motion control - Industrial Technology Magazine

www.industrialtechnology.co.ukIndustrialTechnologyJuly 2008THE ESSENTIAL MAGAZINE FOR PRODUCT DESIGN ENGINEERS AND MACHINE BUILDERSMotors & gearmotorsEnclosures, cabinets & fansMotion control & positioningp20p24p30Springs, gas springs & dampersConveyorsFasteners & adhesivesp36p42p44Sensors & systemsHydraulics & pneumaticsMachinery safetyp48p54p60

COMMENT & ANALYSISIndustrial Technology ISSN 0967-5787 www.industrialtechnology.co.ukEDITORIALEditorMark Simms BSc Tel: 01732 773268PO Box 342, Fax: 01732 365676Tonbridge TN10 4WDmark.simms@itmagazine.uk.comADVERTISINGRegional Director (Home Counties & South East)Mark West Tel: 020 8857 3661PO Box 49256, Fax: 020 8857 6330London SE9 4WTmark.west@itmagazine.uk.comRegional Sales Manager (Midlands & South West)Helen Hardwick Tel: 01926 484648Unit E3 Holly Court, Fax: 01926 484690Holly Farm Business Park,helen.hardwick@itmagazine.uk.comHoniley, Kenilworth CV8 1NPRegional Sales Manager (North of England & Scotland)Jan Anderson Tel: 01978 3147301st Floor, Hesketh House, 3 School Road, Fax: 01978 314731Sale, Cheshire M33 7XYjan.anderson@itmagazine.uk.comDeutschland/Suisse/ÖsterreichEisenacher Medien Tel: +49 228-2499860Welckerstrasse 22, Fax: +49 228-65007653113 Bonn info@eisenacher-medien.deOverseasGeorge Bennett MA Tel: + 44 161 374 56151st Floor, Hesketh House, Fax: + 44 161 374 64363 School Road, Sale, it.marketing@itmagazine.uk.comCheshire M33 7XYPRODUCTIONProduction ManagerSarah Curl Tel: 0161 374 56151st Floor, Hesketh House, 3 School Road, Fax: 0161 374 6436Sale, Cheshire M33 7XYsarah.curl@itmagazine.uk.comMAILING ADDRESSESPress Releases: PO Box 342, Tonbridge TN10 4WDAdvertising Copy (Production Office): 1st Floor, Hesketh House3 School Road, Sale, Cheshire M33 7XYCirculation 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 sent free ofcharge to individuals in the UK who meet the terms and conditions of thepublishers. To apply for free regular copies, write to the CirculationDepartment. To those not meeting the terms and conditions, the magazine isavailable on UK subscription at a cost of £60 per year (10 issues). Singlecopies are £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 Headley Brothers, Ashford, KentOrigination by Sarah & Marknew wavePUBLISHING LTDAUDIT BUREAU OF CIRCULATIONSBUSINESS PRESSIt was never likethat back in my day…As a child of the ’70s, I grew up with the likes of Thunderbirds, Joe 90, UFO andCaptain Scarlet, happily absorbing whatever producer Gerry Anderson wanted tothrow at me. Knowing that these were programmes targeted at children, Andersonmust have been mindful of the limitations of a youngster’s attention span, andemployed the trick of using a teaser at the beginning of each episode that montaged some keyelements of the action; not enough to spoil the ending, but more than enough to keep youalong for ride. Fast forward three decades, and programme makers are still going all out to getus to the end of their offerings, but the strategies have changed.And they sure ain’t changes for the better.A big advantage for them is that hour-long TV programmesdon’t actually last an hour. Once you’ve allowed for the ad breaks,your episode now only needs to last 45 minutes. And forproducers worried about the attention spans of their audience,these little ad breaks are a godsend, ensuring that no viewer needsto concentrate for anything more than 12 minutes at a time.Where even twelve minutes might be a bit of a challenge, theproducers get around this by spending the last couple of minutesof any segment telling us what’s coming up after the break, andthe first few minutes of any segment reminding us what happenedbefore the break. That means that in any given hour-long slot, there’s probably only around 25minutes of programme to absorb. That shouldn’t be a problem for anyone. Should it?Well, the various members of my household have taken to watching a particular makeoverprogramme on Channel 4, where some hapless lady who has aged before her time and lost allgrip on the rules of fashion is put through an intensive programme of cosmetic surgery, fulldental work, lessons in make-up use, a radical hair restyling and a wardrobe upgrade. It’spretty gruesome stuff, and you’d think that that fact alone would keep viewers glued to theirscreens. But just in case, the producers have long employed all of the tricks we’ve discussedso far. And now they’ve found one more: to reveal the ending of the programme right at thevery beginning. There’s more, too, because at the end of the programme they also show youthe ending of next week’s show. Surely a line has been crossed here.At a time when the UK is trying to set itself up as a global hub of innovation and designexcellence, this is pretty worrying stuff. We seem to be suggesting a contradictory picture of apopulace who can’t offer any project their full attention for more than ten minutes at a time,and who demand instant results without any consideration for quality. Further, I reckon earlyexposure to Anderson’s futuristic visions were among the things that inspired me to take up acareer in engineering. What I wonder, might today’s TV inspire? Answers on a postcard...Mark SimmsEditormark.simms@itmagazine.uk.comFACT file...Think Automation and beyond...Slim power supply saves youtime, space and moneyPower + Signal + Display + Control + Switch + Safety = SolutionsWe are the obvious alternativeT. 08707 558 700 E. marketing@uk.idec.com W. www.idec.com• Universal AC/DC input• Output - 24Vdc @ 15, 30, 60, 90, 120 & 240 W• Over current and over voltage protection• SELV compliant (Safety Extra Low Voltage)• Long life - 70,000 hours minimum• SEMI F47 compliant (120& 240W only)• Approvals - CE, UL508, UL, C-UL, TUV, EMC & LVD• DIN rail mounting for easy installation• Finger safe - screw up terminalsMore details: Write in 30 on the free information card3

Contents1438This month in history: (1932) Disney releasesfirst cartoon in colour; (1949) First jet, theDe Havilland Comet, makes maiden flight; (1958)US Congress establishes NASA; (1964) Ranger 7takes first close-up photographs the moon6 INDUSTRY NEWS6 Diplomas will fail students8 Manufacturing shines through the gloom10 Urgent need for innovation in energy14 Design report: rail industry20 MOTORS & GEARBOXES20 Precision positioning sets air motors apart22 Motors and gearboxes: new products24 ELECTRICAL EQUIPMENT Enclosures, Cabinets and Fans24 Hermetic packaging incorporates heatsink26 Enclosures, cabinets and fans: new products30 DRIVES & CONTROL SYSTEMS Motion Control30 Servo research points the way to improved dynamics32 Servos broaden appeal to general purpose motion control36 MECHANICAL COMPONENTS Springs, Gas Springs and Dampers36 Coiled spring pins help to reduce assembly costs38 Springs make car interiors more comfortable40 Springs, gas springs and dampers: new products42 AUTOMATION COMPONENTS Conveyors42 More options for your conveyor requirements44 MECHANICAL JOINING Fasteners and Adhesives44 Adhesive dispensing with pneumatic valves45 Seeing the light with UV curing46 Fasteners and adhesives: new products48 SENSORS & SYSTEMS48 Solving automation challenges with moisture detection sensor50 Remote monitoring and control of plant and facilities52 Sensors and systems: new products54 FLUID POWER Hydraulics and Pneumatics54 The changing shape of pneumatics56 Modularising machine design and build58 Hydraulics and pneumatics: new products60 MACHINE BUILDING & AUTOMATION Machinery Safety60 Brake motor system meets ATEX standards62 Machinery safety: new products48ON THE COVERPneumatic cylinders madeto order for you withinfour hours See centrespread for detailsENGINEERING LITERATUREEssential reading fordesign engineers p16THE BIG QUESTIONHow do we deal with theconfusion over ATEX?p17COMPUTER AIDED DESIGNPTC helps bring advancedvehicle to market p18ENGINEERING DIARYJohn Richardson’s monthin viewp65EAR TO THE GROUNDBecky Silverton on the issuesaffecting manufacturing p66ALSO IN THIS ISSUE:FactfindersEvents CalendarIndex to Advertisersp64p66p66Next issue of Industrial Technology: The water and waste industry • Brakes, clutches and couplings • Linear and rotaryactuators • Cable management • Fasteners and adhesives • Sensors and systems • Machine building and automation • Safety4

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INDUSTRY NEWSwww.industrialtechnology.co.ukDiplomas will fail pupilsfor the working worldThere are mixed views on the latestraft of proposals for the sectorspecific proposals, with detractorssaying they could undermine theintegrity of traditional subjects, andeven arguing that their lack ofpractical work will ultimately failboth students and employersThe new diplomas, due to be introduced in September, willbe catastrophic for the education system and will notprepare students for the working world in the slightestaccording to leading recruitment specialist, ResourcingSolutions. Five diplomas are being rolled out which will includeconstruction and engineering, but despite them being hailed as thequalification of choice by Children’s Secretary Ed Balls many arealready wary of their introduction, including top class universities.Richard Lawrance, managing director of Resourcing Solutionscomments: “It is ludicrous that students can pass the constructiondiploma without even stepping onto a building site! It is essential forstudents to have experienced the practical side of the industry sowhat is the point in having these diplomas when they don’t even takestudents into the field. By allowing pupils to pass their diploma withwork experience in a shop for example and not even remotelyrelevant will be totally detrimental for the industry.”Huge government mistakeNot only will they have little practical experience, students who wantto pursue a career in construction may not even be accepted intotheir chosen university as many universities have said that theywould not automatically accept diplomas as they would A levels.Lawrance continues: “The Government has made another hugemistake. Some universities are already thinking of introducingentrance exams as they feel that the new AS levels are easier thantheir predecessors; so who knows what will happen to every studentin the country that chooses to take these diplomas.“We need to take a stand as there is already a skills shortage inthe construction and engineering industry and with pupils not evenhaving the right qualifications to carry out the roles, we are going toface great problems in the future.”It is fair to say that there are mixed feelings on the diplomasacross industry. Overall, employers have backed the sector relateddiplomas as a parallel qualification to GCSEs and A levels. They werecreated with substantial business input and retain the strong supportof employers. However employers are worried about the more recentproposals in the government’s diploma strategy to introduce a newrange of academic diplomas in areas including sciences. And CBImembers fear they would not have any greater value to young peopleor to employers than the existing GCSEs or A levels, and wouldinstead be an unnecessary distraction.The CBI says that it is fully committed to supporting the followingpriorities: improving school-leavers’ basic skills; continuing toenhance GCSEs and A levels; and making sure the more vocational,sector-specific diplomas are a real success. And the CBI is also keento work with the government to ensure the business communityunderstands the diploma grading system properly. But it is urgingpolicy-makers to streamline the number of levels of diploma to two,rather than increase it from three to seven as is proposed, whichwould simply be be confusing.There are also concerns that the over-loaded education systemcould not cope with all the planned reforms given the lack ofresources available, including too few specialist teachers in mathsand science, and a poor careers advice service. Going ahead withthese plans without tackling concerns, employers fear, could lead toa fractured two-tier education system with private schools opting forGCSEs and A levels, or even the International Baccalaureate, whilestate schools use diplomas.CBI director-general Richard Lambert comments: “We know thatemployers are really keen to have a positive role to play in educatingour young people. There has been genuine enthusiasm for the sectorspecific,vocational diplomas as firms recognise that they have thepotential to add real value to students who are keen to learn in-depthabout a particular sector and gainvital employability skills. Howeveremployers understand and valueGCSEs and A levels and firmlybelieve that these should remain acornerstone of the educationsystem.”Tackling theissues affectingmanufacturingNow in its fourth year, theEuropean ManufacturingStrategies Summit is theconference and networkingevent at which to find outthe answers to the keyquestions affecting allmanufacturing industriesacross the globe.The four day event from6-9 October begins withtwo exclusive tours takingplace in Leipzig: one atDHL’s new flagship Air Hubfor a demonstration of thelatest logistics principlesbeing implemented and theother at BMW’s state of theart production plant wherecutting edge best practiceand technology is beingused to maximise outputand manufacturingefficiency. Find out more atwww.ems-summit.com.Orders holdingup as prices riseWhile manufacturers saw amodest improvement intheir order books in June,the rise in prices ofmanufactured goods willcontinue almost unabatedover the next three months,warns the CBI.Ian McCafferty, the CBI’sChief Economic Advisersaid: “Manufacturingdemand is holding upreasonably well.Manufacturers, especiallythose exposed to the globaleconomy, have been lessaffected by the slow-downin domestic spending thanother sectors. At the sametime, however, there hasbeen no let up from theimpact of higher costs onmanufacturers, and theCBI’s data shows firms stillhaving to pass them on inhigher prices.”customised solutionsSpecialists in Brake MotorsFor stopping any applicationTo order a catalogue please contact us below.For the very latestproduct information,most up to date industrynews, plus companyprofile information, visitthe pages of IndustrialTechnology online atindustrialtechnology.co.ukTel. 01270 270022 Email. lafertuk@lafert.com www.lafert.com6More details: Write in 60 on the free information card

