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www.industrialtechnology.co.ukIndustrialTechnologyTHE MAGAZINE FOR PRODUCT DESIGN ENGINEERS AND MACHINE BUILDERSNovember 2010Full speed ahead withFesto’s H HandlerIndustry news p8Sensors & systemsRapid prototyping p12Electric motorsBearings & lubricants p14Machine buildingEnclosures & fans p18Packaging industryFasteners & adhesives p24Machinery frameworksw w w . i n d u s t r i a l t e c h n o l o g y . c o . u kp26p32p38p40p44SPECIAL REPORTRapid prototyping isnow even fasterPage 12

Full speed ahead!Ready-to-install high-speed handling units with an innovative belt drivefacilitate highly dynamic assembly operations. They can be used whereverfast, flexible and inexpensive positioning is requiredNigel DawsonProduct ManagerFixed motors reduce inertiaKeeping the X and Y axis motorsstatic, reduces inertia and thereforeimproves performance. As bothmotors act on a single belt, eachaxis can draw on the performance ofboth motors, therefore increasingperformance even further, givingusers more cycles per minute.Modern production techniquesdemand faster and more flexiblesystems, yet these two parametersare often mutually exclusive.Festo have used their experience inmechanical structures, combinedwith their expertise in motioncontrol to look at handling in adifferent way. Mass and dynamicsare usually inversely proportionalso by reducing mass we gain anincrease in dynamics and thereforea higher productivity in ourcustomers’ machines.This is the guiding principle behindthe single belt H Handler fromFesto, a ready to run 4 axis robotcapable of high speed handling andminimal vibration and shockloading.Robust guidance in a low profilehandlerThe Y axis sits within the X axis onthe H Handler and not on top. Thisreduces the moment loads on there-circulating caged ball bearingguidance and allows even higherdynamics of the system without theneed for overdesigned multi railguidance. This reduces the cost ofthe overall system, making theguidance more cost effective than atraditional Cartesian gantry.Reduced inertia delivers additionaladvantagesReducing the inertia is not onlyabout improving performance.Smaller motors can be used,reducing the cost of the systemeven further. In addition to themotor size, the machine base sizecan be reduced, smaller sectionsused and less material employed,saving manufacturing and shippingcosts for the entire machine.Reduced cable managementimproves reliabilityA major cause of failure in robotsand handing is the failure of cables.High speed movements bend cablesin three dimensions causingpremature failure and machinedowntime. By using a single beltand static motors the cablemanagement requirements in a twoaxis system is halved, thereforereducing the failure probability by50%.Innovative vertical lift androtate unitOf course, it is a fruitless task,reducing the inertia on twohorizontal axis, if you add all thesaved mass onto the vertical axistherefore Festo have developed aninnovative independent lift androtate axis in a compact packagethat reduces the inertia andloadings on the Y axis bearings,increasing performance evenfurther.

Flexible controller for up to 6 axisThe H Handler is not just for simplepick and place tasks. By utilising theFesto CMXR robot controller we cancontrol up to 6 axis with fullyinterpolated control. Applicationslike laser cutting, water cutting andgluing can be performed simply withfull circular and linear interpolationmotion. By utilising standard servodrives from the Festo range,communication is kept simple andcompatibility guaranteed. With a0.5mm path accuracy throughoutthe entire working area, the HHandler is controlled precisely evenwith speeds of 5m/s andaccelerations of 50m/s2.At a glanceKey Features• Maximum dynamics comparedwith all other Cartesian gantrysolutions• Scalable axis combinations foreasy adaptation to anyapplication and for a widerrange of possibilities comparedwith other picker solutions• Reduced moving mass andmaximised dynamics, thanks tostationary motors andintegrated energy supplyconcept• High acceleration in both axialdirections• Optimised use of rectangularworking area• Ready-to-install 2, 3 and 4 axisconfigurationElectric DriveAutomationCommon belt offers compactdimensionsBy utilising a single belt, both the Xand Y axis remain on the sameplane, making the whole handlingsystem extremely compact. Thisreduces overall height, allowingimproved communication and visionin ever complex production lines.Technical data• Acceleration: 50 m/s²• Speed: 5 m/s• Repetition accuracy up to±0.1 mm• Max. stroke: X=2,000 mm,Y=1,250 mm, Z=200 mm,further strokes on request• Max. load: 6 kg (Z-axis, gripperand working load)• Max. working load with optionallinear-rotary module: 0.8 kgSee it in actionVisit our website to see a video ofthe H Handler in action:www.festo.com/gb/hhandlerFesto wins IntersolarAwardHigh-speed H-gantrywins over the expertsFesto has won theIntersolar Award inthe category “PVProduction Technology”at Intersolar Europe inMunich, the world'slargest exhibition ofphotovoltaic and solarthermal products.For more informationcontact us:Festo LtdT: 01252 775057F: 01252 775015E: info_gb@festo.comwww.festo.com/gb/edrives

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COMMENT & ANALYSISIndustrial Technology ISSN 0967-5787 www.industrialtechnology.co.ukEDITORIALEditorMark Simms BSc Tel: 01732 773268mark.simms@itmagazine.uk.comADVERTISINGRegional Director (Home Counties & South East)Mark West Tel: 020 8467 3613mark.west@itmagazine.uk.comRegional Sales Manager (Midlands)David Harman Tel: 0161 374 5615david.harman@itmagazine.uk.comRegional Sales Manager (North of England & Scotland)Jan Anderson Tel: 01978 314730jan.anderson@itmagazine.uk.comDeutschland/Suisse/ÖsterreichEisenacher Medien Tel: +49 228-2499860info@eisenacher-medien.deOverseasGeorge Bennett MA Tel: + 44 161 374 5615it.marketing@itmagazine.uk.comMAILING ADDRESSESPress Releases: mark.simms@itmagazine.uk.comPO Box 342, Tonbridge TN10 4WDAdvertising Copy: production@itmagazine.uk.comHead Office: Victoria House, 2 Mornington RoadSale, Cheshire M33 2DAEmail: it.marketing@itmagazine.uk.comCirculation Department: PO Box 85, Sale M33 2BBEmail: it.circulation@itmagazine.uk.comGENERAL ENQUIRIESEmail: it.info@itmagazine.uk.com Tel: 0161 374 5615As a controlled circulation journal, Industrial Technology is sentfree of charge to individuals in the UK who meet the terms andconditions of the publishers. To apply for free regular copies,write to the Circulation Department. To those not meeting theterms and conditions, the magazine is available on UKsubscription at a cost of £60 per year (10 issues). Single copiesare £7. Overseas subscriptions (airmail) are as follows: Rest ofEurope including Eire £80 (single copies £9); USA $155 (single$18); Elsewhere £90 (single copies £10).Printing & production by Stephens and George Ltd, Merthyr TydfilIndustrialTechnologyWill you please stop theincessant screaming...Staying with some friends over the weekend, I was treated to the full-on X-Factorexperience. I may be showing my age here, but I can’t say it was entirely pleasurable,hearing a host of Elton John songs put to the sword by a succession of artists ofquestionable ability. In fact it was painful in the extreme; but you can’t argue that it’snot highly compelling television. I feel sorry, though, for people of real talent who will probablynever get their moment of fame: I saw a chap busking in Tunbridge Wells the other week whoI reckon had more talent in his little finger than most of the X-Factorcontestants have in their entire bodies. But I’ll put aside these littlegripes about ability, because what really annoyed me about theprogramme was the audience screaming all the way through thesongs and all the way through the judges comments. Regardless ofhow highly you value the judges themselves, the whole point ofhaving them there is to listen to what they’re saying.Talent shows are nothing new. I’m just about old enough toremember the tail end of Opportunity Knocks with Hughie Green, andit’s 1970s rival New Faces. There were revivals of and alternatives tothese shows through the 1980s, but I’m sure the audiences weremuch more restrained. Polite applause through the 1970s, andperhaps a little cheering through the 1980s. Certainly there was the odd sharp intake ofbreath when a panelist delivered a particularly damning verdict. But where, I ask you, has thisincessant screaming come from?Many of today’s biggest and most enduring stars came through these seminal talentcontests. I could point to the likes of Lenny Henry, Victoria Wood, Jim Davidson, Dave Allenand more. Even pre Take That Gary Barlow came to prominence after entering a 1986 BBCCarol Competition. This five-time recipient of the prestigious Ivor Novello Award has since beenvoted the greatest British songwriter of all time. But how many of this year’s X-Factorcontestants will we still be talking about a couple of decades from now – or even a couple ofyears from now.I think I’ve detected a pattern between audience reaction and the real value of the artist. Itseems to me the greater the bluster, the smaller the significance.Now, this is actually quite interesting, because we can extrapolate into real life. Consider,for example, the low carbon economy. Through the old government to the new, when it comesto manufacturing all we seem to hear about is the importance of creating a low carbonmanufacturing base, which could one day support up to 150,000 jobs. But that’s a drop inthe ocean compared with the three million or so jobs that the wider manufacturing basesupports. I’m not saying that the low carbon sector isn’t important – indeed in so many waysit’s absolutely vital. And it’s driving some of the most significant technological developments ofthe moment. But UK manufacturing is about much more than that, and we really need somerecognition from government of the vital contribution the wider manufacturing base makes toGDP and overall economic growth. Or perhaps bluster is the way forward. Instead of a rippleof polite applause each time the ONS stats show how important UK manufacturing really is,maybe it’s time to shout and scream. Deep breath everyone, and after three...Mark SimmsEditormark.simms@itmagazine.uk.comthe difference is onlineeta-enclosures.co.ukSuccessful Growth1999 - 2009innovative enclosure solutions forindustrial & electronic applicationsETA ENCLOSURES (UK) LIMITEDUnit 2, Ignite, Magna Way, Rotherham, S60 1FDt: 01709 386630 f: 01709 369524e: info@eta-enclosures.co.ukw: www.eta-enclosures.co.uk5

4028ContentsIn this issue: Getting more from combined rollerbearings (p12); Poison plastics: do you knowwhat’s under the lid? (p20); Feeling alright?Measuring machinery vibration signatures (p28);Torque motors help reduce energy costs (p32)328 INDUSTRY NEWS8 Positive signs for manufacturing investment10 European shortage of engineers12 Rapid prototyping14 MECHANICAL COMPONENTS Bearings, Slides and Lubricants14 Getting more from combined roller bearings16 Mounting and dismounting large sized bearings18 ELECTRICAL EQUIPMENT Enclosures, Cabinets and Fans18 Intelligent latching solutions boost enclosure security20 Poison plastics: do you know what’s under the lid?22 Enclosures, cabinets and fans: new productsON THE COVERFull speed ahead withFesto’s H handlersee page 2 for detailsCAD ROUNDUPDave Brown with thismonth’s CAD storiesp1224 FASTENERS & ADHESIVES24 Answers on adhesives: dispensing units26 SENSORS & SYSTEMS26 Measuring the rotation angle of large diameter shafts28 Feeling alright? Measuring machinery vibration signatures30 Load sensor gets smart32 DRIVES & CONTROL SYSTEMS Electric Motors32 Torque motors hold the key to reduced energy costs34 Are these the world’s most compact integrated steppers?36 Electric motors: new products38 MACHINE BUILDING & AUTOMATION38 Real-time Ethernet for drives and motion networks40 Vision system ensures carton caps are spot on42 Reaping the benefits of predictive maintenance44 Machinery frameworks, profiles, guards and screensENGINEERING LITERATUREEssential reading fordesign engineers p48ENGINEERING DIARYJohn Richardson’s monthin viewp49EAR TO THE GROUNDBecky Silverton on the issuesaffecting manufacturing p50ALSO IN THIS ISSUE:NetfindersEvents calendarIndex to Advertisersp48p50p50In the next issue of Industrial Technology: Brakes, clutches and couplings • Bearings, slides and lubricants • Sensors andsystems • Fasteners and adhesives •Electric motors • Industrial PCs and HMIs • Energy efficiency and environmentally friendly design6

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INDUSTRY NEWSwww.industrialtechnology.co.ukPositive signs for investmentin manufacturing technologiesThe past six-months has seen investment stabilise or increase inmanufacturing technologies according to the latest survey fromthe Manufacturing Technologies Association (MTA)Looking forward over the next six months, 35% ofrespondents to a new MTA survey indicatedinvestment would be higher or much higher incomparison to the previous six months, and only5% said investment would be lower or much lower –hinting at a positive start for 2011. These results indicatethat after a reduction in spending during 2009 and into2010, businesses are looking to invest more to helpreinvigorate the sector over the next two quarters.The September survey also showed a high level ofinquiries, and consequently business confidence,following a seasonal dip over July and August. Althoughinvoiced sales were unchangedcompared to the August results, themajority of respondents reported amonth-on-month increase in ordersin September. Employment resultswere also positive in Septemberwith almost 20% of respondentsreporting an increase in the numberof people they employ, extendingthe run of this positive balance inemployment to three months.The CBI’s latest QuarterlyIndustrial Trends Survey alsoreflects this growing confidence, highlighting that themanufacturing sector expects a solid rise in output overthe next three months, driven by predictions for astronger increase in export orders. Of the 420manufacturers that responded to the Quarterly IndustrialTrends Survey, 32% expect a rise in output volumes, and14% a fall, giving a balance of +18%. This follows afigure of +9% for the last three months.This is primarily driven by expectations of a fasterincrease in exports in the coming quarter, with a balanceof +15% expecting volumes of export orders to rise.Domestic order growth is more subdued with a balanceof +2% expecting an increase. Looking ahead to the nextquarter, the volume of total new orders is expected togrow to a balance of +12%, similar to the +11%recorded for the past three months.The expected predictions of strong output growthfollow a slightly softer patch over the past three months,as the temporary boost to second-quarter output from theturn in the stock cycle faded. Stockbuilding will have lessof an impact going forward. In the coming quarter 14%expect stocks of finished goods to increase, while 18%said they would fall, giving a balance of -4%, comparedto a balance of +3% for the three months to October.Following four consecutive quarters of rising optimism,overall business sentiment was little changed on threemonths ago. The survey showed that 24% ofmanufacturers said that they were more optimistic thanthe past quarter, and 23% said they were less so, givinga rounded balance of +2%.Employment and investment trends in themanufacturing sector are positive. Employment saw thegreatest rise since January 1989 with a balance of +6%of firms saying that they had taken on new staff. Inaddition, investment intentions for the coming year havestrengthened further. Manufacturers said they plan tospend more on plant and machinery over the year ahead:a balance of +10% said that they would increase capitalexpenditure in this area, with investment plans at theirstrongest since July 1997 (+21%). Furthermore, fewermanufacturers (41%) think uncertainty about demandwill limit their investment plans over the next 12 months.This is the lowest figure since January 2008 (41%) andcompares with 54% for the previous quarter.Manufacturers’ profit margins were squeezed furtheras costs rose by more than prices. Average unit costsclimbed particularly sharply for the third successivequarter, with 36% saying that they increased, and 8%saying that they fell, giving a rounded balance of +29%.This is the highest figure since October 2008 (+56%).But prices were raised only very slightly: the balance foraverage domestic prices was +3%, and +5% for exportprices. Ian McCafferty, the CBI’s Chief Economic Adviser,says: “The recovery in the manufacturing sector is wellgrounded and looks set to continue, despite a soft patchlast quarter, when production growth slowed as firms hadexpected. Over the next three months, firms predict astrong rise in output driven by predictions of firmer exportorders growth, while support from stockbuilding fades.“It is particularly encouraging that firms have taken onmore staff and plan to invest more in plant andmachinery in the year ahead. However, cost pressuresshow no sign of receding, driven by higher commodityprices and import costs. This is putting increasing strainon manufacturers’ profit margins, given that costs are notbeing fully passed on as higher prices.”Looking ahead, credit or finance is seen as aconstraint to output growth over the next quarter by 9%of manufacturers, compared with 3% in July. This hasrisen for the first time since January and is back above itslong-run average (4%).The latest ONS figures gave further reason foroptimism, with good news for manufacturing and ahigher than expected Q3 GDP. But with a word of caution,Graeme Allison, Head of Manufacturing, Transport andLogistics, Barclays Corporate, says: “There remains thepotential for further challenges ahead, and an ongoinglack of manufacturing investment in comparison to keyinternational competitors looks set to keep UKmanufacturing well behind the global curve.”david.b@atlas.co.uk8INDUSTRIAL TECHNOLOGY • November 2010

