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Industrial 

Technology 

June 2008 

THE ESSENTIAL MAGAZINE FOR PRODUCT DESIGN ENGINEERS AND MACHINE BUILDERS 

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COMMENT & ANALYSIS 

Industrial Technology ISSN 0967-5787 www.industrialtechnology.co.uk 

EDITORIAL 

Editor 

Mark Simms BSc Tel: 01732 773268 

PO Box 342, Fax: 01732 365676 

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new wave 

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AUDIT BUREAU OF CIRCULATIONS 

BUSINESS PRESS 

Do androids dream 

of electric sheep… 

I’m hoping some time soon to be heading off to the cinema to see the new Indiana Jones 

movie. I’ve tried not to listen to any reviews, or to check out the spoilers on the plot. In 

fact, so far all I’ve seen has been the official trailer, and all I’ve heard has been a radio 

interview with Harrison Ford. The interviewer was talking afterwards to the radio show 

presenter about his conversation with the star. In particular, he mentioned some of Ford’s 

views on his previous films, and how Blade Runner was one of his least favourite. 

By any standards, Blade Runner was a box office flop. I’ve seen it myself a few times, and I 

reckon that it’s mostly okay, although ultimately unsatisfactory. I always felt that it could have 

been better; that it promised far more than it actually delivered. It 

seems to me that the makers somehow missed the mark, and 

didn’t deliver the feature that the market really wanted. 

Made in 1982, the film was set in 2019, where we have 

begun to supplement the human workforce with replicants – 

human clones with fixed lifespans. But when the replicants go 

renegade, they are declared illegal, and are ordered terminated. 

Enter the blade runners – a division of the law tasked with 

tracking down and terminating replicants on the run. I have my 

own views on the weaknesses of the film, but what was it, I 

wondered, that rankled with Ford? Well, it turns out that he wasn’t 

keen on the way director Ridley Scott wanted him to play his 

character, blade runner Rick Deckard, with the very flat, almost monotone line delivery. And in 

particular he didn’t like the fact that the Deckard character was also a replicant. 

Whoa, back up there. When did Deckard turn out to be a replicant? How did I miss that in 

a film I’d seen on several occasions? Surely it should have been obvious. 

Well, let’s just say that what is blindingly obvious to the maker is not necessarily remotely 

clear to the market. And I’m not the only one who’s missed the supposedly obvious, because 

there have been numerous attempts to ‘fix’ the film over the years, with a Director’s Cut, 

various special editions and, in 2007 to mark the 25th anniversary of the film, an Ultimate 

Final Cut. And still I’d argue that this most critical aspect of the film is far from clear. 

I mention all of this because in the world of industrial design there are lessons in Blade 

Runner for each of us. First off, if the market wants a particular feature, and you fail to deliver 

that feature, then there’s no way you’re ever going to have a successful product: and a host of 

designers subsequently revealing that their own, more successful creations were heavily 

inspired by yours is no consolation. Secondly, if you’re building in some new feature that’s 

going to make your product unique, then make it clear to the market, because if you don’t get 

that feature right the first time, no amount of fixing will ever really rescue your product. 

Mark Simms 

Editor 

mark.simms@itmagazine.uk.com 

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18 

58 

Contents 

This month in history: (1579) Drake claims 

California for England; (1906) First Grand Prix is 

staged at Le Mans; (1934) Ferdinand Porsche 

contracted to design people’s car; (1995) Space 

shuttle Atlantis docks with space station Mir 

50 

6 INDUSTRY NEWS 

6 Revolutionising aircraft wing development 

8 UK set for manufacturing fightback 

10 Counterfeit bearing problems solved 

14 Design report: packaging industry 

20 MECHANICAL JOINING Fasteners and Adhesives 

20 Lightening the load as aluminium replaces steel 

22 Fasteners and adhesives: new products 

24 POWER TRANSMISSION Gears, Chains and Belt Drives 

24 Gearbox design eliminates the need for couplings 

26 Aluminium gearboxes reduce system building costs 

24 Gears, chains and belt drives: new products 

30 MECHANICAL COMPONENTS Bearings, Slides and Lubricants 

30 Lubricants rise to a marine challenge 

32 Slides are stronger than ever 

34 Bearings, slides and lubricants: new products 

44 SENSORS & SYSTEMS Special Purpose Sensors 

44 ID code readers, 3D laser profilers and precision potentiometers 

46 DESIGN COMPONENTS Pumps and Blowers 

46 Do you repair or replace damaged pumps? 

48 Pumps and blowers: new products 

50 DRIVES & CONTROL SYSTEMS 

50 Reducing the costs of automation 

52 Making the case for vacuum contactors 

54 Drives and controls: new products 

56 MACHINE BUILDING & AUTOMATION 

56 Linear motion technology boosts plant productivity 

58 Automating the packaging process for medical supplies 

60 Electromechanical actuators designed for press-fit joining 

62 Intelligence added to pressure regulators 

64 Dynamic signals deliver cost savings in machinery safety systems 

67 Machine building and automation: new products 

68 Machinery safety: fasteners deliver protective solutions 

ON THE COVER 

Linear guides for large 

and small production 

machines See centre 

spread for details 

ENGINEERING LITERATURE 

Essential reading for 

design engineers p16 

IN THEIR VIEW 

Industry leaders air 

their views 

p17 

COMPUTER AIDED DESIGN 

Autodesk Inventor accelerates 

Antarctic research p18 

THE BIG QUESTION 

What do manufacturers need 

to do to succeed? p37 

ENGINEERING DIARY 

John Richardson’s month 

in view 

p73 

EAR TO THE GROUND 

Becky Silverton on the issues 

affecting manufacturing p74 

ALSO IN THIS ISSUE: 

Factfinders 

Events calendar 

Index to Advertisers 

p72 

p74 

p74 

Next month in Industrial Technology: The rail industry • Electric motors • Enclosures, cabinets and fans • Motion control 

and positioning • Springs, gas springs and dampers • Conveyors • Sensors and systems • Hydraulics and pneumatics • Safety 

4

More details: Write in 50 

5

INDUSTRY NEWS 


Investing to revolutionise 

aircraft wing development 

A £103 million Next Generation 

Composite Wing programme, 

co-funded by the Technology 

Strategy Board will revolutionise 

aircraft wing development in UK 

The Technology Strategy Board is to invest £25 million in 

a major new research and development programme that 

will improve future wing design processes and help to 

maximise the eco-efficiency of future aircraft designs. Part 

of the Technology Strategy Board’s collaborative research and 

development programme, Next Generation Composite Wing will 

see 17 industrial partners – led by Airbus – join forces in one of 

the most significant aviation research and technology programmes 

launched in the UK for many decades. 

The total value of the programme is £103 million. In addition 

to the Technology Strategy Board’s £25 million investment, nine 

regional development agencies and devolved administrations will 

invest a total of £26 million while the 17 industrial partners will 

contribute £52 million. The programme follows an invitation 

issued by the Technology Strategy Board in 2007 for businesses 

to submit proposals for innovative collaborative research and 

development in design engineering and advanced manufacture. 

Next Generation Composite Wing (NGCW) will keep the UK at 

the cutting edge of innovation in aircraft wing development. 

NGCW will ensure the UK is competent and well-equipped to 

maximise the use of weight-saving composite materials in future 

wing design and development. The skills and capability to design 

and manufacture in composite materials is vital in the aerospace 

industry today, helping to improve efficiency and performance 

while lowering both operating costs and gaseous emissions 

through burning less fuel. 

Leading organisations collaborating 

The three-year programme will bring together 17 leading British 

organisations, both industrial companies and research bodies. The 

programme is led by Airbus in partnership with Advanced 

Composite Group, Aircraft Research Association, Atkins, 

Bombardier Aerospace, Delmia UK, Eaton Aerospace, GE 

Aviation, GE Digital Systems, GKN Transparency Systems, 

Goodrich Actuation Systems, Hyde Group, KuKa Automation, 

Messier – Dowty, Morgan Professional Services, QinetiQ and Spirit 

Aerosystems. 

The nine regional development agencies and devolved 

administrations taking part in the programme are: Advantage West 

Midlands, East Midlands Development Agency, East of England 

Development Agency, Invest Northern Ireland, North West 

Development Agency, Scottish Enterprise, South East England 

Development Agency, South West Regional Development Agency 

and Welsh Assembly Government. 

Welcoming the programme, Secretary of State for Innovation, 

Universities and Skills, John Denham said: “Aerospace is a vibrant 

industry. Quite rightly there is pressure to develop new 

technologies so that new aircraft have a reduced impact on the 

environment. This project is an important part of meeting that 

ambition. Our investment is further proof of Government’s 

commitment to help British business respond to those demands”. 

Commenting on the decision to invest in the programme, the 

Technology Strategy Board’s chief executive, Iain Gray, said: “The 

Technology Strategy Board’s role is to ensure that the UK is in the 

forefront of technology-enabled innovation. One of the 

organisation’s key themes, as outlined in the strategic plan 

launched recently, is to invest in high value manufacturing 

technologies, where the UK leads 

or could lead. We are delighted to 

support this vital programme, 

which will also benefit the UK’s 

regions by bringing inward 

investment and generating 

high value jobs.” 

Europe well 

positioned to lead 

eco-innovation 

Policy-makers, patent scientists 

and business representatives 

gathered in Ljubljana to assess 

the performance of the current 

patent system and put the 

spotlight on a crucial factor for 

Europe’s bid to lead the world 

against climate change. 

Alison Brimelow, President 

of the European Patent Office, 

said: “Europe has set global 

standards with its policy on 

climate protection. If effective 

climate protection is a political 

aim of the EU, then the same 

must apply to its innovation 

policy and the intellectual 

property rights that support 

that policy.” Referring to a new 

set of statistics on patenting 

trends in energy-related 

technologies, Brimelow 

explained: “The current 

patenting trend is clearly 

focused on new and alternative 

energy sources. Europe is well 

positioned in the field of energy 

generation and transformation 

technologies, but past 

performance does not 

guarantee future success.” 

UK Patent office 

is 150 years old 

To mark the 150th anniversary 

of The Patent Office, listeners 

of Radio 4 programme Today 

were asked to nominate and 

then vote for the best and 

worst inventions. 

Top of the favourite 

inventions was the bicycle with 

a massive 70% of the vote, 

followed by cat’s eyes, the 

computer, the internal 

combustion engine and the 

internet. Inventions such as 

penicillin and the light bulb did 

at least get a mention. The 

internal combustion engine also 

made the list of the worst 

inventions, as did mobile 

phones, speed cameras, and 

the Sinclair C5. 

6 


For the very latest 

product information, most 

up to date industry news, 

plus useful company 

profile information, visit 

the pages of Industrial 

Technology online at 

industrialtechnology.co.uk


7

INDUSTRY NEWS 


UK economy primed for a 

manufacturing fight back 

The credit crunch could be good news for manufacturing, and 

industry is being urged to take a rare Chinese ‘opportunity’ 

Economic conditions are set for a long awaited 

fight back by UK manufacturing, according to a 

prominent economist and leading industrialists. 

At a recent private briefing, hosted by Siemens 

Automation & Drives and attended by a number of 

leading manufacturers, the economist David Smith 

outlined his thesis that the crisis in the financial services 

sector and the fall in the value of the pound could lead to 

a long-awaited rebalancing of the UK economy back 

towards the manufacturing sector 

and away from services. 

“The combination of a financial 

services sector facing weaker 

growth, the falling value of the 

pound and a manufacturing sector 

which is naturally hedged by its 

reliance on a diverse range of 

markets, limiting exposure to the 

American economy and a UK 

consumer downturn, is already 

resulting in strong growth and 

excellent export figures for 

manufacturers,” asserts Smith. “There is no known 

instance of manufacturing in any country permanently 

reversing the natural decline that is associated over time 

with a bigger share for the service sector, but rules are 

made to be broken and it would be good if British 

manufacturers could break this one.” 

Juergen Maier, managing director of Siemens 

Automation & Drives, welcomed Smith’s comments: 

“There is a very positive manufacturing story that is 

unfolding in the UK, which is based on investment in 

automation, efficiency and productivity improvements. 

This should now be acting as a counterweight to the 

doom and gloom of the services sector. After all 

manufacturing still represents half of all British exports at 

£175 billion. 

In a wide ranging speech, Smith also urged UK 

manufacturers to continue their efforts to increase 

efficiency and productivity and to look upon China and 

India as significant opportunities rather than a continuing 

threat. “How manufacturing rises to the efficiency 

challenge is a key question, particularly in an era when 

the UK will be looking for a bigger contribution from 

exports and credit will be tighter,” he says. “Evidence 

suggests that British manufacturers are responding 

positively to the challenge from China and India, but the 

balance sheet remains firmly on the side of the Asian 

economies at this time.” 

His comments are echoed by Maier: “We are no 

longer competing merely on cost. The UK is leading the 

world in high value-added manufacturing which is highly 

prized by our export markets. There is growing evidence 

that many issues associated with low cost economies, 

such as quality, servicing and after-sales support are 

encouraging the return of some manufacturing to UK 

shores from low cost economies. We believe this 

trend is set to continue.” 

david.b@atlas.co.uk 

Skills shortages are hitting hard... 

...and it will be at least five years before we begin to see the benefits of any remedial actions 

Amajor skills shortage continues to blight the 

manufacturing and engineering sectors, 

according to specialist manufacturing 

recruitment company EMS Sigma. And while 

steps are now being made to plug the gap, it will be at 

least five years before the fruits of these efforts are seen, 

according to Roy Davies, managing director of EMS 

Sigma, which has regional offices in the north-west and 

Yorkshire. (Runcorn and Leeds) 

Mr Davies first warned of a potential crisis situation 

two years ago in a bulletin produced in association with 

The Learning and Skills Council. In it, he revealed that in 

2003 just 17,000 manufacturing and engineering 

graduates were coming out of UK universities, of which 

40% were overseas students likely to return to their own 

countries. “This left us at an all-time low,” he says. “And 

while figures have recovered slightly since to around 

23,000 graduates annually, there are still serious inherent 

problems as these people will take some time to feed 

through into the system proper. 

“With not enough young people undertaking 

engineering degrees or HNDs, there are, quite simply, 

insufficient qualified engineers coming through the ranks 

– and problems will increase as manufacturing continues 

to grow because there will be less and less people to do 

the jobs available. This situation is even more acute 

because the number of people going into apprenticeships 

is also at an all-time low – a direct result of cost-cutting 

by some companies. In addition, many skills have been 

lost from the industry sector because when redundancies 

were made during the last recession, people tended to 

look to retrain and move into other sectors. 

“Fortunately, the Learning and Skills Council is now 

working hand in hand with other organisations, such 

as the Manufacturing Institute, to redress the balance, 

while we are also beginning to see the green shoots of 

the resurrection of apprenticeships, as more and more 

companies realise that they must grow their own 

workforces of the future. While these are positive 

signs, there is still a long, long way to go and it will be 

at least five tough years before we see these efforts 

bearing fruit. 

8 

INDUSTRIAL TECHNOLOGY • June 2008

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9

The Virtual Industrial Exhibition 

INDUSTRY NEWS 

.com 

3 million monthly visitors 

6,800 exhibitors 

Counterfeit 

problems 

resolved 

NSK Europe has resolved a problem of 

counterfeiting of its bearing products, and 

taken a series of measures to ensure fake 

products are kept out of the market 

NSK Europe has resolved a 

major problem of 

counterfeiting of its 

bearing products in the 

German market. The problem, which 

concerned mainly deep groove ball 

bearings – some up to 500mm 

diameter – and smaller quantities of 

cylindrical and taper roller bearings, 

came to light as a result of customer 

claims. These were investigated, 

quickly, revealing that the failed 

bearings did not meet NSK’s quality 

levels in terms of material 

specification and life. The source of 

these bearings was subsequently 

identified and the proper steps are 

being taken. 

Critical components 

“Counterfeiting of any manufacturers’ 

products is illegal and puts safety at 

risk,” said Dr Jürgen Ackermann, 

managing director of the European 

Bearings Business Unit. “Bearings 

are safety critical components in all 

Why not you ? 

Industry leaders 

meet to share ideas 

Brammer UK’s manufacturing forum 

has been hailed as a great success 

Attended by over 150 

directors and senior managers 

from manufacturing 

industry, Brammer’s first 

UK Manufacturing Forum has been 

hailed as an outstanding success. 

Led by independent experts, the 

Forum gave delegates the chance to 

learn, network and share experiences 

with industry peers. 

Aimed at sharing ideas, bestpractice 

and innovation around key 

issues central to the competitiveness 

of UK industry the event provided a 

host of interactive workshop sessions 

design by Brammer to highlight new 

opportunities for cost-reduction, 

showcase new advances in 

technology and how these 

improvements have reduced energy 

consumption or increased production 

output and efficiency, and discuss 

the latest thinking in supplier 

relationship management. 

Attending the event himself, Ian 

Ritchie (pictured), managing director 

of Brammer UK, said: “Manufacturing 

remains a key part of the UK 

economy. In an increasingly 

competitive and regulated market, 

this kind of collaborative forum is an 

important opportunity for UK 

industry to come together to share 

best practice and ideas in order to 

compete as a stronger entity in 

the global market.” 

10 More details: Write in 100 on the free information card 



Manufacturing turns 

full circle in Cardiff 

Renold has returned all 

sprocket and wheel 

manufacturing to its factory 

in Cardiff after an absence 

of over twenty years, demonstrating 

its confidence and long-term 

commitment to the factory and its 

workforce. 

Renold’s Cardiff factory was 

initially opened in 1946 as a 

dedicated sprocket manufacturing 

facility and moved to a modern 

purpose built factory in 1991. By this 

time sprocket manufacturing had 

been transferred to other facilities 

allowing what had now become 

Renold Clutches and Couplings to 

concentrate on its core product range. 

Wheels and Sprockets up to 1.3 

metres in size will now be 

manufactured by Renold Clutches and 

Couplings, strengthening the 

manufacturing capabilities of the 

Cardiff facility. Martin Slade, Renold 

Clutches and Couplings’ sales director 

said: “We’re delighted that sprocket 

and wheel manufacturing has been 

returned to Cardiff as the factory was 

originally constructed here for that 

very purpose. It is also recognition of 

the excellent and dedicated workforce 

we have here who put everything into 

the quality of our products whilst 

maintaining high levels of 

productivity and customer care.” 

types of equipment and machinery, 

and their reliable performance is a 

safeguard for personnel against 

catastrophic failures that could cause 

injury. However, this safeguard is 

totally invalidated by the use of 

counterfeit bearings, which do not 

have the quality guarantees provided 

by reputable manufacturers. Initially 

users may be attracted by the low 

price of counterfeit bearings, but 

ultimately there may be a very heavy 

price to pay as a result of premature – 

and even catastrophic – failure of 

these bearings.” 

Preventive measures 

NSK has undertaken measures to help 

prevent any further supply of 

counterfeit versions of its bearing 

products into the market. The 

company is warning customers to 

beware of bearings that are being 

offered at very much lower prices, 

compared to NSK’s standard price 

list. Also as an effective 

countermeasure, NSK is increasing its 

product training for NSK Authorised 

Distributors, to enable them to 

recognise counterfeit products easily. 

NSK already trains all its internal 

sales engineers so that they are 

capable of distinguishing an original 

NSK bearing from a counterfeit unit. 

“The best safeguard of all, during 

problems of this type, and generally, is 

only to source bearings from NSK 

Authorised Distributors,” said Dr 

Ackermann. “These bearings are 

underwritten by NSK’s outstanding 

quality in manufacture and 

operation.” 

In further news, NSK has 

announced that it has signed a multiyear 

contract with Moventas Oy in 

Jyväskylä, Finland, for the 

procurement and delivery of NSK 

rolling bearings for the Moventas 

Wind Gears business. The term of the 

contract is initially four years, with the 

option of continued cooperation 

beyond this contract period. The value 

of the contract is several tens of 

million Euros. 

This new contractual agreement is 

the result of the positive working 

relationship that these two leading 

companies have enjoyed for several 

years, and is the logical next step of 

the partnership. 

The contract is also to provide 

long-term security for supply, as both 

companies have planned extensive 

investments in new production 

capacity to support the future 

potential growth in wind power 

stations. Both companies are 

continuously expanding their market 

share in this field. 

Moventas is a leading expert in 

mechanical power transmission. The 

company designs, manufactures and 

markets mechanical power 

transmission solutions and services 

for the process and energy 

industries. 

June 2008 • INDUSTRIAL TECHNOLOGY 


11

COMPANY NEWS 

Ready to 

Rightsize! 

Dealing with 

end of life TVs 

Hepco bearings prove immune to ingress 

by glass dust in CRT recycling machine 

CRT Heaven has created a 

cathode ray tube (CRT) 

screen splitting process that 

is unparalleled in its speed, 

energy efficiency and reliability. The 

very nature of that process however 

creates sub-5 micron glass dust that 

can – and did – play havoc with 

system’s linear bearings. Dust 

infiltrated the ball-race causing 

premature failure of the bearings on 

the first ever CRT Angel machine but 

a swift change to HepcoMotion linear 

bearings made the problem shortlived. 

This move to minimise downtime 

and maintenance was an important 

one as this CRT processing 

technology is now in worldwide 

demand. As a result of recent trade 

shows the company expects to install 

five of these machines in the coming 

months. As its name suggests CRT 

Heaven deals with end-of-life 

televisions and monitors. Its Angel 

CRT recycling system quickly and 

accurately separates the unleaded 

and leaded glass portions of the 

tubes, a process that allows the use 

of these raw materials in the 

manufacture of new CRTs and other 

emerging products. This technology 

is vital in the light of the European 

WEEE Directive that became law last 

year. CRTs are now classified as 

hazardous waste primarily because 

of their lead content which can 

account for up to 25% of their 

weight. Accordingly they cannot be 

sent to landfill. 

Government figures suggest that 

in the region of five million CRTs are 

set to enter the UK waste stream per 

year over the next decade and 

beyond. The need for a cost- effective 

method of material reclaim is clearly 

evident and this has prompted the 

introduction of the CRT Angel, an 

efficient machine that automates an 

important part of this process. 

L-force 8400 Inverter Drives 

The new generation of frequency inverters. 

Perfectly matched for your machine. Consistent in build, startup, 

operation and service phases. Three versions - the BaseLine, 

StateLine and HighLine - with distinctly graduated 

functionality and behaviour means the right 8400 inverter is 

ready for you. Thats what we call Rightsizing! 

www.lenze.co.uk 

Lenze 

Name change for 

Amco Marelli 

Amco Marelli has announced a 

change of operating name to Marelli 

UK. The move reflects closer 

integration with the Italian 

manufacturing plant, MarelliMotori, 

and the continued strengthening of 

the Marelli brand within the FKI 

Energy Technology Group. 

Jiskoot acquired 

by Cameron 

The Measurement Systems division 

of Cameron as announced the 

acquisition of Jiskoot. For Jiskoot, 

the power and capital behind a 

company of Cameron’s size and 

reputation allows the operation to 

take advantage of emerging global 

opportunities for larger projects and 

engineered sampling systems. 

ABB signs up two 

new distributors 

ABB has appointed TLA UK and 

CSE Industrial Electrical Distributors 

at the front line of its Strategic 

Industrial Partner (SIP) channel for 

industrial and automation products. 

These distributors have been 

selected on the basis of their 

extensive stock of ABB products and 

commitment to the ABB brand. 

Saint-Gobain 

acquires Rencol 

Saint-Gobain has acquired Rencol 

Tolerance Rings, a UK based 

subsidiary of ERIKS, for a total of 

£12.5 million. The arrangement 

includes the company’s activities in 

Bristol and Japan, and the 51% 

controlling interest in Rencol MMI 

Technology in Singapore. 




Vacon and PPT help 

drive energy savings 

Vacon and PPT Drive Systems 

have joined forces to offer 

energy efficient solutions 

based on variable speed AC 

drives. The partnership offers free site 

surveys, energy saving calculations 

and complete solutions to tackle 

climate change. 

Using variable speed drives 

(VSDs) to control the speed of motors 

delivers big energy savings, enabling 

more cost effective production, 

reducing the carbon footprint and 

playing a part in meeting government 

emission targets. Despite this, less 

than one in ten electric motors in the 

world is fitted with a VSD, whereas 

there is financial justification for using 

a VSD with at least one in three 

electric motors. 