Designed tobe a part ofeverythingyou build.More details: Write in 70As a design or production engineer you're constantly looking for ways to simplify assembly.At the same time, of course, you want to reduce costs and improve performance. It’s a hardequation to balance. But it can be done – The Loctite range of engineering adhesives andsealants will help you do exactly that... and more. It’s the reason our products are usedand specified by manufacturers around the world. All Loctite products can be applieddirectly from the bottle or using Loctite Dispensing Equipment.To receive yourFREE sample, *log ontowww.loctitesolutions.com/ukFor further information contact one of our adhesive specialists.Call 01442 278100, email technicalservice.loctite@uk.henkel.com,or visit www.loctitesolutions.com/uk*Free sample restricted to the first 100 replies. Offer not open to distributors or stockists and ends in November.7

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INDUSTRY NEWSRightsizingin actionUrgent needfor innovationin energyGovernment Minister says innovation isvital, as the age of cheap power is overThe right drive technologyThe right choice of modelsThe right optionsThe right software toolsLenze drives & automationEnergy Minister MalcolmWicks said: “The age ofcheap power is over – sothere is an urgent need formore innovation in the powerindustry, to keep control of prices,increase efficiency, ensure reliabilityof supply and tackle climate change.”His remarks came as he opened theEnergy Innovation Centre atCapenhurst, near Chester – ahothouse for new energy businessesand technologies, which is expectedto create 18 new companies.Wicks added: “Britain is a nationof innovators and entrepreneurs, butwe often fail to bring the twotogether. The Energy InnovationCentre is an excellent opportunity totarget investment on good ideas,which will generate a stream ofvaluable new technologies.”Enter the dragonThe Energy Innovation Centre is thebrainchild of independent powerengineering specialist EA Technology,which is hosting the Centre at itsCapenhurst headquarters, andproviding business and technicalsupport that fledgling companiesneed to turn their ideas intocommercial reality. Financial supportfor members is allocated by aDragon’s Den style investment forum,representing four of Britain’s Biggestelectricity companies: Scottish andSouthern Energy, ScottishPower, CEElectric and Electricity North West.The NWDA and EA Technology arealso represented. Enterprises canalso become associate members,working off site.Innovation projectsEA Technology managing directorRobert Davis explained: “Theadvantage of this approach is thatthe companies that are going to buyand use the new technologies aredirectly involved in choosing whichones to invest in and develop. Thatgives new members a real flyingstart.” Davis also used the opening tolaunch a £1000 Grand Ideas Rewardscheme, offered to anyone whonominates an energy innovationproject which is subsequently takenup by the investment forum.The Northwest Regional DevelopmentAgency is sponsoring theCentre with a £1.5 millioninvestment. NWDA Board MemberPeter Hensman said: “The energyRightsizing for:smaller sizeslower costsfaster buildsmore performancewww.lenze.co.ukLenze10 More details: Write in 100 on the free information cardINDUSTRIAL TECHNOLOGY • July 2008

‘Green’ Power Generationindustry employs more than 50,000people and is worth £5 billion peryear to the region’s economy. TheEnergy Innovation Centre is anoutstanding example of co-operationbetween the private and publicsectors, which will stimulate moreinvestment in the North West’scontinuing tradition of innovation andthe advancement of new energytechnologies.”So what sort of technologies mightbe key in the advancement ofenvironmentally friendly energy? Well,Renold Clutches & Couplings hashelped to design a revolutionary newtransmission system for wind powerturbines that makes them lighter andmore efficient in operation. Renold’steam modified an overrunning spragclutch and vee pulley assemblyconnected to a gearbox via aRenoldflex torsionally rigid coupling.The gearbox is able to change thepitch angle of the turbine’s rotors indifferent wind conditions.Constant power levelConventional wind turbines normallyemploy fixed-speed rotors and in highwind conditions they have to contendwith large torque fluctuations that cancause power output variations,through the generator, of up to 100%.The new design counters this problemby employing a unique gearbox andclutch combination that allows rotorspeed adjustment through variationsin the pitch angle of the blades. Thisenables power output, through thegenerator, to be maintained at aconstant level regardless offluctuations in wind speed. In cases ofoverspeed the rotor reaches a fullyfeathered position and cuts out, butthe clutch allows the generator tocontinue running.A conventional system requiresextremely heavy and robust assembliesin order to contend with the largefatigue loads in high wind conditions.The new design, which incorporates aswept blade diameter of 33m, canattain speeds of 50rpm and is about50% lighter than conventional windturbines. This improves the cost toweight ratio and reduces operatingcosts as only three percent of therated power is consumed by thecomponents.Condition monitoringAs the use of wind turbines continuesto spread across the globe, systemsthat are able to remotely monitor thecondition of the rotating equipment isbecoming increasingly important,helping to give wind farms advancewarning of any impending turbinecomponent failuresFAG Industrial Services (F’IS) isthe maintenance and conditionmonitoring company within theSchaeffler Group. In early 2006, atotal of 49 ‘FAG WiPro’ (Wind TurbineProtection) systems were installed fora customer in two major projects inAustralia, and most recently thecompany has developed the ProCheckonline condition monitoring system forlarger wind turbines where the size ofthe components make it necessary touse additional sensor technology andto perform additional measuringtasks.Jointly developed with NationalInstruments, this innovative onlinecondition monitoring system canaccommodate up to 16 sensorchannels plus additional analogue anddigital inputs and outputs, and so canbe expanded from monitoring anindividual machine, right up tomonitoring complete production plantsystems or wind farms. Multiple FAGProCheck units can be connected to anetwork and managed using thesame database.www.mayr.co.uk“It’s onlywhensomethinggoes wrongthat youreallyappreciatethe value ofprotection!”Safety Clutches Safety Brakes Shaft CouplingsMayr Transmissions LtdValley Road Business Park, Keighley, West Yorkshire BD21 4LZT: 01535 663900 F: 01535 663261 E: sales@mayr.co.ukMore details: Write in 110 on the free information cardLubrication systemslllllCentralised lubrication systemsChain lubricationMinimal quantity lubricationCirculating oil lubrication systemsSpandau pumpsContact SKF today for furtherinformationSKF (U.K.) Limited01582 490049www.skf.co.ukJuly 2008 • INDUSTRIAL TECHNOLOGYMore details: Write in 111 on the free information card11

INDUSTRY NEWSwww.industrialtechnology.co.ukCoating allows composites tobe used at high temperaturesAerospace applications to benefit from the opportunity to preventcomposite delamination in high temperature environmentsAnew ceramic thermal barriertechnology will allow highstrength, lightweight materials tobe used in high temperatureenvironments for which they havepreviously been unsuitable. Believed to bethe only product of its type availablecommercially, the process is so effective itallows composites to function intemperatures above their melting point;testing for a typical application gave areduction in composite surfacetemperature of more than 125ºC.The new process, for which a patentapplication has been filed, offers theopportunity to ‘engineer’ the coating tosuit specific customer requirements,adjusting the coating properties boththrough-thickness and across the surfaceof a component to cope with ‘hot spots’and differing forms of heat transfer suchas radiant, conductive or convectiveheating. This new coating allowssignificant thermal protection with onlyminimal weight gain.Zircotec’s range of plasma sprayedcoatings is already successfully applied tometallic components reducing surfacetemperatures by over 170ºC in someapplications. The UK based firm has beendeveloping its composite coatings forsome time, and the Zircotec ‘engineered’multi-layer solution can now be adjustedto suit the operating environment,Rapid guide andshaft deliveryPrecision bearing and automotivecomponent manufacturer Schaeffler(UK) is now offering UK customersa rapid delivery service for itscomprehensive range of linear guides andmachined shafts. The Linear Quick-Centrewas opened recently at Schaeffler UK’smanufacturing plant in Llanelli, SouthWales. The well-equipped facilities enableSchaeffler to offer customers 24-hourdeliveries on linear systems, rails, shafts,cages and carriages, as well as twoworking days for delivery of machinedshafts.Schaeffler can machine shafts up to5m in length and monorails up to 3m inlength, with diameters between 5mm and80mm. Materials include inductionhardenedsteel, stainless steel andaluminium support rails.preventing delamination or structuralfailure. Still based on Zircotec’sproprietary ThermoHold technology, thecoating is designed to be robust and ishighly resistant to vibration andmechanical damage.Appropriate coatings“The thermal environment in aerospaceapplications is not always conducive tothe use of composites,” says Zircotec’ssales manager Peter Whyman. “ThisAward for consistent,high quality bearing supplyIn recognition of its quality products,processes and supply, the KaydonBearings Division has just received theprestigious Bell Helicopter PremierSupplier Award. Only AS9100 certifiedsuppliers can qualify for this award andthe winner must have maintained theconsistent delivery of quality-assuredproducts at a minimum frequency rate of98%. The helicopter sector is a primeresults in the use of heavier materials orbulky heat shields, which can reduceoverall performance. Our solution allowsengineers to access a range of materialspreviously unavailable.” To ensureoptimum results the Zircotec technicalteam prefers to work alongside thecustomer to specify the coatingarrangement that is most appropriate forthe application. Drawing from a range ofcoating parameters Zircotec is confident itcan offer a solution to any thermal issue.market for the Kaydon custom-engineeringand performance critical bearings. In theUK these products are supplied by RARodriguez; typical examples are rotormast and swashplate bearings. Theswashplate is a device that translates thepilot’s commands via the helicopter flightcontrols into motion of the main rotorblades.For more than 30 years, RA Rodriguezworldwide has been providing fullengineering support to aircraft companies.Indeed its aircraft products are fitted to alarge number of military and civil aircraftin the Western World including manyspacecraft. They are also used in manyother leading edge technologies such asoptical sighting systems and laser rangefinding.ERIKS strengthensSMC relationshipERIKS UK has signed an extendeddistribution contract with SMCPneumatics (UK). Under theterms of the new agreement,ERIKS UK becomes a Level 1National Distributor for the entireSMC range of pneumatic productsand services.MiniTec growswith acquisitionMachine building and framingspecialist MiniTec Maschinenbau,the parent company of MiniTecUK, has acquired the Spanishflexible assembly line and beltconveyor systems company Profiteam.The acquisition will addstrength and depth to MiniTec’sUK and world-wide presence withthe ability to provide an evenwider range of products andsolutions for machine builders andOEMs, including fully integratedflexible manufacturing systems aswell as belt, chain and rollerconveyor based assembly and testlines built to customerspecifications.Monitran sets upnew R&D operationMonitran has establishedMonitran Technology as itsformal research and developmentarm. The new company willconcentrate on the design ofinnovative products that exploitthe use of new materials,technologies and techniques,particularly where joint venturesor knowledge transfer partnershipsare involved.Global roboticspartner programTo help system integrators andmachine builders to differentiatetheir business and succeed in thefast expanding robot-basedautomation market ABB hasdeveloped a Global PartnerProgram. The Global PartnerProgram demonstrates ABB’scommitment to supporting activeintegrators and machine builderswith robots, software and servicesolutions that are customised foreach application. Partners haveaccess to ABB Robotics completeportfolio to help design andsupport their systems, machinesand solutions.12INDUSTRIAL TECHNOLOGY • July 2008

REQUEST YOURS NOWTHE ANSWER TO YOUR PROBLEMhave you got it yet?400 Pages Packed With ProductsContains Over 10,000 ProductsClear And Concise Line DrawingsAnd Data TablesFull Colour, Detailed Photographs23 Colour Coded SectionsEasy Search Via A Pictorial IndexAt The Front Of Each Section3D CAD Models Available OnlineOrder Your Free Copywww.c4mc.co.uk/intec07 or call 0845 606 1444More details: Write in 130 on the free information card 13

in. Two Moeller T0 switches have beenfitted in the cab to enable the driver toeasily switch the systems on and offFor such an application, the compactand robust design of the T0 rotaryswitches is ideal.Control functionsThe T0 range can be used for anumber of different switching andcontrol functions such as On-Offswitches, main switches, maincircuit/auxiliary circuit control switchesand instrument selector switches.Through their adaptability, versatilityand high degree of safety, such asfinger proof terminals and clearoperating state indication, theswitches in the T0 range can be usedfor a wide range of applications.All switches can be fitted instandard 22mm fixing hole ormounted by three-hole fixing, helpingto save time on mounting andwiring the products.MORE INFORMATION:Enter G145 or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for furtherdetails from Moellermobilized STEELcold rolled open sections andtubes for transportWelser Sections (UK) Ltd.Sovereign House, Stockport RoadCheadle, Cheshire • SK8 2EA / Great BritainTel (+44 161) 491 52 10 • uk@welser.comwww.welser.comMore details: Write in 150 on the free information cardMore details: Write in 151 on the free information card15