INDUSTRY NEWSAre we heading forEuropean shortageof engineers?A potential shortage of trained engineers hasbeen confirmed through independent researchby the European Federation of NationalEngineering Associations (FEANI)FEANI has identified that whilsta potential shortage ofengineers varies from countryto country, it seems that in Europe asa whole the number of studentsenrolling in science and engineeringcourses is simply not high enough tosatisfy industry’s current needs.Dave Westbury, engineering andtechnical services manager at SMC inthe UK says: “We are reallyconcerned for the industry that theseresearch findings indicate a reductionof young people selecting engineeringfor their future career.”In view of the need for moreengineers in Europe, FEANI is nowconsidering undertaking a mediafocusedrepositioning campaign tomake European engineering moreattractive to students usingcommunication messages such as,“Engineers Make A World OfDifference” and “Engineers HelpShape The Future”. With a new EU2020 Strategy to help promote andaddress this recruitment problem,FEANI has already confirmed that theemphasis will be to strongly linkengineering and engineers toinnovation.Westbury concludes: “Weapplaud the use of thiscommunications campaign by FEANIto help change the misconceptionsthat some students may have aboutengineering. As an organisation thatdevelops around 40-50 new orupdated products each year andbrings the latest developments inautomation technology to Europeanstudents through our InternationalTraining Division we also firmlybelieve that both innovation andengineering are inextricably linked.”SMC, which credits its continuedsuccess in Europe to its engineeringstrength, remains firmly committed tohaving the largest fully trainedtechnical sales teams in theirelectro/pneumatic industry sector.www.smcpneumatics.co.ukRS introduces its ownrange of quality productsRS Components (RS) hasintroduced its own range ofproducts, ‘RS Essentials’,designed to deliver major costreductions without ever compromisingon quality. RS has always providedthe widest range of products,competitive pricing and industryleadingservice. Now it has put allthis into its own wide range ofproducts across key technologies. ‘RSEssentials’ offers more choice withcost savings when compared to theleading brands.Over the years, RS has learned alot from its customers and has builtup a vast knowledge-base of whatthey need to operate efficiently andwhat they expect from the productsthey buy. It is this knowledge,together with keeping pace withtechnological developments, whichhas enabled RS to create its hugeown-brand range combining bestvalue with best quality. The ‘RSEssentials’ range comprises over30,000 products.‘RS Essentials’ products providereal value for money. Prices areregularly checked so that they stayahead, and in these difficult timeswhen margins are squeezed, RS saysthat choosing ‘RS Essentials’ will savecustomers money. On average, ‘RSEssentials’ are 20% cheaper thanmanufacturer prices, with some itemsoffering even greater savings.http://rswww.com10INDUSTRIAL TECHNOLOGY • November 2010

www.industrialtechnology.co.ukParker and Brammer’sstrategic partnershipParker Hannifin and Brammerhave signed a strategic pan-European partnershipagreement, which is designed toextend considerably the level ofsupport and product availability thatboth companies offer to customersthroughout the fluid power sector.Initially covering fifteen countriesand targeting growth in key MROmarkets, the new agreement willprovide guaranteed supply of Parkerpneumatic, hydraulic, filtration andinstrumentation components andsystems to key accounts and endusers, in industries includingmanufacturing, process, transport,construction and logistics.Charly Saulnier, Parker HannifinEMEA President, explains: “Thepartnership will enable us to benefitfrom Brammer’s internationalexpertise in commodity managementfor multi-national companies, whilegiving Brammer fast access to ourextensive portfolio of fluid powertechnologies.www.brammer.biz, www.parker.comEaton’s hydraulics helpfree the Chilean minersJust dry it...We have the rightcomponent dryingsolution for yourbusiness.Several of Eaton’s hydraulicproducts were at work on therescue of the 33 miners whohad been trapped more than half amile underground in the San JoséMine in Copiapó, Chile. Eaton‘s Char-Lynn low-speed motors, Eaton andVickers piston pumps, Vickerssectional valves, and Aeroquip hoseand fittings are strung head-to-toe onthe high-powered T130XD hydraulicdrills rig made by Schramm.The T130XD drill rig widened theshaft that was drilled as anevacuation route for the miners. ASchramm T685 drill rig, alsoequipped with Eaton products,drilled the initial bore hole thatlocated the miners, who hadbeen trapped since August 5,when the main mine shaftcollapsed. Eaton’sproducts wereperforming hoist liftand lowering functions on theT130XD drill. The evacuation shaftwas first widened by approximately12 inches and then an additional 14inches as it tunneled its way some2,300 feet (700 meters) belowground.The two Eaton-equipped drill rigswere being used by area Chileancontractors for mining, energy,geothermal and water drilling whenthey were called to duty to help savelives in the mine disaster – withperfect results in the endThe drilling progress was muchfaster than initially expected, and therescue took place after 69 days onOctober 13th. Schramm hadequipment and service personnelon site at the northernChilean copper and goldmine to help in anyway possible.www.eaton.comACI Airknife Drying Solutions are the efficient and costeffective method for surface drying applications.ACI is a leading manufacturer of industrial air movement productsand Airknives are a proven tool wherever elimination of surfacewater is required. For a FREE ON-SITE demonstration, or paybackanalysis please contact us.Find out more at:www.aircontrolindustries.comAir Control Industries LtdWeycroft AvenueMillwey Industrial EstateAxminster Devon EX13 5HUUnited KingdomT: +44(0)845 5000 501F: +44(0)845 5000 502E: sales@aircontrolindustries.comAir Control IndustriesNovember 2010 • INDUSTRIAL TECHNOLOGY11

DAVE BROWN’SCAD ROUNDUPComputer aided design, engineering and manufacturingRapid prototyping hasnow got even fasterWant a part made from one of the Iglidurrange of materials from Igus? Well, chooseyour material and you could have mouldedparts within 24 hours. And the same processcan also provide the essential bridge toolingyou need to take you through to productionof up to a few thousand partsPolymer specialist Igus hasdeveloped a new toolingmethod for injectionmoulding which can getcustom designed parts delivered inless than 24 hours. As there are nominimum order quantities, Speedigusis suitable for one offs, prototyping,low volumes and bridge tooling.“Standard tool manufacture cantake 4-8 weeks and is normally onlyavailable for minimum orders ofaround 5,000 pieces,” says MattAldridge of Igus UK. “But, withSpeedigus you can get a single partin just one day. All we need is therequired quantity and a 3D CAD fileof the part.”Igus currently manufacturesSpeedigus parts in eight commonIglidur materials (Iglidur G, J, W300,X, M250, P, A180 and H2) as well asStandard tool manufacture can take4-8 weeks with minimum orders ofaround 5,000 parts. But with Speedigus“you can get a single part in 24 hours”Igumid G, the Igus E-Chain material;the designer selects the material bestsuited to the application, using thesimple online selection tool:www.igus.co.uk/speedigusAs Iglidur materials aremaintenance- and lubricant-free, longlasting and have a low coefficient offriction, the majority of Speedigusparts manufactured to date arecustom design components that havea bearing function.“Because Speedigus usesstandard Igus materials, the Igususeful service life calculationprogram is still valid,” addsAldridge. However, engineers canalso draw upon other featuresand benefits of Iglidur materials,such as the combination of lightweight with electrical conductivity,chemical resistance or hightemperatures. The Igumid E-Chainmaterial additionally offers designpossibilities for structural parts, suchas brackets, side plate or covers.Ideal for orders up to a fewthousand parts, prototypes or one-offsSpeedigus can accommodate partsthat fit into an envelope up to 475 x750 x 200mm, with wall thicknessesdown to 0.5mm. All that is requiredfor a quotation is a 3D CAD file,preferably a STEP file, and therequired quantity.Standard Speedigus tooling leadtime is fifteen days from placement oforder, but parts can be produced in aslittle as 24 hours. Every Speedigusquotation comes with full technicalcomponent information including leadtime options. Tooling charges for thespeedigus systems start from £1000and unit costs are from just 10 pence.As part of this service Speediguscustom tooling is kept for repeat ordersas and when required. If productionshould move to high volumes, thenigus manufacture a standardproduction tool, and unit costs thenreduce considerably.www.igus.co.uk/speedigusVacuum casting formedical lightingBrandon Medical has teamed upwith Laser Prototypes to producethe latest in its range ofinnovative medical lighting. TheHD LED Quasar lighting systemhas been designed by BrandonMedical with production of finalproduct parts facilitated throughthe partnership between thesetwo companies. To overcome thechallenge of producing these highvalue lights in low volumes,Brandon Medical turned to rapidprototyping bureau LaserPrototypes for assistance.Laser Prototypes suggestedvacuum casting as the idealsolution to reducing productioncosts without compromising onlead times or part quality.Through the use of VacuumCasting, Laser Prototypes wereable to ship high qualityproduction parts in days, allowingBrandon Medical to meet clientlead times while eliminating theneed to hold large volumes of lowvalue stock.www.laserproto.com3D technologies fordesign and printingA1 Technologies has been busydemonstrating the advantages ofits complete portfolio of low-cost3D digital technologies for everystage of the design, engineeringand production life-cycle. Withthe advent of the Chameleon, 3Ddesign, and therefore 3D printing,are now available to, and usableby, everyone. The Chameleon 3D‘haptic’ modelling applicationfrom delivers a high quality,immersive 3D design experienceto its users for only £495.Chameleon combines 3Dmodelling software, with a touchenabling(haptic) device and issuitable for modeling andconstructing 3D objects.Completed models can be directlyprinted on the RapMan and BfB3000 3D printers.www.a1-tech.co.uk12INDUSTRIAL TECHNOLOGY • November 2010

Make more of Industrial Technologywith our Quick Links enquiry serviceThe eagle-eyed among you will by nowhave noticed that the enquiry numbersenquiry numbers we used to run at theend of each story and each advertisementhave been replaced instead by a web addressfor the company. So does that mean we’vescrapped our ‘more information’ service?Not a bit of it. Instead, what we can nowoffer you is a vastly improved service –a‘more information’ system for the 21st Century,that better reflects the way you tell us you liketo work. We’ve moved to a vastly improvedonline enquiry service.Visit www.industrialtechnology.co.uk andclick on ‘advertisers’, and you’ll find everyadvertisment in this issue of the magazine,with the option to view a PDF of each ad. Andwith one is an array of further informationoptions, allowing you to go straight to thesupplier’s website, request a phone call fromthe supplier, request for information to beemailed to you, or ask for information to beposted to you.You can also forward the information to acolleague. The same is true of the stories inthe issue: click on ‘new products’ and you’llfind a list of all the stories in the current issue,with the same options to request moreinformation.Those of you who’ve registered emailaddresses with us will also receive a ‘QuickLinks’ email, listing all the advertisers in thisissue, and giving you all the same ‘moreinformation’ options, plus the ability to quicklyview a PDF of the relevant advert. What weAdvertisers in the November 2010issue of Industrial Technologycan offer, then, is a complete one-clickenquiry service. We hope that this is a serviceyou will find useful, and which will provide agreat help as you look to source theinformation that will give your designs andsystems a competitive edge.www.industrialtechnology.co.ukNovember 2010 • INDUSTRIAL TECHNOLOGY13

MECHANICAL COMPONENTSBearings & LubricantsGetting more fromcombined roller bearingsWhat is a combined roller bearing, and what sorts of problemsdoes it solve. We asked the experts at Euro-Bearings for theanswers, and for advice on the many uses to which combinedroller bearings and mating steel profiles can be putThe combined roller bearing is an inherentlysimple product, and yet it is a fundamentalmechanical solution that solves a number ofproblems in demanding applications. When alittle imagination is applied to combined roller bearingsand their mating profiles, then high performance linearguidance systems can be quickly developed to meet theneeds of many diverse industries and environments.So just what is a combined roller bearing? It comprisesa cylindrical roller bearing – a ‘maximum capacity’ type(ie full of steel rollers and without a cage to separatethem) – as part of a non-separable design which rotateson a weldable steel hub, known as the radial roller. Insidethe hub and set at 90º to the radial roller is anotherbearing – a needle roller, again of ‘max capacity’ type.This is the axial roller. Both bearings are sealed with ahybrid rubber/metal seals.These products can solve many heavy duty linearguidance problems in a diverse range of industries andenvironments, carrying loads from tens of kilos up tohundreds of tonnes.Simple mountingTo use the combined roller bearing, a hole the same sizeas the spigot on the rear of the hub is drilled or milled ina steel member. The hub is then welded into place, fillingthe 45º weld fillet around the circumference of the spigotwith weld. An optional mounting plate is available thatallows the user to pre-weld the bearing to the plate andthen attach the plate using bolt and nut through clearanceholes or machine screws into the threaded holes in theplate. In use the combined roller bearing engages in a Cor H section profiled steel section. The radial rollerengages on the flanges of the profiled section and theaxial roller engages on the web of the profiled section.These sections are much thicker and heavier in sectionthan ‘standard’ beams or columns. The profile is formedto exactly match the bearing outer profile.This system has a number of performanceadvantages. It can be used both vertically and horizonally,and will accept cantilevered loads and telescopes.Further, the design means that operation in even theharshest of environments is not a problem. Mostimportantly, when designing a heavy duty sliding systemit is very unlikely that the radial bearing will crab or lockin its steel section because any twisting action isimmediately counteracted by the axial bearing runninginto and along the web. Because bearings are cylindricaland needle roller types they immediately want to rotateunder dynamic load.Heavy duty applicationsCrabbing has traditionally been an issue in heavy dutyapplications across a range of industries, and engineershave struggled with means to combat the problem. Forexample, truck manufacturers have been aware for manyyears that there was a tendency within the mast for thebearings they were using to crab. This meant that themast bearing would actually skid or crab or even, in theworst cases, lock in the mast channel. To get around this,many fork truck manufacturers used a second ‘side loadroller’ bearing to prevent that from happening. Thecombined roller bearing simply brings this solution intoone unit by combining the main load carrier (radialbearing) with the anti-twist bearing (axialbearing).This provides an inherently simplersolution which, combined with the simplemounting, effectively ‘engineers out’ manyoperations required in mounting a bearingas a track roller.Although there is very little truckmanufacturing still carried out in the UK,there are numerous areas of industry wherethese combined roller bearings and steelprofiles are being used and providingperformance advantages. Many find theirway into specialised handling equipment,with one example being the special liftmechanism created to lift the 50 tonne wingof the A380. Massive Jumbo bearings andspecial welded and profiled rails were usedto achieve this. At the other end of the spectrum, aproduction engineer can use four small combinedbearings and two of the smallest steel profiles to create alow cost slide to move a workpiece from one machine tothe next.Wide ranging applicationsThe range of applications where these products are foundis almost limitless. They have successfully solvedengineering problems in oil drilling and explorationequipment, and in marine cable and pipe layingequipment. They also provide good solutions in the likes ofpalletisers, goods lifts, vehicle lifts, test rigs, manufacturedconcrete and aggregate conveyors and other materialshandling equipment tasks. They have been used in avariety of theatre and film applications, for example forlighting gantries. Their precision has made them attractivefor medical equipment, while their ability to operatereliably in demanding environments has made them agood choice for furnace chargers/dischargers and for brickmaking. In vehicle applications, combined roller bearingsanswer th needs of agricultural equipment, trailers,specialised vehicles, fork truck attachments and fleetsupport. In short, this really is one of those products wherethe designer’s imagination is the only limit to its use.Euro-Bearings has a small but very experienced teamwho can assist in developing ideas that use thisversatile products. And they love a challenge.www.euro-bearings.com14INDUSTRIAL TECHNOLOGY • November 2010

PARTNERSHIP BASED ON TRUST –AND TRUST BASED ON QUALITY.Total Quality by NSK: Premium technology for the beverage industry.Fully automated processes, strict hygiene regulations and operating conditions such as cold, heat andmoisture – call for bearings which will withstand these extreme conditions and facilitate cost-effectiveproduction processes. NSK bearings for the food and beverage industry are robust and corrosion-resistantthanks to their stainless steel construction and are characterised by extremely long lubrication life. The specialsolid lubricant Molded Oil TM is designed for use in hygiene-sensitive areas and guarantees long service life.These bearings are self contained and their oil lubrication is provided by the NSKMolded Oil TM system which also reduces the risk of oil leakage.More about NSK at www.nskeurope.com or call us on +44 (0) 1636 605123Molded Oil TM BearingsNSKUKLtd · Northern Road, Newark, Nottinghamshire, NG24 2JF · Telephone +44 (0) 1636 605123 · Fax +44 (0) 1636 643075 · info-uk@nsk.com