The partnership between Vacon 

and PPT Drive Systems offers 

customers from all industrial 

segments the opportunity to see how 

energy efficient drives can reduce 

energy usage and cut their energy 

Wittenstein is new name 

for Alpha Gearheads 

From 1st July, Alpha Gearheads 

will change company name to 

Wittenstein, taking on the name 

Colour sorters for 

PET recycling 

Closed-Loop Recycling has placed 

an order valued at £266,000 for 

S+S Spektrum colour sorters for 

its new food grade plastic 

recycling facility being built in 

Dagenham. The new plant, due to 

come on-line later this year, will 

recycle 35,000 tonnes of mixed 

plastic drinks bottles that would 

otherwise have been exported for 

recycling or sent to landfill. 

New appointment 

for Parker Seals 

Michael Forstner has assumed 

overall responsibility for the 

O-Ring Division of the Parker Seal 

Group Europe. He succeeds 

Markus Becker, who has moved to 

the Parker Tube Fittings Division. 

bills. Richard Horsman of PPT Drive 

Systems comments: “Vacon is one of 

the world’s leading AC drive 

manufacturers, and PPT specialises in 

the applications of VSD products and 

systems. The partnership between us 

offers a solid resource, and by tackling 

climate change through energy 

efficient drive systems, we can offer 

our customers versatile solutions and 

substantial cost savings.” 

of its parent company. Alpha already 

sells products under both its own and 

the Wittenstein names, so says that it 

makes perfect sense to operate under 

one common brand worldwide. 

Wittenstein drive technology is 

predominantly used in applications 

with special requirements in the most 

diverse branches of industry, at 

locations near and far under the most 

extreme conditions. Examples include 

crude oil exploration, Formula 1 

technology and aerospace simulation. 

Wittenstein is setting benchmarks 

worldwide with outstanding 

performance and individual solutions. 

Wittenstein AG is active in seven 

fields of business: servo gearheads, 

servo drive systems, medical 

technology, miniature servo units, 

innovative toothing technology, 

powerful actuator systems and 

intelligent electronic solutions. The 

companies that use the Wittenstein 

name are committed to paving the 

way for greater freedom of innovation 

in the future. Alpha’s web address will 

change to www.wittenstein.co.uk, but 

all telephone numbers will remain 

Extra 

NKE AUSTRIA makes the most frequently used deep groove ball 

bearings extraordinary, with numerous technical improvements: 

> Newly developed double-lip 

labyrinth seal RS2 

> New, special low-noise lubricant 

> Superior surface finish on 

raceways 

> Closer grade balls 

> 100% noise testing 

The new NKE POP range single row deep groove ball bearings 

ensure low running noises and long service life even for 

demanding applications. 

Please contact us for further 

information: 

NKE AUSTRIA GmbH 

Ennser Strasse 41a 

Steyr-Gleink Austria 

Tel: +43 7252 86667 

Fax: +43 7252 86667 59 

e-mail: info.a@nke.at 

www.nke.at 

ORDINARY! 

The new NKE POP range 

Single row deep groove ball bearings 

> Quality in the premium class 

Old 

NEW 

Noise [dB] 

Old 

NEW 

Vibrations [µm/s] 

The new NKE POP range single row 

deep groove ball bearings with reduced 

running noise and vibrations. 

B E A R I N G S 



IT 

13

DESIGN REPORT 

Packaging Industry 

Bottling solution 

is in the bag 

When Knight Warner Limited was presented 

with a very specific design brief for a new 

bottle debagging machine, Siemens A&D’s 

expertise and technology meant the company 

was able to rise to the challenge 

Established in 1998, Knight Warner started out 

as an industrial automation control integrator, 

operating mainly within the food and beverage 

sector. Six years later, and in an attempt to 

increase the company’s market share and to enable the 

team to take on more complex projects, Knight Warner 

expanded its operation to include mechanical handling. 

This led to the appointment of technical director, Colin 

Powell, whose expertise in mechanical handling, having 

worked with and alongside many blue-chip clients, 

meant that Knight Warner was now well placed to 

provide clients with both bespoke machinery and 

technical solutions across a wide range of industry 

sectors. 

This was put to the test recently when Knight 

Warner was approached by a customer who had a very 

specific design brief for a new bottle debagging 

machine. 

High speed operation 

There were several things the Knight Warner design 

team had to factor in. The customer wanted the new 

machine to be capable of much greater speeds than its 

existing line without increasing its footprint and that line 

integration of the new machine had to be simple, 

efficient, cost-effective and reliable. In addition, it was 

also paramount that the lightweight bottles going 

through the machine remained stable and that required 

feed speeds of bottles per minute were also met. 

“Meeting the specifics of this design brief presented 

the team with quite a challenge,” comments Pete 

Warner, sales director at Knight Warner. “Although the 

team had experience in developing equipment 

specifically to handle lightweight and 

delicate products, they had never developed a 

machine to this kind of design brief before.” The team 

set about designing the debagging machine and 

identified that the key to success would be working in 

partnership with a company that had experience in this 

field and a history of supplying reliable technology. 

All encompassing package 

“Having worked with many manufacturers in the past, 

we were familiar with a number of different systems,” 

continues Warner. “However, the deciding factor was 

whether a supplier could provide a good, all-round 

package, including expert technical support should we 

require it. Following a detailed selection process we 

chose Siemens A&D. The main reason for this was the 

fact that the company was able to provide the project 

hardware we required, including the servo drives, PLC 

and HMI and we were confident in the company’s 

ability to work alongside us throughout the project, 

guaranteeing success for both ourselves and our 

customer.” 

In order to meet the objectives of the design brief, 

Knight Warner needed to design a machine that could 

achieve accurate and seamless control, moving the 

bottles smoothly throughout the debagging process. By 

opting for Siemens’ servo drives in all main movements, 

together with a front retaining mechanism and vacuum, 

Knight Warner ensured bottle stability despite the fact 

the bottles would be moving in single file and at a very 

high speed into a filling system. 

“We are delighted with the final machine,” 

comments Warner. “Not only have we achieved our 

customer’s goal of developing a machine 

with a relatively small footprint of 1.8m by 6m, 

we have also achieved bottle speeds in excess of 

any existing filler. With this high output 

capability our machine will definitely increase 

our customer’s line efficiency and productivity and 

the success of this project means we can apply the 

same technology to other machines, increasing the 

number of customers who can benefit. 

“The support offered by Siemens throughout the 

project was invaluable and they became valued 

members of the team whilst we were designing this 

machine,” he continues. “Having benefited from both 

the company’s expertise and technology, we would 

definitely consider working with Siemens again in the 

future.” 

Adding value 

Keith Thornhill, business development manager for 

packaging machinery solutions at Siemens A&D 

comments: “We are at our best when we can add value 

and integrate a complete Siemens control solution, 

based on our Totally Integrated Architecture approach, 

all networked on Profibus – from HMIs via the PLC to 

the Drives and multi axis motion control aspects of the 

project. “This was a great project to be involved in with 

some very specific design criteria and objectives. 

Working closely with Knight Warner we were able to 

help them develop a machine which far exceeded 

both their own and their customer’s expectations.” 

MORE INFORMATION: 

Enter F145 on the card, or visit ‘latest issue stories’ at 

www.industrialtechnology.co.uk for further details from 

Siemens Automation and Drives 

ELESA (UK) Ltd. 

26 Moorlands Estate 

Metheringham 

Lincolnshire LN4 3HX 

sales@elesa.co.uk 

www.elesa.co.uk 

CFS. hinges with built-in 

safety switch 

Two functions in one body to enter in safety 

machine protections areas 

Technopolymer hinge body for assembly on the most common 

aluminium profiles; switch set with positive opening integrated 

in the hinge body for a quick, easy and tamper proof assembly. 

For more information on automation 

equipment, and other machine 

building technologies, visit 


14 


YUASA 

The most reliable industrial batteries in the world! 

No small claim - but then we’re no small company! 

Since the early part of the 20th Century Yuasa has been producing reliable battery power for world industry. 

Today - Yuasa is one of the largest producers of batteries in the world for industrial, commercial and leisure applications. 

As an International Group owning many production plants strategically located around the globe we also hold the very 

strong belief that we must identify, develop and invest in emerging battery technologies to meet the demands of a 

power-hungry global economy. 

From high capacity, heavy duty batteries through to small Nickel Metal-Hydride cells, Yuasa batteries are a first choice 

for anyone demanding a totally reliable power source. And that choice is one of the widest! It covers batteries for UPS, 

Telecom, Electronics, Mobility, Security, Electrical, Emergency Lighting, Medical, Automotive and Leisure applications. 

To complement our products Yuasa also offer a full technical support and customer care service as dependable as our 

batteries – batteries that we believe to be the most reliable in the world! 

For a full presentation on Yuasa and all of our products please contact our 

Sales Department on 08708 500 312 or visit www.yuasa-battery.co.uk 

www.yuasa-battery.co.uk 

enquiries@yuasa-sales.co.uk 

More details: Write in 150 on the free information card 15

ENGINEERING LITERATURE 


Catalogue for 

drive systems 

By turning to pages two and three 

of the new product range 

catalogue from Framo Morat, 

readers will be left in no doubt that the 

company has a rich heritage in 

manufacture of quality drive systems 

components. These products are now 

available from RA Rodriguez in the UK 

and many offer performance benefits. 

The Framo range includes compact 

slip-on geared motors, linear actuators 

and push-pull linear chains. All are based 

on modular design principles and are 

customised to suit each application. Full 

technical data on all of these products are 

provided, along with application notes. 

Want a copy? .........................Enter F163 on the card 

Guides for your book shelf 

and the latest brochures 

Every month, your hard working Industrial Technology team 

brings you the best of the latest industry guides 

Aerotech has released an updated 

Automation Solutions brochure for 

laser processing, medical device 

manufacturing and life sciences. The 36 

page industry and market specific 

information resource demonstrates 

Aerotech’s ability to deliver low cost of 

ownership motion system solutions 

through advanced motion controls and 

superior mechanical systems that 

provide increased speed and throughput, 

superior accuracy and improved 

reliability. The brochure is available in 

both English and German. 

The brochure covers positioning 

systems solutions for laser cutting, 

drilling, welding, marking and ablation 

with highlighted sections on hermetic 

seam welding, medical stent 

manufacture and other cylindrical 

materials processing applications. 

Want a copy? ......................Enter F164 on the card 

Vacuum equipment 

Edwards 

This 400-page catalogue from 

Edwards features information 

on the company’s range of 

vacuum pumps and equipment 

for scientific, industrial, 

biofuel, semiconductor and 

vacuum coating applications. 

Grid couplings 

Rexnord 

The Falk Steelflex coupling 

offers significant savings over 

alternative designs when 

comparing initial cost, spare 

parts, installation and 

maintenance. It includes a five 

year heavy-duty warranty. 

Enclosures 

Spelsberg 

Spelsberg has released a new 

product catalogue crammed 

full of wiring products and 

accessories, including its huge 

range of GRP polycarbonate, 

polystyrene and aluminium 

enclosures. 

Pressure gauges 

Bailey & Mackey 

This new brochure covers 

Bailey & Mackey’s ranges of 

diaphragm and differential 

pressure gauges. Running to 

25 pages, it provides technical 

information, specifications and 

working drawings. 

Dispensing 

EFD 

EFD has released a new 

catalogue featuring a wide 

range of products for applying 

adhesives, lubricants, sealants, 

solder pastes and other 

assembly fluids in accurate, 

repeatable amounts. 

Want a copy? .....Enter F165 on the card 





16 


In Their View... 

Two industry heavyweights air their 

views on the key topics of the moment. 

visit us on 

STAND E12 

HALL 4 

FARNBOROUGH 

INTERNATIONAL 

AIRSHOW 

Why are we surprised? 

Politicians are always being hauled over the 

coals these days, with whistle blowing events 

usually by their mates in the House, who 

probably have not managed to get their snouts 

sufficiently far into the trough. The cry goes up, and 

reviews of the rules are called for to help the poor 

dears avoid these ‘administrative errors’. This I can 

assure you will be a total waste of time and money. 

How cynical, I hear you say. It must be very easy 

for a man not to notice £100,000 landing in his bank 

account, or not to realise that funding your sons’ 

education through the public purse is a sensitive act 

that, even if justified, should be scrupulously 

documented to avoid doubt. But these people who 

manage our affairs seem not to do this and lose 

documentation with an ease which in itself should be 

a crime. Could you imagine the outcry if in the 

engineering world, should a job go awry, no drawings 

or calculations could be found; unthinkable. 

But why are we surprised? We elect to the House 

of Commons a breed of people who are in the main 

lawyers, economists, people who have just studied 

politics, etc. What tend to be in a minority are 

engineers, surveyors, builders and so on – or should 

we just call them ‘real wealth generators’. Those who 

have dealt with the law at any level know that the 

main thing to suffer with this side of our society is the 

truth: they are trained to distort and create 

interpretations of documents which the man in the 

street can only marvel at. It therefore follows that 

whatever rules for good and moral behaviour are put 

in place, the majority of our political friends will find a 

way of distorting them 

This country at a turning point. We have a balance 

of payments that is surely unsustainable, relying for 

too long on a thoroughly incompetent Finance 

industry to keep us afloat. Now the words are 

beginning to be heard from politicians that 

manufacturing matters but do the people saying them 

understand the real meaning? Let us all who are in 

engineering hope so. 

Ian Morris 

Director 

British Fluid Power Association 

What price fluid power? 

UK manufacturing is experiencing a sustained 

period of growth, without output and orders at 

a ten year high. Success has been hard won, 

and has demanded a focus on productivity, 

operational flexibility and cost control. However, if this 

resurgence in UK manufacturing is to continue, then 

the use of traditional production methods needs to be 

questioned. 

In particular, fluid power technologies may no 

longer be capable of delivering the levels of 

performance and cost-effectiveness that will be 

required in ever more competitive global markets. 

Pneumatics and hydraulics systems can generally 

be complex, wasteful and expensive. For example, 

compressed air systems consume more than 15% of 

all factory energy, while the capital, operating and 

maintenance costs of hydraulic systems are often 

extremely high. In addition, the long term 

development potential of these technologies is limited, 

especially in their ability to offer ever higher levels of 

performance, accuracy and energy efficiency, with a 

high return on investment. 

By comparison, an emerging generation of 

sophisticated electro-mechanical drive technology now 

looks set to offer manufacturers a number of exciting 

opportunities to reduce costs and increase productivity 

still further. Perhaps, as importantly, this technology 

offers clear advantages for precision control and 

positioning, giving instant power on demand and 

greater flexibility in a wide range of production 

applications. 

The bottom line is that the through-life cost of 

electro-mechanical technology can be considerably 

lower than for traditional fluid power systems. 

Combined with greater functionality, precision control, 

less noise and contamination and the potential to 

build production systems that can easily be adapted 

as manufacturing needs change, this truly gives 

engineers a technology that will support the 

continuing success of UK manufacturing into the 

future. 

Nick Brooker 

Marketing Manager 

SKF UK 

In our business, 

motor failure 

isn’t an option… 

In the hostile reaches of outer 

space, motor malfunction can 

threaten an entire mission. 

That’s why NASA chose maxon to 

supply 39 of the motors in each of 

its latest Mars rovers. 

And why aerospace designers 

worldwide turn to maxon for that 

same dependability when human 

lives are at stake. 

With a legendary reputation for 

reliability, maxon components are 

the first choice for applications 

where there is no room for failure. 

Artificial hearts… formula one 

engines… satellite navigation 

equipment… surgical tools… in 

fact everything from robots on the 

surface of Mars to welding 

machines at the bottom 

of the North Sea. 

Don’t take 

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More details: Write in 170 on the card 

17

DAVE BROWN’S 

CAD ROUNDUP 

Computer aided design, engineering and manufacturing 

Autodesk Inventor accelerates 

Antarctic research 

Autodesk Inventor is helping the British 

Antarctic Survey team get products that 

right first time and into the field faster 

When your window of 

opportunity to get new 

equipment into a site for 

critical environmental 

research is just once a year, time is 

very clearly of the essence. So it is for 

the engineering team at British 

Antarctic Survey, a UK Government 

organisation responsible for 

undertaking the majority of Britain's 

scientific research on and around the 

Antarctic continent. The engineering 

“ 

team’s remit is to produce or 

‘ruggedise’ equipment for use in the 

Antarctic research and on its ships. 

Key to delivering its vital support 

projects on time, and within limited 

Government budgets, is the 

engineering team’s use of the latest 

technology. Specifically, it uses 

Autodesk Inventor to design and 

prototype the products it must produce 

to support the important work that 

takes place in one of the most hostile 

environments on the planet. 

Andy Tait is a mechanical design 

engineer at British Antarctic Survey 

Improving vehicle design at Honda 

Computational fluid dynamics 

software FLUENT for CATIA 

V5 was chosen by Honda R 

for fluid flow analysis and has 

contributed significantly to improving 

design process efficiency. Honda R is a 

research and development subsidiary 

of Honda, one of the world’s leading 

automotive manufacturers. 

At Honda R, computer-aided 

engineering (CAE) has long been 

considered an important foundation in 

support of the company’s highly 

(BAS), within technical services in the 

Antarctic and Marine Engineering 

Group. “We support the scientific 

Thanks to Inventor, we were able to get 

our models right first time, and deliver the 

finished product with incredible speed” 

” 

research being carried out in the 

Antarctic, and support all of BAS’s 

different divisions,” he explains. 

Tait is something of a fan of 

Autodesk Inventor – a dynamic 3D 

package enabling highly accurate and 

easy-to-visualise digital prototyping. In 

fact, it was only thanks to Inventor 

that Tait’s team managed to turn 

around a very last-minute project to 

design a probe-based ground radar 

system, to be mounted on the front of 

a snowcat. Its purpose is to look for 

cracks on the snow surface and 

prevent the snowcat from plunging into 

advanced technology. To enhance 

efficiency in design and manufacturing, 

the company introduced computational 

fluid dynamics (CFD) into the design 

cycle as well as in research and 

development. 

“CATIA V5 already has structural 

analysis features, which now are used 

efficiently by designers,” says Honda R 

chief engineer Kouhei Oosono. 

“Equipped with the highly reliable 

FLUENT solver as its core, FLUENT for 

CATIA V5 technology has made CFD 

a crevice. “This was an important 

project, but it came to us very late in 

the day,” Tait explains. “Yet we were 

able to get it right first time thanks to 

Inventor, and deliver the device with 

incredible speed.” 

Summarising some of the key 

benefits of Inventor, Tait says: “The 

solid modelling side, for us, is the way 

forward. Inventor grows in its 

capabilities every year, with the 

addition of new features. But what we 

love about Inventor is that it is photorealistic. 

Not only does this help us get 

our models right first time, it enables 

the scientists to feature the devices in 

their presentations. With the financial 

restraints we are operating under, we 

can only produce one finished product 

which then gets sent out to the 

Antarctic, but with Inventor, the 

scientists can demonstrate the product 

to help them explain their work when 

presenting their discoveries to the 

Science Institute at conferences and 

seminars.” 


Enter F184 on the enquiry card 

analysis as easy as structural analysis. 

This has resulted in increased 

significance of CAE tools in our 

development work.” The development 

of by ANSYS of FLUENT for CATIA V5 

technology was motivated by the need 

to bring the superior fluid analysis 

capability of FLUENT software into the 

CATIA V5 environment. ANSYS 

engineers developed the product in 

concert with Honda. 



PTC announces 

CoCreate 2008 

PTC has announced CoCreate 

2008 – the latest release of its 

explicit CAD, PDM and 

collaboration software. CoCreate 

2008 brings new time savings to 

companies challenged with 

shrinking design cycles and 

pressures to quickly create 

product designs in intensely 

competitive markets. These 

capabilities will help users 

explore more style options 

quickly and keep product designs 

aligned with manufacturing 

processes. 



Free simulation 

results viewer 

Moldflow Communicator 2.0 is a 

free simulation results viewer 

that allows distributed product 

teams to visualise, quantify and 

compare Moldflow analysis 

results. New features allow the 

Communicator to be accessed by 

a wider audience and updates to 

the user interface and new 

operating system support should 

result in increasing its position 

as the leading plastics simulation 

results viewer. 



C# Synchronizer 

for Artisan Studio 

Artisan Software Tools has 

launched the C# Synchronizer for 

Artisan Studio. It facilitates a 

‘best-of-breed’ methodology for 

C# programmers by enabling 

software architecting to be 

undertaken in UML using Artisan 

Studio while allowing them retain 

the context of C#-aware features 

by implementing the coding 

detail using their preferred C# 

IDE or program editor. 



18 


INTEGRATE – Add electrical 

controls data to create a more 

complete digital prototype. 

CREATE – Build a digital model 

using Autodesk ® Inventor 

software to define form, fit 

and function. 

VALIDATE – Simulate 

real-world performance 

before ever building a 

physical prototype. 

HOW DIGITAL PROTOTYPING 

ENABLES 17,000 PARTS TO 

WORK FLAWLESSLY BEFORE 

THEY’RE EVER BUILT. 

autodesk.com/digitalprototyping 

Image courtesy of Mastenbroek LTD 

Imass 

Gateshead \ Inverurie 

+44 (0)191 213 5555 

+44 (0)1467 629900 

www.imass-ids.co.uk 

Imass with its award winning services is the ideal 

choice when moving to 3D. Take your design process 

& business to the next level with Autodesk’s leading 

UK supplier of manufacturing design tools. 

 

 



Laser sensors 

for displacement, 

position & thickness 

MECHANICAL JOINING 

Fasteners & Adhesives 

Lightening the load as 

aluminium replaces steel 

Arnold Umformtechnik has replaced steel with aluminium in a new 

range of fasteners, providing major weight advantages and meeting 

the need for fastening challenging materials such as magnesium 

New sensors: 

- Series 2210 for large offset 

distances 

- Series 2220 for extreme 

fast measurement: 

Measuring rate 20 kHz 

- Series 2200LL for metallic, 

shiny surfaces 

The correct sensor 

for your application: 

Measuring ranges 2 to 750 mm 

Linearity from 1 μm 

Resolution from 0.03 μm 

Measuring rate up to 37 kHz 

Largest selection worldwide 

www.micro-epsilon.co.uk 

Micro-Epsilon UK Ltd. 

Call +44 (0) 151 355 6070 

info@micro-epsilon.co.uk 

In almost every area of industrial 

production, aluminium and magnesium 

are now established as innovative 

structural materials for use in multiple 

combinations. For example, magnesium has 

the appropriate mechanical and physical 

properties needed to manufacture thinwalled 

die-cast parts. To ensure that housing 

sections, brackets and stiffeners made from 

magnesium can be securely fitted and 

assembled, the material composition of the 

screw fasteners has to be carefully 

considered. 

Arnold Umformtechnik has addressed 

this requirement with the development of 

the Alufast range of screws. The Al 6065 

alloy used has consistently proved to 

possess the properties required to fasten 

magnesium components. Alufast provides 

an optimised pairing of materials, distinctive 

mainly for heat expansion and anti-corrosion properties and 

for recycling. At the same time Alufast products comply with 

the high specifications regarding clamp load, stability at 

temperature and weight saving. Comprehensive trials have 

shown that Alufast meets the markets’ needs to the fullest 

extent. 

Alufast in place of steel 

Magnesium elements place special challenges on the screw 

fastening. When steel screws are used, the low rigidity values 

of the backing run and the nut thread require deep 

penetration depths or large head support surfaces. This 

creates screw lengths that can rapidly counter the weight 

advantage gained from the material. The widely differing heat 

expansion characteristics of the combined materials can also 

quickly result in loss of clamp force, putting the functional 

properties in jeopardy. Contact corrosion places a further 

burden on the quality of the fastening. 

High-strength aluminium screws in Arnold’s Alufast range 

are the proven answer to these challenges. Alufast fasteners 

are distinctive for the appropriate aluminium alloy selected for 

use, combined with a perfected heat treatment process for the 

screws. Alufast products are particularly suitable for creating 

screw fastenings on magnesium components under corrosive 

and thermal load. The Al 6056 alloy, together with the 

adapted heat treatment process, assure the process reliability, 

tensile strength and expansion properties of the screw. While 

steel screws require very large head settings for fastening 

magnesium, with Alufast a standard design is sufficient. 

