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18 P&TR Nov/Dec 2011 P&TR Products Bearing isolator and grounding ring combination The new Garlock SGi Shaft Grounding Bearing Isolator protects motor bearings from electrical damage as well as from lubricant loss and contamination. Maintenance-free, the Garlock SGi bearing isolator combines the proven technologies of Garlock’s GUARDIAN non-sparking bronze labyrinth seal together with an AEGIS shaft grounding ring in a single unit. It is ideally suited for motors controlled by variable frequency drives (VFDs) running pumps, fans, high-speed spindles, and other equipment in severe-duty applications such as mining and the processing of pulp/paper, food, pharmaceuticals, chemicals, and water/wastewater. Commonly used to save energy, VFD’s induce motor-shaft currents that can damage bearings, completely wiping out any energy cost savings. Standard bearing seals only keep out contamination and prevent leaks, but the Garlock SGi diverts harmful currents safely to ground, bypassing the bearings entirely and extending motor life. The patented AEGIS FiberLock Channel built into the Garlock SGi permanently secures circumferential rows of conductive micro fibres, preventing their dislocation and the resulting accidental contamination of the bearing. The micro fibres themselves, proven in hundreds of thousands of installations to protect bearings from harmful currents, are engineered for flexibility to prevent breakage and ensure that the SGi will last for the service life of the motor. Designed for long-term total bearing protection, the SGi also provides an IP56 non-contact isolation seal that withstands dust and powerful jetting liquids. It replaces contact lip seals and traditional bearing isolators commonly used in industrial applications and withstands operating temperatures from -30°C to 149°C (–22°F to 300°F). The unit is available for motor-shaft sizes ranging from 22.2mm to 152.4 (0.875 ins to 6 ins) in flanged, flangeless, and custom configurations. For reader enquiries, please mention PTR: Gerry Morgan, Garlock Ltd, Tel: +44 (0)1422 313600 www.garlock.co.uk Eaton Introduces AxisPro , a New Generation of Proportional Valves Diversified industrial manufacturer Eaton Corporation today announced a new generation of proportional valves created to provide integrated programmable control capabilities in sophisticated electro-hydraulic axis control applications. Eaton’s new AxisPro valves are designed to support both centralized and distributed axis control architectures in highperformance applications in woodworking, wind turbines, pulp and paper production, metal forming, plastic injection and blow molding, primary metals, and other industries. Eaton AxisPro valves contain both programmable onboard electronics and integral spool Linear Voltage Differential Transformer (LVDT) sensors to provide precise, accurate, responsive axis control capabilities. The initial products are offered in ISO-3 and ISO-5 sizes with rated flows of 40 lpm and 100 lpm (10.6 and 26.4 gpm), Dynamic bandwidth for the ISO-3 valves is 150 Hz and 100Hz for the larger ISO-5 models. Both have 350 Bar (5,075 psi) rated P, A and B ports and 250 Bar (3,625 psi) rated T-port. “These valves are building blocks for the next generation of electrohydraulic sophistication,” said Colin Cooper, product manager, industrial valves. “Their modular design delivers four levels of control capability ranging from an entry level valve that is quick and easy to configure, right through to a valve that can be uniquely customized by uploading application code created using Pro-FX Control software based on the IEC-61131-3 programming standard. Additionally the valves can be selected with CanOpen field bus communication and control capability, a range of optional sensor inputs, an embedded on-board pressure and temperature sensor capability and easy-to-read LED status indicators”. “We have optimized AxisPro valves for performance, flexibility, reliability and easy diagnostics. They give customers machine and application performance benefits, which translate into significant improvements in efficiency, productivity and repeatability for many applications,” Cooper added. “AxisPro valves also have best-in-class IP65 and IP67 protection against dirt and moisture ingression, and best-inclass 85° C ambient temperature ratings.” New high power field controller from Sprint Electric Sprint Electric has added 3 phase field controllers to the product range of DC drives for control of high current excitation fields on DC motors. The new product with the brand name QLX will be introduced in November at SPS/ IPC/Drives, the international trade fair for electric automation, systems and components, in Nuremberg, Germany. The QLX uses 3 phase supply power to provide a controlled DC field current. It will work with the armature controller to provide all usual field control functions including field reversal. The model range spans currents from 12 to 2250 Amps, with fully digital control and all the usual communications facilities. QLX 3 phase field controllers are ideal for controlling the high current excitation fields of DC motors used in applications such as a hot rolling mill and steel handling. The QLX 3 phase field controller has the same digital functions as Sprint Electric’s established PLX range of DC drives, including field bus options such as Profibus, DeviceNet, CanOpen, Modbus TCP/ IP, EtherNet etc. The QLX range consists of five frame sizes with the maximum current capability of up to 2250 Amps. It offers Field Reversal and Auto Field Weakening for high power fields. It also has a built-in Standby Field mode. For start and stop functions, the QLX directly interfaces with the main armature controller such as the PLX or other. It cost-effectively adds reversing to large DC motors where the facility does not already exist, or exists only with contactors. Sprint Electric offers a wide range of DC motor control, with over 150 models covering both 1 phase and 3 phase, regenerative and nonregenerative DC motor applications, together with digital slip ring motor controllers. Sprint Electric’s full range of products include analogue and digital DC drives from 12 up to 2250 Amps. Whether in retrofits or original equipment, DC drives from Sprint Electric are being used in many different applications including metal processing, the pulp and paper industry, rubber and plastic processing, lifting equipment, food processing, leisure industries and many more. QLX high power 4 quadrant DC field controller from Sprint Electric. For reader enquiries, please mention PTR: Sprint Electric Ltd. Mr. Gary Keen, Peregrine House, Ford Lane, Ford, Arundel, West Sussex, BN18 0DF Tel: +44 (0)1243 55 80 80 Fax: +44 (0)1243 55 80 99 Email: gary@sprint-electric.com www.sprint-electric.com