Looking for aHEAVY DUTYLinearMotion System?Combined Roller Bearings EURO-BEARINGS LTDTel 01908 511733 Fax 01908 511713www.euro-bearings.com17

ELECTRICAL EQUIPMENT & DESIGNEnclosures, Cabinets and FansIntelligent latching solutionsboost enclosure securityA conventional lock might keep undesirables out of your enclosure, but suppose you need a higherlevel of integrity; something a bit more sophisticated with a higher degree of monitoring capability?In many enclosure applications, physical security is amajor concern. Access control therefore plays a vitalrole in their design, construction and implementation.With increasing quantities of business-criticalhardware being deployed into enclosures, controlling andrestricting access to enclosures is a growing issue.A key element in enhancing security – and addingvalue to enclosure design through access control features– is the selection of reliable, intelligent latching systems.The right access control solution will also help reducecosts through energy efficiency and improve product andsystem reliability. Equally important is the selection ofaccess hardware which can be connected to existingsoftware to enable control and monitoring – such as whohas gained access and, when.Ulrike Sturman, Industry Marketing Manager forDiversified Technologies at Southco, explains: “With allthese vital issues to consider, it is no wonder thatcompanies are looking to collaborate with specialistpartners like Southco when it comes to actual accesshardware. At Southco, we have combined our expertise inengineered access solutions with innovative electroniclatching and access for the ultimate in intelligent, secure,ergonomic access control.”Southco provides a variety of electronic accesssolutions devices to suit application needs – from simplestandalone keypads and electronic keys to RF-based proxreaders and RF remote control systems. The company isadamant that its electronic latching technology offers theone of the best solutions in the market place, primarilyachieved by the operation of an electro-mechanicallatching system through a gear motor which makes itmore reliable and less-energy consuming.At the heart of the Southco offering is its flagship H3-EM Swinghandle – an electronic locking swing handlewith an eye-catching blue LED status indicator providingthe intelligent local and remote functionality of a manuallatching system with the addedbenefit of electronic locking andunlocking. The modular designaccommodates single or multipointlatching with a low power,gear motor driven lock mechanismand high security DIN lock manualoverride. The lock directlyintegrates with industry standard rack monitoring / accesscontrol systems and integrated sensors detect both lockedand latched status.Other key electronic access solutions (EAS) developedby Southco to meet increasing physical security andaccess demands include the push-to-close R4-EMelectronic rotary latch – enabling the convenience ofelectronic access control with the security of a proven, allmetalrotary latch design in a compact integrated package– and the EM-10 electronic keeper. This ‘next-generation’access control solution provides the convenience ofelectronic access and push-to-close operation in one unit.Its low installed cost, compact design and versatileinstallation options make it an easy, affordable solution fornew or retrofit enclosure applications.All Southco electronic access solutions provide anelectronic ‘signature’ each time the lock is actuated.Combined with a unique input credential, the system canprovide the necessary output to enclosure control andmonitoring systems. Each product has been designed asa drop-in replacement for existing mechanical latches.www.southco.com18INDUSTRIAL TECHNOLOGY • November 2010

Die-cast enclosureis sealed to IP66The latest addition to theextensive selection of diecastenclosures fromHammond Electronics is the1550Z family, a range of thick wall(3 to 4mm depending on size) IP66sealed boxes for use in applicationswhere impact protection andenvironmental sealing are primaryrequirements.The 18 industry-standard sizes inthe family range from 50x45x30mmto 223x147x83mm, and asstandard they are supplied in eithernatural with a smooth vibra-finish orin a tough black polyester powdercoated finish. Economically priced,the units offer outstanding value formoney, achieved by multi-impressiontools and automated machining andfinishing during manufacture.Environmental sealing is achievedthrough a combination of a tongueand groove construction and a preformedone-piece silicone rubbergasket; to ensure the integrity of theseal, the fixing screws are outsidethe gasket area. Depending on thesize, the lid is secured with two, fouror six stainless steel machine screwsgoing in to factory-tapped holes toaid repeated opening and closingwww.hammondmfg.com19

ELECTRICAL EQUIPMENT & DESIGNEnclosures, Cabinets and FansPoison plastics: do youwhat’s under the lid?While EU legislation has long banned the use of halogens such as polybrominated biphenyl(PBB) and polybromilated diphenyl ether (PBDE) as flame retardants in plastics and otherproducts, the halogen problem is a long way from being over. Chris Lloyd, of Spelsberg els UKdiscusses some of the issues and dangers that all specifiers of enclosures should be aware ofEvery year, in Europe alone, fire leaves more than4,500 people dead and 40,000 severely injured,with economic damage estimated to cost €25billion. We can see, then, the importance ofeffective fire retardants to inhibit the combustion process.The flame retardants themselves, though, have comeunder increasing scrutiny in recent years, with growingconcerns over the impact of these chemicals on healthand the environment. The earliest flame retardants,polychlorinated biphenyls (PCBs) were banned in 1977when it was discovered that they were toxic. Industriesshifted to using brominated flame retardants, mostnotably polybrominated biphenyl (BPP) andpolybrominated diphenyl ether (PBDE), but these, too,were found to be extremely harmful.Bromine is one of the halogen family of elements ingroup VII of the periodic table, which includes fluorine,iodine, chlorine and astatine – all naturally occurringelements, frequently combined with other elements toform the salts group. But halides, when they burn, releasehighly toxic dioxins, a group of chemicals known toincrease the likelihood of cancer, as well as increasing thelikelihood of reproductive, developmental and immuneproblems. And they cause problems with recyclability.At their peak, bromine based flame retardants wereapplied to 2.5 million tons of polymers annually, with theannual consumption of PBDEs being in excess of 40,000metric tons. Research in Sweden from the late 1990srevealed that PBDEs were accumulating in breast milk,while studies in the USA showed that nearly allAmericans tested had trace levels of flame retardants intheir bodies. Action had to be taken, and in the EU theintroduction of the RoHS regulations and the WEEEdirective banned the use of these most commonly usedflame retardants.Fortunately from a fire prevention sense, newformulations of plastics were quickly brought to marketthat offered effective flame retardant properties withoutthe use of harmful halogens. As an example, thehalogen-free duraplastic used within Spelsberg’s WKseries enclosures can withstand temperatures up to700°C, does not burn after UL 94 V-0, and is glow wireproof to VDE 0471.Prevalence of PVCSo have we seen the end of the halogen problem?Unfortunately, these hazardous compounds are still verymuch a feature of our daily lives, most notably in polyvinylchloride, or PVC as it is better known. Second only topolyethylene in the prevalence of its use in plasticsproduction and consumption, PVC is used in an enormousrange of consumer and industrial products, many ofwhich tend to have short service lifespans, exacerbatingthe problem. Vinyl chloride is one of the most toxic of thehalides. The circulatory, nervous and immune systemscan all be affected, with exposure over a long durationleading to the development of a number of life-threateningdiseases, including liver cancer, brain cancer, lung cancerand angiosarcoma.PVC causes health and environmental problemsthroughout its lifecycle, from manufacturing throughconsumption to disposal. The production of PVC requiresthe use of highly polluting chlorine and cancer-causingvinyl chloride monomer (VCM). The best efforts ofmanufacturers do not seem to be able to contain thesecompounds: residents of the town of Mossville, Louisiana,USA which hosts a vinyl chloride chemical facility werefound to have levels of dioxins in their blood that werethree times higher than normal.In product use, dioxins can bleed into the atmospherefrom PVC products as they are broken down by UV light,building the potential for health problems. And then thereare the dioxin emissions from the millions of annual firesthat burn buildings, vehicles and consumer products – allmajor applications for PVC. But it is perhaps in thedisposal of these products where the problems reallyaccumulate. PVC disposal represents the largest source ofdioxin-forming chlorine. PVC is difficult to recycle:20INDUSTRIAL TECHNOLOGY • November 2010

knowbecause there are so many different formulations of PVC,there is no generic process to separate the PVC into itsoriginal formulation for recycling. And when PVC productsare mixed with the recycling of non-chlorinated plastics,they contaminate the entire recycling process. Introducingjust one PVC bottle into the recycling process couldcontaminate 100,000 bottles, rendering the entireplastics stock unusable.PVCs in landfillIncineration is no solution, since burning forms dioxinsthat are released into the air or disposed of on land asash. As a result, most PVC products end up in landfill. Atthis point, many of the other chemicals and additivesused in the manufacture of PVC find their way into theenvironment causing further contamination.Governments and industry are taking action toeliminate PVC. The Danish and Swedish governments arerestricting PVC use, hundreds of communities worldwideare eliminating PVC in buildings, and leading companieshave committed to eliminating PVC from their products.Spelsberg is among them, building its market leadingsranges of enclosures from plastics such as polyethylene,polypropylene, polycarbonate and polystyrene. The costand performance of these alternative compounds all buteliminates the need for PVC, completely removing healthrisks while dramatically improving the overall recyclabilityat the end of life of products.With plastics so diverse in their applications and soprevalent in our daily lives, the regulations that controltheir use are becoming steadily tighter, focusing on airquality, end-of-life, toxic substances and fire safety. ForPVC, a tightening of the regulations surely cannot comefast enough. For its part, Spelsberg is committed to a PVCfreeenvironment, and is confident in its ability to meet anyuser application requirement for enclosures with any of anumber of other innovative, high performance, costeffective, and completely safe compounds.www.spelsberg.co.ukNovember 2010 • INDUSTRIAL TECHNOLOGY21

ELECTRICAL EQUIPMENT & DESIGNEnclosures, Cabinets and FansTechnically advanced productsfrom a new strategic partnerThe innovative Industrilas hardware range isnow available in the UK through Albert JaggerIn an effort to help build on areputation for product diversity andto meet increasing market demandfor technically advanced products,Midlands based distributor Albert Jaggerhas announced the appointment of anew supply chain partner, Industrilas.Albert Jagger will not only offer localstock for this extensive product rangebut also technical support andconsultancy services in applications forthese innovative products.A Swedish based company whichspecialise in the production of a diverserange of integrated industrial hardware,Industrilas products include IP ratedswing handles, latching systems, hingesand sealing technology for a wide rangeof applications. Among the products onoffer are the Vision range of swinghandles, rod latch systems and hingesfor enclosures, data cabinets and forelectrical engineering, the Klima-flexrange of handles, locks and hinges forinsulated doors in HVAC equipment andclimate control units, and the Vectorrange of locking T-handles withcompression function designedspecifically for vehicles and dieselgenerators.With extensive in-housemanufacturing facilities, Industrilas hasover 30,000 different components inproduction, and can customise theproduct to match your exact need,including providing a full range ofindustrial surface treatments. Even thestandard programme includes a widevariety of products that can beassembled in a modular system tocreate a high level of customisationoptions.Industrilas combines quality, designand function in technically advancedproducts that are guaranteed to workunder the most demanding industrialenvironments. Looking for a UK agent,Industrilas turned to Albert Jagger onthe strengths of its nationwide salesnetwork, significant centraliseddistribution facilities, next day deliveryservice and in-house technical expertise.Albert Jagger will act as much morethan just a UK stockist for Industrilas.Rather it will operate as the UK arm ofthe company, providing a high level oftechnical support. Sales Director JohnWollaston comments: “Industrilasprovides an extensive range of hardwareproducts that have been designed tosolve numerous design problems. Theseinnovative products offer a number offeatures that are new to the UK andwhich will address many of the issuesthat engineers have with traditionalcabinet hardware options.”A full range of 3D CAD models areavailable for easy integration into designdevelopment, as is a comprehensivecatalogue listing the full range ofstandard stock components.www.albert-jagger.co.ukExtruded PCB enclosuresTEKO has launched the ‘TEKAM’range of aluminium instrumentcases. These modern and robustenclosures have been designed for fastinstallation of slide-in PCB assemblies.The all aluminium design provides goodlevels of EMC protection.Typical applications will includehandheld test and measurement devicesand radio control equipment, plus wallmounted monitoring systems, securitydevices and building control equipment.Each enclosure consists of anextruded case body with two die castend panels assembled by self-tappingscrews. The case extrusion includesinternal guide rails for the PCBs.www.teko.co.uk/tekamClevises offerlong service lifeNew from ETA Enclosurescomes the CS Compact rangewhich offers the customer thechoice to use the product as either awall-mounted or free-standingenclosure system. A large opening inthe base enables easy cablemanagement and the range comes asstandard with an interior cable baseplate, internal door rails and threepoint door latching with a knife-edgegasket ensuring optimum sealing.Now available from UK stock insingle and double door options therange covers twelve popular sizes from600x1200x400mm to1200x1400x400mm which arepainted in a heavy duty polyesterpowder RAL7035 finish. Completewith fitted mounting plate theseenclosures are delivered wooden palletmounted for ease of factory floormovement.The CS Compact range issupported by a host of accessoriessuch as plinth bases, wall fixingbrackets, internal mounting rails,lifting eyes and ETA’s machiningprogramme can add holes, cut-outs,and special paint colours to thecustomers specific demands in aquicker than 3 weeks turn round.www.eta-enclosures.co.ukWant more information aboutsomething you’ve read in this issue.Just Click on ‘Current issue’ atwww.industrialtechnology.co.uk22INDUSTRIAL TECHNOLOGY • November 2010

Enclosures, Cabinets and FansELECTRICAL EQUIPMENT & DESIGNThermoelectriccooler functionsas heater, tooLast year Rittal launched itsnew award winningthermoelectric cooling unit intothe market. With a 100W coolingcapacity and only weighing 3kg it isclaimed as the lightest and mostefficient thermoelectric cooling unitavailable.As it does not use any refrigerantor compressors, it provides anexcellent low vibration, lowmaintenance compact solution thatstill maintains air separation for harshenvironments, ideal for HMI panelsand small enclosures.Rittal has now taken this a stepfurther adding an additional heatingfunction in addition to the coolingfunction. The unit automaticallyNew applications for unseentechnology of sealing sectionsWhere would engineers be without the ubiquitous and highly adaptivesealing profile? Now EMKA has found this translated to a trend formany new applicationsSealing profiles are the unsungheroes of cabinet sealing,vibration damping, dustexclusion, safety gap fillers andventilating management. EMKA says ithas excellent visibility of the sealingrequirements presently demanded, andit is from this perspective that thecompany has greatly expanded therange of sealing profiles offered withinits program since this type of materialcontinues to find an ever-increasingrange of applications across traditionalcontrol cabinets, through commercialvehicles to railway rolling stock, intospecialist disability equipment, healthand safety, security and monitoringarenas.The EMKA gasket program nowincludes in excess of 500 sections withor without spring clip mounting spinefor environmental sealing, equipmentprotection or personnel exclusion.Profiles in neoprene, epdm, PVC, blacknitrate and natural rubber covertraditional expanded closed cell (selfadhesive)foam, through wiping bladeand bubble or P type sections, to morecomplex multi-functional and customdesigns.This changing role is indicated byincreasing requirements forcompression locks and up to IP65sealing. The EMKA sealing profilesincorporate a large number of stocksections and an extensive customproduction capability. Many profiles areavailable as simple mouldings, but it isalso possible to have sections mouldedonto spring carriers even in smallcustom quantities.Profiles include wiping designs,fillers and flocked weather strips andsupported sections with internal orflange structural support. Specialistconsiderations regarding shorehardness, tensile strength, recoilelasticity, abrasion resistance andclimatic/chemical resistance can alsobe advised upon and allowed for incustom production.www.emka.co.ukClip fit rod guides speed assemblyswitches between heating and coolingto maintain precise temperatureconditions of ±1K if required.An easy to use software packagehas also been included in the boxwith a USB lead to allow the user tomonitor and set a number ofparameters from a laptop or PC.The unit has an optional supply of24V DC or 100V to 240V AC50/60Hz and an operatingtemperature range of –20°C to +55°C(DC +60°C).www.rittal.co.ukFDB Panel Fittings has introduced a new clip fit guide forround locking rod systems to complement the flat rodversion recently introduced. This round-rod-guide will suitall those panel builders using the traditional and cheaper roundrod systems, while speeding assembly. Such multi-point rodmechanisms are common in larger cabinets from 1200mm toover 2m in height where they optimise clamping of doorgaskets.These quick fit rod guides require no tools and offer zerodefectassembly with correct fitment being audibly confirmed.In addition, rattling of the rods (often a problem in oldersystems) is virtually eliminated by the internal spring elementsof the guides.www.fdb.co.ukThe Ultimate incustomisedenclosuresFor further informationplease contact:tel: 01642 604 400email: sales@fibox.co.ukweb: www.fibox.comNovember 2010 • INDUSTRIAL TECHNOLOGY23

