IT Jan 2008 - Industrial Technology Magazine

www.industrialtechnology.co.uk 

Industrial 

Technology 

January 2008 

THE ESSENTIAL MAGAZINE FOR PRODUCT DESIGN ENGINEERS AND MACHINE BUILDERS 

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Bearings & lubricants 

Brakes, clutches & couplings 

p12 

p16 

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Motion control 

Fasteners & adhesives 

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p32 

p36 

Machine building & automation 

Hydraulics & pneumatics 

Machinery safety 

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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 

Tonbridge TN10 4WD 

mark.simms@itmagazine.uk.com 

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Sale, Cheshire M33 7XY 

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BUSINESS PRESS 

Cost of raw materials set to be the biggest cost 

constraint on UK manufacturing: The global 

competition for raw materials is predicted to have 

the greatest impact on UK manufacturers in the 

coming year, according to research released in the 

annual Grant Thornton International Business Report 

on Manufacturing. Of the 200 UK manufacturing 

business owners and senior managers surveyed as 

part of a wider global report, more than a third 

(38%) cite the cost of raw materials as having the 

number one impact on their business. 

Surveying 2,700 manufacturers in 32 countries 

globally, the research found raw materials were also 

predicted to have the biggest impact next year by an 

There’s a ‘hole’ lot of 

inefficiency out there… 

The discovery of a gas leak outside my home a couple of weeks ago was something 

of a concern, but I’m relieved to report that the relevant body responded very 

quickly. A chap arrived within the hour armed with a sniffer, and confirmed that 

there was a leak somewhere along the pipe leading into my house. He made a call, 

and around 35 minutes later a full team of workers arrived to fix the problem. A key part of 

the job was the digging of a very big hole across my driveway – about four feet deep and 

about the same it width – which made access something of a 

hazard, but I really didn’t feel it was appropriate to complain. 

The alternative was certainly a lot worse. 

The hole took a good few hours to dig, and watching one 

of the chaps go down into the hole in full breathing gear 

was a bit like watching John Hurt going down into the belly 

of the alien ship in the Ridley Scott epic. Fortunately he 

emerged unscathed shortly afterwards, and with the feeding 

of a new yellow plastic pipe through the innards of the old 

corroded pipe, I was once more leak-free. 

What surprised me a little, though, was to discover that 

the hole was still there after the gas team had gone, 

surrounded by swathes of cones and red and white boarding. Apparently, although it was 

their job to dig the hole, it was the job of another team entirely to fill it in. Four days later, 

a second team duly arrived to fill in the hole – but not to tarmac over the top and make 

good on the work. That was left to a third team who arrived another two days on. 

Still, though, that was not the end of the job. The hole then had to be inspected, by a 

lone worker who wandered around filling in forms, taking photographs of the area and 

making a number of phone calls. Inevitably, there was a problem – not with my hole, but 

with a slight indentation in the pavement very close to my hole which looked as though it 

had not been filled in properly. The gas team was summoned back to the scene to confirm 

that this second hole had nothing to do with them. But they did put a cone on it just to 

make sure no one could trip and find cause to sue. 

So, nine days, four teams, one hole. What, I wonder must it have cost the tax payer to 

dig my hole and then fill it back in again? Could there ever be a clearer illustration of the 

inefficiencies that accrue when different departments in an organisation fail to 

communicate and decline to cooperate? The whole job, I’m sure, could have been done in 

a single day by a single team were there to be a bit less bureaucracy and bit more trust. 

But I’ll tell you what: the whole episode has made me take a much closer look at 

some of my own work practices and processes. When you realise how ridiculous some 

inefficiencies can look to the outside world, it really does give you the impetus to 

streamline. And I’m happy to report that I’m already working more efficiently as a result. 

Mark Simms 

Editor 

even greater proportion of manufacturing 

respondents worldwide (47%). Bob Hale, head of 

manufacturing at Grant Thornton, said that despite 

positive sentiment within the sector overall, the cost 

of raw materials continued to be a major concern, in 

large part due to the ever-increasing demand for 

resources including base metals and agricultural 

products from fast-developing economic giants China 

and India. “Supply chain management is now top of 

the agenda, with UK manufacturers exploring far 

more options to secure a cost-effective and reliable 

flow of raw materials for their operations.” 

Hale said that the reported concern around 

energy was almost completely down to oil price. 

“With the price of a barrel skirting the US$100 

mark and a seemingly insatiable appetite from 

developed and developing economies alike, oil 

efficient manufacturing should now be a key part of 

every manufacturing business’s strategy.” 

However, despite worldwide competition for 

resources, globalisation was still being welcomed by 

UK manufacturers, with 77% either positive or 

neutral about the effects of a more globalised 

business environment, while just 22% saw 

globalisation as a threat. On a general positivity 

scale, UK manufacturers continue to defy the doom 

merchants, with more than half (58%) positive 

about their prospects. 

mark.simms@itmagazine.uk.com 

January 2008 • INDUSTRIAL TECHNOLOGY 

3

10 

38 

Contents 

This month in history: (1860) Etienne Lenoir 

patents the first successful internal combustion 

engine; (1950) President Truman announces the 

development of the H-bomb; (1886) Space shuttle 

Challenger explodes 73 seconds after lift off 

34 

6 INDUSTRY NEWS 

6 Manufacturers resilient in tougher climate 

8 UK to become a beacon for innovation 

10 Linear motion hits the right note 

12 Machine Building, MTEC and IPOT preview 

16 MECHANICAL COMPONENTS Bearings, Slides and Lubricants 

16 Protective materials and coatings for harsh environments 

18 POWER TRANSMISSION Brakes, Clutches and Couplings 

18 Brake motor helps bottle crusher break into new markets 

22 DRIVES & CONTROL SYSTEMS Motion Control 

22 The case for soft starters in high inertia applications 

24 Motion Control: new products 

32 MECHANICAL JOINING Fasteners and Adhesives 

32 Adhesive alternative to solvent bonding 

ON THE COVER 

New drives are optimised 

for servo tasks requiring 

high peak torque, 

dynamic response and 

ease of use. See centre 

spread for details 

THE BIG QUESTION 

We look for answers to 

the key industry questions p14 

ENGINEERING LITERATURE 

Essential reading for 

design engineers p20 

34 Fasteners & Adhesives: new products 

36 SENSORS & SYSTEMS 

IN THEIR VIEW 

Three industry leaders 

air their views 

p26 

36 Industrial Ethernet delivers the universal networking solution 

40 Harmonics: pay attention or pay the price 

42 Sensors & Systems: new products 

46 MACHINE BUILDING & AUTOMATION 

46 Industrial Computers: the choice of PC for machine control 

48 Hydraulics & Pneumatics: a new paradigm for pneumatic control 

50 Machinery Safety: changes to the guard interlocking standard 

52 Machinery Safety: new products 

ENGINEERING DIARY 

John Richardson’s month 

in view 

p31 

EAR TO THE GROUND 

Becky Silverton on the issues 

affecting manufacturing p54 

ALSO IN THIS ISSUE: 

Factfinders 

Events calendar 

Index to Advertisers 

p53 

p54 

p54 

Next month in Industrial Technology: Electric motors • Laser sensors • Bearings, slides and lubricants • Enclosures, 

cabinets and fans • Drives and control products • Springs, gas springs and dampers • Welding and riveting • Machinery safety 

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INDUSTRY NEWS 


Manufacturers resilient despite 

the tougher climate, says EEF 

Output and order balances remain 

firm, with export orders picking up 

despite the weak dollar. Confidence 

remains strong, although optimism is 

down on the previous quarter 

Manufacturers continue to record healthy growth and 

remain upbeat about the future despite tougher trading 

conditions, according to a leading barometer of the 

sector published by EEF, the manufacturers’ 

organisation and Grant Thornton. Furthermore, EEF also released 

figures showing that the recent credit crunch has had a relatively 

limited impact so far on manufacturers, with only a small percentage 

of companies seeing a significant increase in the cost of finance. 

Commenting, EEF chief economist Steve Radley said: “Despite 

rising oil prices, a falling dollar and a more uncertain economic 

outlook, manufacturers recorded another quarter of healthy growth 

and are looking to the future with a degree of confidence. Investment 

intentions also remain strong, reflecting their continuing commitment 

to drive up productivity. Though the economic outlook remains 

unclear, manufacturers’ greater resilience should mean that growth 

continues into 2008.” 

Order and output balances were both in positive territory for the 

ninth consecutive quarter. In contrast to the last quarter, export 

orders to both EU and non EU countries picked up whilst domestic 

orders edged down slightly. However, the balance of firms reporting 

falling margins on export sales indicate the weaker dollar is beginning 

to take its toll. The decline was most marked in those sectors that 

are particularly exposed to movements in the dollar such as 

electronics and aerospace. All sectors reported positive output 

balances over the past three months with motor vehicles and 

electrical equipment reporting the strongest balances for the second 

quarter running. With the exception of basic metals, balances on 

order volumes were a touch weaker, although for most sectors they 

remained in double digits. Once again all regions reported positive 

balances on output. 

Though weaker than the unusually high figure recorded in the 

previous quarter, investment intentions remained firm and above their 

long-term average. The continued commitment to raising investment 

reflects improved company balance sheets, confidence about future 

prospects and the need to keep raising productivity if manufacturing 

is to remain competitive. Separately, the survey also asked about the 

impact of the current turbulence in financial markets on company 

finance, only 2.4% of the 577 companies who responded to this 

particular issue said that they had seen a significant increase in the 

cost of finance from Banks or other financial providers. Almost 

40% of companies said there had been no change. 

Cleaning revealed as main cause of 

production downtime across industry 

Time taken to clean machinery has been revealed as the main 

cause of downtime within UK production, with over half 

(52%) of companies polled citing this as their main 

frustration, according to a poll by peristaltic pump 

manufacturer, Watson-Marlow Bredel. With machinery downtime 

representing one of the greatest losses in production and revenue, it’s 

important for manufacturers to be able to look for ways to minimise 

the time that equipment is out of use. 

Along with cleaning, 24% of companies cited faulty machinery as 

a main cause of production downtime and 13% claimed human error. 

Encouragingly, only 7% claimed to have issues with contamination 

and 4% with labour shortages. Watson-Marlow Bredel’s Ashley 

Shepherd said: “Minimising downtime is massively important to 

production companies, because ultimately it results in lost revenue. 

While cleaning equipment appears to be a major frustration in 

reducing downtime, there are solutions available to help minimise the 

need to shut down production in order to clean some equipment. 

“For example, using a peristaltic pump for fluid transfer or 

dosing means that product is contained within a tube and never 

comes into contact with the pump. Neither do the pumps require 

additional seals and check valves for their operation. At the end of 

a shift or when a different duty fluid 

is used, the tube can be removed 

and replaced within minutes – a 

new tube creates a new pump. 

Some pumps are CIP/SIP capable, 

further reducing the need for 

downtime.” 

UK cannot afford 

to be average on 

skills, says CBI 

Finland once again took the 

number one spot in OECD’s 

three-yearly PISA test of the 

abilities of a sample of 15- 

year old secondary-school 

students, followed by Hong 

Kong (China) and Canada in 

second and third place. 

The PISA survey, based 

on tests carried out in 2006 

in 57 countries that together 

account for nearly 90% of 

world GDP, is the most 

comprehensive and rigorous 

international yardstick of 

secondary-school students’ 

attainments. PISA 2006 

tested students on how much 

they knew about science and 

their ability to use scientific 

knowledge and understanding 

to identify and address 

questions and resolve 

problems in daily life. 

The UK was ranked a 

lowly 14th, only slightly 

above the OECD average. 

Commenting on the 

OECD’s international 

comparison of educational 

performance Richard 

Lambert, the CBI’s Director- 

General said: “The OECD 

figures make for disturbing 

reading. At a time of 

increasing global 

competition, the UK cannot 

afford to be ‘average’. We 

must help our young people 

to attain the world class 

performance they are 

capable of. We need a 

renewed sense of urgency in 

tackling the UK’s 

underperformance in literacy 

and numeracy.” 

Perhaps most worryingly, 

across the across the OECD 

area as a whole learning 

outcomes have generally 

remained flat, while 

expenditure on education in 

OECD countries rose by an 

average of 39% between 

1995 and 2004. 

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Technology online at 

industrialtechnology.co.uk 

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INDUSTRY NEWS 


UK set to become a beacon 

for innovation and technology 

Iain Gray, the new head of the Technology Strategy Board, has 

set out his vision for the future of the UK, and backed this up 

with news of multi-million pound investments in innovation and 

technology centres, and in research and development projects 

Giving his first speech since becoming Chief 

Executive of the Technology Strategy Board last 

November, Iain Gray said that his role would 

be to “live and breath innovation”. Explaining 

that he had a passion for 

innovation, and that innovation 

had been part of his whole life, 

he said that he would like the 

Technology Strategy Board to 

create a “groundswell in the UK – 

for innovation to be part of every 

community and business up and 

down the country.” 

Gray gave credit to the 

Government for setting up the 

Technology Strategy Board as a 

new model for managing 

innovation, adding that he would 

“bring some of the rigours of business to the Technology 

Strategy Board, efficiencies that focus on delivery, 

performance and outcomes.” 

Gray said that his prime task for his first 90 days as 

Chief Executive was to “align the Technology Strategy 

Board team to drive our ambitious agenda.” Describing 

the range of work carried out by the Technology Strategy 

Board as “hugely exciting”, he acknowledged that his 

learning curve would be steep and that “the changes you 

want, that we all want, won’t happen overnight.” 

However, in conclusion, Iain Gray said that the 

Technology Strategy Board was going to “make a 

difference to the innovation landscape of this country – a 

real difference.” 

Giving weight to his words, the Technology Strategy 

Board, along with The Engineering and Physical Sciences 

Research Council (EPSRC) and Biotechnology and 

Biological Sciences Research Council (BBSRC) are 

seeking bids from leading universities who wish to host 

two new Innovation and Knowledge Centres (IKCs). The 

IKCs will promote the early commercialisation of world 

class research, by combining within a single integrated 

centre the best research with the best business 

development, market analysis and commercialisation 

skills and partnerships to accelerate its exploitation. 

The two new Innovation and Knowledge Centres will 

each receive financial support of about £9.5 million, 

spread over five years. The EPSRC (together with the 

BBSRC where appropriate) and Technology Strategy 

Board will contribute £7 million and £2.5 million 

respectively, with further funding coming from 

universities, industry and other sponsors. 

Universities have been invited to express an interest in 

hosting one of the centres. After a thorough assessment 

and selection process it is anticipated the new centres 

will be announced in September 2008. 

Exploiting emerging research 

EPSRC’s Chief Executive, Professor David Delpy, said: 

“We are delighted that the Technology Strategy Board is 

to join with us to help establish these two vital new 

centres. The prime goal of IKCs is to accelerate and 

promote business exploitation of an emerging research 

and technology field. The centres will combine world 

class research with the skills and partnerships to 

accelerate commercial exploitation.” 

Commenting on the decision to fund the new centres, 

the Iain Gray added: “This is an excellent example of how 

the Technology Strategy Board and the Research Councils 

can work together for the benefit of UK society and 

business. Exploiting emerging technologies is key to the 

UK increasing future global competitiveness. The 

Technology Strategy Board’s involvement in these new 

centres will help to provide the critical commercial skills 

and support needed to realise the potential of exciting new 

emerging technologies coming through from research." 

Only leading edge research groups, who have 

identified emerging technologies and who have the 

scientific strength to ensure these can be developed into 

major commercial opportunities, will be successful. The 

IKCs will provide support for five years of intensive early 

stage development and commercialisation, which will 

bring technologies close to market. 

This latest news comes hot on the heels of an 

announcement from the Technology Strategy Board of a 

£12 million investment into materials technologies 

research and development. The Technology Strategy 

Board and the EPSRC have allocated the money to fund 

highly innovative industry-led collaborative research and 

development projects that will enable the UK to rapidly 

meet the urgent and difficult challenges posed within the 

global energy sector. 

The investment will support the research and 

development of materials technologies that offer either 

specific or generic solutions to problems within the 

sector. The focus of the projects will be on the 

development of technologies and materials for energy 

generation (including fossil fuel, nuclear and renewables), 

energy transmission and distribution (including electrical 

and liquid gas), energy storage and energy conservation 

(with a focus on improved insulation materials in the built 

environment). 

The Technology Strategy Board is to invest £10 million 

into the projects, with a further £2 million from the 

EPSRC. Together, they will provide partial investment in 

winning projects that address one or more of these areas, 

and which involve businesses working collaboratively with 

other businesses and/or with research organisations and 

academic institutions. The projects, which can last for two 

to three years, can range from small, highly focussed basic 

research projects, aimed at establishing technical 

feasibility, through to applied research and 

experimental development projects. 

david.b@atlas.co.uk 

8 

INDUSTRIAL TECHNOLOGY • January 2008


DESIGN NEWS 

Linear motion hits the right note 

in guitar string manufacture 

The sound quality of British manufacturer 

Rotosound’s guitar strings has made them the 

choice of successive music generations. Jimi 

Hendrix, ELO’s Jeff Lynne, 10CC’s Eric Stewart 

and Iron Maiden’s Steve Harris count amongst its 

high-profile customers. 

This enviable reputation derives from 

Rotosound’s careful choice of raw 

materials and the bespoke 

winding process that 

gives its strings their 

distinctive sound. 

The process itself 

is fundamentally 

the same today as 

it was when the 

current Chairman’s father started 

the business in the 1960s. Also unchanged is 

Rotosound’s use of HepcoMotion linear slides to 

guide the cradle that carries the wire spool set. Indeed 

the Generation 1 Hepco slides that were specified for 

the first winding machines are still working today, more 

than 30 years later. 

Rotosound came into being as a result of zither 

collecting. Having learned to play the instrument in the 

Army, James How started to 

buy old zithers most of which had 

missing strings. As a typical instrument 

can require up to 150 strings the need to 

mechanise the winding process became 

apparent to make restoration viable. As he was 

working at the Royal Ordnance Factory in Woolwich 

at the time James had the means to design and make 

the machine which was ultimately to form the basis of his 

guitar string manufacturing business. 

“The late ’60s was a good time to start,” explains 

Jason How, the founder’s son and Chairman of 

Rotosound since the mid ’90s. “Floyd, The Who 

and The Beatles were at their peak and there 

were virtually no imported US strings into the 

UK so the potential was considerable.” The 

reputation of Rotosound’s products travelled 

with those bands and a global market soon 

opened up for this Sevenoaks-based company. 

The first generation of the Rotosound winding machines were 

highly labour intensive. They required the wire to be fed manually 

and their throughput was just 20 to 30 strings per hour. The 

process involves wrapping various types of cover wire over a 

choice of base core wires and then, in many cases, gluing on 

a final layer of silk. As demand for the product has grown so 

Cool Acoustics’ 

polymer guitar 

collaboration 

Cool Acoustics, the Loughborough University 

venture developing foamed polymer technology 

for acoustic guitars, has unveiled its Secret 

Valentine project. This yearlong 

collaboration with renowned UK guitarist 

Gordon Giltrap and master guitar-maker 

Rob Armstrong has resulted in a specially 

commissioned studio album recorded on a 

stunning new polymer acoustic guitar. 