Moreover Alufast offers excellent corrosion properties in 

contact with magnesium. Lower potential differences mean 

much lower corrosion potential compared with steel versions. 

The mechanical properties of the screws remain fairly stable 

over a long-term period of load, up to a temperature of around 

150°C. Short-term temperatures of up to around 180°C 

likewise produce no critical incidents. Alufast screws can be 

used uncoated to fasten standard magnesium die-cast alloys, 

such as Az91 HP. They require no further surface coating, and 

the corrosion resistance of the parts remains stable 

throughout the entire operating period. 

Relaxation processes, especially in screwed magnesium 

parts, can lead to loss of clamp load, particularly where the 

location of the fasteners is subjected to a high temperature 

loading. When steel screws are used at these high 

temperatures the screw fastening is subjected to a thermally 

induced additional load, which would then normally result in 

a relaxation process in the magnesium – possibly even 

causing plastification – and creating a drop in clamp load at 

higher operating temperatures. However, cold temperatures 

can cause the gauge of the clamped magnesium component 

to be thicker than the length of the steel screw. When steel 

screws are used this also results in a conspicuous loss of 

clamp load, which can cause the fastening to fail. 

With their similar heat expansion behaviour Alufast screws 

show a much lower loss of clamp load in fluctuating 

temperature ranges. 

Further, Alufast aluminium screws are three times lighter 

than the steel alternatives. If we look for example at a major 

engine part such as a gearbox, the weight-saving in a gearbox 

which uses 20 screws can be as much as 340 grams. Over 

an annual production run of, say, 100,000 gearboxes, that 

would translate to a saving of well over 30 tons. And the 

weight can be reduced even further because when Alufast 

fasteners are used, it is possible to select a much smaller 

size of screw, without loss of quality. 


Enter F205 on the enquiry card or visit ‘latest issue stories’ at 

www.industrialtechnology.co.uk for further details. You can also find more 

stories from Arnold Umformtechnik and more news on fasteners 

20 



TOX ® -Round-Joint 

Sheet metal joining technology 

RIVETING 

WITHOUT RIVETS 

• More cost effective than spot welding 

• Many material combinations 

Proven quality 

• Millions of applications in the automobile and 

white goods industries 

• Worldwide presence 

• Reliable with the TOX ® - Monitoring-Network 

TOX ® 

PRESSOTECHNIK Ltd. 

Room 23, Stafford Business Village 

Dyson Way 

Staffordshire Technology Park 

Beaconside, Stafford 

ST18 0TW 

Tel. +44(0) 1785 887903 

Fax +44(0) 1785 887927 

www.tox-uk.com 


TRISERT-3 

THE NEW STAINLESS STEEL INSERT 

FROM TAPPEX 

• For plastic and 

metal alloy 

applications in 

critical environments 

• Stainless Steel 303 

and 316 plus case 

hardened steel with 

a zinc nickel, trivalent 

passivated finish 

new extensive 

technical literature 

now available 

+44 (0) 1789 20 66 00 

sales@tappex.co.uk 

www.tappex.co.uk 


 

 

 

 

MASTER BOND EP30P 

■ Adhesive/sealant, coating, 

encapsulation compound 

■ Cures at ambient temperatures 

■ Low-viscosity 

■ Optically clear 

■ High bond strength to similar 

and dissimilar substrate 

■ Superior electrical insulation 

properties 

■ Outstanding chemical resistance 

■ Low shrinkage 

■ Easy to use 

■ Convenient packaging 

Prompt Technical Assistance 

Grades Available Which Meet NASA, UL, and USP Class VI Specifications 

Leading Insert Technology 

TECHNICAL SALES REPRESENTATIVES: 

Tel: +44-(0)207-039-0034 ■ Fax: +44-(0)207-060-0628 

www.masterbond.com ■ eutech@masterbond.com 

More details: Write in 212 on the free information card More details: Write in 213 on the free information card 21

APPLICATIONS • PRODUCTS • ENGINEERING EXCELLENCE 

• CUSTOM DESIGN = ALL COME AS STANDARD 

MOTION CONTROL 

SOLUTIONS 

PRE-LOADED 

RACK AND 

PINION DRIVES 

DIGITAL 

TENSION 

CONTROL 

SYSTEMS 

HIGH 

PERFORMANCE 

SERVO 

PLANETARY 

GEARHEAD 

MECHANICAL JOINING 

Laser power for 

remote welding 

Rofin CO2 slab lasers are key to a new 

remote welding system that offers speed, 

efficiency and large working envelope 

The latest innovation from Rofin to 

incorporate its efficient and reliable 

slab laser sources is the Remote 

Welding System. The Remote Welding 

System (RWS) concept has the laser 

system mounted above the working area, 

on a gantry, with the laser beam being 

delivered to the working area below by a 

series of mirrors. The complete system is 

enclosed by perimeter safety guarding 

allowing for safe and easy operation. 

Depending upon the application 

being considered, the system can 

incorporate one of a range of CO2 slab 

lasers available from Rofin. One option 

available is the Rofin DC 060W, a CO2 

Slab laser with an average output 

power of 6kW and beam quality factor 

of better than 0.9. This laser can 

produce a spot diameter of 600µm for 

the longest focal length offered of 

1600mm. 

The nearly perfectly Gaussian beam 

of the Rofin slab laser gives a depth of 

focus measured in tens of millimetres 

and the effective working envelope of 

the RWS has now been increased to 

1500mm by 2000mm, driven by the 

need to enhance application flexibility. 

Placing the beam-steering mirror on an 

independent high-speed linear-motor 

driven axis further extends the overall 

travel of the focusing lens thus further 

increasing the working envelope in the 

Y axis. This ability to determine the 

position of the beam steering mirror 

Fasteners & Adhesives 

provides even greater flexibility for the 

operator when programming around 

clamping fixtures and part tooling. 

The high powered motion motors, 

together with increased processing 

power in the motion controls, now gives 

typical indexing times of less than 

50ms between weld stitches. The rapid 

traverse motion between individual 

processing points, described as “rapid 

move”, sets new standards with regard 

to speed of operation in multiple spot 

weld applications. 


Enter F227 or visit ‘latest issue stories’ at 

www.industrialtechnology.co.uk for more info 

from Rofin-Baasel 

Fastening 

protection for 

plastic moulds 

Engineered fastener manufacturer 

Spirol Industries has introduced 

the new CL101 

and CL111 range 

of solid knurled 

compression 

limiters. They 

are designed 

to preserve 

the integrity of 

a plastic 

threaded joint 

when a metal bolt is 

inserted, preventing creep, 

loosening and eventual failure of 

the joint. 

The CL101 is unheaded and the 

CL111 is a headed compression 

limiter. Both are available for M3 to 

M8 bolt sizes and in lengths of 3mm 

to 20mm to suit the length of the 

fastening. They are made from brass 

and can be either moulded or pressed 

into position. 

The compression limiter absorbs 

the load when the bolt has been 

tightened to its recommended value. It 

isolates the plastic from any excessive 

compression loads with individual 

compression limiters having rated load 

levels from 2.20 to 17.04kN. 

All versions have square ends to 

ensure optimum contact with the 

mating surface and the knurl feature 

ensures excellent retention values. The 

headed CL111 version eliminates the 

need for a washer. 


Enter F225 on the card, or visit ‘latest issue 

stories’ at www.industrialtechnology.co.uk for 

further details from Spirol Industries 

Approval in low outgassing tasks 

HIGH 

PRECISION 

LOW 

BACKLASH 

BEVEL 

GEARBOXES 

Andantex Ltd, 

Rowley Drive, Coventry CV3 4LS 

Tel. 024 7630 7722 

Fax. 024 7630 4499 

sales@andantex.co.uk 

www.andantex.co.uk 

Master Bond has developed a high 

temperature resistant epoxy resin 

system called EP121CL for service 

up to 260°C. The two component, 

optically clear, low viscosity epoxy 

resin system features high thermal 

stability, superior electrical insulation 

properties and outstanding 

dimensional stability for casting, 

sealing, potting, encapsulation and 

impregnation applications. 

Especially noteworthy are its 

mechanical properties of 12,100 psi in 

tensile strength, 17,200 psi in compressive 

strength, and its exceptional electrical 

insulation properties including, a volume 

resistivity greater than 3x10 14 ohm-cm, a 

dissipation factor of 0.020 at 1MHz and a 

dielectric constant of 3.34 at 60Hz. 

EP121CL is an elevated temperature curing 

epoxy resin system that passes NASA’s low 

outgassing test. It cures to a tough, strong 

solid with excellent long term durability and 

chemical resistance even when exposed to 

adverse environmental conditions. 




Master Bond 

22 





POWER TRANSMISSION 

Gears, Chains & Belt Drives 

Gearbox design eliminates 

the need for couplings 

Catalogue 

Now 

Online 

2 questions... 

Gears from stock? 

Gears made to order? 

...1 answer, DAVALL GEARS. 

info@davall.co.uk | www.davall.co.uk 

Tel: 01707 283 100 Fax: 01707 283 111 

The new range of Yilmaz D Series gearboxes, from the 

Richard Alan Group combine the benefit of hollow 

shafts for compactness, efficiency and cost reduction 

with high strength helical gears, and the flexibility for 

the widest range of mounting options. 

Because the D series gearboxes are mounted directly onto 

driven shafts, there is no need for a coupling, chain drive or 

reducer. This arrangement offers the user several advantages. 

First, the gearbox assembly is very compact, saving both space 

and weight. Second, the fact that no couplings are required 

improves the efficiency of the power train, helping to optimise 

the input from high efficiency motors. 

Robust in construction the D Series gearboxes are 

manufactured with high quality cast iron bodies (GG22 25 with 

GG50 upon request), which house high strength precision 

hardened helical gears and heavy duty bearings, enabling the 

gearboxes to deliver the highest power density, reliability and 

extended life in demanding quarrying, mining, mixing, and 

materials handling applications. 

Performance advantages 

The D Series bodies are designed as monoblock units, based 

upon a one piece housing, which offers advantages as regards, 

rigidity, gear strength, operating noise levels and oil integrity. All 

bearings within the gearboxes are supported by the housing 

itself and not by cover plates; and all axis are machined at the 

same mounting plate, which gives high precision on all axes 

with very tight tolerances. Available in seven different sizes with 

a wide range of ratios, the D Series gearboxes are rated for 

operation in applications requiring from 130Nm to 4,800Nm of 

torque. The gearboxes are manufactured to a European 

footprint which means that they interchange directly with most 

of the leading makes on the market. They are manufactured 

under ISO 9001 conditions, which means that they offer high 

quality and reliability. And they offer the OEM an extremely 

price competitive package, especially when provided as a 

package with Gamak motors. 

The D series gearboxes are stocked in component form by 

the Pumps and Gearboxes division of the Richard Alan Group. 

This provides great flexibility for the user, as it enables 

New hollow shaft gearboxes require no couplings, 

so optimising the efficiency of power trains using 

high efficiency EFF1 and 2 motors 

gearboxes to be assembled to exact customer specifications at 

very short notice. In addition, the Pumps and Gearboxes 

Division has extensive machining capabilities, which means 

that the flexibility of the customer-specific build approach is 

extended further, in respect of shafts and special mountings. 

Another addition to the Yilmaz portfolio is a range of ATEX 

compliant helical gearboxes. These gearboxes are suitable for 

applications in zones where explosive atmospheres may occur, 

and also zones characterised by the presence of gas mixtures 

and/or dust (zones 1 and 21). To ensure compliance, every 

Yilmaz ATEX gearbox undergoes a special painting cycle, which 

avoids the problem of electrostatic discharge, and is supplied 

with a specific User Instruction Manual and Conformity 

Statement according to CEE94/9/CE Directive, Enclosure VIII. 

Inherent flexibility 

The ATEX compliant gearboxes are foot/ flange-mounted units 

from Richard Alan’s M/N range of helical gearboxes. Supplied 

with solid or hollow output shafts, these gearboxes are 

designed for a wide range of industrial and processing 

applications; they offer up to 3-stage operation and provide 

nominal torques up to 8,547Nm. In common with the standard 

Yilmaz series of helical gearboxes, the ATEX compliant 

gearboxes are designed as monoblock units, based upon a one 

piece housing, which offers advantages as regards, rigidity, gear 

strength, operating noise levels and oil integrity. All bearings 

within the gearboxes are supported by the housing itself and 

not by cover plates; and all axis are machined at the same 

mounting plate, which gives high precision on all axis with very 

tight tolerances. 

Commenting upon the launch, operations director Edward 

Jennings says: “The Richard Alan Group is very active in 

chemical processing, marine and petro-chemical markets, so 

we are fully aware of the competitive pressures, even for the 

supply of equipment into hazardous areas.” 




the Richard Alan Group and more news gears 

24 More details: Write in 240 


Those who are already contemplating tomorrow’s solutions today must be at one with 

the future. 

With a single objective: We want to make you more successful. 

We use our products, ideas and emotions to realise your visions. Six decades of experience 

have helped us develop a spirit for innovation and an uncompromising passion. The 

result: A group of companies with a clear philosophy that sets standards in outstanding 

servomechanical drive systems. High-tech products manufactured by WITTENSTEIN are 

launched into space, win Formula 1 races, widen the boundaries of mechanical engineering 

and pave the way for advanced medical technology. 

United under one symbol worldwide. 

We are now all WITTENSTEIN 

WITTENSTEIN – being one with the future 

www.wittenstein.co.uk 




High efficiency gearboxes now offered 

with aluminium housings 

Nord has launched a new range of gearboxes 

that significantly reduce system building costs 

Helical-bevel gearboxes provide a 

speed reducer function that can 

deliver power transmission 

efficiencies of over 95% for 

machinery builders. This can be up to twice 

that of the worm style gears that are 

commonly used, providing major savings in 

energy consumption. Nord Drivesystems has 

now lowered the entry costs to this advanced 

reducer technology with a new range of twostage 

helical-bevel gearboxes in lightweight 

diecast aluminium housings. 

In addition to energy savings, the 

highly efficient gearboxes allow 

automation builders to reduce costs by 

specifying smaller sizes of electric motor. 

Nord's SK 92 series of helical-bevel 

gearboxes provide a right angled drive 

capability that can be configured to 

provide speed reduction ratios from 3:1 to 

72:1, satisfying a very wide range of 

applications from baggage handling and 

conveying, to packaging and processing 

machinery. Five reducer sizes are 

available spanning a power range from 

0.12 to 9.2 kW. 

The new reducer gearboxes can 

significantly reduce system building costs 

for automation vendors. Two-stage 

helical-bevel gearboxes support a wider 

choice of ratios than is possible with 

worm gears. Each SK 92 case size can be 

configured with a choice of up to 21 

ratios, compared with perhaps nine for 

single worm gearboxes. In many 

applications, this can eliminate additional 

components such as a belt or chain 

system. Most helical-bevel reducers , says 

Nord, are also typically based on three 

stages, with a helical input, followed by 

bevel and helical reductions. SK 92 

gearboxes are implemented using just two 

stages, eliminating gear, bearing, shaft 

and other minor component parts, and so 

minimising the implementation costs of 

the technology while maintaining higher 

power transmission performance. 

Longer operating life is another 

important attribute of helical bevel gears. 

Compared with worm gears, helical bevel 

units are virtually wear free, and run 

cooler. And modular design principles 

allow the SK 92 series of reducers to be 

customised using a broad range of 

accessories, to provide optimised power 

transmission for virtually any 

application. 




further details from Nord Gear 

ADVERTISEMENT FEATURE 

Chain Solutions 

Renold has brought together all of its high-tech, problem solving 

chain products under the new banner of Solutions Products. 

The move serves to emphasise the 

opportunities available to engineers who 

are trying to overcome application 

challenges caused by anything from 

lubrication and corrosion to wear, fatigue and 

abrasion. 

The Solutions Products range is spearheaded 

by Renold’s high performance Synergy chain 

which is solving problems all around the world on 

applications where companies are suffering from 

short wear life and unacceptably high levels of 

downtime to replace worn out chain. On some 

applications Synergy has slashed chain 

replacements from once a month to once a year, 

and one American customer recently described 

Synergy’s performance as, ‘astonishing’. 

The complete range of Solutions Products 

includes, Syno, a range of chain that requires no 

lubrication, and, uniquely to Renold, this includes 

a polymer bush version for arduous, heavy-duty 

and outdoor applications. There is a range of 

stainless steel chain for applications where 

corrosion might be a problem, such as in the food 

industry. 

Conveyor applications 

Another Solution Product is Klik-Top polymer 

block chain for conveyor applications. Unlike 

other, similar, products Klik-Top chain has no 

sharp edges coming into contact with conveyed 

goods and the polymer blocks can be clicked on 

and off individually without the need to remove 

the whole chain from the application. 

The Solutions Products range also includes 

Sovereign chain for abrasive applications where 

there are significant amounts of dust and debris 

that would cause a standard specification chain 

to wear rapidly. Finally there is Renold's Hydro- 

Service 

chain, which 

has been treated with 

a series of coatings to protect against corrosion. 

So effective is the Hydro-Service anticorrosion 

treatment that chain treated with it will resist 

corrosion up to 30 times longer than a standard 

carbon steel chain, but has the same working 

load capabilities as standard steel. 

To contact Renold for more information on its 

Solution Products range, call UK Sales on 01283 

512940, e-mail ukchain@renold.com, or visit 

www.renold.com. 


26 


POGGI SPIRAL 

BEVEL GEARBOXES 

Spiral bevel gears 

with hardened 

ground steel shafts 

Get all the information you 

need for choosing and using 

spiral bevel gearboxes, in 

this free brochure from 

Francis and Francis. 

This brochure introduces the 

high quality Poggi range, 

offering: 

● 

● 

● 

● 

Low cost aluminium monobloc casing 

2/3/4-way, 1:1/1:2/1:3 gearing 

0.5 to 10HP at 1400rpm, 10,000 hours life 

Independent, hollow and manual disengage/reverse 

output shaft options 

The Stables Works, Phone: 020 8688 9792/3 Fax: 020 8668 9793 

Station Road, 

email: sales@powertransmissions.co.uk 

Kenley, 

francisandfrancisltd@tiscali.co.uk 

Surrey CR8 5JA, 

Web: www.powertransmissions.co.uk 

England. 

www.francisandfrancisltd.co.uk 

flexible 

coupling 

solutions 

Whether the accent is on high torsional 

stiffness, generous misalignment capability, 

high speed operation, recyclable hubs, or a 

capacity for operating in push/pull mode, 

Huco offer the answer to all your flexible 

coupling needs. Call now for our new 

Flexible Couplings catalogue or visit our web 

site at www.huco.com 

Merchant Drive 

Hertford, SG13 7BL 

United Kingdom 

t: +44 (0) 1992 501900 

f: +44 (0) 1992 509890 

www.huco.com 

Bellows - Huco Flex B 

Membrane - Huco Flex M 

Sliding - Huco Oldham 

Universal Lateral - Huco Unilat 

Beam Type - Huco Multi-beam 

Double Loop - Huco-Flex P 

Jaw Type - Huco Flex G 






Lambda chain range extended 

for use at higher temperatures 

Tsubaki is providing all the non-lube, 

low maintenance benefits of its well 

proven Lambda chain in a heat 

resistant version that has an operational 

temperature range from 150°C to 230°C. 

The new heat resistant Lambda shows no 

degradation at high temperatures and 

offers over four times the wear life of 

standard RS50 chain at 230°C. 

Poly-steel chain 

needs no lube 

Renold has launched a new polysteel 

chain that requires no 

lubrication, has no metal-on-metal 

contact and is therefore able to operate 

even if submerged under water. The new 

Syno PC Chain is an addition to Renold’s 

extensive range of Syno chain products 

designed as solutions for applications 

where lubrication is either difficult or 

undesirable. 

It will solve maintenance problems on 

applications where an all-metal chain is 

not the best option, such as in certain 

areas of the food and drinks industries. 


Enter F285 on the enquiry card, or visit ‘latest issue 


more info from Renold Chain 

The launch of HT Lambda extends the 

lube-free, elongation-free characteristics of 

Lambda chain into applications such as 

heat sealing in packaging, semiconductor 

production, dry and steel furnaces and die 

casting, for components such as 

automotive parts. Previously these 

processes would have been served by 

standard chains with special coatings, 

which were both costly and did not offer 

good wear life. 

Tsubaki’s HT Lambda overcomes this 

problem, as its design is a proprietary one 

purely for high temperature operation. 

This offers many advantages, not least 

that, unlike standard chain, HT Lambda 

does not have to be derated for high 

temperature operation, due to chain 

rollers and plates losing their strength. To 

account for this problem standard roller 

The OFG40 from Ondrives is a 

precision oil-filled worm gear 

reducer. It is available with shaft 

inputs from 5Nm to 18Nm in ratios 

varying from 5:1 up to 120:1 as 

standard with other special ratios 

available on request. There is a separate 

breather supplied 

loose with 

the 

chain generally has to be much larger 

when used at higher temperatures. As a 

result, it is more costly, takes up more 

space and uses more energy to transmit 

the same power as the HT Lambda chain. 

In tests performed in a 230°C 

environment, Tsubaki’s HT Lambda chain 

achieved over four times the wear life of 

RS50 standard chain and about three and 

half times the life of Tsubaki’s standard 

Lambda chain, which is not designed for 

high temperature operation. Importantly, 

although the standard chain showed 

degradation at this high temperature, HT 

Lambda did not. 




further details from Tsubaki 

Oil-filled worm gear reducers 

gearbox to be installed by the end user 

with the typical breather configuration 

being on top of the gearbox. Optional 

breather configurations are available by 

special request. 

The units measure just 129mm from 

shaft to shaft and so offer a viable option 

for small and confined spaces. Other 

advantages include high duty cycles 

compared to a grease filled gearbox and 

a higher specification on the sealing of 

the unit as well as corrosion resistance of 

the natural hard anodised aluminium 

casing. They come as standard with a 

hardened worm and therefore lower 

backlash. 




further details from Ondrives 

Seamless 

protection 

The protective rollers 

employed on roller chains 

are intended to extend the 

working life of the chains by 

reducing fatigue caused by 

running impacts and provide wear 

resistance. This protection has 

been enhanced for Rexnord roller 

chains through the use of 

seamless rollers, which further 

increase the working life of chain 

plus give smoother quieter 

running. 

This protection against 

dynamic loading, such as might 

be experienced with pallet 

handling duties is achieved by 

eliminating the point of weakness 

present with seamed rollers. Tests 

have shown Rexnord’s seamless 

rollers are able to withstand 

approximately 25% higher vertical 

loads than conventional curled 

rollers. 

Rexnord produce chain with 

two different types of seam-free 

rollers; one is cold formed the 

other is produced from precision 

tubes. 


Enter F288 on the enquiry card, or visit 

www.industrialtechnology.co.uk for 

further details from Rexnord 

® 

Reliance 

Precision Mechatronics LLP 

Comprehensive Gear Range 

• Precision cut: Plain and anti-backlash AQ14, ISO quality 3 gears. Ideal for precision 

measurement and light instrumentation 

• Fine pitch ground: Gears with high accuracy and higher torque capacity. Hardened to 

49 - 55HRc. Available down to 0.5 module 

• Brass: An economical balance of accuracy and load capacity against cost gears. Can 

be run with minimal lubrication 

• Specials: Non-standard data transmission and actuation gears. Produced to BS EN ISO 

9001:2000 and AS9100 revision B, ideal for the aerospace and defence industries 

Call our Sales Team on +44 (0) 1484 601002 

Visit us at www.rpmechatronics.co.uk 

Unique Solutions from Proven Concepts 

28 


think of the possibilities 


FINE CYCLO ® 

F2C-C Series 

the ultimate in 

precision motion control 

Drives & 

Controls 

Hall 3 

Stand D24 

> Large hollow bore input 

> Input shaft bearing support 

allows total drive flexibility 

> Zero backlash for precision 

applications 

> Maintenance-free, completely 

‘sealed for life’ design 

> High torsional stiffness 

> Low moment of inertia 

> High shockload capacity 

> Can be used confidently for 

any zero backlash/ precision 

application 

> Available in three sizes which 

complement the existing 

FINE CYCLO range 

> Straightforward mounting 

arrangement as standard 

> Simple motor fitting allows 

total/easy integration 

> For more information 

call the sales team on: 

01274 531034 

post@centa-uk.co.uk 

www.centatechnology.co.uk 

TRANSMISSIONS 

Leading by Innovation 


MECHANICAL COMPONENTS 

Bearings, Slides & Lubricants 

Lubricants rise to 

a marine challenge 

Speciality lubricants made by Klüber Lubrication enhance the 

reliability of winches on AHTS vessels while at the same time 

reducing operating costs, by effectively protecting the gears 

Anchor handling winches pose particularly 

stringent requirements for their dependability 

and operational reliability. Their open gears 

have to function under enormous stresses and 

extreme weather conditions. In this context, the 

lubricant’s role is a crucial one. Firstly, it has to provide 

reliable protection against corrosion, and secondly it is 

required to minimise wear on the gears being lubricated, 

ensuring reliable operation. 