INDUSTRIAL TECHNOLOGY Q&A...ANSWERS ON ADHESIVESWe continue our series of articles on engineering adhesivesand with the help of Henkel, manufacturer of Loctite brandproducts, we turn our attention to dispensing unitsAre there cost efficiencies to be made byusing dispensing equipment? Without adoubt – and the savings and benefits are notlimited to cost. The use of applicationequipment can ensure that only the required amount ofproduct is dispensed for each specific situation. Thisalone can mean that savings of up to 50 per cent –when compared to manual application – can beachieved. Other efficiencies revolve around the factthat more throughput can be achieved by employingautomated dispensing. In many cases, dispensingequipment can apply a product to a joint at the rate ofone unit every two seconds. Furthermore, theapplication of product is precise – thus cutting downon reworking. It’s also worth mentioning thatapplication equipment means a cleaner – and safer –working environment.Presumably, there are standard, off the shelf,dispensing units, but can equipment be designed tomeet specific purposes? Yes! Although mostmanufacturers offer a standard range that will fulfilmany requirements, there will be tasks that necessitatea dispensing unit to be made for a specific application.Clearly, custom-built equipment is created to ensurethe application is completed in the most effective waythat is possible.What are the factors that need to be consideredregarding dispensing equipment? There are fourfundamental issues – adhesive type and viscosity,dispense pattern, production targets and the degree towhich automation can be incorporated into themanufacturing procedure. When it comes toadhesive types, it will be obvious that single partadhesives demand quite different requirements to dualcomponent products that require mixing before orduring application. Anaerobics – those adhesives thatcure on metal surfaces when deprived of oxygen – callfor equipment which, quite clearly, incorporates nometal. In addition, the adhesive must be dispensedfrom a container that allows the presence of some air.Premature curingTo prevent premature curing, ultra-violet curingadhesives must be dispensed from a container andthrough tubing that restricts natural light.When it comes to viscosity, the key factor iswhether the adhesive is a liquid or paste. That willdetermine the type of equipment required.The dispense pattern can embrace single andmultiple spots, linear beads and the uniform coating ofthe inside of bores. For spots – where their size can beanything from 0.01ml upwards – metering theadhesive is crucial for effective application. In suchcases, equipment that includes such a device isessential. At the other end of the sizescale, products such as gasket sealantsare most effectively dispensed by highpressurepumps capable of‘tracing’ around a specifiedprofile. Such units are usually connected to ananthropomorphic or a Cartesian robot. Where theadhesive needs to be applied to the bore of a circularcomponent – engine core plugs are one example –arotaspray configuration can be utilised.The final consideration involves production targets.The decision to employ automation will frequently bedictated by production volumes – the larger thethroughput, the more justification there is for capitalexpenditure. That means the application equipmenthas to provide payback in terms of quality andfinancial returns.Just how does dispensing equipment work? Thereare several different principles involved. Probably themost common involves pressure/time technology. Thisis a method of dispensing liquid materials using airpressure for a specific period of time to force theadhesive, sealant or gasketing material through adispensing needle. Typically, a syringe or pressure potis used as the reservoir for the liquid material.Another involves peristaltic pumps – a technologythat has been employed in hospitals to control blood orliquid flow, but which is also applied to adhesivedispensing. This is where rotating wheel pinches andreleases a tube carrying adhesive from the reservoir tothe dispensing nozzle. The speed at which the camrotates can be adjusted and this, in turn, regulates theamount of adhesive. A foot or finger switch on thedispensing nozzle controls when the adhesive isapplied.This occasional Q&A series will continue withfurther questions and answers on key technologies. Ifyou have any specific queries about adhesives, pleasedirect them to adhesives@techie.com and we’ll do ourbest to provide answers in future issues of themagazine.www.loctite.co.uk24INDUSTRIAL TECHNOLOGY • November 2010

SENSORS & SYSTEMSEncodersMeasuring the rotation angleof large diameter shaftsTraditional rotary encoders can be readily fitted toshaft diameters of less than 2in, but what happens ifyour design needs a much larger diameter shaft orbore? Mark Howard of Zettlex describes the traditionalapproach and a new, more accurate approachThere are many devices for measuring shaft angle.Potentiometers, resolvers and optical encodersare the most common. Potentiometers offer asimple, low cost solution but are not suitable forharsh environments or continuous rotation. Resolvers arereliable even in tough conditions, but high cost. Opticalencoders are not as robust as resolvers but are widelyavailable and keenly priced. There are many types ofoptical encoder; the most popular have a small (typicallyless than 1/2in diameter) input shaft with incrementalpulse or absolute digital output. Through shaft versionsare available but the bore is usually limited to less than2in. Above this, encoder prices increase dramatically andavailability dwindles.So how do you measure the angle of a large diameterthrough shaft of, say, 3in or larger? Traditionally, a smallersecondary shaft is used and its motion geared to thelarger primary shaft. In other words, the angle of theprimary is measured indirectly from the angle of thesecondary. Since the secondary shaft is usually small,there is a wide choice of rotary encoders and mechanicalmounting is easy. But there are accuracy and reliabilityproblems with this indirect approach, particularly if therequired measurement accuracy is less than 1 degree.Inaccuracy comes from the number of factors in theindirect system’s tolerance stack up. For a system coupledFactors affecting indirect system accuracy1. Encoder measurement accuracy2. Encoder thermal coefficients – ie drift in the encoder’soutput due to temperature3. Differential thermal expansion in gears, shafts, bearings,mounts, etc4. Gear backlash5. Gear Wear6. Concentricity of gears on shafts7. Gear train/tooth strain versus torque8. Shaft concentricity9. Variation of gear position with shock or vibration10. Tolerance on gear tooth position around the pitch circles11. Tolerance on primary and secondary shaft centre distance12. Variation in shaft centre distance – due to load or bearingclearances13. Variations in lubrication – due to amount, type and thermaleffects14. Mechanical friction – especially stiction at lowspeeds/torque15. Effect of foreign matter on gear teeth surfaces16. Twist due to torque in shafts17. Shaft bending due to side loadingby gears, the key factors arelisted in the table opposite.Each of these effects alone isprobably not a major influenceon accuracy. The problemarises because all theseeffects stack together.Experience shows that factors1, 2, 3, 5 and 10 are largerthan most engineers expect.A common misconceptionin factor 1 is that an encoderwith 1,000 counts perrevolution is accurate to1/1000th of a revolution. Ifyou read the small print in the encoder specification, itsoon becomes clear that resolution is not the same asaccuracy. Also, any accuracy calculations should accountfor thermal coefficients and thermal expansion/contractionat the temperature extremes.Gear tooth position toleranceFactor 9 is notable, as this is often overlooked. A typicaldesign approach is that if the primary gear has 100 teethand the secondary gear has 10 teeth, then – because thegears are coupled (ie cannot jump a tooth) – when theprimary rotates once the secondary gear rotates 10 times.This part is true, but when the primary gear rotates0.37125 times, the secondary will not have rotatedexactly 3.7125 times. This is because there is a toleranceon gear teeth position around the gear’s pitch circle. Thiswill cause a periodic non-linearity. In other words,inaccuracy. Depending on how good the gears are, thesecondary will have rotated 3.7125 ±0.1000 times.As regards reliability, most engineers know that thereliability of any mechanical system is proportional to thenumber of parts in it – especially moving parts. Gear,pulley or chain systems are susceptible to foreign matter– especially in a large reduction gear train. This can oftenbe overlooked by engineers who expect their equipmentwill always be operated within the specified envelope andall servicing will be done by diligent, skilled personnelwho always replace baffles and seals.Experience shows this is wishful thinking. Foreignmatter often arises from unexpected, sometimes bizarre,conditions. Examples of foreign matter to consider aredust, sand, mud, rain, snow, ice, hail, condensation,insects, rodents, rodent waste, mould, fungus, roguemechanical tools, rogue mechanical fasteners, swarf(from original production), particles (from wear), coffee(from accidental spillage), cola, pollen, air-borne seeds,vegetation, water residue, smoke/cordite residue, insectfaeces/secretions, snails, worms, brake/clutch dust, hair,textile fibres. Far fetched? In my experience, unexpectedforeign matter is to be expected. Recently, a CCTV had amajor product recall after their housings became the idealplace for wasps to build their nests. Dead bees, bits ofhoneycomb, larvae, honey, pollen and bee waste willdefeat a gear and optical encoder system.As a general rule, if the position of an object is to bemeasured accurately then the measurement should bemade at, or close to, the object. Measuring shaft angledirectly simplifies the system and reduces the tolerancestack up. The result is improved accuracy and reliability.So why doesn’t everyone use direct measurement? Thereason is that, until recently, large bore rotary encoderswere disproportionately expensive, delicate and difficult tofit. Ring style optical encoders have been around for yearsbut are expensive, bulky, need careful installation and areprone to failure with foreign matter. Similarly, large boreresolvers have been around for many years but their price,complex electrical supply/signal processing and bulkmake them unsuitable for most mainstream applications.New generation inductive devices enable a simple,effective and accurate way to measure the angle of largediameter shafts. These devices work on similar principlesto contactless resolvers and are just as reliable in harshconditions. Rather than wire spools or windings they useprinted, laminar windings. This enables a low profile,annular encoder ideally suited to large diameter shafts.The electrical interface is simple due to on-boardelectronics – DC voltage in; absolute digital data out. Themechanical arrangement of these new generation devicesis simple and eradicates all gearing. The result is asimple, compact, lightweight, low inertia, accurateand reliable solution.www.zettlex.com26INDUSTRIAL TECHNOLOGY • November 2010

Cylinder sensors workover wide voltage rangeControls using AC voltagesare still not uncommon, sowhen position indication isneeded on pneumaticcylinders but feedback is 110V, asolution is at hand in the form of theMR range, from IFM Electronic.The MR range has many morefeatures than just the operatingvoltage of course; the simplicity offitting them cannot be overemphasised.If the cylinder has aT-shaped slot, the sensor just dropsin and a twist of the fastening discsecures it. If there is a tie-rod oranother cylinder form, not a problem:IFM supplies many adapters forcommon cylinder types.The insert moulding techniqueused to manufacture the MR range ofreed switches renders themextremely robust mechanically andalso absolutely sealed againstmoisture ingress. LED indication isstandard, and in-line connectors areoffered. Operating voltage of thesetwo-wire devices range from 5 to120V AC or DC (limted to 50V AC or60V DC in the connector versions)which on DC will switch PNP orNPN.IFM is committed to workingclosely with its customers to developproducts which precisely match theirneeds, and the company providesexpert, readily accessible technicalsupport to help users maximise thebenefits they gain from IFM products.www.ifm.com/uk27

SENSORS & SYSTEMSVibration SensorsFeeling alright?Changes in a machine’s vibration signature tend to provideone of the earliest indications that something is wearing oris likely to fail. Andy Anthony, Operations Director withMonitran, provides an introduction to vibration sensorsAs we all know, times are still difficult; and forthose involved in manufacturing and processing,surviving (let alone prospering) often requiresmaintaining existing machinery and equipmentin favour of spending out on new. Essential to the wellbeingof the machinery and equipment is of course thehealth of their respective drives, motors, gears, pumps,fans and so on. Thankfully, monitoring the condition ofthese components, either on a regular or continuousbasis, allows for the detection of the early signs of failure.Moreover, data captured can feed into a conditionbasedpredictive maintenance (CBPM) strategy; apractical, cost-effective alternative to both failure-basedmaintenance and conducting maintenance on a periodicbasis irrespective of machine use.As for which conditions to monitor, temperature andpower consumption are obvious contenders, but bothhave drawbacks. Some faults can manifest themselveswithout a change in temperature, and monitoring powerconsumption may not tell you where the fault is. Forexample, a motor may start drawing more power becausea gearbox, drive shaft or other mechanical componentdown line is failing, while the motor itself is mechanicallysound. Accordingly, it is now widely accepted within theengineering community that vibration – or rather changesMost accelerometers are piezoelectric devices, comprising amass bonded to a piezoelectric crystal that produces an electricalcharge proportional to acceleration. Most also include conditioningcircuitry to provide different types of output at different sensitivitiesfor a wide range of applications.Size matters......or rather ‘sizing’ does. It is important tomake the best use of a sensor’s output(voltage or current, depending on sensortype) range, and to do that you need toknow what vibration levels it willexperience. Fortunately there are anumber of portable handheld vibrationmeters on the market. Using one will notonly enable you to select a sensor with asuitable sensitivity but it’s also an easymeans of identifying the vibration hotspotson your machineryin a machine’s vibration signature –provides one of the earliest indicationsthat something is wearing or is likely tofail in some way. Moreover, analysis ofthe vibration signature can provide much intelligenceregarding the nature of the fault that is developing.Protection and analysisAt the risk of taking you back to your school-day physics,and experiments involving toy cars and tickertape, it is worthrecapping on how vibrations are essentially displacementsoccurring over, typically, short periods of time; and a movingsurface/object does so with velocity and that the rate ofchange of velocity is of course acceleration. More often thannot, vibration sensors are called accelerometers, even if theirinternal circuitry is conditioning velocity and the outputvoltage is proportional to mm/s.There are essentially two types of vibration sensor, thosewith DC outputs and those with AC. The former are bestsuited to ‘machine protection’ as they produce an outputproportional to velocity or acceleration, in the range 4-20mA, and so are ideal for interfacing with PLCs or similarmonitoring/shut-down circuitry. Most general purposesensors will have a frequency response of about 2Hz to1kHz. Various sensitivity ranges will be available and youshould select one that makes the best use of the 4 to 20mAoutput. For example, 0 to 20mm/s is common for a velocitysensor and 0 to 10g (RMS) is typical for an accelerometer.To identify the optimum sensitivity range you need todetermine what the normal levels of vibration are anddecide at what levels alarms should be raised and/ormachinery shut down. However, you will probably need tofactor in machinery start-up vibrations; which maytemporarily exceed your alarm and even (presumablyhigher) automatic shutdown levels. You can do this in yourPLC or custom control circuitry, but it’s worth noting thatthere are now some very clever vibration switch modules onthe market that have dual outputs (one for an alarm andone to trigger a shutdown) and which can ignore the firstfew seconds worth of vibrations (ie start-up).As for sensors with AC outputs, they are best suited toanalysis, as the output (which tends to be proportional toacceleration rather than velocity) can be fed into an FFTanalyser to yield information on the amplitude and structureof the vibration. Compared to DC output sensors, thesetend to have a slightly wider frequency response (0.8kHz to12kHz) and operate between ±80g. They will require aconstant current source, of just a few milliamps, and mightbe able to output between ±8V.Different sensitivities will be available, so again it is acase of deciding how best to make use of the sensor’soutput. If levels of ±80g will be experienced then, asensitivity of 100mV/g will give you a full output swing. Butif ±8g is the maximum the sensor will ever be exposed to,why stick with 100mV/g? You’d only see a voltage swing of±0.8V. At 1V/g sensitivity though, the ±8g is representedacross the full ±8V range.Importantly, vibration sensors need to be fit-for-purpose,as they could be protecting equipment worth severalthousands of pounds. Thankfully, the majority of generalpurpose vibration sensors will suffice for many seemingly‘novel’ applications; it just requires a sensible approach tosensor selection. In addition to selecting the optimumsensitivity, give thought to operating temperature ranges,sealing and hazardous environments. There are also a hostof mounting and wiring considerations.As for what constitutes a ‘special purpose’ sensor, thismight be one capable of operating at up to a few hundreddegrees Centigrade, or provide higher sensitivity thannormal. Other ‘specials’ include charge outputaccelerometers, dual output devices for combined analysisand monitoring, devices which measure acceleration andtemperature, tri-axial sensors and seismic accelerometers.And when standard and even special purpose sensorsdon’t seem to quite fit the bill, it is worth rememberingthat a number of sensor OEMs offer a full custom designservice. Indeed, truth be known, it is through developingcustom sensors that off-the-shelf special purpose onescame into being.www.monitran.com28INDUSTRIAL TECHNOLOGY • November 2010

