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INDUSTRY NEWSwww.industrialtechnology.co.ukThe first small steps tohelp manufacturersManufacturers have welcomed theGovernment’s business aid package,but are urging further measures tohelp with cashflow problemsSkills Secretary John Denham has pledged £350m to helpsmall companies put staff on short courses aimed atincreasing productivity, and says he is in talks with themajor banks to ensure they continue to lend to SMEsduring the economic downturn. However, despite announcingaction on late payment issues, the Government has rejected Toryproposals to reduce National Insurance liabilities for small firmsand allow for deferred payment of VAT bills.The funding to support training will be drawn from theGovernment’s ‘Train to Gain’ programme – the scheme thatsupports and subsidises staff training. Funding for the programmeis planned to rise to £1 billion by 2010-11. In allocating theplanned increase in spending on this programme over the next twoyears, the Government will give top priority to meeting demandfrom small businesses in the private sector (those with up to 250employees).The key elements of the £350m Train to Gain package areinclude a relaxing the rules to allow funding for “bite-sized chunks”– small units or modules of qualifications in subjects known to beimportant to SMEs, such as business improvement, team-working,customer service, and risk management. There will also be helpfor groups of SMEs located together in business parks so that theycan increase their purchasing power and share resources tosupport the training of local SME staff. The package extendsDIUS’s leadership and management programme so that moreSMEs can benefit from it, including in companies with just 5-10workers. And there is a relaxing of the rules to allow workers to gettraining up to level 2 even if they already have a previousqualification at this level, and more funding for level 3 training.Minimising bureaucracyPromising to deliver funding for training with the minimum level ofbureaucracy or delay, Denham said: “Small businesses are animportant engine of our economy and we must make sure that wesupport them during tough economic times. We know that firmswhich invest in skills do better than those that don’t, which is whywe will be urging small businesses to take up this offer fromGovernment.”The UK’s new business secretary, Peter Mandelson, made hisown pledge to help SMEs beat the downturn. Appearing before acommittee of MPs, Mandelson said that he would ensure thatGovernment bodies paid suppliers on time – by speeding uppayments, as small companies are often the most vulnerable tolate payment problems. “We have taken a very strong lead inannouncing that central government will pay money to itssuppliers, many of whom are SMEs as soon as possible,” he said.Denham clarified this, announcing that all Governmentdepartments and agencies have been told to pay small businesssuppliers within 10 days - a move welcomed by the Federation ofSmall Businesses.Help with cashflow neededEEF, the manufacturers’ organisation, has welcomed the measuresto help business address the current economic turmoil but urgedthe government to go further in the forthcoming pre-budgetstatement with proposals to maintain cashflow and investment.Commenting, EEF Chairman, Martin Temple, said: “Governmentclearly understands the pressures companies are under and this isa useful first building block. However, we need to build on thisurgently with measures to assist companies with their cashflow,ensure responsible lending together with a delay in the plannedincreases in taxation and new regulatory measures.”To assist companies with their cashflow EEF has proposed anurgent look at the small company rate of corporation tax. Thephased increase in the small company rate of corporation taxrepresents a £500m tax rise this year, rising to £1bn next year.The increase in April 2008 should be reversed and the smallcompany’s rate frozen at 20% until 2010, at the earliest. EEF isalso asking for greater, temporary support for investment duringthe economic downturn, by raising the Annual InvestmentAllowance from £50,000 to £250,000 for a period of 18 months.In addition, 50% first year capital allowances for small businesseswould help prevent a retrenchment in business investment. Theupfront cost to the Exchequer would be offset by increased taxrevenues further out. Finally, EEFsays increases in the landfill tax,aggregates levy and climatechange levy should be postponedand rates maintained at theircurrent level to minimise thecost burden on business.Capital projectswill prop up theailing economyThe news that Alistair Darlingplans to boost Governmentspending to help the economyweather the impendingrecession has been welcomedby UK specialist recruiter,Resourcing Solutions.Managing director RichardLawrance stated: “This is atime when you have to supportthe economy and the bringingforward of major capitalinvestment projects should beseen as a vital injection of hopein the construction andengineering sectors.”Darling announced plans toprop up the economy byembarking on big Governmentprojects, singling out housing,energy and small businesses asareas that would benefit from aso-called ‘reprioritisation’ ofspending plans. Lawrancecontinued: “He also signalledthat new proposals for two newaircraft carriers and areplacement for the Tridentnuclear deterrent would goahead.”He continued: “There is nodoubt in my mid that thispump-priming of the marketwill protect investment andjobs in the critical constructionand engineering sectors formany years to come. There isalready a shortage of goodquality candidates in thesemarkets and we envisage thatthat position will not change forsome time to come.To fund this programme theGovernment borrowed a recordamount in September, theOffice for National Statisticsdata shows. Public sector netborrowing hit £8.092bn inSeptember, up from £4.775bnin the same period a yearearlier, marking a record for themonth. The amount borrowedthis financial year stands at£37.6bn so far, more than thetotal borrowed in 2007.8More details: Write in 80 on the free information cardFor the very latestproduct information, mostup to date industry news,plus useful companyprofile information, visitthe pages of IndustrialTechnology online atindustrialtechnology.co.uk

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The Virtual Industrial Exhibition.com3 million monthly visitors7,400 exhibitorsCOMPANY NEWSKeeping model trainsPeco, the trading name for thePritchard Patent Product Co, isfamous throughout the worldfor scale model railwayproducts of the highest quality andprecision. Progressive in its businessoutlook, the company has always soughtinnovative manufacturing and assemblysolutions for its classic track, locomotive,rolling stock and lineside products.The most recent example of that isan electrically conductive track joiner forits OO/HO and N gauge flexible trackagesystems. This particularly challengingprecision part is made in nickel silver byUK metal pressings manufacturer,Clamason Industries. The tiny stamping,16mm long by 5.35mm wide by 0.2mmthick, is supplied by Clamason in twovariants, for an OO/HO gauge, “Code100” rail 0.1in deep (2.5 million a year)and an N gauge, “Code 80” rail 0.08indeep (1.2 million a year, on a laterdelivery schedule).These new components are requiredto hold a tight linear tolerance (twothousandths of an inch) and toaccommodate both curves and straightsof flexible trackage. They featureenhanced springiness and memory forrepeated assembly and disassembly bymodel train enthusiasts wishing toalter their track configurations.One end of the Clamason railWhy not you ?Moog invests in windenergy companyMoog has made bought a 40%ownership of the wind energybusiness of the privately-heldcompany LTi REEnergy GmbH. Thecompany specialises in the designand manufacture of servocontrollers, as well as complete drivesystems for electric rotor bladecontrols for wind turbines. Moogexpects to acquire the remaining60% in twelve months subject toconventional conditions of closing.Michell Instrumentsacquires CoreciMichell Instruments has acquired therelative humidity business of theItalian Control and Automationcompany, Gefran SPA. Located inLyon, France, the relative humiditybusiness was formerly known asCoreci SA. It will continue to operatein Lyon as a division of MichellSARL. The acquisition strengthensMichell’s position in humiditysensing technology.New challenger inpower transmissionA new global force has announcedits presence on the European marketfor power transmission products.Altra Industrial Motion, a leadingglobal manufacturer and supplier ofclutches, brakes, couplings, gearing,belted drives, linear actuators andpower transmission components, iscommitted to achieving synergyacross its many leading brands.Repeat order forstainless motorsChemineer is a world leadingdesigner and manufacturer of mixingsolutions. The latest offering to itscustomers for whom hygiene iscritical is a stainless steel motorbasedagitator drive. Supplied byLafert, the ‘Marlin’ stainless motorsare being employed initially for abio-pharmaceutical application.Lafert’s Marlin motor is employedbecause of its inherent superiorhygiene features over conventionalAC motors.10 More details: Write in 100 on the free information cardINDUSTRIAL TECHNOLOGY • November 2008

www.industrialtechnology.co.ukon the right trackjoiner is assembled automatically at Pecoto slide along the bottom of the rail. Thisdedicated bowl-fed assembly unit,developed and supplied by Clamason asa well-known provider of assemblysolutions, achieves a substantial timesaving.So, in addition to the development ofthe pressed joiner itself, the Clamasonunit assembles and crimps each joiner toa piece of rail with very little room forerror, given the tight tolerances of bothtrack and joiner. This new assemblymethod yields much increasedproductivity andimproved process consistency, whilstremoving potential health and safetyhazards.Although the production andinstallation of an assembly machine tocrimp a joiner to a piece of rail maysound simple, the unit is complex andversatile enough to be used for a numberof track variations with a minimalchangeover time.The other extremity of the track joineris a free end, with a distinctive curl-overshape to minimise sharp edges for safesthandling, enabling the user to make alight and easy press fit onto the undersideof the next piece of rail.Train for the newMachinery DirectiveMajor changes to the machinerydirective will put even greater healthand safety responsibility on thosedeclaring compliance – and heavypenalties for those that fail to meetthem, says Laidler Associates, whichhas put together a series oftraining seminars to helpaffected companies. The coverthe requirements that all UKmanufacturers and suppliersof new machinery make surethat the machinery that theysupply is safe.Camera innovationrecognised in awardsAt this year’s Plus X Awardsceremony in Cologne, FLIR Systemslearned that it had not only scoopedup a phenomenal six Plus X Awardsfor two of its thermal imagingcameras but that ithad also won‘The MostInnovativeBrand of TheYear’ award.Virtual exhibitionembraces videoDirectIndustry, the virtual industrialexhibition, has launched a major newservice, allowing engineers to checkout company information and productdemonstrations using videopresentations. There are already over1,600 videos online. The servicemakes it easy to check out companyinformation and complex products.November 2008 • INDUSTRIAL TECHNOLOGYMore details: Write in 110 on the free information card11

INDUSTRY NEWSwww.industrialtechnology.co.ukCompetitions open for share of£72 million research fundingThe Technology Strategy Board says it is to invest a further £72million in innovative research and development projectsThe Technology Strategy Board chief executiveIain Gray has announced that it is to invest afurther £72 million in innovative new researchand development projects in eight key areas. Theten new competitions, in important areas such asphotonics, high value manufacturing, intelligent transportsystems, network security and energy generation andsupply, will be split into three phases, with the first threecompetitions opening in November.The purpose of the competitions is to stimulateinnovation, with businesses working together and withacademic and research institutions on new research anddevelopment that will lead to successful new productsand services. The invitation to submitproposals was made at theInnovate08 conference and exhibition,held in London.Announcing details of thecompetitions, Gray, said: “It is vitalthat the UK maintains its coreexpertise in the key technologieswhich underpin business growth. Andit is no less vital to maintain a pipelineof new advances, in order to keep UKbusinesses at the leading edge. Weare confident these competitions willgenerate proposals for innovative new research anddevelopment projects. We look forward to seeing someexciting proposals.” Phase 1, which opened on 10November, invites submissions on photonics (NextGeneration Optical Internet Access), advanced materials(Sustainable Materials and Products) and intelligenttransport systems and services (Informed PersonalTravel). Phase 2 opens on 19 January 2009 and willcover high value manufacturing (Step Changes inCompetitiveness), value systems (Energy Generation andSupply: Maximising Recovery of UK’s Oil and GasResources), a second round of photonics (NextGeneration Optical Internet Access) and low impactbuildings (Design and Decision Tools). The final phase,opening 16 March 2009, will invite submissions oncreative industries (Accessing and CommercialisingContent in a Digitally Networked World), energygeneration and supply (Fuel Cells and HydrogenTechnologies) and network security (Interdependency,Complexity and Risk).The Technology Strategy Board is a business-ledexecutive non-departmental public body, established bythe government. Its mission is to promote and supportresearch into, and development and exploitation of,technology and innovation for the benefit of UK business,in order to increase economic growth and improve thequality of life. It is sponsored by the Department ofInnovation, Universities and Skills (DIUS).david.b@atlas.co.ukManufacturers welcome interest rate cutThis month’s 1.5% cut in interest rates is awelcome bold move by the Bank of England andpasses the baton for further measures to thegovernment in its forthcoming pre-budgetstatement according to EEF, the manufacturers’organisation. EEF had called for a significant cut in ratesin response not just to the recent turmoil in the financialmarkets but also the accelerating downturn inmanufacturing. Whilst further cuts in interest rates maybe needed, EEF believes the government also has a roleto play in the forthcoming pre-budget statement.Commenting, EEF chief economist, Steve Radley, said:“The Bank has clearly recognised that uncharteredterritory requires unconventional measures and has tornup its previous script. The baton now passes togovernment to do its bit with timely and targetedmeasures in the forthcoming pre-budget statement.”In his own comment on by decision by the Bank ofEngland’s Monetary Policy Committee (MPC) to reduceinterest rates by 1.5% to 3.0%, CBI director-generalRichard Lambert said: “This is a bold and welcome moveby the Monetary Policy Committee, and achieves whatthe CBI had been calling for. Business and consumerconfidence has been deteriorating sharply in recentmonths, and recession has replaced inflation as the majorthreat to the economy over the next year or two. This cutof one and a half percentage points should help to easeconditions in the credit markets, and allow banks to passthe benefits on to their customers.”The TUC’s head of economics Adam Lent said themove was the right call: “It shows the Bank nowunderstands that the problem is recession not inflation.”Meanwhile, the Institute of Directors (IoD) said interestrates could touch record lows of 2% or less by this timenext year. “The sooner we get interest rates down the lessis the risk of a long and deep recession,” said IoD chiefeconomist Graeme Leach. The Bank of England’s interestrate move came after a series of figures released thisweek provided further evidence that the UK economy issliding towards recession. The Office for NationalStatistics said that manufacturing output fell for a seventhmonth in September - the longest run of monthly declinessince 1980. Manufacturing output fell by 0.8% inSeptember, much worse than some analysts’expectations, making output 2.3% lower than a yearearlier, the sharpest decline since May 2003.The UK cut was followed by a less dramatic move fromthe European Central Bank, which lowered eurozoneinterest rates from 3.75% to 3.25%, to try to boosteconomic growth in the region. What’s more, the globalfinancial body the IMF sharply revised down its forecasts foreconomic growth around the world in 2009. It predictedthat developed economies as a whole would contract nextyear for the first time since World War Two. Shadowchancellor George Osborne said: “This is a shot in the armfor the economy, but it shows how sick the patient is.”Have your say via feedback@itmagazine.uk.com12INDUSTRIAL TECHNOLOGY • November 2008

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RightsizingLenze drives & automationRightsizing for:smaller sizeslower costsfaster buildsmore performancein actionDrives that are not too bignot too smallbut sized just rightPowerful selection softwareExpert technical adviceMore details: Write in 140THE GREAT ENGINEERINGAs Industrial Technology hosts this forumon high value manufacturing, Mark Simmskicks off the debate with some thoughtsabout where the next generation oftalented engineers will come from...The UK government is telling usall that we need to move ourdesign expertise towards aknowledge-based economy,and our manufacturing towards highvalue products and processes. Thoseare laudable goals, and we can all seethe logic. But what that’s going to needis a serious pool of engineering talent.We’ve talked before within thepages of this magazine about theimbalance that exists between the UK’smanufacturing aspirations and theengineering base to support them.Right now, it’s difficult to see where thenext generation of engineers is going tocome from. So what sort of measuresmight it take?The celebrity factoryA month or so ago, when Jamie Oliverwas promoting his new TV series‘Jamie’s Ministry of Food’, andresponding to criticism that he hadpainted Rotherham as a town of“kebab-eating numpties”, I heard himbeing interviewed on the Jeremy Vineshow on Radio 2. Arguing against himon the show was a politicalrepresentative of the town whose nameI’m afraid I didn’t catch.Now, whenever two politicians arebeing interviewed on the Vine show,they are forever talking over each other,shouting each other down, andgenerally doing their best to ensure thatthey get not only the last word, but allthe words through the beginning andmiddle as well. And so it was not at allunexpected when, as Jamie got into hisflow, the politician opposing him beganairing his own views at the same time.With complete assurance, Jamie simplysaid, with a firm voice: “I’m sorry mate,I’m talking.” And the opposingpolitician immediately piped down, andwaited his turn.Now of course this demonstratesgood manners, but you’d never haveseen those manners in a debatebetween two politicians. What you haveto suspect, then, is that politicians runscared of celebrities. And you only haveto look at the way politicians courtcelebrities to try and boost their ownstandings with the public to see thatthis must be true.But how does this impact onengineering? Well, consider thelack of support James Dysonreceived from the governmentwhen he tried to set up anengineering school in Bath.His aim was to establish a facilitythat would teach 2,500 14- to 19-yearolds design, engineering and enterprise.Dyson proposed his School of DesignInnovation in 2006, with the JamesDyson Foundation putting up half of theestimated £22m costs and the restcoming from government.It all sounded good, until red tapebegan to tangle the project. Finally, inOctober this year, Dyson was informedthat an application for funding from anew government skills academyinitiative had been rejected, his despitebacking from the likes of Rolls-Royce,Williams Racing and Airbus. Faced withthe red tape and the rejection of thefunding application, Dyson said he hadno choice but to abandon the plans.Academy for enterpriseNow, contrast Dyson’s fortunes withthose of Peter Jones of Dragon’s Denfame. His plans for establishing a newNational Enterprise Academy forEnterprise to unlock entrepreneurialtalent seem to have been fast-trackedby the government with £8m funding.In the same week that he informedDyson that he had not been successful,Secretary of State for Innovation,Universities and Skills, John Denhamsaid: “I am delighted we can confirmthe funding to further expand theNational Skills Academy Network. Ledby British entrepreneur Peter Jones, thenew National Skills Academy forEnterprise will help tackle the existingskill shortage in enterprise, crucial forthe future success of our economy.”I certainly wouldn’t want to suggestthat Peter Jones’ academy will be anyless worthwhile than James Dyson’sproposed facility. But you do have towonder how much of the decision towww.lenze.co.ukLenzeINDUSTRIAL TECHNOLOGY • November 2008

DEBATEfund one project andreject funding for theother came down to PeterJones’ own celebrity and high publicprofile. What would have happened,for example, if James Dyson had had asimilarly high public profile – enoughcelebrity, in fact, to influence the waypeople feel about the government?High profile engineersPerhaps I am reading far too muchinto the situation. But I think we canall agree that there is a decided lack ofcelebrity engineers in this country whowill inspire a new generation to takeup the baton. There was a brief flurryof interest when Top Gear’s JeremyClarkson make the case for Brunel asthe greatest Briton, but the low takeupof places in the manufacturing andengineering academies clearlydemonstrates that that interest has notbeen maintained. So, given a lack ofcelebrity in the field, what might ittake to draw today’s school childreninto an engineering career?Could it be that obtaining a decentscience-based qualification is seen asbeing too difficult? That is possible,especially when the government iscontinually telling us that standardsare being maintained and exams aren’tgetting any easier. On the other hand,you don’t have to make the examseasier if you’re simply lowering thepass marks. Apparently just 20% willget you a grade C in your scienceGCSE. If those sorts of standards arereflected through A levels and highereducation, then getting an engineeringqualification shouldn’t be beyond themasses. Of course, this raises anotherproblem – that of the lack of ability ofthose engineers who do comethrough the system. We have toofew engineers, seemingly able tocommand salaries beyond theiryears because of issues ofsupply and demand, but whodon’t have the abilities to warrantthose salaries. Is it any wonderthat so many companies arelooking overseas for staffto plug their engineeringholes. Indeed, a couple ofcompanies I have spoken to recentlyhave said, in all seriousness, that theengineers they have recruited fromoverseas have been more highly skilledand more committed to the company. Iasked, “But what about theircommand of the English language?”They replied: “Oh yes, that’s bettertoo.”I suspect that one of the majorissues to overcome is the cost to theindividual of undertaking a sciencebased degree, which could be as muchas double that of an arts degree,saddling graduate engineers with debtsof £25-30k before they’ve earned asingle penny.The colour of moneyA few years ago, we had a desperateshortage of nurses. In response, thegovernment started a bursary scheme.In addition, today student nurseseducated at universities are notcharged full tuition fees. A similarresponse has helped to swell thenumbers of teachers to moreacceptable numbers, with bursaries ofup to £9000 available.So why shouldn’t the samethinking be applied to attract studentsto science based subjects. If you wantto attract the best people, and youwant them to work hard to achieve thehighest possible standards, then youhave to be realistic about theincentives.These are just some of my views,but I’d like to build a debate aroundsome of yours. Email me any thoughtsvia feedback@itmagazine.uk.com.ExtraNKE AUSTRIA makes the most frequently used deep groove ballbearings extraordinary, with numerous technical improvements:> Newly developed double-liplabyrinth seal RS2> New, special low-noise lubricant> Superior surface finish onraceways> Closer grade balls> 100% noise testingThe new NKE POP range single row deep groove ball bearingsensure low running noises and long service life even fordemanding applications.Please contact us for furtherinformation:NKE AUSTRIA GmbHEnnser Strasse 41aA-4407 Steyr-Gleink AustriaTel: +43 7252 86667Fax: +43 7252 86667 59e-mail: info.a@nke.atwww.nke.atORDINARY!The new NKE POP rangeSingle row deep groove ball bearings> Quality in the premium classOldNEWNoise [dB]Vibrations [µm/s]The new NKE POP range single rowdeep groove ball bearings with reducedrunning noise and vibrations.More details: Write in 150 on the free information cardOldNEWNovember 2008 • INDUSTRIAL TECHNOLOGYIT15