This is not always easy. The tooth flanks are the 

critical point: during the running-in phase, large forces 

act on the un-polished surfaces. The initial surface 

roughness causes the stress on high points to be 

massively increased in operation, and since the pinion 

and the girth gear are mounted separately, their axes will 

rarely be parallel, causing uneven wear along the tooth 

flanks. 

Demanding requirements 

Running-in and operational lubricants have a number of 

difficult requirements to meet. They have to be miscible 

with one another, provide good adhesion, be suitable for 

trouble-free use in central lubrication systems, and be 

available worldwide. In addition, high load-carrying 

capabilities and good corrosion protection are essential. 

If these criteria are not met, the consequences can be 

dramatic. It’s not only the repair costs that have to be 

considered. The sometimes protracted repair work, in 

addition to the ship lying idle in the yard, entail massive 

amounts of lost earnings for the operators concerned. 

For these reasons, Klüber has developed a special 

combination of carefully matched running-in and 

operational lubricants for open transmissions on ships. 

Depending on the outdoor temperature involved, Klüber 

offers a range of selected products for Rolls-Royce and 

Ulstein Brattwaag anchor handling winches. 

Improved load distribution 

Grafloscon B-SG 00 ULTRA is a running-in lubricant that 

has proven to be ideal in recent years. It supports rapid 

elimination of the surface roughness always encountered 

on new gearwheels, increasing the load-bearing area and 

improving load distribution, thereby decreasing stress. 

This leads to an extended lifetime for the gears while at 

the same time significantly reducing the maintenance 

and repair costs involved. By reducing corrosion or 

seizing of the tooth flanks (which will usually result in a 

transmission failure), operational reliability is 

significantly increased. Correct matching of the runningin 

lubricant to its operational counterpart means that it’s 

no longer necessary to clean the gearwheels before 

changing over to the operational lubricant. And runningin 

lubrication is possible with all lubrication methods! 

The Klüberfluid C-F range of operational lubricants 

provides a suitable product to suit all climatic conditions 

The difference compared to conventional lubricants is 

immediately visible: the lubricant is transparent, not 

black, enabling the condition of the tooth flanks to be 

continuously monitored and significantly reducing 

contamination should drops of lubricant escape. But the 

transparent look is not the main benefit: the Klüberfluid 

C-F Ultra range excels primarily in ensuring a long 

lifetime for the components involved, with consequent 

substantial cost savings. This is due not merely to 

Klüber’s field-proven protection against corrosion and 

wear, but also to the lubricant’s good adhesive properties 

and its freedom from bitumen, heavy metals, chlorine 

and solvents, which renders very much less costly. 

Tested and approved 

According to Klüber, no lubricant currently achieves 

better performance than the combination of its two 

products. The life of the gearwheels is prolonged, the 

consumption quantities are dramatically reduced, and 

the servicing intervals significantly extended. All this 

produces very substantial cost savings. And the products 

are tested and approved by the biggest names in the 

game. Following an intensive course of testing, the 

world’s leading manufacturer of anchor handling 

winches, Rolls-Royce/IP Huse has decided that only 

Klüber lubricants meet the toughest of criteria. This 

means that anchor handling winches from Rolls- 

Royce/IP Huse should be run in using Klüber lubricants 

at the commissioning stage. And for ongoing operation, 

too, the recommendation is unequivocal: only Klüber 

lubricants will ensure such continuously trouble-free 

operation. 



www.industrialtechnology.co.uk for further details from Klüber and 

more news on lubricants 

30 


Easy 

peasy... 


High-precision Linear Ball Bearings 

featuring the following advantages: • Suited for high temperatures, all-steel 

• Noiseless and jerk-free, synthetic as well as different models of shafts 

ball bearing housing 

and hollow shafts. 

• Linear and rotating, for combined 

movements 

Togni WA, Bienne 

… lightweight, low-price EasyChains ® : simply 

push the cables in place by hand, filling from 

the inside or outside. Short installation time! 

Now even more sizes and versions available: 

inner height from 5 to 45 mm, inner width from 

5 to 140 mm, with multi-chamber system for 

separate cable tracking. 

SFERAX S.A. 

CH-2016 CORTAILLOD (Switzerland) 

Tel. ++41 32 843 02 02 

Fax: ++41 32 843 02 09 

e-mail: info@sferax.ch 

www.sferax.ch 

igus ® (UK) Limited 

51A Caswell Road 

Brackmills Ind. Estate 

Northampton NN4 7PW 

/en/easychain 

Energy Chains Systems ® within 3-10 days 3D-CAD online 

Phone 01604-677240 

Fax 01604-677242 

sales_uk@igus.co.uk 

plastics for longer life ® 




Slides are stronger than ever 

With the next generation of its HDS slide system, HepcoMotion 

now offers even more options for heavy duty linear motion 

to meet the needs of tougher materials handling tasks 

The new Heavy Duty Slide System 

HDS2 from HepcoMotion is the 

iron man of linear motion with 

system capacities up to 68kN. It 

has been engineered to provide an 

exceptionally rugged product to meet 

increased load and life requirements. In so 

doing it addresses new markets in heavy 

materials handling that involve much larger 

X-Z gantry systems. 

HDS2 has retained the best features of 

its forerunner and incorporated them in a 

considerably expanded range. It is however 

a technically superior product to the 

original Heavy Duty. An important aspect of 

this is the introduction of specific 

components that reduce the engineering 

time required by the customer to get the 

system up and running. 

These components include larger 

bearings with increased load capacity, 

three sizes of construction beam, single 

edge V slides and flat tracks as well as 

a range of drive options. All 

this, with an option 

for stainless 

steel or 

corrosion 

resistant 

components 

as standard 

enables HDS2 

to satisfy most 

high load application 

needs. 

Buying options 

HDS2 can be supplied in 

component form or as a ready 

mounted assembly complete with rack 

driven carriages. Customers can also 

choose from low cost commercial slides for 

general use or high precision ground slides 

for applications where superior accuracy 

and greater smoothness are prerequisites. 

Slides and tracks are 

available in single piece construction 

up to 4 metres long which in itself will 

save on assembly time. They are 

supplied in single or double edge 

format both as V slides or flat track. 

The V slides have a simple alignment 

facility to achieve parallelism and the 

flat tracks overcome the need to align 

two slides exactly parallel. 

Increased forces 

Greater driving forces for heavier 

loads are achieved through a range of 

spur or helical rack and pinion 

options. The helical racks are ideal for 

applications that require a smoother 

transition of the driving force and 

consequently are quieter. The 

engineering package is complemented 

by a range of rack driven 

carriages, complete with automatic 

lubrication facility, with helical bevel 

gearboxes that can be driven by AC or 

servo motor. 

For maximum design flexibility, 

versatile construction beams with 

multiple slide and track mounting 

options are a feature of HDS2. In line 

with the new larger slides the HDS2 

programme includes a larger 

aluminium beam that eliminates the 

need for the customer to machine a 

steel structure. Also available is a 

compact version of the beam that is 

ideal where space is at a premium. 

Alternatively it can be used to create 

a high capacity lifting Z axis. Where 

customers need the extra rigidity 

offered by a steel beam, all slides can 

simply be fitted and aligned using the 

keyway option with dowel pins. 

There is also 

the option of 

mounting 

directly to Hepco- 

Motion standard backplates, 

again using the alignment 

facility. 

Naturally HDS2 includes an 

increased range of bearing sizes. 

New introductions include a 150mm 

diameter vee bearing and a 144mm 

diameter roller incorporating high 

capacity taper bearings. Maximum 

bearing capacity is now 50kN, a 

substantial increase on the previous 

20kN and all bearing options are 

available in stainless steel. All 

bearings are now offered in removable 

format so that, in the unlikely event of 

bearing failure, they can be replaced 

without the need to remove the 

carriage from the system. 

In addition to providing higher 

load capacity the double row bearings 

are exceptionally tolerant of debris. 

Low friction cap wipers expel dirt in 

harsh environments and provide 

automatic lubrication to provide a 

long service life. A removable cover 

allows easy system adjustment 

without disassembly. Lubricators also 

offer an alternative method of 

lubrication and can be applied to both 

bearings and slides. They will be a 

lower cost option where conditions 

are not hostile. 

“HDS2 really provides an 

exceptionally flexible programme for 

arduous applications,” concludes 

sales director Chris Rees. “The 

additions to the range will enhance its 

performance and will provide 

customers with far more 

application possibilities.” 



stories’ at www.industrialtechnology.co.uk 

for further details from HepcoMotion 

32 



Giving you 

total flexibilty 

Delivering superior product capability 

Cage design and materials specially selected for 

individual applications. Standard bearings with 

optimised load distribution for better balance 

and lower stress. Tougher technology for wind 

turbines with 23% higher loads. They’re just a 

part of the full range of ball and roller bearings 

that gives NSK the flexibility to meet even the 

most challenging industrial gearbox application. 

An acknowledged leader in advanced motion 

technology, NSK invests over 60 million 

annually to develop innovative products and 

solutions that extend product lifetimes, increase 

reliability and lower maintenance. Our gearbox 

industry experience is unmatched and backed by 

professional, knowledgeable and service-oriented 

authorised distributors. From sophisticated failure 

analysis to bearings selection, calculation and 

lubrication recommendation, our flexibility is 

totally geared around you. 

NSK EUROPE 

 

 

 

 

 

 

 




Miniature guides deliver high 

accuracy in harsh environments 

Roller bearing 

pillow blocks 

from Rino 

Schaeffler has expanded its range of 

miniature linear guidance systems, 

offering machine builders and 

designers lighter, more compact designs 

that provide optimum positional accuracy 

and repeatability, even in harsh 

environments. The miniature plain 

guidance systems are linear locating 

bearings with at least one carriage. The 

units can support forces from all 

directions – apart from the direction of 

motion – and moments about all axes. 

The guides are ready-to-fit and 

maintenance-free, for stroke lengths of up 

to 3m. The carriage and guideway are 

both constructed from extruded, anodised 

aluminium and so offer high resistance to 

chemical substances and other 

contaminants. The guides are ideal for 

use in lightweight, aluminium machine 

Polymer bearing 

is 80% lighter 

than steel 

SKF has released its latest generation 

of polymer ball bearings, which 

offer a lightweight and lubricantfree 

alternative to conventional steel 

bearings. The range has been developed 

to offer resistance to corrosion and 

chemical damage, making the bearings an 

ideal solution for applications subject to 

moisture or aggressive chemicals. 

The bearings consist of polymer rings 

and cages, and can be specified with 

balls made of stainless steel, glass, 

polymer or other materials, depending on 

the characteristics required. Each of the 

bearings offers low friction and resistance 

to wear and fatigue, providing a long, low 

maintenance service life. 

Perhaps as importantly, the latest 

bearings also weigh up to 80% less than 

conventional all-steel designs, with a high 

strength to weight ratio that makes them 

a vital component for design engineers 

looking to minimise the weight of 

equipment without sacrificing 

performance. 




further details from SKF 

designs, as well as applications with low 

loads, moment loads, dry running or 

harsh environments. Operating 

temperatures are from –40°C up to 80°C. 

New to Schaeffler’s existing range of 

miniature profiled rail linear guidance 

systems is the KWEM double row 

miniature ball monorail guidance system, 

Cost-effective protection 

against bearing corrosion 

For bearings exposed directly to 

humid or corrosive environments, 

NKE Austria offers a special coating 

solution that provides a simple and cost 

effective protection against corrosion. 

NKE’s coating can be used for all parts 

exposed to corrosive environments and 

provides reliable protection against water, 

condensation, weakly alkaline and weakly 

acidic cleaning agents. The new coating 

technology is Cr(VI) free and is therefore 

Ceramics for motor cycle bearings 

Boca Bearing Company has 

expanded its range of bearings and 

lubrication products for 

motorcycles. The bearing range now 

includes full ceramic bearings and 

ceramic hybrid bearings, with the 

company also offering an ultra dry lube. 

The full Zirconia ceramic bearings are 

available in both radial and insert styles. 

Full ceramics offer the least resistance of 

which comes in four 

sizes with corresponding guideways 

(TKDM). 




further details from Schaeffler UK 

compliant with the RoHS Directive.The 

SQ171 coating can be applied on 

standard or special bearings to 

guarantee a significantly longer 

service life compared to uncoated parts. 

The thin coating of about 8µm 

ensures interchangeability of coated and 

uncoated parts. Due to the plating 

process by trivalent chrome passivation 

the coating contains no toxic hexavalent 

chrome or Cr(VI) – a material banned by 

the RoHS Directive. The coating has been 

tested with the neutral salt spray test 

method in accordance with DIN 50021. 

Compared to other anti-corrosion methods 

such as stainless steel, NKE says its 

SQ171 coating offers outstanding anticorrosion 

protection at relatively low cost. 




further details from NKE Austria 

all bearings, are significantly lighter than 

steel and will never corrode. The ceramic 

hybrid radial and insert bearings are 

available in a wide assortment of 

configurations. 




further details from Boca Bearing Company 

Rino Industries has a new 

range of roller bearing 

pillow blocks with many 

advantageous features. Single, 

twin and double pillow blocks are 

all available as standard. They are 

fully adjustable to allow for easy 

radial clearance and they are 

self-aligning 

(single 

units only) 

due to their unique design. In 

most applications, the double and 

twin models also either match or 

exceed the tolerances for 

misalignment offered by the 

recirculating ball pillow block. 

They offer good corrosion 

resistance as they are constructed 

of an aluminium body and the 

exposed surfaces have a black 

oxide finish to resist corrosion. 

Higher speeds, interchangeability 

and longer life and shaft 

protection are all advantages 

offered as standard. 




further details from Rino 

Rollers offer 

high rigidity 

With its RU series, THK 

presents a new 

generation of cross roller 

rings. The new RU type is a very 

compact, single-row cylindrical 

roller bearing for high axial and 

radial loads and moment stress, 

and the one-piece inner and outer 

rings provide very high rigidity. 

The mounting holes are 

integrated in the rings, enabling 

easy design and quick mounting. 

Special housings or fixtures are not 

necessary. Significant cost savings 

are possible thanks to fewer pieces 

and the easy mounting. 




further details from THK 

34 


NEW 

UtiliTrak ® – Lightweight 

U Channel Guideway 

• Hardened and ground steel track 

• 3, 4 or 5 Wheel carriage options 

• Aluminium track and polymer wheel options 

• Available in stainless steel 

• Easy installation and smooth running 

Superb control combined 

with faultless performance 

The range of BishopWisecarver Linear slides from HepcoMotion, offer the 

user unique features and a cost effective means of solving a broad range of 

industrial applications. 

• DualVee ® enables long lengths and wide spans to be achieved, with simple 

mounting using the NEW lower cost integral bush option 

• LoPro ® is the ideal choice where low assembled height is critical 

DualVee ® – Single 

Edge Slide System 

LoPro ® – Aluminium 

Based Slide System 

Request 

our updated 

catalogue 

HepcoMotion ® 

Tel: +44 (0)1884 257000 E-mail: sales@hepcomotion.com 

Tiverton Way, Tiverton, Devon EX16 6TG Fax: +44 (0)1884 243500 



35

✁ 

CUT OUT AND KEEP 

TECHNICAL INFORMATION PAGES 

Heidenhain takes the lead in safety 

related position measuring systems 

Heidenhain is the first 

encoder manufacturer 

to offer a purely serial, 

single-encoder 

solution for cost-effective safetyrelated 

positioning measuring 

systems giving all the benefits of 

serial data transfer, diagnostics, 

automation, commissioning and 

rapid formation of position. 

The latest legislation and 

heightened safety regulations 

are associated with positional 

measuring systems that are 

designed to reduce risks that 

occur during normal or impaired 

operations of equipment. There 

are several variations available, 

within the law, of systems able 

to capture independent position 

values such as the use of two 

encoders per axis. 

However, recent 

developments by Heidenhain 

make it the first manufacturer to 

offer a purely serial, singleencoder 

solution according to 

TEC 61508 or performance level 

‘d’ of ISO 13849 in applications 

requiring control category SIL-2 

for the following safety functions: 

● 

● 

● 

● 

● 

● 

● 

Safe switch-off 

Safe stop 

Safe controlled stop 

Safe reduced linear or 

rotational speed 

Safe limited jog increment 

Safe limited absolute position 

Safe limit of torque/power. 

Integrated safety and improved 

encoder quality with ExN 1300 

ERA 4000 – a new generation 

of Heidenhain angle encoders 

for dynamic applications 

The latest ExN 1300 series of 

rotary encoders with EnDat 2.2 

interface from Heidenhain 

incorporate the latest optoelectronic 

scanning and evaluation electronics 

using digital data transmission that is 

ideal for use in safety critical 

applications requiring a high 

tolerance to contamination. 

The new optoelectronic scanning 

technique, that does not require 

digital signal compensation but uses 

highly reliable 14-bit interpolation in 

the chip, helps to reduce 

interpolation error by half, eliminates 

any need for costly or elaborate 

interpolation in the subsequent 

electronics. The transmission of data 

is not influenced by external noise. In 

addition, while control loop 

performance is increased with 

improved signal quality, a reduction 

in both velocity fluctuation and 

thermal influence is achieved over 

the entire temperature range. 

The latest scanning and evaluation 

electronics used by Heidenhain 

significantly improves reliability and 

therefore overall performance and 

accuracy. Also, by optimising the 

scanning and internal compensation, 

the internal signal quality is improved 

by a factor of 4 or 5 enabling reliable 

14-bit interpolation to be carried out in 

the chip. 

The EnDat 2.2 serial interface used 

by Heidenhain has high noise immunity 

because data is transmitted without 

having to simultaneously carry 

analogue signals. Also, because cables 

with six cores and a single shield are 

used, depending on the cable length, 

savings of up to 50 per cent can be 

made on system costs. 

Developed for 

highly dynamic 

applications 

such as direct drive 

technology requiring 

precise angular 

measurement to within 

a few angular seconds, 

the Heidenhain ERA 4000 series of compact angle 

encoders has high signal quality and a greater numbers 

of signal periods. 

The grating structure of the encoder is produced using 

the latest METALLUR® technique, Heidenhain’s 

innovative method of homogeneously combining 

materials. In the ERA 4000, several layers of gold, a 

transparent spacer and chromium are applied to the steel 

scale drum. A laser is then used to create the 

graduations in the chromium layer to provide the encoder 

with particularly high edge definition. As a result 

maximum performance is ensured with high quality 

output signals and high factors of interpolation in 

conjunction with its photoelectric scanning. 

The scale drum is available in a range of differing 

shapes to suit the application. Versions include a 

compact, or for instance a T-profile for use with low 

weight and moment of inertia requirements. The angle 

encoder has also been designed for quick and simple, as 

well as accurate installation. 

36 


QIndustrial Technology asks 

the important 

uestions... 

feedback@itmagazine.uk.com 

What do we need to do to succeed, as 

our overseas competitors get stronger? 

Martin Stevens of Unimatic has the answer 

In the April edition of Industrial Technology, the leader column 

introduced the concept of “Shift Happens”. If you want to find out 

more, just search the internet and you will come up with about 

596,000 links. There is obviously rather a lot of shift hitting the fans 

at the moment. According to recent news reports, UK manufacturing is in 

a healthy state at the moment, partly due to the exchange rate and partly 

because we have got better at manufacturing over the past ten years or so. 

But with the continuous and continuing global competition (and it’s not 

going to get any easier), we need to get even better and keep improving. 

There is no end game. 

So what do we need to compete and to succeed, particularly as our 

overseas competitors are getting better day by day. And don’t forget, your 

competitor is not the guy down the road or elsewhere in the UK; your 

competitor is in China, or Turkey, or Vietnam or Russia or any number of 

other countries across the globe. I suggest that we can distill it down to 

three key issues: 

1. Skills – Without best-in-class people, how will we compete with the 

millions (literally) of graduates pouring out of universities around the world 

each year? Industry needs to engage with schools, colleges and 

universities as much as we can. The forthcoming Diplomas provide a good 

mechanism. We need them to be aware of our agenda, of our 

requirements. Personally, I think the Design & Technology curriculum forms 

a great basis for all the skills – and I mean all the skills, not just the 

technical ones – that the commercial world needs, but nobody seems to 

listen to me! We must also put pressure on government about the STEM 

agenda (the need for good science, technology, engineering and maths 

teaching and learning) as well as our requirements for softer skills, such as 

team working, motivation, innovative thinking. All of which neatly brings 

me to my second point: 

2. Innovation – We need to do things differently, to design products 

well, to find the added value which customers will clamour for and for 

which they will pay a premium (turn your products into iPods and 

watch the value of your company grow). Some innovation 

“ 

Although it would be nice to design 

the next iPod, chances are that you 

will be looking for a niche product, 

which meets the need of a specific 

market. For that to work, your 

production line needs to be flexible, so 

” 

that you don’t pay a fortune every time 

you want to tailor your offering. 


comes out of employing good people, some from creating a supportive 

culture for innovation, and some from employing the latest available tools 

– which takes me to my third point: 

3. Tools – Start with 3D CAD, which will enable you to cut time, waste 

and errors from your design process. Once you have your fantastic, new, 

innovative design, you want to get it to market as quickly as possible, and 

certainly before your competitors do. You need to invest in rapid 

prototyping. There are many different technologies, and although prices are 

dropping all the time, and capabilities are increasing rapidly, you can 

always use a bureau service until you know which one is right for you. 

This really helps to speed up your product development. Finally, invest in 

automated computer controlled production equipment; although buyers 

will flock to your door to buy your new design, you also need to keep the 

production costs low, so that when the overseas clone hits the market, you 

will still be able to compete. 

Although it would be nice to design the next iPod – a product which 

everyone wants and which achieves absolute market dominance – the 

chances are that you will be looking for a niche product, which meets the 

need of a specific market. For that to work, your production line needs to 

be flexible, so that you can ring the changes, target closely, and yet not 

pay a fortune every time you want to tailor your offering. 

Finally, as soon as you have designed your new product, start working 

on the next one. Product cycles continue to drop, and you cannot afford to 

be left behind. And there are plenty of companies around the world, 

wherever they may be, whose main aim is to render you and your 

company irrelevant. Don’t let it happen to you. 

Martin Stevens is managing director of Unimatic Engineers and chairman 

of Made in London, which represents of London’s 20,000 manufacturing 

companies. He will be contributing further thoughts on successful 

manufacturing in the UK throughout the year. 

37

Schaeffler UK provides a 

comprehensive range of 

INA linear guidance systems 

– from large profiled 

rail and miniature 

systems to shaft 

guidance systems. 

Profiled rail linear guides are ideal 

for large production machinery. 

Schaeffler’s new RUE100 E-L 

profiled rail linear guide offers 

machine builders optimum 

running characteristics, high load 

ratings and a robust, compact, 

low friction design. 

The RUE 100 E-L is a profiled rail linear guidance 

system ideally suited to large production 

machinery, including high efficiency machine tools 

and presses. 

The static load carrying capacity of the unit 

amounts to 149 tonnes, with dynamic load 

capacity of 63 tonnes. The unit provides the 

smooth, uniform running characteristics and high 

dynamics that are ideal for precision linear 

movement of heavy loads. 

Even at these high load carrying capacities, the 

unit offers a compact design so that, apart from 

the required mounting faces, there is no need to 

take account of any special data for integration in 

the machine structure. Machine builders and 

designers of production machinery can now 

benefit from a range of linear guides that offer 

high load ratings, robust design, high rigidity, 

high precision and excellent sealing. Speeds of 

up to 4m/s and accelerations of up to 100m/s 2 

are possible. 

