouble-freeconnection of hardware such as servosystems, inverters and I/O, and robustdata communication between devices (forexample PLC-to-PLC or PLC-to-PC/HMI).Omron’s Sysmac platform stands forone machine control through oneconnection and one software. Omron saysit represents a milestone in its ten yearplan, aiming at strengthening andglobalising its dominant position in themachine automation. The powerful androbust automation platform includes thenew NJ series machine automationcontroller that integrates motion,sequencing, networking and visioninspection, a new software program(Sysmac Studio), that includesconfiguration, programming, simulationand monitoring, and a fast machinenetwork (EtherCAT) to control motion,vision, sensors and actuators.An immediate benefit of the newarchitecture is the seamless integration ofOmron’s core competences within onecontrol platform. Machine control andmotion control are now one; field devicesare controlled across one machine networkand programmed by single software.Customers can design their machines withone control platform and then easily scaleup their machines according to theapplication without affecting machinespeed and performance.What else might become morecommonplace in the machine controlPLCs of the future? Hitachi’s Rupperathpoints to the ongoing integration ofrelated components such as drives andsafety, as well as enhanced integrationwith IT environments and higher levelbusiness systems. Rockwell Automation’sPethick adds that we will begin to seeincreased integration of securitycapability into controllers, reducing therisk of cyber attack in the industrialenvironment.In addition he points to the scaling ofthe highly integrated solutions associatedwith large automation investments tolower cost machines, with a primeexample being servo controls. Finally, hesees migration towards the vast majorityof controllers offering a level of safetycontrol built in. Typically this would bePLd as a minimum. And perhapsinevitably, as Festo’s Hanbury points out,the trend for tablet PCs and smart phoneswill lead into the industrial market makinguser interfaces the key in the future. Wecan already see this with the plethora ofapps available to order and monitorproduct. “As this functionality becomesproperly embedded we will see intuitiveprogramming and parameterisation formachine control PLCs,” she says. “Thiswill lead to a reduction in the time andcost required to solve more and morecomplicated control, communicationand data handling applications.”www.industrial.omron.co.ukwww.idec.com.ukwww.rockwellautomation.co.ukwww.mitsubishi-automation.comwww.festo.co.ukwww.softstartuk.comApril 2012 • INDUSTRIAL TECHNOLOGY41

COMPETITIVE ADVANTAGE:Smart engineeringWith Automation Studio 4, B&R has set a new standard in‘smart engineering’, combining useful automated functions,functionally equivalent architecture models and collaborationtools with the convenience of object-oriented programmingWhen it comes to automation systemdevelopment, software engineers arelooking for tools that provide optimumutilisation of all the resources involved inthe software development process. This focus onefficiency should cover not only the hardware aspect ofthe system design, but also the IT infrastructure andultimately the most efficient deployment of thedevelopment team's resources.Alongside efficiency, software engineers are alsolooking for tools that provide a high level of sustainability –taking efficiency beyond the project currently beingdeveloped to focus both on the whole product lifecycle andon subsequent projects. So how does Automation Studio 4address all of these requirements?Automation Studio 4 introduces the concept of projectmodularisation, an approach that not only allows thevarious development tasks to be assigned to differentmembers of the development team, but also allows eachindividual project to be divided into modules. Thesemodules increase efficiency by allowing multiple developersto work simultaneously in a single parallel step to shortenthe development time for the current project. The modulesalso ensure sustainability since they can be reused in othersimilar projects to accelerate new developments and reduceoverall testing and development costs.This latest version of Automation Studio makes it simpleto manage today's increasingly complex programs. Thisbegins with the hardware configuration, which is frequentlythe first step in developing a new system. The majority ofthis work is performed in the new System Designer. Thesystem's topology view is created by arranging photorealisticimages of the hardware components – a graphicrepresentation of how the components would be arrangedin a control cabinet – and then connecting them. In thebackground Automation Studio uses the device propertieslisted in the hardware catalogue to carry outconfiguration checks and set the firstparameters.Additional parameters canbe set simultaneouslyfor any number of components selected in the tree view,and the configuration can be edited by copying/pasting,dragging/dropping or inserting either individual