The new Rob Armstrong Secret 

Valentine guitar is a handmade hybrid 

acoustic guitar, featuring a wooden body 

and neck but with a Cool Acoustics 

soundboard. The soundboard is the flat 

front panel that shapes the majority of a 

guitar’s sound and is traditionally made of 

spruce or cedar. But these materials are 

vulnerable to tonal and structural changes 

caused by fluctuations in temperature and 

humidity, and there can be a variation in the 

tonal quality of guitars that are massproduced 

to a standard construction. Cool 

Acoustics soundboards are manufactured 

from foamed polycarbonate, a manmade 

10 

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too has the need reduce labour costs, improve consistency and increase output. That 

is precisely what the latest design of the ‘How’ winding machine has been designed 

to do. The basic mechanics of the original machine remain relatively unchanged, as 

Jason explains: “Why change a system that is working well?” What was needed 

however was the introduction of a programmable electronic drive to improve the 

consistency of the feed and improve productivity. 

Thanks to its vee profile and bearing set-up, the design benefits of the original 

Generation I Hepco slide remained central to the friction-free movement of the 

carriage plate and overall rigidity of the system. So in specifying elements for the 

prototype of the semi-automated version of the machine, Jason naturally chose 

Hepco again. “In truth I have never considered any systems other than Hepco. I know 

of designers who have used recirculating technology in the way of shaft and ball 

bushings but I didn’t feel this could give me the rigidity I needed. There was danger 

of deflection in the end supported shafts, any load could cause the shaft to wobble,” 

he says. Rigidity, allowing the carriage to run true and steady, is vital to maintaining 

the constant tension of the core and wrap wires and their respective feed angle. 

Rotosound has gone straight from Generation I Hepco slides to the latest GV3 

System for the new machines. The only specification change has been the 

introduction of a dual slide system that is mounted in parallel with a set of bearings 

on each slide track which carries the wire feeder mechanism. In common with the 

original slides, the GV3 System runs dry to keep the process as clean and frictionfree 

as possible; by comparison recirculating systems need regular lubrication 

intervals and are therefore not maintenance-free. 

Another important design benefit of both generations of Hepco systems is their 

eccentric adjustment that allows pre-load to be controlled simply to acquire the 

necessary rigidity on the carriage plate. Compensation for wear can be 

accommodated in a similar way but as the winding traverse only requires linear 

speeds of just 50-70mm/sec, Jason cannot recall having to adjust for this purpose. 

The successful design of the new semi-automated machine led to the building of 

a further ten units that went into production last year and their introduction has added 

£0.25m of additional product sales with no increase in labour cost. These machines 

are producing 60 to 80 strings per hour – more than double that of the manual 

version – and responsible for more 95% of the company’s output. 

material that avoids the shortcomings of softwood and provides 

outstanding tonal quality. Professional guitarist Gordon Giltrap 

jumped at the chance to be involved in the new project, having been 

won over from his first audition of Cool Acoustics instruments in 

1999. The Secret Valentine guitar has been designed and 

developed to Gordon’s exacting specifications, and takes its name 

from one of his favourite personal compositions. Gordon was so 

impressed by the guitar the he has used only this instrument to 

record his first solo studio album for 16 years. 

The appeal of polymers is the promise of low cost, easily 

manufactured, visually differentiated and consistently highquality 

instruments with special appeal to beginner guitarists. 

The ‘polymer acoustic guitar project’ was originally proposed 

in 1993, and work commenced in earnest in 1995 as part 

of a practice-led PhD into materials and manufacturing 

expertise for industrial design. Subsequent to this study, 

the agenda for the guitar project switched to product 

development. Pressure on the supply and use of 

rarer tonewoods was leading manufacturers to 

consider alternative materials with greater vigour, 

whilst the use of innovative plastics technology had 

potential to revitalise the manufacture of acoustic 

guitars in Western economies. 

The academic agenda of the polymer guitar 

project is now changing focus, to engage in 

the technical debate and to advance the 

engineering science and technological base 

for polymer acoustic guitar design. The 

intention is to contribute new knowledge and 

understanding targeted at scientists and 

makers. Ultimately there is a hope to bridge 

the gaps that currently exist concerning 

collaboration and mutual understanding 

between these two communities. 

 

 

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January 2008 •INDUSTRIAL TECHNOLOGY 

11

EXHIBITION PREVIEW 

On the road to the NEC 

February 13-14 sees the NEC turned over to a hugely 

popular collection of exhibitions, including IPOT, MTEC 

and Machine Building. Lookout for the logos for 

exhibitor updates throughout this issue, whilst in this 

short preview we look at some of the highlights 

If you’re looking to see first hand the latest developments in 

industrial automation, machine building, drives, motion 

systems, compressed air technology, sensors, instrumentation, 

vision systems and other related technologies, then you’ll find 

them all at the NEC from February 13-14. 

In the Machine Building section of the exhibition, Aerotech 

will be demonstrating its ‘Probot’ automated multi-axis pick and 

place system combining direct drive and ball screw driven linear 

stages, tightly synchronised by a distributed network of EnsembleT 

panel-mounted intelligent drives and communicating with an Allen 

Bradley PLC using an Ethernet/IP network. Showing Aerotech’s 

engineered systems capability to the full, the complete 7-axis 

system includes a 3-jaw gripper, the machine base with enclosure 

and full cable management. 

The EnsembleT CP/MP/CL multitasking, DSP equipped, 

intelligent servo drives feature deterministic real-time Ethernet 

networking for up to ten axes – allowing tightly synchronised motion 

and machine control with microsecond level interpolation. 

On the MiniTec UK stand you’ll find several new components 

from its innovative Profile System and Linear System machine 

framing and modular positioning system ranges which have grown 

considerably since the last Machine Building show. The 

comprehensive machine building ranges are now supported with a 

new 372 page hard-cover catalogue covering well over 600 items 

which are all aimed at saving time and reducing costs for OEMs, 

machine builders and system integrators. 

Heavily featured on the stand will be the innovative and 

patented Powerlock fastener that allows rapid assembly with no 

pre-machining or pre-drilling. 

Linear motion products 

RA Rodriguez will be showing products from its own linear range 

and from the Werner range, but it has also recently been appointed 

the exclusive UK representative for drive manufacturer Framo 

Morat. This range of systems includes the Compacta slip-on geared 

motor with built-in limit switches. This is an ideal actuator for 

reverse motion and is available in four sizes with torques up to 

600Nm. In a similar vein the MINI is a range of extremely compact 

linear actuators with acme screws that are sealed to IP65. 

Minimum space requirement is also the main selling point of 

LinearChain that is capable of long strokes despite its small size. 

Meanwhile, HepcoMotion will be emphasising both its systems 

capability and the wide range of off-the-shelf linear motion 

components for customers with in-house design and assembly 

facilities. Several new products will be highlighted and amongst 

them will be the recently extended Utilitrak linear motion system. 

This highly economical linear guide provides a narrow, compact 

profile that is well suited to a variety of production environments 

where smooth, high speed motion is required. 

Rittal will be exhibiting its new electrical automation software, 

EPLAN Electric P8, a revolutionary engineering platform that offers 

the latest in CAE with optional graphical and object orientation, 

sophisticated technology and complete data transfer from EPLAN 5 

and 21 – allowing for the first time applications to communicate 

directly with each other. Building on the proven time saving benefit 

of EPLAN macros, Electric P8 now 

offers Macro variant technology with 

the ability to insert sections of circuits 

(macros) with up to eight graphical 

variants containing pre-engineered data. 

Igus will be promoting its bus cables, cable 

carrying energy chains and new stock bar, in 

particular. Chainflex bus cables are highly flexible and 

capable of high speed data transmission. The range 

includes FireWire, USB and GigE cables and these are 

ideal for digital camera technology. Beyond this, there 

are fibre optic cables which can transmit data over 

long distances up to several hundred metres. 

In the MTEC section of the exhibition, Baldor will 

be showing a new version of a popular ‘all-in-one’ 

motion solution for the first time in the UK. Offering 

control for servo and stepper motor axes, together with 

onboard I/O and fieldbus connectivity, the new 

NextMove-ESB2 expands servo control capability from 

three to four axes. This could be employed to provide a 

complete X-Y-Z and Alpha axis positioning control 

solution, for example. Combined 

with control for four stepper 

motor axes, and I/O for material 

handling and general machine 

control functions, the 

NextMove-ESB2 module offers 

an economic standalone 

solution that can be used for a 

wide range of machinery 

applications. 

The IMC Group, formed in 

2007 by the amalgamation 

of Lamerholm Electronics, 

Hanwell Instruments and 

Jekyll Electronic Technology, 

will be showing a host of 

new products at MTEC 

2008, including the new 

ELMO energy monitoring 

system and Tel2 industrial 

modem ranges from Jekyll and a working 

demonstration of the new Evolution wireless signal conditioner 

from Hanwell. Other new products include AlarmWatch – an 

innovative system alerting laboratory managers or maintenance 

personnel when the inside temperature of a fridge or freezer rises 

above a pre-set temperature. 

In the IPOT section of the exhibition, Flir Systems will be 

demonstrating just how easy and quick it is to integrate thermal 

imaging into the design and production process. In its new 

ThermoVision A-Series the company has taken the easy 

connectivity common in the visual camera sector and applied it 

to infrared. And for those involved in high speed, high resolution 

R&D applications FLIR Systems’ top-of-the-range SC6000 

will also be put through its paces. 

This ‘all-in-one’ motion system from Baldor is a servo or 

stepper motion controller with I/O, fieldbus and USB 

MiniTec’s Profile System machine framing range just 

keeps on growing, and includes stainless steel options 

The MINI from RA Rodriguez is a range of extremely compact 

linear actuators with acme screws that are sealed to IP65 

IMC Group’s AlarmWatch sends an alert 

when temperature rises above a pre-set limit 

12 


See us at the 

Machine Building Exhibition on Stand 2205 


More details: Write in 131 on the free information card More details: Write in 132 on the free information card 13

QIndustrial Technology asks 

the important 

uestions... 

feedback@itmagazine.uk.com 

Does effective machine safety have 

to mean sacrificing machine efficiency? 

recycling. Indeed, this last point is brought out in a number of standards 

Terry Hayward of Schmersal has the answer 

under the heading of safety life cycle such as BS EN 61508, BS EN 

62061 and of course, the latest BS EN 13849. 

Recently Schmersal has been running a series of seminars 

There need not be a conflict of interest between operator safety and 

explaining the implications and application of the new standard machine efficiency. What is needed is an acceptance that the latest safety 

BS EN ISO 13849:2006. I introduced the programme, rather systems can, by accommodating many different machine operating modes, 

controversially you may think, by saying: “If you think 

comply with legislation whilst contributing to the machine’s efficiency. 

machinery safety is simply about complying with the latest legalisation, 

This is reinforced by a recent study in the HSE document, ‘Out of 

then I think you are wrong.” 

Control’, which states that accidents generally happen in a machine’s nonautomatic 

Whilst this point of view may indeed be controversial I believe it needs 

mode rather than its automatic mode – for example during 

to be aired. So many people build the machine first and then say “OK, setting up, fault finding, maintenance and modification. Whilst not directly 

let’s make it safe”, which often means doing the minimum required to covered by legislation, emerging standards do require machine 

meet current legislation. The machine is in effect ‘retrofitted’ with fairly manufacturers to consider all anticipated operating modes when preparing 

basic relays and guard interlocks, in what has become common practice a safety specification. 

for safeguarding the operator. 

This will ensure that when adjustments or changes need to be made, 

The fact that the machine will almost certainly under perform, fall well engineers can disable certain parts of the machine and allow the rest of it 

short of its production targets and may never realise its true manufacturing to operate safely whilst still protecting those operating it. This new concept 

potential, is offered up on the altar of machine safety as the sacrifice of functional safety is being driven by the introduction of many innovative 

needed to make the machine safe! And the unfortunate end user may have safety devices, and requires a change in the mindset of designers and 

bought a machine that complies with the latest legislation but is of little or safety officers alike. 

no use to the production manager because it constantly trips out, can’t be To get the most from a machine requires both disciplines to look 

easily maintained, can only be used in automatic mode, and can’t even beyond meeting legislation at the lowest cost and concentrate instead on 

provide feedback to explain why? 

designing a safety system that takes account of the different modes of 

The situation isn’t helped by the fact that, in a typical plant the safety machine operation and their effect on production efficiency. 

officer’s role is to protect operators from the machine to the levels 

A simple analogy is the way electronic diagnostics have evolved in the 

stipulated in the appropriate standard, often with no reference to the automotive industry. Today’s cars can tell you if a tyre’s pressure is low, or 

machine’s efficiency or to maximising the plant’s output. So does the if a light has blown, but it doesn’t stop the car. An even better example is 

modern manufacturing plant need a new breed of safety officers who can the air suspension fitted to some luxury cars and 4x4s. If a fault is 

make a positive contribution on machine output? Perhaps, but it also detected, the car’s management system displays a warning light to alert 

needs a new breed of engineers with their minds open to an alternative the driver but it doesn’t stop the car. The driver is allowed to continue to 

approach to machine safety. 

the nearest dealer at a reduced speed of up to 50mph. 

At the risk of being branded a ‘safety hippy’ for using the two words in So ask yourself, do you really want to buy a machine that stops 

the same sentence, the ALTERNATIVE is a more HOLISTIC approach because it isn’t designed to provide prior warning of a guard door switch 

where safety is addressed at every stage of machine design and 

that is misaligned or about to fail? Surely it’s more efficient for the 

implemented for every phase of operation including installation, 

machine to warn you of the failure and allow you to make the repair in 

commissioning and maintenance – and even its eventual dismantling and complete safety without interrupting production. Similarly, if a cross-wire 

“ 

fault is detected in a traditional safety relay the machine instantly shuts 

down, even though there is no immediate danger to the operator. Contrast 

Specified correctly, machinery safety 

that with ‘smart thinking’ functional safety, which signals the machine that 

systems will increase the efficiency of it will be allowed to run till the end of the shift (safety bodies agree that 

up to six hours is acceptable), when maintenance can fix the problem 

automated processes and be capable of before the next production cycle begins. 

Pulse-echo and non-contact devices are examples of technologies that 

protecting both man and machine. 

enable functional safety. They also provide much improved machine 

However, if the only consideration is to diagnostics, which make an invaluable contribution to machine efficiency. 

So, to sum up, it is possible using the new generation of safety devices 

conform to legislation, manufacturers 

to achieve effective machine safety without sacrificing machine efficiency. 

will have missed the point and their 

” 

Terry Hayward is managing director of Schmersal, and will be 

customers an important opportunity. 

contributing his thoughts on machinery safety throughout the year. 

14 


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Choose a model with our award-winning IDMax software for tough DPM codes, or our new IDQuick 

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MECHANICAL COMPONENTS 

Bearings, Slides & Lubricants 

Protective bearing 

materials and coatings 

for harsh environments 

Dr Steve Lacey, engineering manager at Schaeffler UK, discusses the 

importance of selecting the appropriate special coating or corrosion 

resistant material for rolling bearings operating in harsh environments 

While standard bearings from reputable 

manufacturers offer optimum performance 

and a long service life, in some harsh 

operating environments or for special 

applications a standard bearing material or coating may 

need to be upgraded in order to prevent wear or corrosion of 

the bearing and to improve the service life. 

Coatings are applied to the surfaces of rolling bearing 

components without forming a material bond, for example 

by diffusion, between the coating and base material. In 

many cases, it is sufficient to coat only part of the bearing 

or one of the parts that come into rolling contact. Schaeffler 

can advise customers when a coating is appropriate and 

what type should be used in certain applications. 

Corrosion resistance can be particularly important for 

rolling bearings that operate in challenging environments. 

While standard steel bearing materials provide satisfactory 

corrosion resistance in many applications, for higher 

performance requirements, highly corrosion-resistant, 

nitrogen alloyed martensitic HNS (high nitrogen) steels – 

such as Schaeffler’s Cronidur and recently developed 

Cronitect steels – are also available. 

Cronitect is a new high-grade martensitic hardening 

steel, developed for rolling bearings, which offers maximum 

corrosion resistance under extreme conditions – for example 

in dry running applications or when the bearings are in 

contact with aggressive media such as water, acids and 

cleaning agents. In contrast to Cronidur, Cronitect has 

nitrogen introduced into the structure by means of a surface 

layer hardening process. 

Based on the consistent refinement of high-grade 

NIROSteels, Cronitect achieves a very high hardness 

through its unique chemical composition, in combination 

with a new thermo-chemical surface layer treatment 

process. The material is therefore able to withstand extreme 

conditions, including salt spray testing in accordance with 

DIN 50021 SS without any problems, even after 600 

hours. Cronitect’s resistance to corrosion is many times 

better than that of conventional NIROSteels. Rolling 

bearings that use Cronitect come in either a sealed or nonsealed 

version. Both Cronidur and Cronitect are superior to 

conventional corrosion-resistant steels for rolling bearings in 

terms of corrosion resistance, wear resistance and fatigue 

strength. This means they have very high corrosion 

resistance against aqueous media and heavily diluted acids, 

alkalines or salt solutions. Potential applications can be 

found in clean rooms, electronic component manufacturing 

plants, pharmaceuticals and food production. 

Other special materials include ceramic rolling bearing 

components, which provide excellent characteristics for 

certain applications. Silicon nitride balls, for example, are 

light and offer a longer operating life than standard steel ball 

elements. 

High performance plastics such as PEEK can also be 

used for bearing components operating in corrosive 

environments. PEEK is resistant to high temperatures and, 

depending on the load, is suitable for operating 

temperatures of up to 250°C. The wear resistance is 

strongly influenced by the filler materials and is significantly 

better than that of the standard material PA66 with glass 

fibre reinforcement that is often used for bearing cages. 

Special coating materials 

Schaeffler offers three special coatings that improve the 

corrosion-resistance and/or wear resistance of the surface. 

Corrotect is a relatively low cost, 0.5 to 5μm thick zinc alloy 

coating with cathodic protection, which is effective against 

condensation, rainwater, contaminated water, and weak 

alkaline and weak acidic cleaning agents. Under load, the 

coating is compacted into the surface roughness profile and 

is partly worn away. The chromate coating and the 

passivation increase anti-corrosion protection and contribute 

to the optical appearance of the component. Corrotect is 

ideal for small bearings and bearing mating parts that need 

to have a greater resistance to corrosion, for example drawn 

cup needle roller bearings with open ends and thin-walled 

components in large numbers. 

Protect A is a pure, matt grey coloured chromium 

coating with a pearly surface structure. The coating is 

applied by electroplating, so the coated parts retain full 

dimensional stability. Lubricant is retained between the 

pearls, therefore effective anti-wear protection is achieved, 

even under mixed friction or slippage conditions. During 

running-in, the rolling elements and seals burnish the 

surface, which leads to reduced friction coefficients. Protect 

A is resistant to various chlorides, oils, sulphur compounds, 

chlorine compounds and weak acidic media. 