The range is modular and so customers can select 

from a range of accessories to suit their 

application. 

The range also benefits from Schaeffler’s patented 

injection moulding technology, which enables 

perfect rolling element guidance in the load and 

return zones, optimised transitions and the best 

possible running characteristics with very low 

stroke pulsation. Schaeffler has also reduced the 

number of components in the design, resulting in 

more robust, reliable rolling element guidance. 

Labyrinth seals on the rolling element recirculation 

system improve protection against contamination. 

Uniform lubrication is guaranteed by a 

completely closed and sealed lubrication duct. 

The design of the guides also incorporates an 

efficient sealing concept, comprising standard 

seals: single lip upper seals, double lip lower 

sealing strips, as well as double lip end wipers. 

The end plates fitted as standard in front of the 

contact end wipers provide extra protection 

against coarse contaminants, which means the 

contact end wipers retain their full performance 

capability even in environments with fine, often 

aggressive contaminants. Other sealing 

arrangements are available as an option. 

38 


Miniature linear guides offer high 

positional accuracy in harsh environments 

New shaft guidance 

reference guide 

Schaeffler has expanded its range of 

miniature linear guidance systems, 

offering machine builders and designers 

lighter, more compact designs that 

provide optimum positional accuracy and 

repeatability, even in harsh 

environments. 

The miniature plain guidance systems are 

linear locating bearings with at least one 

carriage. The units can support forces from 

all directions – apart from the direction of 

motion – and moments about all axes. 

The guides are ready-to-fit and 

maintenance-free, for stroke lengths of up 

to 3m. The carriage and guideway are both 

constructed from extruded, anodised 

aluminium and offer high resistance to 

chemical substances and other 

contaminants. 

The guides are ideal for use in lightweight 

machine designs, as well as applications 

with low loads, moment loads, dry running 

or harsh environments. Operating 

temperatures are from –40°C up to 80°C. 

An addition to Schaeffler’s existing range 

of miniature profiled rail linear guidance 

systems is the KWEM double row miniature 

ball monorail guidance system, which 

comes in four sizes with corresponding 

guideways (TKDM). 

The units are extremely compact and are 

designed for medium load carrying 

capacity, medium to high moment loads, 

accelerations of up to 50m/s 2 and speeds 

of up to 180m/s. 

The double rows of balls are in four-point 

contact with the raceways. The double row 

assemblies consist of at least one carriage 

with full-complement ball system, locating 

face and ball retainers, as well as a 

guideway with two locating faces. The units 

are pre-loaded and greased and operate in 

temperatures from –40°C up to 100°C. 

Special seals are provided at the carriage 

faces to prevent ingress of dirt. 

Relubrication is carried out via lubrication 

holes at the carriage end piece. 

The guideways can also be 

combined with all 

available carriage 

types within the 

same size and 

preload class. 

The KWEM- 

MKS has a 

metal end 

piece, which 

makes the unit 

suitable for 

high temperature 

environments or for applications with high 

dynamic forces. All metal parts are made 

from corrosion-resistant steel. 

Miniature linear ball monorail guidance 

systems are ideal for applications in which 

linear movements of high positional and 

repeat accuracy are required. They are 

suitable for use in production and technical 

mounting systems, assembly equipment, 

microelectronic systems, medical 

engineering and other high precision 

handling machines. 

Schaeffler UK has published a free reference 

guide to its range of shaft guidance systems, 

including linear bearings, housed units, shaft 

support blocks and rail guidance units. 

As well as providing technical data on individual 

products, the hard-backed ‘Shaft Guidance 

Systems’ guide also includes useful information 

for mechanical engineers and design engineers 

on load carrying capacities, friction, lubrication, 

design of bearing arrangements, operating 

clearances and the fitting of shaft guidance 

systems. 

Shaft guidance systems 

comprise shafts or shaft and 

support rail units combined 

with low friction linear ball 

bearings or Schaeffler’s 

Permaglide ® plain bearings. 

The shafts can be either solid 

or hollow, while shaft 

and support rail units 

are always solid. 

For easy mounting, 

the guidance systems 

are also available as 

complete linear bearing and housing units. 

Linear bearings can support high radial loads, 

while having a relatively low mass and enable 

the construction of linear guidance systems with 

unlimited travel. The bearings come in ‘closed’ 

versions or with a segment cut out for supported 

shafts. 

The radial clearance can be adjusted on certain 

versions, which means the user can achieve 

clearance-free or preloaded guidance systems. 

Depending on the application, linear bearings are 

unsealed or are fitted with contact seals on both 

sides. 

With linear ball bearing housed units, the bearing 

is integrated in a strong, rigid housing, which 

comes in closed, open, slotted or tandem 

versions. These units are well suited to reduced 

mass applications with high loads and where 

higher acceleration and travel speed are required. 

For a free copy of the ‘Shaft Guidance Systems’ guide, or for more information on 

Schaeffler’s complete range of linear guidance systems, please visit www.schaeffler.co.uk 

or telephone the marketing department on 0121 351 3833. 

www.schaeffler.co.uk 

Schaeffler (UK) Ltd Tel: 0121 351 3833 Fax: 0121 351 7686 E-mail: info.uk@schaeffler.com 

39

40 


42 


SENSORS & SYSTEMS 

Special Purpose Sensors 

New ID readers provide total 

confidence code reading 

Any code. Any surface. Any 

marking method. That was the 

challenge Cognex has set itself with 

its code readers, which now include the 

newly launched DataMan 700 series 

From printed barcodes on labels to the most 

challenging 2D codes directly marked on metal 

parts, DataMan readers provide total 

confidence industrial ID reading every time. 

“The new DataMan 700 handheld readers really round 

out our ID product family,” says Carl Gerst, Cognex 

senior director and business unit manager for ID 

products. “We now have a reader for every need, so 

customers can rely on Cognex for all their industrial code 

reading requirements.” 

The DataMan 700 series includes two new readers: 

The DataMan 750 model is ESD-safe, making it ideal 

for reading 1D and 2D codes in the electronics and 

medical device industries. It also utilises the awardwinning 

IDMax decoding software to handle code 

degradations that result from differences in material 

types and surfaces. The DataMan 710 model features 

IDQuick decoding 

software for fast, 

consistent reading 

of high-quality 1D 

and 2D codes, as well 

as low-contrast codes on 

uniform backgrounds. It is said to provide 

exceptional performance on labels and other 

well-marked codes. Both models use an 

advanced image formation system to 

optimally illuminate marks on a wide range of surfaces. 

The intuitive DataMan user interface (shared by all 

DataMan models) has been optimised for quick setup 

and ease of use. Compact size and ergonomic design 

make the 700 series exceptionally easy to use, while the 

rugged design ensures long-term reliability in industrial 

environments. Also new from Cognex is the DataMan 

100S fixed-mount ID 

reader. It is ideal for 

reading codes on slowmoving 

parts or where index 

motion is used. The 

DataMan 100S joins 

other members of 

the DataMan 100 

family, which includes 

models for reading the most 

challenging DPM codes and codes 

marked on fast moving parts. 



www.industrialtechnology.co.uk for further details. You can also find 

more stories from Cognex and more news on ID readers 

Single box solution for 3D profiling 

Micro-Epsilon has raised the bar on 3D profile sensing again, with a 

new highly compact device that features an integrated controller 

Anew, non-contact laser profile displacement 

sensor has been developed, which unlike 

conventional laser line scanners on the market, 

provides an integrated controller in the sensing 

head. Despite this, the sensor is still incredibly compact. 

The user requires no other components to evaluate the 

measurement data and the unit is also easy to set up, 

configure and adapt for different applications. 

The scanCONTROL 2700 sensor from Micro-Epsilon 

is the company’s latest generation of laser profile 

sensors. The compact design of the sensor and 

integrated controller makes the unit ideal for industrial 

automation tasks and machine building applications, 

where space is often restricted. Typical uses include the 

measurement of angles, channels, gaps, edges and 

clearance; weld seam inspection; detection of beads 

(bulges or bumps) of adhesive; door edge detection; 

robot guidance and positioning; groove width and depth 

measurement. 

Launched at the recent Hanover Fair in Germany, the 

scanCONTROL 2700 is available with measuring ranges 

from 25mm or 100mm. A small output module for DIN 

rail mounting is also available to convert the sensor 

output data into common fieldbus systems. Chris Jones, 

managing director of Micro-Epsilon UK comments: “The 

scanCONTROL 2700 is the first high accuracy profile 

sensor with integrated electronics in a compact 

footprint. Other profile sensors with integrated 

controllers are either very bulky, often two to three times 

larger, or their measurement performance is reduced due 

to the restriction in space for the processing electronics. 

“We’ve also worked very hard to engineer a product 

that offers the level of precision and accuracy that 

modern users require. There are multiple interface 

options that enable ease-of-use in a variety of software 

platforms and at a very low price level, which other 

profile sensor manufacturers will be unable to match.” 

Like its predecessor, the scanCONTROL 2700 uses 

the laser line triangulation measurement principle. The 

sensor has an integrated, highly sensitive CMOS array, 

which enables measurements of almost any difficult 

surface such as shiny or reflective surface, independent 

of the reflection from the target. This means excellent 

accuracy, resolution and reliability are achieved, even at 

high measurement speeds. 

The system itself comprises a sensor and integrated 

controller, which calculates the dimensions of the bead 

or groove. The system works in two ways: either in a 

stationary mode, with the sensor fixed and looking at 

moving targets, or in a scanning mode, where the sensor 

works in combination with a motion control device or 

robot. The sensor uses an innovative CMOS array with a 

real time, high-speed electronic shutter, which captures 

the entire profile and processes the information 

instantaneously. 




more stories from Micro-Epsilon and more news on laser sensors 

44 


Precision potentiometer 

suits harsh environments 

Variohm Eurosensor has 

launched a new range of 

heavy-duty rotary 

potentiometers from the German 

sensor manufacturer Novotechnik 

for precision angle measurement 

in extreme environmental 

conditions. With a choice of 

IP67 or IP69K protection ratings, the 

durable IPX series is available in 

single or true redundancy output 

versions with a choice of 120º, 200º 

or 350º electrical ranges and with 

independent linearity to better than 

±0.1% 

The compact range has a 

hermetically sealed housing in 

standard anodised aluminium or 

optional stainless steel with 

dimensions of just 79 mm in 

diameter and 35 mm length. The 

robust design includes a double ball 

bearing shaft support with a variety 

of stainless steel shaft options plus 

mounting flange, lever arm and other 

drive accessories. Electrical 

connection for each sensor channel is 

via an M12 threaded connector for 

IP67 rated use or with sealed PG 

style cable glands for IP69K 

protection applications. 

The range is based on the proven 

Novotechnik conductive plastic 

element and multi-finger wiper 

technology that offers more than 100 

million cycles of lifetime. 



www.industrialtechnology.co.uk for further 

details from Variohm Eurosensor 



45

DESIGN COMPONENTS 

Pumps & Blowers 

Do you repair or replace? 

Belzona Polymerics has developed a repair solution which can 

alleviate the need to replace your damaged machinery or equipment 

– sometimes at 1/10th of the cost – and reduce your downtime 

To replace or repair damaged machinery is 

always a dilemma, with different issues needing 

to be addressed. Do you sacrifice costs to 

reduce your down-time? Which is more 

important, efficiency or reliability? What is the single 

most important factor for your company? Of course, all 

companies want their machinery to run efficiently and in 

good working order, but is it all too easy to order a new 

part rather than looking at a more efficient and, cost 

effective solution over the longer term? 

Many companies are based in remote locations or 

work under extreme conditions and, therefore, have 

limited maintenance options at their disposal. 

Downtime can cost thousands, sometimes millions, of 

pounds a day. For over 50 years, Belzona has been 

conducting a rigorous Research and Development 

programme to introduce quick turnaround maintenance 

issues. The company has developed a number of 

polymer repair solutions which can be applied in 

extremely harsh and difficult conditions. National sales 

manager Gordon Cairns explains: “We have worked 

closely with our customers across many industries, 

including power, petrochemical, utilities, paper and pulp, 

to find out what they really need from a Belzona repair 

system. The most overwhelming feedback was ‘time is 

money’, so reducing downtime is essential. 

“We deal with hundreds of applications each year 

and are constantly reviewing their effectiveness in the 

most difficult environments. The customer needs a 

speedy, efficient, cost effective solution that will prolong 

(Right) Metso ash/slurry pump stripped down and awaiting 

Belzona treatment. (Below) Pump Impeller rebuilt with Belzona 

back to original OEM profile 

the lifespan of the machinery and cause the minimum 

amount of disruption possible. Many customers are 

faced with the choice of whether to replace the damaged 

part or not and tell me that ordering a new part can take 

days, sometimes weeks, to arrive. Repairing the 

equipment is invariably their last option.” 

Repairing erosion damage 

Putting theory into practice, the company has a 

comprehensive portfolio of case studies which support 

the claim, as its power industry specialist Jamie 

Gallagher explains: “An excellent example of a repair 

being better than replacing is a project we worked on at 

a major power site in Scotland. The job was to rebuild a 

Metso slurry pump, in which the pump had severe 

erosion to its suction impeller and the volute casing. This 

unit was used to impel slurry and fly ash, which are both 

highly abrasive. The worn pump components were in 

excess of 500 Brinell hardness but they were still badly 

eroded. The impeller had approximately 10–15mm 

missing from the leading edge and the volute had 

cavities approximately 200mm in depth. 

“The component parts were rebuilt with Belzona 

composite repair system back to their original pump 

profile and machined with diamond cutting tips. The 

impeller and volute case were then coated with the 

Belzona material, which is a highly specialised 

composite, combining extremely hard, closely packed, 

abrasion-resistant material in a polymeric binder to resist 

future attack.” 

Gordon Haylot of Norec, who operates the coal and 

ash plant, comments: “The Belzona repair was half the 

cost of a new pump, whilst offering an extended life, in 

comparison to a new unit.” 

As well as repairing erosion damage, Belzona 

composites can also repair holed and cracked pump 

casings, restoring structural integrity and protecting 

against future erosion damage. They can also restore 

cutwater profiles in pumps where the cutwater is directly 

exposed to impingement or entrainment from the pumps 

fluid. In such cases, rapid mechanical losses can be 

experienced and mechanical damage can also occur if 

extraneous solids enter the pump, leading to severe loss 

of efficiency. 

The repairs are suitable for all sorts of pump designs, 

and Belzona has over the years rebuilt numerous cracked 

and holed casings, rebuilt rotary pump casings, rebuilt 

reciprocating pump valve seals, repaired scored cylinders 

in reciprocating pumps, and coated peristaltic pump 

casings to prevent chaffing of liners. In scroll pumps, for 

example, the clearance between the bore of a scroll 

pump and the rotor is critical to the operation of the 

pump. If this clearance is increased then the pump will 

not operate. Damage to the bores can be caused by 

corrosion, erosion in the form of abrasion, or more 

commonly, a combination of both. Belzona’s range of 

erosion-corrosion resistant coatings can be applied to 

minimise the effects of the working environment and 

thus extend the maintenance intervals of the pump. 

With rotary positive displacement pumps, the 

clearance between the end cover of the pump and the 

end cover of the rotor is critical to the pump’s operation, 

since if the gap between the two becomes too large then 

the liquid being pumped will short circuit within the 

pump body. Such damage can be readily repaired. 

A Belzona repair can prolong the lifespan of the 

equipment for between five and ten years, depending 

on the working conditions of use. 



www.industrialtechnology.co.uk for further details from Belzona and 

more news on pumps 

46 



On the safe side 

SAMSON Type 3241 

Valves, which are listed in 

the EXIDA database, ensure 

that you stay on the safe 

side. You won’t have to 

worry about them failing 

thanks to their high MTBF. 

Step response tests are 

automatically performed 

and the resulting data 

stored in the device. 

Stay safe and sound 

with products from 

SAMSON 

Call 01737 766391 today for further details 

SAMSON CONTROLS (LONDON) LIMITED 

Perrywood Business Park, Honeycrock Lane, Redhill, Surrey RH1 5JQ. 

Fax: 01737 765472. Email: Sales@samsoncontrols.co.uk 

Internet: www.samsoncontrols.co.uk 


Need 

DESIGN COMPONENTS 

to get 

things 

Dry? 

Choose ACI’s Airknife drying systems for real 

financial savings over conventional alternatives. 

If your objectives are to increase 

throughput, eliminate quality problems 

associated with other methods of 

drying/blow-off, or significantly reduce 

energy costs, ACI will engineer a cost 

effective system for you … with 

guaranteed results. 

• Free Customer Site Evaluations (UK Mainland Only) 

• Free Payback Analysis provided 

ACI’s AirKnife Systems are powered by the company’s 

Centrifugal Blowers, delivering high velocity, warm, dry air with 

no pressure fluctuations for reliable, consistent, drying results. 

Please contact us for further detailed specifications and to 

discuss suitability for your application. 

www.aircontrolindustries.com 

the solution providers for air movement problems 

Air Control Industries Ltd 

Silver Street, 

T: +44(0)845 5000 501 

Chard, 

F: +44(0)845 5000 502 

Somerset,TA20 2AE, UK E: sales@aircontrolindustries.com 

Internal gear pump 

boosts the power 

Rexroth’s PGH Series 3X 

internal gear pump features a 

significant increase in power 

over previous generations and now 

covers power classes that used to be 

reserved for pumps of larger 

displacements. 

Based on the predecessor model, 

the completely revised PGH Series 

3X from Rexroth operates at a 

higher nominal pressure of 315bar, 

or 350bar in intermittent operation. 

Its speed range has also been 

extended for all sizes up to 

3,000rpm. In the lower speed 

range, up to 200rpm, the new 

power pump is suitable for pressureholding 

functions and closed-loop 

position control. 

Designed in particular for 

variable speed drives in stationary 

and mobile applications, Rexroth’s 

Progressing cavity pump 

manufacturer Netzsch has 

introduced the iFD-Stator®, a 

new dual-stator system comprising 

of a stator and stator housing that 

the company claims differs from all 

existing stators by offering significant 

PGH Series 3X is available in two 

frame sizes covering a range from 

20 to 250ccm, adding to the 

previous PGH Series 2x pumps at 

these sizes. A new feature on the 

PGH Series 3x is a standard test 

port that simplifies bleeding during 

commissioning. This test port also 

allows for condition monitoring 

systems to be attached for 

condition-related servicing of the 

complete drive system. 

Fitting seamlessly into Rexroth’s 

hydraulic product range, users can 

combine this universal pump with a 

wide range of axial piston units, 

vane, radial piston and gear pumps. 



www.industrialtechnology.co.uk for more 

info from Bosch Rexroth 

Dual-stator system 

helps boost capacity 

advantages in capacity, economy 

and environmental protection. 

The iFD-Stator, which is 

compatible with all NEMO pumps 

from the NM series, prolongs stator 

lifetime and reduces lifecycle costs 

thanks to its manoeuvrability within 

the two-part reusable housing. The 

use of a separate housing and stator 

means that, when worn, only the 

stator needs to be replaced. 




info from Netzsch 



Pumps & Blowers 

Vacuum pumps and air 

compressors 

Gast has expanded its ranges of 

vacuum pumps and air 

compressors to solve the 

broadest spread of OEM 

applications. The range covers 

rocking piston pumps, rotary 

vane pumps and miniature plastic 

pumps among others. 

The lightweight, rugged, quiet 

and oil-less rocking piston pumps 

(pictured) are available in standard, 

twin, and miniature styles with air 

flow rates to 9.35m 3 /h (3.4 lpm to 

5.5 cfm), vacuum capacities to 

31mbar (29in. Hg) and pressures up 

to 12bar (175 psig). Corrosion 

resistant and tank models are 

available as well as a complete range 

of recommended accessories. 

Bespoke versions can also be 

manufactured to special order for 

OEM quantities. 

The rotary vane pumps are 

available with oil-less, oil-lubricated, 

motor-mounted or separate drive 

styles. They provide a long, very low 

maintenance life, are simple and 

economical to install and operate. 

The low vibration design means that 

Rotary lobe pumps suit 

hygienic applications 

Mono NOV has launched a 

new range of hygienic rotary 

lobe pumps that has been 

specifically developed to significantly 

improve processing quality and 

efficiency for food and beverage 

manufacturers. The Luna range of 

rotary lobe pumps consists of high 

efficiency positive displacement 

pumps, which feature a modular and 

simple design that minimises 

maintenance requirements and 

delivers a long reliable life. 

Commenting on the launch of the 

new range, general manager Simon 

the range is ultra-quiet in operation. 

Units offer a wide range of pulse-free 

airflow rates from 0.31 to 112 cfm 

(0.53 to 190m 3 /h) without the need 

for a separate receiver tank. Vacuum 

ratings range from 65 to 335mbar 

with pressure ratings from 5 to 25 

psig (0.4 to 1.7bar) and motor 

outputs from 1/45 to 15 HP (0.02 to 

11.1kW). 

Gast’s range of lightweight 

miniature plastic vacuum pumps and 

compressors are ideal for light-duty 

OEM applications where a small, 

quiet source of vacuum or pressure is 

required. 




info from Gast 

Lambert says: “The new Luna pump 

has been specifically developed to 

meet stringent hygiene standards, 

including 3A and EHEDG. It has also 

been designed with C-I-P (Clean-in 

Place) and S-I-P (Sterilise-in-Place) 

procedures in mind. Wetted parts are 

manufactured in 316L stainless steel 

as standard, with other materials 

available that can withstand the most 

arduous regimes and corrosive 

cleaning chemicals. In addition, a 

range of hygienic fittings are also 

available, ensuring all market 

requirements are met. 

With maximum flow volumes up 

to 300m3/h, Mono’s Luna lobe 

pumps are able to handle a wide 

range of viscosities and temperatures 

–40°C and 100°C as standard, with 

optional performance up to 200°C. 




info from Mono 

We’re just full of 

hotair 

coolair,warmair,dryingair, 

slowair,fastair,smoothair, 

what ever air you want we got 

fans and blowers for extraction, cooling, 

ventilation, aeration, vaccum and drying 

A complete design and manufacturing service 

is offered by ACI for its extensive range of 

small to medium industrial fans. Options are 

based upon a comprehensive range of motor 

specifications and accessories. ATEX approved 

formats 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 airflow 

and noise testing 

• ebm-Papst UK Distributor for special applications 

Please contact us for further detailed specifications and to 

discuss suitability for your application. 

www.aircontrolindustries.com 

the solution providers for air movement problems 

Air Control Industries Ltd 

Silver Street, 

T: +44(0)845 5000 501 

Chard, 

F: +44(0)845 5000 502 

Somerset,TA20 2AE, UK E: sales@aircontrolindustries.com 



49

DRIVES & CONTROLS 

Process Automation 

Variable speed drives 

reduce the costs 

of automation applications 

A new family of drives from Baldor includes economy solutions for clean-area 

automation and food/pharma processing. Their effective speed adjustment 

provides a valuable mechanism for reducing energy consumption 

Baldor has launched a family of frequency 

inverter drives for AC motors that has the 

ability to reduce total cost of ownership 

substantially for common process automation 

equipment. The drives offer a very simple user interface 

that provides ‘out of the box’ solutions for a large 

proportion of variable speed motor control applications. 

They are also available with a range of environmental 

protection, from a standard industrial housing to a dustand 

splash-proof version (IP55 or NEMA 12), and even 

a full washdown duty (IP66 or NEMA 4X) variant. The 

latter version is unusual in this smaller power sector of 

the market. 

The new Baldor VS1MX family of drives is expected 

to help machine builders to reduce costs substantially in 

automation for common applications such as fan and 

pump control, as well as in clean area processing zones 

in the food and pharmaceutical industries. The drive 

range includes both single-phase and three-phase 

versions, for motor control power requirements from 

0.37 to 7.5kW (0.5 to 10HP). A Modbus RTU 

communications port is provided as standard. 

VS1MX drives have been designed to be as simple as 

possible to apply. Every version can be supplied ready to 

use, with an integral EMC filter. Simple front panel 

mounted user interfaces allow any of the drives 

to be made operational in minutes. Although 

the drives come with a control language of 45 

parameters – supporting the programming of 

quite complex applications – the first menu 

level presents a subset that allows the most 

common applications to be set up in a few 

minutes. These commands include motor 

voltage, current, frequency or speed, 

maximum/minimum speed, preset speed 

and acceleration/deceleration ramp. 