hardwareicons or entire branches. The system automatically fills inthe required configuration parameters in the background,which shaves off a considerable amount of time typicallyspent in this phase, while also eliminating the possibleerrors that can creep into the design with a conventionalsystem. All this establishes Automation Studio as anelegant top-down conceptual design tool that makes itquick and easy to evaluate design variations and verifythem. The details can be worked out successively once thefundamental decision has been made.Mechatronic system developmentMechatronic-oriented developers are supported by theconsistent integration of mechanical, electronics andautomation software. Automation Studio 4 provides abidirectional interface to the database system of theleading electronic CAD system on the market, EPLANElectric P8. This not only preserves the freedom to choosea planning system, it also enables the integration of fluidplanning systems for hydraulic and pneumatic elements aswell as CAD engineering systems for mechanicalintegration of the automation hardware.Similar interfaces between Automation Studio 4 andvarious simulation programs offer a multitude ofpossibilities for intermediate testing independently of thehardware, which is often not yet ready in this phase of thedesign. The results of these simulations can then beimported into Automation Studio 4 to serve as a startingpoint for concrete development. In this way, the softwaredevelopment process is based on tested processes rightfrom the start.When it comes to communications, with AutomationStudio 4 B&R has seamlessly integrated the OPC UnifiedArchitecture communication protocol. This provides itsown convenient and easy-to-use functions to aidsoftware developers. Moreover,its open architecture is establishing it as a marketstandard, which ensures compatible communication withnumerous third-party systems.In addition, widely-used Web technologies are directlysupported in Automation Studio 4 with its own dedicatedlibraries. This makes it easier to create applications forvisualisation, process monitoring and remote maintenance,and to implement location-independent operating andproduction concepts.By making software projects easy to expand or modify,Automation Studio 4 helps system developers to buildsustainability into their designs. Individual systemelements are clearly distinguished and managed under theintegrated source control system to ensure the best resultsduring every phase of development. These do not endangerto the rest of the system and provide a valid basis fordecisions on how to proceed, which helps keep projects ontrack from start to finish. At the same time, thedevelopment environment covers control, visualisation andmotion control to prevent inconsistencies between thevarious elements of a system.Further, Automation Studio 4 includes all the necessaryinterfaces and transfer mechanisms needed to ensure thatthe finished product can be managed in this developmenttool throughout the entire product life cycle. This ensuresthat valuable input can be found when and where it isneeded, contributing to the sustainable development offuture product generations.Taking advantage of object-oriented C++programming, the smart editor supports programmers withcontext-based suggestions drawn from both the includedfunction libraries and sections of code that have alreadybeen programmed. This significantly accelerates thesystem development while at the same time ensuring thecode is easily reusable, which ultimately reduces the effortrequired for subsequent modifications.Visualisation templates for designing user interfacesin Visual Studio are also reusable and easy to modify,shortening the time required to complete thisdevelopment task. Features such as standardisedscreen dimensions in particular help to acceleratedevelopment.It can be seen, then, that Automation Studio4.0 enables users to create a clearly structuredsoftware architecture not only during initialdevelopment but throughout all other phases ofdevelopment, such as creating variants and optionsor performing program maintenance. Its smartfeatures aid developers in creating elegantsolutions that are a easy to work with.B&R AutomationTel: 01733 371320 • www.br-automation.com42INDUSTRIAL TECHNOLOGY • April 2012

World-Class Measurement: Kistler – the Leading BrandPressure0,1 mbar ... 10 000 barForceTorque1 mN ... 20 MN 0,01 N·m ... 20 000 N·mAcceleration3 μg ... 100 000 g901-019e-01.08Kistler sensors measure pressure, force, torque andacceleration. Around the world, Kistler works closelywith research institutes and leading companies. Thiscooperation, together with continuous investment inR&D, is the foundation of Kistler's innovation. Sensorsand systems by Kistler stand for competenceand quality, for knowledge and advisory services, forworldwide sales presence and range of services – inengine and vehicle development, assembly and testing,plastics processing and biomechanics. Perfectmeasuring technology. Efficient systems. Convincingsolutions.www.kistler.comKistler Instruments Ltd., 13 Murrell Green Business Park, London Road, Hook, Hampshire RG27 9GR, United Kingdom,Tel. +44 1256 741 550, Fax +44 1256 741 551, sales.uk@kistler.comRegister to receive your regular copy of Industrial TechnologyWritten by engineers for engineers, Industrial Technology provides a mixture of lively comment,informed debate, educational articles and technology updates. Industrial Technology is theessential magazine for:●●●Engineering designersMachine buildersSystems integratorsRegister today at www.industrialtechnology.co.uk to receive your free copy, and keep up to datewith the latest design thinking and engineering news.www.industrialtechnology.co.uk43