ENGINEERING LITERATUREDatasheet forlong life batteryYuasa Battery has published a newdatasheet covering its latest longlife standby 12V valve regulatedlead-acid (VRLA) batteries that aredesigned especially for use intelecommunications power applications.The four page datasheet providesdetailed specifications and information onthe Endurance ENL100-12FT batteriesthat feature 15 year design life and havebeen designed from the ground up to fitinto standard telecom equipment racks.Both terminals are at the front of the cellmaking it easier to connect batteries whensituated in power cabinets.The battery shape is different fromstandard designs being longer andnarrower so that just a single row ofbatteries is required in a telecoms rack.The front terminal design makes it easierto connect multiple batteries in systemsand also makes maintenance and replacementof batteries a simple operation.Engineers can simply slide out andreplace a cell without having to reach overmultiple cells and connect top terminals.Want a copy? .........................Enter G163 on the cardGuides for your book shelfand the latest brochuresEvery month, your hard working Industrial Technology team bringsyou the best of the latest industry guides, the most interestingcatalogues, and news of important updates to supplier web sitesThe New Moss Plastic Parts2008 – 2009 catalogue ispacked with over 11,000components suitable formillions of applications andmarkets. The catalogue has over320 pages and features over1,500 new products, including;a vast range of PCB supports,new style hinges and latches,machinery mounting feet, adhesivefixings, display products and manymore.The new product offeringrepresents the latest phase in aperiod of rapid product enhancement.During the last five years, Moss havemore than doubled their productoffering in order to provide a one-stopsolutionto its vast array ofcustomers. Many existing ranges havebeen extended to include a widerselection of popular sizes andcoloured items.The easy to use cataloguecontains technical productinformation and is indexed and colourcoded by product type. Thecoloured sections detail solutionsto satisfy a wide range ofindustries, with all productsfeatured delivered from stockwithin 24 hours.The new catalogue is availablein both, traditional print and onlineformat. The web version offers asearch facility, allowing selection byproduct name, description or partnumber. In addition, free productsamples can be requested online, 24hours a day.“This is our best and mostcomprehensive catalogue ever,” saysMatt Taylor, managing director for thecompany.Want a copy? ................Enter G164 on the cardActuation systemsPower JacksThis 275 page design guidefrom Power Jacks providesdetailed information for the useof screw jacks, electric linearactuators, roller screws, bevelgearboxes and othercomponents for buildingcomplete actuation systems.A leading manufacturer ofthese products, Power Jackssupplies its components worldwideas individual units or ascomplete motion systems,focusing on precise actuation,power transmission, andmechanical jacking.DC motorsParvaluxParvalux has a new 164 pagecatalogue for its range of DCbrushed permanent magnetmotors and gearboxes. Thiscompletely revised edition isthe result of a thoroughdevelopment process, andreplaces all previous materialrelating to the product line.The catalogue details 15permanent magnet motors withIEC and NEMA mountingoptions, 107 gear-motorcombinations, a full range ofintegrated planetary gearedmotors, and various add-ons.Control solutionsHawco ControlsHawco Controls has justpublished its latest Quick Pickfocus product guide, whichdetails product ranges that arealways available off the shelffor immediate delivery. Nowcustomers have more than1000 products to choose from,and prices have been reduced.Hawco’s Simon Dugdalecomments: “The QP catalogueis one of a number of tools thatwe have established to helpwith our customers’ dailyproduct demands anddecisions.”Electric motorsOEM AutomaticNew from OEM Automatic is acomprehensive cataloguefeaturing Panasonic, one of thelargest motor manufacturers inthe world, which has designedand developed a new range ofCE/UL/cUL and CCC globallyapproved geared motors.They cover powers from 6to 90W with improved motorefficiency, and all ball bearinggearboxes are rated to 10,000hours lifetime. Motors in therange consist of single phase230V and three phase 230Vor 400V models.Bearing replacementNSKNSK’s new BearingReplacement Guide is acomprehensive specificationand selection guide, whichenables bearing users toconvert to NSK bearings fromother manufacturers’ that arein need of replacement, buthave been withdrawn or areunavailable.The guide’s layout andcontent have been specificallydesigned to help bearing usersselect the best type ofreplacement bearings for theirapplications.Want a copy? ....Enter G165 on the cardWant a copy? ....Enter G166 on the cardWant a copy? ....Enter G167 on the cardWant a copy? ....Enter G168 on the cardWant a copy? ....Enter G169 on the card16INDUSTRIAL TECHNOLOGY • July 2008

QIndustrial Technology asksthe importantuestions...feedback@itmagazine.uk.comHow do we deal with the issues ofconfusion and ambiguity over ATEX?Mark Neal of Armagard has the answerDespite being in force for two years this month July, the Europeanexplosive atmospheres directive ATEX 137, is still causingconfusion to manufacturers. Although we have had ATEXlegislation since 2003, ensuring all new equipment adheres tosafety standards, it was only in July 2006 that ATEX 137 was introducedto cover all existing equipment which has to be assessed regarding risk ofigniting an explosion. Under ATEX employers are required to do a riskassessment of areas where explosive atmospheres might be present,establish hazardous areas (zones) and use ignition protection in theseareas. Failure to do so can invoke enforcement action from the Health andsafety Executive.However, many companies have found the ATEX directive misleadingwith some describing it as ‘overkill’ whilst others are over-zoning, which ispossibly costing them unnecessary expenditure in replacing equipment thatdoesn’t need changing. Richard Kay, marketing manager with sieves andseparators company Russell Finex, which supplies ATEX approvedequipment, reckons that only 50% of companies had not heard of ATEXwhen it was first introduced, but that although more companies were nowaware of the directive, it has led to all sorts of misinterpretation. Hecommented: “We are finding more people are aware of ATEX now butmany people are confused. Some food manufacturers are telling us it isoverkill and that they feel their areas have little explosive risk so ATEX isan unnecessary cost to them, while another manufacturer with an identicalplant may overzone the same area and replace all the equipmentunnecessarily.”The directive is there to give guidance but it is just too ambiguous. Itneeds to be simplified with companies knowing exactly what areas shouldbe zoned as. We regularly hear of companies that have replacedequipment unnecessarily from entire production lines when just a fewminor alterations may be needed. Some companies assume that allzones require the same treatment when in fact a zone 2 or zone 22area has a very low risk of explosion and may cost very little toensure the area is safe. Under the ATEX directive areas have to“More people are aware of ATEX nowbut many people are confused. Someare describing it as overkill, whilstothers are over-zoning. The directiveis there to give guidance but it is tooambiguous. It needs to be simplified”with companies knowing exactly whatareas should be zoned as.July 2008 • INDUSTRIAL TECHNOLOGYbe zoned with zone 20 being the highest risk zone for dust and zone 0 forgas while zones 22 (dust) and zone 2 (gas) are areas where an explosionis unlikely to occur. Recognising which zone you are dealing with is highlyimportant as the cost involved to meet the requirements of zones 20 or 21can be severe compared to zones 2 or 22 which may be relativelyinexpensive to adhere to. The Health and Safety executive says that it isaware that confusion over ATEX may exist but that it is doing everything itcan to assist businesses. A spokesman said: “It is a challenge for the HSEto engage with small businesses over the whole range of health and safetyissues. Recognising that explosions and fires from combustible materialsare a known hazard within the food industry, about a year ago HSE alsoproduced a web-based information sheet for the food industry on theprevention of dust explosions. Manufacturers and suppliers of explosionprotectedequipment are also doing much to raise awareness of the needfor employers to designate hazardous areas and use the right equipmentwithin them.”He added that companies wishing to know more about ATEX and otherhealth and safety issues should visit the HSE website at www.hse.gov.uk.Specific resources offering more information on dangerous substances andexplosive atmospheres are at www.hse.gov.uk/pubns/indg370.pdf andwww.hse.gov.uk/food/dustexplosion.htm.Mark Neal is MD of ATEX approved enclosure supplier Armagard.17

DAVE BROWN’SCAD ROUNDUPComputer aided design, engineering and manufacturingWrightbus brings advanced vehicleto market with PTCProduct innovation winner implements PTCWindchill and Pro/Engineer to improvetime-to-market and product developmentWrightbus, the UKmanufacturing divisionof Wright Group and oneof Europe’s leadingproviders of passenger transportsolutions, has adopted Windchill forproduct lifecycle management (PLM).Windchill, the PTC content andprocess management solution, hasenabled Wrightbus to significantlyimprove its collaborative productdevelopment processes.Wrightbus has been a user ofPTC’s integrated CAD/CAM/CAEsolution, Pro/Engineer since 2000, and“the selection of Windchill providesWrightbus with the additional benefitsof the PTC integral ProductDevelopment System (PDS)strengthening the business processesthat keep this innovative and awardwinning company ahead of its globalcompetition. “We believe thatWrightbus is the most innovativesupplier in the market,” says MartinGraham, director of IT and logistics atAccelerating microwave designAcceleware and Vector Fieldshave announced a partnershipto accelerate microwavedesign by combining VectorFields’ Concerto automation softwarepackage with Acceleware’s FDTDAccelerator solution.“Our partnership with Vector Fieldsallows Acceleware to leverage anothersoftware channel partner to furtherpenetrate the electromagneticsimulations market, providing asignificant boost in simulation speedthat allows users to push theWrightbus. “In order tomaintain that position werecognised that ourengineering processesneeded to become a seamless part ofthe overall business process. Byadopting Windchill as our commonproduct information managementplatform we are now able tosynchronise all our internal processesand our aim is to eliminate 50% ofnon-value-add activities inengineering.”Established in 1946 and based inBallymena, Northern Ireland,This highlights PLM as a critical areaof business investment, as market leadersstrive to increase operational efficiency”Wrightbus is still a family owned andmanaged company. A pioneer of lowfloorbuses in the UK, Wrightbus isrenowned for producing vehicles thatare stylish, durable, of the highestquality and with innovative features –such as their hybrid diesel-electricvehicle which won the RenishawAward for Product Innovation in 2007.With a growing customer base, whichhas expanded into Central Europe andboundaries of innovation,” says SeanKrakiwsky, President and CEO ofAcceleware Corporation. “As simulationbecomes more complex ourpartnership will provide superiorquality design to the broader market.”Vector Fields produces software formodelling and analysingelectromagnetic equipment and effects.Acceleware develops the fastestelectromagnetic solver technologyavailable on the market. Together, thetechnologies will offer RF engineers thetools they need to experience a 20the US, the company recognised thatthe existing product developmentprocesses couldn’t sustain furthergrowth. So Wrightbus initiated aprogram to improve productdevelopment and manufacturingprocesses.Wrightbus has establishedWindchill as its PLM platform tosatisfy its needs of improving productstructure management, changemanagement and work flow control.This in turn has enabled the release ofproduct structure data to theproduction system using an optimisedprocess flow and provided accuratedata release from the PLM to the ERPsystem. Joshua Fredberg, vicepresident for product and marketstrategy at PTC, says: “Wrightbushighlights the momentum of PLM as acritical area of investment in businessinnovation as market leaders strive toincrease operational efficiency andmaximise productivity in productdevelopment.”MORE INFORMATION:Enter G184 on the enquiry cardtimes performance increase in theirelectromagnetic simulations –shortening design cycles while greatlyincreasing the integrity of productdesign and safety.“Model sizes are getting bigger,”says Vector Fields’ Dr Kevin Ward.“But project timescales are going theother way. Acceleware-boostedConcerto simulation gives developersan edge to get right-first-time ideasproduced very early in market cycles.”MORE INFORMATION:Enter G183 on the enquiry cardMoldflow acquiredby AutodeskAutodesk has completed itsacquisition of MoldflowCorporation. Moldflow is aleading provider of softwaresolutions that allow designers topredict and optimise how plasticcomponents will perform duringeach phase of the design andmanufacture process. Autodeskacquired Moldflow for $22 pershare, or approximately $297million, less the amount inMoldflow’s cash balance andproceeds from options exercises.MORE INFORMATION:Enter G185 on the enquiry cardMaplesoft to sellMaple directMaplesoft has announcedchanges to its relationship withThe MathWorks, which hasresold the Maple engine underthe product names SymbolicMath Toolbox and ExtendedMath Symbolic Toolbox. As thepartnership between Maplesoftand The MathWorks is changing,the Maple engine will be soldexclusively by Maplesoft. TheMathWorks will continue to sellversions of the Symbolic MathToolbox and Extended SymbolicMath Toolbox which use theMaple engine.MORE INFORMATION:Enter G186 on the enquiry cardMechanica usergroup reformsFollowing the recent release ofMechanica Wildfire 4.0T the UKMechanica User Group hasannounced that it has reformed.After several years of inactivitythe newly reformed group willhold its first meeting in July. Thegroup supports all users ofPro/Mechanica which providesFEA tools for structural andthermal analysis. You can findmore at www.promechuser.org.uk18INDUSTRIAL TECHNOLOGY • July 2008

New distributors forUK and GermanyIntegrated Engineering Software,a developer of hybrid simulationtools, has announced theextension of its global network ofdistributors. The company hasforged relationships withMagtronics in the UK andTrimerics in Germany. The moveindicates Integrated’s intention toexpand its European market.MORE INFORMATION:Enter G195 on the enquiry cardSixth generationbrings PLM to lifeDassault Systèmes announcedthe market introduction of V6, anext generation PLM 2.0platform and solution set. Thissixth generation version leveragesthe success of DS brands and V5PLM. V6 harnesses the power ofWeb 2.0, Web 3D and DassaultSystèmes’ technology portfolio.MORE INFORMATION:Enter G196 on the enquiry cardCraft Pattern halves delivery timeswith PowerShape design softwareDelcam software has enabled a precisionparts maker to cut the time to producecastings from a month just to two weeksCraft Pattern & Mold hasreduced its delivery times byup to 50% in the ten yearsthat it has been usingDelcam’s PowerSHAPE designsoftware and the PowerMILL CAMsystem. The company provides rapidprecision plastic or metal prototypes,and low-volume production parts forleading companies in the aerospace,agriculture, automotive, consumerproducts, electronics, medical and toy“industries.Established in 1986 to providehigh-quality moulds and patterns forthe foundry industry, Craft Pattern cannow ship machined prototype partswithin 14 days of receiving thecustomer’s CAD file. According toowner Tony Cremers, “By combiningour technical knowledge with thelatest manufacturing technologies, weare dramatically reducingthe development time forour clients.” The companyusually produces six to tendifferent patterns a week,depending on their size andcomplexity.According to Cremers,the Delcam software allowshis company to create models andsecondary tooling in a day or evenhours. “Previously, it might have takenup to a month to turn around castingsor machined parts, but with theDelcam software, we can go from thecustomer’s CAD file to patterns tocastings in one to two weeks,” hesays. “The speed with which we canPreviously it might have taken a month toturn around castings, but with Delcam wecan produce castings in one to two weekscreate toolpaths not only keep deliverytimes to a minimum, but keeps ourshop running consistently.”MORE INFORMATION:Enter G194 on the enquiry card”More details: Write in 190 on the free information card19