Configuration programs can also be stored 

on a simple external memory stick type 

device, and reloaded as required. A remote 

keypad may also be fitted to the drives, to 

simplify the layout and construction of 

automation. 

Improved low speed torque 

Despite the focus on economy, Baldor’s VS1MX drives 

offer an advanced new-generation V/Hz control algorithm 

that provides much tighter regulation of speed, and 

greatly improves torque at low speeds, making the drives 

capable of starting up even high inertia loads. The 

standard industrial version of the drive (protected to 

IP20) is DIN rail mounting. The 

two higher-specification versions 

are panel mounting, and come 

with a built-in isolation 

mechanism that ensures that 

operators can switch the system 

to a safe state for maintenance 

purposes, or for dealing with dayto-day 

issues such as clearing a 

jam. The dust- and splash-proof 

version can also be ordered with a 

front panel mounted potentiometer, 

to provide a simple 

speed control mechanism for 

applications such as conveyors. 

There are eight choices of 

drive available for single-phase 

applications, spanning motor 

output ratings from 0.37 to 

2.2kW (0.5 to 2.9HP), plus a 

further 13 choices of three-phase 

versions for motor outputs from 

0.37 to 7.5kW (0.5 to 10HP). All the drives also 

incorporate built-in analogue and digital I/O and a NOC 

relay output, providing users with facilities to create 

custom remote control panels, and to integrate the drive 

into a process. 

The drives’ command parameters have been specially 

selected to provide a simple upgrade path for users of 

previous generations of low-power frequency inverters 

from Baldor. 

With energy costs spiralling, it’s likely that Baldor’s 

new VS1MX range will provide a return on investment 

extremely quickly. Variable speed capability is a very 

important technology for manufacturers today in the fight 

to reduce energy costs. Many potential applications still 

use motors in direct-online configurations for example, 

running at full speed. If the speed can be reduced, the 

energy consumption costs can drop substantially. This is 

particularly the case for many centrifugal fan and pump 

applications, as the torque required to turn them is 

proportional to the square of the speed. In this case, a 

20% reduction in speed can save up to 50% energy. To 

complement such energy saving possibilities, Baldor 

offers a range of compatible AC motors that offer 

efficiencies in excess of the European high efficiency 

EFF-1 rating, in both metric and NEMA frames. 



www.industrialtechnology.co.uk for further details from Baldor and 

more news on variable speed drives 

50 




Contactors 

Why not vacuum 

In low-voltage applications, controlgear designers are curiously 

reluctant to specify vacuum contactors, despite the many and 

important benefits that they have to offer. Steve Rickard of Moeller 

Electric believes that it’s time for things to change 

When it comes to medium-voltage equipment, 

vacuum contactors are commonplace, but 

how often do you see them in low-voltage 

panels? The answer is very rarely. In fact, many 

controlgear designers specify air-break contactors almost 

automatically, without giving a thought to whether vacuum 

devices might be a better choice for the application. 

Why is this? One reason is undoubtedly familiarity. 

Designers of LV control panels are used to working with airbreak 

contactors, but vacuum types are something of an 

unknown. I believe, however, that there is no reason for 

undue caution: vacuum contactors are just as easy to specify 

and use as their air-break counterparts. There are no hidden 

traps for the unwary. Another reason often given for shunning 

vacuum contactors is price, and it has to be said that, rating 

for rating, they are considerably more expensive than airbreak 

products. That’s not quite the whole story, however: in 

appropriate applications the lifetime cost of a panel using 

vacuum contactors can be much lower than that of an 

apparently equivalent panel fitted with air-break contactors. 

To see why I’m so enthusiastic about the virtues of 

vacuum contactors let’s start by taking a look at the types of 

applications where they score. Typically, these involve large 

loads – in excess of 250kW or so – and severe switching 

duties. In such applications, air-break contactors are prone to 

failure and invariably have short operating lives. Watch the 

contactor in operation, and it’s easy to get a clue to the root 

cause of the trouble. Spectacular arcing is the order of the 

day and, while this may be interesting to observe, it’s not 

doing anything good for the life of the contactor. 

Here comes the science. The real problem is the way that 

air-break contactors interrupt heavy currents. As the contacts 

part, an arc forms which is fed by ionised gases. The arc 

starts at a tiny point on one of the contacts, and ends at a 

similar tiny point on the other. A particular characteristic of 

arcs struck in air is that these points don’t move – they 

remain fixed until the arc is extinguished. 

What this means is that the contact surfaces at these 

points reach very high temperatures and many even melt, 

resulting in rapid erosion and, in bad cases, even allowing the 

contacts to weld. And it gets worse! If we’re lucky, the arc will 

be extinguished the first time the load current passes through 

zero but, more often than not and particularly in severe 

applications, the arc re-ignites and is not extinguished until 

the second current zero after the switching operation. When 

this happens, the arcing time and, therefore, the potential for 

damage to the contact is at least doubled. 

Minimising contact erosion 

Let’s make no bones about it, vacuum contactors also 

produce switching arcs, but the way they behave is very 

different. First of all, instead of a single arc there are multiple 

arcs between the contacts and, crucially, the start and end 

points of these arcs are constantly in motion. As a 

consequence, no local hotspots are produced on the contact 

surfaces, so the rate of contact erosion is very much lower 

than in air-break contactors. It’s also worth noting that the 

arc in a vacuum contactor is always extinguished at the first 

current zero, which means that the length of time during 

which contact erosion can take place is kept to a minimum. 

The differences in the way arcs behave mean that, in 

applications involving severe switching duties, vacuum 

contactors will always outperform their air-break 

counterparts by a very wide margin in terms of electrical life. 

In itself, this is enough for me to encourage designers to look 

favourably on the use of vacuum contactors but, in fact, there 

is whole range of additional benefits that should also be 

taken into account. Consider, for example, the locations in 

which contactors with severe switching duties are likely to be 

used. Many will involve very poor environmental conditions 

that can rapidly have a detrimental effect on switchgear. With 

air-break contactors, the contacts are exposed to the poor 

environment, but with vacuum devices, the contacts are 

completely sealed within the vacuum bottles. They are, 

therefore, totally protected against contamination, tarnishing 

and other forms of degradation. The sealed construction of 

the vacuum bottles also has another benefit: it prevents arc 

by-products from escaping. This means that the possibility of 

flashovers to surrounding metalwork during switching 

operations is eliminated. As a result, clearance distances can 

be reduced, so panels that use vacuum contactors can be 

made much smaller than similar panels based on air-break 

devices. In some situations, such as on-board ship, this can 

be a very significant advantage. 

If you’re still not convinced, consider this. The best of 

modern vacuum contactors incorporate electronically 

controlled coil mechanisms. Not only do these ensure that 

the force on the contacts is optimised throughout the whole 

of the closing stroke, thereby preventing noisy operation and 

contact bounce, they are also much more energy efficient 

than conventional coil circuits. That means smaller, less 

costly control transformers can be used and that far less heat 

is generated in the control panel. 

I would like to suggest that in appropriate applications 

the technical benefits of vacuum contactors are convincing. 

But what about cost? Whilst their purchase price is higher 

than that of air-break devices, it is important to take into 

account operating life. If, in a demanding application, an airbreak 

contactor has to be replaced several times to equal the 

life of a vacuum contactor, the cost equation quickly shifts in 

favour of vacuum. And that doesn’t take the cost of downtime 

into account. 

Enthusiastic as I am about vacuum contactors, even I 

wouldn’t suggest that they’re going to replace air-break 

devices in run-of-the-mill applications, or even that they 

should. I do believe, however, that in applications involving 

large loads and severe switching duties, their technical and 

even cost benefits are enormous. So, designers of LV control 

systems, when you’re next called upon to produce a panel for 

a particularly demanding application, don’t forget that 

vacuum contactors can provide an efficient and cost 

effective way of addressing the many challenges you face. 



www.industrialtechnology.co.uk for further details from Moeller 

Electric and more news on contactors 

52 


motion and 

mechatronics 


DRIVES 

AND 

ROLLERS 

THE HEART OF CONVEYOR TECHNOLOGY 

Permanent magnet and hybrid stepper 

motors 

Low inertia dc motors 

Synchronous and brushless motors 

Optional tachos, encoders and brakes 

Precision spur instrument gearheads 

Industrial and ultra low backlash planetary 

gearheads 

High resolution industrial linear and rotary 

incremental and absolute encoders. 

Stepper, DC servo and AC Brushless servo 

drive and control modules 

Customised motion control and 

mechatronics systems 

Contract EMC Facilities 

W W W .IN TERROLL.COM 

INTERROLL 

CORPORATE 

ART 

● 

• Motorised Drums 80mm - 215mm Dia. 

• Drives for all makes of modular belts 

• Zone Controlled Roller Drives 

• Gravity Rollers 

• Fixed & Friction Drive Rollers 

• Tapered Rollers• Conveyor Wheels 

• Omniwheels • Ball Transfer Units 

• Roller Tracks • Pallet Drives / Rollers 

Interroll Ltd., Brunel Road, Earlstrees Industrial Estate 

Corby, Northants, NN17 4UX 

Tel: +44(0) 1536 200 322 • Fax: +44(0) 1536 748 505 

gb-sales@interroll.com • www.interroll.com 

Mclennan Servo Supplies Ltd. 

Unit 1, The Royston Centre 

Lynchford Road 

Ash Vale 

Surrey 

GU12 5PQ 

UK Tel:+44 (0) 8707 700700 

Email:sales@mclennan.co.uk 

www.mclennan.co.uk 



New Products 

Digital drive reduces the need 

for PLC or PC based systems 

A new module for Sprint’s drives makes it easy to 

tailor your control strategy to your application 

Sprint Electric offers a Programmable 

Logic Arithmetic unit (PLA) with 

extended functionalities for diverse 

applications and motion tasks. The PLA is 

a stand-alone applications module that 

can compliment and enhance any 

analogue or digital drives system, simplify 

system design and reduce or eliminate the 

need for PLC or PC based systems. 

Designed primarily for use by system 

integrators, the PLA offers a powerful and 

flexible method of processing analogue 

and digital signals via easy to use 

configurable software blocks. The PLA 

enables the user to define a control 

strategy to exactly meet the demands of 

the process or application. The block 

diagram created is flexible and has a 

unique ‘Configuration Checker’ detecting 

shorts within the user-defined 

connections. The standard application 

blocks in the PLA include diameter 

calculator, taper tension calculator, torque 

compensation for inertia and friction, 

motorised pot simulator with power loss 

memory, two high performance PIDs with 

gain profiling, two summers with inverting 

scaling clamping and hysteresis, two 

filters with precision time constants from 

milliseconds to 30 seconds, delay timer 

with roll-over facility, linear or ‘S’ ramp, 

and many more. 

All the facilities can be programmed 

and interconnected with each other 

and/or the extensive input/output facilities 

in the PLA. All source and target 

parameters are described in English or 

selectable other languages. Additional 

input/output facilities can be programmed 

and monitored in engineering units. 




further details from Sprint Electric 

Servos join 

the Ethernet 

revolution 

Joining the rise of Ethernet as 

a simple, multi-platform 

factory communications 

protocol, Lenze-AC Tech has 

launched the latest generation of 

its PositionServo drive with full 

Ethernet connectivity as standard. 

PositionServo is a powerful but 

simple introduction to a good 

quality reliable servo controller 

without the usual cost and 

complexity normally associated 

with servo automation solutions. 

Open standards and the 

proliferation of PC control in 

Dedicated drive 

for HVAC tasks 

Control Techniques Drives has 

launched Affinity – a new range of 

HVAC/R drives focused especially 

on the needs of the building automation 

industry world-wide. Rated up to 132kW, 

with models available in 200V up to 

690V, Affinity is offered in both IP20 and 

IP54 formats with BACnet, Metasys N2 

and Modbus communications all 

integrated as standard along with 

LonWorks as a simple plug in option. 

The Affinity specification includes the 

industry recognised fireman’s mode 

operation, easy to use LCD keypad with 

‘Hands-Off-Auto’ control plus dual PID 

loops. Easy programming is from either 

Control Technique's PC tools or simple 

Smart Card. 




further details from Control Techniques Drives 

Parker launches intelligent 

multi-axis servo drives 

Parker Hannifin has extended its 

family of Compax3 drives with the 

launch of the Compax3M (C3M) 

servo drive. This new drive has been 

developed specifically for use with a wide 

range of multi-axis applications, providing 

a powerful yet easy to use system that is 

also extremely compact; indeed, Parker 

believes the C3M could well be the 

slimmest servo drive currently available. 

In common with the Compax3 family, 

the new C3M can be programmed using 

the standard IEC61131-3 language, with 

support for conventional industry 

protocols including Profibus, Ethernet 

Powerlink, EtherCAT, CANopen and 

DeviceNet. Dynamic, synchronised multiaxis 

control is provided either internally or 

through an optional external PLC module. 

The C3M offers a wide range of 

features, intended to simplify setup and 

operation, and to improve reliability, 

performance and productivity. This 

includes the capability of straightforward 

positional control, with function modules 

based on PLCopen, or cam function 

modules for more 

complex 

positioning applications. In addition, the 

drive provides fast control loops, with 

positional response being 125µsec, while 

jerk-limited setpoint generation 

guarantees a longer service life of 

mechanical components. Similarly, the 

system offers automatic acquisition of the 

load moment of inertia, motor ratings and 

motor position feedback, and has as 

standard eight digital inputs and four 

digital outputs, two analogue inputs and 

outputs, and both RS232 and RS485 

interfaces. 

Reducing installation costs 

The C3M is available for use with 

applications of up to 30A, with the 5, 10 

and 15A versions measuring only 50mm 

in width, and the larger 30A versions 

being 100mm wide. Just as importantly, 

the new drive allows OEMs and end users 

to minimise installation costs, by the 

integration of components such as mains 

filters and braking resistors into the drive 

system and the ability to reducing 

wiring. In addition, the modular design of 

the C3M enables it to be used with 

different voltage supply sources. 




further details from Parker Hannifin 

factory automation means that the 

new PositionServo is now fully 

compatible with what is becoming 

the least-cost solution for many 

applications. 




further details from Lenze 

Plug-in drive 

has CANopen 

The PIM2401 intelligent 

plug-in minidrive from 

Technosoft is specially 

designed for motion control 

applications where space is 

limited. Its miniature size (and 

weight allow it to be mounted 

horizontally or vertically, inside the 

machine or near the motor. PC 

and PLC motion libraries are 

available, and the PIM2401 

supports CiA standard DS-30 

v4.02 CANopen. 




further details from Technosoft 

54 


High performance five 

phase stepper motor 

combined with... 

...a low vibration micro stepping 

driver offering a unique, smooth 

drive function. 

AC Induction motors 

AC Induction motors, available 

with output from 6 to 90 watt. 

With reversible and electromagnetic 

brake options. 

BLF 

Brushless DC motor/driver 

package with digital operator. 

Multispeed operation. 

Oriental Motor (UK) Limited 

Unit 5 · Faraday Office Park · Rankine Road · Basingstoke RG24 8AH 

t: 01256 347090 · f: 01256 347099 

e: larsen@oriental-motor.co.uk · web: www.oriental-motor.co.uk 



MACHINE BUILDING & AUTOMATION 

Linear Motion 

maintenance intervals and long operating life. Properly 

specified linear motion technology can increase the 

efficiency of machinery considerably, enabling, for 

example, quick size adjustments and product 

changeovers, vital for busy industrial applications. 

In addition to making the building of effective 

automation systems simpler and more cost effective in 

the medium to long term, the latest mechatronics 

technology can also help plant managers ensure that the 

health and safety of employees is safeguarded, in 

contrast with conventional automation solutions, which 

can pose a number of safety risks. 

Hydraulic systems, for example, can be potentially 

hazardous, requiring fluid to be stored under incredibly 

high pressures and, therefore, reaching extremely high 

temperatures. The risk of oil leaks presents a potentially 

dangerous scenario to staff as well as being likely to 

A more productive plant 

It is now easier than ever for plant managers to boost productivity 

and minimise costs thanks to the latest generation of linear motion 

technology, explains Nick Brooker of SKF’s Industrial Division 

With plant managers under increasing 

pressure to optimise productivity levels 

while at the same time minimising costs, 

automating industrial processes offers an 

effective means of achieving both objectives. However, 

for automation systems to be able to deliver the precision 

and repeatability demanded of many of today’s industrial 

applications, extremely sophisticated engineered 

products and systems are generally needed, requiring 

significant investment. The latest mechatronics 

technology is offering a high performance yet cost 

effective solution, enabling automation systems to be 

created simply and efficiently. These products are able to 

provide accurate and reliable operation with extended 

service intervals, minimising operating costs for users. 

A wide range of linear motion devices are now 

available to enable bespoke automation systems to be 

built that meet the requirements of specific industrial 

applications. These devices are capable of extremely 

high levels of performance over long, low maintenance 

operating lives, able to position even heavy loads with 

sub micron levels of precision. This is offering end users 

the opportunity to realise vital increases in line efficiency, 

and, consequently, increase profitability. Furthermore, 

the products are allowing operating costs to be cut 

considerably, as they require little maintenance or 

manual intervention. 

Linear motion technology 

Linear motion technology is now a proven method of 

enabling an object to be positioned or actuated in one or 

more directions. These positioning systems can either be 

sourced as complete units or created by combining a 

guide and a drive. With a wide range of linear guides 

now available, including linear bearings, profile rail 

guides, precision rail guides and cam-roller guides, the 

right solution can be found for any application, 

depending on the weight of the load to be positioned and 

the level of precision required. Furthermore, whereas ball 

screws have typically been used as the driving element 

to move the object, more robust roller screws can also 

now be sourced, offering higher levels of load carrying 

capacity as well as greater positional accuracy and 

repeatability. 

Additionally, for industrial applications where a space 

efficient and discreet solution is required, compact and 

quiet running linear actuators are available. These 

devices can take a wide variety of shapes and sizes to 

meet the specific needs of an application. For example, 

telescopic pillars and rotary actuators are increasingly 

common, in addition to sophisticated control units, 

which have been developed to make it simple to design 

application specific automation systems. 

Design considerations 

It is important to consider the requirements for linear 

motion technology early in the machine design process 

so that the cost and performance benefits that the latest 

devices offer can be optimised. Leading manufacturers 

such as SKF are able to offer expert advice and support 

at this stage to ensure that all the relevant factors are 

taken into account, such as the environment and 

conditions in which the system will need to operate, in 

addition to the required load carrying capacities and 

precision levels. 

By paying close attention to these factors throughout 

the design process, an automation system can be built 

that combines effective performance with extended 

result in equipment downtime. Likewise, pneumatic 

automation systems can put operators at considerable 

risk, with poorly secured attachments or tools carrying 

considerable force, leaving no time to react and avoid a 

collision. If compressed air filters are not managed 

correctly an oily mist can enter the atmosphere, putting 

employees at risk and creating an environmental issue. 

By contrast, cutting edge electromechanical linear 

motion technology offers an intrinsically safer solution, in 

addition to minimising the risk of contamination and 

injury through a reduction in maintenance and 

lubrication requirements. 

Save your energy 

Helping plant managers cut costs further is the energy 

saving potential of the latest linear motion technology. 

Conventional hydraulic and pneumatic systems require 

significant amounts of energy to operate, with pneumatic 

systems generally estimated to consume between 10 

and 15% of a typical plant's electrical energy. By 

upgrading to electromechanical solutions combining the 

latest efficient drives and linear guides and positioning 

systems, these costs can be reduced considerably, 

having a significant impact on a plant’s carbon footprint 

as well as its bottom line. 

With plant managers under increasing pressure to 

boost the productivity of machinery, while at the same 

time minimising maintenance and operating costs, the 

latest electromechanical linear motion technology is 

offering an effective solution. By enabling safer and more 

energy efficient automation systems to be built, the 

technology is allowing engineers to realise bespoke 

solutions that meet the needs of a specific industrial 

application, enabling both financial and productivity 

targets to be reached quickly and simply. 



www.industrialtechnology.co.uk for further details from SKF and 

more news on linear motion technology 

56 



57


Medical Device Manufacture 

Suck it and see 

Pennine Healthcare has used a range of Mitsubishi 

equipment to automate the sterile bagging of its range of 

Yankauers – suction devices used by surgeons to remove 

excess fluid from patients during surgical procedures 

Derby based Pennine Healthcare makes an 

extensive range of single use medical devices, 

with all manufacturing being undertaken in a 

medical quality clean room. With over 60 

million individual products made a year, automation is 

vital as it helps avoid contamination through human 

intervention, maintains quality and consistency and 

contains costs. 

A yankauer is essentially a rigid extruded PVC tube, 

with one end attached to a suction line. The free end is 

chamfered to avoid sharp edges, has a series of radial 

holes and is angled for ease of use. Further back along 

its length, the bore diameter is enlarged (through an air 

injection during extrusion) and a larger hole is provided 

to allow suction control during use. As well as surgeons, 

they are commonly used by dentists and vets. 

Manufacture of these has essentially always been 

partially automated, but until recently bagging them into 

poly sealed packaging was a manual process. “We were 

aware that this was a production bottleneck, that the 

operatives had to maintain very strict hygiene routines 

and that inner packing was disproportionally expensive 

compared to the rest of the processes,” says plant and 

systems engineer Darryl Orridge. “So were keen to look 

at automation.” 

Manufacturing expertise 

Many of Pennine’s manufacturing processes are unusual, 

if not unique. Add to this the discipline for clean room 

operation and its engineering expertise has to be first 

class. “For us, manufacturing technology is not a 

commodity that can simply be 

bought in as required,” says 

Orridge. “It’s a core skill within 

the framework of the company 

and we have a highly skilled 

team dedicated to the 

development of our own high 

performance and sophisticated 

custom-built manufacturing 

systems.” 

Control technology 

Pennine has long favoured 

Mitsubishi for control technology 

and systems and it was 

the launch of the new Q series 

programmable automation 

controller (PAC) that encouraged 

Orridge to consider options for yankauer packing. 

“The process can be broken down into distinct stages,” 

he says. “We have to load the yankauer into the 

packaging machine, make the bags from a roll of flat 

tube polythene, insert the product into the bag then seal 

and label it. There is a 200W Mitsubishi J3 servo axis 

advancing the bag, the 

sealer/perforator, labeller, 

interlock, data handling 

and several other 

functions. In total there 

are 262 inputs and 

outputs, all handled by a 

Q01 PAC plus an E1032 

HMI for local control and 

monitoring.” 

The Q series is a 

flexible unit with dual 

central processors, which 

Pennine use in a mutual redundancy configuration, and 

a bespoke array of modules for each of the functions 

under control. Because the machine is compact, loading 

requires the products to travel a route around several 

obstructions. This is done with a Mitsubishi RV3SB sixaxis 

robot, controlled via the Q series. The main conveyor 

within the cell is controlled by small induction motors 

with Mitsubishi 0.18kW FR500 inverters for speed 

matching. “This is the 

first time we’ve used the 

new J3,” says Orridge. 

“Previously it’s been the 

J2. By comparison the J3 

is smaller, faster, more 

powerful and easier to 

programme; it’s no harder 

to set up than a 

conventional AC motor.” 

In another innovation 

Orridge has also made 

considerable use of 

fieldbus communications. CC-link is used for 

communications between the robot bagging machine 

and packaging machine, while ASiSafe is used for the 

safety interlock. 

Fieldbus revelation 

“Fieldbus has been a revelation for me,” comments 

Orridge. “It’s so easy compared with conventional wiring: 

just run the bus cable around the machine and link in the 

various devices locally. I reckon we saved several days of 

wiring up and troubleshooting in the build phase, and in 

use repairs and alterations are the work of moments. We 

have decided that CC-Link is going to be the company 

standard from now on.” 

Pennine’s commitment to automation matches its 

commitment to continuing manufacturing in the UK and 

will continue to further automate its processes. 

Significantly this helps keep costs down so that exports 

are competitive even when compared to products from 

low cost economies. Currently half of all production is 

exported, a proportion that has been growing steadily 

for many years. 



www.industrialtechnology.co.uk for further details from Mitsubishi 

and more news on automation technology 

58 


6-7, Faraday Road | Aylesbury 

Buckinghamshire HP19 8TX 

Tel 01296 398865 | Fax 01296 398866 

e-Mail: rkgb@phoenix-mecano.co.uk 

www.rk-online.co.uk 


AEROTECH 

Preconfigured and 

Engineered Motion Systems 

Aerotech 

is a world leader 

in innovative precision 

motion control systems for all 

areas of industry and research. 