MACHINE BUILDING & AUTOMATIONMachinery SafetyGuidelines to improvemachinery safetyFesto is launching a new safety guideline to assist designers to improvethe safety of their machines and aid them in meeting the requirementsof the latest Machinery Directive. The guidelines group commonlyrequired safety functions and provide off the page ‘black box’ solutions.These include individual safety products and sub-systems along withthe required information and data for popular software documentationpackages for both pneumatic and electric drives. Steve Sands explainsSafety management of a machine design startswith the risk analysis and assessment; once therisks have been identified various measures canbe taken to reduce these include designmeasures aimed at reducing the hazards, technicalmeasures (which the Festosafety guidelines address)and thenthe morepeople oriented, softer elements of training, signage,warnings etc.In technical wording terms, to comply with theMachinery Directive, designers incorporating safetyrelatedcontrol systems are seeking a presumption ofconformity. More commonly, they can demonstrate theyhave met their obligations and protect themselves andtheir company through the use of the relevant standardssuch as EN ISO 13849, ISO 14121, IEC 62061 or IEC61508. A commonly asked question of our technicalspecialists is “when to use which standard...”, and whilstthere are more complex reasons for electing to use onerather than another, there is a clear distinction formechanical systems. ISO 13849 specifically refers tosystems where wear needs to be considered, such asusage rates have an effect upon the safety of componentswithin the system.For example a pneumatic valve which is operated300 times an hour will have a different life and reliabilitycompared to one operated once a day. High frequencyusage or infrequent use both have a potential impactupon apneumatic valveused in a safety circuit.Diagnostics, monitoring andultimately built in redundancy willall play a part in increasing the reliability of the system.When a safety component is a complex part in its ownright, designers require a lot more data to enable them todetermine the reliability of their solution. This data has tobe derived by the manufacturer by thorough tests,calculations and analysis. Testing a statistically soundbatch of components enables Festo to determine theprobability of a part failing within that life time andanalysing whether the mode of failure is critical to thesafety function. This is expressed as a life time that 90%of components are predicted to reach without failure.Combining this figure with the expected duty cycle(number of actuations per year) derives a Mean Time ToFailure, another part of the safety jigsaw.Festo’s approach is to offer standard solutions basedon the most commonly required functions. Reducingtechnical measures to just seven pneumatic and sevenelectrical drive functions makes it considerably easier fordesigners to select the components and systems theyneed in the form of components, circuits andengineering.www.festo.co.ukSteve Sands is product manager at Festo44INDUSTRIAL TECHNOLOGY • April 2012

Make more of Industrial Technologywith our Quick Links enquiry serviceRemember the enquiry numbers that weused to run at the end of each story andeach advertisement? These have nowbeen replaced by a web address for thecompany where you can find further details.But that doesn’t mean that we’ve scrapped our‘more information’ service.Not a bit of it. Instead, what we can nowoffer you is a vastly improved service – a‘more information’ system for the 21st Century,that better reflects the way you tell us you liketo work. We’ve moved to a vastly improvedonline enquiry service.Visit www.industrialtechnology.co.uk andclick on ‘advertisers’, and you’ll find everyadvertisment in this issue of the magazine,with the option to view a PDF of each ad. Andwith one is an array of further informationoptions, allowing you to go straight to thesupplier’s website, request a phone call fromthe supplier, request for information to beemailed to you, or ask for information to beposted to you.You can also forward the information to acolleague. The same is true of the stories inthe issue: click on ‘new products’ and you’llfind a list of all the stories in the current issue,with the same options to request moreinformation.Those of you who’ve registered emailaddresses with us will also receive a ‘QuickLinks’ email, listing all the advertisers in thisissue, and giving you all the same ‘moreinformation’ options, plus the ability to quicklyview a PDF of the relevant advert. What weAdvertisers in the April 2012 issueof Industrial Technologycan offer, then, is a complete one-clickenquiry service. We hope that this is a serviceyou will find useful, and which will provide agreat help as you look to source theinformation that will give your designs andsystems a competitive edge.www.industrialtechnology.co.uk45