Ideal for aggressive atmospheres at high temperatures, 

Protect B is a coating comprising two layers: a thin 

chromium coating covered by a chromium mixed oxide 

layer, the latter providing corrosion-resistance by supporting 

the lubricant. The coating offers high anti-wear protection 

together with high anti-corrosion protection. Protect B is also 

ideal for applications in which continuous lubrication of the 

bearing cannot be guaranteed. 

For corrosion and fretting corrosion, Schaeffler has 

developed a range of coatings to protect bearings, including 

zinc iron coatings for rolling mill applications, zinc nickel for 

bearings used in automotive engineering and zinc 

phosphate for applications exposed to salt or sea water. 

Black oxidising coatings are also available, which are ideally 

suited to rollers and rings for bearings in wind turbines and 

rail traction motor bearings. These coatings are ideally suited 

to applications in which there is a minor risk of slippage. 

Thin dense chromium coatings (TDC) also offer effective 

wear protection in mixed-friction conditions for small ball 

and roller bearings and are suitable for raceways on high 

precision bearings and spindle bearings. 

A copper coating is also available for emergency 

lubricant on bearing cages, whilst silver coatings are used for 

the same purpose on aerospace bearings. Titanium nitride 

offers wear protection in jet engine bearings. 

As many rolling bearings are used in electric motors, the 

bearings must be electrically insulated to prevent passage of 

electric current. The outside diameters and the faces, or 

alternatively the bore and the faces, are coated with 

aluminium oxide. Schaeffler offers two different coating 

thicknesses: thick insulating coating with a high resistance 

to prevent current passage even in moist environments; or a 

thin insulating coating with a low resistance to current 

passage. This coating has sturdier edges due to the lower 

coating thickness. 

Schaeffler’s corrosion-resistant coatings and 

materials can be used throughout the company’s product 

range. For applications in the food industry, housings 

and insert bearings can be protected using Corrotect and 

the housings themselves can also be made from a 

corrosion-resistant (stainless) sheet steel or plastic (glass 

fibre reinforced PBT). Plastic housings are highly 

resistant to moisture, UV radiation, bacterial and fungal 

attacks, as well as many chemical media. These bearing 

units are used predominantly as locating bearings, but 

are also suitable as non-locating bearings under low 

loads and speeds. 

MORE INFORMATION: 

Enter Z165 on the enquiry card or visit ‘latest issue stories’ at 

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

more stories from Schaeffler UK 

16 


More info... www.moore-international.com 

MOUNTS & 

ROD ENDS 

Mounts available in 

all types and sizes, 

also stainless steel 

grades and specials 

made to your spec. 

Rod ends 

bronze lined, plastic 

lined, PTFE lined, 

stainless steel 

MOUNTING SOLUTIONS 

Linear Bearing 

A range of Linear Rails 

hardened and crowned shafts, 

end supports including 

ball bushings 

Rolled Ballscrews 

Longer life and better effiency 

over Acme / trapezoidal threads 

• Wide range of sizes stocked 

• Low cost stocked in the UK 

STANDARD SIZES 

5-32 MM DIA 

PITCH 1-50 MM 

Precision Ground 

Screw 

A new range of 

precision ground screws. 

METRIC SIZES 

12-80 MM DIA PITCH 4-70 MM 

IMPERIAL SIZES 

3/16-3 INCH DIA 

PITCH 0.05-1.875 INCH 

Lead screws & nuts can be made to your own sizes and specifications 

call for more information or visit our web site. 

Tel: +44 (0) 1202 743222 

www.moore-international.com sales@moore-international.com 

Please see us at Southern Manufacturing Week, Stand G1 



Drives and Controls 

Exhibition and Conference 

22nd - 24th April 08 NEC, Birmingham 

CAN YOU AFFORD NOT TO BE THERE? 

Drives & Controls is the UK's premier event for 

power transmission, motion control and automation 

In 2006, Drives & Controls was co-located with Electrex, MACH, Airtech, Subcon and Environmental Technology/NEMEX 

to create the biggest event for the UK manufacturing and engineering sector with over 40,000 visitors attending. 

In 2008, this is set to grow further with the addition of other internationally renowned events like 

IFPEX 'The International Fluid Power Exhibition' which returns to the NEC after an 8-year absence and Independent 

Power and Energy Europe (IP&EE). These, combined with the new Plant and Works Exhibition, will mean that visitors will 

be able to assess and fulfil all of their manufacturing strategy with just one visit to the NEC. As always, each event will be 

complemented with a comprehensive series of invaluable seminars and workshops. 

To register for FREE entry go to: www.drives08.com 

For details on exhibiting contact. . . 

Doug Devlin, Sales Director: 01922 644766 or 07803 624471 Email: doug@drives.co.uk 

Michael Jacobs, Sales Manager: 01403 250614 or 07879 652020 Email: michael@dfamedia.co.uk 

Co-located events 

Primary Partners 


POWER TRANSMISSION 

Brakes, Clutches & Couplings 

Special brake motor helps bottle 

crusher break into new markets 

An innovative product for the licensed trade that 

can save time, space and therefore money has 

been developed by Bottleworks of Normanton, 

West Yorks, with Lafert brake motors key 

Bottleworks has developed a selfcontained, 

bottle crusher that 

reduces space requirements for 

empty bottles by as much as 

80%. It’s compact enough to be stowed 

behind a bar, taking the same space as a 

typical bottle bin, and is no more noisy 

than a glass washer. 

Because it reduces the volume of 

bottles so effectively, bar staff leave the 

bar area (where they should be serving 

customers) far less frequently to exchange 

bins. The space saving efficiency that the 

bottle crusher offers (and the reduced 

collection charges) has already resulted in 

success with major pub chains, clubs and 

on ferries. 

An integral component of the bottle 

crusher is the single phase motor from 

Lafert Electric Motors. It is a special high 

torque unit with progressive brake. The 

motor has been specially engineered to 

accept peak loads as bottles/broken 

glasses enter the crushing section of the 

machine whilst having appropriate braking 

characteristics for quiet, non-vigorous 

stopping that might otherwise cause the 

unit to ‘travel’. 

Suitability for purpose 

“Because this is such an innovative 

product targeted at a very profit sensitive 

market we had to be sure of its ‘suitability 

for purpose’ before we launched it,” says 

Collin Waller, director of Bottleworks. “It 

had to be visibly acceptable, robust and 

quiet but chiefly it had to function as 

intended. Hence, we need a motor that is 

man enough to do the job with the 

performance characteristics required. The 

Lafert motor meets all those criteria.” 

Lafert’s expertise is in special motors. Out 

of 4,000 motors produced daily by the 

company, over 70% of them are specials. 


Enter Z184 on the enquiry card, or visit ‘latest issue 

stories’ at www.industrialtechnology.co.uk for 

further details from Lafert Electric Motors 

New range of steel couplings are 

backlash free and torsionally stiff 

Couplings meet the needs of applications with frequent stop-starts 

Renold Clutches & Couplings has 

launched a new range of steel 

couplings that are backlash free 

and torsionally stiff. The new Renoldflex 

couplings are designed around a disc 

pack of stainless spring steel as the drive 

element. Two carbon steel hubs are 

connected to either side of the discs by a 

system of micrometric precision bushings 

and highly resistant screws. 

This design ensures a high degree of 

torsional stiffness and backlash free 

operation. This is important on 

applications with frequent stop-starts, 

reversing, accurate positioning and 

for applications on packaging 

machinery, servo motors, printing 

presses, machine tools and 

general automation. 

High temperatures 

Additionally, because of the 

coupling’s steel construction it is 

suitable for use in high 

temperature applications up to 240 

degrees centigrade. According to Renold 

the new Renoldflex couplings offer a long, 

completely maintenance-free life and do 

not even need cleaning or lubricating. The 

couplings also reduce wear to other 

components within the power 

transmission system as the flexibility of 

the disc pack absorbs vibrations that 

safeguards the system and reduces wear. 

The new couplings are machined with 

very close manufacturing tolerances for 

concentricity and perpendicularity and are 

therefore suitable for high speed 

applications, even where irregular torques 

might be present in the system. The 

range includes series one couplings, with 

a single spring pack, that can be used to 

compensate for angular and axial 

misalignment and series two couplings, 

with a double spring pack and spacer, 

that can additionally compensate for 

radial misalignment. 




further details from Renold Clutches & Couplings 

Couplings 

handle high 

misalignment 

Ruland Manufacturing offers 

oldham couplings that 

accommodate large 

amounts of parallel misalignment. 

Applications for oldham couplings 

include encoders, positioning 

systems using servo and stepper 

motors, and other light duty drives. 

They are also useful in applications 

where easy component removal for 

cleaning is desired. In higher rpm 

applications, the couplings feature 

a balanced design for reduced 

vibration. 

Oldham couplings are a three 

piece design comprised of two 

hubs and a floating centre disc. 

The centre disc, which is available 

in acetal for high torsional 

stiffness, or nylon for shock 

absorption and vibration 

dampening, is the torque 

transmitting element. Torque 

transmission is accomplished by 

mating slots in the centre disc 

with the drive tenons on the hubs. 

The slots fit with a slight press fit, 

are on opposite sides of the disc 

and are oriented 90 degrees 

apart. The press fit allows the 

coupling with acetal disc to 

operate with zero backlash. In 

operation, the centre disc slides 

on the tenon of the hub to 

accommodate misalignment. 

There are many advantages to 

oldham couplings, but its most 

distinctive feature is the ability to 

accommodate large amounts of 

parallel misalignment with light 

bearing loads. In addition, oldham 

couplings accommodate small 

amounts of angular misalignment 

and axial motion. 

Ruland oldham couplings are 

offered in seven sizes of set screw 

or clamp style hubs with bores 

from 3mm to 57mm. The hubs 

are anodised for improved lubricity 

and increased life. 


Enter Z188 on the enquiry card, or visit 

www.industrialtechnology.co.uk for 

further details from Ruland Manufacturing 

18 


New silicone insert 

couplings offer high 

electrical isolation 

One of the latest developments 

from mechanical drive 

component specialist Rino 

Industries is a silicone insert shaft 

type coupling. 

The silicone part is bound to the 

hubs and is backlash 

free. This means 

that any shafts 

are electrically 

isolated and 

the silicone is 

heat resistant 

from –50 to 

+150ºC. The 

coupling has a soft 

start/stop mechanism and is 

available in three different sizes with 

bores ranging from 4.4mm minimum 

to 19mm maximum. 

Specials are available to order 

where required, customers are 

requested to send their drawings or 

sketches for a no-obligation quote. 

Rino has also recently launched a 

range of simplified shaft clamp 

couplings. These backlash free, 

simplified shaft clamp design 

couplings are dubbed the “EASY” 

couplings, due to their universal 

constructive 

elements which 

are independent 

of shaft size. 

The bores can 

be adjusted 

easily making 

sure stocks can 

be modified quickly 

for customer requirements. There 

are three sizes available at present, 

with others being available as 

specials where necessary. 


Enter Z194 on the card, or visit ‘latest issue 

stories’ at www.industrialtechnology.co.uk 

for further details from Rino Industries 

COUPLING AND 

GEARBOX 

INNOVATIONS 

SCHMIDT OFF-SET COUPLINGS 

…for ‘positively displaced’ shaft connections 

■ Extensive parallel off-set capability 

■ Fully variable – even in drive 

■ Exceptionally short space-saving length 

■ Three or more link arm crank action 

SCHMIDT SEMI-FLEX COUPLINGS 

…for ‘in-line’ shaft connections 

■ Up to ±13mm radial off-set capability 

■ 45 to 250,000 Nm 

■ Short length/internal boss options 

■ Hollow centre allows for quill shafts, etc 

SCHMIDT CONTROL-FLEX COUPLINGS 

…for ‘encoder etc’ shaft connections 

no radial offset forces 

on shaft support 

bearings 



bearings 

■ Up to ±4mm radial (1.5° angular) capability 

■ Light, Delrin flexural element 

■ 0.3 to 410 Nm, up to 22,000 rpm 

■ Fast, simple clamp lock shaft fixing 



bearings 


POGGI GDR GEAR COUPLINGS 

…crowned and barrelled gear teeth couplings 

■ Low cost GDR polyamide sleeve 

■ 6 to 700 Nm 

■ Full stock of unbored, imperial and metric bores 

■ GDA ‘all-steel’ option up to 55,000Nm 

POGGI ANGLE GEARBOXES 

…spiral bevel gears with hardened ground steel shafts 

■ Low cost aluminium monobloc casing 

■ 2/3/4-way, 1:1/1:2/1:3 gearing 

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

■ Independent, hollow and manual disengage/reverse 

output shaft options 

POGGI LOK-FIT RINGS 

…for friction coupling of components onto shafts 

■ Low cost, easier installation eliminating keyways 

■ For flywheels, pulleys, gears, disc cams, etc 

■ Self-centering designs 

■ Up to 210,000 Nm, for shafts 14 to 300 mm 

…from 

Francis and Francis Limited 

The Stables Works, Station Road, Kenley, Surrey CR8 5JA 

Telephone: 020 8668 9792 Fax: 020 8668 9793 

E-mail: Franci.Kenley@ukgateway.net 

www.powertransmissions.co.uk 


19

ENGINEERING LITERATURE 

Highlighting over 

18,000 products 

Phoenix Contact’s new catalogue set 

is available, highlighting a 

selection of its products across six 

individual publications. The new 

catalogues have been expanded by more 

than 1200 new innovations to give a 

comprehensive selection guide to the 

company’s product lines. 

The full catalogue set includes of over 

18,000 products, broken down into 

Clipline (industrial connection 

technology), Combicon (PCB connection 

technology and electronic housings), 

Pluscon (industrial connectors), Trabtech 

(surge protection), Interface, and 

Automation(components and systems). 

Want a copy? ........................................Enter Z204 

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, the most interesting 

catalogues, and news of important updates to supplier web sites 

One hundred and twenty five 

years since the forerunner 

of the IEE’s Wiring 

Regulations was first 

published, the latest edition has been 

formally approved for publication. 

The 17th Edition of BS 7671, 

Requirements for Electrical 

Installation, also known as the 

IEE Wiring Regulations, will be 

published this month. 

The publication is produced by 

the Institution of Engineering and 

Technology (formerly the IEE) and 

plays a key role in safety and 

standards within the electrical 

installation industry. The IET 

manages the UK’s national wiring 

committee which prepares and 

updates the regulations and publishes 

the Wiring Regulations. 

The 50-strong committee 

representing the electrical industry 

has been reviewing the current 

regulations for the last two years. 

Over 2,500 comments were received 

from industry during a three month 

public consultation period. The 17th 

edition will run to almost 400 pages. 

A great deal of progress has been 

made on international standards work 

in IEC and CENELEC since the 

publication of BS 7671:2001, requiring 

both structural changes to the British 

Standard and also significant technical 

advances to be included. There are now 

requirements for renewable energy 

generation and combined heat and 

power. These changes affect all areas of 

the Standard, so the decision was taken 

by JPEL/64 (the national committee 

responsible for BS 7671) to publish the 

revised Standard as the 17th Edition. 

As a result the 17th edition now 

includes additional requirements to 

ensure the safe connection of lowvoltage 

generating sets including small 

scale embedded generators and solar 

photovoltaic (PV) power supply 

systems. 

Published in paperback and 

costing £65, the new IEE Wiring 

Regulations will be available from the 

sales department at the IET, which 

can be contacted by phone on 01438 

767328 or by email via 

sales@theiet.org. 

Vibration sensors 

Monitran 

Monitran has released an 

innovative product selector 

guide. It presents the top-level 

features and benefits of 64 of 

Monitran’s general and special 

purpose accelerometers – all in 

a concise, A4 fold-out booklet. 

Within the sensor guide 

products are split into three 

categories, namely general 

purpose analysis (AC), general 

purpose monitoring (DC) and 

special purpose, and then further 

refined into families. The guide 

also includes a page devoted to 

selection tips. 

Machinery framing 

MiniTec UK 

MiniTec UK Limited has 

launched a new 372 page 

catalogue for its Profile System 

range of machine framing 

systems and components. The 

hard cover 21 section resource 

comprehensively details over 

600 items from the range of 

cross sectional aluminium 

profiles and machine framing 

components. 

The full range covers, 

profiles, fasteners, wheels, 

supports, hinges, doors, 

panels and many more 

components. 

Joysticks 

Penny & Giles 

Penny & Giles has launched a 

new finger-operated joystick 

controllers brochure. Complete 

with technical information, 

including a designers’ guide for 

ordering and installation, the 

free brochure is user-friendly 

and offers information about an 

extensive range of products for 

precision control of critical 

functions in a wide range of 

industrial applications. 

The brochure details the 

choice of six models in Penny 

& Giles’ range of fingeroperated 

joysticks. 

Flying shears 

Gefran 

Gefran UK has released a new 

motion control application 

guide for flying shear and feedto-length 

cutting systems 

based on its SIEIDrives XVy-EV 

family of high performance 

servo drives. 

The guide includes data 

sheets and detailed instruction 

manuals that describe all the 

controls and parameters 

available for users to configure 

their own dynamic web 

processing applications. Also 

included are videos showing 

various cutting applications. 

Automation 

Routeco 

Routeco reports that the 

primary function of its new 

catalogue is to provide 

customers with a unique 

purchasing experience. The 

catalogue is easy to use and 

the colour coded sections at 

the front of the catalogue are 

also reflected in the sections 

found on the new Routeco 

website. 

Featuring over 8000 key 

products and divided into 25 

easy to use coloured coded 

sections, the catalogue is an 

invaluable reference. 

Want a copy? .....Enter Z205 on the card 





20 


Application 

Door closer mechanism 

for underground train 

Solution 

Linear Ball Bearing KS 

First in Line 

The world's largest range of linear systems from a single source 

INA linear bearings and guidance 

systems from Schaeffler UK offer first 

quality products to meet linear guidance 

requirements across a comprehensive 

range of applications. 

From simple guidance mechanisms 

for low to moderate accuracy to heavy 

duty systems offering high rigidity and 

load carrying capacity, the INA range is 

first in line. 

Taking the quality envelope that bit 

further are X-life premium products 

that feature enhanced characteristics 

including increased load carrying 

capacity, higher rigidity, lower operating 

temperatures and reduced noise levels. 

So, whether you are designing a new machine 

tool, packaging machine, medical device, 

door closing mechanism or anything else 

that involves linear motion, the INA linear 

product range can provide the perfect solution. 