Laser sensorsfor displacement,position & thicknessDESIGN COMPONENTSSeals & GasketsInnovative cup seal forhigh speed bottlingNew sensors:- Series 2210 for large offsetdistances- Series 2220 for extremefast measurement:Measuring rate 20 kHz- Series 2200LL for metallic,shiny surfacesThe correct sensorfor your application:Measuring ranges 2 to 750 mmLinearity from 1 μmResolution from 0.03 μmMeasuring rate up to 37 kHzAn innovative cup seal is the key to majorimprovements in the bottle filling processImproving safety and performanceare the key benefits resulting fromthe reduction of glass inclusion inthe bottle filling process in leadingbreweries, wineries and soft drinkmanufacturers, thanks to Super Seal, anew cup seal. The revolutionary SuperSeal has been developed by Uni-Spray,represented in the UK and Europe byBETE.Rapid automated processThe device is intended to replace rubberbased seals and centering cups whichare used extensively in the NorthAmerican bottling industry as part of therapid automated process of filling glassbottles with a wide range of drinks.Today’s fast, highly efficient bottlingfilling processes however, are notwithout risks: for example breakages canoccur randomly, depending on thestrength and quality of the glass bottle.On some bottle filling systems anautomatic decontamination alarm isactivated when breakages occur andthese activate waterand airspraysto flush and decontaminate the affectedarea. However, when breakages occurthe risk of potential glass ingress withinthe soft, rubber based seal significantlyincreases.Alternative materialsThis led Uni-Spray to focus its attentionon alternative materials as a way ofminimising the major risks of glassinclusion in seals and centering cups.Prevention, as opposed to cure. Choiceof materials was critical in overcomingthe problem and Uni-Spray designednew polyurethane seals and centeringcups, including a patented autodecontaminationsystem, a combinationwhich significantly reduced instances ofglass inclusion.The polyurethane material (which isFDA approved) also provided increasedlifespan – on average twice the life of acomparable cup seal manufactured froma rubber based material. A secondarybenefit of the polyurethane material is itsability to be easily colour coded, sohelping users and maintenance staff tocorrectly identify the right cup seal forthe right bottle filler. The Super-Seal cupseal has applications wherever highspeedbottling is required for a widerange of liquids such as beer, wines,ciders, water or carbonated drinks.A further development from Uni-Spray is a two composition, colouredcup seal and holder for KHS, one of theleading manufacturers of bottlingequipment in the USA. These new sealsoffer superior changeability, wearabilityand sanitation, yet at lower cost.Improved efficiencyMaximising safety and improvingefficiency are essential in today’s highspeedbottling environments and thedevelopment of the Super-Seal productis a good example of Uni-Spray’s skillsas a full-service moulding companyoffering a complete manufacturing anddesign service. Representative BETEis based in Lewes, East Sussex.MORE INFORMATION:Enter K165 or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for furtherdetails from BETELargest selection worldwidewww.micro-epsilon.co.ukMicro-Epsilon UK Ltd.Call +44 (0) 151 355 6070info@micro-epsilon.co.uk16More details: Write in 160INDUSTRIAL TECHNOLOGY • November 2008

FREEMaintenance productsl Mechanical toolsl Induction heatersl Hydraulic equipmentl Lubricants and lubricatorsl Condition monitoringContact SKF today for your free160-page catalogueSKF (U.K.) Limited01582 490049www.skf.co.ukwww.euro-bearings.comMore details: Write in 170 on the free information cardMore details: Write in 171 on the free information card 17

✁TECHNICAL INFORMATION PAGESCUT OUT AND KEEPHeidenhain absolute encoders guarantee positioningIt is fifteen years sinceHewlett-Packard’s Indigodivision introduced digitaloffset colour productionprinting to the world.Since then HP Indigohas achievedconsistent growth anda market-leadingposition worldwide.Now the company hasunveiled its newWS6000 digital printingpress, which benefitsfrom Heidenhain absoluteencoder technology.Designed to delivermedium-run colour print jobsprofitably by optimising printefficiency, the WS6000 featuresControl Techniques’ Digitax STIntelligent servo drives. ControlTechniques, in turn, specifiedHeidenhain’s single- and multiturnabsolute rotary encoders forfeedback of speed andposition. Accuracy ofregistration is the definingfactor when printing colourseparations onto a substrate,and this depends on precisemeasurement of the speedand absolute position of theWS6000’s printing drum. TheHeidenhain ECI 1319 singleturninductive absolute encoderprovides 19-bit resolution(524,288 counts per revolution),which allows fast sample timesto be set in the Digitax STcontroller for precise speedcontrol of the winders andprinting drum, together withaccurate position control.For the ‘active dancer’adjustment that tensions theweb on which the substrateprogresses through the printingpress, Heidenhain EQI 1331multi-turn absolute encodersprovide 12 bit turns (4096revolutions) and 19 bit (524,288)positions within a revolution.Both the ECI 1319 and EQI1331 encoders incorporate theEnDat serial data interface thatprovides a digital link to thedrive. This helps with driveperformance and low-costcabling solutions.Giant telescope movedwith extreme precisionAfter seven years of construction, the largest opticaltelescope in the northern hemisphere, the GranTelescopio Canarias (GranTeCan), will focus fourmillion times more accurately than the human eye andwill enable astronomers to detect more details than everbefore.This involves Heidenhain ERA 780C angle encoderspositioning the giant telescope with unrivalled precision.The 105 million euro system rotates about two axes –the elevation (vertical motion) and the azimuth(horizontal motion).The angle of the azimuth axis is measured over adiameter of some 15 m, which requires a scale tape witha length of 48.48 m, while 1,212,000 lines with a scaletapegrating period of 40 microns are available for theangular measurement. Thanks to the high quality of themeasuring signals, each grating period can beinterpolated by a factor of 4096 to provide 10-nanometermeasuring steps for positioning the azimuth axis. Thisresults in an angular resolution of 0.0003 arc seconds.Calibration and compensation of systematic errorsbring a system accuracy of 0.06 arc seconds over13.2°.The positive effect of linear encodersThe thermal behaviour of machinetools is an important consideration,given that conditions duringproduction are constantly subject tochange. This is why there is a differencein machining accuracy between usingmachines equipped with linearencoders, which fully compensate forthermal expansion of ballscrews, andthose that don’t.With this in mind, Heidenhain isactively promoting the use of linearencoders – such as the LC100 series, toprovide absolute position measurementfor measuring lengths up to 4.2m - pointingout that‘machinetools notfitted withlinearreasonable. And the value of theresultant benefits in terms ofproductivity, accuracy, profitability andcompetitive edge are easily realised.In practice, changes in ballscrewlength as a result of thermal drift,typically 100 microns/m within 20 mins,can introduce significant errors tocomponents produced on a machineequipped only with rotary encoders. Thisis because changes in the drivingmechanics due to wear or temperatureincrease resulting from highencoders for positioning may notbe accurate enough for the increasinglyhigh performance demands made uponthem’. According to Heidenhain, whenviewed against the overall cost of amajor capital investment in a machinetool, the additional cost of specifyingprecision linear encoders is veryspeeds and rapid acceleration are notcompensated for in a semi-closed loopmode of operation.If, however, a linear encoder is usedfor measurement of the slide position,potential errors in the transfer elementsof the machine have a lesser influenceon the accuracy of the positionmeasurement.18More details: Write in 180 on the free information card

ENGINEERING LITERATURENew guides and brochures for your bookshelfInnovative automation, motioncontrol and electronic productsIndustrial automation, motioncontrol and electroniccomponent specialist, IMOPrecision Controls haslaunched its new short formcatalogue, covering a wide rangeof innovative new products in thekey market sectors of processcontrol, panel building, safety,drive systems and electronics.Addressing the needs ofOEMs, panel builders and endusers, the new short formcatalogue includes some of thebest selling products amongIMO’s 15,000 product lines, themajority of which are backed bythree-year or, in the case ofdrives, five-year guarantees.Extending to 53 pages andincluding 27 product categories,the catalogue is available in bothhardback and CD formats. TheCD (IMO Resources) is the morecomprehensive of the two,providing additional cataloguesfor DIN rail terminals, pushbuttons, relays, sensing andswitch products, and terminalblocks, plus user trainingmanuals, configuration andprogramming software, and alsofull technical datasheets on theentire IMO product range.Included in the new productsappearing in the catalogue for thefirst time are the i 3 (iCube)integrated logic controller, JaguarVXR inverters, C4 motor circuitbreakers, iCon signal conditionersHIGHLIGHTOur featuredpublication ofthe monthand DIN rail power supplies. Allof these products are designed toprovide high levels of flexibilityand performance.Want a copy? .........Enter K194 on the card2009 RS CatalogueRS ComponentsRS Components has launched itsnew 4-part catalogue. Used byindustrial engineers nationwide itcontains over 160,000 products,of which all are available fromstock, with free next day delivery.Want a copy? ..........Enter K195 on the cardDC motorsParvaluxParvalux is pleased to announcethe release of a new catalogue forits 2009 range of DC brushedpermanent magnet motors andgearboxes with an extendedchoice of ratios.Want a copy? ..........Enter K196 on the cardHydraulic FluidsBFPAAnybody involved with hydraulicsshould have a copy of ‘HydraulicFluids – A Practical Guide’ in theirtechnical library. Priced at just£39 the new book is an extremelyuseful guide.More info? .............Enter K197 on the cardThis month on the web...Chain selectionRenold ChainAmongst the most populardownloads from Renold Chain’sweb site is a free chain-selector,that takes all the hit-and-miss outof specifying the right size andtype of chain. The company hasalso produced an excellenttroubleshooter guide in PDFformat.www.renold.comPrecision bearingsBarden CorporationThe Barden Corporation haslaunched a brand new websitethat offers easier navigation,improved functionality, as well aslots of useful technicalinformation on the company’scomprehensive range of superprecision bearings and custombearing solutions.www.bardenbearings.co.ukLinear motionHepcoMotionThe HepcoMotion website hasalways featured a first rate CADsection, providing swift access to3D models, specifications andperformance data. And nowHepcoMotion has also added 2DCAD acknowledging the fact thatmany of its customers still utilisepackages such as AutoCAD LT.www.hepcomotion.comNovember 2008 • INDUSTRIAL TECHNOLOGYMore details: Write in 19019

We’re just full ofhotaircoolair,warmair,dryingair,slowair,fastair,smoothair,what ever air you want we gotfans and blowers for extraction, cooling,ventilation, aeration, vaccum and dryingA complete design and manufacturing serviceis offered by ACI for its extensive range ofsmall to medium industrial fans. Options arebased upon a comprehensive range of motorspecifications and accessories. ATEX approvedformats are standard options.• Flow rates up to 6000m?/hr (3500CFM)• Pressures upto 250mBar (100in.SWG)• ATEX versions• Volume and specialised bespoke supply• Wide range of motor specifications and accessories• Full design and testing facilities, including airflowand noise testing• ebm-Papst UK Distributor for special applicationsPlease contact us for further detailed specifications and todiscuss suitability for your application.ELECTRICAL EQUIPMENTPoetry in motionJim Ford of Southco looks at the keyconsiderations when evaluating positioningtechnology hardware options for productsAcommon challenge inapplications as diverse asvideo display panels,industrial lighting, andenclosure doors is the need to controlthe position, motion and feel ofmovable design elements. Designerslooking to fine tune user interactionwith their product can turn toengineered positioning technology tohelp meet the challenge.The use of position control devicesis widespread amongst modernproduct designs from compact flipopen phones to automotive in-floorstorage. Used well, positioningtechnology helps fine tune the userexperience, making heavy objects feellighter and easier to move or makinglight objects feel more substantial. Itcan hold panels open or closed,remove vibration, and ensure smooth,maintenance-free operation, throughoutthe life of the product.The use of engineered positioningtechnology can improve a product inmany ways, including:● Managing motion – controllingdoor positioning for safety, convenienceand unobstructed access.● Ergonomics – enabling quick andeasy adjustments such as anglingdisplay screens or positioningheadrests to suit individual userrequirements.● Aesthetics – streamlining productdesign by avoiding the need forsecondary support, struts or springs.● Economy – reducing total installedcomponent costs by combiningmultiple functions into one positioncontrol device.● Reliability – providing consistentrepeatable operation, withoutmaintenance for the life of theproduct.● User experience – Customising the‘feel’ of a product to enhance the endusersperception of a product.While a full understating of theoperating environment is important inall access hardware applications, thisis even more critical where positioningtechnology is involved. The selectionof the appropriate positioningtechnology and its successfulintegration into the overall productdesign requires careful considerationof many factors. These include thephysical properties of the application,applied forces, desired motion andoperating efforts.Early considerationOne thing that can never be stressedstrongly enough is the importance ofconsidering any type of accesshardware early in the design process.This is especially true with positioncontrol devices. While it is possible toadd position control features late inthe design cycle, doing all of thecalculations at the outset andintegrating positioning technology aspart of the overall product designensures the best user experience atthe lowest total cost.Considering the positioningrequirements early in the design cyclecan allow the integration of off-theshelfposition control hinges into thedesign. The location and attachmentof the positioning hinge can have amajor impact on the overall productperformance. While Southco offers afull range of off-the-shelf products,many positioning applications requirea custom-engineered solution.Working with a positioning technologysupplier which has the capabilityto offer a tailoredsolution,www.aircontrolindustries.comthe solution providers for air movement problemsAir Control Industries LtdSilver Street,T: +44(0)845 5000 501Chard,F: +44(0)845 5000 502Somerset,TA20 2AE, UK E: sales@aircontrolindustries.com20 More details: Write in 200 on the free information cardINDUSTRIAL TECHNOLOGY • November 2008

APPLICATIONS • PRODUCTS • ENGINEERING EXCELLENCE• CUSTOM DESIGN = ALL COME AS STANDARDMOTION CONTROLSOLUTIONSPRE-LOADEDRACK ANDPINION DRIVESDIGITALTENSIONCONTROLSYSTEMSHIGHPERFORMANCESERVOPLANETARYGEARHEADHIGHPRECISIONLOWBACKLASHBEVELGEARBOXESAndantex Ltd,Rowley Drive, Coventry CV3 4LSTel. 024 7630 7722Fax. 024 7630 4499sales@andantex.co.ukwww.andantex.co.ukELECTRICAL EQUIPMENTEnclosures, Cabinets & FansJust going through a phaseIntertec is claiming a world first with aninnovative passively cooled enclosure thatcould slash the costs of instrumentation andelectronics for remote environmentsIntertec has launched a passivelycooled enclosure that exploits anovel phase-change material tomaintain the temperature ofelectronics equipment at 10 degreeslower than peak ambient temperatures.Requiring no power supply to operate,Intertec has produced a standard coolingenclosure with enough internal space tomeet common application requirements,such as the pressure transmitters andprocess analysers used on oil and gaspipelines running through desertenvironments. Intertec believes this tobe the first application of phase changematerials to process instrumentation.“Protecting sensitive electronicsequipment against very hightemperatures has traditionally been anAphase change material (PCM) is asubstance with a high heat offusion which, melting and solidifyingat a certain temperature, is capable ofstoring and releasing large amounts ofenergy. PCMs latent heat storage canbe achieved through solid-solid, solidliquid,solid-gas and liquid-gas phasechange. However, the only phasechange used for PCMs in practicalapplications is the solid-liquidchange.Liquid-gas phase changes are notpractical for use as thermal storagedue to the large volumes or highpressures required to store thematerials when in their gas phase.Liquid-gas transitions do have ahigher heat of transformation thansolid-liquid transitions. Solid-solidphase changes are typically very slowand have a rather low heat oftransformation.Initially, the solid-liquid PCMsbehave like sensible heat storage(SHS) materials; their temperaturerises as they absorb heat. Unlikeconventional SHS, however, whenPCMs reach the temperature at whichthey change phase (their meltingtemperature) they absorb largeamounts of heat at an almostconstant temperature. The PCMcontinues to absorb heat without aexpensive exercise, especially if theapplication also demands explosionproof protection, or involves a locationthat is not served by an electricityinfrastructure,” says Martin Hess ofIntertec. “This new type of passiveenclosure gives remote equipmentdevelopers a valuable new option,providing a very simple and costeffective means of protecting smallerscaleelectronics equipment inenvironments with temperature swings,such as deserts.”Phase change materials (PCMs) canprovide a cooling mechanism byabsorbing and storing the large quantityof energy needed to change thematerial’s state from solid to liquid asthe melting point is passed – during thePhase change materials – background readingsignificant rise in temperature until allthe material is transformed to theliquid phase. When the ambienttemperature around a liquid materialfalls, the PCM solidifies, releasing itsstored latent heat.The most commonly used PCMsare salt hydrates, fatty acids andesters, and various paraffins (such asoctadecane). Recently ionic liquidshave also been investigated as novelPCMs. As most of the organicsolutions are water free, they can beexposed to air, but all salt based PCMsolutions must be encapsulated toprevent water evaporation or uptake.Both types offer certain advantagesand disadvantages and if they arecorrectly applied some of thedisadvantages becomes an advantagefor certain applications.As phase change materialsperform best in small containers, theyare usually divided in cells. The cellsare shallow to reduce static head. Thepackaging material should conductheat well, and it should be durableenough to withstand frequent changesin the storage material’s volume asphase changes occur. It should alsorestrict the passage of water throughthe walls, so the materials will not dryout (or water-out, if the material ishygroscopic).normal daytime temperature rise. Thisenergy is then released as the PCM resolidifiesduring cooler periods, making itideal for use in desert locations withtheir cold night time temperatures. Forthis application, Intertec has chosen aPCM with a phase change temperatureof 34°C.Passive coolingThe first enclosure produced by Intertec,the PCM Passive Cooling System,provides approximately 25 litres ofusable space for mounting electronicsequipment, and will dissipate up to 10Wof heat. Moreover, there is no need toadd fans or vents, so an enclosure’senvironmental ingress protection (IPrating) against dust and water remainsunchanged.The phase change material is locatedat the back of the enclosure, behind amounting panel. The electronics deviceor equipment to be protected is attachedto this panel with as large a contact areaas possible to aid heat conduction.Intertec offers ready-to-use pipe clamplikeaccessories for mounting processtransmitters, and will also fabricatesimple mechanical panel-mountingaccessories for other equipment shapessuch as small electronics modules.The enclosure itself is fabricatedusing special insulated constructionprinciples developed and field proven byIntertec over many years. The basicmaterial used is long fibre reinforcedglass-reinforced polyester (GRP)sheeting, which provides great structuralstrength, combined with high resistanceto weather and the corrosive effects ofaggressive chemicals.Special mounting and constructionprinciples for the internal componentsthen ensure that the very high degree ofthermal insulation provided by this shellis not compromised by providing a pathfor heat conduction. The enclosure isalso compatible with Intertec’s standardrange of accessories including sunshades to protect the top and/or sides, toprovide further optimisation of theenclosure for use in hot environments.Intertec’s new enclosure can delivermajor reductions in system building22More details: Write in 220INDUSTRIAL TECHNOLOGY • November 2008

Compatible withTS 8 accessoriescosts. Alternative cooling mechanismssuch as air conditioning and vortexcoolers usually involve thousands ofpounds of extra hardware costs, aswell as the need for a local powersupply to power the pumps orcompressors required. These costs canescalate again if explosion proofprotection is required, as is typicallythe case for pipeline equipment.Low efficiencyPeltier coolers are an alternative forsmaller-scale electronics, but theirrelatively low efficiency means that asubstantial local power supply can berequired. Such cooling methodstypically necessitate connectionsbetween the internal and externalenvironments as well, such as vents orfans, complicating the provision ofprotection against dust and rain.Intertec’s unpowered PCM PassiveCooling System costs typically lessthan $1500 in and has zero runningcosts and no regular maintenancerequirements. A range of otherenclosure and PCM material blocksizes are optionally available, to suitlarger or smaller electronics equipmentand varying heat dissipationrequirements.Intertec’s portfolio of enclosure,cabinet and shelter solutions forprotecting field instrumentationincludes GRP enclosures andprotective shades in a range of shapesand sizes, GRP cabinets and sheltersfor use in almost any climate orweather conditions, accessoriesincluding heating systems, and customdesign and turnkey system assemblyservices. Intertec supplies most of theworld’s major oil, gas, petrochemicaland chemical organisations, from itsnetwork of manufacturing and salesoffices worldwide, and via a largenetwork of agents and distributors. Todate, Intertec has supplied well overhalf a million protection systemsworldwide.MORE INFORMATION:Enter K225 or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for furtherdetails from IntertecRittal CM -Compact System EnclosureThe idea: Compact enclosures that offer the installationflexibility of large cabinets• The answer: Rittal Compact System Enclosure CM• Diversity: Complete interior installation with TS 8 systemaccessories• Fast: Rapid attachment, the mounting plate is insertedat the bottom and simply secured at the top with clips• Flexibility: All cable entry option covered, more space,more stability and more opportunities for cable entry.• Automatic: Automatic potential equalisation through therail systemFor further information:Rittal Limited, Braithwell Way, Hellaby Industrial Estate,Rotherham, S Yorks S66 8QYTel.: 01709 704000 – Email: information@rittal.co.uk.www.rittal.co.ukNovember 2008 • INDUSTRIAL TECHNOLOGYMore details: Write in 230 on the free information card23