FLUID POWERNew electro hydrostaticdesign concept unveiledReliable hybrid technology used ina new energy-saving solution for avariety of industrial applicationsCombining hydraulic and electric technology in aself-contained system, Moog’s innovative ElectroHydrostatic Actuator (EHA) concept integrateshigh performance Moog products including aServo Motor, Hydraulic Pump, Hydraulic Valves,Manifold, Accumulator, Controller and Software.Moog’s engineers leveraged the company’s expertisein both electric and hydraulic technologies to develop thisoptimised energy-efficient and reliable system. “At Moog,we refer to ourselves as ‘technology-neutral’ because wedesign both hydraulic and electric solutions,” says Dr.Sherif El Henaoui of Moog Industrial. “Therefore we havedeveloped a deep understanding of the advantages anddisadvantages of each technology for particularapplications. This solution leverages this know-how tocreate innovative hybrid designs that combine bothtechnologies, in compact, reliable and highly efficientsystems.”Unlike an electric actuator, Electro Hydrostatictechnology requires no screws or gearing. It differs fromhydraulic actuators in that it requires no hydraulic piping,thereby reducing cost and improving reliability. Thesystem is fully self-contained as all hydraulic and electriccomponents are highly integrated in the actuatorassembly.Electro Hydrostatic Actuators receive power from anelectric source by wire and transform a typically electronicinput command signal into motion. EHA uses fluidictransmission between the electric motor and actuator.Motors rotate only when movement is demanded, savingenergy and wear. Low duty cycle or actuation on demandapplications, that require the high force density of ahydraulic system, can benefit greatly from the energysavings of an EHA system. EHA includes hydrauliccomponents and fluid, both are self-contained within theactuator assembly, eliminating the potential of leaks andenvironmental contamination.This hybrid solution of hydraulic and electric drivetechnology allows the selection of the benefits of bothtechnologies: the low energy consumption of the electricsystem by power only on demand, the easy energy storagefor the fail safe movement and the high reliability of thehydraulic system. EHAs also offer a number of overallsystem benefits and cost savings. Moog’s EHA designoffers machine builders high energy efficiency andreliability, reduced envelope size, less wear onEHA uses fluidic transmissionbetween the electric motor and theactuator. Motors only rotate whenmovement is demanded, savingenergy and wearcomponents and up to 40% less weight. The selfcontainedEHA package removes the need for longhydraulic line lengths and rotary couplings, offeringsignificant cost savings in applications such as oil and gasand power generation equipment. The integrated systemsapproach means greater reliability for the customer asless individual components are required, lowering costsand downtime. Redundancy and fail-safe features are alsofully integrated offering minimal impact on cost, weight,envelope and reliability.EHA is an ideal option for applications that have highforce requirements and require redundant or advancedfail-safe systems, while also delivering energy, cost andenvironmental benefits. “The motion control industry isseeking new technologies that address the need for betterenergy efficiency and reliability at lower weight and size,”concludes Dr. El Henaoui. “Smart systems like EHAhybrid technology offer a new and innovative solutionsuited to a range of industrial applications.”.Moog has been providing industry-leading EHAsystems for flight controls for over 18 years and now hasbegun working with machine builders to apply thisexpertise to industrial applications that require high force,energy savings, environmental cleanliness andelimination of hydraulic piping.www.moog.co.ukBig output, small footprint with quad headsBuilding on its success with the VToil free range of low noise aircompressors, Bambi hasdeveloped a new 1.8kW versioncombining ultra compact dimensions with aclass leading air output. With noise levelsstarting as low as 74 dB(A), thesecompressors can be sited near the workingarea without causing noise nuisance. Thesilent VTS version has just 55dB(A), soperfect for location at point of use or even ina quiet office.The heart of the new VT250 range is ahighly compact, four-cylinder veearrangement pump unit, which is 100% oilfree in design, smooth running, vibrationfree and has a high delivery for its physicalsize. This format means the compressor’ssize is small enough to allow integrallocation for OEM applications.The internally coated air receiverprotects against corrosion and each model isavailable with an optional twin tower airdryer ensuring hygienic quality air.Bambi reports that sales have alreadybeen established in applications as diverseas large format printing, autoclaves,packaging, pharmaceutical andlaboratory, industries.www.bambi-air.co.uk46INDUSTRIAL TECHNOLOGY • April 2012