POWER TRANSMISSIONMotors and GearboxesPrecision positioning capabilitysets these air motors apartHuco Dynatork says that its air motors can offer drive characteristicssimilar to those offered by performance stepper motors, and the latestgeneration has addressed a number of design considerationsThe continuous development of the HucoDynatork air motor has now led to theintroduction of the next generation of models(pictured right). According to the company, theserepresent the only air motors capable of precision positioncontrol. The new generation also addresses some of thedesign issues of the original design.On the original design, the pneumatic tubing wasexternal to housing and made the product vulnerable tosome degree. It also made it more sensitive totemperature extremes (although this problem that couldhowever be overcome by the specification of coppertubing). But the new generation overcomes all of theselimitation. The pneumatic porting on the latest models isnow an internal feature making them far more robust.Huco Dynatork has also recessed the fasteners to reducepotential bug traps to the benefit of hygiene conscioussectors. Because of their exceptionally clean operation,availability with non-lube air supply and corrosionresistance these air motors are ideal for the food andpharmaceutical production environments.Floating piston designThe indexing and positioning operations common in thesesectors are particularly well served by a Huco Dynatorkpiston air motor. Alternative makes operate with a systemof metal pistons and connecting rods that are unable toprovide instant stop/start. Not only is controllabilitycompromised but so too is service life as these partswear. The floating piston design of the Huco Dynatork airmotor transmits the maximum torque on start-up whichcan be adjusted to fine limits by standard air-flow valves.Pulse counters can be specified to allow programming ofdirection of rotation,speed and numberof revolutions,andeven fractionsof a revolution.This means the motorscan provide near instantstop/start/reversal anddrive under load withcharacteristics similarto those of astepper motor.These qualitiesare complementedby air consumptiononlya fraction ofthat used byvane motor designs,providingsignificant costsavings even atmaximum torque.There are a variety ofdifferent applications forHuco Dynatork piston airmotors that require precise speedcontrol. These motors excel in stop startapplications where speeds are below 800 rpm. Paintstirring is just one of them.Paint stirring considerationsIf the motor drives the impeller too fast then cavitationoccurs. The resultant bubbles in the paint will give a poorfinish. And if the paint is metallic, its suspended metalflakes will get crushed, producing an aesthetically flat andtherefore equally unacceptable finish. Conversely if thespeed is too low the paint will simply settle out. The HucoDynatork air motor is ideal in such an application asunlike a vane motor it is eminently controllable. Its freefloatingpiston design transmits maximum torque onactuation which can be regulated to fine limits by a selfadjusting control valve set on the air inlet.Pulse counters can be specified to programmedirection of rotation, speed and number of revolutions.This means the motors can provide near instantstop/start/reversal and drive under load withcharacteristics similar to those of a stepper motor.In common with their predecessors the new HucoDynatork air motors are available with maximum torquesup to 16Nm (or 550Nm with gearbox). Models areavailable in aluminium or acetal and may be specifiedwith a choice of motors and gearboxes or leadscrews. Afurther new introduction is a controller available in twosizes to suit the motor. Until now an electronic controllerwas the obvious choice for these motors but now HucoDynatork has introduced its own pneumatic regulatingvalve set that ensures constant speed regardless of load.This new Huco Dynatork controller comprises twocontrol valves. The first controls air pressure and thesecond adjusts flow rate. The controller works by sensingpressure drop across an orifice. Any reduction in pressureis proportional to flow rate and by feeding back this valueto the flow control valve via a diaphragm air flow isadjusted accordingly. This enables theconstant speed of the air motor to bemaintained automatically.Complementing the launches ofthe new motor and controllerproducts, Huco Dynatork hasalso introduced the MSworm gearbox withintegral torquelimiter. It stopsrotation of thelow-speedshaft wheneverthe stalltorque exceeds thecalibrated value ofthe internal torque limiter.In the event of a power cut this safetygearbox effectively locks and in the majority ofapplications this is an appropriate consequence.For others however it is a disadvantage.Dealing with loss of powerTake for example a motorised factory door. Whilst undernormal circumstances the MS gearbox would ensure safeoperation, loss of power can leave the door stuck open orclosed. It is for applications such as this, then, that HucoDynatork has introduced the MRV50.LS safety worm gearbox with disengaging torque limiter. A disengaging leveressentially provides a manual override so that, in ourapplication example, the door can still be operated untilpower is restored.The built-in torque limiter comprises a symmetricalcone on the output shaft acting against a hollow cone onthe worm wheel, all rotating in an oil bath. This givesprecise adjustment and consistency in the slipping pointduring torque overload. The low contact pressurebetween the conical hub and the worm wheel of thegearbox make constant adjustment unnecessary duringthe life of the product.Disengaging models are available for single-, threephaseand DC operation, with 40-80mm centres. Powerrange is 0.09kW to 3kW. These aluminium gearboxes aremanufactured in Italy by TS Power Transmission, acompany with considerable pedigree in the design andproduction of motors and gearboxes. In addition to itsextensive standard range the company is also able toaccommodate special requirements.MORE INFORMATION:Enter G206 on the enquiry card or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for further details. You can also findmore stories from Huco Dynatork and more news on air motors20INDUSTRIAL TECHNOLOGY • July 2008

Those who are already contemplating tomorrow’s solutions today must be at one withthe future.With a single objective: We want to make you more successful.We use our products, ideas and emotions to realise your visions. Six decades of experiencehave helped us develop a spirit for innovation and an uncompromising passion. Theresult: A group of companies with a clear philosophy that sets standards in outstandingservomechanical drive systems. High-tech products manufactured by WITTENSTEIN arelaunched into space, win Formula 1 races, widen the boundaries of mechanical engineeringand pave the way for advanced medical technology.United under one symbol worldwide.We are now all WITTENSTEINWITTENSTEIN – being one with the futurewww.wittenstein.co.ukMore details: Write in 210 on the free information card 21

POWER TRANSMISSIONMotors and GearboxesStainless steel drive productssuit outdoor and hygienic tasksA new range of stainless steel drive productsincluding motors, geared motors, actuators andcouplings is available from LenzeMachinery such as that usedto prepare meat and poultry,beverages, dairy, fruit,vegetables and tobaccousually consists of a mix of high asepticand low aseptic modules. In the highaseptic areas washdown with highpressure jets is needed. This in turnmeans surfaces that will not corrode andwithout dirt traps. Lenze now offers asolution for these applications in the formof both standard AC motors and servomotors in stainless steel.The standard AC motors are availablefrom 0.18 to 7.5kW and can becombined with worm gearboxes instainless construction and IP66Performancemotor bringsenergy savingsAnew high-performance motorintended for the OEM market thatoffers significant savings onrunning costs and space requirementsthat can be engineered to matchcustomer applications has beenintroduced by Lafert. Savings onoperating costs can amount to more than80%, says the company whilst themotor’s superior output to that ofstandard AC induction motors enablessignificant frame size reductions plusweight savings.The new Lafert high performancemotor combines the technology of bothbrushless permanent magnet motors andconventional AC induction motors.MORE INFORMATION:Enter G226 on the enquiry card, or visit ‘latest issuestories’ at www.industrialtechnology.co.uk forfurther details from Lafert Electric Motorsenclosure. The synchronous servo motorscan be combined with stainless steelplanetary gearboxes for rated outputtorques up to 450Nm in IP67 enclosure.Also meeting the washdown requirementis a range of linear actuators for forces upto 4500N and strokes to 750mm. Thesehave 12 to 42V DC actuation andenclosure up to IP68.Food and beverage machinery usuallyhas areas where the requirement is ‘lowaseptic’. Here the drive components needto resist moisture but not high pressurehosing. Lenze offers a wide range ofproducts, for example industrial PCs withtouch screen in an IP65 housing andIP65 enclosed inverter drives up to7.5kW. Spring applied brakes for holdingand emergency stop up to 235Nm arealso IP65 enclosed, as are a range ofLED signal towers. Flexible couplings,universal joints and locking bushes canbe supplied in stainless steel.MORE INFORMATION:Enter G225 on the enquiry card, or visit ‘latest issuestories’ at www.industrialtechnology.co.uk forfurther details from LenzeCompact servo motorsbring precise controlABB’s HDP range of asynchronousservo motors offers high dynamicperformance motors for machinebuilders and original equipmentmanufacturers (OEMs) from 19 to1400Nm (2 to 270kW). The motorsfeature high power density and a squareshape, making them easy to build intomachines. The motor sizes emulatethose of DC motors and can replacethese size for size. The HDP range hasexceptionally high dynamic performance,using a light rotor with small diameterto minimize inertia.The new motors willfind uses in areas asdiverse asinjectionmoulding,windersandunwinders inpaper production,cranes,lifting and conveying, test benches,theatre scene automation, park rides andspindle drives. They are robust andsuitable for operation in harshenvironmental conditions.The new range of motors includesmounting form B3, B35, V1 and V35with IP54 protection and axial cooling,and IP23 protection with radial fan. Awide range of accessories is available,including speed and positiontransducers, resolvers, encoders, holdingbrakes, insulated non drive end bearingsand winding temperature protection.Maximum speed is 9000rpm and themotors feature forced air cooling.Available in voltages from 400V up to460V, they are supplied with four polesfor frame sizes 132, 160 and 200, andwith six poles for frame size 100. Ballbearings are standard, whileroller bearings can besupplied as an option.The HDP servo motorfamily is optimisedfor operationwith the ABBmachinery drive,a performancerange ratedfrom 0.75 to45kW that usesstandard AC drive technology but whichoffers significant performanceimprovements.MORE INFORMATION:Enter G224 on the enquiry card, or visit ‘latestissue stories’ at www.industrialtechnology.co.ukfor further details from ABBCompactwheel driveFor in-hub applications thenew Framo MoratDiscPower electric motordriven gearbox provides a spacesavingand economical solution.The assembly comprises adynamic, brushless andmaintenance-free synchronpancake motor with integrated,low backlash planetary gearbox.DiscPower models areavailable from 0.42W up to 1kWwith up to 110Nm torque. Thecompact planetary gearbox withlifetime lubrication is available intransmission ratios from 5:1 up to50:1. It is smaller and lighterthan other gear configurations,has a higher efficiency and isexceptionally quiet running.This latest addition to the RARodriguez Framo Morat range canbe combined with a range ofmotor feedback systems such ashall effect sensors, encoders orresolvers to suit the application.MORE INFORMATION:Enter G228 on the enquiry card, or visitwww.industrialtechnology.co.uk forfurther details from RA RodriguezCompactbevel gearboxThe KBX range of single anddouble shaft outputgearboxes from Rino are acompact and simple design. Lownoise and high efficiency are justtwo of the key characteristics ofthese units, and they are easy touse and install as they can beinstalled in any direction ororientation. High grade grease issealed into the unit beforeshipping so that they aremaintenance free.MORE INFORMATION:Enter G227 on the enquiry card, or visitwww.industrialtechnology.co.uk forfurther details from Rino Industries22INDUSTRIAL TECHNOLOGY • July 2008

Space saving option forrotary positioning tasksArange of brushless servomotors with a separate rotorand stator design, aimed atthe smooth precise control anddirect-drive of large inertia or hightorque loads, is available fromHeason Technology. The Megafluxthin-ring torque motor from USAmanufacturer Emoteq Corporationhas an inherently large diameter-tolengthratio – from 150x30mm to760x123mm – and coverscontinuous stall torque from 3Nm toover 2000Nm.The frameless construction andspace-saving form factor of theMegaflux allows the motor to bedirectly integrated on the driven shafteliminating the resonance associatedwith flexible couplings. And with noneed for a gearbox, the hightorque/low cog output is backlashfreeensuring precise control.The large through-hole isespecially useful for accommodatingelectrical wiring and other servicessuch as slip ring assemblies andbeam delivery systems whilst theform factor will suit OEMs requiringrotary positioning axes in spacerestricted applications.Heason can supply the Megafluxthin-ring motor as a separatecomponent along with commutationand positioning encoders, servodrives and motion controls. Themotor can also be assembled oncustomer supplied components orbuilt into complete solutions.MORE INFORMATION:Enter G234 on the card, or visit ‘latest issuestories’ at www.industrialtechnology.co.ukfor further details from Heason TechnologyMore details: Write in 230 on the free information cardMore details: Write in 231 on the free information card23