ELECTRICAL EQUIPMENTEnclosures, Cabinets & FansCasting a logo within a logoThe pin-point detail of rigid polyurethane enablesone company to inset the outline of a lizard intojust one letter of its logo, 20mm acrossThe outstanding properties of rigidpolyurethane, of fluidity atmoulding, strength when set andvariety of finishes, are provinginvaluable in enclosures for scientific,medical and laboratory instrumentation.Add to these parameters the economicproduction of small quantities, evenprototypes and one offs, and the materialpresents a very attractive package tomarkets where ergonomics and style areimportant but modest quantities are thenorm.Triton Technology, working through itsdesign specialist company, employedNorse Precision Castings for the enclosureof its identiPol QA which assesses thequality of thermoplastic materials. Theproduct is based on a wider range ofanalysing apparatus and gives injectionmoulding companies the ability to rapidlyassess the quality of polymers andplastics batch to batch without theservices of a skilled material scientist.Critical precisionThe rigid polyurethane is cold poured,presenting a high degree of precision,critical throughout. The quality of detailin the incorporated Triton logo isexceptional, the fluidity of the materialenabling the Triton lizard to be cut intoone edge the recessed ‘O’. Rigidpolyurethane also maintains a lowtolerance on warp and overall fit, allowingthe parts to fit together neatly withoutpost moulding machining. The property ofpreserving the characteristics ofembedded components is illustrated inthe smaller part which has brassthreaded inserts for ease of assembly.The textured finish, painted incomplementary colours adds a littleelegance. Norse Precision, withsubstantial in-house capabilities, has anenviable record of ‘right first time’.MORE INFORMATION:Enter K245 on the enquiry card, or visit ‘latest issuestories’ at www.industrialtechnology.co.uk forfurther details from Norse Precision CastingsHeaterefficiencyincreasedRittal has increased theefficiency and thermaloutput of its enclosureheaters by incorporating the latesttechnology and optimising thedesign.Available with outputs from 10to 800W, the heaters prevent thetemperature inside the enclosurefrom dropping below operationallevel and facilitate in the reductionof condensation. A new ‘heat flowdesign cover’ that uses thechimney effect ensures a moreefficient and even distribution ofheat output.The heaters are easily installedby either using snap-fasteningonto 35mm support rails orsimply screw fastening directlyonto the mounting plate.Spelsberg brings Bimedcable glands to the UKCustom casesdesigned quicklySurtech Distribution can now offercustomers the facility to designtheir own enclosures or modifystandard Surtech products usingspecialist CAD software. This is the firsttime that a distributor has offered such aservice. Customers get exactly what theyrequire, resulting in tremendous benefitsincluding a reduction in time to market.The CAD system’s 3D imaging capabilityalso allows customers to see and approvetheir designs before placing an order.Customers work alongside Surtech’stechnical team to decide on the mostcost-effective design, then view it in 3D,obtaining a visual check that they havespecified exactly what they require.Once the design is agreed, the model fileis transferred directly to themanufacturing plant. The service is idealfor batch production.MORE INFORMATION:Enter K246 on the enquiry card, or visit ‘latest issuestories’ at www.industrialtechnology.co.uk forfurther details from Surtech DistributionSpelsberg, best known for supplyinga range of electrical enclosuresand junction boxes, hasannounced that it will now offer theentire range of Bimed cable glands in theUK. Spelsberg’s enclosures are wellknown for their built in high qualitypush-fit entry seals, whereas the Bimedrange has been introduced to offer moremechanical cable retention and higher IPratings where required.Graham Fox, Spelsberg UK MD, says:“Spelsberg selected Bimed cable glandsas they are well respected around theworld, with a varied range that will meetthe demands of UK customers. Thecable glands offer ingress protection upto IP68 and are supplied in a range ofsizes and materials. The designs arequick and easy to install and provideusers with a secure entry seal and highcable retention.”It is easy to overlook the importanceof choosing a good quality cable gland, itis often forgotten that a poor gland willcompromise the integrity of the wholeapplication. To ensure that Spelsberg’senclosures are as secure as possible theywill now be supplied with the option ofBimed cable glands. Bimed is a worldleader in its field; its products are sold toover 30 countries worldwide.Durable materials are used to ensureall the glands produced are high techand high quality. The glands areavailable in either tough plasticpolyamide form or brass nickel plated.Both constructions are highly durable inharsh environments. Each provides IP68ingress protection with a range ofopening sizes between 13mm and59mm.Variations include spiral topped strainrelief glands, and the ‘Conus’ pressurescrew type cable glands (as the top isscrewed down the sealing ring isclamped against the cable which createsa strong and water tight grip). Brassnickel plated glands are also available ina number of styles including the DSglands, featuring a double silicone seal,which provides temperature resistanceup to +300°C.MORE INFORMATION:Enter K244 on the enquiry card, or visit ‘latestissue stories’ at www.industrialtechnology.co.ukfor more info from SpelsbergMORE INFORMATION:Enter K248 on the enquiry card, or visitwww.industrialtechnology.co.uk forfurther details from RittalProtectionfrom waterIf your installation has to bepositioned underwater or in anenvironment where sea spray,moisture, soil or dust areprevalent, you’d normally have toopt for the highest IP ratingavailable. But there is analternative: the Magic Box 100from GH Lucas.The system comprises astandard box, complete withmulti-choice knock-outs, ready topour gel, glands and stoppingplugs that offer contractors a trulyuniversal, multi-purpose IP68 boxavailable as a ready to use kit.MORE INFORMATION:Enter K247 on the enquiry card, or visitwww.industrialtechnology.co.uk forfurther details from GH Lucas24INDUSTRIAL TECHNOLOGY • November 2008

protectioninside & outin grade 304 or316 stainless steelFor more information, contact Lee ProductsInnovation in Miniature Tel: 01753 886664Fax: 01753 889588www.industrial-microhydraulics.co.uke-mail: sales@leeproducts.co.ukLee Products Limited, 3 High Street, Chalfont St Peter, Bucks SL9 9QEMore details: Write in 250 on the free information cardETA’s been developing high qualityenclosure solutions for over 30 years and isfast becoming the preferred choice amongstSpecifiers and installers looking for qualityproducts with innovative features!We provide a very broad range of standard and modifiedenclosure solutions serving many industries that depend oncompetitive products delivered on-time.Our focus on customer service elevates us ahead of thecompetition and positions us a more than just a “Me-Too”supplier but a company who candeliver time and time again.Moving Small parts inthe right direction is easy withAlwayse Mini Ball transfer units!Miller Street, Birmingham B6 4NF. England.Telephone: 0121 380 4700Facsimile: 0121 380 4701Email: sales@alwayse.co.uk Website: www.alwayse.co.ukCall ETA now and put yourenclosure requirements in the handsof a professional organisationalways striving to exceedexpectations now and in the future.innovative enclosure solutions forindustrial & electronic applicationsETA ENCLOSURES (UK) LIMITEDUnit 2, Ignite, Magna Way, Rotherham, S60 1FDt: 01709 386630 f: 01709 369524e: info@eta-enclosures.co.uk w: www.eta-enclosures.co.ukMore details: Write in 251 on the free information card More details: Write in 252 on the free information card25

FASTENERS & ADHESIVESMedical Device ManufactureAdhesives prescribedfor medical devicesBob Goss of Henkel, maker of Loctite brand products, discusseswhere adhesives have presented a medical device solutionIn order to meet the particular demands of themedical device industry, adhesives manufacturershave created a range of special products for thischallenging field. Compared to other joining methods,adhesives frequently offer design advantages, speedassembly, increase production efficiency and quality andimprove overall product performance. Furthermore, whenthe total cost of a finished device is considered, adhesivesare often the most economical assembly choice.But that’s not all; adhesives provide a range of extrabenefits, including the facility to bond dissimilar anddifficult substrates, create even stress distribution andaccomplish excellent gap filling capability. In fact,adhesives make an excellent choice when it comes tojoining medical devices – as several real-life examples willhelp illustrate the wisdom of that selection.At the cutting edgeBirmingham based e-Medix is dedicated to themanufacture of ophthalmic blades for eye surgery. This isa highly specialised procedure, so much so that there areonly around twenty companies worldwide making suchblades, with e-Medix being the only British producer. Thecompany utilises powerful computerised technology fromdesign, through manufacture and into inspection toproduce these quality blades. Clearly ophthalmicsurgeons expect their instruments to operate withcomplete safety – and in order to ensure that the bladesremain firmly in place in their holders, e-Medix uses acyanoacrylate instant adhesive. The procedure involvesthe blade units being bonded into moulded polycarbonatehandles just prior to cleaning, packaging and sterilisation.To find the most appropriate adhesive for this key task,e-Medix tried a number of products. In the end it camedown to the fact that a Loctite product fulfilled thedemanding criteria, was medically approved and couldreadily be dispensed from an automated system. For thisparticular application, the product is a low bloom, lowodour, single component, medium viscosity, instantadhesive that cures within seconds. To make applicationeasy and precise, it is applied using a bench topperistaltic dispenser. This uses a rotating mechanism thatdraws up product from the bottle and then feeds it to thedispense tip for application to the component. Thequantity of adhesive is readily regulated by adjusting thespeed at which the cam rotates. A finger or foot switch onthe dispensing nozzle is employed to control when theadhesive is applied. There is an additional feature thatprevents unwanted adhesive from dripping from thenozzle.Safe syringesAnother example involves the manufacture of syringesused for eye surgery where, traditionally, the hub ismoulded around the needle. However, because of thefineness and sharpness of the cannula needle, there issometimes the risk of damage during assembly. Henkelwas asked to investigate at the design stage of a newproduct the best method of bonding the stainless steelcannula to the syringe body. The customer’s demandsincluded automated dispending, consistency ofapplication, and a minimum pull strength of 20N.Trials revealed a light curing acrylic adhesive was mostsuitable for the substrates. Furthermore, the productionprocess could be readily automated – with a cure time ofaround 5 seconds under a high intensity light cureconveyor being easily attained. Once production started,run targets were met without difficulty and, what’s more,a pull strength of some four to five times greater than therequired 20N was sustained.A similar light curing acrylic was recommended foruse on a soft, flexible catheter for bonding the stainlesssteel needle halves to lightly-tinted polycarbonate wings.This catheter design utilises a ‘peel away’, split needleintroducer and a unique insertion system that is ideal forfragile veins. After insertion, the needle’s wing assemblysplits apart and is discarded. This does away with theneed to re-inject repeatedly the skin. This same adhesivehas proved extremely versatile and is now used to bondand seal housing halves, encaps, and fittings in blood andmembrane oxygenators, cardiotomy reservoirs, heatexchangers, blood and centrifuge bowls. It has also(Above) A Loctite CA adhesive is used to secure the blades inthese ophthalmic knives. (Below left) Some of the ophthalmicknives produced by e-Medixproved perfect for bonding sub-assemblies in bloodpressure transducers, anteriograph manifolds, stopcocks,fittings, adapters, and arterial filters. Although it isnormally used for polycarbonate, acrylic and PVC, theproduct also shows excellent adhesion to a variety of othersubstrates, including metals and glass.Flexibility and securityA further instance of adhesives answering productiondifficulties relates to the manufacture of a lower limbprosthetic device. Here, the company creates prosthesesmade of carbon fibre – chosen for is high strength,flexibility, and imperviousness to the elements. It alsocopes well with corrosion and stress. Use of this devicewould provide amputees with proportional movementresponse, an active heel with natural ankle motion and a95% energy return. Obviously, the components needed tobe joined such that there was no chance of device failure,however at the same time the parts needed to be flexibleenough to enable simple and straightforward use.The only realistic solution was bonding, and as aresult, a black, rubber toughened industrial cyanoacrylatewas selected. This particular adhesive provided thestrength necessary to preserve appropriate torque on thestainless steel fastener that was used in customising thefit of these prostheses. Not only that, the product wasreadily visible for inspection purposes, removable for anymaintenance tasks, and was rapidly applied without therequirement for activators or primers.Alongside the cyanoacrylate, an industrial anaerobicthreadlocker was designated for the larger 25mm preassembledfasteners to prevent loosening while in use. Inthis application, the adhesive was applied to the malethread of the fastener. When the fastener was screwedinto the threaded hole, the oxygen is removed from thejoint and the bond made secure.So, whether a medical device assembly demands anadhesive that is biocompatible, can be sterilised, or canaccommodate a myriad of other performancecharacteristics, there’s almost certainly one that will suitmost applications. Repeatedly, adhesives have introduceddesign benefits, reduced assembly times, improvedfinished product performance, and increasedmanufacturing efficiency and quality. In many instances,when the total cost of a completed medical device ismeasured, adhesives present the most economicalassembly choice.MORE INFORMATION:Enter K265 on the enquiry card, or visit ‘latest issue stories’www.industrialtechnology.co.uk for further details from Henkel andmore news on fasteners and adhesives26INDUSTRIAL TECHNOLOGY • November 2008

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FASTENERS & ADHESIVESQuick Acting FastenersThe quarter turn revivalThe quick acting fastener is making a comeback, according to theexperts at Unifast. Market forces are seeing OEMs rethink theirfastening strategies, and reviving a system that for years has beenthought of as too expensive for general commercial useThe quarter turn was originally developed in 1932when William Dzus created his famous fastenerfor use in the fledgling US aviation industry.Designed for fastening panels over areas whereregular servicing or frequent access was required thequarter-turn became a widely used standard with manyapplications. By the time of Dzus’ death in 1964 therewere around 6000 variations of the fastener. But althoughmany tried have to develop it to reduce overall in-placecost, the quarter turn, with its separately milled externalspiral cam has historically been unable to bridge the costgap caused by Far Eastern bulk production, and thereforeremained an expensive proposition for OEMs.But the picture is changing, with manufacturers suchas Unifast taking the quarter turn principle and redevelopingit. Unifast’s Fast Turn quick acting system ismanufactured through a cold forming process to make theentire stud, significantly reducing waste and time, andcompleting it without needing to mill on the external spiralcam. Cold forming delivers near, or absolute, net shape,eliminating the need for secondary operations. And as ituses 100% of the metal it leaves no scrap or swarf, savingon material cost as well as through the production processby reducing downtime needed for cleaning andmaintenance.“We employ cold forming not only because it deliverscost savings, but also because it adds to the quality of themanufactured component,” says Unifast’s LucaBergadano. “Machining a part from metal bar can disruptand break its crystalline structure, which could introduceweakness into the part. Cold forming is done under hugepressures, which make the grain in the metal flow into thecontours of the product, enhancing the grain structure andaccording to a US study strengthening the part by asmuch as 18% compared to a milled part.”While cold forming has allowed Unifast to cutproduction cost, the key to the real savings its Fast Turndelivers is in the stage beyond fastener production andeven beyond the OEM, where the end user is befittingfrom the OEM’s choice to use a quick acting fastener.These days it is harder to differentiate manufacturers bytheir products so instead customer choice is driven moreby the ability to provide the added value of pre and aftersales services. Indeed, it was this very reason that ledcommercial vehicle giant Iveco to select a hand-operatedversion of the Fast Turn quick acting fastener to securegearbox noise shields.Performance advantagesFast Turn’s simple system consists of a hardened steelstud, a spring steel retainer and a slip-on spring steelreceptacle. The stud is rotatable with a spiral cam,needing less than a 180-degree turn to engage and lockit, with a tangible click, to the receptacle. Fast Turn’s studremains in place in the panel even when undone thanksto its retainer, and the receptacle is simply clipped ontothe opposing panel, installation is completed in seconds.To demonstrate the benefits for Iveco, Unifastdesigned a simple test, comparing the performance of twofastening systems, the Fast Turn and a standard clip-on Unut and bolt, by removing the pan of an Iveco commercialtruck gearbox noise shield from its retaining sides, andthen re-attaching it. The shield is made from blackcomposite plastic, with the pan weighing in at nearly 3kgand needing ten fasteners to hold it in its fixed position.The test was designed to simulate a service operation,with the noise shield in an as near-to-life position aspossible.The test examined the operational performance of thefastening systems in their designed role, and showed thefollowing results. Using Fast Turn, only one operative wasrequired to safely remove the pan, with one handsupporting the panel and one gloved hand undoing thestuds. By contrast, the U bolts ideally required twooperators, because whilst removing the bolts from the Unuts could be completed using only one operative, theneed to use one hand to hold up the pan and the other tohold the power tool meant the bolts when removed had tobe allowed to fall directly onto the floor. Clearly this is asafety hazard and a major cause of lost bolts. Further, toachieve the same pull-up and location as the Fast Turn’saction required at least five complete revolutions of the Unut’s bolt – a negligible difference on a one to one basisbut adding up to a significant time saving over multipleoperations with multiple fasteners. With the Iveco noiseshield, the tests demonstrated up to a 60% saving on thereal in-place cost for the Fast Turn, despite it beingmarginally more expensive to produce than the U nutsystem.Of course, there is more to the performance of asystem than just cost, even in-place-cost. Resistance tovibration, particularly in automotive applications, is a keyperformance indicator for any system. A threaded systemuses friction to hold the energy used to tighten it and keepit in place – what’s known as pre-load. Where vibration isexcessive, a locking mechanism may be needed, addingto the overall costs. Fast Turn, however, exhibitsparticularly good vibration resistance as standard.Other areas of concern with threaded systems includeoperator error: using parts with dirty or oiled threads iscommon and dramatically reduces the effectiveness of thefastener. A study of joint failures in the US SkyLab projectfound that 29% were a direct result of improper assembly,while a further 14% failed because of incorrect pre-load.Fast Turn offers performance benefits that overcomethese problems.MORE INFORMATION:Enter K285 on the enquiry card, or visit ‘latest issue stories’www.industrialtechnology.co.uk for further details from Unifast andmore news on fasteners and adhesives28INDUSTRIAL TECHNOLOGY • November 2008

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FASTENERS & ADHESIVESNew ProductsSpeeding up the fastening processA new automated insert driver is the latest additionto the Spirol range of fastening process machineryNew knobin kit formfor clampingNew from Spirol Industries isthe PH Platen Heat InsertDriver, the PH Platen-Stylemodel. This machine providesan accurate and consistent means ofinstalling multiple inserts into a plasticmoulded component. This is loaded intoa fixture nest on a manual linear slideand the inserts are manually loaded intotheir corresponding bosses.The slide is pushed into position andthe machine is activated. The platenhead advances, axially engaging as manyas twelve heated tips into the inserts, andcontinues to advance until the inserts arehot melted to a preset depth. The platenthen retracts, withdrawing the tips. Theoperator then pulls back the slide,uploads the completed assembly andrepeats the process.Easily interchangeable platens andelevation adjustments ensure easychangeover from part to part. Pneumaticflow controls adjust insertion and retractstroke speeds. The entire insertion platenhead can be easily raised and lowered toaccommodate various host shapes andsizes. The PH Platen machine willaccommodate all heat style inserts indifferent sizes from and internal threads.MORE INFORMATION:Enter K305 on the enquiry card, or visit ‘latest issuestories’ at www.industrialtechnology.co.uk forfurther details from Spirol IndustriesAnew knob in kit form isnow available from Bülte.Plastimont CO258 isperfect for meeting clampingneeds. The plastic wing knob is apopular choice for applicationsrequiring finger tip control andlower torque tighteningrequirements.You make the knob yourselfusing wing Plastimont body andinserting a hexagonal screw or nutmade of steel, stainless steel,Clear indicationof the cureIntertronics’ sales partner Dymax hascreated ‘See-Cure technology as avisual indicator for its UV cureadhesives by colour changing fromoriginal blue to clear during the curingprocess. This greatly aids industrialassembly processes where it is essentialto know that sufficient adhesive has beendispensed and that a full cure is effected.See-Cure colour change technology letsyou determine this at a glance.Because the blue colour is extremelyvisible, simple vision systems can beincorporated into assembly processes toidentify adhesive coverage and profile.MORE INFORMATION:Enter K306 on the enquiry card, or visit ‘latest issuestories’ at www.industrialtechnology.co.uk forfurther details from IntertronicsCustom converted 3Mreclosable fastenersFabrico offers custom convertedScotchmate reclosable fasteners forassembly and fasteningapplications. The hook-and-loopreclosable fastener features stiff hooksthat mesh with pliable loops to create aquick and easy closure for a variety ofsurfaces and applications.The hook-and-loop fasteners providea clean, tailored appearance for indoorand outdoor fastening applications suchas displays and exhibit booths, homeand commercial offices, and automotiveinteriors. Fabrico offers Scotchmatereclosable fasteners with both pressuresensitiveadhesive backing and plainbacking, available in rolls, pre-fabricatedparts, and custom designs.MORE INFORMATION:Enter K304 on the enquiry card, or visit ‘latestissue stories’ at www.industrialtechnology.co.ukfor more info from Fabricobrass, nylon or other material. Thestandard colour is black but Bültecan supply these parts in a widerange of colours to suit yourrequirements, including white,red, yellow, green and blue.The standard material isPolyamide (nylon) which isresistant to various chemicalproducts, has excellentmechanical properties includingwear resistance, low frictioncoefficient, high melting point andgood impact resistance and is alsovery light.MORE INFORMATION:Enter K307 on the enquiry card, or visitwww.industrialtechnology.co.uk forfurther details from Bülte Plastics30More details: Write in 300 on the free information card