Amplifiers designedfor wet environmentsWith low outputvoltage from atransducer it isfrequentlyessential to provide signalamplification close by toensure good noise immunity.When this also happens to bein a wet environment thenRDP Electronics’ S7 amplifierseries supplied in rugged diecastaluminium housings withcable glands and seals rated toIP65 meet this environmentalprotection need and provideseffective electrical screening.RDP’s S7 amplifiers contain allthe necessary circuitry for transducerexcitation, zero and scale adjustmentand amplification with a choice ofvoltage and current outputs.Designed for use with RDP’sextensive range of LVDT and HalfBridge displacement sensors, theS7AC DC powered version forexample is easy to set up andcalibrate, having a gain of 500 in 8steps, with ‘fine’ control and abandwidth of 500Hz. Alsoincorporated is an ‘over-range’indicator which warns if thedemodulator input exceeds the linearrange.The output can be configured forBipolar or Unipolar operation havinga maximum of ±10V or4-20mA, using a choice of DC or230/115V AC power supply voltages.www.rdpe.comLOW COSTCAPACITIVESENSORS for......ACCELERATIONRange ±1g to ±1000gHigh outputBody weight 3.5 grammes...INCLINATIONRange ±1º to ±80ºResolution from 0.001ºIntegrated electronicsAnalogue or digital outputsWe offer low cost OEMsolutions formeasurement problemson many applicationsincluding vehicles,buildings, seismic, processmachines, cranes, bridges,mining, safety, etc.Sensors UK Limited137a Hatfield Road, St. Albans AL1 4LZTel: 01727 841692 Fax: 01727 844272www.sensorsuk.comCAP1

SENSORS & SYSTEMSNew ProductsLoad sensor gets smartA smart load sensor developed in the UK by SensorTechnology provides all the information needed tooptimise efficiency and increase profitability of awide range of industrial operationsAnew development from SensorTechnology allows weighingprocesses to be fully integratedwith handling operations. Alllive data is captured in real time and canbe transferred to a database, stored,totalised and analysed. For instance, youmay need to know how much materialyou have transported, or you could behandling two or more materialssimultaneously which need to beaccounted individually; or if working formultiple customers at the same time youcan bill each appropriately.The development, called LoadSense,is an intelligent load sensor that can beintegrated with a crane hook, fork lift orother handling device. It has an on-boardsingle-chip computer for recording,analysing and archiving readings, andwireless communications capability whichcan transfer data in real time to a hostcomputer. Designed and manufactured byBanbury-based Sensor Technology,internal batteries make LoadSense’soperation completely autonomous. Assuch it can be deployed with minimaldisruption to operations, and willautomatically begin transmitting data. Nospecial training is required to install oroperate the unit.LoadSense is built around anintelligent load sensor, a hand-helddisplay and a receiver. The load sensor isbased on proven strain gauge technology,and is calibrated as standard in the range1-5 tonnes, with other ranges availableon request. The transmitter (operating onan unrestricted 2.4GHz waveband),enables accurate load data to be sent tothe display, a full colour, TFT touchscreencomputer, running the familiar WindowsXP and LabVIEW. The display providesreal time measure of the load, while thecomputer records and processes real-timevalues.Wide ranging applicationsSensor Technology’s Tony Inghamexplains: “Our main markets are materialshandling and warehouse operations,where the intelligence will convert rawdata into instant stock counts. We havealready had enquiries about raisingnuclear fuels rods, monitoring windowcleaners’ cradles on high rise buildingsand winching and weighing buildingmaterials.”Theatre stage hands could lift andlower scenery from the wings rather thanfrom a remote control room. UsingLoadSense with a tractor-mounted winch,you could assess roadside trees’susceptibility to wind speed. Forapplications involving liquid discharge, asystem could be configured to monitorand control flow.”LoadSense could be wirelesslyintegrated into a SCADA or ManufacturingEnterprise Systems control system,producing instant operating reports and e-mailable customer bills. It also improvesoperating safety because operators arefree to remove themselves fromdangerous locations.www.sensors.co.ukVersatile and high quality load cellsZEMIC, one of the largest sensor and transducer manufacturers in the world,offers a complete range of load cells through Variohm EuroSensorAs one of the largest sensor andtransducer manufacturers in theworld, ZEMIC load cells arecharacterised by high quality,versatility and competitive pricing. TheAsian based manufacturer produces itsown wide range and also suppliesbranded products for the European andAmerican load cell market. As itsexclusive UK distributor, and with overthirty years experience in weighingsystems, Variohm EuroSensor providescomplete technical and full servicesupport across the comprehensive ZEMICrange; with stock delivery andprofessional consultancy available forstandard load cells and customiseddesigns alike.The ZEMIC load cell range coverssingle point or platform cells,compression cells, S-type, shear beamand dual shear beam as well as spoketype designs with complete weighingassemblies, junction boxes andtransmitters available forinstallation convenience. Loadcapacities from a few hundredgrams to over 500 Tons areavailable for applications aswide ranging as pricing scalesto weighbridge platforms andfrom in-vehicle weighingsystems to hopper scales.Construction materials includestainless steel, plated alloy steel andanodised aluminium with protectionclasses from IP65 to full IP68, and withaccuracy up to 4000 divisions. OIMLapproved load cells with R60 ‘legal-fortrade’versions are fully available.For extreme application areas such aswash down and hazardous environments,ZEMIC’s new BM6G series single pointload cell has all-stainless constructionwith IP69K rating, OIML-R60 approvaland C3 class accuracy. With cornercorrection to fit platform sizes up to 800x 800mm and for off-centre loads from100 to 500kg, the BM6G is aimed atfood industry weighing applications wherecleaning by high pressure water jet isessential. Other approvals availableinclude EMC and ATEX.www.variohm.comLaser scannerfor welding atup to 500°CSensors UK Ltd are pleasedto announce the new M2-iLAN laser scanner for usein welding, motion control andinspection applications with anoperating temperature of 500°C.The M2-iLAN has a 100Hzscan rate while surface reflectionsand variations in colour do noteffect the qualityof surface recognition. Avariety of interfaces areavailable including LAN, PLC,Serial, etc, which allows for easyset up and control of theapplication.The MelTrax software givesvarious algorithms to providecontrol outputs for motion controlof automated equipment.Applications include seamtracking, height, width, angle, andslope while also checking theseam for shape, holes, pores,stability etc.www.cognex.com/8000Thermostatssealed againstcondensationFor anti-condensationapplications and accuratetemperature control, nothingcompetes commercially ortechnically with the Matsuo rangeof thermostats from ATC Semitec.Their unique twin-bimetal systemcreates a control that is capableof switching over a million cycleswith minimal drift.They are totally sealed fromthe outside environment with anIP64 rated PBT housing and areeasily incorporated into traceheatingsystems. Available downto -10°C with accuracies to±1.5K and differentials down to3±1K, very accurate, long-termcontrol can be guaranteed using aMatsuo thermostat, suiting themto use in isolated areas wheremaintenance costs would be high.www.atcsemitec.co.uk30INDUSTRIAL TECHNOLOGY • November 2010

Gravity referencedservo inclinometerSherborne Sensors announcesthe T935 series, highprecision closed loop gravityreferenced servoinclinometers designed for use wherespace is limited. The fully selfcontained units are available inranges from ±1° to ±90° withresolutions down to 0.1 arc seconds.Typical applications are found inbore hole mapping, structural healthmonitoring, antenna aiming andother high precision applications. Therugged, fluid filled unit can also bestacked to provide dual axis x and ymeasurements. The servo sensorshave been designed for ruggedapplications and are able towithstand 1500g of mechanicalshock with an operable temperaturerange of –18°C to +70°C.Mike Baker, Managing Director ofSherborne Sensors says; “We aredelighted to build upon thecontinuous improvements across ourproduct range with the release of ournew T935 series. This unit showsfurther enhancements over the T435series after listening to ourcustomers’ feedback.”Sherborne Sensors can customiseall of its inclinometers’ designs toconform to specific customerrequirements.www.sherbornesensors.comGet your FREE GUIDEto sensing technologyAn excellent introduction to pressure, load, forceand rotary measurement, this 16-page guide alsohighlights the wide productrange and the capabilities,skills and expertiseof Sensor-Technik.I’m Morten Moller, managing directorof Sensor-Technik UK, with over 25years of industry expertise behind me.When you deal with Sensor-Technik UK,all the advice and support I can giveyou comes as part ofthe package.SENSOR-TECHNIK UKUnit 10, The GranaryMill Road, SharnbrookBeds MK44 1NNTel: 01234 782049info@sensor-technik.co.ukwww.sensor-technik.comThe CANbus, pressure, force & rotary measurement specialist31

DRIVES, MOTORS & CONTROLSElectric MotorsTorque motors hold keyto reduced energy costsWith plastics extruders and injection moulding companieslooking to reduce energy usage, minimise maintenance costsand boost productivity, the role of the direct drive torque motoris coming to the fore. Andy Parker-Bates of Parker SSD DrivesDivision explains how the technology differs from conventionalmotors, and explores the benefits it can bringThey’re known by many names – torque motors,direct drive motors, drum motors, framelessmotors – and often they are thought of as a newtechnology that needs to be more proven beforeit becomes a mainstay of industrial automation. So justwhat are torque motors? First off, it’s worth making thepoint that this is not an unproven technology. It is a newtake on existing brushless servomotor technology that hasbeen around for decades, and is amongst the mostreliable technologies available. In short, a torque motor isa rotary brushless servomotor optimised for low speedoperation, typically in the order of 50-500rpm. It is adirect drive solution, so there is no need for mechanicaltransmission elements such as gearboxes.There are two different kinds of torque motors. Thereis the more traditional looking motor with frame, coolingsystem, terminal box and feedback sensor, and then thereis is the so-called drum motor – a frameless motor madeup of two independent elements (rotor and stator)intended to be tightly integrated into the mechanics of theapplication. Typical applications for the frameless versioninclude semiconductor manufacture and machine tools,while the framed version meets the needs of applicationssuch as paper machines, crushers, extruders and injectionmoulding machines. In specific applications such asplastics extruders and injection moulding machines, at atime when end users are looking to reduce operatingcosts, through betterenergy utilisation andlower maintenancerequirements, torquemotors can offersignificant advantages.For starters, a direct drive solution is inherently moreenergy efficient than a motor/gearbox combination. Evena good motor/gearbox combination may be only 80%efficient. Old DC motors and gearboxes will be worse still.Additionally, traditional motor/gearbox solutions will alsooften require belts and pulleys as part of the drive train,further reducing efficiency.Torque motors, by contrast, improve in efficiency atlighter loads. Thus the direct drive torque motor can easilybe between 5% and 10% more efficient than amotor/gearbox combination. Replacing a hydraulic motorto drive the screw on an injection moulding machine, thetorque motor could easily offer energy savings in excess of20%, and deliver higher productivity and clean operation,without the need for fluid changes or risk of fluid leakage.Use of a torque motor also slashes maintenance costs,firstly because it is an inherently low maintenancetechnology and also because there no additional drivetrain components to wear. Also, without the need for all ofthese ancillary components, torque motor systems arequicker and easier to install: having to install and alignmultiple motors, gearboxes, belts and pulleys onsomething like an extruder is a process that can takedays. By contrast, installing the corresponding number oftorque motors can be achieved in just a few hours.Torque motors are a low noise, low vibration option.The European Noise Directive 2003/10/CE sets themaximum recommended noise level exposure limits foroperators in order to protect against health and safetyrisks, and sets a maximum noise exposure limit of 87dBA.Above 80dBA, special protective measures must betaken. In a conventional motor/gearbox set-up, just thegearbox alone can often be producing above 90dBA. Thetorque motor, in contrast, is an inherently quiettechnology, producing below 80dBA in most cases, andtherefore can play a key role in minimising overallequipment noise levels. Similarly, it is a low vibrationtechnology. This again contributes to reduced noiselevels, but it also has reduced physical impact on therest of the machinery – ensuring greater reliability – aswell as helping to ensure a more uniformproduct quality.We also have to look at the costs ofdowntime in the event of a powertransmission failure. Plastics extrudersrepresent some of the most demandingmotor applications. Once productionhas started, the one thing you don’t want to be doing ishalting production. The extruder is typically located at thebeginning of the production line, so stopping it will call ahalt to all production. Because it has to be heated, thereare long ramp up times before production can begin. Andwhen there are defects in the output, products cannotsimply be recycled and disposal costs are high. Reliabilityis therefore paramount. With fewer components in thepower train, the direct drive solution is inherently morereliable than a typical motor/gearbox combination, andcertainly much easier to replace in the event of a fault,allowing production to be restarted much more quickly.From the machine builder’s point of view, the torquemotor solution is generally much more compact than themotor/gearbox combination. The motor itself may beslightly larger, but eliminating the need for the extra powertransmission components delivers dramatic spacesavings. The motor can also offer build-in advantages forspecialist extruder manufacturers. An integrated thrustbearing can be added to support back pressure from thescrew. This is a nice added feature on injection mouldingmachines, but is a mandatory feature on plasticsextruders. Also, a screw extraction mechanism can bereadily built in, making it easy to remove the screw fromthe extruder for routine maintenance or to allow a newproduction batch to be set up. And, as discussed, thescrew can be cooled by water through the motor, whichcan be an extremely useful feature on large extruders.Typical torque motors cover torque ranges from1200Nm to 22,100Nm, and speeds from 50 to 500rpmdepending on size. Water cooling is standard on manydesigns, but natural ventilation is possible withsuitable derating.www.parker.com32INDUSTRIAL TECHNOLOGY • November 2010

Your life inour hands.NEW2010/11CATALOGUEAND DVDThrough an incision thinnerthan a pencil, the Da Vincisurgical system performslifesaving surgery on abeating human heart.Lives depend on the robot’s precision andreliability – so it’s no surprise that it’s powered by39 maxon motors.But you don’t need to be a heart surgeon to putworld-leading technology in your device.Every motor, drive, gearhead and controller in themaxon catalogue bears our famous reliability…You might say, you can trust them with your life.See for yourself – for your FREEcopy call us on 01189 733 337or visit www.maxonmotor.co.ukmaxon RE brushed motorwith planetary gearheadmaxon motor uk, Maxon House,Hogwood Lane, Finchampstead,Berkshire RG40 4QW33

DRIVES, MOTORS & CONTROLSIntegrated stepers arehighly compact designClaimed to be the world’s most compact integrated NEMA34stepper motors, these new motors are also said to offer thehighest microstepping resolution in the industryJVL has launched a newintegrated stepper motorwith RS485 and CANopenserial interface andprogrammable motion controller.All the necessary electronics in astepper system are integrated inthe motor itself. JVL has used thenewest technology to obtain anincredibly high step resolution of819200 step/revolution –resulting in smooth and silentrunning. The length is only 95mmwhich is said to make it theshortest motor in the world withbuilt-in controller.The motors are available inthree sizes: MIS340 with 3.0Nmtorque and length of 95mm;MIS341 with 6.1Nm torque andlength of 126mm; and MIS342with 9.0Nm torque and a lengthof 156mmThe motor contains everythingneeded to solve a modern controltask as stand-alone or controlledfrom a PLC or PC. Eight I/Opoints can be individuallyconfigured to digital input, digitaloutput or analogue input. ModbusRTU and CANopen provide easyconnections to a PLC or HMI. AnActiveX/OCX driver is available tomake interfacing to LabView,Excel, VB or other Windowsprogramssimple. The MAC motorstandard protocol enables MACmotors and QuickStep motors andSMC85 controllers to beconnected on the same RS485bus with up to 254 axes.Networking optionsThe integrated stepper motor canbe delivered with wirelessBluetooth, ZigBee or WLAN. Themotor is also prepared for futureoptions like Profibus andIndustrial Ethernet like EtherCATand EtherNet/IP and absolutemultiturn encoder withoutexternal battery. The PCB withstepper motor controller as usedinside the motor is also availableas a separate unit.Flange size is 86x86mmwhich corresponds to theNEMA34 standard and shaftdiameter can be either 9.53mmor 14mm with key depending ontype. Planetary gears that fit themotor directly are delivered fromstock.www.jvl.dkABB first motor maker to receiveIECEx conformity mark licenseABB is the first motormanufacturer in the worldto be granted a license touse the IECEx Conformity Markwhich allows ABB to display theIECEx Conformity Mark onproducts covered byan IECExCertificate of Conformity, as wellas on packaging and promotionalmaterials. The IECEx ConformityMarkshows that aproduct has beengranted an IECExCertificate of Conformity.IECEx Certification confirmsthat the product has theappropriate protection for use inexplosive atmospheres and that ithas been manufactured undersystems subject to ongoingsurveillance by CertificationBodies. It is recognised in all thecountries participating in theIECEx System, and also meansthat the product can be suppliedto the market without the need foradditional tests.The IECEx Conformity MarkSystem was introduced in 2008.IECEx Conformity Mark Licensesare issued by approvedCertification Bodies in IECExparticipating countries.www.abb.co.uk/energy34INDUSTRIAL TECHNOLOGY • November 2010