NeedELECTRICAL EQUIPMENTto getthingsDry?Choose ACI’s Airknife drying systems for realfinancial savings over conventional alternatives.If your objectives are to increasethroughput, eliminate quality problemsassociated with other methods ofdrying/blow-off, or significantly reduceenergy costs, ACI will engineer a costeffective system for you … withguaranteed results.• Free Customer Site Evaluations (UK Mainland Only)Hermetic micropackaging withheat sinksThese hermetic packagings are specificallydesigned for electronics destined for theharshest environments including theaerospace and military marketsSouriau claims to be the firstequipment manufacturer inthe world to providehermetic titanium packageswith embedded heat sinks that canlower the temperature inside thehousing by as much as 50%. Thisinnovation has succeeded thanks to• Free Payback Analysis providedACI’s AirKnife Systems are powered by the company’sCentrifugal Blowers, delivering high velocity, warm, dry air withno pressure fluctuations for reliable, consistent, drying results.Please contact us for further detailed specifications and todiscuss suitability for your application.www.aircontrolindustries.comthe solution providers for air movement problemsAir Control Industries LtdSilver Street,T: +44(0)845 5000 501Chard,F: +44(0)845 5000 502Somerset,TA20 2AE, UK E: sales@aircontrolindustries.com24 More details: Write in 240 on the free information cardINDUSTRIAL TECHNOLOGY • July 2008

Enclosures, Cabinets & FansWe’re just full ofhotaircoolair,warmair,dryingair,slowair,fastair,smoothair,what ever air you want we gotthe formulation of a proprietary newbrazing joint. Electronic equipmentmanufacturers can benefit from theweight saving and low expansionadvantages of titanium whileproviding excellent thermaldissipation coefficient.Thermal conductivityThe hermetic housings are used tokeep sensitive electronic circuits ormulti-Chip-Modules in an inertatmosphere (argon or a neutral gas) toensure their good performances andreliability. Until now, the trade-off touse titanium properties (hardness,light weight, low expansioncoefficient, resistance to corrosion andnon-magnetic qualities) was to giveup on the thermal conductivity of thehousing. Indeed, due to titanium poorthermal conductivity coefficient, theheat created by the electroniccomponents encapsulated inside thepackaging could lead to over-heating,and eventually to failure. No externalcooling solutions can be implementedbecause the housings are hermetic.Today, the compromise betweenmechanical strength and heatconductivity is over. The R&D teamsat PA&E (Pacific Aerospace &Electronics, a member of Souriaugroup) have developed an innovativeproprietary brazing formulation thatcan be used to braze coppermolybdenumor aluminium-siliconcarbide inserts into a titaniumpackage, ensuring a leak rate lessthan 10-9 atm.cm3.s-1. The heatgenerated by the electronics locatedinside the packagings can thus bedissipated through the heat sinks. Theposition and shape of the heat sinkscan be customized to match the hotspots of aspecific application. The packagingcan be equipped with hermeticconnectors or simple feedthroughsindividually sealed to the housing.The connectors – usually micro-Dsor high-frequency RF connectors – arelaser welded to the housing ensuringlong term hermeticity. This assemblymethod also offers the advantage toeliminate the solder joint fatigueissue. Finally, such technology makesthis housing technology suitable forvery high temperature applicationsoperating continuously at 200°C andhigher.The individual feedthroughs aresealed with Kryoflex ceramic, aproprietary, patented, low firingtemperature substance materialdeveloped as an alternative for glassand metallized alumina ceramics, formaximum hermetic integrity.Dissimilar metalsPlating, such as nickel/gold plating forexample, can also be applied to thehousing, in spite of the presence oftwo dissimilar types of metal.Titanium is the material of choicefor housings because of itsconventional machining and lowdensityattributes. Being three timesstiffer than aluminium, titanium canbe used to redesign an existingaluminium box to be stiffer, lighterweight, more reliable, and betterthermally with the integration ofPA&E’s brazed heat sinks innovation.MORE INFORMATION:Enter G246 or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for moreinfo from Souriaufans and blowers for extraction, cooling,ventilation, aeration, vaccum and dryingA complete design and manufacturing serviceis offered by ACI for its extensive range ofsmall to medium industrial fans. Options arebased upon a comprehensive range of motorspecifications and accessories. ATEX approvedformats are standard options.• Flow rates up to 6000m?/hr (3500CFM)• Pressures upto 250mBar (100in.SWG)• ATEX versions• Volume and specialised bespoke supply• Wide range of motor specifications and accessories• Full design and testing facilities, including airflowand noise testing• ebm-Papst UK Distributor for special applicationsPlease contact us for further detailed specifications and todiscuss suitability for your application.www.aircontrolindustries.comthe solution providers for air movement problemsAir Control Industries LtdSilver Street,T: +44(0)845 5000 501Chard,F: +44(0)845 5000 502Somerset,TA20 2AE, UK E: sales@aircontrolindustries.comJuly 2008 • INDUSTRIAL TECHNOLOGYMore details: Write in 250 on the free information card25

ELECTRICAL EQUIPMENTEnclosures, Cabinets & FansIP67 push-fit grommet sealsare quick and easy to installSpelsberg introduces an innovative alternativeto cable glands that are 90% faster to fitSpelsberg has extended its range ofenclosure accessories to includethree new grommet seals fromSwedish manufacturer TST. The rangeincludes a basic gland seal, the TSSgrommet for less demanding low-costapplications, the rubber based Rutasealand the innovative Klikseal lockinggrommet. All three are push-fit designsand so are very quick to install, taking90% less time than a conventional cablegland. They provide ingress protection toIP67 and cost also considerably less thana traditional plastic cable gland.The Klikseal provides most of theadvantages of a cable gland whileavoiding many of its disadvantages,including its high purchase cost. Themain advantage is the fitting time for aKlikseal, which can be as low as tenseconds, compared with minutes for acable gland. The reduction in fitting timecan speed-up installation, and reducecosts on large installations and OEMassembly lines.Strong cable anchorageKlikseal is constructed using twomaterials, a high integrity plastic cageprovides the ‘click’ push-fit as the titlesuggests, adjusting to wall thicknessesfrom 1.5mm to 5mm automatically andexpanding to clamp the seal in place onceinserted. The shape of the cagecomponent also provides strong positivecable anchorage once the cable isinserted, something that was previouslyonly available from traditional cablesglands with internal clamping andlocknuts. Once fitted the Klikseal providesa total seal until the cable is insertedwithout the need for blanking plugs.Other advantages offered by all threesealing products include ease of fitting inconfined spaces where there is no roomto use the spanners needed to effectivelytighten a lock-nut.MORE INFORMATION:Enter G264 on the enquiry card, or visit ‘latest issuestories’ at www.industrialtechnology.co.uk forfurther details from SpelsbergHandle easeshot-swappingof boardsSchroff has introduced a newhot-swap-capable handle forthe insertion andwithdrawal of AdvancedTCAcarriers and MicroTCA mid-sizemodules. Featuring a rugged diecastmetal construction, the IEAhandle can be used withstainless-steel or aluminium frontpanels.The AdvancedTCAspecification defines two positionsfor the hot-swap microswitch: inthe plunger style, the switch isoperated from above, while in theTelescopic staysfor cabinet doorTelescopic cover stays from Emka areused for support of horizontal orvertical covers on control panels, forsupport or simply as a wind stay. Now thenew 1097 variants incorporate a facilityfor manual pushbutton or pull cordoperation. Use of a pull cord facilitatesoperation of widely spaced multiple stayson very wide covers. It also enablessimple operation and enhanced safety.Standard features of the 1097 seriesinclude automatic or manual release typesin sizes up to the new 710mm 1097-U6version. Automatic release operates whenthe open cover is raised then closed.Manual release ensures an added level ofsafety, requiring somebody to physicallypush the release button or pull the cordfor release.MORE INFORMATION:Enter G266 on the enquiry card, or visit ‘latest issuestories’ at www.industrialtechnology.co.uk forfurther details from EmkaETA takes a no-compromiseapproach to enclosuresIf you tend to buy standard enclosuresand then spend time and additionalmoney fitting those cabinets out withaccessories or having them coloured tosuit your needs, then ETA reckons it canoffer you big savings with its nocompromiseapproach to enclosuresupply.With its assemble to orderprogramme, ETA is offering to take awaythe strain of fitting cabinet accessories.The company can pre-assemble mostcabinet accessories for shipment,including plinth bases, additionalmounting plates and doors, and can stillship your enclosure to you within 48hours.If the standard colour is not suitable,then that’s no problem either. ETA’sspecial paint colour programme enablesthe company to paint its enclosures tomeet most customer requests. On volumebatches, ETA says the additional costs areminimal, and lead times are as little asthree to four weeks. On smaller batches,ETA can have your painted enclosure withyou in less than 72 hours.Machining servicesIf you need your enclosures machined toallow the installation of control products –for example, to accommodate pushbuttons and displays in the panel door –then for volume requirements ETA canprovide a machining service for boxes andcabinets in under three weeks and withminimal costs.ETA says it also understands theimportance of supplying not only theempty enclosure but also anycomplementary items such as powerdistribution and thermal managementproducts. To that end, it has partneredwith two of the biggest names in themarket – Wohner, which manufacturespower distribution systems, andCosmotec, a leading manufacturer ofcabinet cooling systems.MORE INFORMATION:Enter G267 on the enquiry card, or visit ‘latest issuestories’ at www.industrialtechnology.co.uk forfurther details from ETAlever style it is activated from thefront. The new handle is thereforeavailable in two versions to allowfor the correct activation of theswitch in both of these positions.MORE INFORMATION:Enter G268 on the enquiry card, or visitwww.industrialtechnology.co.uk forfurther details from SchroffHandles withmore styleAstylish recessed handle fromElesa makes carrying ofcases or mobile or traymounted equipment much easierthan struggling without hand grips.The recessed GN425.4 folds downflat when not in use and opens outto provide a sturdy secure handgrip when it is required. Itcomprises a robust diecast backingplate in black finish with four-pointattachment, housing a 10mmchrome plated steel carry handle.MORE INFORMATION:Enter G269 on the enquiry card, or visitwww.industrialtechnology.co.uk forfurther details from Elesa26INDUSTRIAL TECHNOLOGY • July 2008

AZ_TopPult_a4_4c_engl.indd 1 12.11.2007 10:28:36The aesthetics of functionality.New Rittal TopConsole.CompatiblewithTS 8 accessoriesThe new Rittal TopConsole enclosure system adds a touch of style to machine control.After all, it is not only the sleek design which enables it to blend seamlessly into everyconceivable work environment, but also the infi nite confi guration possibilities with systemaccessories of the TS 8 and CM enclosure series or the Rittal Industrial Workstation.Assembled or converted in a matter of minutes, the new Rittal TopConsole leaves no wishesunfulfi lled with regard to ergonomics and functionality. Rittal. Switch to perfection.Rittal Limited, Braithwell Way, Hellaby Industrial Estate, Hellaby, Rotherham, S Yorks S66 8QYTel.: (01709) 704000 Fax: (01709) 701217 Internet: http://www.rittal.co.uk eMail: information@rittal.co.ukMore details: Write in 270 on the free information card 27

ELECTRICAL EQUIPMENTMains board reduces deliverytimes for panelbuildersABB is dramatically reducing thetime it takes to specify andassemble mains distributionboards, with the launch of its Triline-Renclosure range. With availability to thecomplete ABB product range, Triline-Rwill reduce delivery times down toseven to 15 working days.With most components preinstalled,the Triline-R enablespanelbuilders to realistically deliver amains board to their customer withinjust a few weeks after ordering it fromABB. Nick Reidy, product manager forenclosures at ABB, says: “We trialledthe Triline-R in the UK last year, andwere surprised by the level of demandwe experienced. This high level ofinterest has led to us offering it to amuch wider audience. We’re reallyexcited about this product, because itwill change the whole process ofconfiguring and delivering a mainsdistribution boardto users.”Designed toreduce the processof configuring theboard, ABB hasalso produced thePanel DesignConfigurator (PDC)software tool, toenable panelbuilders to configure aboard themselves. Available free topanelbuilders from ABB, it includes aparts list, circuit diagrams and agraphical representation of the frontview of the distribution board.Using the software panelbuilderscan now select and plan their board,and choose the parts required. Partscan be dragged and dropped onto thefront view image to check compatibility.The software tool will confirm that theparts builders selected are suitable.They can then be placed onto an orderform and sent to ABB.The PDC software also provides theflexibility to export data and parts liststo other Windows programs. It can alsobe used for project planning purposes,storing and managing data alongsidebuild projects.MORE INFORMATION:Enter G286 or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for more infofrom ABBMini breathersfor electronicsenclosuresBrownell has introduced MiniImmersion Proof Breatherswhich eliminate pressure buildupfrom heat within electronic productenclosures that can otherwise fracturelightweight housing materials,allowing equipment to breath butpreventing water and dust ingress incorrosive and hostile conditions.Made in plastic and metal able tosuit aggressive and high or lowtemperature environments, thesebreathers solve the electronicequipment design dilemma of eitherrestricting applications or increasingenclosure strength. They canwithstand driving rain or even totalimmersion in water for long periods.The units can pass high flow ratesof air resulting from rapid changes intemperatures and pressure.MORE INFORMATION:Enter G285 or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for more infofrom BrownellMore details: Write in 280 on the free information card28