Schaeffler (UK) Ltd 

Tel: 0121 351 3833 Fax: 0121 351 7686 

E-mail: info.uk@schaeffler.com 

Web: www.schaeffler.co.uk 

World Leaders in Rolling Bearings, Plain Bearings, Linear Systems and Engine Components 


AEROTECH 

Advanced Motion Controls and 

Drive Technologies 

PWM Amplifiers 

High performance DSP based 20 kHz PWM 

power stages for brushless, brushed and 

stepper motors - to 150 A peak 

Digital current, velocity, and position 

loops for improved motion stability 

HP/CP/MP packaging options to suit 

application and budget 

Linear Amplifiers 

High performance, DSP based linear 

power stage for brushless and brushed 

motors - to 20 A peak 

Available for low noise and ultra-high 

perormance positioning 

HL and CL packaging options to suit 

application and budget 

Soloist TM Standalone Intelligent Single-Axis Drive 

Available in models up to 30 A peak 

current 

Ethernet, USB or RS-232 connectivity 

Programming options include 

AeroBASIC TM , C#, Microsoft.Net, C++, 

and LabVIEW® 

PWM and Linear drive stages 

Ensemble TM Standalone Intelligent Multi-Axis Drive 

High-speed serial interface to coordinate 

up to ten axes of multi-tasking motion 

Panel mount or rack based configurations 


AeroBASIC TM , C#, Microsoft.Net, C++, and 

LabVIEW® 

PWM and Linear drive stages 

Automation 3200 Software Motion Controller 

IEEE-1394 Firewire® protocol provides 

high-speed, deterministic distributed 

control of motion and I/O for up to 32 

axes 

Available with a range of soft machine 

control modules for HMI, Vision and 

PLC. 


AeroBASIC TM , C#, Microsoft.Net, C++, 

and LabVIEW® 

Matching Ndrive® PWM and Linear 

drives 

DRIVES & CONTROL SYSTEMS 

Making the case 

for soft starters 

in high inertia tasks 

For heavy-duty motor applications fluid 

couplings have historically been regarded as 

the industry standard for starting loads that 

have a high inertia. Peter Costello of 

Siemens Automation and Drives argues the 

case for electronic soft starters as an 

efficient and economical alternative 

Fluid couplings have for many 

years offered a good solution 

for companies involved in 

key specialised industries. 

Typically these applications are 

associated with extraction and 

processing of raw materials, for 

example coal mining and quarrying. 

The big advantage with a fluid 

coupling is that the transmission of 

torque to the load takes place after the 

motor has been started and at a point 

in the speed torque profile where the 

motor is developing maximum torque. 

For the motor the starting profile is 

similar to that of a centrifugal, 

pump with load torque increasing 

exponentially. With such a relatively 

‘easy’ starting requirement, the motor 

Software packages are available which make 

it simple to correctly size the soft starter to 

cater for the starting currents 

can be started direct-on-line (DOL), or 

for larger machines via star-delta. 

A fluid coupling requires inspection 

on a frequent basis. The downtime 

required to carry out such frequent 

inspections adds to the general 

maintenance cost of the application, 

due to the loss in productivity. 

The soft start alternative 

Using an electronic soft starter to 

replace an existing fluid coupling is a 

feasible proposition for some 

applications, provided that a full study 

of the load requirements is undertaken 

and also the supply network is 

checked to see that it can handle the 

starting current. 

The load seen by the motor is now 

one of constant torque, so it is 

important to check that the motor will 

deliver sufficient torque to accelerate 

the load to full speed. Starting times 

Aerotech Ltd. 

Jupiter House, Calleva Park, Aldermaston 

Berkshire RG7 8NN, United Kingdom 

Tel: +44 (0)118 940 9400 

Fax: +44 (0)118 940 9401 

Email: info@aerotech.co.uk 

Dedicated to the 

Science of Motion 

www.AEROTECH.co.uk 

See us at 

Machine Building 2008 

NEC -Birmingham 

13-14 February 2008 

Stand 2000 

22 More details: Write in 220 on the free information card 


Motion Control 

NEW 

servo drive from ABB... 

0.75kWto110kW 

FILM & FOIL CONVERTING 

FILM & 

FOIL CONVERTING 

Soft starters offer the benefits of reduced 

maintenance, dynamic braking capabilities 

and increased monitoring capabilities 

of over a minute can be expected 

and therefore the motor overload 

protection needs to be able to cater 

for this. It is recommended that 

thermistor protection is used to 

measure motor heating directly. 

Soft starter advantages 

There are three distinct advantages for 

the electronic soft starter in these 

applications. First is the limited 

maintenance costs: oil changes and 

inspections are no longer required, 

saving money on general up-keep of the 

application. The need for maintenance 

downtime is decreased, thereby 

reducing the effect on productivity. 

Then there is the advantage of the 

dynamic breaking capabilities. High 

Inertia loads mean longer stopping 

times, and before cleaning or tool 

changes can take place the motor 

needs to be brought to a standstill. 

Dynamic braking systems which use a 

specialised form of DC current 

injection can be incorporated within 

the soft starter to reduce the motor 

stopping times and therefore boost 

productivity. In one example, a motor 

stopping time of over five minutes was 

reduced to less than 60 seconds, with 

a huge subsequent increase in 

productivity. 

Finally, there is the potential for 

increased monitoring capabilities. The 

more sophisticated soft starters on 

the market incorporate motor overload 

protection and can monitor motor 

performance and power consumption 

on a continuous basis. For example, 

if motor current falls below a set limit 

a warning can be generated to alert 

plant personnel. Statistical data such 

as motor running hours can be stored 

and accessed later so that 

maintenance can be planned in 

advance. 

Serial communications to a PLC 

can greatly reduce plant wiring and 

allow data to be accessed centrally. 

It is important to remember that 

electronic soft starters work most 

effectively when the mains supply is 

robust and therefore located nearby. 

Typically where a mains supply is onsite 

or closely located the soft starter 

will have four times the rated current 

capacity of the motor, leading to 

increased application efficiency. 

To ensure long term reliable 

operation the soft starter needs to be 

correctly sized to cater for the starting 

currents that will be sustained for 

longer periods when compared 

to ‘standard’ applications. Special 

software packages such as the Win- 

Soft Starter programme from Siemens 

could be used to evaluate both the 

motor and load characteristics. The 

software will then generate a starting 

profile which will predict motor current 

and torque as a function of the load. 

There are some applications that 

because of the nature of the load 

require a fluid coupling but in those 

applications where a study has been 

made, electronic soft starters can offer 

an alternative, and in some cases, a 

more flexible and easy to maintain 

alternative. The financial savings that 

can be made from integrating this 

product far outweigh any short-term 

upheaval associated with replacing an 

existing starting system. Further cost 

savings are made with the reduction 

in maintenance and better 

diagnostics operating data. 


Enter Z225 or visit ‘latest issue stories’ at 

www.industrialtechnology.co.uk for further 

details from Siemens Automation and Drives 

FOOD & BEVERAGE 

FOOD & BEVERAGE 

...brought to you by 

Motion Control Products Ltd 

11-15 Francis Avenue 

Bournemouth 

Dorset, UK 

BH11 8NX 

Tel: +44(0)1202 599 922 

PICK & PLACE 

PICK & PLACE 

ABB’s new ACSM1 provides high 

performance speed, torque and motion 

control for demanding applications. The 

servo performance can control induction, 

synchronous and asynchronous servo 

and high torque motors with various 

feedback devices. 

To discover more about this world beating 

product visit: 

www.motioncontrolproducts.co.uk and 

DOWNLOAD the new brochure TODAY 

PRINTING 

PRINTING 

MATERIAL HANDLING 

MATERIAL HANDLING 



23

DRIVES & CONTROL SYSTEMS 

Motion Control 

Belt actuator combines 

accuracy and durability 

Toothed belt driven, this new actuator from 

Parker allows for multiple motor drive options 

to provide dynamic horizontal positioning for 

feeding, sorting, indexing and packaging tasks 

Anew linear belt actuator from 

Parker Electromechanical and 

Drives offers a cost-effective 

solution for applications that demand 

accurate repeatability, durability and low 

maintenance. 

Called the LCB range, it comes in two 

sizes of profile section 40mm and 60mm. 

They offer 6kg and 30kg typical payloads, 

maximum strokes of 2.0m and 5.5m and 

static bearing loads of up to 1,250N and 

3,850N respectively. The LCB040 has a 

maximum thrust of 160N and the 

LCB060 560N. Both have speeds up to 

8m/s, accelerations of 20m/s 2 and 

repeatable accuracy of ±0.2mm. 

LCB actuators are supplied as 

complete assemblies with standard 

mechanical interfaces, including 

mountings for stepper and servo 

motors, gearboxes. This drive option 

flexibility enables the LCB to be 

configured easily according to speed 

performance and accuracy required. 

Because the actuator is of a selfsupporting 

design, complete with integral 

guides, the number of components is 

minimised which results in high reliability, 

low maintenance plus extended service 

life. The ‘minimal’ design of the LCB also 

imparts low inertia, permitting it to 

achieve high cycle times with 100% duty 

cycle. This efficient mechanical design 

has also eliminated the need for 

lubrication of the drive train and the travel 

guides. All these features are 

complemented by the LCB’s sliding 

guides. These ensure high-dynamic 

performance, low noise levels (even at 

high speed), an operating efficiency 

greater than 90% and low energy 

consumption. 

The LCB is ideal for integration with 

other Parker actuators (electric and 

pneumatic), and vacuum suction grippers 

to achieve cost-efficient robot solutions. 




further details from Parker Electromechanical 

Drives get real 

time Ethernet 

modules 

The latest option module to 

extend the functionality of 

Control Technique’s variable 

speed drives range, including the 

Unidrive SP family, is SM-EtherCAT, 

providing support for real-time, high 

performance Ethernet 

communication. 

“We have been monitoring the 

market and listening to our 

customers, and this has resulted in 

us initially choosing EtherCAT over 

PowerLink,” says Control 

Techniques’ Imad Rajraji. “We also 

believe that EtherCAT potentially 

offers customers a greater benefit. 

EtherCAT is the first in our planned 

range of real-time Ethernet solutions 

with more protocols to follow.” 

The module is for use with 

Control Technique’s full range of AC 

and servo drives from 0.37kW 

simple conveyor or pump control, 

through high precision servo 

applications to high power 1.9MW 

multi-mode drives. This allows 

Maxon is boxing clever with 

intelligent compact drives 

Motion system 

on a single chip 

The M3000 motion control IC, from 

System Semiconductor provides a 

complete system for motion control, 

handling time-critical motion and motor 

tasks in silicon to control and position 

multi-phase step motors. 

The solution utilises a highly 

integrated, mixed signal system-on-a-chip 

architecture combining major motion and 

motor control building blocks while 

simultaneously working as a high-speed, 

general purpose microcontroller, 

incorporating extensive communication, 

analogue functions and system functions 

for general machine control. 




further details from System Semiconductor 

Ever eager to make life easier for 

designers, Maxon Motor has come 

up with a ‘box of tricks’ that 

combines a motor, a sensor and a 

controller into one unit – packaged in a 

neat, compact, aluminium casing. It’s 

called the Maxon compact drive MCD 

EPOS. 

The controllers are taken from 

Maxon’s EPOS (Easy POsitioning System) 

range, which has proved tremendously 

popular since its recent introduction, 

while the motors and encoders are triedand-tested, 

off-the-shelf Maxon products 

whose performance and reliability are well 

established. Together they form a highly 

dynamic, space-saving, maintenance-free 

positioning drive with excellent 

functionality and great efficiency. The 

system delivers a maximum output of 60 

watts. One of the most attractive features 

of the boxed MCD EPOS is its quick startup 

procedure. It arrives optimally tuned 

and ready for use, and the need for wiring 

is minimised thanks to its facility for 

direct connection to a CANopen bus or an 

SPS controller. A programmable version 

(MCD EPOS P) is also available, equipped 

with a processor and memory for 

standalone operation. Both versions come 

complete with all the necessary software, 

free of charge. 

Applications for these extremely 

flexible compact drives will be found in 

the likes of automation, robotics and 

laboratory equipment. 

“Designers have responded very 

enthusiastically to EPOS and we are sure 

that they will welcome the new MCD 

compact packages, particularly when they 

see the price,” says Keith Ellenden, CEO 

of Maxon Motor UK. “The EPOS range is 

already competitively priced but believe it 

or not the compact MCD costs less than 

the sum of its individual parts.” 




further details from Mclennan Servo Supplies 

customers to standardise their 

network across the whole machine. 

The SM-EtherCAT module is the 

latest in a wide range of 

communication options that already 

include Ethernet/IP, Modbus TCP/IP 

as well as traditional fieldbus. 

Increasingly, EtherCAT is being 

requested by customers because of 

its excellent performance and 

bandwidth, allowing users to get 

good dynamic performance from 

their drives. It covers the whole 

range of communication 

requirements from high-end motion 

control through to central factory 

computer control of conveyors and 

pumps. Control Techniques’ 

SM-EtherCAT module can operate at 

cycle times down to 250μs 

synchronising the drive’s position or 

speed loop to the communications 

network, improving overall system 

performance. 




further details from Control Techniques 

24 


LOW COST 

CAPACITIVE 

SENSORS for... 

...ACCELERATION 

Range ±1g to ±1000g 

High output 

Body weight 3.5 grammes 

...INCLINATION 

Range ±1º to ±80º 

Resolution from 0.001º 

Integrated electronics 

Analogue or digital outputs 

We offer low cost OEM 

solutions for 

measurement problems 

on many applications 

including vehicles, 

buildings, seismic, process 

machines, cranes, bridges, 

mining, safety, etc. 

Sensors UK Limited 

137a Hatfield Road, St. Albans AL1 4LZ 

Tel: 01727 841692 Fax: 01727 844272 

www.sensorsuk.com 

CAP1 




In Their View... 

Three industry heavyweights air their views on the key topics of the 

moment. You can have your say, too, via feedback@itmagazine.uk.com 

Serving two masters 

We all know that running a profitable business 

isn’t easy, and for some years climate change 

considerations have made it even more 

difficult. But now the Climate Change Bill requires that 

we address both of these simultaneously. The 

imperative to make money remains, but now there is a 

need to show equal aptitude at reducing carbon. In truth 

very few companies are prioritising carbon reduction in 

their development plans and very few business 

managers list carbon as a high priority, although a few 

talk about cost saving through energy efficiency. 

Critically, most business managers today are concerned 

far more with financial success than carbon reduction. 

The disciplines required for maintaining profitability 

in competitive markets oblige companies to focus on 

the short-medium term. They find it very hard to look 

more than a year or two ahead. An investment that 

will pay back handsomely in five years is very much a 

dent in the bottom line for the preceding four years. 

Politicians, on the other hand, love the long-term. 

They know that their life at the top of the 

governmental tree is probably going to be about five 

years. They think it makes them look good if they set 

grand ten year targets and they can leave the detailed 

implementation up to their successors. 

Resolving this to its simplest form we see that 

carbon reduction is required for the long term 

continuance of the human race, but this is transformed 

in a free market economy into energy management 

driven by economic criteria. These two approaches are 

in fact fundamentally different, but currently 

coincident. Left to their own devices they will drift 

apart again relatively soon. 

The European Energy Trading Scheme should allow 

investors to realise a return on expenditure in low 

carbon technologies, but the problem is that its 

sophisticated economic analysis requires a 

commitment to long term investments. Large parts of 

an open economy do not do these things: small 

businesses, low margin operators and rapidly growing 

markets are going to be very hard to get on side. 

Jeff Whiting 

Energy Spokesman 

Mitsubishi Electric 

The death of the PLC 

Both inverter and servo technologies appear to 

be near the limit of their design capabilities, 

but the final refinements will in fact improve 

their performance levels considerably. The twin holy 

grails of inverter design are full regenerative capability 

and zero harmonics. Both are possible, but neither is 

commercially viable in standard drive systems at 

present. However both are within reach. 

The great gains for servo drives will come in the 

form of far greater dynamic responsiveness, because we 

can confidently expect that processing speed of the 

controlling electronics will increase at least four fold over 

the coming years. Equally important, prices will drop 

significantly and user-friendliness will reach levels such 

that a servo can be installed and programmed by a 

relatively unskilled person in a matter of minutes. This 

will open up whole new fields of applications of servos. 

Both servos and inverters will become very much 

more intelligent that they currently are. The technology 

for achieving this already exists, we are just waiting for 

the market to appreciate the fact and start using it. 

Interestingly this will reduce the need for local 

controllers such as PLCs and we can forecast that 

PLCs will have to adapt. It is realistic to consider that 

large and medium PLCs will either disappear 

altogether or evolve into something just about 

unrecognisable from today’s stand point. Small PLCs 

will actually fare better; they will become smaller with 

fewer I/O because there will be greater reliance on 

remote and distributed I/O. The small PLCs will 

perform a higher functionality processing, physically 

connecting different parts of a control system together. 

In a parallel development, some PLCs will 

become ‘soft PLCs’, software programs that function 

like a physical PLC. To date determinism has been an 

issue, but it seems obvious to me that it is not beyond 

the wit of programmers to build adequate determinism 

into their industrial control programs. The fact that 

they have not done this yet does not indicate that it is 

impossible, simply that so far they have been paid 

more money to concentrate on other areas. 

Stuart Harvey 

Managing Director 

Silverteam 

Forgotten heroes 

Mechanical engineers will be at the forefront of 

all the most important technical and scientific 

developments for the next fifty years. Yet for 

some reason they are the forgotten heroes – the 

backroom boys who never step up to the limelight to 

receive praise for their contributions. 

I can understand people wanting to avoid the public 

gaze, but if there is no recognition of engineers’ 

contribution, there can be no general appreciation of 

their efforts. It’s little wonder that kids are not enthused 

to go into engineering careers. If we are not constantly 

nurturing the next generation of engineers, I wonder 

what will become of the national economy. 

Nearly all fields of human endeavour require an 

element of mechanical engineering. Yet how many 

mechanical engineers today achieve the celebrity status 

of geneticist Prof Sir Robert Winston, historian Michael 

Sharma, architect Norman Foster, retailer Philip Green, 

businessman Richard Branson? 

Perhaps we should merge engineering with 

entertainment – engitainment if you will – and push TV 

executives to create a couple of ‘celebrity engineers’. 

They’d be more entertainer than engineer, but perhaps 

they would do for technology what celebrity chefs have 

done for British cuisine. There are precedents, too: 

Stephenson and Brunell, Barnes-Wallis and Whittle, who 

in their day were embraced by the public. And we are 

nearly there now with TV programmes like The Great 

Egg Race and Scrapheap Challenge. We just need to 

shift the balance slightly more towards appreciating the 

technology and the engineers. 

If we are to solve many of the problems facing the 

human race, mechanical engineers will have to play a 

major role. Mechanical engineers created the industrial 

revolution, enabled global trade in Victorian times, 

created a new world order for the Edwardians, led the 

development of aircraft and the push into space. Their 

role today and tomorrow is just as vital and a little more 

recognition would be appropriate and would 

undoubtedly help secure some economic certainty for 

the future. 

Ray Barnes 

Managing Director 

Hoerbiger-Origa 

26 


NEW 

Servo drives range 

Intelligent, Compact and Dynamic 

From 0.72Nm to 19.3Nm (57.7Nm Peak) 

www.controltechniques.com 

27

THE ULTIMATE SERVO DRIVE 

Meeting the demands of modern lean manufacturing environments 

requires smaller more flexible machinery. Digitax ST is the first 

ever drive designed to help machine designers and system 

integrators meet these challenges, the ultimate compact servo 

drive with an unmatched depth of flexible integration features. 