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MECHANICAL COMPONENTS Bearings, Slides & lubricantsRolling on airPhil Burge, Marketing Manager at SKF, explainshow magnetic bearings work and introduces thelatest technology offering an energy efficientsolution for demanding industrial applicationsIn applications where heavy equipment needs torotate extremely quickly, steadily and safely,specialist bearings that are capable of considerablespeeds and load carrying capacities are required.Furthermore, for companies to maintain a competitiveedge, these heavy loads need to be supported in the mostenergy efficient way possible. Magnetic bearings are idealin these cases; by eliminating contact between a bearingand the shaft it supports, friction is reduced to virtuallyzero, with the added benefit that no lubrication isnecessary.Supporting rotating equipment without physicalcontact may sound impossible, but that’s exactly whatmagnetic bearings do. Rather than using conventionalrolling elements, the bearings surround the shaft with aseries of electromagnets, which act in opposition tolevitate the shaft in the centre position. To achieve stablecontrol of the shaft, the electromagnets need to becontinually adjusted, requiring dedicated sensors andcontrollers.Extreme rotational speedsEradicating the friction that arises from rolling elementsbeing in contact with the bearing housing offers a numberof benefits to OEMs, system builders and end users. Forinstance, the latest magnetic bearings can accommodateextreme rotational speeds of up to 100,000rpm withoutwear. This enables the components to withstandconsistently high loads over their long service lives,minimising the cost and inconvenience of having toreplace bearings. With no friction to overcome, magneticbearings are also extremely energy efficient, helpingcompanies to balance high performance with cost savingsand environmental consciousness. In addition toeliminating friction and wear, magnetic bearings also takeaway the need for lubrication as there are no rollingelements to grease. Aswell as reducing costsand maintenance requirements,this makesthe bearings ideal for use in a vacuum or in contaminationcritical environments, such as clean rooms. With nocontact between the shaft and bearing, vibration isminimised too, enabling smooth, precise motion to beachieved. This is one of the reasons why magneticbearings are used as an integral component of speciallydesigned trains.High performance solutionsThe latest generation of magnetic bearings makes itsimple for OEMs and system builders to integrate thetechnology into their applications, offering end users costeffective, high performance solutions. Magnetic bearingscan be tailor-made to meet the needs of an application oroperating environment, with specific load carryingcapacities, dynamics and dimensions. Radial, thrust, orconical designs are available, which combine the benefitsof all magnetic bearings with their own individualstrengths. Canned designs can be specified forhermetically sealed applications and high temperaturemagnetic bearings have been developed, which offerreliable performance in temperatures of up to 220°C.Integral to all these magnetic bearing types are stateof-the-artposition sensors, which enable theelectromagnets to be continually adjusted for the moststable and reliable control. The sensors can be configuredas either a multi-sensor ring or an individual tube sensordesign. Small sensor rings can be installed in areas of amachine where tube sensors cannot access, and can beprecisely mounted so that no further adjustment isneeded after installation. By comparison, tube sensorsallow users to adjust sensitivity and offset while they areinstalled on a machine, makingmaintenance simple and costeffective.To help OEMs and systemsbuilders capitalise on the benefits ofmagnetic bearing technology, a seriesof motors and spindles has also beendeveloped. The latest spindlescombine magnetic bearings with amotor, housing, controller andcabling, and can achieve speeds of upto 60,000rpm with power ratingsranging from 0.3 to 55kW. Thespindles’ shafts have a versatileinterface for mounting different typesof payload, and can also be extendedto meet the payload requirements ofan application, whether it’s aturbopump impeller or a neutronabsorbing disk. Fit-for-purpose frameless, brushless DCmotors can be used with these magnetic bearing spindles,combining high power density with high efficiency, asrunning temperatures and energy losses are kept to aminimum. The latest motors can be specified with statorand rotor canning for protection from harsh environments,using Inconel 718, 316 SS, Monel 400, titanium andother materials. The motors can be cooled by convection,forced air, liquid, or, for applications in a vacuum, usingradiation alone.Advanced controlFor these magnetic bearings, spindles and motors todeliver the high performance levels required by today’sdemanding industrial applications, advanced controlsystems are needed. The latest magnetic bearing digitalcontrol systems range in size and power to match specificdynamic load requirements. The smallest systems start ata compact 2A/40V for the most sensitive machines withlight dynamic loading, and can be specified to include anintegrated motor drive for brushless DC motors. Forheavier machines, powerful 50A/200V control systemsare available.Whatever their size and power rating, fundamental toall of these control systems is advanced control software.For example, SKF controllers are founded on MBScope2000 analysis and tuning software, which provides userswith access to comprehensive diagnostic information.Software packages such as these make it simple for usersto configure and monitor magnetic bearing controlsystems using a suite of intuitive graphical tools. Bearingscan be tuned, calibrated, and continually adjusted tomeet specific parameter loading and eliminate vibration.System performance can be optimised simply andefficiently thanks to on-screen snapshots and real timerepresentations of positions, currents and forces, whilealarm settings can be programmed to warn users of anyunusual events, and capture system variables before andafter the incident for analysis.The latest generations of magnetic bearings areoffering new and exciting opportunities for OEMs, systembuilders and end users. With virtually all industrial sectorsnow focussed on reducing the energy consumption ofapplications, while maintaining, or improving,performance levels, digitally controlled magneticbearings can offer an efficient solution.MORE INFORMATION:Enter K325 on the enquiry card, or visit ‘latest issue stories’www.industrialtechnology.co.uk for further details from SKF and morenews on bearings, slides and lubricants32INDUSTRIAL TECHNOLOGY • November 2008

Giving youcomplete controlDelivering advanced product capabilityEndless demands for greater productivitypush high performance bearings to their limit.To support a competitive steel industry, NSKapplies the latest technology to design, tribologyand manufacturing to match its demands.Like improving cage resistance to wear at higherspeeds over longer operating periods, doublinglifetimes and halving maintenance to reducereplacement costs and lower downtime.A world leading manufacturer of ball and rollerbearings, NSK invests over 60 million everyyear to develop unique products and solutionsthat deliver higher performance for ever widerapplications. Our steel industry experienceis unmatched and backed by professional,knowledgeable and service-oriented authoriseddistributors. Giving you the complete controlonly a committed global and local alliancecan achieve.NSK EUROPEMore details: Write in 330 on the free information card 33

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ApplicationDoor closer mechanismfor underground trainSolutionLinear Ball Bearing KSFirst in LineThe world's largest range of linear systems from a single sourceINA linear bearings and guidancesystems from Schaeffler UK offer firstquality products to meet linear guidancerequirements across a comprehensiverange of applications.From simple guidance mechanismsfor low to moderate accuracy to heavyduty systems offering high rigidity andload carrying capacity, the INA range isfirst in line.Taking the quality envelope that bitfurther are X-life premium productsthat feature enhanced characteristicsincluding increased load carryingcapacity, higher rigidity, lower operatingtemperatures and reduced noise levels.So, whether you are designing a new machinetool, packaging machine, medical device,door closing mechanism or anything elsethat involves linear motion, the INA linearproduct range can provide the perfect solution.Schaeffler (UK) LtdTel: 0121 351 3833 Fax: 0121 351 7686E-mail: info.uk@schaeffler.comWeb: www.schaeffler.co.ukWorld Leaders in Rolling Bearings, Plain Bearings, Linear Systems and Engine ComponentsMore details: Write in 370 on the free information card 37

MECHANICAL COMPONENTSBearings, Slides & LubricantsC-Lube Linear Way20,000km or 5 years withoutmaintenance is achievableMaintenance Free & InterchangeableC-Lube Linear WayMaintenance Free C-LubeLinear Roler Way Super MXMAG Maintenance FreeC-Lube Linear Ball SplineINTERCHANGEABLESERIES IS AVAILABLEC-Lube slide units can be suppliedseparately, and can be matched,replaced and added freely to theinterchangeable track rail. Thisseries will be useful in machinedesign, facilitating standardizationof product specifi cation and quickchanges of specifi cation.Nippon Thompson Europe B.V.Sheffi eldstraat 35-393047 AN RotterdamThe NetherlandsTel: +31(0)10 4626868www.ikont.euNippon Thompson Europe B.V.UK Branch2 Vincent AvenvueCrownhill Milton KeynesBucks MK8 0ABUnited KingdomTel: 01908 566144E-mail: sales@ iko.co.ukInnovation Know-how OriginalityInternational standard forlubricants in food processingKlüber says it is readyfor the ISO 21469certification processToday, product safetyrequirements in the food andpharmaceutical industries arehigher than ever before. Thepertinent stringent laws and regulationsapply to all materials and substancesused in the manufacturing processes,for example compressed air, lubricants,disinfectants or mould release agents.As a general rule, manufacturers shouldproactively identify any hazards andprevent errors.A key factor is the consistent use oftested materials as part of an effectiveproduct safety and qualitymanagement. There is therefore atangible demand for an internationalstandard for H1 lubricants to be usedin the food and pharmaceuticalindustries. This is why in 2006, thetechnical ISO committee for lubricantswith incidental product contact issuedthe ISO standard 21469 (ISO EN21469:2006 – Safety of machinery –Bearing doctoris the antidoteto failuresNSK’s ‘New Bearing Doctor’publication is the ideal tool toassist factory managers andmaintenance engineers in identifyingand preventing bearing failures to avoidcostly productiondowntime.The freepublication runs to35 pages and dealswith all aspects ofbearing operationincluding careand handling,mounting,lubrication andmaintenance,types of bearing damage andcountermeasures that can be adopted.MORE INFORMATION:Enter K386 or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for furtherdetails from NSKLubricants with incidental productcontact – Hygiene requirements).While the previous standard EN1672-2:2005 for hygiene requirementsto be met by food-processingmachinery had only stipulated the useof “food-grade” lubricants, the ISOstandard 21469 provides a detaileddefinition of these lubricants, and itsrequirements for product contact applynow also to cosmetic products,pharmaceuticals, tobacco and animalfeed. The ISO standard lays downhygiene requirements regarding theAdjustable clearance, lubricationfreerunning and resistance tocontamination are currenttrends in linear technology. Keeping inline with these, plain bearing expertIgus has developed a DryLin W linearguide with a ‘turn-to-fit’ function formanual setting of the clearance.You decide whether the standardclearance is required or if the unit is tobe pre-tensioned to be free fromclearance. The tolerance of themaintenance-free DryLin W system canbe adjusted over the whole bearingsurface by turning a knurled adjustmentscrew integrated into the side using anAllen key. Adjustment is in smallnotched steps that can be both heardand felt. Then the bearing fits the shaftcorrectly and can be moved linearly. Ifwear occurs, the system can simply bereadjusted.Lee Wilkins, DryLin productmanager at Igus, comments: “The aimwas to give engineers more freedomformulation, manufacture and use oflubricants which might have incidentalcontact with the product. It requiresthe lubricant manufacturers to developa hygiene strategy, taking into accountchemical, physical and biologicalhazards in the intended lubricantapplication. Based on the ISO 21469,the National Sanitation Foundation(NSF) has developed a certificationmethod.The new certification methodoffered by NSF enables lubricantmanufacturers to have themselvescertified according to ISO 21469 by anindependent and recognised institution.Klüber Lubrication has opted to live upto this international standard andentered an intensive dialogue with NSFfor this purpose. “Our goal is to haveone of the most comprehensive H1lubricant portfolios with worldwideavailability certified,” explains DavidLaing, industry group manager atKlüber.MORE INFORMATION:Enter K385 or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for furtherdetails from Klüber LubricationLinear guides featureadjustable clearanceand to improve precisioneven further.”The guide is made up of a housingand a gliding film made of technicaltribo-plastic. As well as the basicstructure and continually testedmaterials, further features include asmall design height, very low frictionand excellent wear resistance. Theguide requires no maintenance, is lowweight and has high resistance to dirtand humidity.MORE INFORMATION:Enter K387 or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for furtherdetails from Igus38More details: Write in 380INDUSTRIAL TECHNOLOGY • November 2008

Combined Bearingsand Profiles• No. 1 in heavy load handling 1kg to 50 TONNE• Extensive bearing & rail options• Corrosion resistant coatings• Ex stock availability• Competitive pricingRust-freeex-stock.Requestcataloguefor further detailsHigh TemperatureCombinedBearingsVULKOLLAN + POLYMIDECombined BearingsSmooth & SilentNEWNEWCombined Bearingsand ProfilesAdjustableCombined BearingsUnit JCCombined Bearingsand Profiles inStainless SteelNEWNEWYou will find the perfect iglidur ® plastic plainbearing that lasts longer and costs less from us.9,600 plain bearings made from special polymers… all lubricant- and maintenance-free.Available immediately ex-stock.HepcoMotion ®Tel: +44 (0)1884 257000 Fax: +44 (0)1884 243500E-mail: sales@hepcomotion.comTiverton Way, Tiverton, Devon EX16 6TGigus ® (UK) Limited51A Caswell RoadBrackmills Ind. EstateNorthampton NN4 7PW/en/Phone 01604-677240Fax 01604-677245sales_uk@igus.co.ukplastics for longer life ®More details: Write in 390 on the free information card More details: Write in 391 on the free information card 39

POWER TRANSMISSIONIn-wheel motorsdrive the futureThe Hi-Pa Drive in-wheel motorcould be the breakthrough thegreen car industry has beenwaiting for, delivering thepromise of electric vehicles. Andas Mark Simms discovers, it’s aBritish invention, no lessThe Government has announced plans to acceleratethe development of the low carbon vehicle marketby committing £100 million of public money toincentivise the automotive industry and consumerdemand. The initial steps include a £10 million scheme toencourage manufacturers to develop electric and ultra lowcarbon vehicles, and a £20 million investment in researchaimed at making green cars more practical and affordable.With electric cars, much of the recent focus has beenon the battery technology, but developments in motortechnology will also provide a key enabler. So thedevelopment by Hampshire-based PML-Flightlink of therevolutionary new Hi-Pa Drive brushless electric motorlooks as though it could provide the vital breakthrough thegreen car industry has been waiting for. Systems integratingHi-Pa Drive motors into each of a car’s four wheels toprovide both power and regenerative braking have alreadybeen successfully trialled, with projects including the VolvoReCharge concept car, the Ford F150 pickup truck, and theexciting Lightning GT electric sports car.The in-wheel design represents the ultimate “hybrid andpure electric” solution, with no compromises, helping carmanufacturers to significantly reduce both fixed andvariable costs by removing parts and complexity from thevehicle design. PML-Flightlink says its Hi-Pa Drivetechnology will help carmanufacturers toprofitablybuild plug-in series hybrid electric vehicles with superiorrange, lower costs and more attractive design. The in-wheelmotor acts as both driver and brake and is several timeslighter, smaller and more powerful than the conventionalelectric propulsion systems and generators it replaces.The PML-Flightlink package includes not just the motor,but also the power electronics, energy management systemand drive software. The embedded control electronicsreliably, efficiently and precisely manage the control of themotors to provide smooth operation at any speed. Theintegrated power management system efficiently distributesdrive power to the motor and then recaptures and feedsmost of that energy back into the battery using thecompany’s unique regenerative system. And the intelligentcontrol software helps engineers optimise energy efficiencyand vehicle performance while giving drivers more controlover the driving experience.Hi-Pa Drive in actionElectric vehicles have maximum available power at thewheels at any speed, unlike a petrol engine wheremaximum power is only obtained high up in the rev range.That ought to make the technology a natural choice for highperformance cars. No surprise, then, at the stunningperformance of the Lightning GT, which claims a 0-60 timeof just 4.0 seconds, with its in-wheel Hi-Pa Drive motorsproducing a power of 700bhp. And with a top speed ofmore than 130mph, the electric Lightning is adifficult proposition to beat. TheLightning40 More details: Write in 400INDUSTRIAL TECHNOLOGY • November 2008

Electric Motors(Top) The Lightning GT puts aHi-Pa Drive motor in eachwheel and accelerates from0-60 rpm in just 4.0 seconds.So forget electric cars thatcompromise the drivingexperience. (Left) The Hi-PaDrive has also become themotor of choice for Volvo, whichhas incorporated thetechnology into its ReChargeconcept car, launched at theFrankfurt Motor show last year.(Above) The Hi-Pa Drive FordF150 proves that a vehicle doesnot have to be small,unprofitable or underpoweredto be green. The truckrepresents an elegant solutionfor automakers and integratorswho want to build a plug-inseries hybrid electric trucksand SUV’s that are popular,powerful and profitable.A further development of theHi-Pa Drive is the Nano Wheel,demonstrated in a powerassisted wheeled suitcase anda new fully powered golf trolley.Because there is not gearbox ordrive shaft, the Nano Wheel iscompact and light, with a highpower to weight ratio.Car Company says the sensation ofharnessing power and performance willbe felt by the sheer exhilaration of thepower pushing you back in your seat asthe car accelerates.The compact, energy-efficient,electric wheel motors produce unrivalledlevels of torque with internal heavy-dutytapered roller bearings that canwithstand heavy radial loads for robustuse. Yet they achieve the power to weight ratio importantfor the performance sports car capability of the Lightning.As a further example of how electric and plug-in serieshybrid electric vehicles can remove oil, carbon and costfrom driving without compromise, PML-Flightlink and DSTIndustries worked with Ford to build the Ford F150prototype vehicle. They chose the F150 because it’s theworld’s best selling pickup, and demonstrated that thevehicle does not have to be small, unprofitable orunderpowered to be green.The truck represents an elegant solution for automakersand integrators who want to build a plug-in series hybridelectric trucks and SUV’s that are popular, powerful andprofitable. Its four Hi-Pa Drive motors deliver more powerand torque than the 320 horsepower 5.4 litre V8 enginethey replaced. And on a full charge, the F150 has aprojected range of 100 miles, with zero emissions.Impressive as all of this is, the Hi-Pa Drive motor is farfrom a one-trick pony. PML’s new Nano Wheel is a simpler,cheaper development of the Hi-Pa Drive technology, whichthe company reckons could revolutionise hub motor designand end-user friendliness across huge swathes of wheeledproducts. A Nano Wheel has its electric motor enclosedwithin its hub and costs just tens of pounds (depending onquantities supplied). So, at little extra cost, PML’s newNano Wheel will transform something you struggle to pushor pull into something that can be power-assisted or fullypowered. Compact, light and simple, the Nano Wheel’shub motor develops between 2 and 10Nm of power.MORE INFORMATION:Enter K405 on the enquiry card, or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for further details from PML Flightlinkand more news on electric motorsNovember 2008 • INDUSTRIAL TECHNOLOGYMore details: Write in 410 on the free information card41