Enclosures, Cabinets & FansVariable technology fitsmodular Slim-Box VarioRittal has introduceda new range ofhorizontally cooledhousings for CompactPCIor VME systems. Completewith integrated powersupply and climate controlfeatures, the 19in rackmounted Slim-Box Variooffers a powerful solutionfor small electronicenclosures.Space saving Slim-Box Variohousings are 300mm deep anddesigned for the installation of cPCI,cPCE Express or VME64x boards in3U or 6U format and optional rearI/O boards. Two slots per U or heightare available at the front and rear.The housings contain a VME64x orcPCI backplane, which can bemonolithic with integral powerconnection for hot swap applications.Optimum ventilationTo accompany the horizontalarrangement of the boards, DC fansin the left hand side panel provideoptimum ventilation of the housing,via a slide-in fan unit with air filterand 12V DC fans. The fan unit andIP65 sealed enclosureis stylish and ruggedHammond’s new 1457 rangeextends the capabilities ofthe 1455 extrudedaluminium family of small enclosureswith the addition of IP65 sealed diecastaluminium end panels, enablingthe enclosure to be used in dusty andwet environments. The end panelsfilter mat is easily removed forservice and cleaning. With fans tothe left and memory to the right,Slim-Box Vario provides sufficientinstallation room for a slim CD-ROMdrive and for a standard 3.5in harddisk drive.Power is supplied either by anATX power supply or optionally as ahot-swappable, plug-in power supply.Accessories include guide rails,monitoring components and frontpanels. Housings can be customisedusing a range of standardcomponents.MORE INFORMATION:Enter G295 or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for moreinfo from Rittalare available with or without integralflanges that enable the enclosure tobe mounted to an external surface.The 1457 Series are designed tohouse PCBs, mounted horizontallyinto internal slots in the body of thecase; they can also be used to houseany small electronic, electrical orpneumatic components. They areavailable with clear anodised ortextured black painted finish for goodresistance to wear and tear. The IP65sealing is achieved through the useof O-ring screw seals and closed cellpolyethylene sealing gaskets.An initial six 1457 sizes areavailable, ranging from80x59x31mm to 160x104x55mm.The largest size will accept astandard 160x100mm Eurocard.MORE INFORMATION:Solid partnerwith FlexibleSolutionsAn instinctive mixture of incrediblyrobust, yet elegant Italianstyling, fused with innovative qualityand design, is what sets us apartfrom our competitors.And when you add twenty five years of productdevelopment experience coupled with the flexibilityof standard or tailored solutions, you willsee that experience becomes visible in everyone of our products from the smallest terminalbox to the largest modular cabinet system.So why compromise? Call ETA today.ETA ENCLOSURES (UK) LIMITEDAnd from first order tofinal delivery, our totalcommitment to customerservice and satisfactionis FIRST CLASS!Ignite, Magna Way, Rotherham S60 1FDTel: 01709 386630 E-mail: info@eta-enclosures.co.ukFax: 01709 369524 Internet: www.eta-enclosures.co.ukEnter G296 or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for moreinfo from HammondJuly 2008 • INDUSTRIAL TECHNOLOGYMore details: Write in 290 on the free information card29

MOTION CONTROL & POSITIONINGImproved DynamicsServo research points the way toimproved dynamicsEngineers want to use servos in ever moredemanding application, and research and has ledto the development of vastly improved dynamics,even with the most challenging of loadsThe ease of set-up of modern servodrive systems, combined withsteadily reducing costs, has madeservo control an attractiveproposition across the spread of motioncontrol applications in a wide range ofindustries. Despite the developments ininverter technology which promise nearservoperformance, in the most demandingapplications which require a fasterresponse and precise control of position,velocity and torque, only true servo systemscan really cut the mustard.Ready access to servo technology, andthe steadily increasing capabilities of servocontrollers, has seen machine designspushing the boundaries ever further, withfaster system response becoming anincreasingly common industrialrequirement.With a perfect load, this would notrepresent a problem. But no load is perfect.Practical mechanical drive systems can becomplex, incorporating several non-stillinterconnecting shafts and elasticcouplings, all characterised by a dominantresonant frequency. Fast impulse signalsfrom the servo controller excite torsionalresonances through the drive train, leadingto controller instability – particularly badlyas the servo controller bandwidthapproaches the resonant frequency of theload. This torsional resonance, then, is asignificant factor which limits the ultimatedynamic performance achievable byeven the best servo systems. Inlooking to damp these oscillations,the obvious answer is to measure andcontrol the torsional resonance usingshaft torque feedback techniques, buttraditionally this has proved achallenge because the lack of reliable,low-noise, low-cost shaft torquetransducers that are non-invasive tothe mechanical drive system haveprecluded the use of direct torquefeedback in all but a minority ofspecialises closed-loop servo drivesystems.Simple solutionNow, though, research in the PowerConversion Group at ManchesterUniversity, led by Dr Nigel Schofield,is focusing on the use of a noncontact,digital torque measurementsystem developed by SensorTechnology. Based on SurfaceAcoustic Wave (SAW) technology,these TorqSense transducers providea low-cost mechanically simple,torque measurement solution forbrushless servo drive-systemapplications, providing activedamping and/or resonance ratiocontrol.Using the SAW based TorqSensetransducer, it is possible to accuratelymeasure instantaneous shaft torquefrom the various mechanicalcomponents of the drive train inducedby the fast transients from thecontroller. Coupling of the signals tothe outside world is via anelectromagnetic coupling device,allowing non-contact torquemeasurement.The primary frequency ofoscillation can be chosen anywherefrom 100 to 1000MHz, with thedifference frequency varying up to1MHz. Operating at such highfrequencies, these transducers aremuch less susceptible to electricalinterference than conventional torquesensors, and this high immunity tomagnetic fields in particular makesthem eminently suitable for use withmotors.The Sensor Technology TorqSensetransducers built on SAW technologyare designed to operate with a PLC orPC, making it easy to interface themwith standard controllers, and sofurther reducing the overall cost ofintegration in servo drive systems.Being compact and wireless, theyalso greatly simplify the mechanicaldesign and so further reduce theoverall cost of the whole system.Easily embedded within the drivesystem, the TorqSense technology canwithstand heat, dirt and mechanicalvibration that represent problems foroptical sensors in particular and theirnon-contact coupling between theshaft and the controller eliminatesany issues of mechanical compliance.The system integration andcontrol studies at the University ofManchester are already highlightingmajor benefits for tomorrow’s servodrive systems, offering the potential ofservo drive trains that are ‘intelligentlyrigid’ and so free from torsionallosses. The result could soon becommercial servo products thatdeliver improved performance andvastly superior system dynamics witheven the most demandingmechanical loads.MORE INFORMATION:Enter G305 on the card, or visit ‘latest issuestories’ at www.industrialtechnology.co.ukfor further details from Sensor Technology30More details: Write in 300 on the free information cardINDUSTRIAL TECHNOLOGY • July 2008

Geared Motors \ Industrial Gear Units \ Drive Electronics \ Drive Automation \ Worldwide ServiceThe New DR Motor-Efficiency Classesto meet all your requirements24HOURDESPATCHMotor range interchangeablewith DT/DV designAll efficiency classes areconfigured from just one seriesMotor conforms to allefficiency standards worldwideIncreased cost effectivenessdue to different brake sizeoptions24 hour despatchExtensive UK stocks for allefficiency modelsSEW-Eurodrive Ltd.Normanton,West YorkshireWF6 1QRTel: +44 (1924) 893855Fax: +44 (1924) 893702www.sew-eurodrive.co.uksales@sew-eurodrive.co.ukCompact design with costsavings24hr EmergencyTel: 01924 896911WHAT WE DRIVE...WE CONTROLMore details: Write in 310 on the free information card 31

MOTION CONTROL & POSITIONINGServo SystemsServos broaden their appeal togeneral purpose motion controlSilverteam managing director Stuart Harvey looksat the reasons behind the fast growth of servosystems, and examines the benefits users canexpect to reap by embracing servo technology ina broad spread of motion control applicationsThe latest findings from IMSresearch paint an astonishingpicture for servo motiontechnology. First there was thenews that the global market for generalpurpose motion control has reached a valueof around $6,208 million. And secondlythere was the truly surprising aspect wasthat the rapidly increasing market for servoproducts currently accounts for 80% of thattotal motion control market.What must this mean in terms ofmachine design? Simply, that today’sengineers are pushing the envelope ofmachine capabilities harder than everbefore. Abandoning the race to compete oncost with the imports from the low wageeconomies, UK machine builders arestriving to deliver machines which boostproductivity and reduce downtime, givingend users the best possible chance toachieve world class OEE figures.Doubtless there will be many who stillshy away from servo technology. We mayall recognise the benefits, but theperception of the servo system is still of onewhich is costly and complex to design intoan application, and which requires aspecialist to set it up. But the sameadvances which have made standardAC drives so appealing in automationapplications are also permeatingupwards into servo products. Servodrive manufacturers have put manyyears of development into productswhich are now virtually as easy toinstall and tune as a general purposedrive – and certainly no more complexthe design into an application thanthe mainstream inverters boastingservo-like performance.Falling servo pricesPrices for servo drives have also fallendramatically in recent years – by asmuch as 30% since 2003 accordingto IMS. Some of this has come fromthe usual ongoing reductions inmicroprocessor prices year on year,but the servo manufacturers have alsorecognised the potential benefits ofremoving many of the highlyspecialised functions that tailored theproducts for only a very limitednumber of specific applications,further relaxing prices. The net resultof these two factors has been that, asthe requirements for machine controlhave trended up towards the servoend of the performance market, so theprice and performance appeal of theservo systems has trended downtowards the general purpose end ofthe market.The specific advantages of servodrives and motors are well known.Servo systems offer the highest levelsof dynamics in a given application,able to rapidly accelerate anddecelerate even the most demandingloads at high rates with absoluteprecision. The low coggingcharacteristic of servo motors givesthem extremely smooth rotation atlow speeds, while closing thefeedback loop between the motor andthe drive ensures the greatest levels ofpositioning accuracy.Servo motors are highly compact– much more so than standardinduction motors – which can be akey factor in modern machine design.But more important than the physicalsize of the motors is their ability todrive a given load directly, without theneed for some complex mechanicalequipment in between.All of these characteristics areembodied by the latest Hitachi servoproducts from Silverteam – Hitachi’sautomation partner in the UK. Inparticular, Hitachi has developed apatented ‘Advanced MotorTechnology’ which delivers up to 65%reductions in cogging torquecompared with conventional servomotors. This significantly reducesvibration for smoother rotation at lowspeeds, as well as ensuring thehighest response speeds for moreprecise control. Partnered with aHitachi AD series drive, positioningspeeds of just 0.84msec can be easilyachieved, with stable rotation at eventhe very lowest speeds.Set-up is aided by the PC-based‘AHF’ software which provides agraphical environment for settingparameters and monitoringpositioning, speed and torque. Thedrives also feature an auto-tuningfunction which enable them toautomatically set the most desirablecontrol gains to optimise systemperformance.MORE INFORMATION:Enter G325 on the card, or visit ‘latest issuestories’ at www.industrialtechnology.co.ukfor further details from Silverteam32More details: Write in 320 on the free information cardINDUSTRIAL TECHNOLOGY • July 2008

More details: Write in 330 on the free information cardMore details: Write in 331 on the free information card 33

Adoption of Lean ManufacturingTechniques at ASCO NUMATICSImproves Responsiveness andIncreases ProductionThese days it is rare for an international manufacturingcompany to be moving production into the UK but that isexactly what is happening at the ASCO NUMATICS LTDplant in Skelmersdale, Lancashire.ASCO NUMATICS manufacture a rangeof fluid control and fluid power productsat their Skelmersdale facility. Therange includes coils, solenoid valves,pneumatic cylinders and manifolds. The companyhas seen production steadily increasing over thelast few years. These increases are attributedto the employment of Lean manufacturingtechniques, which have also had a direct impacton the service that the company is able to offer toits UK customer base.There are two distinct sides to the business atSkelmersdale. These are the manufacture of theNUMATICS pneumatic cylinder ranges and themanufacture of ASCO solenoid valve and coils.Lean manufacturing techniques have enabled thecompany to dramatically reduce the delivery timeson its cylinders - bringing benefits to the customer- as well as impacting on the production of coils.Reducing the cost of coil manufacture has led tothe transfer of production from other Europeanmanufacturing plants to the UK.Lean manufacturingLean manufacturing, in its simplest formis about getting the right quantity of the rightthings, to the right place, at the right time, whileproducing the minimum amount of waste andbeing flexible and open to change. A key principalis that the employees who build the products ownthe process. Lean is a combination of provenmanufacturing and operational philosophies suchas Just in Time, Kaizen, Kanban and Total Quality.“Previously, cylinders used to be manufacturedin accordance with an MRP (ManufacturingResource Planning) process that was heavilycomputerised and complex,” said Works ManagerHarry Vicary. “Each cylinder that was manufacturedhad its own unique BOM (Bill of Materials) that hadto be loaded onto the computer system. Whenevera customer required even a minor change it wasnecessary to create a new BOM which was thenstructured to show all the piece parts required.For a manufacturing company that is able toaccurately predict customer requirements thisis fine. However, it does not lend itself so well tocompanies like us that need to respond quickly tourgent customer needs.”The employees that build the products own the process34More details: Write in 340 on the free information card