Designed around you 

Digitax ST is optimised for servo applications requiring high peak torque, 

dynamic response, ease of use and flexible integration features. Four 

product variants ensure that the drive’s personality perfectly matches your 

servo applications. 

● Digitax ST – Base 

Optimised for centralised control, to operate with motion controllers, 

motion PLCs and Industrial PC based motion systems using a wide range of 

digital or analogue interface technologies. 

● Digitax ST – Indexer 

Designed for simple stand alone positioning applications using an 

onboard position controller. Fieldbus, Ethernet and I/O enable 

connectivity to other automation components. 

Global Service 

Control Techniques’ 54 Drive Centres located in 31 countries ensure 

that service, support and expertise are just around the corner, all 

around the world. 

● Digitax ST – EZ Motion 

This drive offers a stand alone solution for many common indexing and 

synchronised motion applications. This is achieved using a unique, PC 

programming interface that guides the user through the drive, I/O and 

motion configuration. 

● Digitax ST – Plus 

Features a full functionality motion controller, optimised for high 

performance machine cells requiring drive-to-drive networking and 

precision synchronisation. The motion and communications are 

configured within a flexible IEC61131-3 software development 

environment using PLCopen function blocks. Fieldbus, Ethernet and I/O 

connectivity enable interfacing with other automation components and 

Intellectual Property protection ensures that your valuable knowledge 

remains secure. 

Reliability and Innovation 

Digitax ST is designed using a well proven development process that 

prioritises innovation and reliability. This process has resulted in Control 

Techniques having a market leading reputation for both product 

performance and quality. 

LISTED E171230 

28 

www.controltechniques.com

VALUE YOUR TIME 

Reduced Development Time 

Three motion programming options allow you to choose the style you 

prefer, either CTSoft index motion, IEC61131-3 environment with 

PLCopen functions or PowerTools Pro, drag and drop functionality and a 

BASIC-like programming language. Servo and fieldbus option modules are 

independently certified for conformity with open standards to ensure 

interoperability. CAD files in both 2D and 3D formats make it easier and 

quicker to design the drive into your machines. 

Quicker Installation 

Innovative mechanical design reduces the installation time considerably. The 

mounting arrangements enable the bottom of the drive to be quickly 

clipped on to standard DIN rail and the cable management system features 

rigid mounting and earthing brackets. Pluggable control terminals enable 

looms to be easily prepared. Click-in option modules mean the drive can 

be customised to your needs at the point of installation without specialist 

tools and gives the flexibility to customise the functionality at a future time. 

Reduced Commissioning Time 

Digitax ST is quick and easy to set-up. The drives may be configured using 

the removable keypad, Smartcard or the supplied commissioning software 

to guide the user through the configuration process. Selected Unimotor FM 

models enable the motor dimensions to be stored onboard the encoder as 

an 'electronic nameplate'. This data is stored during the motor 

manufactuing process and provides Digitax ST with the motor dimensions 

enabling automatic motor setup, further reducing the commissioning time. 

Auto-tune features help you to get the best performance by measuring the 

machine dynamics and automatically optimising the control loop gains. 

CTScope, a real-time software oscilloscope, is supplied for tuning the drive 

and monitoring performance. 

Smarter Thinking 

The Smartcard, included with 

every drive, enables 

parameters to be safely stored 

and copied quickly from one 

drive to another. This feature 

significantly reduces the 

commissioning time when 

installing multiple servo systems 

with similar configurations. 


www.controltechniques.com 

29

COMPACT & COMPLETE 

More Compact Machinery 

Digitax ST is an extremely compact servo drive that can be mounted sideby-side 

with other drives or components without leaving space. The result 

is an incredibly high packing density for multiple axes. Onboard features 

such as synchronised motion control and Safe Torque Off reduce the need 

for external components further reducing cubicle sizes and cost. 

Matched Motors 

Unimotor FM is a performance matched range of servo motors. FM means 

Flexible Motor, available in six different diameters with a wide range of motor 

lengths, rated speeds and feedback devices.Factory fitted options include 

integral brakes and servo gear boxes. Digitax ST operates successfully with 

other manufacturers’ servo motors including linear motors and almost any 

feedback device. 

Increased Value 

How do you increase 

the value of your 

machines while reducing 

your costs? Digitax ST 

offers reliability, and the 

performance to increase 

speed, repeatability and 

accuracy while also 

reducing the size and 

cost. Digitax ST 

addresses all of the 

challenges associated 

with modern 

machine design. 

Digitax ST - 

Base 

Digitax ST - 

Indexer 

Digitax ST - 

EZ Motion 

Digitax ST - 

Plus 

Two option module slots ✔ ✔ ✔ ✔ 

Digital and analogue I/O with pluggable connector ✔ ✔ ✔ ✔ 

Smartcard ✔ ✔ ✔ ✔ 

High speed Freeze input for position capture ✔ ✔ ✔ ✔ 

Safe Torque Off (Secure Disable) ✔ ✔ ✔ ✔ 

CTSoft and CTScope commissioning software ✔ ✔ ✔ 

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RS485 PC programming port ✔ ✔ ✔ ✔ 

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Index motion programming within CTSoft 

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Drive-to-drive networking 

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30 

For more information call Control Techniques UK drive centre 

on 01952 213700 or visit www.controltechniques.com

John Richardson’s ENGINEERING DIARY 

In the spirit of environmentalism, I took the bus into 

town recently instead of using my car. Whilst on 

longer trips I always try to use the train, I have to 

admit that on shorter hops I have been rather guilty of 

always falling back on my own private transport. But we all need 

to be considering our carbon footprints these days, and seeing as 

I had to go out, the bus seemed the lesser of two evils. 

In the event, I suspect my bus trip contributed more to the 

greenhouse effect than leaving my car at home saved. A journey 

that would have taken me 15 minutes by car took 45 minutes 

by bus, and the bus itself appeared to have one of those 

throttles that was either open or closed, with nothing in 

between. In fact, so jerky was the ride that a couple of 

pensioners in front of me were in serious danger of being thrown 

out of their seats. 

So there we are. One small step for a man, but not even a tiny 

contribution really to the giant leap needed for mankind. And it 

still seems completely topsy turvey to me that when it comes to 

travel up and down the country, the fastest, cheapest way for me 

to get around – ie to take a plane – is also the most 

environmentally damaging. I may be able to pat myself on the 

back for taking the train, but there’s certainly a sting in the wallet. 

Small crumbs of comfort 

Still, I can at least draw comfort from the fact that the UK’s 

greenhouse emissions are already down to 15% below 1990 

levels, some 2.5% below the Kyoto targets which the 

government committed us to meeting by 2012. 

Or can I, because a recent study casts doubt on the figures, 

saying the government’s claims to have tacked global warming 

are an illusion. While the government figures focus solely on the 

production of carbon, the new analysis measures the actual 

consumption of carbon, and incorporates the effects of pollution 

from aviation, shipping, overseas trade and tourism, all of the 

which the government figures conveniently ignore. According to 

this new analysis, UK carbon output has actually risen by 19% 

compared with 1990 levels. To quote the report: “This is a 

dramatic reversal of fortune. It merits an immediate, more 

detailed and more robust assessment. It suggests that the 

decline in greenhouse gas emissions from the UK economy may 

have been to a considerable degree an illusion.” 

Among the many failings of Kyoto was clearly the fact that 

major polluting powers such as the USA were never on board. 

Could the climate change summit in Bali change all that? 

Officials from 189 countries met to try and agree a road map for 

climate change before meeting in Copenhagen in 2009 to thrash 

out a successor to the Kyoto Protocol. In the event, as perhaps 

we all expected, the EU’s insistence on clear targets proved to 

be a sticking point. The suggested wording read: “The 

unequivocal scientific evidence... Will require Parties included in 

the Annex 1... to reduce their emissions in a range of 25 to 

40% below 1990 levels by 2020.” 

Alternative wordings 

This was never going to be acceptable to the likes of the 

Americans, Canadians and Japanese. And then of course you 

have China, which, having seen the USA grow rich and fat on a 

foundation of fossil fuels, clearly feels it has a right to do 

likewise, and is building enormous amounts of coal capacity, 

basically adding the equivalent of Germany each year. So, late 

into the proceedings the EU delegation caved in to the 

opposition, and ditched specific target percentages. Instead, the 

final document says countries recognise that “deep cuts in 

global emissions” will be required, and calls for a “long term 

global goal for emissions reductions.” 

Somehow, everyone coming away from the summit seemed 

to think that this was a success. UK Environment Secretary 

Hilary Benn hailed it as an historic breakthrough, whilst Prime 

Minister Gordon Brown said that he was delighted. 

The various campaigners and non-governmental 

organisations, meanwhile, aghast that the hard science of the 

first draft has effectively been relegated to a footnote, are calling 

the agreement nothing less than a suicide pact. 

You have to feel some sympathy. The absence of any firm 

targets will effectively make any successor to Kyoto little more 

than a voluntary agreement rather than something which is 

legally binding. The problem, though, as we have seen, is that 

even when there are firm targets in place, the reality of life in the 

twenty-first Century, where soundbytes and headlines count for 

more than genuine substance, is that even quoted figures in the 

end mean nothing. We have only to look at the UK’s own 

emissions crisis for evidence. If a country which has been one of 

the strongest proponents of Kyoto, and which claims to be 

leading from the front on emissions reduction, can be some 34% 

out in the reality of its quoted figures, then what hope is there for 

the world in general? Answers on a postcard accepted as always, 

but remember that a nice movie could win you a Nobel prize. 

feedback@itmagazine.uk.com 


31

MECHANICAL JOINING 

Fasteners & Adhesives 

As the terms imply, solvent bonding or solvent 

welding are processes that involve surfaces of 

thermoplastic parts being joined by means of 

a solvent. In most cases, that solvent is 

cyclohexane. In these bonding procedures, the solvent 

diffuses into the surfaces of both components of the 

joint, and initiates the mixing together of the plastic 

molecules. As a result, the solvent evaporates and 

causes a bond to be formed between the surfaces. 

The whole process is relatively quick and, just as 

important, the cost is often quite low. However, there 

are downsides, too. Where dissimilar materials are 

involved or where there are gaps in the assembly, 

solvent bonding can be unsuitable. There is sometimes 

a risk – depending on the type of plastic to be bonded 

– that over-application of the solvent will cause stress 

polyethylene, polypropylene, fluoropolymer, and acetal 

homopolymer. 

Light curing acrylic adhesives cure by means of a 

reaction that forms thermoset resins when exposed to 

light of the appropriate wavelength and intensity. Like 

cyanoacrylates, light curing acrylic adhesives are 

available in a wide range of viscosities from low 

(around 50 cPs) to thixotropic gels. Furthermore, light 

curing adhesives vary in final cured form, ranging from 

hard, glass-like material to soft flexible resins. 

Of necessity, light must reach to bondline if the 

adhesive is to cure as required. It goes without saying, 

therefore, that any adhesive to be found in shadowed 

areas will not cure. While light curing acrylic systems 

will cure to a maximum depth of approximately 12mm, 

in practice a typical measurement is around 2mm. 

Solvents or adhesives? 

cracking of components. But perhaps more 

importantly, there are environmental issues 

surrounding any solvent. Although solvent bonding is 

used in a variety of industries, the assembling of 

medical devices is perhaps the most common. And it 

is here that adhesive technologies have offered a viable 

alternative to solvent bonding. 

Cyanoacrylate, light curing cyanoacrylate, and light 

curing acrylic adhesives are all commonly used for the 

assembly of medical devices. In general, adhesives 

offer several benefits over other medical device 

assembly methods. These include the ability to fill 

large gaps, the opportunity to bond dissimilar 

materials, the capability of distributing stress evenly 

across a bondline, and the capacity to form a hermetic 

seal when confined between two substrates. 

Formulation properties 

Cyanoacrylate adhesives, which first appeared in the 

1960s, undergo a polymerisation reaction when they 

come into contact with moisture. This moisture – 

which is essentially present on all surfaces – triggers 

the reaction that causes the linear chains to form and 

thus start the curing process. When fully cured, 

cyanoacrylates (CAs, for short) form thermoplastic 

resins. Before use, CAs are maintained in their liquid 

form through the addition of weak acids which act as 

stabilisers. A wide variety of cyanoacrylate 

formulations are available with varying viscosities, 

cure times, temperature resistance and strength 

properties. 

Alongside improvements in ethyl cyanoacrylate 

technology, there have been significant advancements 

in primer and accelerator formulations. These not only 

enhance the speed of cure, but also introduce the 

ability to bond ‘difficult-to-bond’ plastics. The primers 

also allow for significant increases in bond strength of 

most of the hard to bond materials, including 

Solvent bonding has been a popular joining method for many 

years. But there are issues that call into question its continuing 

acceptance. Bob Goss of Henkel, maker of Loctite brand 

products, looks at the viable alternatives 

Another consideration when selecting a light cure 

adhesive is the equipment required for processing the 

product. Light curing adhesives require specific radiant 

(in other words, light) energy in order for the 

polymerisation reaction to occur. It is, therefore, 

critical that the adhesive be matched with the 

appropriate light source. 

Light curing acrylic technology offers the significant 

benefit of rapid fixture and cure (as little as five 

seconds for certain joints) following exposure. This has 

the effect of minimising work in process. In addition, 

light curing acrylic formulations are intended for 

bonding a wide variety of substrates, and yield a clear 

bondline when utilised on thin sections. 

A winning combination 

A new technology introduced in the United States in 

1998 combines the benefits of cyanoacrylate 

technology and light curing acrylic technology. These 

aptly named light-curing cyanoacrylates are ethylbased 

products to which photoinitiators have been 

added to the formulation. The end result is fast 

fixturing – like that of a traditional light curing acrylic 

– and cure in shadowed areas. 

As the light curing cyanoacrylates are ethyl 

monomer based, the overall physical performance 

characteristics are similar to those obtained with a 

traditional cyanoacrylate. Additional benefits gained 

with the new technology include minimised 

blooming/frosting since exposed uncured cyanoacrylate 

can be immediately cured using ultraviolet and/or 

visible light, increased depth of cure over the 

traditional cyanoacrylate adhesive, and compatibility 

with primers for 'hard-to-bond' plastics. 

Making a choice 

So, to recap... Solvent bonding is just one of many 

assembly methods for plastic materials. This method 

has its advantages and disadvantages just like any 

other process. Adhesive technology, on the other hand, 

presents some significant advantages. Recent 

improvements in the areas of UV curing acrylics, 

cyanoacrylates and light curing CAs have increased 

their potential for meeting the requirements of those 

companies that have previously used solvent bonding 

techniques. It really is worth investigating these 

alternatives with an adhesive supplier. 

It’s also worth knowing that, in addition to 

expertise on adhesive technology, the supplier can offer 

knowledge in the areas of materials selection, specially 

adapted dispensing equipment and full support in 

process technology. Indeed, the adhesive supplier 

should work with a total systems approach involving 

the device designer and equipment provider to 

develop an efficient and effective process. 


Enter Z325 on the enquiry card, or visit ‘latest issue stories’ at 


more stories from Henkel Loctite 

32 




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MECHANICAL JOINING 

Getting stuck into 

the Love Truck 

The problem involved a 

painted steel substrate, 

hand placed glass/ceramic 

tiles, substrate flexing and 

widely varying vibration over 

extended periods in outdoor 

conditions – in short a Tiki Love 

Truck! An unusual project for 

Intertronics but nonetheless well 

within the capabilities of the Adhere 

IRS 2125 flexible epoxy adhesive. 

The project was conceived by 

Baroness von Reichardt as a Tiki 

Love Truck based around the tiki 

symbology of a large carved talisman 

in humanoid form, common to 

Polynesian cultures of the Pacific 

Ocean. The ‘Tiki Love Mobile’ is a 

magical automobile, driven by two 

lovely hula girls who give out 

messages of love and peace as they 

drive by. 

The base vehicle was a standard 

Nissan diesel pick-up truck to be 

covered in glass tile mosaics and 

ceramic Polynesian. The Baroness 

‘Googled’ adhesives and discussed 

the project with Intertronics’ 

technical advisors who suggested the 

Adhere IRS 2125 flexible epoxy 

adhesive. It is a black epoxy resin 

system with a combination of 

flexibility and high adhesion strength 

on materials such as metal, glass, 

rubber and many plastics, including 

cable insulations and connector 

backshells at temperatures up to 

150°C. Originally developed for 

This suggestion proved to be a 

complete success over the five hours 

a day, seven day installation. The 

Baroness explains: “As an artist I 

find the process of mosaic very 

therapeutic, and this adhesive 

certainly facilitated that process. It is 

nice to use because you don’t have 

to mix it, and with a convenient 

setting time. The tiles have been 

solid as a rock ever since.” 




for further details from Intertronics 

Ultrasonic metal welding 

Contax has entered into an 

exclusive agreement with 

ultrasonic specialist, Telsonic 

UK to distribute its ultrasonic metal 

welding equipment throughout the 

UK for the wire and contact 

industry. These products are ideally 

suited to the automotive industry, 

or other manufacturing 

environments that use wire harness 

applications. 

Stuart Hall, Technical Director at 

Telsonic UK, explains: “Contax is 

the perfect distributor for our 

products. Although we are known 

worldwide for our ultrasonic 

equipment, we had not previously 

concentrated on the UK market. 

Contax brings the industry 

knowledge and contacts, and we 

can supply the right systems. We 

believe that it will be a very 

successful partnership.” 




for further details from Contax 



Fasteners & Adhesives 

Nanosilica filled UV 

curable reinforced epoxy 

Anew nanosilica filled one 

component UV curable 

epoxy called UV22 has been 

introduced by Master Bond. This 

compound has been developed for 

coating, sealing and encapsulation 

applications. It features superb 

abrasion resistance, excellent 

optical clarity, low shrinkage and 

high physical strength properties. 

UV22 cures rapidly at room 

temperature upon exposure to a UV 

light source and is not oxygen 

inhibited. It has a service operating 

temperature range of –50°C 

to150°C. Post curing the UV22 

material enhances its temperature 

resistance profile. Adding heat (90- 

125°C for 30 minutes) will give it a 

glass transition temperature of 

135°C, far higher than traditional 

UV systems. The post curing is 

also effective in increasing its 

chemical resistance to solvents, 

acids and bases. In addition, UV22 

is easy to use. Despite the 

relatively high percentage of 

nanoparticles, it still retains high 

transparency and low viscosity 

without sedimentation due to the 

agglomerate-free colloidal 

dispersion of the nanoparticles in 

the resin. UV22 has a Shore D 

hardness of over 80 and a tensile 

strength of greater than 4,600 psi. 




for further details from Master Bond 

LOST 

for a solution? 

If you can’t find it, I bet we can. 