POWER TRANSMISSIONMotorsBrushless DC motors integratespeed control electronicsThis compact, high performance brushless motorfrom Mclennan is ideal for small precision pumps,scanning heads, fans and medical devicesMclennan Servo Supplies hasreleased a new miniaturebrushless DC motor withintegral drive electronics forprecision speed control from AlliedMotion/Premotec. Measuring just 32mmdiameter with a nominal length of 42mm,the compact BL30 EB delivers an outputtorque of 30mNm at 3500 rpm with an11W power output rating.The motor’s outer rotor design ensuresminimal cogging and a high-load bearingsystem and IP54 protection sealingmakes it an ideal choice for applicationswhere compact design, long life and highperformance is essential. The BL30 EBincludes an integrated speed control loopwith a speed-set input to adjust themotor speed from 200 to 5000 rpm.Available in CW and CCW variantswith 12V DC or 24V DC supply, atwo-wire version operates from a simpleDC voltage and the four-wire alternativeincludes an 18 pulse per rev tachometeroutput for speed monitoring.The motor fully complies with EN55014 for EMC and protection isincluded for reverse supply voltage andthermal overload with automatic recovery.The BL30 EB is supplied with a 4mm diameter x 12.5 mm long outputshaft as standard with front- face spigotmounting with M3 fixing holes.Customised versions are available withspecial shaft modifications, alternateflange mounting, custom leads andconnector configurations, as well as rearmounted encoders and gearbox options.As with all motion control componentsand equipment supplied by Mclennan,the BL30 EB is available for evaluationfrom stock to ensure a fast delivery.MORE INFORMATION:Enter K425 on the enquiry card, or visit ‘latest issuestories’ at www.industrialtechnology.co.uk forfurther details from Mclennan Servo SuppliesNew servomotors topthe chartsThe new MCA and MQAseries of asynchronous servomotors from Lenze delivermore power than comparablemotors as a result of a revisedcooling concept. A commonmechanical design with threedifferent forced ventilation optionscan deliver up to 200% morepower at a given inertia. Lenzesays that, combined with otherstate-of-the-art features such asinsulated bearings and electronicnameplates, this makes the MCAand MQA motors an ideal choicefor economy and long life.MCA and MQA motors areavailable with rated torques up to125Nm and a massive reserve forpeak torques up to 500Nm. Thehigh power density is a result ofthe forced ventilation design. AtFewer partsand reducedmaintenanceHelp for manufacturersin addressing ETSAfamily of hollow actuators fromOriental Motor effects fast andhighly accurate positioning ofinertial loads. And, by allowing the directmounting of an index table or arm, theactuators reduce both parts count andmaintenance frequency.Introduced as the DG Series, thesehigh-performance actuators feature alarge diameter hollow section having anoutput table on which a table or arm canbe mounted directly, simplifying wiringand piping. With their use of a 2-phasestep motor and closed loop control, theSeries eliminates the risk of mis-stepsand enables higher speeds for fasterpositioning. Yet the user-friendly featuresof a stepping motor are retained.The highly accurate positioningoffered by the DG Series is a function ofthe actuator’s gear reduction mechanism,which assures a repetitive positionalaccuracy of ±15sec. Available in 16frame sizes from 2.36 to 7.87sq.in, theDG Series is RoHS-compliant, andconforms with UL, CSA and CE safetystandards.Earlier this year the CBI called onEuropean policymakers to take thesteps necessary for business togive its full support to the third phase ofthe Emissions Trading Scheme (ETS).Phase 3 will require EU members tomake tough carbon reductions and kicksin after 2012, so British manufacturersare increasingly seeking energy efficientproducts and systems to help themreduce their carbon footprint.One product that is certainly makingits contribution is the Huco Dynatork airmotor. This is a piston air motor asopposed to a vane air motor and thatdistinction provides important energysaving benefits. In simple terms the vaneair motor comprises a cylinder insidewhich is a rotor with vanes that spinslike a windmill. There clearly needs to bea gap between the edge of the vane andthe casing to allow its free movement.And it’s this aspect that makes the vanemotor very difficult to seal and as aresult it wastes a lot of air.The unique free-floating piston in aDynatork air motor is much easier toseal. It is therefore far more cost efficientas most of the energy stored up in thecompressed air is converted into motion.This motor therefore consumes up to80% less air than a vane motorproviding significant cost savings even atmaximum torque.As result of changing from traditionalvane motors to Huco Dynatork nonlubricatedair motors for paint stirring,one UK automotive plant is saving in theregion of £90,000 per annum in powercosts and plant renewals alone.The customer’s original purchasingcriteria for the motors were greaterreliability on 24/7 operation and freedomfrom lubrication to avoid the possibilityof contamination. However by changingto the Huco Dynatork this manufacturerhas gained considerably more than itsoriginal specification criteria.the lowest levelare IP54 motors with conventionalexternal forced cooling. Achievingan increase of about 10% at theexpense of reduced enclosure toIP23 is done with a radial blowerthat forces air through internalchannels in the motor. A furtherincrease of about 25% is availablethrough a larger blower mountedradially.All three versions deliver highpowers and torques for their size,but the radially blown models areexceptional in combining highpower and high torque with lowinertia. Compared to other motorsof a similar inertia, these motorsare claimed to deliver two to threetimes more power. There is spacesaving too – these motors give 20to 30% more power for a givenvolume. The result is betterdynamics on high speedmachinery from the increasedability to inertia match togetherwith savings in cost and space.MORE INFORMATION:MORE INFORMATION:MORE INFORMATION:Enter K426 on the enquiry card, or visit ‘latest issuestories’ at www.industrialtechnology.co.uk forfurther details from Oriental MotorEnter K424 on the enquiry card, or visit ‘latestissue stories’ at www.industrialtechnology.co.ukfor more info from Huco DynatorkEnter K427 on the enquiry card, or visitwww.industrialtechnology.co.uk forfurther details from Lenze42INDUSTRIAL TECHNOLOGY • November 2008

Rotor UK boosts itsstandard motor rangeRotor UK – previously knownas Exico – reports that it hasbeen steadily growing itsmarket share of non-standard motorsin the UK, and is now looking toreplicate this success with sales ofits own standard motors. Nationalsales manager Lucie Hodkovacomments: “We are a distributor ofSiemens electric motors and this hashistorically been our standardproduct range. We will continue tosell these, but in addition we areintroducing our own Rotor NLstandard motors.”Rotor UK has an immensestocking facility in Wellingborough,which is supplemented by a networkof distributors across the UK, someof whom hold a consignment stockon behalf of the company. “We feelwe are in a really strong position atthe moment,” says Hodkova,“introducing the standard range ofRotor motors, as well as providing aWebstock facility to our customersenabling them to browse through ourstock online at their convenience.”On the company’s non-standardrange, Hodkova comments: “Ourparent company in Hollandpossesses highly technicalmanufacturing and testing facilitieswhich enable us to supply nonstandardmotors on really short leadtimes. Wherever possible we modifystandard ‘off the shelf’ motors, somany non-standard motors areavailable in a matter of days.”MORE INFORMATION:Enter K435 on the enquiry card, or visitwww.industrialtechnology.co.uk for furtherdetails from Rotor UKMore details: Write in 430 on the free information cardOriental Motor’sMultifunctional, easy to usebrushless DC-drive ...... has IP65 protection for boththe motor and the detachableoperation panel.EZSEZS II Series motorized Highprecision Linear slide foradvanced positioning applications.Compact construction, maximumtravel 850mm.CRKStepper motor/driver unit,combining a high performancefive phase stepper motor with alow vibration micro steppingdriver offering Oriental Motorsunique smooth drive function.Oriental Motor (UK) LimitedUnit 5 · Faraday Office Park · Rankine Road · Basingstoke RG24 8AHt: 01256 347090 · f: 01256 347099e: larsen@oriental-motor.co.uk · web: www.oriental-motor.co.ukMore details: Write in 431 on the free information card43

USB-poweredpressure sensor●●●●●●●USB pressure sensorPlugs directly into your PC:No interface box requiredHigh resolution, good accuracyFree PC softwarePush-click connectorField testedAvailable ex-stockGEInspection TechnologiesMeasure materialthickness fromone side onlyPortable thickness gauges from GEbring you compact, accurate,easy-to-use and affordableinstruments for measuringwall thickness of tubes, pipes,vessels, boilers, tanks orcomplex sections. Digital displaygives instant test results in seconds.To discover how we can measure upto your quality control standards,contact us today or visitwww.ge.com/inspectiontechnologiesHamershamTel: +44 77177 90404 Fax: +44 1977 695665www.hamersham.com nick@hamersham.comGE imagination at workGE Inspection Technologies • Coventry CV4 8AF • tel: 0845 6015771More details: Write in 450 on the free information cardMore details: Write in 451 on the free information cardDISPLACEMENT/POSITION • LOAD/FORCE • PRESSURE • VELOCITY• ROTARY & REACTION TORQUE WITH COMPLETE INSTRUMENTATION.Choose RDP products and get the assurance that only more than 40 years of developmentand applications experience can give, backed up by the ISO9001:2000 quality system.Call today for advice and a complete measurement system from transducers to your PC.RDP Electronics LtdGrove Street, Heath TownWolverhampton, WV10 0PYTel: +44(0) 1902 457512Fax: +44(0) 1902 452000Making sensors make sense.www.rdpe.comMore details: Write in 452 on the free information card 45

SENSORS & SYSTEMSNon-Contact Displacement MeasurementSensor technologies comparedMicro-Epsilon (UK) managing director Chris Jones compares the technical pros and cons of fourtypes of non-contact displacement measurement technologiesThe use of non-contact displacement technologiesin the field of precision measurement is rapidlygrowing, pushing the development of newtechnologies, and also the adaptation of already existingtechnologies to meet the new measurementrequirements and to improve measurement accuraciesand resolutions. Against that background, let’s reviewthe strengths and limitations of each non-contactmeasurement principle.on-contact displacement sensors come in a widevariety of shapes, sizes and measurement principles,including eddy current and laser triangulation sensors,capacitive senors and confocal sensors. The key isselecting the most appropriate sensing technologyfor the customer’s application.The eddy current measurement principle(right) is an inductive measuring method basedon the extraction of energy from an oscillatingcircuit. This energy is required for the inductionof eddy currents in electrically conductivematerials. A coil is supplied with analternating current, which causes amagnetic field to form around the coil. If an electricallyconducting object is placed in this magnetic field, eddycurrents are induced, which form an electromagneticfield according to Faraday’s Induction Law. This fieldacts against the field of the coil, which also causes achange in the impedance of the coil. Thecontroller calculates the impedance byconsidering the change in amplitude andphase position of the sensor coil.The advantages of the eddy currentprinciple are that it can be used on allelectrically conductive, ferromagnetic andnon-ferromagnetic metals. The size of thesensor is relatively small compared to othertechnologies and the temperature range is high dueto the resistance measurement of the sensor andcable. The technology is high accuracy and isimmune to dirt, dust, humidity, oil, high pressuresand dielectric materials in the measuring gap.Restrictions of the technology also need to beconsidered. Output and linearity depend on theelectric and magnetic features of the target material.Therefore, individual linearisation and calibration isnecessary. Cable length has a maximum of 15mand the diameter of the sensor (and therefore theeffective measuring diameter) increases as themeasuring range increases.With the capacitive principle (right), sensorand target operate like an ideal parallel platecapacitor. The two plate electrodes areformed by the sensor and the opposingtarget. If an AC current with constantfrequency flows through the sensorcapacitor, the amplitude of the ACvoltage on the sensor is proportional to thedistance between the capacitorelectrodes. An adjustable compensatingvoltage is simultaneously generated inthe amplifier electronics. Afterdemodulation of both AC voltages,the difference is amplified andoutput as an analogue signal.Because the sensor isconstructed like a guard ringcapacitor, almost ideal linearity and sensitivity tometals is achieved. The technology also offers hightemperature stability, as changes in the conductivity ofthe target have no effect on the measurement.Capacitive sensors can also measureinsulators. However, thetechnology is sensitive tochanges in the dielectric sensor gapand so is therefore ideal for clean, dryapplications. Cable length is alsorelatively short due to the effect of thecable capacitance on the oscillatingcircuit tuning.In the laser triangulation principle(left) a laser diode projects a visible point of lightonto the surface of the object being measured. Theback scattered light reflected from this point is thenprojected onto a CCD array by a high quality opticallens system. If the target changes position with respectto the sensor, the movement of the reflected light isprojected on the CCD array and analysed to output theexact position of the target. The measurements areprocessed digitally in theintegral controller and thenconverted into a scaledoutput via analogue (I/U) anddigital interface RS232,RS422 or USB.With the confocalprinciple (below left), thetechnology works byfocussing polychromaticwhite lightonto the targetsurface using amulti-lens opticalsystem. The lenses are arranged in such a way thatthe white light is dispersed into a monochromaticlight by controlled chromatic deviation. A certaindeviation is assigned to each wavelength by afactory calibration. Only the wavelength that isexactly focussed on the target surface or materialis used for the measurement. This light reflectedfrom the target surface is then passed via aconfocal aperture to the receiver, which detectsand processes the spectral changes. This uniquemeasuring principle enables displacements anddistances to be measured very precisely.Both diffuse and spectral surfaces can bemeasured and with transparent materials suchas glass, a one-sided thicknessmeasurement can be accomplishedalong with the distance measurement.Confocal technology offers nanometre resolution andoperates virtually independent of the target material. Avery small, constant spot is achieved and the technologyoffers one-sided thickness measurement of transparentmaterials. Miniature radial and axial versions of thetechnology are available for measuring drilled or boredholes. White light is used instead of a laser. Restrictionsof the technology include the limited distance betweenthe sensor and target. In addition, the beam requiresa clean environment.MORE INFORMATION:Enter K465 on the enquiry card, or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for further details fromMicro-Epsilon and more news on sensors and systems46More details: Write in 460 on the free information card

LOAD CELLSfor INDUSTRYAll configurations:- Shear beam, ‘S’,Washer, Button, Column,Pancake – Oem & bespoke cellsGEInspection TechnologiesNow you can see right insideenclosed spacesYou can pass a probe through the narrowestof apertures to capture real-time views andimages from inside voids such as tubes, pipes,machines, engines and enclosed structures.GE offers you a comprehensive choice ofremote viewing equipment, from basicborescopes and fiberscopes tomeasurement-capable digital videoborescopes, and pan-tilt-zoom (PTZ)camera systems.To discover how we canmeasure up to your qualitycontrol standardscontact us today or visitwww.ge.com/inspectiontechnologiesSENSORS UK LTD135a Hatfield Road, St. Albans, AL1 4LZTel 01727 859373 Fax 01727 844272www.sensorsuk.com LOA1More details: Write in 470 on the free information cardGE imagination at workGE Inspection Technologies • Burford OX18 4DW • tel: 01993 822613More details: Write in 471 on the free information cardMore details: Write in 472 on the free information card 47

SENSORS & SYSTEMSIndustrial EthernetSimple solution forvibration proofingAn innovative bracket is providing a low cost solution to secureconnections for copper, fibre and power cable on Ethernet switchesGarrettCom Europe has introduced an innovative,low cost, retrofittable solution for its 6KQ rangeof Ethernet switches to eliminate the possibilityof cables coming loose in high vibrationenvironments. The answer is a slotted bracket which issimply attached to the 6KQ via one of its existing screwmounting points, allowing all cables to be held securely inplace with standard cable ties.There are a plethora of secure connectors available forswitch manufacturers to use, but that meanscompatibility between various types can be a major issue.Proving the old adage that the simple solutions are oftenthe best, the GarrettCom solution of a bracket providesall the connection assurance that you might get by movingto secure connectors, but without the added cost or therequirement for much bulkier products. The bracket alsosignificantly improves on conventional secure connectorsolutions, which are only suitable for replacing the RJ45copper connectors, and do nothing to secure either fibreoptic connectors or power connectors.Industries such as the rail sector have to deal withvibration as a fact of life, and GarrettCom reports that keyusers in this sector have already welcomed the newbracket. It will also provide an ideal solution in a myriadof other transportation sectors, and on machinery and inplants where vibration is a recognised issue, or indeed toprovide added security in fixed panels that have to betransported to their end location, where the assurance ofsecure connections will help to speed commissioning.Simple solutionGarrettCom Europe business development manager DavidMoss comments: “Vibration is a very real problem acrossa whole spectrum of industries, but how to tackle iteffectively has always been something of a conundrumwhen it comes to Ethernet connectivity. We consideredoffering a secure connector option to replace the standardRJ45 connectors for the copper cable ports, but theseconnectors are so much bulkier that it would beimpossible to offer the same port densities on our existingform factors. Either the products would have to be muchbigger, or we’d have to compromise on capability. Offeringsecure connectors would also add a significant cost to theproducts and does nothing to secure the fibre connectorsor the power connectors. But our bracket option is asimpler, more cost-effective, and ultimately moresatisfactory solution.”The 6KQ is a rugged managed field switch that can beconfigured with up to twelve 100Mb fibre ports. Highlycompact, the 6KQ has been developed to meet userrequirements for small form factor Gigabit Ethernetswitches in demanding industrial applications. It is sealedto IP53 for dust and water resistance, and features aunique case design for maximum heat dissipation. The6KQ draws upon the 6K family’s modular architecture toprovide the greatest configuration flexibility in itsclass.MORE INFORMATION:Enter K485 on the enquiry card, or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for further details fromGarrettCom Europe and more news on industrial Ethernet productsDistributed control and monitoringManaged Ethernet I/O modules offer complete connectivityKorenix UK has launched a new range of DIN railmountedmanaged Ethernet I/O modules fordistributive monitoring and control. The newmodules have a built-in OPC server and supportModbus/TCP protocol, which is commonly used in mostindustrial environments.The Korenix Jet I/O 6500 Series is equipped with oneRJ45 Ethernet port and multiple analogue and digital I/Ochannels, as well as temperature measurement(thermocouple, RTD) connectors. Users can thereforecollect I/O data, configure rules for pre-defined alarms,automatically activate events (by SNMP trap) and changethe status of devices through their Ethernetnetwork.The built-in OPCserver and Windowsbasedmanagementutilities mean that userscan easily monitor andcontrol I/O devices andintegrate easily withSCADA and HMIsoftware applications.Modbus/TCP usesencoded binary dataand TCP/IP’s errordetection mechanismto enable temperature and humidity measurement, thencommunicating the result between the connected devices.Supported network protocols include IP, TCP, UDP, SNMP,HTTP, Telnet, BOOTP and DHCP.Andy Cross, business development manager atKorenix UK comments: “The 6500 Series boasts anunrivalled combination of industrial open standardstechnology and therefore enables users to easilycommunicate with their existing industrial SCADA andHMI systems. With all Korenix products, users alsobenefit from a clear cost advantage and technicalexcellence.” The Jet I/O 6500 Series incorporates a 16-bit, 100MHz, RISC-based processor, built-in watchdogtimer and real time clock. The modules have analuminium housing and are protected to IP31. Moduledimensions are 120mm (H) by 55mm (W) by 75mm (D)and the units operate in temperatures from –20°C upto +70°C.MORE INFORMATION:Enter K486 on the enquiry card, or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for further details fromKorenix and more news on industrial Ethernet products48INDUSTRIAL TECHNOLOGY • November 2008

More details: Write in 490 on the free information cardMore details: Write in 491 on the free information cardMore details: Write in 492 on the free information card 49

SENSORS & SYSTEMSNew ProductsMixed signal oscilloscope familysets a new standardOffering an exceptional price/performancespecification, the DLM2000 series combineshigh end features with a compact form factorThe new Yokogawa DLM2000Series is a new family of mixedsignaloscilloscopes (MSOs) thatthe company says represent amajor step forward in terms of price,performance and ease of use.With up to 500MHz bandwidth and2GS/s sampling speed, the newoscilloscopes are said to have the longestmemory (up to 125M points) and fastestupdate rate (up to 450,000 waveformsper second) in this class of instrument. Inaddition, the combination of flexibleanalogue and digital inputs, plus a largescreendisplay in a compactergonomically styled body, makes theinstruments exceptionally easy to use. Inaddition to the key performancespecifications, the DLM2000 Seriesfeatures a number of advancedmeasurement and analysis features,including histogram and trendingfunctions, up to 20,000 historymemories, digital filtering, zoomwindows, user-defined mathematics andserial bus analysis.“Mixed-signal oscilloscopes representthe fastest-growing sector of theoscilloscope market, and this new rangebrings advanced MSO performance intothe same affordable price bracket asportable general-purpose oscilloscopes,”comments Yokogawa’s Terry Marrinan.“We believe that the DLM2000’scombination of high performance, userfriendlyfeatures and affordability willmake it a real winner.” Prices for theDLM2000 Series start at €3300.MORE INFORMATION:Enter K505 on the enquiry card, or visit ‘latest issuestories’ at www.industrialtechnology.co.uk forfurther details from YokogawaUSB outputfor torquesensorNew from Futek is theTFF400 reaction torquesensor with a brand newUSB Digital Interface with 16 bitsresolution. This USB sensorsolution provides an easy plug andplay with basic software makingsystem integration even simpler.The TFF400 features a flangeto flange mounting solution withtorque measurements rangingfrom ±0.04-60Nm. It utilisesmetal foil strain gauge technologyand features an overloadprotection for the low capacityunits to help prevent overloaddamage that may occur duringinstallation.Accurateaccelerometerfor ultra low gSherborne Sensors has launched itsA320 range of robustaccelerometers for use in highlyaccurate measurement of low-gacceleration. The fully self-containedlinear acceleration sensors can measurefrom an ultra low, industry leading±0.1g up to ±2g. The sensors simplyconnect to a DC power source and areadout or control device for a completeoperating system.Closed loop, servo balance technologyconfers these sensors with extremely highprecision for measurements in low-gapplications. Despite their low measuringrange, the A320 series is very robust andcan withstand shocks of 1500g andvibrations of 35g rms and operate intemperatures ranging from –18 to 70°C.The new sensors are ideally suited togeo-physical and civil engineering studiesand the predicative monitoring of largestructures – something that is becomingincreasingly important in many parts ofthe world. They are also suitable for arange of other applications in sectorsincluding transport, industrial, militaryand aerospace.MORE INFORMATION:Enter K506 on the enquiry card, or visit ‘latest issuestories’ at www.industrialtechnology.co.uk forfurther details from Sherborne SensorsContrast sensor iscompact and robustFor contrast sensors used in thelikes of the packaging, assembly,handling and printing industries todistinguish colours, labels or printedmarks, a colour-neutral vision of theobject is essential. The FT 20 WTcontrast sensor from Sensopart thereforefunctions with white light, which enablesthe detection of many more colourdifferences in comparison to a singlecolouredLED light source. It also has ahigh resolution of 30 contrast levels. Theresult is an unusually high sensitivity: thesensor switches quickly and reliably evenat the slightest difference in contrast andthis over the entire colour spectrum.The scanning range of the FT 20 WTis 17mm, with a depth of focustolerance of ±2mm. The sharp,rectangular light spot of 1.5x4mm 2 alsoenables the detection of small objects.With its maximum pulse frequency of5kHz, the sensor is also suitable for fastapplications: for example, reliabledetection of printed marks is guaranteedwith a belt speed of up to 900m/min.Sensopart has succeeded in fitting allthese performance characteristics into avery compact (32x20x12mm 3 ), robustplastic casing. The company says thatmakes the FT 20 WT the smallestcontrast sensor on the market, withsome competitive products withcomparable characteristics being overthree times its size.Another key feature of the FT 20 WTis its ease of use. Instead of timeconsumingfiddling with potentiometers,which is often the case in this sensorclass, the FT 20 WT offers three userfriendlyteach-in modes. Fine adjustmentof contrast in particular – virtuallyimpossible with a potentiometer – is nolonger a problem. As well as theconventional static teach-in mode,Sensopart also offers dynamic teach-in inwhich objects can be virtually taught ona ‘running conveyor belt’, and externalteach-in, which is particularly helpfulwith sensors that are difficult to access.MORE INFORMATION:Enter K504 on the enquiry card, or visit ‘latestissue stories’ at www.industrialtechnology.co.ukfor more info from SensopartMORE INFORMATION:Enter K508 on the enquiry card, or visitwww.industrialtechnology.co.uk forfurther details from FutekHall-effectfoot pedalcontrollerFeteris Components has anew generation foot pedalcontroller, the H80FCL, thatcan be used for speed control andrudder control on vehicles, limitrobots, medical devices,construction machinery, and otherequipment.It employs a Hall Effectcontactless position transducer todetect foot pedal motion. Thistechnology comes with a muchlower price tag than conventionalpotentiometric footpedals, and asit is non-contact has a life of over2 million cycles.MORE INFORMATION:Enter K507 on the enquiry card, or visitwww.industrialtechnology.co.uk forfurther details from Feteris Components50INDUSTRIAL TECHNOLOGY • November 2008