The new Lean philosophy has eliminated a lotof wasted time and unnecessary paperwork fromthe process. As an order is received it is postedto the computer system which is then updated onthe shop floor every ten seconds. Every componentthat is required to make the cylinders is on Kanbanwhich is a signalling system used to “pull” workthrough the system as opposed to the “push”system used in MRP. When components in anyof the Kanbans reach their reorder levels then theteam leader has direct access to the supplier andcan arrange for more material to be delivered.The team leaders routinely check thecomputer for new orders. They also check thecustomers required delivery to ensure that all of thecomponents that are needed are in stock. Providingthe order can be completed it is acknowledgedand entered to the production plan. If any of thenecessary components are not available then theorder is rejected, however this currently representsless than .002% of all orders. If a requested deliverycannot be made due to stock shortages then thecustomer is immediately contacted with an expecteddelivery date.Dependant on requested delivery, ordersare moved from the production plan into work inprogress (WIP). This generates a demand signalthat immediately propagates through the entirechain, pulling all the necessary componentsthrough. The number of jobs in WIP at any one timeis tightly controlled and once there, they should becomplete within one hour.Four hour deliveryThe changes that have been made tothe manufacturing processes enable ASCONUMATICS to offer cylinders, made to orderand ready for delivery within four hours of orderreceipt. Making to order enables a vast range ofcylinders to be produced to specification insteadof a customer having to accept a cylinder froma limited range held in stock. Providing contactis made before 1:00 pm, ASCO NUMATICS canhave a cylinder ready to ship that day. Cylinderscan be despatched by taxi, overnight courier, orthe buyer can collect.The same Lean manufacturing techniquesemployed on the cylinder line have also beenadopted for the manufacture of solenoid valvesand solenoid coils. The company manufacturesthe complete coil from winding through toassembly, encapsulation and testing. AdoptingLean techniques has seen the cost of productiondrop significantly and as a result, production fromother European plants has been transferred toSkelmersdale.Originally manufacturing for the UK marketonly, ASCO NUMATICS output was 100,000 coilsper annum in 2002; now it manufactures 1.2 Million.This is expected to increase to more than 2 Million.“Key to the success of our plant is ourworkforce,” said Jean Christophe Serkumanian,Managing Director of ASCO NUMATICS in theUK. “Responding to these changes, our workershave risen to the challenge, taken ownership anddriven these changes through. We are now muchmore responsiveto customer needsand in turn areimpacting on thelocal economy bysecuring continualemployment.”Jean ChristopheSerkumanian,Managing Director ofASCO NUMATICS inthe UKWhen your factory has stopped.Every second counts.With an extensive range of pneumatic cylinders, made toorder within four hours, ASCO NUMATICS is able to get mostplants running within a few hours of a breakdown.By manufacturing to order we are able to supply exactly whatyou need, and not compromise on plant efficiency or safety.To challenge us call 01695 713600.www.asconumatics.co.uk4 hourServiceMore details: Write in 350 on the free information card 35

MECHANICAL COMPONENTSSprings, Gas Springs & DampersCoiled spring pins help toreduce assembly costsIn any assembled component there are two ways to reduce theoverall cost of the assembly: reduce the cost of the individualcomponents or reduce the cost to assemble the components. Thisadvice from Spirol highlights the role of the coiled spring pinThe coiled spring pin is designed to be aversatile, integral, and cost-effective solution tomany assembly problems. It can lowerassembly costs by reducing the complexity oflarger, more expensive components, or by combiningfunctions into one pin, eliminating the need foradditional pieces. In addition to simplifying the designof an assembly, the coiled spring pin is easy to usedwithin automated processes, thereby reducing assemblytime and the labour required for completion.Coiled spring pins have several uniquecharacteristics that allow them to reduce total assemblycost. The coiled spring pin is designed to be aninterference fit part that conforms to the shape and sizeof the mating component’s hole. By coiling, or flexing,during insertion into the hole, the pin provides aretention force that will keep it in the hole for the life ofthe assembly. Unlike other types of spring pins thatbend only opposite the seam during installation, theentire coiled spring pin deflects, thus providingcomparatively low insertion forces and nearly uniformcontact stresses on the inside surface of the hole. Thisis important in protecting the mating component, sincepoor insertion and high contact stresses can lead topermanent damage to the mating component. It is notunusual to have a poorly designed pin skive either basematerial or plating from the host part during assembly,thereby causing poor joint performance or possiblyreduced corrosion protection.In comparison to solid pins, when coiled spring pinsare used there is no permanent damage to the host partduring assembly. Pins having external knurls or grooveswill always, by design, cut into the mating part. Evenhardened ground dowel pins, when driven into aprecisely reamed hole, will damage the hole whenremoved. It is no accident that a standard series ofoversize dowel pins is available. This method ofassembly results in the inability to rework a part eitherin the factory or in the field. With a coiled spring pin, itis simply a matter of driving the pin out, the host partis like new.Unmatched characteristicsDuring its use, the coiled spring pin brings a level offlexibility and shock absorption that is impossible tomatch with any other type of pin. A gear pinned to ashaft may have a near constant shear load appliedwhen running under a constant load, but upon startupand braking, significant increases in shear loads arerealised. When using a solid pin, this peak shear loadmust be accounted for, often requiring larger shafts orstronger materials which all increase costs. When usinga coiled spring pin, the pin will deflect slightly,absorbing some of the excess startup energy. Oncesteady state operation is achieved, the coiled spring pinwill return to it’s original condition without damagingeither itself or the mating parts. Compared to otherspring pins, coiled spring pins can absorb considerablymore deflection.In many applications, coiled spring pins can be usedto replace a non-pin alternative. Axles, gasket retainers,pivots, hinges, and levers are all common uses of coiledspring pins where the inherent benefits of the coiledCoiled spring pins suit a myriad of automotive under bonnetapplications, including automatic transmission shift housings,intake manifold control valves, ignition coils and gears, as well asmore general automotive tasks such as storage cases, fuelassemblies, accelerator pedals, door handles and glove boxesspring pin enable it to replace a traditionally non-pincomponent. Hole preparation is another importantfactor in reducing costs. coiled spring pins operate inholes with relatively wide flexibility under load: coiledspring pins continue to flex after insertion when a loadis applied to the pin. tolerance. In most operations,coiled spring pins can be installed in holes that havebeen drilled rather than prepared with an expensivereaming operation. The flexibility of the coiled spring pinalso means that holes do not need to be accuratelyaligned. It is no longer necessary to drill and pin atassembly – you only need to pin. In addition, stamped,fine blanked, cast, sintered, or laminate assemblies areall suitable hosts when using coiled spring pins.None of these features are beneficial if the pincannot be easily presented for installation. The coiledspring pin has square, burr free ends with concentricchamfers on both ends, and is manufactured to tightlength tolerances. These features allow for easyengagement with the hole, and problem free bowl andtube feeding. The coiled spring pin does not need to beoriented within the mating parts, thereby permittingsemi or fully automated assembly systems to operate inlieu of labour intensive pinning operations.To further enhance the ability of the coiled spring pinto reduce costs, it is available in three duties so that thepins may be tailored to the host material or applicationrequirements. A wide variety of standard materials andfinishes provide for the necessary strength, corrosionresistance, fatigue life, and appearance to suit anyneed. Finally, special configurations are possible, furtherassuring the coiled spring pin can meet nearly anypinning application need.When trying to reduce costs, it is important toremember that individual component costs are not asimportant as total cost. Sometimes the moreexpensive component pays back big dividends.MORE INFORMATION:Enter G365 on the card, or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for further details from Spirol andmore news on springs, gas springs and dampers36INDUSTRIAL TECHNOLOGY • July 2008

More details: Write in 370 on the free information card 37

MECHANICAL COMPONENTSSprings, Gas Springs & DampersAutomotive interiorsrelying on springsfor comfortThe design team at William Hughes have developed a specialtorsional spring for a specific automotive task, focusing onthe ergonomics as the primary design considerationWhatever make of car you drive, speciallydesigned springs are playing a vital role. Ina modern car interior you will find springsin the centre console, glove box, cupholders, grab handles, sun visors and door mechanisms,the design of which has to take into account factors astactility and strength, available space and operationallife. With so many options available, many car interiormanufacturers are using the total design serviceavailable from William Hughes to engineer individualsprings that provide the most cost-effective solution foreach application.Torsion springs provide a perfect solution for manyautomotive applications. They can be either single,which gives a higher force in a smaller space, or double,which provides a balanced force or torque. To overcomefriction springs can be coated with special materials orthe spring geometry can be optimised to minimise theeffect. Other options include tension or compressionsprings in a range of sizes and materials.In modern vehicles, each part of the car interiorneeds to impart the right ‘feel’ to the driver. So when thedesign engineers at William Hughes were asked todevelop a special torsion spring to release anarmrest catch on a central console,ergonomics were the primary consideration.The catch mechanism had to be designed toslow the movement of the console to makeit open gently. It also needed to be easy tooperate with minimal effort.The team at William Hughes was provided with acomplete set of parameters for the operation. The designengineer needed to fully understand every aspect of theapplication to ensure that the proposed design would beboth economical and fully compatible with the plasticsand fabrics also used in the assembly. The designerneeded to consider how the unit could be assembledquickly and easily.With the help of the latest computer aided designsoftware and specialised spring data, William Hughesused their knowledge and experience to develop a springthat was optimised for the application. In this instance asingle torsion spring provided the best solution andWilliam Hughes was able to quickly produce prototypesprings for evaluation before the design was finalised forvolume production. Quality systems to AS 9100, ISO9001:2000 and ISO/TS 16949:2002 ensuredconsistency and accuracy while William Hughes’investment in the latest CNC machines and qualityprocedures meant that continuity of supply was assured.In addition to special springs for car interiors, WilliamHughes can also supply a wide range of bent wire formsand sub assemblies for car seats and trim panels. Seatframes are welded or clipped together and supplied ascomplete pre-assembled units. These rigid assembliesare ready for immediate use to suit the requirementsof the foam moulding process.MORE INFORMATION:Enter G385 on the card, or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for further details from WilliamHughes and more news on springs, gas springs and dampers38INDUSTRIAL TECHNOLOGY • July 2008

More details: Write in 390 on the free information cardMore details: Write in 391 on the free information cardwhatspringstomind?Stock springs?We’ve 15,500 differenttypes and sizes of springs.New for 2008Constant force springsREDUX wave springsMillions in stockand custom options.Call us on 0118 978 1800 or visit www.leespring.co.ukLee Spring Limited, Latimer Road, Wokingham, Berkshire, RG41 2WATelephone: 0118 978 1800 Fax: 0118 977 4832 Email: info@leespring.co.ukMore details: Write in 392 on the free information card 39

MECHANICAL COMPONENTSSprings, Gas Springs & DampersLocking gas spring simplifiesdesign of concealed elementsSpring shaftscan handlehigh speedsSKF has launched thelatest addition to itsStabilus LIFT-O-MATrange of gas springs.The LIFT-O-MAT PTLfeatures an internalmechanical lock in thecompressed position, openingup new opportunities for designerslooking for a simple way to createconcealed elements and storage areasinto furniture and specialised products,which can then be revealed quickly andeasily with just a light push.The innovative gas spring operates ina similar way to a ball point pen, lockingwhen compressed and disengaging toallow the spring to extend at a controlledContact springgives long lifeIn electronic devices, certaincomponents may require one or morespring contacts to achieve reliableelectrical connection. This is whereAbssac can help with its bespokeprecision electroformed products.Utilising a bellows spring contact, theelectrical connection can become a nonpermanent connection particularly whenthe parts are to be inserted, removed andre-inserted.The two types of spring contacts bestsuited for these applications are goldplatedwire mesh cylinders and goldplatedminiature metal bellows. Theseare available as standard stock items orcustom made to individual specification.Abssac’s Servometer bellows type contactsprings are manufactured from electrodeposited nickel, and then are goldplated to enhance their conductivity.They are both flexible and dynamic andare designed to provide a lifetime ofreliable interconnection.MORE INFORMATION:Enter G406 on the enquiry card, or visit ‘latest issuestories’ at www.industrialtechnology.co.uk forfurther details from Abssacrate when pushed. In addition tocontrolling the elevation of the objectreliably and smoothly, the gas spring alsofeatures an end position stop, eliminatingthe need for additional fixing elementsand minimising production andinstallation costs.As with the entire LIFT-O-MAT range,the PTL gas spring is able to offer acontrolled rate of elevation usinghydropneumatictechnology; as thepiston inside thecylinder moves from gasto oil, the spring slows to a dampenedpace, coming to a controlled stop. Adynamic damping feature allows users tospecify the rate of elevation for aparticular application, making the LIFT-O-MAT an extremely flexible solution.Due to its combination of carefullycontrolled elevation and innovativelocking functionality, the LIFT-O-MAT PTLis ideal for a diverse range ofapplications, including power towers inconference tables, back, arm andheadrest adjustments in sofas, andconcealed drinks cabinets in bar areas.MORE INFORMATION:Enter G405 on the enquiry card, or visit ‘latest issuestories’ at www.industrialtechnology.co.uk forfurther details from SKFVibration dampershandle 40,000N loadsLWA vibration damping units fromElesa feature natural rubberdamping pads built into anadjustable levelling foot design Theyhave been designed to damp vibrations,shocks and noise from movingcomponents or nonbalanced massessuch as rotating machinesThis vibration can damage operatorhealth as well as reducing the lifespanof the machine or adjacentequipment.Active machineisolation suits vibrationproducing equipmentsuch as presses,machine tools andtransfer equipment.Passive isolation suitsequipment that might beadversely affected by externalvibration, such as quality testing,measuring or performance assessmentequipment.The damping elements range from80mm to 200m in diameter withmaximum static load capacity of40,000N. They are made up of threemain elements: a zinc-plated steelbase with natural rubber disk, azinc-plated levelling disk, and athreaded stem to allow an easyand precise levelling of themachine.The vibration dampingelements are available indiameters of 80, 120, 160 and200mm.Documentationprovidestechnicalguidance on theselection toprovide the rightdamping/isolationlevel for thefrequency of vibration,static load andamplitude/deflection of the equipment.MORE INFORMATION:Enter G404 on the enquiry card, or visit ‘latestissue stories’ at www.industrialtechnology.co.ukfor further details from ElesaRino Industries has releasedflexible spring shafts thatare suitable for thetransmission of rotational motionThey provide flexibility, strengthand endurance. They can operatecontinuously under high speedsand their shock-dampingproperties are excellent.There are a wide variety oftypical applications, these includeremote control instruments,transmission of rotationalmechanical power, shaftconnection and control ofoverhead parts. They can be usedin both left and right handrotations and it is advisable tochoose a left hand shaft to turnclockwise and a right hand shaftto turn counter-clockwise.Right hand shafts are availableas standard. The drive shafts areusually protected by a flexiblesteel sheathing and havecouplings on either end. They areavailable in lengths up to5000mm, but most are between500-1500mm.MORE INFORMATION:Enter G408 on the enquiry card, or visitwww.industrialtechnology.co.uk forfurther details from Rino IndustriesSaint-Gobainbuys Rencolfrom EriksSaint-Gobain PerformancePlastics has acquired RencolTolerance Rings, a UK-basedsubsidiary of Eriks, for £12.5million The arrangement includesthe company's activities in Bristoland Japan and a 51% controllinginterest in Rencol MMI Technologyin Singapore. As a wholly-ownedsubsidiary of Saint-GobainPerformance Plastics, the companywill be integrated into the BearingBusiness Unit and change itsname to Saint-Gobain PerformancePlastics Rencol.MORE INFORMATION:Enter G407 on the enquiry card, or visitwww.industrialtechnology.co.uk forfurther details from Saint-Gobain40INDUSTRIAL TECHNOLOGY • July 2008