Our product lines include patented and award winning direct-drive linear and rotary 

nano-positioners; airbearings; linear motor gantry systems, linear motor stages and systems, multi-axis 

motion controllers and drives. Aerotech also specialises in clean room and vacuum systems. Our ability to 

customise automation solutions specifically designed for our customer's applications is unmatched. 

Aerotech Ltd - Jupiter House - Calleva Park - Aldermaston - Berkshire RG7 8NN - UK 

Tel: +44 (0)118 940 9400 - Fax: +44 (0)118 940 9401- Email: sales@aerotech.co.uk 

Dedicated to the Science of Motion 

www.AEROTECH.co.uk 



Electromechanical Joining 

Electromechanical actuators 

prove a good fit for joining 

At Mach Kistler launched a new series of electromechanical 

NC press-fit systems. The compact servomotor actuators with 

piezoelectric force monitoring provide a ready alternative to 

hydraulics in a host of demanding joining applications 

There are many applications where we love 

hydraulics, but there are as many again where 

the very nature of the technology, the associated 

gubbins, the integration headaches and the 

maintenance requirements mean it’s less than ideal. If 

there was a ready alternative that could offer us the 

same force and controllability, then let’s be honest we’d 

jump at it. 

It’s no surprise, then, to see electromechanical 

actuators increasingly supplanting the traditional 

hydraulic products in press-fitting applications. The 

benefits of switching to electromechanical joining 

systems include better environmental compatibility, a 

more favourable energy balance, compact design, 

minimal installation effort and very low-maintenance 

operation. But that alone probably wouldn’t prove the 

clincher in making us switch. It is primarily production 

aspects such as increased flexibility, exact positioning, 

extremely high reproducibility and accurately defined 

press-fitting forces that make a really compelling 

argument for the system designer. 

Joining is the connection of two or more components 

within the elastic limits of the material. Depending on 

how the cohesion at the junction is obtained, the 

connection might be press-fit (force transmission by 

friction at the joining faces), form-fit (force transmission 

by matching geometric forms) or preloaded form-fit (a 

combination of press- and form-fit force 

transmission). In all cases, the key is quality 

joining is to ensure that the parts are 

correctly positioned and that the 

correct force is applied. These are 

things that can only be tested 

during the process step itself. 

With its expertise in all 

things to do with force, torque, 

pressure and acceleration, 

Kistler has taken a new look at 

the requirements of electromechanical press-fit 

systems, and reckons it has significantly improved over 

existing solutions with the development of its new 

generation NCFH. This offers a particularly compact and 

precise system solution for a wide range of force 

displacement monitored press-fitting and joining tasks. 

Typical applications are found, for example, all over 

the automotive industry, from pinning of clutch disks and 

calking of steering shafts through to pressing of valve 

seats and assembly of race car suspensions. When it 

comes to gear assembly, the NCFH is suitable for joining 

of gearwheels on shafts by monitoring force over 

position, for joining out bearing rings into bearing cups, 

for joining of inner bearing rings onto shafts and for 

joining of shaft seal rings into position. In chassis 

assembly, the NCFH can join rubber metal dampers into 

chassis components by monitoring force over distance, 

assemble sealing elements and test dampers, and join 

wheel bearings. In the assembly of wheel carriers, it can 

press axle taps to a force, squeeze axle taps and improve 

quality control by storing the force curves. But the 

applications go beyond the automotive industry, to 

encompass the likes of joining of rotors onto shafts, 

pressing of bearings into washing machine drives, and 

joining of pinions and commutators in starter 

assemblies. 

Highly compact design 

The actuator builds a hollow shaft servo motor directly 

around the threaded spindle drive, providing an 

extremely compact product. The design also 

allows gearing to be eliminated, ensuring 

highly responsive operation. But 

perhaps most important is 

Kistler’s integration of 

piezoelectric force 

measurement 

technology which 

allows forces up to 60kN 

to be covered by just two spindle 

sizes – a small one for forces to 10kN, 

and a larger one for forces to 60kN. 

Previously, such a range would have 

required seven. This makes the NCFH incredibly 

flexible, with the switchable measuring range of the 

integral force sensor allowing a single product to be used 

in a wide range of machine operations. 

When you think about the characteristics of 

piezoelectric measurement technology – generous 

overload protection combined with consistent accuracy 

over a wide measurement range – then it’s easy to see 

why it’s such as good fit for joining technology 

applications. 

Highly compact, and particularly short when 

compared to alternative solutions, the electromechanical 

NCFH press-fit systems are suitable for under-bench 

mounting. With an overall height of either 475mm or 

795mm depending on the model, they offer strokes of 

200 or 400mm, which allow them to reach extended 

end-points, such as bearings in transmission half shells. 

But despite these long travel distances, you can also 

expect quick return strokes thanks to the high speeds of 

up to 300mm/sec, which shortens machine cycle times, 

giving you the room to boost the production capability. At 

the same time, the fact that tension and compression 

forces are always available as standard leaves 

considerable machine design freedom. 

The force signal employed by the force 

displacement monitoring system is used to 

control the movement in highly specialised 

joining tasks. The force control system 

increases the application versatility of this 

press system. Thus spring elements, for 

example, can be loaded to specific values or 

compensation applied with constant force in case of 

displacement of parts. Two central lubrication points for 

guide and bearing ensure very low-maintenance 

operation. The threaded spindle drive is permanently 

lubricated. 

As the active compression compensation system 

eliminates the effect of the bending of the spindle and 

customer’s assembly, the positional accuracy is no 

longer influenced by the force. The standard holding 

brake permits the use of particularly heavy tools as it 

prevents the ram from dropping when the module is 

switched off. 

In summary, we can see that the NCFH modules 

combine exact positioning and extremely high 

reproducibility levels with accurately defined press-fitting 

forces. Compared with hydraulic solutions, Kistler 

reckons you can expect to benefit from considerable 

energy savings, higher process reliability, improved 

product quality and more cost-effective production. 



www.industrialtechnology.co.uk for further details from Kistler and 

more news on electromechanical actuators 

60 


Profile 


Conveyor 


Linear 

Motion 

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Guard Rails, Treads, Platforms 

and Workstations for the office, 

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cost advantages through 

standardization 

uncomplicated project 

management 

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solutions 

reusability of components 

and modules 

the product range enables 

complete system layout 

without compromises 

more flexibility for growth 

and expansion 

professional advice and 

layout, CAD drawings and 

electronic catalog 

THE ENGINEER’S CHOICE 

Powerlock fastener means NO machining 

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Full range of Machine Guards, 

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mk Profile Systems Ltd. 

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Phone +44 (0)1257 263937 

Fax +44 (0)1257 271409 

www.mkprofiles.co.uk 

info@mkprofiles.co.uk 


NEW 

Now available in stainless steel. 

T: 01256 365605 

E: info@minitec.co.uk 

www.minitec.co.uk 



Dynamic pressure 

control goes large 

Intelligent and individual, these new 

electronic pressure regulators meet the 

widest spread of application requirements 

Hoerbiger-Origa has 

extended its Airfit Control 

range of proportional 

pressure regulators with 

new models that for the first time 

bring truly dynamic control and 

precise regulation to applications 

requiring large and rapidly changing 

pressure differences, high flow rates, 

or extremes in input or output 

pressures. Combining advanced 

electronics with an innovative twin 

poppet valve configuration, the new 

models extend the Airfit range into a 

host of new applications, delivering 

high performance and fast response. 

The Airfit Control pressure 

regulators cover size ranges from 

0.25in (G¼) to a massive 2in (G2) 

in a single range, meeting the widest 

spread of application requirements 

without compromise. They deliver 

precise and reliable pressure 

regulation in even the most 

demanding of applications where 

there may be high temperatures, 

high levels of vibration or high levels 

of contamination. 

The construction of the new 

Airfit regulators uses two directional 

valves for converting electrical 

pulses to pilot pressure. This forced 

ventilation of the pilot chamber 

means there is no permanent air 

consumption, and means that the 

quantity of air required during the 

regulation process is extremely low. 

Further, the self-regulating seal 

between the pilot 

chamber and the 

output prevents the ‘stick-slip’ 

phenomenon. The result is a design 

that combines precise control with 

high dynamics, whilst offering a 

long and reliable service life. 

The eight variants in the 

extended Airfit range cover input 

pressures up to 16 bar, whilst the 

elimination of ‘stick-slip’ means the 

products will operate reliably at the 

very lowest input pressures. Even 

with fluctuating input pressures, the 

Airfit Control series will offer 

precisely regulated outputs between 

0 and 10 bar. The innovative design 

also allows the products to deliver 

reliable regulation at high flow rates 

of up to 40,000 l/min. And all this 

comes in a highly compact design 

that will meet the needs of 

applications where space is at a 

premium. 

The regulators are controlled via 

PLC or potentiometer, with either 

0-10V, 0-20mA or 4-20mA. 

Environmental protection is to IP54 

as standard, increased to IP65 

where required. 




info from Hoerbiger-Origa 



New Products 

Stepper package offers 

increased performance 

Oriental Motor has released 

a compact high 

performance new stepping 

motor and driver package. 

The RBK series comprises a 2-phase 

stepping motor and DC input micro 

step driver. The micro step function 

divides the basic step angle of the 

motor (1.8 deg/step) by up to 128 

without the use of a reduction 

mechanism or other mechanical 

element. Sixteen different resolutions 

are available from 1.8deg/step to 

0.0140625deg/step. 

A vibration suppression function 

is also included which reduces the 

risk of missteps due to vibration. A 

wide voltage range driver is used 

with a range of 20 to 75V DC and 

4.5 A/phase. This enables the series 

to operate from a wide range of 

power sources. The motor is 

available in two frame sizes, 

56.4mm and 85mm, and is certified 

to IP65 standard of moisture and 

dust protection. The RBK series 

conforms to CE, UL and CSA 

standards. 




info from Oriental Motor 

Rodless cylinders cover 

a wider payload range 

Festo has launched two high 

performance pneumatic 

linear actuators, extending 

the load-bearing capabilities 

of its DGC family to unprecedented 

levels. The new DGC-50 and 63 

actuators feature internal piston 

diameters of 50mm and 63mm 

respectively, providing significantly 

more force and higher payload 

capacities than other actuators in the 

same series. The top-of-the-range 

version of the DGC-63, for example, 

can accommodate payloads in excess 

of one tonne. 

Festo’s DGC family of pneumatic 

rodless actuators now spans eight 

cylinder sizes, ranging from a tiny 

8mm to 63mm. Standard models 

within this series offer velocities up 

to 3m/s, forces as high as 1870N 

and up to 5m stroke lengths as 

standard. DGC actuators employ an 

angled sealing mechanism between 

the carriage drive and the actuator 

body, which unusually for rodless 

actuators ensures virtually zero air 

leakage and facilitates the 

manufacture of extra long actuators 

for special applications. Festo has 

supplied DGC actuators with stroke 

lengths of up to 9m to special order. 

DGC series actuators offer a 

choice of three types of carriage 

guide, to best suit the application 

and the load. The basic guide 

features a plain polymer bearing 

suitable for light loads; the medium 

load guide also uses plain polymer 

bearings running on a guide rail 

compactly integrated as part of the 

actuator extrusion, and is factoryadjusted 

for optimum performance; 

and the high-performance guide uses 

stainless steel caged and sealed 

recirculating ball bearings. The latter 

can handle very smooth and high 

speed movements, has zero 

backlash, and is capable of 

accommodating loads that apply a 

high moment of torque to the 

carriage. 




info from Festo 

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63


New Products 

Dynamic signals in machine 

safety deliver cost savings 

Jokab Safety has taken a new approach to connecting multiple 

safety devices which it reckons will deliver significant cost 

savings for machine builders, and still meet safety requirements 

It has been common practice in the machine building 

industry to use a two-channel switching method in 

order to achieve a high safety level. This means that 

two different supply sources are generated from a 

control unit, such as a safety relay, and these sources are 

then connected to a field safety device and fed back to 

the control unit for monitoring. 

The control unit will monitor for symptoms such as a 

short circuit or if one supply source is removed (an open 

circuit), as well as the safety device itself. In order for the 

machine builder to maintain the highest safety level, 

each safety device must be connected to its own 

monitoring control unit. Therefore, if a machine has four 

emergency stop buttons and four safety switches fitted to 

the doors, the machine would need eight safety relays in 

order to meet the safety level of Category 4/SIL3. As a 

result, this is an expensive method, not just because of 

the number of safety devices being used, but also 

because of the wiring and installation time involved. 

Jokab Safety has developed a system which allows 

the machine builder to enjoy the benefit of seriesconnecting 

multiple safety devices, while at the same 

time still meeting the highest safety requirement. This 

safety system, called the Vital Solution, consists of a 

control unit – the Vital 1 – which is the same size as a 

standard safety relay. This control device has two 

functions. One is to provide two safety outputs in the 

form of two, twin channel, volt-free contacts to switch 

the main power circuit when a safety device in the field 

has been activated. The second is to produce 

a coded signal from a monitoring circuit. This 

coded signal is transmitted to the first field 

safety device. It is received and inverted using a 

tiny interface, before being sent on to the second field 

device. Again, the signal is inverted, back to the original 

form sent from the Vital 1, and sent on to the third 

device. This transmission and inversion of the signal 

continues until the last device in the circuit, whereby the 

signal is received back into the Vital 1. 

External interface options 

The interface which transmits and inverts the signal is 

incorporated into certain Jokab Safety devices, such as 

the Eden non-contact sensors, Spot safety light beams 

and Smile emergency stop buttons. However, in order to 

assist engineers when they need to include other 

manufacturers’ safety devices on to the system, there is 

a whole range of external interfaces available which are 

able to accommodate components such as mechanical 

switches, emergency stop units, safety mats, strips and 

bumpers, and light guards onto the Vital circuit. These 

interfaces are called Tina adapters and can be used in 

conjunction with safety devices which already exist on 

the machine, giving engineers the advantage of not 

having to change any existing safety devices. 

The Vital 1 can support up to 30 field devices 

connected in series within a 500m cable run. The Vital 

system means that manufacturers can enjoy a costreducing, 

functional safety system without compromise 

of to the safety level. At component level, machine 

manufacturers can enjoy a saving of up to 30%. The 

added benefit of an increase in productivity during 

installation means the cost savings can go even higher. 

Another feature is realised when compared to a single 

channel fault in a conventional system. Then, the normal 

action is to replace the safety relay or power it off and on 

again. However, the single channel fault is still there and 

appears again when the device in the circuit is activated. 

This is not possible with the Vital system because of the 

unique use of coded signal monitoring. There is no 

programming or addressing involved during installation 

and no PLC experience is necessary when designing a 

safety system. The only requirement is for a hard-wire 

short-circuit across two terminals on the Vital 1 to 

confirm an even number of safety devices are connected 

(left open for an odd number). The Vital 1 needs this so 

that it knows in what form to expect the received 

transmitted signal. 



www.industrialtechnology.co.uk for further details from Jokab Safety 

and more news on machinery safety 

Geared up for different accuracies 

Accuracy across different budgets is the focus of 

the new comprehensive gear range from 

Reliance Precision Mechatronics LLP. For a very 

economical balance of accuracy against cost, 

the brass spur gears in the range are designed for less 

demanding applications where accuracies up to ISO 

9/10 are required. 

Higher accuracy applications 

benefit from the 

choice of stainless 

steel and aluminium 

alloy precision cut gears or stainless steel fine 

pitch ground gears. The plain or anti-backlash precision 

cut gears are designed for long life and low torque 

transmission capabilities. The fine pitch ground gears go 

down to a 0.5 module and are accurate to ISO 5. These 

gears are easily tailored to suit interface requirements 

and offer higher torque transmission capabilities. 

For ultimate accuracies or 

application specific designs 

the bespoke gear design 

service 

uses Reliance’s exceptionally accurate and repeatable 

fine pitch gear manufacture and specialist knowledge 

and inspection facilities to produce gears in stainless 

steel, aluminium, brass and delrin with pitches between 

0.2 and 6 module. 

Past bespoke design applications that Reliance has 

been involved with have included accurate data 

transmission through to highly loaded fin and flap 

actuation components. 

This new extended range of quality gear products, 

combined with the company’s broad experience and 

extensive knowledge makes Reliance an ideal supplier 

for your precision gear requirements, whatever 

budget you might happen to be on. 



www.industrialtechnology.co.uk for further details from Reliance 

Precision Mechatronics and more news on gears 

64 



whatspringstomind? 

Stock springs? 

We’ve 15,500 different 

types and sizes of springs. 

New for 2008 

Constant force springs 

REDUX wave springs 

Millions in stock 

and custom options. 

Call us on 0118 978 1800 or visit www.leespring.co.uk 

Lee Spring Limited, Latimer Road, Wokingham, Berkshire, RG41 2WA 

Telephone: 0118 978 1800 Fax: 0118 977 4832 Email: info@leespring.co.uk 


66 


New Products MACHINE BUILDING & AUTOMATION 

Class 1 laser for 

distance sensor 

Analogue 

inputs for 

micro PLC 

IFM Electronic’s O1D laser 

distance sensor is now available 

with a safe Class 1 laser source. 

The O1D155 will measure up to 6m, 

with the features and performance of 

the established O1D versions. 

Beyond 6m the background is 

suppressed and in fact the 

background suppression extends to 

fully 100m. 

Under EN60825-1 a Class 1 

laser is deemed safe for the human 

eye under all operating conditions, 

making it increasingly popular for 

sensing applications. Like its 

predecessors the O1D155 offers 

the user two selectable 

switchpoints, or a single switched 

output combined with a scalable 

analogue signal. In a robust diecast 

housing only 42mm wide by 

45mm high and 52mm deep, the 

O1D has already proved a success 

in its first 10m range versions 

using Class 2 laser. 

The O1D155 utilises IFM 

Electronic’s award-winning pmd 

chip, an innovative method of 

calculating distance by time-offlight 

all on one chip. This keeps 

the dimensions of the sensor to a 

minimum and keeps the cost 

down, while still offering 

tremendous performance. 

Described by academics as “a 

genuine breakthrough innovation” 

at the Hannover Fair, all O1D 

versions are fitted with the 

standard M12 industrial connector, 

and feature a four-digit LED display 

panel on the top of the unit, next 

to the setting buttons. To help 

installation and alignment there is 

also a range of useful accessories, 

including lens covers. 




more info from IFM Electronic 

Continuing the development 

of the MicroSmart/Pentra 

PLC range, IDEC has 

introduced its latest analogue 

expansion module. This four 

channel input module completes 

the range of PLC analogue 

modules which provide inputs 

from two to eight according to the 

module type. In addition one or 

two channel output modules are 

also available. 

The FC4A-J4CN1 offers 16-bit 

resolution, option for either 

voltage or current input and also 

thermocouple and resistance 

thermometer capability. The 

configuration for the inputs are 

software selectable using the IDEC 

WindLDR programming software. 

Each channel can be set to either 

4-20mA, 0-10V, K, J and T 

thermocouples or Pt100/Nt100 

thermometers, independently of 

the other channels. 




more info from IDEC 

Multi-parameter controller for 

effective water treatment 

Burkert’s new mxControl 

multi-parameter controller 

automates the precise 

control of process variables within 

a water treatment system (boiler, 

cooling or reverse osmosis system), 

by integrating all the control, 

monitoring, display, and data and 

event logging functions into one 

compact, easy-to-configure 

controller. 

The mxControl accepts 

analogue inputs from flow, pH, 

temperature, level, analytical and 

conductivity sensors, and provides 

high level computations to 

optimise the water treatment 

process. In addition, the controller 

delivers savings on time, space 

and equipment costs, with one 

controller hardware specification 

providing dozens of configuration 

possibilities, all of which can be 

quickly downloaded via SD card 

(supplied) or via USB or optional 

Ethernet interface. 

The mxControl 8620 is the first 

modular control system designed 

for seamless integration into 

countless chemical or skid control 

applications. The controller meets 

the dynamic and exacting 

requirements of water treatment 

systems in all sectors of industry. 

Employing high-level software, the 

controller provides the continuous 

on-line monitoring and process 

control required to achieve higher 

degrees of precision and improved 

reliability and quality assurance in 

today’s demanding water treatment 

systems. 

The flexible control and easy 

adaptation to processes provided 

by the mxControl is the result of a 

high level software architecture. 

This enables all standard modules 

to be easily loaded by SD Card or 

USB. Alternatively, the optional 

Ethernet interface can be used to 

configure and to parameterise the 

controller, or an operator can 

simply set and display all 

important variables and 

parameters by five soft-touch keys. 

Once this is achieved, control 

algorithms ensure that optimum 

process control is maintained at all 

times. 




further details from Burkert 



67


Machinery Safety 

Watching the directives 

Time-tested fasteners are helping to deliver protective solutions 

for the new Machinery Directive, says John Snyder of Southco 

For machine builders worldwide, operator safety 

is of paramount concern. We’re all familiar with 

the need to design safeguards to protect 

equipment operators, while providing service 

access that minimises downtime. Within the European 

Union, the new Machinery Directive 2006/42/EC going 

into effect on December 29, 2009 is part of an approach 

to harmonise standards and establish the regulatory 

foundation for health and safety requirements of 

machinery throughout that market. This directive serves 

the dual function of promoting free movement of 

machinery for sale throughout the EU market while 

ensuring appropriate levels of protection for workers and 

citizens – including requirements for attaching protective 

devices such as fixed, adjustable, and movable guards 

for restricting access. 

Section 1.4.2.1 of the directive states that “fixed 

guards must be fixed by systems that can be opened or 

removed only with tools. Their fixing systems must 

remain attached to the guards or to the machinery when 

the guards are removed. Where possible, guards must be 

incapable of remaining in place without their fixings.” 

Engineered fixing systems using captive hardware 

minimise problems commonly experienced with loose 

screws, nuts, or bolts. For example, loose hardware 

dropped into equipment can damage mechanical 

components or short out electrical connections. Missing 

nuts or screws lost in the field can tempt workers to 

compromise the performance of important safety guards 

or can extend downtime while replacements are 

obtained. And from a productivity perspective – whether 

during initial production or repetitive maintenance – 

engineered fixing systems that utilise captive, selfaligning 

designs improve assembly speed and 

convenience. Within the requirements of the Directive, 

(Right) Colour-matched high-strength screws for use with hightorque 

drivers enable designers to designate access points by 

colour or to coordinate hardware colour with the equipment's 

industrial design. (Below) Clip-on receptacles for captive screws 

and quarter turn fasteners speed productivity and minimise total 

installed cost. 

equipment designers have leeway in the style, physical 

performance criteria, cost, and convenience of operation 

for fixing hardware they might select. Captive fixing 

systems – where both the fastener and its mating point 

(for example a receptacle, insert, or tapped hole) remain 

attached to their mounting points – come in a variety of 

physical designs, each tailored to a different aspect of 

performance. For example, in applications requiring very 

precise alignment or clearance, captive screws with 

conventional machine threads can provide secure 

mechanical attachment in the most compact space. 

Performance advantages 

Captive screws come in several styles, each with their 

own performance advantages. Standard machine-thread 

screws that provide precise, close-tolerance fit are 

available in multiple installation styles – including pressin, 

flare-in, snap-in, floating styles, and clip-on retainer 

rings – to satisfy specific material, mounting surface, and 

spacing requirements. Available designs include captive 

assemblies that fasten conveniently by hand but 

enhance safety by requiring a tool to release. Other 

designs can be recessed into the face of the protective 

guard to provide a virtually smooth surface on the 

exterior of the equipment. And to address the tool-only 

access requirements of the new directive, head styles 

can include Phillips, Torx, tamper-resistant, or industrystandard 

tool driver styles. 

One limitation of using captive screws is that ease-ofaccess 

can be variable – often determined by how tightly 

the user fastens the screw. In addition, when multiple 

fasteners are used or when the guard is accessed 

regularly, the time required to fasten conventional screws 

can become cumbersome. Where speed and ease-of-use 

are of higher priority, other designs offer increased 

convenience at lower installed cost. These include fastlead 

screws and quick-access quarter-turn fixing 

systems. 