More details: Write in 510 on the free information cardMore details: Write in 511 on the free information cardGet your FREE GUIDEto sensing technologyAn excellent introduction to pressure, load, forceand rotary measurement, this 16-page guide alsohighlights the wide productrange and the capabilities,skills and expertiseof Sensor-Technik.I’m Morten Moller, managing directorof Sensor-Technik UK, with over 25years of industry expertise behind me.When you deal with Sensor-Technik UK,all the advice and support I can giveyou comes as part ofthe package.SENSOR-TECHNIK UKUnit 10, The GranaryMill Road, SharnbrookBeds MK44 1NNTel: 01234 782049info@sensor-technik.co.ukwww.sensor-technik.comThe CANbus, pressure, force & rotary measurement specialistMore details: Write in 512 on the free information card More details: Write in 513 on the free information card 51

THE ENGINEER’S CHOICEMACHINE BUILDING & AUTOMATION Powerlock fastener means NO machining Fastest assembly and ease of adjustment T-slot for standard M8 nuts Cutting service available, 1-2 days Full range of Machine Guards,Workstations, Conveyorsand Customised Enclosures...save time!ConstructiveclimateprotectionMayr Transmissions reckons that thedevelopment of performance-optimisedshaft couplings could play a key role inhelping to reduce energy consumptionNEWNow available in stainless steel.T: 01256 365605E: info@minitec.co.ukwww.minitec.co.ukMachines and systemsshould use as littleenergy as possible sothat CO2 emissions canbe reduced as much as possible. Thisdemand is firmly anchored in the EuP(energy using products) directive. Allcomponents in a system should bedesigned and dimensioned so thatthey contribute towards this targetedgoal. Shaft couplings are purelymechanical parts and therefore don’tbelong in this category, as theythemselves use no energy.However, they certainly influencethe energy balance of the machine.Compact, high performance densitycouplings such as the backlash-freeROBA-DS all-steel coupling have avery low mass moment of inertia withreference to the transmittable torque.In this way, they make a small anddirect contribution towards reducingthe drive power required.The unique construction of theROBA-DS ensures further potential forreductions. During development,Mayr’s engineers succeeded increating the performance density towell above that of many conventionalall-steel couplings. This means thathigher torques can be transmittedwithin a smaller construction space.In turn, smaller construction spacemeans less material consumptionwhen manufacturing the coupling.The savings on material areconsiderable and total 40-70%depending on the coupling size anddesign. If the performance-optimisedand multi-patented ROBA-DS diskpack couplings were to be usedconsistently on all relevantapplications, approximately 600tonnes of steel per year could besaved.Energy savingsIn its ‘Sustainability Report 2004-2005’, Thyssen Krupp stated thespecific consumption of energy forsteel production in its Duisburg plantas being 18.5GJ per tonne of crudesteel. So the economisation of 600tonnes of steel equates to a11,100GJ energy saving. An energyoptimised single-family homewith controlled ventilationhas a yearly energyrequirement of around30kWh per squaremetre of living space.We can see that atypical 100 squaremetre sized houseuses 10.8GJ ofheating energy peryear. So the energyrequired to produce600 tonnes of steelwould be sufficient tosupply over 1000 houses.52 More details: Write in 520 on the free information cardINDUSTRIAL TECHNOLOGY • November 2008

Shaft CouplingsNEWservo drive from ABB...0.75kWto110kWFILM & FOIL CONVERTINGFILM &FOIL CONVERTINGThe savings of 11,100GJ per yearusing the performance-optimisedROBA-DS pack couplings also, ofcourse, reduce CO2 emissions in linewith EuP demands. One litre of fueloil delivers 10kWh or 36MJ of energyon combustion. In theory, in order togain 600 tonnes of steel, 308,333litres of fuel oil must be used. As 3kgof CO2 is produced during combustionof 1 litre of oil, CO2 emissions total925 tonnes for the calculated fuel oilamount. All of these savings aresummarised in the diagram opposite.The ROBA-DS backlash-freecouplings are torsionally rigid butbendable and can compensate foraxial, angular and radial shaftmisalignments. At present, ROBA-DScouplings are offered for nominaltorques of up to 24,000Nm. Diskpack couplings are robust andreliable. They are ideal forapplications in extreme environments,having a resistance to temperatureand a performance density that ishard to match. With correctdimensioning and handling, theypossess almost unlimited lifetime.Selection considerationsDisk pack couplings are wear- andmaintenance-free and can transmittorques with very high torsionalrigidity. Many disk pack couplingswhich are available on the markettransmit the nominal torque definedin the catalogue only partially (50-80%) via frictional locking. Theremainder is transmitted via positivelocking using fitting bolts. Due toloads above the backlash-freefrictional locking torque, tinydisplacements occur in the area of thedisk pack connection.Various disadvantages result fromthis occurrence. Depending on theamount of load and the direction ofthe load, the individual componentschange position. This leads to anunstable balance condition on thecoupling. This constant relativemovement in the area of the disk packscrew connection means that thescrew pre-tension force drops. Thebending components to be absorbedby the screw begin to increase. Thisleads to screw breakage due toexcessive operating forces.In order to avoid thesedisadvantages, such couplings arelimited by the manufacturers withreference to alternating torques or tothe application of service factors. Allin all, a coupling often has to beselected which is one or even twoconstructional sizes up, even throughthe catalogue values seem high.With the ROBA-DS, Mayr has takena different approach. In order tocombine high performance density withabsolute anti-backlash function, thedisks in the area of the clamping partare treated in a special blastingprocedure. Specially-formed collarbushings are used for further backlashfreetorque transmission from the diskpack onto the hubs or onto theintermediate part. These collar bushingsguarantee completely backlash-freeconnection to the hubs via the availablescrew pre-tension forces.In this way, a backlash-free flow offorce with excellent force flow densitycan be produced between the inputand output of a shaft coupling. Forthis, comparatively small screws canbe applied and limitation of themisalignment compensation capabilityto short free bending lengths canbe avoided. The nominal torquesdefined in the catalogue can beused without any limitations.MORE INFORMATION:Enter K525 or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for furtherdetails from Mayr TransmissionsFOOD & BEVERAGEFOOD & BEVERAGE...brought to you byMotion Control Products Ltd11-15 Francis AvenueBournemouthDorset, UKBH11 8NXTel: +44(0)1202 599 922PICK & PLACEPICK & PLACEABB’s new ACSM1 provides highperformance speed, torque and motioncontrol for demanding applications. Theservo performance can control induction,synchronous and asynchronous servoand high torque motors with variousfeedback devices.To discover more about this world beatingproduct visit:www.motioncontrolproducts.co.uk andDOWNLOAD the new brochure TODAYPRINTINGPRINTINGMATERIAL HANDLINGMATERIAL HANDLINGNovember 2008 • INDUSTRIAL TECHNOLOGYMore details: Write in 530 on the free information card53

MACHINE BUILDING & AUTOMATIONGantry SystemsUltrasound test tanks getmodular treatmentLG Motion has worked closely with ultrasound test systemsmanufacturer Precision Acoustics, with the flexibility to supplycustomised positioning systems rapidly and competitivelyDorchester based Precision Acoustics is a worldleading consultancy for acoustic measurementand a designer and manufacturer oftransducers, hydrophones, acoustic materialsand measurement equipment for ultrasound applicationsin healthcare and non destructive testing. Also, as amajor player in ultrasound research, the company hasclose working relationships with the global acousticsmeasurement systems community through leadingequipment manufacturers and academic establishmentsincluding the acoustics group at the National PhysicalLaboratory.As part of its ultrasound quality assurance service,Precision Acoustics has developed and manufactures theUSM2 range of automated test tank scanning systemsused for the verification and standards calibration ofultrasound components. With LabView based softwareand all instrumentation included, these systems providecomplete solutions for the repetitive tasks of dataacquisition, information display, storage and thecomputation necessary for the measurement andmapping of acoustic fields.LG Motion has been a major supplier to PrecisionAcoustics over several years, providing motion controls,gantry positioning stages and test tank support frames asan integral part of these scanning systems that are usedthroughout the acoustics measurement industry – by theOEMs producing medical and NDT ultrasoundmeasurement systems as well as their users in hospitals,university research establishments and industrial testfacilities.As each UMS2 test tank system is customised to suitits end-users’ requirements and the resulting positioningdimensions can vary, each system is effectively a specialfor LG Motion. To maintain the keen delivery times andcompetitive pricing that Precision Acoustics insists uponfor each order, it was important from the outset to selectmodular and adaptable positioning stages, motioncontrols and support frame components that would suitthese changing needs.A typical specification for a test tank positioningsystem is a three axis XYZ gantry with a usable scanningarea of up to 1000x1000x700mm requiring a positionalaccuracy to better than 0.05mm per axis over length oftravel and a positioning resolution to better than0.002mm. One of the most important requirements isfor the scanner’s positional repeatability to be betterthan 0.005mm to guarantee that the ultrasoundmeasurements are well within the bounds of theinternational standards used for transducer andhydrophone calibration. This is specified as aunidirectional value as the software takes care of systembacklash by always positioning each axis from the samedirection for critical measurements.Typical working load is less than 15kg and the speedis up to 20mm per second maximum. Each axis requiresovertravel safety and home position limit switches andthe Precision Acoustics software outputs a combinationof PC serial port commands as well calling preprogrammedmotion sequences stored in the motioncontrollers memory.Both the modularity and specification requirementsfor the mechanical positioning system are completelyfulfilled with LG Motion’s BiSlide range. Based on anextruded I-beam aluminium profile with dual 45 degreeopposing ‘V’ ways for maximum rigidity in all loaddirections, the fully modular range includes low frictionbonded PTFE compound bearing pads on the movingcarriage with fully adjustable pre-load offering long lifeand minimal maintenance.The range is supplied with 1.0mm or 2.0mm pitchleadscrews with an externally adjustable preload. Thedurable range is available in a wide choice of travellengths from 125mm to 2m with a compact crosssectionalprofile of less than 90mm wide and 40mm inheight. Multi-axis orientation is straightforward withintegrated ‘T’ slots providing endless configurationpossibilities with stage to stage and stage to supportframe interfacing using simple cleats and bolts ratherthan adapter plates – saving cost and further simplifyingpositioning system design.The Precision Acoustics gantry is configured withdual, parallel X axes with one side motor driven and theother side supported by a simple linear bearing. The Yand Z axes are single BiSlide units. To achieve theresolution, each axis is driven by a NEMA 23 frame hightorque microstepping motor set at 1000 steps/rev with a2mm pitch precision leadscrew. To meet the accuracyand repeatabilityspecifications, amotor mounted rotary opticalencoder provides positionverification via a ParkerVIX500IM microstepping drivecomparing theoretical and actual positions and ifrequired, making corrections at the end of each move.As the test tank is normally water filled, leadscrewsand bearings are protected with covers which are astandard BiSlide option and each motor/encoder ishoused in an enclosure with an IP65 rated connectorfitted. Provision is also made to manually position axeswith handwheels assembled on rear shaft extension oneach motor. The complete positioning system is suppliedfully assembled, wired and tested and includes a ‘cabletray’ cable management system. Control of each axis ismade easy with the VIX500IM microstepper driverindexer which is integrated into the overall software byPrecision Acoustics. Independent high level commandsfor point to point moves via a serial link from a PC aremixed with pre-programmed motion sequences andsynchronised I/O routines that are be stored in thecontroller's memory to speed and simplify programming.The full modularity of each scanning system is madepossible with support frames built with machine framingcomponents from MiniTec UK which has a very strongalliance with LG Motion. The MiniTec Profile Systemrange of aluminium profiles and machine buildingcomponents also includes the time saving Powerlockfastening method that allows rapid assembly with nopre-machining or pre drilling. The extruded profile issimply cut to size and assembled using a simple M8Allen key, making re-use and system adaptation apossibility if Precision Acoustics’ customer needs tomodify its machine in the future.MORE INFORMATION:Enter K545 on the enquiry card, or visit ‘latest issue stories’www.industrialtechnology.co.uk for further details from LG Motionand more news on machine building and automation54INDUSTRIAL TECHNOLOGY • November 2008

More details: Write in 550 on the free information cardAEROTECHPreconfigured andEngineered Motion SystemsAerotechis a world leaderin innovative precisionmotion control systems for allareas of industry and research.Our product lines include patented and award winning direct-drive linear and rotarynano-positioners; airbearings; linear motor gantry systems, linear motor stages and systems, multi-axismotion controllers and drives. Aerotech also specialises in clean room and vacuum systems. Our ability tocustomise automation solutions specifically designed for our customer's applications is unmatched.Aerotech Ltd - Jupiter House - Calleva Park - Aldermaston - Berkshire RG7 8NN - UKTel: +44 (0)118 940 9400 - Fax: +44 (0)118 940 9401- Email: sales@aerotech.co.ukDedicated to the Science of Motionwww.AEROTECH.co.ukMore details: Write in 551 on the free information card 55

MACHINE BUILDING & AUTOMATIONDC DrivesBreathing new lifeinto the DC marketMany commentators over the years have predicted the deathof DC drives, and certainly the market for these products isonly a tiny fraction of the AC market. But Control Techniqueshas invested 20 man years in the development of a brand newDC product. Mark Simms was at the launch to find out whyThere’s no point arguing against the fact that theDC drive market is a shadow of its former self. Allbut obliterated in the move to AC, sales of DCdrives represent just 4.8 of the global market.Many pundits believe the kindest thing would be to justlet the market quietly die. But are they right? Well, almostcertainly not, and if you’re a DC drive user then you’llalmost certainly welcome the latest innovation fromControl Techniques.Of course, the company has DC in its DNA, virtuallydefining the market for the technology in 1973 with itsoriginal KTK range, and producing the world’s first digitalDC drive in 1984. But does it really see enough marketpotential to justify 20 man years of development in a newproduct? Phil Sewell, Control Techniques executive VP forsales and marketing certainly thinks so, quoting a recentreport from IMS Research which highlighted how the ideathat DC drives are being replaced by AC drives is startingto give way to the notion that these devices are not goingaway, but rather represent a totally different market withanother set of dynamics.Certainly anyone using high power DC drives inindustries such as metals processing, printing, materialshandling, mining, cranes and a host of others will knowthat matching the capabilities of DC with an ACalternative is a challenge. But what Control Techniqueshas done with its new DC offering is to look at the realbusiness issues facing its customers, and how best toaddress those.Motivations to upgradeIn any industry there will always be strong motivations toupgrade equipment if a case can be made for improvingplant throughput and product quality, for reducing wasteand operating costs, and for facilitating equipmentintegration into information networks. But these have tobe balanced against return on investment, the downtimeof the plant during any upgrade, the implications ofhaving to retrain personnel, and of course spaceconstraints. And what Control Techniques has found isthat, time and again, where there is an installed DCsystem, upgrading it with a new DC drive system meansa lower overall cost and risk.At high powers, the drive itself will almost always becheaper than an AC equivalent, and in some cases so willthe motor. But if you already have an installed DC system,there is no need to replace the motor or any othercomponents in the power train: the cost of switching toAC power by contrast means throwing away all thatexisting investment. Further, DC control conceptsand simple and well understood, so the implicationsfor retraining are minimised. And finally, the size of ahigh power DC drive is significantly smaller than anAC equivalent, delivering big savings on panel realestate. We can see, then, that DC drive systems are hereto stay for the foreseeable future, with opportunities forplant upgrades in many industries and in all regions of theworld representing a significant market. The focus fordevelopment for Control Techniques, therefore, has beento bring the many benefits of AC drive technology to theDC market, not least the modern AC drive’s networkingcapability. Enter, then, the Mentor MP, which ControlTechniques says sets a new world standard for excellencein DC motor control.Integration flexibilityMentor MP is designed with both today’s and futurerequirements in mind, its full system integration flexibilityoffering three option module slots and an inbuilt fieldcontroller. These economically priced option modules arecommon across Control Techniques’ AC, DC and Servodrive ranges and include functionality extensions such asadditional feedback options and expanded I/O and apowerful onboard programmable control. The range ofoptional fieldbus connectivity is unique, includingProfibus-DP, Interbus-S, DeviceNet, CANopen and variousEthernet protocols such as Modbus TCP/IP, Ethernet/IPand EtherCAT. Communications gateway solutions canalso be implemented easily and economically within thedrive by installing two or three fieldbus option modules.The number of option modules will increase as ControlTechniques develops new solutions for their completerange of drives.The company says that the Mentor MP’s standardinbuilt, field controller is all most users will ever need butan all new external field controller option, the FXMP25,provides field forcing for high dynamic applications; suchas very fast reversing while a new feature allows reversejogging control with two-quadrant drives for lower-costsystems that do not require fast reversal. In addition,Mentor MP has a field controller mode that allows itself toact as a field control for larger DC motors, where the fieldcurrent can be greater than the capacity of the FXMP25.Mentor MP uses Control Technique’s suite of well-triedand tested software tools, developed to support theprogramming and drive configuration of its AC driveranges. For example CT Soft, used for drive configuration,includes a configuration wizard allowing existing Mentorusers to transfer drive settings from an existing Mentor IIdrive to the new Mentor MP. Existing Mentor II users willalso appreciate the design results that make Mentor MP asimple retrofit, with the same mechanical footprint, mainfixing centres and with power connections located in thesame place as Mentor II.For high performance, cost effective automationsolutions, Mentor MP offers the capability to link multipleAC, DC and Servo drives together with extensive I/O,controlling PCs and operator interfaces by using CTNet tocreate a truly distributed control system. Each drive canhouse a programmable option module called SMApplications which is programmed using SyPTPro, anIEC61131-3 style programming tool with function block,ladder logic, and structured text language capability. Thison-board configuration can often eliminate a stand alonecontroller and so reduce system cost. Further optionmodules can be used to connect with I/O, fieldbus orEthernet protocols for control and monitoring.Natural choiceProduct manager Richard Smith comments: “Mentor MPis the most advanced DC drive on the market, and has theadvantage of using the same control platform as ourintelligent AC drive, Unidrive SP. With such a wide rangeof communications, intelligence and feedback optionsavailable, it is the natural choice for any user or OEM whowants an economic, easy-approach solution either toupgrading an existing DC installation or specifying a newone – providing significantly enhanced performanceand reliability.”MORE INFORMATION:Enter K565 on the enquiry card, or visit ‘latest issue stories’www.industrialtechnology.co.uk for further details from ControlTechniques and more news on drives56INDUSTRIAL TECHNOLOGY • November 2008