• Panel, wire/pipe & electronic 

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With thousands of fasteners and 

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Contact us now for your 

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www.tfc.eu.com 

Tel: +44 (0)1435 866011 E-mail: sales@tfc.eu.com 



35

SENSORS & SYSTEMS 

Industrial Ethernet 

Delivering the 

universal solution 

for plant networks 

Industrial Ethernet is the fastest growing industrial network 

choice, but what exactly is it, how does its implementation 

differ from that of a traditional fieldbus, and does it really 

offer the single universal solution that is so often talked 

about? We put these questions to the experts in the field 

Against a background where there is increasing 

pressure on manufacturers in all sectors of 

industry to improve processes, reduce costs and 

boost productivity, Ethernet technology is being 

hailed as the key to achieving all these goals, and so 

boosting companies’ competitiveness on increasingly 

aggressive global markets. 

The move to industrial Ethernet has been fast paced 

across all sectors of industry, and is a step change from the 

standardisation on the various open and proprietary 

fieldbus protocols that we saw though the 1990s. But 

what exactly is industrial Ethernet? Steve Jones of CLPA 

(CC-Link Partner Association) explains: “Industrial 

Ethernet, in essence, is the use of Ethernet as the data link 

layer protocol in the OSI seven layer model, with a fieldbus 

protocol as the application layer. This is conceptually 

similar to the various fieldbus options that are actually the 

use of RS232/485 as the data link layer, with the fieldbus 

protocol itself at the application layer.” 

There are many advantages to moving to industrial 

Ethernet, not least of which is a vast increase in speed, up 

from the sub-10kbps typical with RS232 to the gigabit 

and beyond potential of Ethernet. Overall performance is 

also increased, and costs are significantly reduced, since 

industrial Ethernet offers the ability to use standard access 

points, routers, switches, hubs and cables which are far 

cheaper than equivalent serial port devices. “From the 

user’s point of view, however, the biggest advantage aside 

from cost is the significantly greater interoperability 

between devices offered by industrial Ethernet,” says 

Jones. “In particular, there is the potential for a seamless 

flow of data from field devices all the way up to higher level 

business systems, and back, delivering huge gains in 

flexibility for manufacturers looking to boost their 

productivity to the max.” 

The latest development in industrial Ethernet promises 

a ten-fold increase in communications rates to 1Gbps. This 

has come with the release of CC-Link IE – the first 

completely integrated gigabit Ethernet network for industrial 

automation. “It really does define the new threshold for 

open standards for Industrial Ethernet,” says Jones. 

Time-critical applications 

It is the evolution of Ethernet technology from a 10Mbps 

bus/tree topology to a gigabit, switch-based topology that 

has really paved the way for using Ethernet to support such 

time-critical applications in industrial networks. The 

infrastructure of switches provides the determinism and 

throughput required for control applications, and switches 

can be added to split the data load between segments, 

resulting in higher performance. 

The Ethernet switch also makes it possible to build 

redundancy into the industrial Ethernet network. Dave 

Cook of GarrettCom Europe comments: “At field device 

level, dual connectivity is the standard approach for 

providing redundancy, but the lack of PLCs and field 

devices with dual connectivity built in for sensor and 

controller applications has made this almost impossible to 

achieve cost effectively. Modern Ethernet switches provide 

a solution to the problem, with the advent of dual homing 

technology built into even the smallest of switch products. 

Offering convenient plug-and-play dual connectivity in a 

physically small package, these products provide high 

reliability to enable redundancy for nodes at the edge of the 

network at a low cost.” 

Further, Ethernet has the unique characteristic of being 

a network with an active infrastructure, enabling the 

network to accommodate a virtually unlimited number of 

point-to-point nodes, and so providing users with 

unsurpassed flexibility in designing networks that 

accommodate their current requirements while enabling 

easy, cost-effective expansion in the future. In addition, 

recent hardware developments have removed the 

communications distance limitations that have been a 

recognised issue with the move to gigabit Ethernet, giving 

users a simple upgrade path to the increased performance 

afforded by this high-speed technology. The new CSG14 

converter switches from GarrettCom Europe allow 

industrial installations with multi-mode fibre to achieve 

2000m gigabit connectivity that has previously only been 

available when using single-mode fibre cable. 

With its performance benefits, then, industrial Ethernet 

is a good fit for applications where the required volume and 

speed of data exchange among plant floor controllers and 

between controllers and information systems is exploding. 

In addition, being based on standard Ethernet, the network 

addresses the increasing need to reduce total cost of 

ownership of production processes across development, 

commissioning, operation, and maintenance. 

Stefan Knauf of Mitsubishi Electric says: “As industrial 

Ethernet extends its reach to even the most lowly field 

devices, so the various controllers, PLCs and ERP systems 

are able to access any sensor connected to the control and 

device network. The result is better information on 

manufacturing processes, with process operators able to 

monitor and fine tune system performance, access plant 

information and communicate directly with their 

production line managers.” 

Perhaps most importantly, and in contrast to the 

fieldbus options of the past, industrial Ethernet frees up the 

user to a far greater extent from the danger of being locked 

into a single solution, enabling the system integrator to 

focus on installing the network without having to worry 

about the protocol that will eventually be used over it, 

whether that be CC-Link IE, EtherNet/IP, Profinet or one of 

the others. “An industrial Ethernet infrastructure will 

happily accommodate multiple application protocols in use 

at the same time, with the switch network routing the data 

packets appropriately,” says Knauf. “This means users can 

make a decision on an industrial Ethernet protocol based 

on today’s requirements, confident that the investment will 

not have been wasted should tomorrow’s requirements in 

a different area of the plant dictate the use of a different 

protocol.” 


CLPA: enter Z365 on the card 

GarrettCom Europe: enter Z366 on the card 

Mitsubishi: enter Z367 on the card 

Or visit ‘latest issue stories’ at www.industrialtechnology.co.uk 

36 


LOAD CELLS 

for INDUSTRY 

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www.sensorsuk.com LOA1 



Promotional Feature 

Unlocking the potential 

of electroformed products 

The electroformed product available from 

Abssac Limited is a formidable package. 

For those engineers familiar with the 

traditional electroforming process, we are offering 

a new way of looking at both complexity of 

shape, wall thickness tolerance, integral strength 

and capability. 

Ask yourself... Do you know what a electroform is? 

Electroforms are manufactured by a process of electrodeposition; 

by building thin layers of metal onto a precision machined 

mandrel with the quality and dimensional accuracy being of 

paramount importance. Then, by refining the electroforming 

process, parts with unusual shapes, thin walls, deep crevices and 

other design features can be controlled to ensure the highest part 

quality. 

So why use electroforms? 

The technology on offer can and has been used on a whole range 

of applications in aerospace, medical equipment, electronic chip 

manufacture, microwave applications, cryogenic cooling and PCB 

automatic testing activity to name a few. Our quality is of the best 

and where miniature metal bellows are concerned, there are none 

that compete with bellows diameters under 6mm and on request 

we can supply down to diameters of 0.07mm. It is not so much a 

product range that we offer but a technology concept, which can 

be measured against other more traditional methods in both 

quality but more importantly with regard to cost effectiveness. 

Some examples of our success include... 

Baffle Electroforms: With a unique patented process a hollow 

electroform with internal baffles can be produced. These integral 

baffles replace the need for costly secondary assembly operations, 

whilst providing structural integrity along with minimal weight. 

The designs of baffle electroforms are used primarily for 

components known as coldshields or radiation shields. The 

aperture openings in the baffles can be cut to any shape and 

orientation, so that the baffled electroform will filter the ‘light’ 

radiation passing through it, by physically blocking some 

wavelengths while not blocking others. These electroforms are 

gold plated on the exterior for reflectivity and blackened on the 

interior for absorption, filtering out the unwanted frequencies of 

the visible and non-visible light spectrum as light passes through. 

Volume Compensator: As the name suggests, an electroformed 

bellows can be designed to compensate for the changes in volume 

of a fluid in a sealed container. As the fluid expands or contracts, 

with changes in temperature, the electroformed bellows will 

compensate for these changes in a predetermined manner. 

Athermalisation Assembly: Quite simply, this converts 

temperature change into a linear motion. Utilising a custom 

bellows assembly the bellows is filled with an engineered fluid 

with a known coefficient of expansion and sealed. As the fluid 

heats up or cools, its volume will expand or contract, which 

translates directly into calculable linear deflection. 

38

Valve Seals: Since bellows are flexible in that they can bend, 

stretch, and compress, they can also be designed to be 

hermetically leak tight and to withstand a specific applied 

pressure. Combining these capabilities makes bellows ideal 

flexible seals in valves eliminating the need for O-rings to seal the 

valve stem. 

Pulse Damper: This utilises the bellows to dampen pressure 

spikes in fluids. Equating them to a spring-loaded piston, but 

without any seams or seals to worry about, the flexibility of the 

bellows allows the assembly to compensate for volumetric 

changes due to sudden pressure surges. The bellows will respond 

to changes in pressure by either compressing or extending, 

effectively absorbing the ‘force’ of the pressure surge. 

Electrical Contacts (dynamic resilient connection): Miniature 

bellows contacts are ideal for applications where contact with a 

delicate component or material is required. By design the contacts 

have low insertion forces, low insertion losses, and extremely low 

DC resistance. They have been designed to provide lifetime spring 

and force repeatability. Our contacts minimise shock and vibration 

in dynamic applications and assist in overcoming tolerance 

buildup and misalignment problems in critical assemblies. 

Interconnectric Contacts (flexible electrical contacts): 

Interconnectric contacts are used in critical applications where 

contact with a delicate component or material is required; they 

can be used individually or as pairs especially where reliability 

and flexibility are a requirement. These unique contacts come 

with either a convex conical or concave conical tip which, when 

paired, will allow them to self-align at interconnection. 

Interconnectric contacts will minimise shock and vibration in 

dynamic applications and will help overcome misalignment and 

tolerance build-up problems in critical assemblies. Interconnectric 

contacts offer the designer a less expensive alternative to high 

cost assembly components with tight tolerances. 

Bellows Shaft Couplings (flexible torque transmission): Utilising 

the low inertia, zero backlash and high torsional rigidity 

characteristics of a bellows, a range of flexible couplings is 

available. Their key strengths include inherently absorbing angular 

and parallel shaft misalignments in combination with axial 

movements, while precisely transmitting motion and torque. They 

are ideally suited for coupling to encoders and resolvers in 

precision positioning applications. 

Custom Electroform (rigid, lightweight structural forms): With a 

truly refined process, custom designed electroforms and thin walled 

hollow metal components for use in a myriad of high tech 

applications can be supplied. These often unique electroforms can 

be used as moulds, coldshields or radiation shields, waveguides, 

for precision tubing, and lightweight structurally rigid components. 

They can be made as small as 0.5mm (0.020in) diameter out of 

nickel, copper, gold or silver, or a combination of all. 

A host of special advantages... 

With the specialised electroforming process, most custom 

electroforms require no significant tooling, which can allow for 

several prototype variations to be supplied and evaluated, as 

opposed to being locked into a design by expensive dies or moulds. 

A major advantage of the electroforming process is the ability to 

provide close tolerance steps and dimensions not easily produced 

with stamping or other mechanical processes. The designs are 

limited only by your imagination. 

For further information, contact the Abssac sales office 

on 01386 833301 or by email at sales@abssac.co.uk. 

ABSSAC 

The Bond Industrial Estate 

Wickhamford 

Evesham 

Worcestershire 

WR11 7RH ENGLAND 

Tel : (+44) 01386 833301 

Fax : (+44) 01386 831500 

www.abssac.com More details: Write in 390 

39


Harmonic Distortion 

Power supply harmonics: pay 

attention or pay the price 

Block UK managing director Bob Liddle has this advice on how 

industrial companies can reduce the effects of harmonic distortion from 

their power supply lines, thereby eliminating equipment failures and 

cutting production downtime, repair and replacement costs 

Power supply networks are the life 

support of modern industry, but 

their quality and reliability are rarely 

questioned. Manufacturers are 

basically interested only in whether current is 

flowing or not. The majority of companies 

never question how good or bad the quality of 

the power source they are using actually is. 

Although the power supply grids in Europe 

are amongst the most reliable in the world, 

this does not guarantee the quality of the 

power they deliver. A pure sinusoidal voltage 

waveform for which most equipment is 

designed to operate on is very rare these days 

in mains supplies. Harmonics that distort the 

waveforms have been on the increase in 

power supply grids for many years. There are 

many sources today of these harmonic 

distortions, including variable speed motors, 

large UPSs, computers, discharge lamps and 

B6 bridge rectifiers used in power electronics 

These systems are generally found as 

loads in all modern power grids. The current 

that they draw is not sinusoidal but pulsating. 

Inevitably, this results in a reverse current 

flowing back into the supply grid. There are 

numerous national and international 

standards limiting these harmonic levels to 

certain values, including DIN EN 61000-4-2; 

DIN EN 61000-3-12 and IEEE 519-1992. 

Unfortunately, in industrial everyday practice, 

these standards are not always being 

adopted. For reliable industrial power 

distribution, having in the main three 

phase loads, the fifth harmonic at 

250Hz and the seventh harmonic at 

350Hz are of primary concern. 

Three phase systems such as 

variable speed drive units and large UPS 

systems utilise three phase rectifiers (6- 

pulse bridge). The order of the 

harmonics depends on the number of 

pulses the rectifier has, and for a B6 

bridge circuit, harmonics with the 

number five, seven, eleven, thirteen, 

etc. are present. Single phase loads 

such as computers and monitors in 

administration buildings generally only 

produce the third harmonic. 

Effects of distortion 

Harmonic distortion on modern power 

grids can harm equipment in different 

ways. For example, vibration and noise 

levels are annoying symptoms, but their 

effect on the operation of machines is 

minimal. Another is the harmonic 

distortion present in communication 

lines and in electronic circuits, which 

can cause malfunction and fault 

conditions. Overheating of transformers, 

cables, motor windings and in capacitor 

banks can also be caused by harmonic 

distortion. These faults can reduce the 

life expectancy of machines and 

equipment, causing unnecessary 

expense and production downtime for a 

company. 

Then there are the hidden costs of 

losses caused by harmonics, including 

copper and iron losses in transformers 

and copper wires. Adding all these 

losses together means that for a typical 

industrial company, around 5% of its 

total electricity bill is comprised of 

losses. Until now, very little attention 

has been paid to these cost factors, 

mainly due to lack of knowledge or lack 

of adequate means of monitoring. But 

modern supply analysing equipment 

makes these problems more 

transparent. With these aids, it is easier 

to track down the source of distortion, 

which is the first step in solving the 

problem. Block UK assists its 

customers, analysing the line supply 

voltage, and helping to decide which 

harmonic filter is best suited for the 

application. 

Up to now, industry has used 

reactors or active filters to protect the line 

supply from harmonic distortion. With 

both systems, a reduction in the level of 

distortion can be achieved. However, 

both methods have distinct 

disadvantages. The effectiveness of a 

reactor is not always adequate, so 

reactors only have a limited 

implementation. Active filters eliminate 

harmonic distortion almost completely, 

but with the drawback that the technical 

expenditure is comparatively high. 

Block has developed a third method 

of dealing with these harmonic 

distortions – the harmonic filter module 

(HFM). During development of the filter 

module, priority was given to the fifth 

and seventh harmonics, which cause 

most problems in industrial applications. 

With the harmonic filter the proportion of 

THD (total harmonic distortion) for any 

frequency inverter and intermediate 

circuit using B6 input bridges is reduced 

significantly, typically by 84 to 95%. 

Depending on the application, a 

filter can be used either directly in front 

of the source of the harmonic distortion 

or as a complete system filter in the 

distribution cabinet. Typically, filters are 

designed for the individual equipment 

and its harmonic distortion level, which 

means the design is relatively 

straightforward. 




for further details from Block UK 

40 



DISPLACEMENTSENSORS 

ROTARYSENSORS 

INCLINATIONSENSORS 

PRESSURESENSORS 

VIBRATIONSENSORS 

JOYSTICKS 

SENSORS & M.M.I. PRODUCTS 

www.feteriscomponents.com 



Pressure sensor technology from 1 mbar … 1000 bar 

Flow sensor Type 200 

Pressure Transmitter Type 663 

Pressure Transmitter Type 698 

0.5 … 240 l/min. 

Based on the principle of Karman’s vortex 

trail, the Type 200 flow sensor has no moving 

parts, a wide application temperature range 

with medium temperatures up to 140°C, 

and excellent media resistance and EMC 

characteristics, making it well suited for 

applications such as integral pump flow 

sensors for central heating boilers. 

–5 … 5 – 2000 mbar 

Type 663 pressure transmitters are designed 

for use with media such as air or nonaggressive 

gases. 

The output signals are temperature 

compensated, linear and amplified. 

0 … 1 mbar – 6 bar 

The pressure modules type 698 are suitable 

for monitoring pressure and flow in air 

conditioning systems and in the laboratory 

sector. 

The module is optionally available with a 

3 digit LED display, two limit value 

switches (potential-free) as well as a square 

root extraction. 

Huba Control AG 

Unit 3 Network Point 

Range Road 

Witney Oxfordshire OX29 0YD 

Tel +44 (0) 1993 776667 

Fax +44 (0) 1993 776671 

info.uk@hubacontrol.com 

www.hubacontrol.com 



New Products 

Endevco licenses NASA 

technology for sensors 

Endevco has 

announced the 

licensing of three 

patents covering hightemperature, 

harshenvironment 

silicon carbide 

(SiC) pressure 

sensors from 

NASA’s Glenn Research 

Center. An Endevco siliconbased 

accelerometer was used 

to validate the initial NASA 

design in 2000. 

The NASA technologies 

licensed by Endevco include a 

packaging technique and chip 

fabrication methods developed 

by a team led by Dr. Robert 

Okojie at Glenn for use in 

aircraft engine combustion 

chambers. SiC pressure 

sensors manufactured using 

these new processes can be 

used to improve testing of jet 

engines, in deep well drilling 

(where pressure and 

temperature rise as drilling 

depth increases), and in 

automobile combustion 

cylinders. 

Silicon carbide used for the 

new NASA technologies, rather 

than the traditional silicon, 

eliminates the need for 

cooling. The current generation 

of SiC-based pressure sensors 

has been demonstrated to 

operate for 130 hours at 

600°C in air, making them 

durable and reliable for use for 

the first time in engine ground 

testing and short duration 

flight test instrumentation. 


Enter Z425 or visit ‘latest issue stories’ 

at www.industrialtechnology.co.uk 

for further details from Endevco 

Vision sensor is economical, 

reliable and simple 

With the FA 45 vision sensor, 

Sensopart says it is driving a new 

paradigm in image processing 

technology. For the first time, 

industrial users can solve demanding 

applications without knowledge of image 

processing technology, using only familiar 

sensor technology. 

With the FA 45, complex functions do not 

mean complicated use. Every technician can 

work intuitively with the FA 45 vision sensor. 

Once unpacked, the FA 45 is positioned and 

connected via Ethernet and M12 sensor 

connectors in no time at all. Parameter settings 

are carried out directly via teach-in using a 

temporarily connected PC and application 

software included in the standard delivery. 

Setup can be repeated and adjusted to new 

features any 

number of times. 