FLUID POWERValve innovation optimisespharmaceutical processesBurkert has developed a new valve design that removes dead legs,minimises hold-up volumes and reduces process timesValve selection is usually a crucial discussionpoint amongst design engineers, withtraditional solutions generally based arounddiaphragm valve technologies. These solutionsmake use of very closely welded cluster arrangements,with the shortest possible tangents and optimisedpositioning according to draining/cleaning requirements.However, even with optimised design, the requirementfor minimised hold-up volumes can often becompromised by complex valve clusters. This isbecause the more valves that are needed, the morewelds, pipe lengths and T-pieces that are required,and, ultimately, the more hold-up volume generated.In addition, valve clusters can also militate againstfast and accurate flow shift, which is essential forprocess efficiency, producing higher product yield andmore efficient batch control. If the accuracy of the flowshift is higher and more reliable, then the relationshipbetween concentrated product and the separation stepcan be controlled more closely. This will subsequentlyreduce product loss and have a positive impact on thereturn on investment of the installation.A further major challenge with the clusteringapproach is that, in larger systems the complexarrangement of valves, as well as their physicalindividual size, can result in large and heavy clustersthat have to be supported, and be easily accessible formaintenance. In addition, the larger the valvesrequired, the more overall space is required, and whenconsidering the need for fully drainable and cleanablesystems, this is not ideal.Such challenges have led to technology andmanufacturing advances, which have resulted in a newdesign based upon unique Robolux valves and custommanufactured stainless steel valve blocks. With thisdesign, hold-up volume is eliminated by reducing – byhalf, or more – the number of valves, diaphragms, pipefittings and welds required in a system.Based on diaphragm valve technology, the newgeneration of patented valves combines independentdual process switching functions or ‘2 seats’ in a singlebody with a single diaphragm and single actuator. Theactuator has independent pistons, one for each seat,offering a compactly-designed multi-port valve requiringabout 40 percent less space than traditional valvemanifolds using conventional diaphragm valves. Sinceless material is used in the valve bodies, they can beheated more quickly to the sterilisation temperaturerequired to destroy micro-organisms. A low internalvolume, and elimination of dead space, also supportsfaster cleaning and, of course, means better processefficiency and higher product yield from the process.Robolux valves are supplied with either manual orpneumatic actuators in sizes from ¼in to 2in. They aremanufactured with a choice of body types: 316-Lstainless steel, ultra-pure polypropylene, polypropyleneUSP V1 and PVDF (polyvinyl-difluoride).www.burkert.co.ukNew grippersboost reliabilityand qualityCamozzi Pneumatics has added a new rangeof pneumatic grippers to its portfolio ofautomation and motion control solutions.Series CGSN 180° angular grippers have beenlaunched as part of a wider initiative which willlead to the redevelopment of the entire gripperrange. Series CGSN is a high performancereplacement for Camozzi’s current CGS Series andis available in four bore sizes(16, 20, 25 and 32mm).These new grippers arecompletely interchangeable withSeries CGS and benefit from manynew features which have beenintroduced to maximise reliabilityand quality.The entire gripperredevelopment programme wasinitiated following the acquisition ofa specialist manufacturer of highprecision machined parts by the Camozzi Group.Each new gripper will therefore now incorporateinternal parts manufactured from within the groupso that high quality is guaranteed.www.camozzi.co.ukSafe fluid powerIMM Hydraulics will be exhibiting andpromoting the full IMM fluid conveying productrange at IFPEX, including its commercialbranded Hypress wire-braid, wire-spiral, and textilehydraulic hose, together with a range of hydraulicfittings and ferrules that have been designed,manufactured and exhaustively tested, ensuringguaranteed compatible products for a safe workingenvironment. The stand will also highlight the newHipac, Kaizen, Marathon, Pilot, 3SK and Longlifewire braid products, and the new Waterblast spiralhose and fittings.www.immhydraulics.co.uk48INDUSTRIAL TECHNOLOGY • April 2012