Electric MotorsMiniature brushlessDC motor rangeRotalink has introduced new miniaturebrushless motors for nominal output torquesto over 250mNm at maximum efficiency andmaximum power ratings to 270WThe new BL brushlessmotors are verycompetitively priced andtogether with Rotalink'sown innovative and uniquelydesigned precision gearboxes,motor feedback devices andmotion controls, offer excellentprice vs. performance for completeminiature power transmissionsolutions. The BL motor range isavailable in both 12 and 24 VDCversions, complete with threephase hall effect commutation forsmooth and precise speed and/orposition control.The highly efficient brushlessdesign has an inherently lowelectrical noise factor and unlikebrushed DC motors is not prone tocommutation sparking; so themotor is ideally suited to EMCsensitive and safe environmentuse. In addition, the noncontacting characteristics will suitapplications where long life andhigh reliability are of primeconcern.The BL range includes fiveframe sizes with nominaldiameters of 29mm, 32mm,45mm, 57mm and 65mm.www.rotalink.comToughened highperformancemotor rangeMaxon Motor hasexpanded its range ofmotors for toughworking environments, byreleasing industrial versions of itspopular RE 50 and RE 65 units,along with a new AB 44permanent magnet brake.With outputs rated at 200Wand 250W respectively, the twobrushed DC motors have beenupgraded to meet the challengingIP54 protection rating for dirt andsplash proofing.Each one boasts a sealedaluminium housing and PG cablefittings, while the shaft is securedwith a radial seal. Between them,the motors offer operating speedsof up to 9,500rpm.www.maxonmotor.co.ukMclennan’s range growswith Allied Motion linesThe long-standing distributionpartnership betweenMclennan Servo Suppliesand Allied Motion has beenextended with the Surrey basedmechatronics specialist increasingits product line coverage ofAllied’s direct-drive torque motors,brushless servo motors, highperformance servo drives andencoders.Mclennan’s close relationshipwith the Allied Motion groupspans more than 30 years withmany thousands of successfulsmall and precision brushed andbrushless motor applications forPremotec – now one of four AlliedMotion engineering/productioncompanies or Technology Units.The new partnership aims tobuild a similar success with AlliedMotion’s Emoteq/COPI TechnologyUnit and will work across all of itsproducts which include framelessand housed torque motors, servomotors, digital servo amplifiers,and incremental encoders.Highlights of the new productsinclude the Megaflux range – largeframeless and separate rotor/statorservo motors, up to 790mm indiameter with with power densityand high speed.www.mclennan.co.ukNew guides and brochuresMicro motors, actuators and moreHIGHLIGHTThis month’sfeaturedliteratureHot off the press from EMS is a fulloverview of its product range. The 16page brochure highlights DCmicromotors, brushless DC motors,gearmotors, low profile motors,stepper motors, drive electronics,linear actuators and custom solutions.The products meet the needs of arange of applications, includingmedical, laboratory, robotics, optics,aerospace, security, buildingautomation and industrial processes.The brochure highlights DCmicromotors, brushless DC motors,gearmotors, low profile motors,stepper motors, drive electronics,linear actuators and custom solutions.www.ems-limited.co.ukNovember 2010 • INDUSTRIAL TECHNOLOGY35

DRIVES, MOTORS & CONTROLSElectric MotorsA new way to save energyInverter optimised motors from Lenze approach IE3efficiency levels, at a cost that is actually lower thanstandard AC motors. The motors deliver additional benefitsof long service and an extremely compact designAlarge gap exists between standard AC motortechnology and that of servo motors. StandardAC motors have low cost, moderate efficiencyand suit mains or frequency inverter operation.Servo motors with rare earth permanent magnettechnology are more efficient but much more expensive.Now Lenze have introduced their MF inverter optimisedmotors positioned in this gap. MF motors can not onlyyield around 5% saving in energy, but also additionaladvantages of smaller dimensions and a purchase costthat is actually lower than standard AC motors. Theenergy saving of 5% is significant (at similarpowers changing from IE1 standard toIE2 high efficiency motors will onlydeliver about 3%) leading to long termsavings and reduction in greenhousegas emissions.Lenze has achieved the twin goals ofhigher efficiency and lowerpurchase costs by takingstandard 4-pole motordesigns and optimising them for use at120Hz, equivalent to a speed of about3500rev/min. Whist this is not sodifferent from 2-pole motor speeds,Lenze have taken steps to ensure along service life. Special shaft sealsare fitted for running at the higherspeeds, and high temperature greaseis used in the bearings. In most casesthe high output speed is not directlyusable, and motors are generally suppliedwith a gearbox.Lenze have a full range of inlinehelical and right angle bevel, helicalbevel and helical worm gearboxes. There is aslight decrease in gearbox efficiency at thesehigher input speeds, but this is more than compensatedby the motor gains.The efficiency of these 120Hz optimisedMF motors increases by typically 5 or 6%compared to a standard 4-pole motor. Forexample at 0.75kW the efficiency ispractically 80% and close to the IE3efficiency level which becomes compulsory in2015. The higher speed increases the rated powerdelivered by the motor. This in turn allows the size of themotor to be reduced by one or two frame sizes leadingto lower purchase costs. For example a 1.5kW MF motoris 71 frame compared to a standard 1.5kW pole motorwhich is 90 frame. Moreover the smaller size meanslower inertia and more dynamic drives. The performancetakes a step towards servo levels with high accelerationand deceleration. Full torque is available over a 1:24speed range.Freestanding or geared motorsCurrently the MF motor is available from Lenzefreestanding or as a geared motor for use with the new8400 motec inverter which can be terminal box or wallmounted. Powers up to 1.5kW were released in the firsthalf of 2010; this autumn the power range will extendto 22kW and use will also be possible with all cabinetmounted inverters of the Lenze 8400 range. A full rangeof options can be added to MF motors This includesspring applied brakes for stopping and holding,incremental encoders, blowers to extend the operatingrange and plug connectors. The new Lenze MF motorswill not suit every application. Their strength lies in lowto medium powers and where output speeds from 60 to500rev/min are required. Here theygive nothing but benefits withreduced energy bills, reducedpurchase costs and increaseddynamic performance.www.lenze.co.ukFor the very latestproduct information, most up todate industry news, plus usefulcompany profile information,visit the pages of IndustrialTechnology online atwww.industrialtechnology.co.uk36INDUSTRIAL TECHNOLOGY • November 2010

“Continuous Slip – Zero Wear”ROBA ® -contitorqueHysteresis MagneticClutch / BrakeBenefits• Contactless Torque Limitation• Wear / Maintenance Free• Accurate Torque Repetition• Load Holding Capability• Low Weight / MMI• Simple to AdjustApplications• Capping / Closing• Tensioning of Foil, Wire etc.• Polishing Spindles• Railway Point Machines• Reeling Machines• General Overload Protectionwww.mayr.co.ukMayr Transmissions Ltd.Valley Road Business Park,Keighley, West Yorkshire, BD21 4LZT: 01535 663900 F: 01535 663261E: sales@mayr.co.uk37

MACHINE BUILDING & AUTOMATIONMotion NetworksSERCOS has become the standard digital drive interface forreal-time communication in high-performance motionapplications, while Ethernet TCP/IP has established itselfas the standard for non-real-time communication on alllevels on automation. Peter Harlow of Bosch Rexroth looksat the combination of these technologies – SERCOS IIIFactory automation has come a long way in termsof communication – 20 years ago all that wasrequired was for simple field buses to transfermeasurement values reliably and activatemodules with precision. The more multi-layered the tasks,such as coordinating several drives (motion control), thegreater the requirements became, and not every field buswas able to handle them effectively.Today production systems demand networks which arealso capable of enabling data to be exchanged betweendifferent processes and machines – hence the migration tothe TCP/IP protocol, which enables computers, controlthe best of both worlds is brought together – itintegrates the proven real-time mechanisms ofthe SErial Realtime COmmunication System(SERCOS) interface with the Ethernet TCP/IPstandard for non real-time communication.Proven communications systemSERCOS has been used in the industry foralmost 20 years, providing real-timecommunications between controllers, drivesand distributed peripherals. It has establisheditself as one of the world’s leading digitalinterfaces, with more than 80 differentmanufacturers offering SERCOS-enabledproducts. As an active member of the SERCOSInternational organisation, Rexroth has workedclosely with its customers and partners toimplement SERCOS III across its platform of drive andcontrol solutions.At the field level – which is where communicationbetween individual drives, sensors and controllers takesplace – SERCOS III real-time functions guarantee therequired level of precision. Connectivity to higher levelcontrol systems is extremely simple with direct access todata at the lowest production level, and every Ethernetenabledcomputer can be connected to a SERCOS III portwithout any additional hardware or software.Thanks to the full-duplex mode, every node can callon the full range of 100 MBit per second in real-timeapplications to be supplied with 8 bytes of cyclical dataand for them to send the same number of diagnoses aswell. This is sufficient for even the most demanding tasks.And SERCOS III delivers a level of performance whichmore than meets the requirements of today’s productionmachines to master complex automation tasks. Forexample, it can allow up to 256 axes on one ring. .The technology which makes cross-communicationbetween the individual nodes possible not onlycontributes to the efficiency and flexibility of SERCOSsolutions, it also increases safety because it enables aSERCOS III network to be organised on the basis of a ringstructure. In the event of a cable failure, therefore, aredundant signal route is available. The SERCOS networkcoordinates itself and offers flexible strategies: a classicallinear structure in order to save materials or a redundantring structure for greater safety. The engineers have thechoice of selecting the most suitable cabling to meetrequirements without having to think about additionalelements for the network infrastructure.The same applies to the safety of data transmission. Toensure that information is transferred safely, SERCOS offersa certified security protocol – called SERCOS safety – thatcomplies with the requirements of the safety standard IEC61508 up to Safety Integrity Level 3 (SIL 3). This coversrisks arising out of or in connection with system failures andwhich may pose a risk to the health of employees, to theenvironment, etc. The elimination of additional hardwarereduces costs without any compromise on safety. SERCOSReal-time Ethernetsystems and machines to exchange information bothinternally and externally. It eliminates any number ofbarriers in the corporate environment, making interactionbetween a wide range of applications feasible.However, Ethernet in accordance with IEEE Standard802.3 is not suitable for horizontal communication inproduction because it allows a single device to block thenetwork traffic even when another device needs to sendan urgent message. In the finely-tuned process typical ofan extruding machine, any such delay in a signal to avalve would produce scrap parts. In contrast, IndustrialEthernet (IE) is a plant, production, process and controlfocused technology targeted specifically to the industrialenvironment, for automation and production machinecontrol. It offers real-time communication so guaranteeingthat every device in the network can receive and senddata at any time.At the same time, however, not all real-timecommunication IE technologies are alike. There arenumerous solutions available that offer the promise ofreal-time compatible Ethernet – in a number of cases thisis with enormous differences. With SERCOS III however,mode. Full TCP/IP consistency is guaranteed at the sametime because non-real-time data packets are forwardedvia a special NRT channel (non-real-time), withoutcompromising the guaranteed cycle times of the real-timedata. This allows parameterization to be undertaken, forexample, without the control system running using astandard notebook and Ethernet interface.Third-generation SERCOS marks the introduction ofEthernet into the fieldbus world, and at data rates of 100Mbit/s, it sets new speed benchmarks. Other new featuresinclude the use of CAT 5 copper cable in addition to thefibre optic technology which is already in use in previousgenerations. This alleviates the apprehension engineershave of handling fibre optic cable in the industrialenvironment, where termination and replacement aredelicate processes. Highly efficient networks can beinstalled using ring or linear topologies and peer-to-peercommunications.At the same time, the cycle time of 31.25µs in realtimemode does not mean that one individual modulewould take up the complete range for itself alone. Instead,it is possible for up to eight drives in motion controlsafety is also protected against potential errors such asrepeats, losses, insertions, incorrect sequences, corruption,delays and the confusion of secure and standard data. Thesecurity protocol is certified in accordance with IEC 61508and was also tested by the German TÜV in respect of safetyrequirements.SERCOS has now definitely made the transition froma specific drive interface to a universal real time Ethernetsolution. However, it must be recognised that in additionto SERCOS III, there are a number of other real-timeIndustrial Ethernet solutions available in the market –including PROFINET RT and EtherNet/IP. Rexroth’sindustrial automation solutions offers master and slaveinterfaces for all of these. This means that Rexroth’sembedded control platform IndraControl can be integrateddirectly into most systems worldwide with multi-protocolcapableinterface connections reducing developmenteffort and simplifying the system design. So developersare no longer forced to decide between network andcomponents – they can simply select the best modulesfor their application.www.boschrexroth.co.uk38INDUSTRIAL TECHNOLOGY • November 2010

MACHINE BUILDING & AUTOMATIONPackaging AutomationVision system ensurescarton caps are spot onVision technology from Cognex has replaced a simple pass/failheight sensor of a capping machine to provide more accurateinformation not only on whether or not the cap is present, butalso on the actual position of the cap, giving increased qualityAt Refresco Bodegraven in The Netherlands,nine thousand one-and-a-half litre packagesfilled with soft drinks or fruit drinks leave theconveyor belt of one of eleven production linesevery hour. The Combiblock packages are fitted with thefamiliar plastic screw cap. After filling by a specialmachine, the cap applicator pushes this cap preciselyinto the right place on the package. Until recently, onlythe presence of the cap was checked automatically. Thiswas done by using a photo sensor which actually onlydetected whether the signal was interrupted at a certainheight. If this was not the case, the product wasrejected. In addition, the operators made a visualinspection and moreover random inspections were madeby means of a torque meter measuring the force requiredto screw the cap off.There was no inspection of the position of the cap. Intheory, the supplier of the cap applicator specified thatthis machine should be able to place the cap virtuallywithout errors, but this turned out to be otherwise inpractice. Sometimes there were minor deviations,damaging the shape of the packaging as well as itsappearance. Sometimes the problems were moreserious: the cap was placed on the wrong side becausethe package was twisted somehow or other in the line,and ended up back to front in the cap applicator. Thisresulted in undesired production failure and, in somecases, the packs were returned by retailers if the errorhad not been detected.Caps placed in the wrong position became an itemhigh on the agenda. Plant manager Patrick van Erpcomments: “The plastic screw caps were not alwaysinstalled at the right place on the package. The finalinspection, using an optical sensor, was not sufficient: itonly checked whether the cap was present. We soonstarted looking in the direction of vision, but we were alittle reluctant in light of our ideas about vision:expensive and complicated systems with PLC-likeprogramming techniques – not something we relisheddoing. On the contrary, we wanted a simple system thatwas easy to implement, and with minimum impact onthe machine.”Immediate improvementAll doubt about vision systems disappeared when VanErp made contact with Digitron Industrial Systems inUden, which sells the Cognex Checker vision systems inthe Netherlands. “When they visited our company, Ifound it absolutely amazing that within half an hour wecame to a functioning solution that did exactly what itwas supposed to do. Final implementation did take moretime, of course, but the improvement compared to theformer situation is absolutely sensational: our first timeright percentage changed from 93.7% to 98.8% partlydue to this. This is an enormous improvement, not onlyin the cost-benefit sense, but also the pride in your work,your production line and your products.”The Checker 3G1 can make and process up to25,000 images per minute, more than sufficient for the9000 packages passing along the Combibloc lines everyhour. The system is implemented in such a way that theoutput to the machine’s controls is exactly the same asthat of the optic sensor that was used previously. For thisreason no adjustments have had to be made to thecontrols of the cap-applicator, which of course is a greatadvantage when the line is already in operation.The Checker is triggered by a fork sensor whichannounces that a package is coming and that a photowill have to be made within an experimentallydetermined period by means of a pulse. This photoshows almost the entire top of the package, but thevision software is only interested in a small part of it: theposition of the lip used to attach the screw cap to thepackage in relation to the fold of the cardboardpackaging. When this space is outside the pre-setspecifications, it indicates that something is wrong andthe machine is instructed to remove the package. Thecap may be missing but it also may have been attachedwrongly.In practice the vision system works virtually withoutmistakes so that the retailer no longer receives defectivepackages. However, there are other advantages, asPatrick van Erp explains: “The batches we run per linediffer from each other quite a bit; sometimes we onlychange products four times per week, but sometimesfour times per day. It depends on all kinds of factors, forexample orders, supplies, shelf life of the product andprocessing time. Scheduling runs with maximum lengthis a real art, but when the product has to be changed theconversion time has to be limited to the minimum. Thevision system is very suitable for this, since the visionsystem is very simple to train.“The operator signals that a new training set iscoming via a button on the control panel. After three orfour packages of the new batch – rejected as a standardprocedure – the system knows what it must payattention to and production can be resumed at fullspeed. The colour of the cap, the design on thepackaging, it is all the same to the vision system.”Variations in lighting hardly throw off the vision systemeither. “We do production runs here seven days perweek, 24 hours per day. There are significant differencesbetween daylight, which shines in through the skylightsin copious amounts, and the fluorescent lighting duringthe night hours. Despite those big differences, addingsome extra light in the machine was sufficient to createequivalent light conditions for the Checker; eliminationof external light sources, much more timeconsuming,proved to be unnecessary.”www.cognex.com40INDUSTRIAL TECHNOLOGY • November 2010