Fast-lead screws offer additional productivity 

advantages. This type of fixing system is designed to 

fasten and unfasten with just a few turns. Its coarse 

thread design and floating assemblies resist cross 

threading and tolerate initial misalignment, while 

providing exceptional vibration resistance. One fast-lead 

screw assembly can accommodate a range of material 

thicknesses. And the variety of available captive 

receptacle designs makes it easier to accommodate a 

wide range of mounting configuration requirements. 

Quick-access, quarter-turn fasteners provide quick 

and easy access that is particularly advantageous for 

repeat-access applications. Various designs available in 

metal and plastic constructions satisfy specific physical 

application requirements – maximum working load, 

dimensional tolerance, or vibration resistance. The 

systems are designed to provide a fixed fastening force 

that allows the designer to control not only access, but 

also the feel that the end user will experience. Each 

quarter-turn system includes a final detent feature 

designed into the fastening systems as a means of 

assuring the user that the fixing system is locked and the 

guard is secure. 

And as with captive screws, numerous quick-access 

fastener head styles provide different options for toolrestricted 

access, and flush or low-profile installation. 

Self-ejecting options also provide a visual indicator for 

unfastened guards, while the spring-ejection feature 

helps clear fasteners out of the way in multiple fastener 

applications. 

As opposed to fixed guards which must be removable 

only with the use of tools, the new Directive specifies 

that “adjustable guards restricting access to those areas 

of the moving parts strictly necessary for the work must 

be readily adjustable without the use of tools.” For these 

applications, controlled-torque positioning devices 

provide the ability to raise, lower, tilt, swivel, and 

position those guards for better safety protection during 

equipment operation and for easy access when 

necessary. These devices can also hold guards in a 

partially or fully open position without secondary 

hardware, to provide unrestricted maintenance access. 

According to the Directive, interlocking movable 

guards must, as far as possible, remain attached to the 

machinery when open, be designed and constructed in 

such a way that they can be adjusted only by means of 

an intentional action, and be designed in such a way that 

the absence or failure of one of their components 

prevents starting, or stops the hazardous machinery 

functions. Tethered quick-access pins with simple pushbutton 

actuation are useful for locking movable safety 

guards into place, as well as for activating electronic 

lockout sensors on movable guards. Additional devices 

such as captive spring-loaded plungers also allow for 

quick positioning and fixing of sliding guards. 



www.industrialtechnology.co.uk for further details from Southco and 

more news on captive fasteners 

68 




Machinery Safety 

New safety light curtain provides 

flexible safety options 

Turck Banner says its latest safety light curtain system delivers 

unprecedented ease of use and safeguarding flexibility 

The new features for the EZ-SCREEN noncontact, 

point-of-operation machine guarding 

safety light screen system make it one of the 

most feature-rich and flexible systems 

available on the market. Key additions include fixed 

blanking to accommodate materials and tooling inflow 

with no reduction of operator safety, a cascading option 

for connection up to four EZ-SCREEN pairs and 

multiple AC interfaces. 

Fixed blanking allows for stationary objects such as 

tooling or materials inflow to be ignored when 

positioned in a defined set of beams. If the objects are 

removed, the system goes into a lockout mode to 

ensure an unsafe gap in the sensing field is not 

created. The cascading option allows up to four 

systems of varying sizes, lengths and resolutions to be 

wired together to form a unified control stop element 

with a single cable interface. 

The Banner EZ-SCREEN system family is intended 

for point-of-operation machine guarding applications 

and other safeguarding applications, including area 

guarding when mounted horizontally and long-range 

perimeter guarding utilising corner mirrors. EZ-SCREEN 

pairs are available in 14mm and 30mm resolution and 

twelve lengths from 150mm to 1800mm. EZ-SCREEN 

Grid and Point systems are also available offering 

single beam point, 2-, 3- or 4-beam grid protection. 

The EZ-SCREEN safety light screen system is a 

redundant microprocessor-controlled, self-checking 

design of Type 4 which exceeds control reliability 

requirements and is certified per CE (Category 4). 

Typical applications include small assembly 

equipment, pick-and-place machines, moulding 

presses, packaging machinery, palletisers, roll formers, 

automated production equipment, robotic work cells, 

and power press applications. 




more stories from Turck Banner and more news light curtains 

Can you be sure your 

machine has stopped? 

Dold has launched a new safety standstill back EMF 

monitor, the Safemaster LH5946. The unit is designed 

to directly monitor three phase, single phase and 

inverter driven motors without the need for external transuding 

elements, by directly looking at the back EMF created by a 

rotating motor. The unit is simply connected to the output 

connections of the motor contactor and, via an adjustable 

voltage setting up to 400mV and an internal adjustable safety 

timer up to 6sec, gives a safe indication of 

standstill, thereby allowing 

electromechanical guard interlocks to 

be released and operator access to 

dangerous machinery allowed. 

The LH5946 has three NO 

outputs and one NC output. 

These are conventional 

redundant safety contact 

outputs with LED indication of 

broken wire detection and 

motor standstill. There is also 

one CO contact and two 

semiconductor outputs for 

status indication. The unit is 

TUV approved for safety applications 

to BS-EN 954-1 Cat 4 and EN 13849-1 to PL e 

and can be fully integrated with Dold solenoid locking devices 

and conventional or programmable safety relays. 



www.industrialtechnology.co.uk for further details. You can also find more 

stories from Dold and more news on safety relays 

Saving you time and money 

Siemens has extended its flexible safety solution portfolio 

Siemens Automation & Drives has 

enhanced its existing portfolio of safety 

integrated solutions with the launch of 

the Sirius 3RK3 modular safety 

system. Developed to sit alongside existing 

Siemens safety integrated solutions, ASi Safe or 

ProfiSafe, the Sirius 3RK3 system offers 

increased choice for what can be complex safety 

application decisions. 

Sitting between a simple safety relay and a 

fail-safe controller, Sirius 3RK3 is suitable for 

use across all sectors and applications. It is ideal 

for circumstances where several safety functions 

have to be evaluated, but expensive connection 

of several switching devices could prove cost 

prohibitive and time consuming. The Sirius 

modular design offers application flexibility as 

users only have to replace the devices applicable 

to that application. However, if the application 

does change over time, more functions can be 

added to the modular unit. 

The system is based on a central unit with 

eight safety-related inputs, one safety-related 

relay output and one safety-related 

solid-state output. Users can 

connect to seven expansion modules 

that can deal with further safety 

functions and an interface module 

enables communication to additional 

higher-level controllers via Siemens 

Profibus. 

Paul Hingley for Siemens 

comments: “Looking at enhancing 

or simply linking numerous safety 

applications can have significant 

impacts both in time through 

undertaking additional wiring, as 

well as the inevitable increased 

costs. The Sirius 3RK3 modular system is a 

valuable addition to the existing suite of safety 

integrated solutions developed by Siemens which 

offers users the flexibility in terms of selecting 

suitable solutions, as well as the ability to save 

time and money.” 



www.industrialtechnology.co.uk for further details. You can 

also find more stories from Siemens Automation & Drives 

70 


Safely reduce cabling 

and reduce costs 

Schneider Electric has 

introduced its new Preventa 

XCSDM3 and XCSDM4 Halleffect 

non-contact safety switches, 

from Telemecanique, a brand of 

Schneider Electric, which have been 

designed to eliminate the need for an 

external safety relay to monitor safety 

circuit input and output integrity. 

Compact, easy to install and 

highly tolerant to misalignment, 

magnetic safety switches are used as 

safety interlocks on movable machine 

guards and/or where frequent wash 

down takes place. Standard safety 

switches are wired back to a panel 

with a safety relay for failsafe 

operation. 

The new XCSDM3 and 4 models 

incorporate a safety relay enabling 

the devices to self-check and detect 

their own failure without the use of 

an additional external safety relays. 

They can directly drive two external 

24V DC contactor coils (via two 

internally OSSD safety PNP outputs) 

and, in the case of the XCSDM4, 

monitor those external contactors’ 

normally closed auxiliaries (known as 

EDM) to directly and safely control 

electric motor driven loads. 



www.industrialtechnology.co.uk for further 

details from Schneider Electric 


EURO-BEARINGS LTD 

stock a whole range of 

Anti-Vibration Mounts including 

bushes, machine mounts, bumpers 

and more... 

For your convenience you can buy 

online at our dedicated website: 

www.novibration.co.uk 

Full supporting technical data (including downloadable 

catalogues) on all of our products can be found at: 

www.euro-bearings.com 

EURO-BEARINGS LTD now have an online shop for 

Linear Motion Products - www.linearonline.co.uk 

Should you need guidance with selection, our technical sales 

team will help. From ball bushings and complete guidance 

systems to heavy duty combined roller bearings, our products 

can be used to solve a whole range of linear motion problems. 

EURO-BEARINGS LTD 

Tel: 01908 511733 Fax: 01908 511713 

www.euro-bearings.com 


71

product and service factfinders 

AIR CONTROL INDUSTRIES Ltd 

Silver Street, Chard, Somerset TA20 2AE 

e-mail: sales@aircontrolindustries.com www.aircontrolindustries.com 

Free Airknife Demos 

ACI Ltd is currently offering customer-on-site Free Demos of their Airknife Drying Systems. 

For any process requiring the removal of surface 

moisture, coatings, dust or contamination from a 

wide range of materials and shapes, ACI Airknife 

systems provide clear performance and efficiency 

advantages over other methods. 

Email sales@aircontrolindustries.com to arrange 

your visit. 

HUBA CONTROL AG 

Branch Office UK: Unit 3, Network Point, Range Road, Witney, Oxfordshire OX29 0YD 

e-mail: info.uk@hubacontrol.com www.hubacontrol.com 

Pressure and Flow 

Measurement 

Huba Control develops, manufactures and markets components 

designed exclusively for the measurement of pressure and flow. 

The extensive ranges of pressure switches, pressure 

transmitters, measuring cells and flow sensors incorporate our 

own range of thick film ceramic cells, special ceramic levers 

and polymer diaphragms all designed and manufactured 

in-house at our Swiss head office. 



ASTROSYN INTERNATIONAL 

TECHNOLOGY Ltd 

The Old Courthouse, New Road Avenue, Chatham, Kent ME4 6BE 

e-mail: astrosyn@btinternet.com www.astrosyn.com 

Hybrid Stepper Motors – 

The Affordable Range 

• Unbeatable price/performance ratio 

• Frame sizes from NEMA 11 to 34 

• Best torque performance at desired speed 

• Smooth, low noise operation with high precision 

• Choice of windings to match custom applications 

• Full range of shaft and connection options 

igus 

51 Caswell Road, Brackmills Industrial Estate, Northampton NN4 7PW 

e-mail: sales_uk@igus.co.uk www.igus.co.uk 

New Cable Catalogue 

The 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 bending 

radii in moving applications and have been tested over 

millions of cycles. They include control cables, robot cables, 

motor cables, data cables and servo cables. 

Request yours today. 



COTEL MOULDINGS 

JG Coates (Burnley) Ltd, Trafalgar Street, Burnley, Lancashire BB11 1TH 

e-mail: sales@cotel.co.uk www.cotelmouldings.com 

New Cotel Mouldings Industrial 

Components Catalogue 

The new Cotel Mouldings Catalogue is the definitive buyer’s 

guide for industrial components and includes: 

• 100s of new products 

• Extended ranges 

• Colour photos, technical drawings and material information 

For our extensive range of stock components including Knobs, Handles and Handwheels, 

Adjustable Feet, Tube End Fittings, Hinges, Plungers, Plastic and Metal Fittings, Fixings and 

Fasteners, Cable Management Products and much more please request your free 100 page 

catalogue today. 


INTERPOWER COMPONENTS Ltd 

10 Kelvin Drive, Knowlhill, Milton Keynes, Buckinghamshire MK5 8NH, UK 

www.interpower.com 

Power Systems Components 

Interpower Components manufacture an extensive range of 

power components such as cords, cable, plugs and sockets. 

The products comply with a host of international standards, 

and carry the relevant approvals. 

To help manufacturers specify the correct power systems, 

particularly on products designed for export, Interpower 

Components have produced this Export Designer’s Reference 

& Catalogue, providing all the required information on the 

international standards and which products comply. 


ETA ENCLOSURES (UK) Ltd 

Unit 2 Ignite, Magna Way, Rotherham, South Yorkshire S60 1FD 

e-mail: info@eta-enclosures.co.uk www.eta-enclosures.co.uk 

The Difference is On-Line 

ETA is a leading manufacturer of industrial and electronic 

enclosure systems offering a broad range of standard and 

modified solutions. 

Offering the very best in style and protection, ETA can deliver to 

your exact requirements on time and within your budget. From 

small terminal boxes to large modular cabinet assemblies your choice is not limited and with 

next day delivery on most items, you can be assured your enclosure needs are in capable 

hands. Visit our website to gain an insight into our products and services or call direct. 

We have moved to new premises – see our new address above! 


SCHAEFFLER (UK) Ltd 

Forge Lane, Minworth, Sutton Coldfield, West Midlands B76 1AP 

e-mail: info.uk@schaeffler.com www.schaeffler.co.uk 

INA Driven Linear Units – 

Publication ALE 

Rapid progress in the automation of production and 

assembly processes has pushed forward the development 

of complete, driven assemblies. These comprise a high 

precision guidance system, a rigid support rail, a wear-free 

servomotor drive and a user-friendly control system. 

INA linear actuators are integrated modular systems containing all the components required 

for operation. A range of INA linear tables is also available which is used to move larger 

masses in one or more axes. 


72 


John Richardson’s ENGINEERING DIARY 

Apioneering new qualification aimed at 

encouraging youngsters to pursue a career in 

manufacturing will be offered to school-children 

in every area of England following its launch in 

September 2009. Twenty-seven consortia – groups of schools, 

colleges and employers – have been given the go-ahead to be 

the first to deliver the new Diploma in Manufacturing and 

Product Design, with at least one successful consortium in each 

English region. In total, almost 2,000 places will be available 

for young people to study the diploma in its first year. 

The Diploma in Manufacturing and Product Design is one of 

17 new diplomas for 14-19-year-olds which will be available to 

all pupils in England by 2013. It is intended to give pupils a 

solid understanding of how the manufacturing sector works and 

equip them with the skills they will need to pursue a career in 

the industry. Now, manufacturing companies are being urged to 

join forces with their local consortia in order to ensure the 

diploma’s success. Derek Jones, head of the project team 

charged with developing the manufacturing diploma, said: “This 

is a once-in-lifetime opportunity for companies to get young 

people excited about the manufacturing industry, to pass on the 

key skills they need in the work place, and to directly inspire 

them in their future career choices. 

“The input of local businesses, especially SMEs, will be 

absolutely vital in bringing the diploma to life. There are plenty 

of different ways to engage with the diploma, from offering work 

placements, to devising projects and giving talks to pupils. 

Employers are also needed to work with teachers and lecturers, 

and help to keep them up-to-date with industry practices.” 

Popular choice for students 

Mr Jones continued: “We believe the manufacturing diploma will 

have a lot of appeal for teachers and pupils, and will become a 

popular choice amongst students. There is room to specialise in 

creative areas such as marketing and design, and it will help 

bring science and maths to life in the classroom. Instead of just 

learning theory from a textbook, pupils will be able to study 

how, for example, oil gets used to make plastics and other 

materials, how medicines and pharmaceuticals are made, what 

goes into our food and how it impacts on health, and how to 

programme a computer to control engineering processes.” 

As part of the diploma, pupils will be taught core topics of 

business and enterprise, product design, materials science and 

process technologies, alongside courses in maths, English and 

ICT. An extensive range of optional modules in specialised 

subjects will also be available to provide a deeper knowledge of 

the different manufacturing sub-sectors. Pupils taking the 

diploma will spend the majority of their time in school but will 

take some classes at college for more specialist areas of study. 

The diploma is available at three levels – foundation, which is 

equivalent to five GCSEs; higher, equivalent to seven GCSEs; 

and advanced, equivalent to three-and-a-half A-Levels. From 

2011, there will be the option to undertake an extended 

diploma at each level, which will offer additional academic 

modules. 

The Diploma in Manufacturing and Product Design is being 

rolled out as part of the second tranche of diplomas, following 

the first five which are due to be introduced in September this 

year, which includes the Diploma in Engineering. We would 

hope that the new diploma would be an outstanding success, 

but what does the take-up of the first five diplomas tell us? Well, 

for starters, take-up of those diploma places has been much 

lower than hoped. No official target figures were ever discussed, 

but unofficially Jon Coles, the director of the 14-19 reform 

group at the Department for Children, School and Families told 

MPs that if all the consortia that had expressed an interest in 

offering diplomas were successful, then the figure could be in 

the region of 160,000. If that sounds unrealistically high, 

consider that the ballpark figure Schools Minister Jim Knight 

gave to the Commons education select committee for the takeup 

by teenagers in the first phase was 50,000. In private, I 

gather those at the sharp end were expecting around 40,000. 

In the event, it appears as if only 20,000 places have been 

taken up, of which the Diploma in Engineering accounts for just 

4232 teenagers. Certainly 4000-odd entering the diploma is 

better than none, but I’m not sure that fits the definition of an 

outstanding success. 

What might have gone wrong? On the face of it, there’s 

nothing wrong with the Diploma in Engineering at all. It was 

developed with the aid of successful engineering firms, so 

should provide an excellent grounding. In 2006, Ian Young, 

executive director of MKW Engineering in Newcastle, said: “The 

engineering diploma will bring a completely fresh approach to 

the delivery of specialist engineering applied learning for 14 to 

19-year-olds. It will focus on inspiring innovation, providing solid 

foundations in cutting edge skills, technology and the application 

of engineering practices, and fostering the business acumen of 

our future engineers.” That sounds ideal to me. 

So what’s holding young people back? Could it be that 

they’re looking at the diplomas and writing them off as being too 

difficult? Or are sectors such as engineering and manufacturing 

simply still not glamorous enough to attract new talent? 

feedback@itmagazine.uk.com 


73

EAR TO THE GROUND • Becky Silverton 

becky@itmagazine.uk.com 

Etiquette and the art of 

innovative manufacturing... 

Lucky girl that I am, I found myself recently 

at an awards dinner at a very fashionable 

restaurant in London, chatting with some of 

the captains of industry over fine wines and 

gourmet food. It’s funny how, at the least likely 

moments, the strangest things can occur to you. 

And so it was that, as everyone was ripping open 

their bread rolls with their bare 

hands, showering crumbs over 

the table, I wondered why it is 

that etiquette dismisses use of a 

knife as thoroughly bad form. 

Staying with strange food 

etiquette, why is it so wrong to 

cut your spaghetti when you’re 

having a bolognese? Wrapping it 

around your fork never really 

works because there’s always that 

trailing length you have to suck in, with the 

inevitable splattering of sauce down your front. 

Here’s a good one: why is the standard rail 

gauge around most of the world 4 foot, 8.5 inches? 

It’s such an odd number. Turns out it dates back to 

the Romans, whose chariots formed initial ruts, 

which everyone else had to then match. And the 

Roman chariots were built just wide enough to 

accommodate the back ends of two war horses. You 

would think that somewhere down the line, 

someone would have revisited the issue. 

Back at the gala dinner, looking around the table 

I noticed that all those wearing waistcoats had left 

the bottom button undone. I wondered if it was true 

that the inability of a portly Edward VII to remain 

holstered within the confines of his garments really 

did dictate that doing up one’s lower button would 

be a tragic fashion faux pas. And if so, why has the 

fashion stuck with us after all these years, when 

doing up all the buttons looks so much smarter? 

Many of the rules that we live by are strange 

and outdated. But we carry on doing these things 

for no better reason than that’s the way we’ve 

always done them. What would happen if we took 

this same attitude into our working lives. Where 

would that leave our industrial design or our 

manufacturing operations, if we could never look 

past doing things the way they’d always been done? 

I brought this up with the various members of 

the party on my table, and unanimously we agreed 

that the need to innovate, to think a little differently, 

to dare to take an approach that hadn’t been tried 

before if the rewards should merit it, were all 

essential to the success of British industry. But you 

know what, boys? Not one of them would agree to 

do up the bottom button on his waistcoat. 

National Electronics Week 

June 17-19, 2008 

Earls Court, London 

www.nationalelectronicsweek.co.uk 

New Events Ltd (01483 420229) 

EtherNet/IP Seminar 

June 24, 2008 

Amsterdam, Netherlands 

www.odva.org 

ODVA (+1 734 975 8840) 

Wireless Technologies 

September 27-29, 2008 

Bochum, Germany 

www.mesago.de 

Mesago Messe Frankfurt 

(+49 711 61946-0) 

Northern Manufacturing 

October 1-2, 2008 

Hallam Arena, Sheffield 

www.industry.co.uk 

Etes (01784 880890) 

Sealing, Adhesive, Elastomer 

October 21-23, 2008 

Nuremberg, Germany 

www.mesago.de 

Mesago Messe Frankfurt 

(+49 711 61946-0) 

SPS/IPC/Drives 

November 25-27, 2008 

Nuremberg, Germany 

www.mesago.de 

Mesago Messemanagement 

(+49 711 61946-0) 

Index to Advertisers June 2008 

ABB ..................................................... 63 

Aerotech .............................................. 59 

Air Control Industries ........................ 48-49 

Air Control Industries ............................. 72 

Alliance Plastic Parts Centre .................. IBC 

Alpha Gearheads ................................... 25 

Andantex .............................................. 22 

Applied Automation ............................... 67 

Arnold Umformtechnik ........................... 23 

Asco Numatics ...................................... 19 

Astrosyn International ............................ 72 

Bailey & Mackey ................................... 71 

Baker & Finnemore ................................ 16 

Baldor .................................................. 66 

Bonfiglioli ............................................. 27 

Bosch Rexroth ...................................... 11 

Centa Transmissions .............................. 29 

JG Coates ............................................. 72 

Davall .................................................. 24 

DirectIndustry ....................................... 10 

Dold .................................................... 71 

E2S ..................................................... 69 

Elesa ................................................... 14 

EMS .................................................... 35 

ETA Enclosures ..................................... 72 

Euro Bearings ....................................... 71 

Expert Tooling & Automation .................. 55 

Francis & Francis .................................. 27 

Heidenhain ........................................... 36 

HepcoMotion ........................................ 35 

Huba ................................................... 72 

Huco Dynatork ...................................... 27 

Idec ....................................................... 3 

IEC ...................................................... 65 

Igus ..................................................... 31 

Igus ..................................................... 72 

Industrial Vision Systems ..................... OBC 

Interpower Components ........................... 5 

Interpower Components ........................... 7 

Interpower Components ......................... 72 

Interroll ................................................ 53 

Albert Jagger ........................................ 21 

JBJ Techniques ..................................... 51 

Klüber Lubrication ................................. 32 

LAC Conveyor Systems .......................... 61 

Lafert Electric Motors .............................. 6 

Lee Products ......................................... 47 

Lee Spring ............................................ 65 

Lenze ................................................... 12 

Machine Building Systems ..................... 57 

Man & Machine .................................... 19 

Master Bond ......................................... 21 

Maxon Motor ........................................ 17 

Mclennan Servo Supplies ....................... 53 

Micro-Epsilon ....................................... 20 

MiniTec ................................................ 61 

Mitsubishi ........................................... IFC 

MK Profile Systems ............................... 61 

Nitto Kohki ........................................... 47 

NKE Austria .......................................... 13 

NSK Europe .......................................... 33 

Oriental Motor ...................................... 55 

mbo Osswald ........................................ 45 

Parker Filtration ...................................... 9 

Pepperl & Fuchs .................................... 45 

Protex Fasteners .................................... 23 

Reliance Precision Mechatronics LLP ....... 28 

Rino Industries ...................................... 31 

RK Rose & Krieger ................................ 59 

RA Rodriguez ........................................ 29 

Rotalink ............................................... 53 

Samson Controls ................................... 47 

Schaeffler ........................................ 38-39 

Schaeffler ............................................. 72 

Sensopart ........................................ 40-43 

Sferax .................................................. 31 

Spirol Industries .................................... 62 

Springmasters ....................................... 29 

Tappex Threaded Inserts ........................ 21 

Tox Pressotechnik .................................. 21 

Yuasa Battery ....................................... 15 

74 



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machine building & automation - Industrial Technology Magazine

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