ROTAFLOW 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.www.rotaflow.comWANT TO BE INCLUDED IN INDUSTRIALTECHNOLOGY’S QR DIRECTORY ?Over the coming months, the Industrial Technology QRDirectory will build into a comprehensive engineeringresource, giving readers quick and easy access tospecific supplier web site pages, videos or other information.If you want to find out more about booking a panel inIndustrial Technology’s QR Directory for your company, andprovide resources of your own for Industrial Technology’sreaders, email us at our specially created addressqrcodes@itmagazine.uk.com.49

EAR TO THE GROUND • Becky Silvertonbecky@itmagazine.uk.comHairdressing and theUK economy: discuss...Areport coming out of the Centre forEconomics and Business Research suggeststhat scrapping bank holidays would add£19bn to Britain’s annual economic output,because of the extra contribution that the servicesector would make over those additional eightworking days. The news station covering the reportspoke of the importance of the service sector to theUK economy, citing – in the same breath, andwithout a hint of irony or themerest trace of a smile – thecontributions of banking andhairdressing.I, like many others listening tothe report I suspect, did somethingof a double-take at this point. Wasthe reporter seriously suggestingthat hairdressing was as key to UKeconomy as banking? And if hewas, would we really be so muchbetter off if hairdressers did the decent thing andworked an extra eight days a year?Outside of shoes and handbags, there is little thatis more important to a girl than her hair. We all tendto have a set number of times a year when have ourhair done, perhaps increased when there is aparticularly special occasion in the social calendar.So what happens if our favoured stylist happens notto be working on a given Monday? Do we think toourselves, “Ah well, that’s it for this month then”? Ofcourse not. There are a fixed number of womenlooking to have their hair done a given number oftimes per year. Opening the salon eight extra days ayear will make no difference to the economicbalance sheets whatsoever. Even for men, I’m givento understand, a hair cut is rarely an all-or-nothingspur of the moment decision. Rather, it’s a case of“really must get than done sometime soon”.What about the banks, then? Well, if one werebeing especially glib and petty, one might argue thatseeing as it was the bankers who got us into thecurrent financial crisis, the fewer days they workedthe less damage they could do.But it’s not just about income lost, is it? Bankholidays tend to be the times when we take longweekends away, or visit tourist attractions, or hit theshops, or undertake those crucial bits of DIY. Howmuch do the bank holidays actually generate inadditional wealth for the country? I’d be willing tobet that it was more than enough to offset any lossin earnings by the service sector being off work.Perhaps there is an argument for having fewerbank holidays, but citing banking and hairdressingmakes for a very poor case indeed. On the otherhand, we are frequently praised in this country forour high levels of productivity. How much of that isdue to the superior work/life balance provided by alittle bit of extra holiday each year?FAST Exhibition NorthApril 26, 2012Pavilions of Harrogatewww.fastenerexhibition.comNewbycom (01844 352916)AutomaticaMay 22-25, 2012New Munich Trade Fair, Germanywww.automatica-munich.comMesse Munchen International(+49 89 9 49-1 15 38 )MTECMay 23-24, 2012NEC, Birminghamwww.mtecukshow.comUBM Canon (07801 346454)Midlands Design& ManufactuirngMay 23-24, 2012NEC, Birminghamwww.manufexmidlands.comUBM Canon (0203 147 4620)Instrumentation ScotlandSeptember 5-6, 2012Aberdeen Exhibition and ConferenceCentrewww.instrumentation.co.ukTrident Exhibitions (01822 614671)Engineering SubcontractorOctober 18, 2012National Motorcycle Museum,Birminghamwww.engsubshow.comNewbycom (01844 352916)Sensors + SystemsOctober 24-25, 2012Silverstone Circuit, Northantswww.sensorsandsystems.co.ukTrident Exhibitions (01822 614671)Index to Advertisers April 2012Albert Jagger ............................................. 23Andantex .................................................. 29Anixter Components ................................... 13Balluff ...................................................... 49Bancroft and Company ............................... 35Blackfast Chemicals ................................... 28Bollhoff Fastenings ..................................... 19Dunkermotoren .......................................... 32EMS ......................................................... 33ETA Enclosures (UK) .................................... 3Euro Bearings ............................................ 23Franke Bearings ......................................... 23Howdon Power Transmission ...................... 27Igus (UK) .................................................. 25Jesa AG .................................................... 24Kingston Engineering ................................. 35Kistler Instruments ..................................... 43KNF Neuberger ......................................... 17Lafert Electric Motors ................................. 