Air motors haveprecision baggedAir motor technology is providing precisepositioning for a food bagging machineTo complete its design of asystem to bag-up meat andcheese and apply appropriatelabel information US packagingmachine manufacturer, Greydon,encountered obstacles. The cost ofmodifying a standard electric motor tosuit the machine’s intended 100%caustic washdown environment hadproved cost-prohibitive. And in anyevent, such an environment is muchbetter suited to a solution involvingminimum electronic components.So the hunt was on to find a low costmotor meeting these credentials butwith a relatively high degree of precisionand control. These qualities wereneeded by the Greydon Bagaire TapedBag Loader not only for efficient bagopening and filling but also forcode-dating with inkjet or contactprinters.“The Huco Dynatorkpiston air motor was agood find for us,” explainsBrian Newman of Greydon. “It iscompact, fitting in a snug space underthe machine. And as the bags areopened with a puff of air from thepneumatic system, an air motor was theideal solution.”The machine presents the bags bywinding up a leader tape and pulling thebags up from the table. Shop air is usedvia an air amplifier to blow open the bagfor manual filling by the operator whosimultaneously breaks the bag awayfrom the tape.The Huco Dynatork motor advancesthe bags quickly and stops themprecisely in exactly the same location foropening and printing. As it is availablewith an acetyl housing, this motor isable to withstand the most caustic acidsand chlorinated sanitizers used in thefood and pharmaceutical industries.The operating principle of the HucoDynatork air motor is simple. Via anintegral rotary valve, air up to 100 psi issupplied to each of three pistons in turn.The free-floating pistons transmit torqueon start-up that can be adjusted via apressure regulator.This results in high torque at variablelow speed and also low noise. As the airmotor traps the compressed air withinthe piston/cylinder maximum energyconversion is assured. Also the motor ismuch easier to seal than its vanecounterpart. As a result the HucoDynatork motor consumes up to 80%less air than a vane motor, providingsignificant cost savings even atmaximum torque.David Lockett, managing director ofHuco Dynatork explains that the motorexcels in constant start-stop applicationsunder load, displaying similarcharacteristics to those of a steppermotor. He says: “By comparison, anelectric motorwill often burnout and avane motorwill stall whensubjected to these conditions.” Airmotors provide an effective, reliable andaffordable option in demandingwashdown environments. Thealternative of a stainless steel sealedelectric motor is more expensive, thegearbox assembly often too heavy, anda specially designed inverter panel orenclosure often too cumbersome.Air motors from Huco Dynatorkcombine precise positioning andefficient operation with the ability towithstand the rigours of even 100%caustic washdown environments. Asstandard, the motors are able tooperate totally immersed in water, soeven high pressure wash downs are nota problem. And with acetal housingsalso available, the motors are able towithstand most caustic acids andchlorinated sanitizers used in the foodindustry.Huco Dynatork air motors areavailable with maximum torque rates ofup to 16Nm or up to 550Nm with agearbox.www.huco.comNovember 2010 • INDUSTRIAL TECHNOLOGY41

MACHINE BUILDING & AUTOMATIONCondition MonitoringReaping the benefits ofpredictive maintenanceManaging processes and equipment through predictive maintenance presents significant benefits.With the rapid evolution of technology, companies can obtain a higher level of intelligence whilemonitoring plants, reducing downtime and cutting costs. Jez Palmer of Schneider Electric, takesa look at how businesses can implement predictive maintenance and the subsequent benefitsIt is not uncommon to find owners and operatorslooking for ways to extend the life of existingequipment as getting more out of an asset can helpa business to reduce costs, and improve productionefficiency, performance and profitability. In addition,there is little doubt that the majority of productionfacilities still have enormous potential for improvementwhen it comes to plant performance.In an industrial facility, maintenance can account fora significant proportion of operating costs. Lack ofknowledge about when and what kind of maintenance isneeded to maintain, repair or replace critical machinery,equipment and systems within a plant or facility, canresult in ineffective use of maintenance expenditure andperhaps more significantly, loss of production.Monitoring the operating condition of critical plantequipment, machinery and systems provides businesseswith the knowledge to effectively manage the maintenanceoperation. As a minimum, it provides the means to reduceor eliminate unnecessary repairs, prevent catastrophicmachine failures and reduce the negative impact ofineffective maintenance operation on the profitability ofmanufacturing and production plants. However, theinformation can also optimise total plant performance,equipment life, and life cycle costs of the facility and itsassets by utilising it for a predictive maintenanceprogramme.Overall Equipment Effectiveness (OEE) is now widelyrecognised by industries as a way of measuring plantperformance and can provide meaningful information thatcan determine a business’ predictive maintenanceprogramme. The success of OEE relies on having access todata in real-time or as close to real-time as possible, fromproduction equipment, and then presentingthe information in a way that can beunderstood. This requires the use of aManufacturing Execution System (MES),which interfaces with existing SCADA, HMIs,other process control and automationsystems (such as variable speed drives) aswell as business systems.Increased visibilityFor predictive or condition-based maintenancework to be effective, it’s less aboutnew technology and more about ways ofbringing data to the user to give morevisibility, which is possible through an MES. By collatingrelevant information, it is possible for intelligence-basedbusiness decisions to be made using real-time information.The level of information provided by an MES can beginwith standards reports covering areas such as alarmsstates and statistics, run hours, tag calculations and valuesfor aspects including kWh and processes marked as shiftparameters.In addition, users can access alarms managementreports focusing on correlation, frequency, major events andlongest standing, which will help identify common problemareas that may require more regular maintenance orhighlight areas that could potentially fail. This ensurespreventative maintenance work can be carried out beforethe problem results in costly and unexpected downtime.Taking the information a step further, businesses canlook at the state of a plant or specific process and analyseits behaviour. Production specific modules can providereal-time data on yield, energy consumption per outputunit, output per shift, as well as actual versus targets onmaterials, energy, waste, emissions and product output.Access to this level of detail can offer economic benefitsin a number of ways. Information on aspects of the plantsuch as identifying ‘lost production’ – the hidden potentialin a machine to deliver additional output; or quicklyidentifying causes that can be detrimental to production,such as operator issues and machine or material issues;or raising production consistency and reducing waste, areall factors that can have an impact on the company’spredictive maintenance schedule.As well as real-time information, historical data canbe used in predictive maintenance. It can assist inplanning a maintenance programme, as the records canbe used to predict when issues will happen in the future,based on trends and patterns. This can help withbudgeting, again controlling costs as the amount ofunplanned, ad hoc work should be reduced.www.schneider-electric.co.uk®ReliancePrecision Mechatronics LLPQuality Range of Precision Couplings• Reli-a-Flex ® Couplings: Highest performance, improves system accuracy, reducedynamic loads and extends system life• Spiral Beam Couplings: Budget coupling with good overall performance• Oldham Couplings: High parallel misalignment capability, electrically insulating• Bellows Couplings: A precision coupling with high torsional stiffness• Flexible Disc Spring Couplings: Spring action discs provide accurate transmissionBore size range from 1mm to 20mm. Reli-a-Flex ® variations include micro, precision,electrically insulated and Reli-a-Grip integral clampCall our Sales Team on +44 (0) 1484 601002Visit us at www.rpmechatronics.co.ukUnique Solutions from Proven Concepts42INDUSTRIAL TECHNOLOGY • November 2010

Failures predictedby virtual engineerScientists at the University ofPortsmouth have created a‘virtual engineer’ which usesartificial intelligencetechniques to predict when machinesneed repairing. The system isexpected to overturn the primitiveconcept of waiting for a machine tofail before calling an engineer.Instead it calculates when a part iswearing out allowing the company toschedule maintenance. In an era of24/7 production lines with machinesrunning around the clock, it couldrevolutionise the way industrymanages machine failure and repair.The new system works by placingsensors on vulnerable parts of themachine, such as the bearings, whilepredictive software monitors andanalyses performance, alertingtechnicians when it detects that apart is not working properly or needsreplacing. Dr David Brown, Head ofthe University’s Institute of IndustrialResearch (IIR), says: “The machinesin many processing plants andfactories are running day and nightand an unscheduled stoppage cancause havoc and can result in hugecosts. This new diagnostic systemprevents potential mechanical failureby identifying the faulty or worn outpart before it causes a problem. It’sthe first time this kind of technologyhas been used on this scale in theprocessing industry.”Dr Brown says that the reallyclever part is that the system isadaptive. “During the process ofmonitoring the machine, thesoftware literally learns more abouthow it works, which parts arebecoming worn and anything elsethat could potentially causemechanical failure.” The IIR’sdiagnostic system can learn theparticular behaviour of eachindividual machine.www.port.ac.uk/research/iirElcomflat belt conveyorsThe Elcom range of flat belt conveyors complete with motorsare available in widths from 20mm up to 1000mm, and witha useful range of belt speeds.Designed around the Item MBprofile system, they guaranteewide compatibility with otherequipment, and have the levelof finish you would expect ofItem itself. With several yearsof proven use in the field,they are the natural choiceeither for incorporating intoother machines or as standalone units.Get your free copyof the Elcom flatbelt conveyorscatalogue todayMachine Building SystemsHeage Road Industrial Estate,Ripley, Derbyshire DE5 3GHTel: 01773 749330 • Fax: 01773 749560www.mbsitem.co.ukConveyors also available from MBS in Athlone, Ireland43

MACHINE BUILDING & AUTOMATIONMachinery Frameworks & ComponentsAssembler software makesmachine frame design easyNew iCAD Assembler software allows machine builders anddesigners to conceptualise, plan and cost their machine designsusing MiniTec's Profile System and Linear System machineframing and automation component systemsNew iCAD Assembler software allows machinebuilders and designers to conceptualise, planand cost their machine designs usingMiniTec’s Profile System and Linear Systemmachine framing and automation component systems.Users can choose the standalone program mode,requiring no CAD platform or specialist CAD knowledge,or work in combination with their preferred CAD softwaresystem.The free of charge software allows straightforwardmenu selection with drag and drop manipulation ofindividual profiles, connectors and ancillary componentswith the ability to fully assemble these elements onscreento realise designs for anything from simplemachine frames to complex automated assemblies.With intelligent selection of suitable connectorelements, iCAD Assembler generates rotatable views foreach component along with detailed dimensioning andtechnical specifications including weights. The softwaregenerates parts lists and BOMs for pricing and providesthe designer with more than 50 data output formatoptions in 2D and 3D which includes AutoCAD,SolidWorks, ProEngineer as well as IGES, STEP4 andmany others. MiniTec says the iCAD Assembler places itat the forefront of design and construction software formachine framing systems and fully complements itsenviable reputation for Profile System, offering themachine designer and system integrator the fastest, mostcost-effective machine framing system available today.MiniTec’s Profile System is a comprehensive machinebuilding system that includes modular aluminium andstainless steel profiles that are assembled using theunique Powerlock fastening system – a fast and effectiveframe connector requiring no special tools or machiningother than cutting profiles to the required length and fixingthem in place with the twist of an Allen key. A full rangeof ancillary components available include wheels, doorcomponents, conveyor parts, panelling, sensors, motors,controls and more.LinearSystem includes ball-bushings, slide units andtorque bearings plus precision ground shafts and shaftsupports that can be effortlessly specified for machineautomation. Together these ranges provide the costeffective building blocks for production and testmachines, materials handling systems, work stations,machinery guards and automated manufacturingsystems.The iCAD Assembler software includes acomprehensive demonstration mode and is available fromMiniTec UK, supplied on a disk or downloadable from theMiniTec website.www.minitec.co.ukMachine guards, frames and screensStandard profiles and accessories enable highly cost-effective and flexible machine designsAluminium profiles are robust, reconfigurable andextremely adaptable, meeting the requirementsof most types of machine guards, protectivescreens and machine frames. Aluminiumprofiles are used extensively across a wide range ofindustries offering a solution for designers and machinebuilders that provides for accurate and rapid constructiontimes.The Paletti aluminium profile system from Boldmancan be constructed both quickly and effectively;furthermore, its modularity offers the designer and builderthe opportunity to make changes and modificationsduring the construction stage. To meet designrequirements the Boldman team uses standard profilesand accessories wherever possible to provide costeffective bespoke solutions. All manner of industries –including aerospace, automotive, pharmaceutical,nuclear, scientific research, optical and audio-visual –have used the benefits of this system. There is no doubtthat the concept of an extruded aluminium profile systemand its range of fasteners and accessories truly havechanged the way machine builders go about producingtheir complex manufacturing systems.Boldman has been extremely proactive of lateintroducing a range of protective systems and industrialscreens, machine guards and a ballistic type protectionwhich is used in the aerospace and oil industries. Theseprotect the work place and personnel during ultrasonicand high pressure testing of composite panels andequipment. Also designed and manufactured at Boldmanare a range of modular access and maintenance platformsdeveloped for working at height solutions.Boldman works closely with its customers during theearly design and development process to ensure themachine frames and guards, platforms and operatorprotection integrates seamlessly into the final designfor trouble free installation.www.boldman.co.uk44INDUSTRIAL TECHNOLOGY • November 2010