The FA 45 vision 

sensor is almost 

square in shape 

with its 

45x45x65mm 

dimensions, 

which is extremely practical. Integrated 

electronics supply reliable results at a clock 

speed of up to 600 parts per minute. It also 

provides a low-cost alternative to complex 

image processing systems. 


Enter Z426 on the card, or visit ‘latest issue stories’ at 

www.industrialtechnology.co.uk for further details from 

Sensopart 

Non-contact measurement on metals 

The IS 50-LO plus and IGA 50-LO plus from 

Impac Infrared are digital pyrometers with 

fibre optics for non-contact temperature 

measurements on metals 

between 250 and 2500°C. 

Due to their short response 

time of less than 1 ms 

these pyrometers ideally suit for the 

measurement of fast heating processes. 


Enter Z427 on the card, or visit ‘latest issue stories’ at 

www.industrialtechnology.co.uk for further details from 

Impac Infrared 

Miniature 

amplified 

load cell 

Feteris Components is 

pleased to announce a new 

miniature amplified load 

cell. Based on strain gauge 

technology the new FALC-01 is a 

tension and compression load cell 

with integral amplification providing 

a high level output signal. 

Machined from stainless steel, 

the FALC-01 has a high resistance 

to overload, shock and corrosion, 

and provides 

environmental 

protection to IP65. 

The operating 

temperature range is from -40 to 

+85°C and the load cell is fully 

compensated for the effects of 

temperature on zero and span. 

The output is ±10VDC, and load 

ranges are from ±250N to ± 2000N 

as standard. 




for further details from Feteris Components 

IEC 60320 three 

function power 

entry modules 

Interpower Corporation has 

introduced a new line of 

three function IEC 60320 

power entry modules to its 

product line. The modules are 

intended for computer, medical, 

general purpose, and/or custom 

indoor type equipment 

applications. They have ratings 

from 6A/250VAC for North 

America and 10A/250VAC for 

international applications. 

The modules are UL, CSA and 

VDE approached, and construction 

is RoHS compliant as standard. 




further details from Interpower Components 

42 




DISPLACEMENT/POSITION • LOAD/FORCE • PRESSURE • VELOCITY 

• ROTARY & REACTION TORQUE WITH COMPLETE INSTRUMENTATION. 

Choose RDP products and get the assurance that only more than 40 years of development 

and applications experience can give, backed up by the ISO9001:2000 quality system. 

Call today for advice and a complete measurement system from transducers to your PC. 

RDP Electronics Ltd 

Grove Street, Heath Town 

Wolverhampton, WV10 0PY 

Tel: +44(0) 1902 457512 

Fax: +44(0) 1902 452000 

Making sensors make sense. 

www.rdpe.com 



NEW 

More 

precision. 

Non-Contact displacement 

and position sensors 

Confocal displacement sensors 

optoNCDT 2400 

Miniature sensors design 

Extreme resolution and stability due to 

white light measurement 

Tiny, constant measuring spot from 7μm 

Measurement against mirrored, 

transparent surfaces 

One sided thickness measurement 

Minature sensors ø 4 mm, measuring 

ranges from 400 μm to 10 mm 

Accurate & stable 

eddyNCDT 

Eddy-current sensors 

Ranges 0.4 - 80 mm 

Linearity ±0.2 % 

Resolution 0.005 % 

Frequency response 100 kHz 

Temperature stability 0.015 % FSO/°C 

High profile frequency 

scanCONTROL 

2D/3D Laser profile sensors 

Ranges 25 - 245 mm 

Linearity ±0.2 % FSO 

Resolution ±0.04 % FSO 

Profile frequency up to 4 kHz 

Measuring rate up to 256 kHz 

Programmable measuring field 

www.micro-epsilon.co.uk 

MICRO-EPSILON UK Ltd. 

Dorset House · West Derby Road · Liverpool · L6 4BR 

Phone +44 (0) 151 260 9800 · info@micro-epsilon.co.uk 

Online trace moisture 

event sensor launched 

The PURA Plus from Michell 

Instruments is an on-line trace 

moisture event sensor designed 

for UHP inert gas applications in 

semiconductor fabs to allow 

installation at multiple locations at 

the final point of entry to the process 

tool. Installed in the gas 

distribution system, the 

PURA Plus provides rapid 

indication (less than 1 

minute) of a moisture event as low 

as 20ppb at 1ppb baseline. 

To achieve this high speed of 

response while maintaining the 

extreme sensitivity Michell has 

invented a unique detection 

algorithm and combined it with a 

newly developed UHP-suitable 

ceramic sensor design. Besides other 

benefits it allows the PURA Plus to 

meet the particulate shedding 

performance required by the 

semiconductor industry. 

The PURA Plus meets the 

highest quality standards for material 

HMI has 

built-in PLC 

Following the successful launch 

of its Touch Panel family of 

operator panels in 2005, VIPA 

is now offering new versions of the 

panel with an integrated PLC 

powered by its leading-edge 

SPEED7 processor technology. 

Retaining all the functionality of 

the Touch Panel family and available 

in screen sizes from 8.4in to 12.1in, 

the PLC supports the Siemens STEP 

7 programming language and can 

maintain logical connections with the 

display. System expansion is via rear 

panel connection using standard I/O 

modules from VIPA’s 100V and 

200V control systems. 



www.industrialtechnology.co.uk for further 

details from VIPA 

and surface finish. It is 

assembled and packed in a 

class 100 clean room environment. 

The PURA Plus is designed to 

operate reliably and without any 

maintenance for a minimum of two 

years. Information is output via 

Modbus, with warning and alarm 

status being indicated with a ‘traffic 

light’ status indicator LEDs. Further 

development will add a 4-20 mA 

output to the instrument. 




for further details from Michell Instruments 

Controller 

makes MUSIC 

ABB’s AC 800M controller 

has achieved Mu Security’s 

Industrial Control (MUSIC) 

Foundation-level Certification. The 

recently introduced MUSIC 

certification enables critical 

infrastructure and process controlfocused 

organisations to verify a 

range of network equipment and 

application protocols to meet 

industry-defined best practices for 

security, robustness and resiliency 

testing. Certification 

benchmarking ensures that 

ongoing plant and product safety 

is not compromised by hidden 

implementation flaws in industrial 

control systems. 

Achieving MUSIC certification 

confirms that the AC 800M meets 

industry-defined best practices for 

safety, reliability and security. 

During the evaluation process, the 

AC 800M met or exceeded the 

requirements of MUSIC’s multifaceted 

security and stress tests. 




further details from ABB 



New Products 

Harsh areas no problem 

for these transducers 

For automation systems in 

industries such as pulp and 

paper manufacture, where 

accuracy and absolute position 

measurement are essential, 

then a transducer that can 

operate reliably in harsh 

conditions such as RDP 

Electronics’ DCW can be the 

answer. 

The short-stroke DCW is a truly 

submersible transducer range of 

LVDTs, which measures small 

displacement variations. Designed 

for displacement measurement 

ranges of between ±2.5mm to 

±10mm with the capability of 

operating at pressures up to 10 

bar, alternative electrical 

connection options are available to 

extend the DCW’s pressure 

handling to 206 bar. 

DCW transducers are ideal for a 

broad range of wet and dirty 

conditions including papermaking, 

valve and sluice 

position applications, structure 

monitoring and underwater cable 

laying. The DCW is constructed 

from welded stainless steel and 

offered with either a sprung or 

unguided shaft and suitable for DC- 

DC operation. 

The DCW series is available with 

a 4-20mA (2-wire) option to 

facilitate the use of very long cables. 




for further details from RDP Electronics 

Get your FREE GUIDE 

to sensing technology 

An excellent introduction to pressure, load, force 

and rotary measurement, this 16-page guide also 

highlights the wide product 

range and the capabilities, 

skills and expertise 

of Sensor-Technik. 

I’m Morten Moller, managing director 

of Sensor-Technik UK, with over 25 

years of industry expertise behind me. 

When you deal with Sensor-Technik UK, 

all the advice and support I can give 

you comes as part of 

the package. 

SENSOR-TECHNIK UK 

Unit 10, The Granary 

Mill Road, Sharnbrook 

Beds MK44 1NN 

Tel: 01234 782049 

info@sensor-technik.co.uk 

www.sensor-technik.com 

The CANbus, pressure, force & rotary measurement specialist 



45

MACHINE BUILDING & AUTOMATION 

Industrial PCs 

The choice of PC for 

machine control 

Compared with an office PC, the industrial PC costs 

significantly more – mainly because the production 

quantities are much lower. So why would you use 

an industrial PC over an office PC? This article from 

Lenze suggests a number of very good reasons 

If you need a PC to control the 

automation on your machine, there are 

suppliers offering powerful and flexible 

industrial PCs. The alternative to the 

industrial PC is an office PC which is likely 

to be lower in cost by a factor of two or 

three. Both are capable of machine control 

and comparable in speed of processing, 

memory capacity and software. 

For the machine manufacturer, using 

an office PC can be rather like putting a 

time bomb into your machine. Years into the 

future, the office PC manufacturer will not be able to 

compete with the long term availability assured by the 

maker of the industrial PC. The IPC manufacturer will 

be careful to make infrequent component changes and 

to hold full historical information on those changes. In 

case of any such changes he will strive to achieve 

compatibility. 

This is very different to the situation with office PCs 

where component and design change is frequent. Should 

problems occur in future years, the choice of an IPC 

means that solutions can be easily found, data is 

available and parts are compatible. 

Electromagnetic compatibility 

Designers of industrial PCs are careful to consider EMC 

requirements. This is a two way situation: the IPC 

should not interfere with electrical controls elsewhere on 

the machine, but equally it should be immune to any 

radiated interference from the other electrical controls. 

Typical design standards for EMC are EN50081 and 

EN55022. Furthermore integrity of the installation can 

be improved with an uninterruptible power supply), an 

optional feature but increasingly one that is built in as 

standard on some models. 

A manufacturer of the IPC can customise the 

product to suit application requirements. In the case 

of the hardware, generally low production batches 

mean that operator screens can be customised, for 

example with logos and colours. Keyboards can be 

customised too, for example to suit the alpha/numeric 

standards in other countries or to add switches as for 

emergency stop. 

In addition, software can be customised if required, 

and the IPC can be delivered with software already 

loaded, ready to run. The IPC manufacturer will have 

knowledge of your 

specification, and the company’s service 

and support personnel will be contactable and able to 

offer skilled advice. 

Another significant area where the IPC differs from 

the office PC is in the area of robustness which in turn 

means long term reliability of the computer. For IPCs 

mounted to the outside of the machine, IP65 protection 

is possible and this can also be extended to keyboards. 

The machine may have to run in hot and cold conditions 

with the PC in a panel that is itself warm. IPCs are 

designed to suit a wide range of conditions: for example 

Lenze offers products that can cope with ambient 

temperatures from 0 to 50°C, humidity up to 90% and 

which are suitable for use up to 3,000m above sea level. 

Further environmental considerations 

With the industrial PC, vibration resistance is also 

improved and there are more cable ties and thicker 

circuit tracks. Often the modern IPC will run at very low 

powers and therefore cooling fans can be avoided. 

However if they are needed dust filters will be fitted. 

Choosing an industrial PC above an office PC is all 

about future-proofing your machine. Most machinery is 

going to need service sometime in the future. Having a 

PC of known specification, where repairs and 

replacement can be made, leads to an enhanced 

reputation for the machine manufacturer and the 

retention of customers. 




more stories from Lenze, and other news on machine control 

46 



Ready · Responsive · Capable 

You can expect more from us at Bancroft 

www.bancroft.co.uk 

sales@bancroft.co.uk 

DC Motors and Gearmotors 

Motors to 100w/250mNm 

Gearmotors to 2800 mNm 

Reliability and performance guaranteed 

Available from stock! 

Free technical assistance! 

Free catalogue! 

Just contact us! 


01444 248884 


3rd generation of logic controllers 

More memory: for your applications 

More comfort: largest display on the market 

More modularity: number of inputs/outputs up to 50 

More simplicity for programming: function Blocks/SFC or Ladder language 

Contact us for a free demonstration version of the software ! 

www.millenium3.crouzet.com 

Crouzet Ltd 

Tel. : +44 (0) 1256 318 935/943 

E-mail : info@crouzet.co.uk 

www.crouzet.co.uk 


47


Hydraulics & Pneumatics 

Low cost proportional pressure regulator 

sets new paradigm for pneumatic control 

A new regulator features user-selectable control 

limitation, offset and step response, and combines 

this with industry-leading linearity and sensitivity 

Festo has launched an innovative proportional 

pressure regulator that is set to redefine costperformance 

expectations in pneumatic control. 

The new VPPM proportional pressure regulator 

combines industry-leading performance with unsurpassed 

control flexibility, yet costs just £300 in one-off quantities 

– less than any competitive product on the market today, 

says the company. The regulator provides design 

engineers with an exceptionally easy and precise means of 

varying the flow rate to pneumatic actuators, facilitating 

accurate control of speed, force, pressure and torque. 

Proportional pressure regulators are used extensively 

in the process industries, for diverse applications. 

Typically these include controlling the contact force in 

polishing and friction welding, controlling web tension, 

providing active load cushioning and weight 

compensation, controlling the speed of pneumatic 

motors, and regulating the applied torque of pneumatic 

wrenches. The regulators are also now beginning to be 

used in the leisure and medical engineering industries. 

There are two versions of VPPM regulator; one is 

equipped with an LED display, the other with a backlit 

LCD. Both versions feature an 1/8 inch proportional 

pressure valve, offer a choice of G1/8 or PRS manifold 

connection, and are available with a pressure range of 

0-2 bar, 0-6 bar or 0-10 bar. The 0-10 bar model 

accommodates a flow rate of up to 1400 l/min. By 

employing an innovative cascaded dual-stage regulator 

design – each with its own pressure sensor 

– the VPPM provides an exceptional level of 

control, with coarse and fine adjustment 

facilities. The use of two pressure sensors 

also helps eliminate drifting due to 

temperature fluctuations - regulation is held 

to just ±0.04%/˚K, which is 

unprecedented in this type of product. 

World-class dynamic performance 

The dynamic performance of VPPM pressure regulators is 

world-class. Depending upon the model, they have fullscale 

linearity, repeatability, hysteresis and sensitivity 

figures of ±0.5%, ±0.2%, ±0.3% and ±0.1% 

respectively. The regulators are controlled by industrystandard 

0-10V DC or 4-20mA analogue signals and are 

exceptionally easy to install and commission, with 

diagnostic feedback provided via their front panel 

displays. Both the LED and LCD versions of the regulator 

are equipped with ‘up’, ‘down’ and ‘edit’ front panel 

pushbuttons and offer three preset step response curves 

– any one of which can be selected via the pushbuttons 

– to facilitate fine tuning of the system without the need 

to set up complex PID loops. 

The LCD version features a bright backlit 

alphanumeric display, together with an analogue bargraph, 

and offers a number of extra control and 

monitoring functions. Both the programmed setpoint 

and the actual pressure value can be monitored, and 

users can choose to display pressure units in bar, 

MPa or psi. 

A control limitation function enables the actual 

operating pressure range of the regulator to be 

programmed; this effectively increases control resolution 

by allowing the same full range of analogue control 

signals to control a limited, user-defined range of 

operating pressures. Users can also define an offset value 

to increase accuracy over the required operating range – 

which is particularly useful for applications such as load 

compensation in air spring isolation systems – and can 

lock the regulator using a personal PIN code. 



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

more news on hydraulics and pneumatics 

Rexroth goes light with new control valves 

Rexroth has introduced the ‘light generation’ version of its HF valve series, delivering a 

lighter-weight valve terminal system with impressive flow rates of up to 700 litres/min 

The new HF03-LG valve series from Rexroth has 

a modular design and can be extended up to 

twelve valves, one at a time. It is is ideal for 

applications in which a modular system needs 

to offer both small dimensions and a high flow rate such 

as in automation, machine construction, or the 

automotive industry. The identical base plate for all valve 

functions, the plug-in procedure, and integrated plug 

connections ensure that valve functions can be changed 

quickly and easily without having to disassemble the 

valve terminal system first. This keeps each Rexroth 

HF03 model flexible to accommodate later changes. As 

Rexroth’s HF03-LG can also be used with other standard 

valves in the HF03 series within one unit, it is suitable 

for a wide range of applications. 

Flexible mounting options 

Designed specifically to be lightweight and space-saving, 

the Rexroth HF03-LG weighs even less than the HF03 

standard version thanks to polymer end plates. Forwardfacing 

pneumatic and electric connections create extra 

mounting options while keeping installation dimensions 

compact to suit individual space requirements. The 

system is also flexible in its electric connections since it 

uses the proven electronics found in the Rexroth HF04 

bus module. Whether multiple plug or fieldbus, the 

connection type can be converted at any time without 

having to disassemble the valve terminal system, which 

saves time. 

Compact and robust, Rexroth’s HF03-LG conforms to 

IP65 (NEMA 4) protection class for use in harsh 

environments. All valve functions (2x3/2, 5/2 and 5/3) 

as well as vacuum ejectors and pressure regulators are 

available for the valve terminal system. Separate exhaust 

connections within the valve terminal system enable 

double pressure operation with different pressures. The 

valve terminal system from Rexroth can be mounted 

directly or onto a DIN rail. Adding further versatility to 

the line, it is available with either metric or inch air 

connections. 



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

Rexroth and more news on hydraulics and pneumatics 

48 


Logic element 

combines flexibility 

with performance 

Integrated Hydraulics is now offering a new 

spool-type logic element that combines 

excellent performance with great flexibility. 

This valve can perform a variety of 

functions by using a control cartridge that 

screws into the back of the main cartridge 

Integrated Hydraulics’ cartridge 

valves have excellent characteristics 

and the new LE402 is no 

exception. Careful sleeve and spool 

design give low pressure drops 

preventing excessive amounts of energy 

from being wasted and the close 

tolerancing of the spool and sleeve 

ensures minimal internal leakage. 

The valve is flexible in its 

application and can be used in many 

hydraulic circuits. It can be controlled 

by a number of different pilot 

cartridges, for example screwing a 

small 1 l/min relief into the back of 

the cartridge enables it to function as 

a main 350 bar relief with flows of up 

to 350 l/min, or if you fit a 

proportional pilot relief valve, it 

becomes a high-flow proportional 

relief valve. 

Alternatively, fitting a pilot 

solenoid valve will produce a 350 

l/min electrically operated dump 

valve. This is an added advantage 

when it comes to inventory costs. 

Only one component needs to be 

stored as interchangeable valves can 

then be screwed into the back of it, to 

alter the function. The product is 

compact because the controlling 

cartridge is simply screwed into the 

back end of the main cartridge. 

Machining required to install the 

cartridge is also minimal, as only one 

cavity is required due to the utilisation 

of piggy back valve technology. 