Elcomflat belt conveyorsThe Elcom range of flat belt conveyors complete with motorsare available in widths from 20mm up to 1000mm, and witha useful range of belt speeds.Designed around the Item MBprofile system, they guaranteewide compatibility with otherequipment, and have the levelof finish you would expect ofItem itself. With several yearsof proven use in the field,they are the natural choiceeither for incorporating intoother machines or as standalone units.Get your free copyof the Elcom flatbelt conveyorscatalogue todayMachine Building SystemsHeage Road Industrial Estate,Ripley, Derbyshire DE5 3GHTel: 01773 749330 • Fax: 01773 749560www.mbsitem.co.ukConveyors also available from MBS in Athlone, IrelandMore details: Write in 570 on the free information cardMore details: Write in 571 on the free information card6-7, Faraday Road | AylesburyBuckinghamshire HP19 8TXTel 01296 398865 | Fax 01296 398866e-Mail: rkgb@phoenix-mecano.co.ukwww.rk-online.co.ukMore details: Write in 572 on the free information card57

MACHINE BUILDING & AUTOMATIONThe key to safety at workBecause you can never get away from the ‘human’ factor, Nick O’Hara of CNES tells Mark Simmsthat risk perception and behaviour management are the real keys to increased safety at workJust outside Scunthorpe there’s a stretch of the A15where, up to the end of August, 58 people had beenkilled – a rate of between two and three people perweek. It may only be a single lane carriageway, butit’s a long straight section of road with clear visibility ofoncoming traffic, and these day’s we’re all well aware ofour reaction times and stopping distances. So why arethere so many casualties?Imagine that you’re driving along that stretch, and youcome up behind a lorry doing a steady 60mph. You lookdown the road at the scene ahead, and you see an oncomingcar in the far distance, but there’s plenty of time to get aroundthe lorry. So you shift down a gear, put your foot to the floorand pull out. Only when you get towards the front of the lorrydo you realise that it’s not a single vehicle after all, but awhole line of lorries nose to tail, all doing a steady 60mph.And the oncoming car is now somewhat closer. You mightstill make it, so do you go for it, or slow down and pull backin? The number of deaths this year on that stretch ofroad seems to suggest that at such times,rational thought goes out the window.Without wanting to pin this on thetruckers, if the lorry drivers knewthat, by driving nose to tail withother trucks, theywere presenting a tangible hazard, would they change theirbehaviour? But moving our hypothetical examination of driverbehaviour on, imagine that you’re back driving the samestretch of the A15, but now lorries, buses and other vehiclesdifficult to see around have been banned. Instead, there is a50mph speed limit. If you knew for certain that there werenever any police patrols and no speed cameras, would youstick to 50, or would you succumb to the driving thrills of along, straight road? I suspect that what we’d all do is drive asclose to the limits as our own abilities allowed.Seeing real consequencesBut install a single speed camera, and we all slow down,because now we know for sure that there is an immediateconsequence to our actions: a £60 fine and three points onour licences. Suppose, though, we knew for sure that,although there was a camera, it only ever had enough film tocapture one speeding car in every 1000. Would we still slowdown to 50?I think we would – hitting our wallets and our licences issomething we all take very seriously. But how is it that wedon’t treat the really dangerous risks – the hazards that couldkills us – with the same respect? In the workplace, accordingto an HSE analysis, 95% of all accidents are triggered by theunsafe acts of personnel. So why do we see the sameaccidents happening time and again, and indeedwhy do we have these unsafe acts in the first place? In short,why does complacency seem to be so evident everywhere?Nick O’Hara, business development engineer for professionalengineering training at CNES reckons that the key problemsare the perception of risk, and the ineffective management ofbehaviour once risks have been identified. “According to theHSE, a ‘suitable and sufficient risk assessment will reflectwhat is reasonably practical to expect employees to knowabout the hazards in their workplace’. But any riskassessment is therefore subject to the ‘perception of risk’ ofthe individuals undertaking the assessment. The presentedinformation is the same for everyone, but an individual’sperception differs to a surprising degree. With thesedifferences in perception, it can be very difficult to have aconsistent approach to the risks the workforce are presentedwith and therefore to the controls to reduce these risks to anacceptable level.”Psychology of perceptionPerception of risk is a big issue, with perception being thepsychological function that enables individuals to receive andprocess information about the environment. Look at a graphshowing the levels of fatal accidents against the number ofyears of service, and you see a big peak in fatalities at around17 years. That can only be down to complacency. Whendecisions are needed, past experiences stored in the memoryare called upon, often subconsciously. But if past experiencedoes not match present circumstances, then you’ve got anaccident waiting to happen. “We all take our eye off the ballfrom time to time,” says O’Hara. “If it had been acrocodile rather than a stingray in front of Steve Irwin,he would probably still be alive now. So when we lookat accident prevention in the workplace, the focus hasto be on behaviour.”So just how do you impact on behaviour? Wellconsider the example of a safety poster givingemployees a list of the safety equipment they should bewearing in a particular plant, telling them that a hardhat, hearing protection, high visibility vests and eyeprotection were all mandatory. CNES found that, in thisparticular plant, around 90% of personnel noticed thewarning, but only around 60% actually read the warning,and less than 30% of people actually complied with it. “Sowe changed the written list for a picture of someone actuallywearing all the safety equipment,” says O’Hara. “Immediatelybehaviour changed, because anyone not complying stood outlike a sore thumb. In effect, we’d turned everyone on theplant floor into a policeman.”Okay, that’s one example. But how do you turn the needto change behaviour into a more general action plan thatcan be rolled out across any industry? Risk assessmentsounds simple – identifying the hazards and estimatingthe degree of risk involved, taking into account the safetyprecautions already taken. But O’Hara says that for toolong we’ve been prescriptive in our hazard assessmentswithout actually telling people why, without telling themwhat the consequences are. “If we can modify theconsequences so that everyone understands them,then in almost every case we can achieve modification58INDUSTRIAL TECHNOLOGY • November 2008

Hazardous Areas// CONTROL TECHNOLOGY // EXPLOSION PROTECTION// MEDICAL TECHNOLOGYAssured safety,even out at sea!The dynamic nature ofindustry today means thattraining needs areconstantly evolving.Furthermore, the successof any learning style is thatit can facilitate competencyin the learner. One strategyfrom CNES is e-Learning,the flexible delivery oftraining solutions via arange of interactive media.The company says this canprovide manufacturing andengineering organisationswith extremely effective,economic and consistenttraining courses for theiremployees. The courses donot rely on the experienceof an instructor and areengaging, interactive andtherefore motivating foremployees.CNES offers a range ofe-Learning courses,including industrial andprofessional engineeringtraining, health and safetyand induction training, tocustomers outside of theCorus Group, tailored to thecustomer’s specific needs.Students can learn at theirown pace, on their own PC.Nick O’Hara comments:“Showing a training orcorporate video in front ofa group of new employeesis not an effective trainingtechnique, but manycompanies do it. Bycontrast, e-learning is themost effective techniquefor training. Studies haveshown that 80 per cent ofwhat we say, we remember,and 90 per cent of what wesay and do we remember.”of behaviour by peers, effectively making everyone on any plantfloor policemen,” he says. Another key, he is keen to point out,is that the consequences are rarely just about the individual.Imagine you’re back on the A15 again, driving much moresafely this time. But you have three passengers, and one in theback is refusing to put his seat belt on, claiming that he’s onlyputting himself at risk – a risk which is minimal anyway. But theworst happens. Another driver pulls out in front of you, and youhit him. Your rear passenger who’s not wearing a seat beltcomes flying forward, hitting the windscreen so hard that hehas no chance of survival. But on the way through he alsosmashes into both you and the other front passenger. You’renow both either dead or critically injured too. The other rearpassenger might have survived, had it not been for the carbehind also failing to stop. He hits your vehicle hard at the rear,and now the passenger who had a first gone flying forward inyour vehicle now comes flying back, smashing into the fourthpassenger. At a stroke, all four people in the car are dead orcritical, just because one refused to wear a seat belt.“This was the content of a real road safety video in Ireland,”says O’Hara. “And it really has worked to change behaviour,because people were seeing not only the consequences of anindividual’s actions to himself but to everyone else in thevehicle. Immediately it put four policemen into every car.”CNES has developed and is successfully delivering trainingcourses that are specifically designed to give attendees – bothCorus employees and external customers – the tools they needto reduce workplace risks. CNES encourages companies to doan ABC analysis of risk, looking at the antecedents (triggers andconstraints), behaviour (focusing on what is valid andreasonable) and the consequences (both positive and negative).Rather than modifying the antecedents, the key to improvingsafety is to modify the consequences so that they have thegreatest impact on behaviour. “Consequences which arepositive, immediate and certain are much more powerful driversthan consequences which are unimportant, negative, future andunimportant,” says O’Hara.Speaking about his own training courses, O’Hara concludes:“Our training providers are practising engineers. With everycourse we deliver, we’ve been through the pains of meeting thatparticular legislation ourselves, and so we think this gives us anedge when it comes to providing training to other industrialcompanies. We know what’s practical and how to interpretthat legislation for the customer.”MORE INFORMATION:Enter K585 on the enquiry card, or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for further details from Corus NorthernEngineering Services (CNES) and more news on hazardous areasWater, salt and the potential for explosions: there is no doubt that offshoreapplications place some of the most stringent requirements onswitchgear. The new EEx 95 position switches with safety function wereespecially designed for use in these demanding environmental conditions.Protection to IP66 means the switches can withstand strongwater jets – up to 100 l/minute from different directions. Seawater resistancehas been assured through extensive saltwater mist testing.And all metal parts are made from stainless steel. The result is a positionswitch that offers safe-assured operation on offshore platforms,tankers, and other offshore or harbour environments. For further detailsplease contact:steute UK & Ireland, Maylite Business Centre, Martley,Worcestershire, WR6 6PQ, Phone 01886/887722, Fax 01886/887725,infouk@steute.com or www.steute.co.ukSAFE SWITCHGEAR FOR DEMANDINGAND CRITICAL APPLICATIONNovember 2008 • INDUSTRIAL TECHNOLOGYMore details: Write in 590 on the free information card59

MACHINE BUILDING & AUTOMATIONMachinery SafetyAuxiliary thoughtsAuxiliary contacts for contactors play a big role indetermining the reliability of control systems: in safetyrelated applications, using the right type of auxiliary isessential. Nevertheless, says Steve Rickard of MoellerElectric, most designers pay far too little attention tothe characteristics and performance of auxiliariesPerhaps it’s because their name – auxiliarycontacts – makes them sound unimportant, orperhaps it’s because designers are not reallyaware that different types with very differentcharacteristics are available. But, whatever the reason,it’s surely true that compared with most othercomponents used in control systems, auxiliary contactsreceive very little thought.It’s easy to think that all auxiliaries are much thesame except, of course, for their ratings and whetherthey’re normally open (NO) or normally closed (NC).Today, that’s simply not true. Take, for instance, theselection of contacts for switching ‘dry’ electroniccircuits, such as the low-voltage, low-current inputs ofprogrammable controllers. Most designers will be awarethat standard contacts, which were primarily designedfor switching 110V or 230V circuits and currents of100mA or more, are not well suited for this kind ofapplication. If they are used, switching is likely to be veryunreliable. The traditional solution is to use gold-flashedcontacts. These solve the immediate problem ofswitching dry circuits, but they create two problems oftheir own.The first is that, because they incorporate gold, theyare invariably more expensive than standard auxiliaries.The second problem is that they are easily confused withstandard auxiliary contacts but, if they are used in highcurrentcircuits, they will be irretrievably damaged afterjust a few switching operations.Safety considerationsNow let’s move on to safety related applications. It’s veryeasy to believe that the status of auxiliary contacts fittedto a contactor will always accurately reflect the status ofthe main contacts. But what happens if an auxiliarywelds or jams? It’s perfectly possible that, under theseconditions, its status will no longer correspond to that ofthe main poles. And if such a contact is used to performa safety function, such as indicating that a contactor isde-energised and that, therefore, a motor is stopped, theresults can be very dangerous indeed.This issue has been addressed but, unfortunately,there is often confusion over the solution. Reference isfrequently made, for example, to “positively drivencontacts” with the implication that mechanical drive forauxiliary contacts of this type is arranged to ensure thatthey always reliably indicate the status of the maincontacts. This isn’t true.Positively driven contacts are defined in IEC/EN60947-5-1 Annex L4, which refers exclusively toauxiliary contacts that are all mounted on the samecontactor. It states that, during the entire lifespan of thecontactor, the normally open auxiliary contacts maynever be closed at the same time as thenormally closed auxiliary contacts. Thiscondition has to be fulfilled even if one ofthe contacts welds. Note very carefully thatthe definition of positively driven contactsrefers only to auxiliary contacts – it saysnothing at all about the main contacts. Inother words, positively driven contacts don’tnecessarily guarantee that the auxiliarieswill always accurately reflect the status ofthe main contacts.The only possible exception is in smallcontactors that can also be used as relays,where the main poles and the auxiliaries are identical inconstruction and means of mechanical drive. Thisexceptional case, however, is the only one wherepositively driven contacts can be relied upon as a certainindicator of the position of the main contacts.Mirror contactsWhat’s needed in all other cases is not “positively drivencontacts”, but “mirror contacts”. These are defined inIEC/EN 60947-4-1 Annex F5 as normally closedcontacts that can never be closed at the same time asthe main contacts. The test to ensure that auxiliariesmeet this requirement is undertaken with the maincontacts artificially welded to simulate worst-caseconditions.Note the narrowness of the definition of mirrorcontacts, which applies only to normally closedauxiliaries and normally open main poles. Nevertheless,mirror contacts are the only type of auxiliary that can berelied upon in safety-critical applications to give anindication of the status of a contactor’s main contacts.This is all very well, but surely we’re looking at a largerange of different types of auxiliary contact to cover therequirements discussed – mirror contacts, positivelydriven contacts, contacts for switching large currents,contacts for switching dry circuits and all possiblecombinations! In the past, that would have been true,but modern auxiliary contact designs, such as thatembodied in Moeller Electric’s new DILA-XHIR11contacts for the company’s popular xStart range ofcontactors, completely eliminate this problem.These innovative contact blocks provide twocontacts that are compatible with electronic circuits,one normally open, and one normally closed. Not muchnew there, except that the same contacts are alsosuitable for switching AC15 (small inductive) loads upto 6A at voltages up to 500V. The contacts are alsofully protected against welding if a 10A gL (slowoperation for small overcurrents, fast operation for largeovercurrents) fuse is included in the circuit. In addition,these newauxiliaries satisfy the requirements for positively drivencontacts and, when they are used in conjunction withappropriate Moeller xStart contactors, the normallyclosed contacts meet the requirements for mirrorcontacts, in conjunction with the contactor’s normallyopen main contacts. In summary, this one type ofauxiliary contact block can be used to satisfy almostevery requirement, which is particularly good news, asit costs no more than a standard auxiliary block.Innovative designTo achieve this exceptional versatility, a new design hasbeen adopted, based on the internal parallel connectionof duplicate auxiliary contact elements in separatechambers. This means that every contact has fourseparate contact points, greatly reducing the risk ofswitching faults – even if, for example, a particle ofcontaminant prevents one of the contact points frommaking, the others will ensure that the switchingoperation does not fail.As a result, when operating at 17V DC and switchinga current of just 5.4mA – worst case conditions forswitching reliability – the contacts have been shown tohave a failure rate of just one malfunction in 100 millionswitching operations.Hopefully this short article has demonstrated thatthere is rather more to auxiliary contacts than is perhapsimmediately apparent. In all situations, they deservecareful attention, if only to ensure equipment reliability.In safety related applications, it is essential that chosenand used correctly. Fortunately, all of this is now mucheasier, as a new type of auxiliary contact is nowavailable that’s equal to almost any task.MORE INFORMATION:Enter K605 on the enquiry card, or visit ‘latest issue stories’www.industrialtechnology.co.uk for further details from MoellerElectric and more news on contactors60INDUSTRIAL TECHNOLOGY • November 2008

Low burst pressure withexcellent characteristicsBS&B Safety Systems has justannounced the introduction ofits GCR-S reverse bucklingdisc. The GCR-S uses SAF (StructuralApex Forming) technology whichenables very low burst pressures to beachieved with excellent openingcharacteristics.This technology also offers a widerange of burst pressures and is idealfor a wide range of sanitary/asepticapplications in the pharmaceutical,biotechnology and food industries. Anintegral energy absorbinghinge is located on the downstreamside of the disk which means theGCR-S can perform in gas or liquidservice with superior flowperformance. Structural Apex Forming,the central ‘dimple’ present in allGCR-S rupture discs, combined withthe unique energy absorbing hingedesign, ensures that a damagedGCR-S disc will rupture at or belowthe marked burst pressure.The GCR-S disc can be used witha sanitary alert sensor on the outletferrule. The sanitary alert sensor is foruse between standard sanitary oraseptic fittings to provide warningof a burst rupture disk (burstingdisc). Leaking disc detection is alsoavailable. Alternatively an integralsensor can be provided as an optionfrom BS&B.MORE INFORMATION:Enter K615 on the enquiry card, or visitwww.industrialtechnology.co.uk for furtherdetails from BS&B Safety Systems1998 - 200810 Years of IndependentMachinery Safety AdviceRisk AssessmentCE MarkingPUWER AssessmentsOnsite EMC TestingTrainingTel +44 (0) 8700 111375Fax +44 (0) 8700 111395Web www.laidler.co.ukeMail enquire@laidler.co.ukMore details: Write in 610 on the free information cardMore details: Write in 611 on the free information card61

MACHINE BUILDING & AUTOMATIONMachinery SafetyLight curtains bring added valueContrinex has announced its entry into the safetylight curtain market with the Safetinex rangeLight andsound foryour panelsContrinex has introduced a newrange of safety light curtainsthat its says set new standardsin terms of reliability and valuefor money. Known as Safetinex, theproducts feature a modular design thatallows fully tested systems to be deliveredon a very short time scale.Contrinex safety light curtainscorrespond to safety Category 4 (EN/ISO13849-1) and Type 4 (EN/IEC 61496 -1and -2) and are designed to be usedwherever risks cannot be eliminatedthrough machine design. A person or anypart of the body entering a danger zone isdetected by the light curtain, resulting inimmediate machine stoppage.Safetinex light curtains consist of arugged sender and a receiver unit thatdemarcate the protection zone around themachine and the range comprises modelswith resolutions of 14mm for fingerprotection and 30mm for handprotection, with a maximum protectivefield width of 3.5 and 12m respectively.The maximum protective height is either1685mm (14mm resolution) or 1822mm(30mm resolution). The signal processingmethod used in the Contrinex systemensures very fast response times andmaximum safety for machine operators.Reliable operationAll Safetinex models offer a choicebetween two operating channels to avoidany likelihood of cross-talk betweenadjacent pairs of safety barriers.Connection is via M12 or M26 connector,short cable (pigtail) with M12 connectoror PUR pre-cabled, up to 10m long.In addition, the product rangeincludes a Category 4 safety relay thatcan be configured for manual orautomatic restart. Additional accessoriesinclude mounting brackets, which enablefull angular adjustment, and T-bolts thatfit into slots along each side of the barrierhousing.MORE INFORMATION:Enter K625 on the enquiry card, or visit ‘latest issuestories’ at www.industrialtechnology.co.uk forfurther details from ContrinexE2S has developed theSpectra family to extend itsindustrial range of audibleand visual signalling devices. TheB100 panel mount beacon isavailable with static or flashingfilament, Xenon strobe or LEDlight sources and is ideal for usein applications such as statuslights, warning lamps and safetyindicators.Using a standard PG29 threadsize, the beacon has pluggableterminal connections to makeinstallation quick and easy, whilethe tamperproof lens allows theuser to change the bulb withoutneeding access to the panel.All versions are protected toIP65 and the LED option hasDirect acting solenoidvalve is ATEX certifiedDust covers toprotect safetyinterlocksFortress has introduced new dustcovers for use with its mGard rangeof industrial safety interlocks. Thedust covers are available as standard orpadlockable and fit over the lockpreventing build up of dust and debristhat could prevent the internal lockmechanism operating correctly.The dust covers are stainless steeland spring loaded, featuring a robustclamp inside that grips the lock body.The new 70 series valve fromMidland-ACS has been engineeredto provide higher flow rates, whileat the same time consuming less powerthan both traditional solenoids andcompetitor valves alike. Using 316stainless steel in the body constructionto offer maximum internal and externalprotection from liquid and gases the 70series is a direct-acting 3/2 hazardousarea solenoid valve for the oil, gas andpetrochemical industries.Designed for actuator control, the 70series is EExd IIC T6 rated with IP67ingress protection, for use in hazardousenvironments. Compliant with the ATEXdirective and entitled to bear the CEmark, the valve is also IECex certified.A key goal of the design process wasto deliver exceptional efficiency in termsof energy usage. Targeting offshore usagein particular, and bearing in mind thepower issues these installations andvessels have regarding the amount ofwattage they use, Midland-ACSengineers set themselves the task tobetter a power consumption rate of 5W.Through various trials and tests a finalpower consumption figure of 3.5W at anambient temperature of –50°C to +60°Cwas achieved, almost halving the originalbenchmark.Compact, reliable and – of increasingimportance to offshore facilities andoperations – lightweight at only 3.2kilos, the valve design removes thepotential for leaks and reduces the riskof hazardous contamination.Available in 12V, 24V and 110V DCoptions, and 24V, 110V and 230V ACoptions, this direct-acting solenoid valvehas already been incorporated into amanifold solution Midland-ACS has beentesting a 250 bar hydraulic version tocomplement its ever widening range ofMidland-ACS valves.Midland-ACS has over 50 yearsexperience, with broad expertise in thesafety conscious OG&P sector.much lower life costs than atraditional filament lamp,particularly in status lampapplications where the beacon isilluminated continuously.Optionally available with anaudible as well as visual output,the Spectra family includes panelmount warning buzzers which givesound outputs up to 95dB and,when used with the optionalneoprene gasket also giveprotection to IP65. All Spectramodels are available in red,amber, blue, clear, green andyellow and are a major addition tothe company’s range of highweatherproof and explosion proofsounders, beacons andloudspeakers.MORE INFORMATION:MORE INFORMATION:MORE INFORMATION:Enter K626 on the enquiry card, or visit ‘latest issuestories’ at www.industrialtechnology.co.uk forfurther details from Fortress InterlocksEnter K624 on the enquiry card, or visit ‘latestissue stories’ at www.industrialtechnology.co.ukfor more info from Midland-ACSEnter K627 on the enquiry card, or visitwww.industrialtechnology.co.uk forfurther details from E2S62INDUSTRIAL TECHNOLOGY • November 2008