MACHINE BUILDING & AUTOMATIONMachinery Frameworks & ComponentsGreater choice of framesfor the European marketMisumi has expanded its range of products in thealuminium frames group and is introducing diversecomponents to Europe that have already beentried-and-tested on the Asian marketAbroad range of diverse products,previously unseen on theEuropean market, is nowavailable to order with the blindconnection parts. Misumi provides fulldetails of the types and series of thesecomponents in an 18-page brochureentitled “Aluminium Frames andAccessories” which includes all technicaland commercial information. Standardaluminium frames are also featured in thebrochure; these are available with thenew connection components and come inmany different types, with variousindividual adjustment options as knownfrom the previous range.The brochure containing these newproducts can be downloaded as a PDFfile (2.9 MB) from the Products section ofthe Misumi website, under Productinformation. In the current Misumicatalogue, “Mechanical Components forSpecial Purpose Machinery Manufactureand Assembly Automation”, this productgroup is spread across 200 pagesbecause of the broad range of productson offer. These include frames withvarying slot widths, curved designs, ultrastiffvariants, flat profiles and products forprotective grids.The choice of connection componentsand accessories is equally sophisticated,for example, over 200 different elbowand corner connections and over 200types of T-slots. In addition, the rangeincludes castors and adjustable feet fordevices, apparatus, hinges, handles,T-slot covers and configurable coveringplates, as well as special connectioncomponents such as blind and threadedjoint parts. Misumi says its product rangestands apart from other providers thanksto its particularly high number of differenttypes of frame, many of which are alsoavailable with a black anodised finish.This is important for applications withvisual functions – such as minimisedreflection – or where aesthetics also playa role.And as usual, Misumi will deliver allitems from the aluminium frames productrange quickly, from quantities of just asingle item, tailored to suit the specificsof your application.www.misumi-europe.comAddressing theEC MachineryDirectiveAs a major supplier toengineering industry, EMKAis aware of the “MachineryDirective 2006/42/EC” whichregulates the installation ofprotective devices in dangeroussituations. This directive clearlydeals with components such ashinges and locking mechanismswhich may be found within theEMKA product range.The text of the directivedifferentiates between guards(bars, doors, hatches and similar)and protective devices andmovable guards. Under thecondition that no or infrequentaccess is required during theworking process then fixed guardsare generally used.EMKA products are expectedto be of interest in the arena ofKanban systemsget scalableinstallationsImplementing Kanban systemsdepends on effective partitions, racks,shelves, conveyor tracks, slide tablesand more, and you want to be able to setthese up quickly, flexibly andeconomically. The Item frameworksystem from Machine Building Systems isthe answer.The Item MB Building Kit System isan inexpensive system with easy andquick handling, and with reusable parts.The system grows with yourrequirements. A structure made ofaluminium profiles and fasteners is avery flexible solution that can beassembled easily. In only few workingstages, you can create stable, reliableand expandable production facilities foran improved production flow.Item has over 30 years experience inthe construction of facilities. More than1,500 modular products can becombined with almost unlimited flexibilityto construct whatever structure you need,tailored to meet your individualrequirements.www.mbsitem.co.ukDust proof conveyorsfor demanding tasksDorner Manufacturing’s new 2300and 5300 Series conveyors arenow part of the new DustPruffamily of conveyors. These new anti-dustand particulate dust proof conveyors areavailable in the UK from AutomationSuppliesThis new conveying system is idealfor environments where dust,particulates or product debris build upand where constant cleaning just isn’tfeasible. Dorner DustPruf conveyorsprovide all the integration flexibility of aT-slot system without the drawback –slots that collect dust and particulates.The patent pending SmartSlot technologyis designed into the frame of eachDustPruf conveyor. The smooth profile ofthe SmartSlot virtually eliminates dustcollection points without giving up theintegration and add-on capabilities of aT-slot by removing slots that collect dustor contaminates. The guiding principle isthat if you remove the slots, and dusthas nowhere to accumulate, but if youleave a void behind the front surface,you can still easily utilize it to add onattachments fast..The DustPruf conveyors are availablein both belt (2300 Series) and plasticchain (5300 Series). The 2300 series isdesigned from the industry leading 2200Series low profile small parts handlingconveyor platform. It offers increasedload capacity compared with thestandard 2200 Series, and has an FDAapproved,low-friction coating onbedplate. The 5300 provides a modulardesign that allows simple configurationand reconfiguration, with straights,curves and inclines to reduce producttransfers and motors required.www.asconveyorsystems.co.ukfixed guards where the followingrequirements are defined:● Fixed guards must be fitted bysystems that can be opened orremoved only with tools.● Their fixing systems mustremain attached to the guards orto the machinery when the guardsare moved.● Where possible, guards mustbe incapable of remaining in-placewithout their fixingsCorresponding products withinthe EMKA program include a widerange of fixed or removable hingesand automatic or ‘slam’ lockingcatches. Examples may be drawnfrom a variety of ‘slam cams’,slam locks, spring loaded lockcylinders, retractable handle andspring closure side panel locks.In addition, EMKA’s range ofELM and Agent E remoteelectronic cabinet locking systemsprovide keyed security plusaccess, control and event logging.This not only enables users tomeet the requirements of theMachinery Directive, but alsoaddresses issues of ‘mischievousoperators’ by limiting access onlyto approved personnel.www.emka.co.uk46INDUSTRIAL TECHNOLOGY • November 2010

ENGINEERING LITERATURENew guides and brochures for your bookshelfFree white paper on electrohydraulic technologiesParker Hannifin haspublished a newWhite Paper lookingat the latest compactElectro-Hydraulic actuatortechnology for use in spacecritical industrial, mobile andremote applications. Thepublication of the new WhitePaper also coincides with thelaunch of a dedicated web sitepromoting the company’srecently introduced CompactEHA Electro-Hydraulic doubleacting actuator; this innovativeactuator is a fully integrated,free standing unit capable ofdelivering extremely high levelsof power density.Parker’s Electro-Hydraulicactuator technology has beendeveloped to provide analternative to the use ofconventional linear motiontechnologies, such aselectromechanical andpneumatic drives, inapplications where high poweris required from actuators witha small envelope, or where nomains power supply is readilyavailable.The new White Paper hasbeen written for use by designand production engineers andexplains how compact Electro-Hydraulic devices work andlooks at their relativeadvantages and disadvantagesover other methods of linearactuation. The White Paper isfree to download from adedicated Compact EHAwebsite where details of theactuator can also be found.www.compact-eha.comHIGHLIGHTThis month’sfeaturedliteraturenetfinderswww.automation-supplies.comAluminium profiles & modular conveyorswww.br-automation.comAutomation solutions from a single sourcewww.balluff.comWorld leading sensor technologieswww.boschrexroth.comDrive & control solutionswww.e2s.comHigh performance signalling productswww.hollinapplications.co.ukDrives, motors, controls and actuatorswww.instrumentation.co.ukSensors, test and control exhibitionwww.kistler.comMeasurement technologywww.lg-motion.co.ukMotion control systems & supportwww.linearactuators.co.ukActuators & slides from 250N to 4000NRoboticsIntertronicsWith benchtop robotics playinga significant part in costreduced/quality-upgradedsmallscale production, this newcatalogue from Intertronics willinterest engineers.MRO cleanersHenkelThe Loctite range of MROcleaners has been developedfor cleaning parts in a range ofdifferent sectors and formaintenance applications ingeneral industry.Power transmissionEriks UKThis 113-page catalogue fromMisumi details different sizesand designs of positioning pins– essential small componentswhich play an important role innumerous applications.www.mayr.co.ukThe specialists in power transmissionswww.micro-epsilon.co.ukExtreme precision measurementswww.intertronics.co.ukNews in brief...www.loctitewww.misumi-europe.comwww.myonic.comMiniature precision ball bearingsServo drivesMotor TechnologyMotor Technology has beenappointed Approved Reseller byItalian servo drive and motormanufacturer, Axor Industries.As well as supplying Axor’sdrives and motors, MotorTechnology will also supply thecompany’s accessories such aspower supplies, shuntregulators and line filters.BearingsRA RodriguezSeveral customer benefits willresult from Kaydon rationalisingits bearings manufacture in theUS. The consolidation of allthin section manufacturing intoits expanded Sumter facilitywill provide UK distributor,RA Rodriguez, with anenhanced service for all itscustomers needs.LubricantsSKFSKF has signed an agreementto acquire leading US basedlubrication systems provider,Lincoln Holdings Enterprises, ina move to strengthen stillfurther its product offering andrange of services. SKF ispurchasing the business forUSD 1 billion on a cash anddebt free basis.www.omega.co.ukProcess measurement & controlwww.rittal.co.ukEnclosure & housing technologieswww.tandler.co.ukGearboxes, couplings & torque limiterswww.motec.co.ukwww.raridriguez.co.ukwww.skf.co.uk48INDUSTRIAL TECHNOLOGY • November 2010

John Richardson’s ENGINEERING DIARYWe all knew that the Government’s Spending Reviewwould hit the public sector hard. Despite thereassurances of how most of the job cuts will comethrough retirement and voluntary redundancy, thereseems little doubt that there will be job losses that are moredifficult to palate. Still, we have been speaking about the need fora rebalancing of the economy for some time. So are we seeingrecognition of that need? As ever, as far as the UK’smanufacturing sector is concerned, it seems there is a sting in thetail. For all the talk of successive governments about theimportance of manufacturing to the economy in bringing us out ofrecession and generating growth, the people at the top don’tseem to be able to resist the temptation to squeeze just a little bitmore from our industries.A change to the Carbon Reduction Commitment (CRC) schemeincluded in the government’s Spending Review has made itsuddenly become even more important for companies to cut theirenergy bills. Monies raised through a levy on major energy users,that were intended to be redistributed to companies who haddone well in reducing their energy consumption, will now goinstead to the Treasury, alongside general taxation. Andy Parker-Bates of Parker SSD Drives says: “Companies that thought theyhad a guaranteed chunk of money coming in through the CRCwill now have to find a replacement. Few markets are so robustthat turning up the sales wick will produce prompt results, so thebest option is to crank up the energy reduction measures alreadyin hand.” Chancellor George Osbourne said that this move was toreduce bureaucracy, but omitted to say how it would affect theprivate sector companies he says he wants to help. (Calculationssuggest that a moderately large company could be £100,000 outof pocket). “The CRC only came into force six months ago,” saysParker-Bates. “Many people have only just worked out a strategyfor being a winner under the scheme, getting a payback greaterthan the levy paid.“It’s tempting to say that Mr Osbourne has made everyone aloser, but there is a definite positive to this. The most sensiblething to do is maintain or even increase the proposed investmentinto energy saving technology and reap rewards that way.”An energy audit will identify areas where energy usage can becut and how to do it. If there is an investment, paybackcalculations will help to identify a schedule of projects. Somethings, like reducing leakage from compressed air lines andturning off lighting when no one is present can produce largesavings at little or no investment. “Most companies will havegone through this phase a few years ago,” reckons Parker-Bates.“But fitting inverters to motors and similar technical solutions stillcreate many more opportunities for energy savings.”Naturally, production companies with manufacturing orprocessing plant will have many motors to be assessed, butmotors are also found in air conditioning systems, driving pumpsin the plumbing, and many other pieces of equipment. All ofthese have the potential for significant energy and cost savings.“Many motors are left running continuously, even through thenight and at weekends; while others could be switched off for anotable proportion of their duty cycle,” says Parker-Bates. “Veryimportantly, it should be noted that a motor’s energyconsumption is proportional to the cube of its running speed. Socut its speed by half and you save 80 percent of the energy.There are huge numbers of motors in British industry that wouldbenefit from the installation of an inverter.”Parker-Bates identifies another strategy, too: “Considerreplacing the motor itself.” Motor efficiency has improved steadilyover the last 10 years, so any motor over a few years old may beinefficient by modern standards. Motors also tend to loseefficiency with use; another reason for considering renewal. “Untila couple of years ago it was common practice to oversize motorsso that they had a bit of extra ‘umph’ should it be needed. Butthis disregarded the increased energy demand. Nowadays, itsconsidered better to use a correctly sized motor and control themotor with a variable speed drive.”feedback@itmagazine.uk.comNovember 2010 • INDUSTRIAL TECHNOLOGY49

EAR TO THE GROUND • Becky Silvertonbecky@itmagazine.uk.comShoes and bags anda girl’s first love...Yes, boys, we know you hate to shop, but it’sone of a girl’s greatest loves. Which is whysome girlfriends and I all headed up toLondon for a bit of pre-Christmas windowshopping, just for a few ideas to add to our lists forSanta. A leisurely stroll along Oxford Streeteventually brought us to Selfridges where, uponwalking through the doors, we were confronted by arather long queue. Guessing it was probably tooearly for Christmas grotto season(and I for one am now just a littletoo old to be sitting on Santa’sknee) we joined the queue andsent a scout on ahead to find outexactly what we were queuing for.She returned a few minuteslater to paint a picture of a ropedoff area, with people being allowedthrough in ones and twos, underthe watchful eye of beefy bouncerjust in case things should get out of hand, and newsthat we were actually queuing to gain access to theLouis Vuitton bag collection. These rather draconianmeasures were being employed to prevent apurchasing frenzy in the wake of an LV shortage.There are many things for which I will toleratequeuing, but this was not one of them. So wemoved on. But, as you’ll imagine, we being typicallygossipy girls, Louis Vuitton became something of atopic of conversation and a recurring theme for therest of the day. I’m sure this is not the first time I’veheard of Louis Vuitton reporting a shortage, and Ibelieve there has been talk of customers beinglimited to purchasing just one product a day.Now I’m not going to question whether thecompany has production issues, and certainly thereis burgeoning demand in Asia for luxury leathergoods. But I wonder what would have happenedhad no announcement of a possible shortage beenmade. It seemed to me that the traffic into the LVsection of Selfridges was higher than it might havebeen normally had there been no worries of a lack ofproducts to purchase.Give us a reason to panic buy, and we generallytake it. In fact, even if you tell us there’s no reasonto panic buy, we still seem to rush to spend.Remember the last time someone told us there wasno reason why there should be a petrol shortage or abread shortage? We all rushed out, drained thepumps and stripped the shelves, thus creating ashortage of these key commodities. In short, howmuch of this is marketing spin to drive up demand?Or indeed, how much is Machiavellian mischiefmaking? I wonder how long it will be before avendor in our sector sees a marketing opportunity inthe recession that is (hopefully) behind us, andspotlights some area of sluggish restocking as acritical product shortage. What will our reaction be?I’d like to think that as an engineers withinsensible industries we’d probably be above any ofthis kind of panic purchasing, but then I do tend tobe prone to wishful thinking. Which reminds me: Ihave bags to dream of and a very important letter toSanta to write.SPS/IPC/DrivesNovember 23-25, 2010Exhibition Centre, Nurembergwww.mesago.de/en/SPS/main.htmMesago Messe Management(+49 711 61946-67)Southern ManufacturingFebruary 16-17, 2011FIVE, Farnborough, Hantswww.industry.co.ukETES (01784 880890)Southern ElectronicsFebruary 16-17, 2011FIVE, Farnborough, Hantswww.industry.co.ukETES (01784 880890)Packaging InnovationsFebruary 16-17, 2011NEC, Birminghamwww.easyfairs.com/piukEasyfairs UK (020 8622 4411)Health & Safety 2011 SouthMarch 1-2, 2011Sandown Park, Esherwww.healthandsafetyevents.co.ukWestern Business Exhibitions(01342 333720)MOTEK FranceApril 5-8, 2011Lyon, Francewww.industrie-expo.comPE Schall (+49 7025 9206-0)Machine BuildingApril 6-7, 2011NEC, Birminghamwww.machinebuilding.co.ukCanon (020 3147 4620)MEDTECApril 6-7, 2011NEC, Birminghamwww.medtecshowuk.co.ukCanon (020 3147 4620)Index to Advertisers November 2010Aerotech .................................................. 37Air Control Industries ................................. 10Air Control Industries ................................. 11Alcatel Lucent Deutschland ........................ 34Automation Supplies ................................. 47B&R Industrial Automation ........................ 39Balluff ..................................................... 31Bambi Air Compressors ............................... 9Boldman .................................................. 47Dell Computers ......................................... 52Elesa (UK) ............................................... 22EMS ........................................................ 35ETA Enclosures (UK) ................................... 5Euro Bearings ........................................... 14Festo ......................................................... 2Fibox ....................................................... 23George Emmott (Pawsons) ......................... 25Henkel Loctite Adhesives ............................. 7Hollin Applications .................................... 48Interroll .................................................... 37Lafert Electric Motors ................................ 36Lee Products ............................................ 41Lenze ........................................................ 9Machine Building Systems ......................... 43Man and Machine ..................................... 13Maxon Motor UK ...................................... 33Mayr Transmissions ................................... 37Mclennan Servo Supplies ........................... 43Micro-Epsilon UK ...................................... 29Micro-Epsilon UK ...................................... 48MK Profile Systems ................................... 47Monitran .................................................. 27NSK Europe ............................................. 15Phoenix Mecano ....................................... 45Poppelmann Plastics UK ............................. 7Protex Fasteners ....................................... 19RA Rodriguez ........................................... 17Reliance Precision ..................................... 42Reliance Precision ..................................... 51Rittal ....................................................... 20Rotalink ................................................... 33Sensor Technik UK .................................... 31Sensors UK .............................................. 29Sensortechnics ......................................... 31Spelsberg UK ........................................... 19Spirol Industries .......................................... 9Spirol Industries ........................................ 17Tandler Precision ...................................... 41Variohm ................................................... 27WDS Component Parts .............................. 45Wymark ................................................... 1750INDUSTRIAL TECHNOLOGY • November 2010

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