31Lenze ......................................................... 7LG Motion ................................................ 13M Barnwell Services .................................. 49Machinery Safety Alliance ........................... 44Maxon Motor UK ....................................... 34Mclennan Servo Supplies ........................... 35Medway Power Transmission ...................... 27MK Profile Systems .................................... 13Moss Express ............................................ 10Moore International .................................... 37Murrelektronik ............................................. 2NSK Europe .............................................. 21Omron ...................................................... 39Ondrives ................................................... 28Phoenix Mecano ........................................ 45Reliance Precision ..................................... 29Reliance Precision ..................................... 52Rittal ........................................................ 14Rotaflow FV .............................................. 49Sensor Technik UK .................................... 37SEW Eurodrive .......................................... 30Spirol Industries ........................................ 19Staubli UK ................................................ 47Tandler Precision ....................................... 27Trident Exhibitions ....................................... 5The Barden Corporation UK ........................ 25Tom Parker ............................................... 16Tom Parker ............................................... 48Wittenstein ................................................. 750INDUSTRIAL TECHNOLOGY • April 2012

Industrial Technology’s QR DirectoryNEWElement stainless process valve rangeMobile optimised page where you can leave your name and emailaddress to receive the latest info on this product rangewww.burkertenquiries.co.uk/mobile/product/elementEnclosure solutions – unlimited possibilitiesLarge range of more than 10,000 precision products for immediatedelivery worldwide makes Rittal a leading system supplierwww.rittal.co.ukABB’s technical guide: dimensioning drive systemsFind out how to correctly dimension a drive, ensuring you achieve thebest possible performance from your installationhttp://bit.ly/xBmJ8JNEWSensors + Systems for Control & InstrumentationAn event that offers engineers an easy route to see and learn all aboutthe latest products in their industrywww.sensorsandsystems.co.ukMaximum performance for any automation taskPerfection in Automation – complete automation solutions from asingle sourcewww.br-automation.comInstrumentation Scotland & Offshore SystemsGo to the web site for more details and to register for the InstrumentationScotland & Offshore Systems exhibition. 5th and 6th September 2012www.instrumentation.co.ukStandard machine elements worldwideAccess new products and latest news for your standard parts needs.Handles, handwheels, knobs, hinges, feet, castors, clamps, latches, etcwww.elesa.co.ukPlastic energy chain, bearings and flexible cablesImprove technology and reduce costs with igus’ lubricant free e-chaincable management systems, cables and bearings and linear slideswww.igus.co.ukOmron’s new compact safety laser scannerOmron introduces the compact new OS32C safety laser scanner, whichprovides Safety Category 3 and complies with global safety standardshttp://itqr.it/omron-safety-laser-scannerTorqSense and LoadSense range of sensorsRotary torque transducers and wireless load sensors for a wide range ofindustrial applicationswww.sensors.co.uk/indtechHepcoMotion: world leaders in linear motionLinear slides, actuators, bearings and continuous and rotary motionsystems. Cost-effective linear motion that needs minimal maintenancewww.hepcomotion.comMiniature motors, transmission and controlThe widest range of motors and gearboxes available with feedback andcontrol, designed to give 21st century OEMs an edge in the marketwww.rotalink.comSensor intelligence from SICKFor reliable and efficient control of processes in factory, logistics andprocess automation, SICK sensors and application solutions are the answerwww.sick.co.ukElectro Mechanical Systems LimitedRange of small to medium sized DC motors utilising a range oftechnologieswww.ems-limited.co.ukPerfecting power – Welcome to BLOCKComprehensive range of transformers, power supplies and filterswww.blockuk.co.ukWANT TO BE INCLUDED?If you want to find out more aboutbooking a panel in IndustrialTechnology’s QR Directory for yourcompany, and provide resources of yourown for Industrial Technology’s readers,email us at qrcodes@itmagazine.uk.com.Components and systems for industrial automationOEM Automatic aims to provide the widest and deepest range ofindustrial automation components on the marketwww.oem.co.ukOver 17,000 different types of stock springsStock and custom springs from Europe’s number one stock springsupplierwww.leespring.co.uk

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