STANDARDS UPDATEElectrical equipmentfor hazardous areasUnderstanding the X-FactorWhen it comes to sourcing electricalequipment for hazardous areas,end users and contractors have toensure that apparatus not onlymeets the appropriate health and safetystandards, but they also have to make thecorrect purchasing decisions, based on the costof ownership of a product. This meansconsidering the related costs of the productthroughout its entire lifecycle, including the costof installation, maintenance,service and repair. Furthermore,the cost of a non-productiveshut down in hazardous areas inorder to service or repair failedapparatus, must be considered.In hazardous areaenvironments, these types of purchasingdecisions are further complicated by Europeanand International health and safety standards,which allow electrical equipment to be markedwith an ‘X’ at the end of the certificate number.In EN 60079-0 You will find following definitionfor the ‘X’: “symbol used to denote specificconditions of use. NOTE: The symbol ‘X’ is used“This is rather like buying a car withoutairbags and being told by the seller that youcan only have low speed impacts.”to provide a means of identifying that essentialinformation for the installation, use, andmaintenance of the equipment is containedwithin the certificate.”This ‘X’ denotes that the equipment issubject to ‘specific conditions for safe use’,which is specified in the schedule to thecertificate. This ‘X’ may denote enhancementsbut can also denote limitations. This means theowner of the equipment must be aware of themeaning of the ‘X’ on the equipment in use. Itcould mean that he must carry out riskassessments on the equipment.It is therefore crucial that engineersunderstand the subtle technical differencesbetween electrical products from differentmanufacturers. Although different products mayboth carry the same ‘ATEX classification’, thecustomer must consider the possible ‘hidden’costs of the ‘X’.As an example, take explosion-protectedcontrol stations or overhead fluorescent lightingfor hazardous areas. As long as the lighting unitcarries the required ‘ATEX classification’ and testcertification, the end user customer may not beduly concerned with any ‘X’ marks on thecertificate. However, the ‘X’ in this particularexample could denote that the control station orlight fitting can only be installed where there isa low risk of mechanical damage. ‘Low risk ofmechanical damage’ is open to the customer’sown interpretation, but may mean that the unitcannot be installed in certain production areas,handling or lifting bays.The ‘X’ on a controlstation or light fitting thendenotes that the housingis rated below the 7Nmimpact test required asstandard for equipmentused in hazardous areas. This is rather likebuying a car without airbags and being told bythe seller that you can only have low speedimpacts.Another example could be a limitation in theambient temperature. Instead of the standardrange (–20°C up to +40°C) the equipment maybe limited for use in an ambient range between0°C up to +40°C. This meansthat the equipment is restricted toindoor use only. On the otherhand, the same ‘X’ could alsorefer to an increased ambienttemperature range.The ‘X’ may also have otherspecial conditions that increase the cost ofownership for the end user. For example, specialinstallation instructions and maintenanceprocedures may be necessary. This might meanthat self-tapping screws are supplied with thelighting to lock the diffuser clamps. These mustbe fitted to maintain the certification. If thecustomer is installing hundreds of lights througha plant, the additional time and cost ofinstallation in this way can be significant.Apart from the possible restrictions createdby an ‘X’ in the certificate, inspection andmaintenance are also key considerations whenpurchasing light fittings for hazardousenvironments. Some light fitting manufacturershave moved from being suppliers of lighting forgeneral industrial use to ‘explosion-protected’versions. Often, these suppliers have to includespecial maintenance conditions. For example,the end user may have to inspect the lightfitting every twelve months, resulting insignificant maintenance costs.Information provided courtesy of Cooper Crouse-HindsNovember 2008 • INDUSTRIAL TECHNOLOGYMore details: Write in 63063

product and service factfindersAIR CONTROL INDUSTRIES LtdSilver Street, Chard, Somerset TA20 2AEe-mail: sales@aircontrolindustries.com www.aircontrolindustries.comFree Airknife DemosACI Ltd is currently offering customer-on-site Free Demos of their Airknife Drying Systems.For any process requiring the removal of surfacemoisture, coatings, dust or contamination from awide range of materials and shapes, ACI Airknifesystems provide clear performance and efficiencyadvantages over other methods.Email sales@aircontrolindustries.com to arrangeyour visit.igus51 Caswell Road, Brackmills Industrial Estate, Northampton NN4 7PWe-mail: sales_uk@igus.co.uk www.igus.co.ukNew Cable CatalogueThe Chainflex cable catalogue is now available from igus.igus has manufactured its own cables since 1989.The high-flex cables withstand the stress of tight bendingradii in moving applications and have been tested overmillions of cycles. They include control cables, robot cables,motor cables, data cables and servo cables.Request yours today.More details: Write in 640 on the free information cardMore details: Write in 644 on the free information cardBALLUFF Ltd4 Oakwater Avenue, Cheadle Royal Business Park, Cheadle, Cheshire SK8 3SRe-mail: sales@balluff.co.uk www.balluff.comBalluff Rolls Out BroadestCapacitive Sensor LineBalluff has introduced a new capacitive sensor line forproximity and level detection applications. With over 250models to choose from, it’s the most extensive capacitivesensor line available. Offering a wide variety of body styles, sensing ranges, harshenvironmental ratings, and advanced functionality, this expansion of the Balluff technologyportfolio creates an unprecedented single-source solutions capability for industrial sensorapplications. Special application types include level and proximity sensors for hightemperature environments (up to 480°F), miniature sensors (as small as Ø4mm), orsensors with IP69K rating for wash down/heavy duty environments.More details: Write in 641 on the free information cardSCHAEFFLER (UK) LtdForge Lane, Minworth, Sutton Coldfield, West Midlands B76 1AFe-mail: info.uk@schaeffler.com www.schaeffler.co.ukNew Boxed Set – UltimateLinear Reference LibraryThree brand new hardbacks, supplied as a BOXED set. Over750 pages. Tabulated sections. Clear illustrations.Book 1: Track Roller Guidance SystemsBook 2: Shaft Guidance SystemsBook 3: Monorail Guidance SystemsIncludes: Track roller guidance systems, bolts, guideways and accessories. Linear bearingsand housing units. Solid shafts, hollow shafts. Support rail units. Shaft support blocks.Linear recirculating roller or ball bearings and guideway assemblies.More details: Write in 645 on the free information cardCOTEL MOULDINGSJG Coates (Burnley) Ltd, Trafalgar Street, Burnley, Lancashire BB11 1THe-mail: sales@cotel.co.uk www.cotelmouldings.comNew Products 2008from Cotel MouldingsPlease request the new Cotel Mouldings catalogue featuring thelatest additions to our comprehensive range of industrialproducts:• New Design Bridge Handles & Wing Knobs• Rubber Dampers • Cam Locks & Latches• Nylon Bushes & Insulation Sleeves • Industrial CastorsFor fast, reliable service please contact us today, and please also visitwww.cotel.safetychannel.com for over 23,000 safety signs and related products.More details: Write in 642 on the free information card.steuteMaylite Business Centre, Martley, Worcestershire WR6 6PQe-mail: infouk@steute.com www.steute.co.ukWireless Technologies CatalogueKabellose Technologien / Wireless technologiesSICHERE SCHALTGERÄTE FÜR ANSPRUCHSVOLLE UNDBRISANTE ANWENDUNGEN / SAFE SWITCHGEAR FOR COMPLEXAND CRITICAL APPLICATIONS// Steuerungstechnik, Explosionsschutz und MedizintechnikControl technology, Explosion protection and Medical equipmentControl Technology• Limit switches, pull wire switches, foot switches, door releasehandles all incorporating EnOcean wireless radio technology.• No batteries, no cables means no maintenance.• Up to 30m signal transmission internally through walls and ceilings, 300m externally.Explosion Protection• All of the above products are also available for potentially explosive atmospheres Atex gaszone 1 and dust zone 21 certified to Ex ib according to DIN-EN 60097, DIN-EN 61214-11.Medical Technology• Medical foot controls with Bluetooth wireless technology.More details: Write in 646 on the free information cardHOLLIN APPLICATIONS LtdThe Station, Wolsingham, Weardale, County Durham DL13 3BLe-mail: itsales@hollinapplications.co.uk www.linearactuators.co.ukMotion Control SolutionsHollin Applications Ltd is one of the UK’s largest distributors of the Danaher Motionproduct range. We have produced a new information leaflet on the range of products westock in the UK and distribute worldwide. We are also pleased to launch our new websitewww.linearactuators.co.ukWe supply • Servo motors • Stepper motors • Linearactuators • Profile rail • Linear bearings and guides• Linear units • Ball and lead screws • Linear ball bushing• Shafting • Precision actuators • Worm gear screw jacks• Plantetary gearheads • Stages and slides etc• Electronics • Handling systems • Actuator repair serviceMore details: Write in 643 on the free information cardJAMES WALKERGlobal Support Centre, 1 Millennium Gate, Westmere Drive, Crewe CW1 6AY, UKe-mail: csc@jameswalker.biz www.jameswalker.bizNew Guide To Global SealingOperationsThe worldwide fluid sealing and materials expertise ofJames Walker Sealing Products & Services is covered in thisnew guide.As well as R&D and new technology, it describes the value ofpartnering contracts, e-commerce systems and thehighly-developed logistics networks that give customers thesurety of supply they need.More details: Write in 647 on the free information card64INDUSTRIAL TECHNOLOGY • November 2008

John Richardson’s ENGINEERING DIARYWalking between Euston station and theBritish Library as often as I do, it’s nicesometimes to vary the route. Depending onhow favourable the weather is, and whereelse I have to be on any given day, there are any number ofroutes I can take to vary the walk slightly. And I frequently findmyself stopping to admire some wonderful piece of Londonarchitecture that I’ve not previously noticed. Indeed, I cansometimes lose myself in thought, completely oblivious to what’sgoing on around me.So I’m immensely grateful to the chap who, on my lastouting, gave me a tap on the arm and a “look out, mate”, as Iturned around, startled, so see a Suzuki G-Wiz car bearing downon me. I simply hadn’t heard it coming – partly, I’m sure,because I was absorbed in my own thoughts, but mostly I preferto think because these strange little electric cars are almostcompletely silent. And as we move towards a brave new futureof electric propulsion, I wonder if anyone has stopped to thinkabout the implications for the motorist/pedestrian relationship.Surely a whole new road etiquette will need to be developed. Orperhaps we really do need cars to be fitted with external soundsystems to generate artificial engine noise.Low carbon vehicle initiativeOf course, these really are secondary considerations comparedwith the bigger problem of getting decent volumes of electriccars onto the roads in the first place. But the TechnologyStrategy Board recently unveiled details of a £10 millioninvestment plan, co-funded by the Department for Transport,which aims to see up to 100 innovative ultra low carbondemonstration vehicles on Britain’s roads by the end of nextyear. This is one of the initiatives announced by the Governmentto encourage a mass market in electric and hybrid cars. Theultra low carbon vehicle demonstration competition will see the100 innovative cars on the road in several locations around theUK and, through real-world situations, will show the benefits tobe gained by using new and emerging low carbon vehicletechnology. The Technology Strategy Board also said that it willhelp co-ordinate a series of public dialogue initiatives to ensurethat the ultra low carbon demonstration fully considers theattitudes of consumers.Technology Strategy Boards chief executive Iain Gray said:“Low carbon vehicle technology is exciting, practical and, mostimportantly, real. Such vehicles are already on our roads and asthe technology continues to improve rapidly they will onlybecome more effective and more widely used. Low carbonvehicles offer the combined advantages of reducing our relianceon oil and reducing emissions. The challenge now is to speed updevelopment of this technology while delivering the benefits toUK business – which is why the Technology Strategy Board isdelighted to announce a further £30m of investment in theresearch, development and demonstration of electric and lowcarbon vehicles.”Underlying infrastructureThe demonstrator and research and development competitionsare the latest initiatives from the Technology Strategy Board’sLow Carbon Vehicle Innovation Platform. The three furtherresearch and development activities will cover electrification ofroad transport (up to £10 million), technologies to decarboniseroad vehicles (approx £7 million), and university-led researchinto lower-carbon vehicle technology (£3 million), funded by theEngineering and Physical Sciences Research Council (EPSRC).The Technology Strategy Board will also work closely with theEnergy Technologies Institute, which will hold a stakeholderworkshop in December to develop a second wave of low carbonvehicle demonstration activity. This builds on the TechnologyStrategy Board’s early pilots and will focus on understanding therequirements of the charging infrastructure.On page 40 in this issue, we report on one of thetechnologies that may prove key in the advancement of electricvehicles, and it’s a British innovation to boot: the Hi-Pa Drivein-wheel motor developed by Hampshire-based PML-Flightlink.Even more interestingly, there are already spin-off productswhich extend the scope of the technology to any rolling wheelwhere a bit of assisted power would be an asset.Whilst the UK produces huge numbers of cars, with massemployment in the sector, it’s been a long time since we couldreally say that we had our own automotive industry. Currently,fewer than 0.1 per cent of the UK’s 26 million cars are electric,and we have a long way to go if we want to be a world pioneerin electric cars. But perhaps the development of electric vehicletechnology represents an opportunity for the UK to take a reallead and, given the current state of the global economy, now isexactly the right time to seize the opportunity. In fact, it’s exactlythe sort of high-value manufacturing opportunity that the UK isparticularly good at embracing.feedback@itmagazine.uk.comNovember 2008 • INDUSTRIAL TECHNOLOGY65

EAR TO THE GROUND • Becky Silvertonbecky@itmagazine.uk.comFunding the re-inventionof forgotten technologies...When Professor Stephen Salter ofEdinburgh University developed hiswave power Duck in the 1970s, itshould surely have heralded a bravenew era of wave energy exploitation, with Britainleading the way. Reports to government in 1982showed that, based on the prototypes, the Duckcould be projected to produce electricity at around 3pence per kilowatt-hour. But by 1983, with thegovernment of the day seemingly looking for areason to shift its investment into wind power, afurther report was producedwhich concealed the Duck’s goodfigures by averaging them acrossall wave power projects. Worsestill it was calculated that capitalcosts would make the Duckunviable.Only recently has it emergedthat some muppet putting thosereports together miscalculated thecapital costs by a factor of ten.Fortunately, despite a lack of government funding,development of wave power by students of Salterhas gone on, and some big, real-world projects arenow in construction. But it makes me wonder justhow many good ideas have been abandoned overthe years because of lack of funding or poorcalculations or simply prejudice.Well, if you often find yourself reminiscing aboutworthwhile projects you worked on decades agothat were abandoned for no good reason, or if youbelieve that forgotten projects might be re-inventedusing technologies that weren’t available at thetime, then finally there’s an opportunity to dosomething about it.Results from the Sustainable TechnologiesInitiative (STI), a recent collaborative researchprogramme, indicate that many ‘forgottentechnologies’ may have significant potential. Theprogramme ended with a workshop on this themeat the Dana Centre in London that includedcontributions from Adam Hart-Davis (presenter of‘What the Romans Taught Us’ and ‘What theVictorians Taught Us’) and Trevor Bayliss, inventorof the Freeplay wind-up radio. Professor DavidEdgerton, Professor of History of Technology atImperial College, contributed from his forthcomingbook ‘The Shock of the Old’.Now Oakdene Hollins, the sustainabilityconsultancy that co-ordinated the STI, is offering£4,000 in consultancy support for the best‘forgotten’ idea that holds potential forenvironmental improvement. The deadline forreceipt of applications is the 10th February 2009,and the date for announcement of the results of thecompetition (which will be judged internally byOakdene Hollins consultants) is 23rd April 2009.If you think you’ve got an idea that deserves asecond chance, you can find more about enteringthe competition on the company’s website atwww.oakdenehollins.co.uk/sti-funded-projects.html.SPS/IPC/DrivesNovember 25-27, 2008Nuremberg, Germanywww.mesago.deMesago Messemanagement(+49 711 61946-0)Manufacture 2008December 8-9, 20086th annual manufacturing conferenceSaint-Etienne, Francewww.manufacture2008.euCTIM (+33 344 67 47 41)Autosport InternationalJanuary 8-11, 2009NEC, Birminghamwww.autosport-international.comHaymarket Exhibitions (020 8267 8300)Southern ManufacturingFebruary 11-12, 2009Farnborough, Hantswww.industry.co.ukETES (01784 880890)Machine Building(including Drives & Automation)March 25-26, 2009NEC, Birminghamwww.devicelink.comCanon Communications (01622 661363)MTECMarch 25-26, 2009NEC, Birminghamwww.devicelink.comCanon Communications (01622 661363)MEDTECMarch 25-26, 2009NEC, Birminghamwww.devicelink.comCanon Communications (01622 661363)Index to Advertisers November 2008Aerotech ....................................................... 55Air Control Industries ................................ 20-21Air Control Industries ..................................... 64Alcatel-Lucent ............................................... 40Alwayse Engineering ...................................... 25Andantex ...................................................... 22Applied Automation ....................................... 63Bailey & Mackey............................................. 51Baker & Finnemore ........................................ 30Balluff .......................................................... 64Bosch Rexroth ............................................... 11JG Coates ..................................................... 64Components4Machinery ............................ 34-35Contrinex ...................................................... 46DirectIndustry ................................................ 10Davall Gears ................................................. 28E2S .............................................................. 61EMS ............................................................. 19ETA Enclosures .............................................. 25Euro Bearings ................................................ 17Expert Tooling & Automation ........................... 55Festo ........................................................... 2-3Feteris .......................................................... 51Futek Advanced Sensor Technology .................. 44GE Inspection Technologies ............................. 45GE Inspection Technologies ............................. 47Hamersham .................................................. 45Heidenhain ................................................... 18Henkel Loctite ............................................... 13HepcoMotion ................................................. 39Hollin Applications ......................................... 64Huco Dynatork .............................................. 43Idec ............................................................... 5Igus .............................................................. 39Igus .............................................................. 64IKO Nippon Thompson ................................... 38Interpower Components .................................... 7Interpower Components .................................... 9Interpower Components ................................. IBCAlbert Jagger ................................................. 27Klüber Lubrication ......................................... 36Kobold Instruments ........................................ 49Lafert Electric Motors ....................................... 8Laidler Associates .......................................... 61Land Instruments ........................................... 51Lee Products ................................................. 25Lee Spring ...................................................... 4Lenze ........................................................... 14Machine Building & Automation Exhibition ..... OBCMachine Building Systems .............................. 57Master Bond ................................................. 31Micro-Epsilon ................................................ 16MiniTec ........................................................ 52Motion Control Products ................................. 53NKE Austria .................................................. 15NSK Europe .................................................. 33Ondrives ....................................................... 29Oriental Motor ............................................... 43mbo Osswald ................................................ 31Penny & Giles Controls ................................... 47Protex Fasteners ............................................ 29RDP Electronics ............................................. 45Renold Chain .................................................. 4Rittal ............................................................ 23RK Rose & Krieger ......................................... 57Rotalink ........................................................ 41Schaeffler ..................................................... 37Schaeffler ..................................................... 64Sensor Technik .............................................. 51Sensors UK ................................................... 47Sherborne Sensors ......................................... 49SKF .............................................................. 17Siemens ....................................................... 19Spirol Industries ............................................ 27Spirol Industries ............................................ 29Spirol Industries ............................................ 31Springmasters ............................................... 27Springmasters ............................................... 31Steute .......................................................... 59Steute .......................................................... 64Variohm ........................................................ 49James Walker ................................................ 17James Walker ................................................ 64The West Group ............................................ 5766INDUSTRIAL TECHNOLOGY • November 2008

More details: Write in 670 on the free information card67

Machine Building &Automation ExhibitionThe event showcases:Custom automation and assembly technologyRoboticsPlacement and handling systemsDrives and controlsMotion and motorsSafety systemsSoftwareMachine hardwareCo-located with:10706_UK_MB09www.advancedmanufacturinguk.comMore details: Write in 680 on the free information card