Minimising risk of leaks 

The maximum working pressure on 

the nose is 350 bar and maximum 

tank line pressure is 210 bar, the 

nominal flow rate is 350 l/min. These 

cartridge valves can be fitted into 

standard line bodies or used, with 

other valves required in a system, in 

hydraulic integrated circuits or 

manifold blocks. If the latter option is 

used, the designer can reduce the 

number of joints in the system, 

minimising the possibility of oil leaks, 

concentrate most or all of the valves 

into one self contained, pre-tested 

block both speeding assembly and 

reducing space requirement. 




for further details from Integrated Hydraulics 

Have you ever considered using 

COMBINED ROLLER 

BEARINGS & MATING STEEL 

PROFILES 

to solve heavy-duty motion problems? 

Originally used on forklift trucks, 

EURO-BEARINGS LTD’s combined roller 

bearings can provide a simple and 

versatile solution in a wide variety of 

engineering applications. 

Full supporting technical data 

(including downloadable catalogues) 

on all of our products can be found 

on-line at: 

www.euro-bearings.com 

NEW!! EURO-VEE BEARINGS & RAIL 

**STOCK** 

CHANNELS & BEARINGS 

STOCK 

Euro-Vee bearings provide an excellent 

alternative for linear motion applications in 

harsh environments, with medium accuracy 

requirements and high speed capabilities. 

The T rail has a hardened & polished vee 

edge & can be mounted against any straight 

 

 

www.euro-bearings.com/veebrgs.htm 

EURO-BEARINGS LTD 

Tel: 01908 511733 Fax: 01908 511713 

www.euro-bearings.com 



49


Machinery Safety 

Kevin Ives, a consultant with Pilz Automation 

Technology, explains how a new addition to EN 

1088 makes important recommendations relating to 

the specification and installation of guard interlocks 

Important changes to EN 1088 

guard interlocking standard 

In July 2007 EN 1088:1995 (Safety of machinery. 

Interlocking devices associated with guards. 

Principles for design and selection) was amended by 

the addition of A1:2007. Rather than write a new 

version of EN 1088, CEN has issued amendment A1, 

which relates specifically to section 5.7 of EN 

1088:1995. It can only be used in conjunction with the 

full standard, as there are references to tables and figures 

in that standard. 

Clause 5.7 covers ‘Design to minimise defeat 

possibilities’. Research into the reasons why operators try 

to defeat interlocks has shown that the need to defeat 

safety systems stems from shortcomings in the design of 

the machine. 

Clause 5.7.1 offers advice on the basic specification 

of the safety function. The aim should be to design a 

safety function wherein measures to minimise the 

possibility of defeat are implemented at system level, so 

there is not a total reliance on the interlocking device 

itself. This can include monitoring in the non-safe control 

system. Measures such as forced cyclical testing, status 

indication and time limitations can be programmed to 

supplement the safety system. 

The other main addition is the need to specify the 

interlocking function so that measures for minimising the 

possibilities for defeat are achieved by removing the 

foreseeable reason for attempting to defeat the 

interlocking device. Furthermore, this section goes on to 

define how to combat “defeat in a reasonably foreseeable 

manner”. It should not be possible to defeat an interlock 

with readily available objects such as: 

● Screws, needles sheet metal pieces; 

● Objects in daily use such as keys, coins, adhesive 

tape, string and wire; 

● Spare actuators or spare keys for trapped-key 

interlocking devices; 

● Tools required for the intended use of the machine 

such as screwdrivers, wrenches, Allen keys and pliers. 

The recommendation is to use coded devices or 

individual coded devices (dependant on the results of a 

risk assessment). These could be mechanical, electrical, 

magnetic or optical, used either singly or in 

combination. There is also a recommendation to use 

additional sensors as shown in figure 4 in the main body 

of the standard. 

Clause 5.7.2 defines the types of switches and 

specific requirements. The main addition is the need to 

secure the switches by fastenings that cannot easily be 

removed or loosened. This includes welding, riveting, 

one-way screws, etc. The same is true for tongue-type 

switches and any other switches that have separate 

actuators. The standard suggests that when the gate is 

open, the switch is shielded so that spare actuators can 

not be used. This is achieved by good design of the 

interlock fixings. 

In conclusion, this addition to the standard 

encourages better design of machinery to reduce the 

temptation to defeat safety devices, but it also tightens 

up on the measures to ensure that safety devices are 

more difficult to defeat. 

50 


The new lifeline from Schmersal 

ZQ/ZT900 & S900 

Schmersal has launched a range of pull-wire, emergency-stop switches and wire-tensioning devices for 

safety-oriented applications ranging from conveyors to large and complex machinery and plant. 

The new pull-wire switches are available in two basic versions – the ZQ900 and ZT900. The 

ZQ900 is a safety emergency switch, similar to an emergency stop switch, which fulfils the 

requirements of the new standard BS EN ISO 13850:2006 by latching in the emergencystop 

position if actuated and requiring a manual reset by means of a release button. 

The ZT900 version has non-latching contacts and is suitable for non safety-related 

applications. 

The S900 wire-tensioning device is an innovative and convenient 

feature for bothZQ and ZT ranges that facilitates the installation of both 

pull-wire switches. 

The wire-tensioning device can be used for 

either one or both ends of the actuating wire 

and replaces traditional clamps to increase or 

decrease the tension of the wire by up to 12 cm 

without being twisted. 

Both switch ranges can be equipped with a 

maximum of four contacts and be actuated from 

any point of the wire, while the convenient location 

of the reset button on the ZQ900 allows the 

triggering of the safety function to be monitored, 

even at large distances. 

For further information on the new range call the 

Schmersal customer support centre on 01684 

571980 or visit www.schmersal.co.uk. 

Sparrowhawk Close · Enigma Park · Malvern · Worcs WR14 1GL 

Tel: 01684 571980 · Fax: 01684 560273 

More details: Write in 510 on the free information card www.schmersal.co.uk · support@schmersal.co.uk 51


Machinery Safety 

Enhanced protection is simple 

and cost-effective to implement 

Combining versatility with multicoded 

actuators that provide a high 

degree of protection against 

tampering, the new LS safety position 

switches from Moeller Electric offer a 

simple, efficient and cost-effective way of 

achieving enhanced protection for 

personnel and processes. The LS range 

includes switches with separate actuators, 

door switches with spring or magnetpowered 

retained actuators and switches 

for hasp and hinge operation. 

Offering IP65 ingress protection to 

ensure reliable operation even in harsh 

environments, all switches in the range 

have operating heads that can be rotated 

through 4x90 degrees, giving a wide 

Curtains keep 

hands and 

fingers safe 

With the introduction of a 14mm 

safety protection resolution 

Leuze Mayser has extended the 

application of its sturdy Solid 4E light 

curtain to now include hand and finger 

protection. 

All standard features of other Solid 4E 

safety light curtains have been 

incorporated in this latest Type 4 

development such as two 

adjustable different light 

beam codings that prevent optical crosstalking 

between neighbouring devices and 

maintenance-free operation due to the 

fail-safe OSSD transistor output. Various 

LEDs and a digital display indicate the 

OSSD status, report weak reception signal 

and help make adjustments or quickly 

perform error diagnostics on site. 

The Solid 4E safety light curtain range 

is now available in five standard 

resolutions (14, 20, 30, 40 and 90mm), 

providing an extremely flexible solution for 

hazardous point or area protection. 




more info from Leuze Mayser 

choice of installation options. In addition, 

the switches feature double-break 

contacts that are configured to ensure 

their suitability for use in redundant safety 

circuits. The contacts are interlocked and 

positively driven, as prescribed by IEC/EN 

60947-5-1, and are suitable for use with 

MK Profile Systems has 

developed yet another new 

product within the machinery 

guarding range: a fully 

welded mesh with a 

raster dimension of 40mm x 40mm, and 

with a black powder coated surface. 

The difference between fully welded 

mesh and the woven corrugated mesh 

generally used for this purpose is that it 

is welded at every intersection which 

gives an inherently stiff, stable mat that 

will not skew. A light profile construction 

is all that is required to support it. This 

results in ease of installation short 

assembly time and therefore offers 

significant cost saving for the customer. 

MK offers two fastening possibilities: 

the wedge clamping system and the 

electronic devices, such as programmable 

controllers, in line with the requirements 

of IEC/EN 61131-2. 

Complying with EN 1088, type 

LS4-ZB and LS-ZB safety switches have 

separate non-retained actuators, and are 

ideal for use with gearbox covers, press 

guards and in similar applications. With 

LS4-ZB switches, the actuator can be 

inserted from either side of the operating 

head, which allows horizontal or vertical 

mounting of the switch. 




further details from Moeller Electric 

Protection made light thanks 

to innovative mesh structure 

stable-shaped welded mesh system. With 

the wedge clamping system, during 

installation only four profiles have to be 

cut to size per fence in order to fix the 

welded mesh into position. 




further details from MK Profile Systems 

Switches offer SIL2 approval 

Impress Sensors & Systems is now 

offering a range of temperature 

limiters/controllers, pressure 

transmitters, screw-in transmitters, 

submersible probes and level control 

switches, all with SIL2 approval for 

hazardous environments. 

The new range, is 

targeted at safety and 

hazardous area applications, including 

process manufacturers, chemicals, oil and 

gas, nuclear and Atomic Weapons 

establishments. The devices are also 

suitable for medical device applications. 

Examples within safety related 

systems for mechanical engineering 

include auxiliary disconnected systems; 

and safety interlock and auxiliary 

disconnected systems for machines; 




further details from Impress Sensors & Systems 

AS-i safety 

included in 

Pluto system 

The Pluto AS-i module from 

Jokab Safety combines the 

functions of the traditional 

AS-i master and AS-i safety 

monitor in a 

single module. 

The Pluto AS-i can monitor safety 

nodes as well as control outputs, 

in total up to 31 safe/non-safe 

nodes. It is also possible to use 

Pluto AS-i to monitor a system in 

the traditional way with a 

separate AS-i master. Up to 32 

AS-i Plutos or 

other Pluto 

PLC models 

can be 

connected in 

a network via 

the Pluto 

CAN bus. 

The Pluto 

AS-i module 

can read 

information 

from the other 

Pluto modules 

and their connected safety 

devices on the bus. The entire 

safety system can be programmed 

with the Pluto Manager 

programming tool with predefined 

safety function blocks, available 

in the library. 




further details from Jokab Safety 

Non-contact 

switch offers 

CAT.4 safety 

The new CES-AR-C from 

Euchner makes it possible to 

monitor several safety guards 

at once. Up to 20 devices can be 

included in one switch chain. 

The non-contact safety switch 

CES-AR-C is particularly suitable 

for systems in which a large 

number of safety guards need to 

be monitored. It can also be used 

as a very compact individual 

switch. 




further details from Euchner 

52 


product and service factfinders 

APPLIED AUTOMATION (UK) Ltd 

Concept House, Langage Industrial Estate, Plymouth PL7 5ET 

e-mail: maytec@appliedautomation.co.uk www.maytec-uk.co.uk 

MayTec Profile System 

Applied Automation are the UK distributors for the MayTec 

Profile System used extensively worldwide in the construction of 

machine frames, safety guarding, protective barriers, display 

systems, conveyors and work benches. 

The range offers a comprehensive variety of profile sections 

harmonised with an extensive range of accessories providing a 

functional and aesthetic solution for your application. Our 

experienced team will probably have looked at an application 

similar to yours before; if not then you’re welcome to challenge 

us! 


HEPCOMOTION 

Lowermoor Business Park, Tiverton Way, Tiverton, Devon EX16 6TG 

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

Complete Catalogue of Motion 

Control 

HepcoMotion has put together a catalogue covering its 

complete product range, including linear motion products, 

driven options, circular and continuous motion products and 

machine construction and automation elements. 

HepcoMotion offers a very broad product range which is 

constantly updated based on market need. The company’s objective is to offer solutions to 

satisfy almost any linear motion requirement. 


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 


ROTAFLOW FV Ltd 

Rotec House, Bingswood Trading Estate 

Whaley Bridge, High Peak SK23 7LY 

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

Robust and Durable Swivel 

Joints 

Rotaflow FV Limited manufacture a range of robust and 

durable Swivel Joints which provide 360° movement 

through a clear bore to transfer fluid under pressure 

without leakage from a static position to a moving point – 

ideal for loading arms or removing the twist in hoses. 

Single-flow, and multiport swivel joints available in carbon 

steel and 316 SS. Sizes 1 ⁄4” to 24” nominal bore, with a choice of seals for maximum 

compatibility. 


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. 


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. 


ETA ENCLOSURES (UK) Ltd 

Kea Park Close, Hellaby Industrial Estate, Rotherham S66 8LB 

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. 


JAMES WALKER 

Global Support Centre, 1 Millennium Gate, Westmere Drive, Crewe CW1 6AY, UK 

e-mail: csc@jameswalker.biz www.jameswalker.biz 

New Guide To Global Sealing 

Operations 

The worldwide fluid sealing and materials expertise of 

James Walker Sealing Products & Services is covered in this 

new guide. 

As well as R&D and new technology, it describes the value of 

partnering contracts, e-commerce systems and the 

highly-developed logistics networks that give customers the 

surety of supply they need. 


January 2008 •INDUSTRIAL TECHNOLOGY 

53

EAR TO THE GROUND • Becky Silverton 

becky@itmagazine.uk.com 

Hold on to your hats... 

here comes the science bit 

There was a time, I’m sure, when the 

various plant extracts that were added to 

shampoos were there purely to make our 

hair smell nice. Now, though, we’re 

generally told that these additives actually have 

some hair health benefits – and the more bizarre 

sounding the additive, the more good it’s likely to 

do you. Looking back, I’m amazed that I ever 

managed to survive before my shampoo contained 

either coconut oil or essence of avocado. 

Our ancestors, I gather, used to wash their hair 

in mud, apparently with surprisingly good results. I 

certainly don’t see myself trying 

that in the near future, but I can 

see how the use of mud could 

have been discovered: some 

hapless lass who tripped into a 

muddy puddle, and came out 

annoyed at the accident but 

pleasantly surprised to find that 

her hair felt a little nicer than 

before the trip. And I can see 

how, generations later, it might 

have occurred to someone to add a little scent to a 

hair product to make it smell nice. But who was it 

that, having done everything else one might 

typically do with a coconut or an avocado, suddenly 

looked at it in a new light and began to wonder... 

I don’t know about you, but I’d like to meet that 

man – and it would have to be a man, because no 

sane, self-respecting woman would ever douse her 

hair in avocado as an experiment. The problem here, 

though, is that eventually you begin to run out of 

bizarre ingredients to add to your beauty product to 

differentiate it from the rivals on the market. Luckily, 

when that happens, you can fall back on hard science 

to bolster your marketing efforts. And now could any 

of us imagine buying a hair colourant that didn’t 

contain something as vital as, say, nutrileum? Or, 

come to that, a probiotic yogurt that didn’t contain 

that essential friendly bacteria bifidus digestivum? 

Honestly, it’s all getting a bit ridiculous. 

Now, don’t get me wrong, I’m all for a catchy 

slogan that will tell me what a product does, or a 

novel TLA (three letter acronym) that will help me 

recall a product’s features. It is the marketer’s job 

to translate the features and functional benefits of a 

product into something the audience will appreciate 

and remember. But this insipid creeping of unlikely 

and unsubstantiated ‘science’ into marketing has 

gone beyond a joke. 

You’d think that we, as engineers, would be 

immune to this sort of nonsense in our working 

lives. And yet, as advances in processor technology, 

for example, level the playing field across a huge 

spread of industrial products, I have found that 

even here the marketers are finding it hard to resist 

the temptation of telling us to buckle up ready for 

the science bit. I’m not pointing any fingers, boys; 

you know who you are. But give us a little credit for 

understanding exactly what you’re offering, and find 

some better ways to highlight the functional 

benefits – before we lose patience and spend our 

money elsewhere. 

Industrial Ethernet Training 

January, 2008 

Gosport, Hants 

www.gcna.co.uk 

GarrettCom Europe (0870 3825 777) 

Southern Manufacturing 

February 6-7, 2008 

Farnborough, Hants 

www.industry.co.uk 

ETES (01784 880890) 

Machine Building 


NEC, Birmingham 

www.machinebuilding.co.uk 

Canon Communications (01638 508477) 

Practical Vacuum 



www.practicalvacuum.co.uk 


MTEC 



www.mtecexhibition.co.uk 


MEDTEC UK 



www.devicelink.com 


Midlands Manufacturing 

March 18-19, 2008 

Ricoh Arena, Coventry 

www.industry.co.uk 

ETES (01784 880890) 

Index to Advertisers January 2008 

ABB .................................................... 23 

Abssac ........................................... 38-39 

Aerotech .............................................. 22 

Applied Automation .............................. 46 

Applied Automation .............................. 53 

Astrosyn International ........................... 53 

Bancroft .............................................. 47 

M Barnwell Services ............................. 49 

Bosch Rexroth ...................................... 13 

JG Coates ............................................ 53 

Cognex ................................................ 15 

Control Techniques .......................... 27-30 

Crouzet ............................................... 47 

Drives & Controls................................... 17 

ETA Enclosures .................................... 53 

Euro Bearings ...................................... 49 

Feteris Components BV ......................... 41 

Francis & Francis .................................. 19 

Futek Advanced Sensor Technology ........ 40 

HepcoMotion ....................................... 25 

HepcoMotion ....................................... 53 

Huba .................................................. 41 

Impac Infrared ..................................... 37 

Industrial Gas Springs ........................... 33 

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

Interpower Components .......................... 9 

Albert Jagger ........................................ 33 

JBJ Techniques .................................. OBC 

Jokab Safety ........................................ 13 

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

Lenze ................................................. IBC 

Master Bond ........................................ 33 

Mayr Transmissions .............................. 19 

Metrix Electronics ................................. 10 

Micro-Epsilon ....................................... 44 

Mitsubishi .............................................. 5 

MK Profile Systems ............................... 13 

Moore International ............................... 17 

Murrelektronik ..................................... IFC 

Omron ................................................. 11 

Ondrives .............................................. 25 

Penny & Giles ...................................... 43 

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

RDP Electronics ................................... 43 

Rotaflow .............................................. 53 

Schaeffler ............................................ 21 

Schaeffler ............................................ 53 

Schmersal ........................................... 51 

Sensopart ............................................ 37 

Sensor Technik ..................................... 45 

Sensors UK .......................................... 25 

Sensors UK .......................................... 37 

SKF .................................................... 17 

Spirol Industries ................................... 33 

Spirol Industries ................................... 34 

Springmasters ...................................... 35 

Tapeswitch .......................................... 42 

TFC .................................................... 35 

The West Group ................................... 47 

Variohm .............................................. 41 

James Walker ...................................... 53 

54 


More than just a drive... 

High speed motion control 

The Lenze solution is complete: supervision by 

IPC or Soft PLC, motion controllers plus I/O and 

HMI interfaces. Controlled speed and torque 

from servo drives and servo geared motors. 

More than motion control, Lenze offer 

actuators, screwjacks, couplings and torque limiters 

too. 

Tel: 01234 321321 

www.lenze.co.uk 

Lenze 

ideas in motion

IT Jan 2008 - Industrial Technology Magazine

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