Nov/Dec 2011 P&TR 19 Closer to Home Specialising in a niche market for UK manufacturers is not something new, but for Stockport based gear manufacturers, Mini Gears, it has recently taken on a whole new meaning. Mini Gears, probably best known for producing medium to high volume batches of commercial gears and racks, has recently diversified into totally different markets, including low volume and very high precision industries such as Autosport, specialist gears for classic cars, high end valves applications, rotor pumps and even as diverse as aircraft seating for first class business travellers. Over the last 18 months the company has been very busy investing in areas such as gear grinding, gear shaving, low volume turning and milling on the newly acquired XYZ machines and this is to compliment the already existing very flexible machining cells that include 3 of the latest Mazak 5 axis CNC multitasking centres and CNC Gear Hobbing. Although Mini Gears’ traditional markets are still holding up extremely well, the fact that so many high volume components have migrated abroad and, in a lot of cases the whole assembly of the product, this has meant that future expansion is very limited in these areas and some 2 years ago the company made the decision to diversify into markets nearer to home. The positive side of this move has created many new jobs at Mini Gears’ UK factory, which employs 80 people and even during the recession the cut backs that we had to make were nowhere near as severe as against most companies in the manufacturing sector. We have also taken on 3 apprentices to train up for the skills gap which is very prevalent in engineering and the areas we are looking to cover are the highly skilled machining side together with the technical, design and commercial side of the business. As well as the new lower volume business we have also seen during the last 6 months a very high number of new enquiries for parts that would normally be sourced overseas and, due to a large cost increases in these regions, we have won back a number of contracts for our UK facility. The recent installation of new hi- tech equipment, particularly in gear grinding, has been a key factor into entering new markets. We invested in a Hoefler Helix 400K CNC Gear Grinding Machine, one of the most modern and up to date machines for grinding a special Mini Gears manufacture gears for cars such as the Triumph TR4 pictured above The Mini Gears team (in black) meeting with Oxford Brookes Racing (in white) profile on the gear tooth. Applications have included power take-off units, very accurate gears for pump rotor systems, Autosport applications for high performance gear boxes and drive trains and, quite ironically, we have used the machine to make reproduction gears for a British company at the very high end of the market who are reproducing a 1930s Roadster to original specifications but with all the latest updates to enable the engine to pass the latest emission controls. With this type of new technology the accuracy of the gears that can be achieved is now so accurate that it becomes necessary to invest in the latest up to date CNC gear checking machines and we have now ordered a brand new Gleason 350 GMS due for delivery in March 2012. Also, at the other end of the spectrum is the ultra modern design of engines and gearboxes used in Formula 1 Racing, plus many other applications at club racing level, mainly used in saloon cars. One of our most recent projects we have been involved in is to supply Oxford Brookes who are one of the leading Universities in engine and gearbox design with a number of gear components for their racing car which competed against 500 universities world-wide in a major racing series. Mini Gears’ parts were displayed at Silverstone’s Formula Student which was attended by Ross Brawn OBE who is Patron of the organisation and who gave a very inspiring speech to all the students. Since then two of the students we dealt with have just started at Renault F1 and Toyota Racing in Germany. Mini Gears also supplies many parts to the Autosport trade and, because we are not in competition with these companies, our parts are now running inside a large number of house-hold named products supplied by blue chip companies. One of the main areas of Mini Gears’ manufacture is the production of gear racks, mainly for the stairlift market, portable drills and electric generators. These parts are normally made in very large volumes and are therefore very price sensitive. Now, going into niche markets, we have targeted much lower Looking for Gears & Machined Parts We manufacture to your BESPOKE requirements • Precision Gears up to 600mm • CNC Gear Grinding up to 400mm • Gear Racks up to 3 metres long • 5 axis CNC machined parts SPECIALIST SUPPLIER to most Power Transmission, Valve and Medical Industries UK & Global manufacture www.minigears.co.uk Top Gear House, Bletchley Rd. Heaton Mersey Ind. Est. Stockport SK4 3ED UK (Left) The newly installed Hoefler Helix 400K CNC Gear Grinding Machine. (Right) A range of precision Ground Gears. volume but very high quality gear racks for such areas as aircraft seating on commercial airliners. We are also now supplying a number of customers with steering racks for cars and these range from the latest up to date racing series through to classic cars where the parts are no longer available. On our gear products we have previously made gears up to 600mm diameter for a many diverse commercial industries. However, recently we have supplied lower volume batches to the trade which caters for the after market parts for a wide range of cars produced from the 1930s up to the 1970s. For this we have had to invest in a specialist gear shaping machine which can cut helical shaped gears which is very unique to our industry. We have literally spent tens of thousands of pounds on new tooling to enable us to produce the old design of gears using the latest technology. Quite literally out with the old and made with the new. By looking at new ideas this has now Contact us: T: +44 (0)161 432 0222 F: +44 (0)161 432 0444 E: enquiries@minigears.co.uk turned into reality and we are extremely pleased with the company’s progress in these new niche areas. Paul Darwent (Chairman) comments on the prospects ahead: “With the advent of escalating costs in low labour cost countries, the Directors at Mini Gears are a lot more confident for the next 5 to 10 years ahead for UK manufacture especially after what we have had to endure for the last 10 years with extremely low cost labour competition. We are all looking forward as a team to the many challenges ahead.” Mini Gears is soon to be featured in a programme called ‘Manufacturing Solutions’ We have not been given the exact date yet so check the news page on our website www.minigears.co.uk where we will give the details as soon as we have them.
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