Burton Road, Sheffield S3 8DATel: 01142 701577Fax: 01142 756947email: sales@turtonsprings.comwww.turtonsprings.comTSL are a Spring Maker specialising in the manufacture ofCoil Springs, Anti Roll Bars and Torsion Bars.Established in 1879 and ISO9000-2000 accredited,we pride ourselves in the ability to offer a service and quality productyou would expect from a World Class Spring Manufacturer.We supply industries such as Automotive, Railways, Commercial Vehicles,Oil & Gas, Quarry & Mining, Aerospace & Agriculture.Our flexibility enables us to offer prototypesas well as volume batches with our engineers at hand todesign and develop Springs to suit your requirements.More details: Write in 410 on the free information cardMore details: Write in 411 on the free information cardSPRINGS...all types and all sizesand... all in stockHigh-performance ranges available®BARNESGROUP INCSee our NEW web site for Gas Strutswww.gasspringstruts.co.ukwww.associatedspring.co.ukFOR EXPERT ADVICEMore details: Write in 412 on the free information card More details: Write in 413 on the free information card 41

AUTOMATION COMPONENTSConveyorsMore optionsfor your conveyorrequirementsFlexMove from Automation Supplies is a flexibleproduct transportation system that provides acompelling combination of high product quality,design and materials together with stunning valueFlexMove is designed toprovide highly competitive,cost effective,incredibly flexible plasticchain (or slat) conveying optionsfor a wide range of industryapplications such as filling,packaging, inspection, storage,general manufacturing andassembly in industries such asautomotive, electronics, pharmaceutical,labelling and many more.With a wide range of options,chain designs and quality ofmanufacture, FlexMove gives theuser real choice when investing ina modular conveying system.One recent application saw theend user switch from a leadingsupplier of modular conveyors tothe FlexMove product, and being morethan pleased with the end result. Theapplication was in a plastic injectionmoulding environment where the enduser wanted to increase the productivityof his moulding machines and reduceoperator interaction within the process.The idea was to have enough capacity inthe handling system to increase the speedof the process and reduce downtime. Thesolution was to pick multiple parts fromthe moulding machine and set up thewhole process at the start of a shift andtake the whole production run from themachine at much less frequent intervals,thereby freeing up the operator to controltwo or more machines.Increased productivityUsing the versatility of the FlexMovesystem, it was possible to create a 5mlong twin lane loop high capacityconveyor system that could handle largepallets 500mm square. This in turnallowed the customer to mould fourimpressions in one machine cycle,remove them with a robotic handlingsystem and place them precisely onto apre-engineered pallet. When full, thepallet receives a signal and moves a newpallet into position and so on until all tenpallets are full, making the total mouldcapacity on the handling system when full3600 pieces. Bearing in mind that theprevious capacity per pallet was 60pcsthe operator involvement has reduceddrastically and productivity is up.Removing the barriersWith FlexMove there are no barriers tochange. Chain widths and design arecompatible with the leading plastic chainsystems, the quality of design isexceptional, the range is comprehensiveand the prices reflect the maturity andexpected reliability of the product in themodern production environment.Automation Supplies delivered theconveyor in simple to re-assemblemodules, having been previously preassembledand load tested beforeshipping. With clear re-assembly markingsand an easy to use assembly guide, thetwo conveyor systems delivered wereassembled in three days.MORE INFORMATION:Enter G425 or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for furtherdetails from Automation SuppliesBelt scraper designsimplifies maintenanceFor conveyor operators everywhere,the combination of dirt,dust, confined space andexpensive equipment presents aconstant challenge. Now, HorizonConveyor Equipment has unveiled itslatest development in belt scrapertechnology, set to play a key role inkeeping conveyor belts running.After consulting widely withoperators in the UK and overseas,Horizon has developed an innovativeconcept called the ‘H’ PrimaryScraper Range. The new system hasbeen designed to eradicatewidespread problems with traditionalprimary belt scraper designs, whereengineers have often been deterred bycomplex fitting and long-termmaintenance issues.According to Alan Bowler,managing director of HorizonConveyor Equipment, for conveyoroperators using primary andThere are several benefits tothe new Item transport trackfrom Machine BuildingSystems. Heavy goods canbe transported easily and quietly. Thetransport track system is tolerant tosoiling, easy to assemble and can beadded to any profile construction.Elevated transport tracks andsuspended constructions (for themanual movement of heavy tools, forexample) are also possible.A typical assembly wouldcomprise an aluminium profileconstructed carrier onto which ismounted four Roller-Units D60 PU,secondary belt scrapers as a cleaningsystem, the primary belt cleaner is avery important part of thatcombination. However, he says it canbe difficult to mount a standardprimary or tangential scraper becauseof restrictions caused by the motor,gearbox, steelwork or simply becausethe chute has limited space.“The ‘H’ Primary Range overcomesthese problems,” he says.“With the ‘H’ Primary Scraper Range,the entire system hangs over the topof the belt frame and is externallychute mounted. This means thescraper can be easily fitted to mostconveyor head chutes.”In the past, engineers have had tocompromise when fitting scrapers totheir conveyor belts because of theessential gear and drive equipmentthat restricts how the system can befitted and maintained. In addition,conventional scrapers are oftenBelt scraper designsimplifies maintenancewhich run in aparallel pair ofTrack-Profile 880x40s. Themodular designmeans that thecarriers can bemade to anysize and theTrack-Profiles placed accordingly. TheRoller-Units (each with a load-bearingcapacity of 800N) are fitted with ballbearingmounted polyurethane-tyresfor smooth and quiet running, andwith spring-loaded lateral guidewheelsto provide sideways support.The Roller-Units have a choice offixing positions which give either aride-height which is flush or 4mmproud of the Track-Profile dependingon the chosen setting, and can also befitted to non-profile carriers. TheRollers can be used independently ofthe Roller-Units, and will run easilywithout the Track-Profiles on levelsurfaces.MORE INFORMATION:Enter G426 or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for furtherdetails from Machine Building Systems42INDUSTRIAL TECHNOLOGY • July 2008

Elcomflat belt conveyorsThe Elcom range of flat belt conveyors complete with motorsare available in widths from 20mm up to 1000mm, and witha useful range of belt speeds.Designed around the Item MBprofile system, they guaranteewide compatibility with otherequipment, and have the levelof finish you would expect ofItem itself. With several yearsof proven use in the field,they are the natural choiceeither for incorporating intoother machines or as standalone units.located in such confined locationsthat maintenance is difficult or evenimpossible. And with constant wear inharsh conditions and the closeproximity of heavy machinery, thatmeans scrapers can quickly becomeineffective. But because of theinnovate design of the ‘H’ PrimaryScraper Range, the scraperadjustment mechanism is kept wellaway from flying debris and withineasy reach for routine maintenance.The system comes with blades mainlymade from polyurethane. The scrapercan be fitted with blade types toaccommodate both mechanicalclip joints and vulcanised belts.MORE INFORMATION:Enter G435 on the enquiry card, or visitwww.industrialtechnology.co.uk for furtherdetails from Horizon Conveyor EquipmentGet your free copyof the Elcom flatbelt conveyorscatalogue todayMachine Building SystemsHeage Road Industrial Estate,Ripley, Derbyshire DE5 3GHTel: 01773 749330 • Fax: 01773 749560www.mbsitem.co.ukConveyors also available from MBS in Athlone, IrelandMore details: Write in 430 on the free information cardProfileTechnologyFactoryEquipmentLinearMotionOur quality for yourproduction line... ConveyorTechnology24 standardconveyingsystemsWide rangeof variantsModular designfor systemintegrationMore details: Write in 431 on the free information cardmk Profile Systems Ltd.Unit 9, Cowling Business ParkCowling BrowChorley PR6 0QLPhone +44 (0)1257 263937Fax +44 (0)1257 271409www.mkprofiles.co.uk/auto.htminfo@mkprofiles.co.ukMore details: Write in 432 on the free information card43

MECHANICAL JOININGFasteners & AdhesivesAdhesive dispensingwith pneumatic valvesThere are many options and considerations when choosing a dispensingvalve, so we got some advice from the experts at specialist IntertronicsThe simple pneumatic dispensingmachine is generally low costand almost ubiquitous. Itimproves the application ofmaterials like single part adhesives,coatings, sealants and inks by enhancinga manual process to one which is morecontrolled and repeatable, while healthand safety benefits include less mess,less exposure to potentially hazardouschemicals and fewer RSI issues.These systems work by filling anindustrial syringe or barrel with the liquidmaterial. Pulses of air then push theliquid out of the other end, usuallythrough a dispensing needle or tip. Thequantity dispensed can be varied by thesize of the needle orifice (from as smallas 0.15mm), the pressure applied andthe time of the air pulse triggered byfootswitch, finger switch or automation.They may be hand-held or mounted onpositioning robots or rotary tables. Lessthan 1% variance is often easilyachievable, and 0.1% not uncommon.Digital timers further improve accuracy.For industrial liquid dispensing,pneumatically controlled valves arerobust, accurate, can be cycled quicklyand in many cases can be implementedat low cost. One of the primary benefitsis the increased accuracy, critical inapplications such as microelectronics ormedical devices thatneed combinationsof higher levelsof accuracy andrepeatability, validationand fine tolerances. Inaddition, challenging materialscan be handled,such as cyanoacrylateadhesives (with verylow viscosity) andthermally conductiveRTV silicone adhesives(which havevery high viscosity).The largest dispensingbarrels aretypically 55ml in volume.For higher daily volumes,some form of largerreservoir is needed. A finalbenefit to consider is that avalve can be fixtured to arobot and provide betterstability than adispensing barrel.Material feedThe material to be dispensed ispresented in a reservoir, generallypressurised to provide flow. Very lowviscosity materials (for example solvent)can be gravity fed but very high viscositymaterials (such as grease) will require anextrusion pump to achieve flow.Dispensing barrels and cartridges can beused to feed dispensing valves. Forexample, the likes of RTV silicones soldin a 310ml cartridge can be fed directfrom their packaging. Other reservoirstake the form of pressure pots of500ml to 10 litres or more.Liquid is fed through a hose, tothe valve actuated by a pulse of airpressure. The amount of materialdispensed can be varied by the sizeof the needle orifice, the pressureapplied to the material reservoir andthe time of the air pulse determined bya pneumatic dispensingcontroller. The exception to thistype of operation would be a positivedisplacement valve, such as a screwvalve, where precise microdepositscan be controlled by therotation of an auger screw. One ofthe main advantages of dispensingvalves is that they snap close, with apositive cut off of material flow, either byspring or reciprocal air pulse. Somedesigns inherently ‘suck-back’ thematerial, reducing the ‘string’ effect.Valve types and selectionThe main material characteristicsinfluencing valve selection are viscosity,cure, reactivity and abrasiveness.Viscosity – very low viscosity liquidsmight be dispensed with a diaphragmvalve or a needle valve, very highviscosity ones, like temporary soldermask, may need a spool or poppet valve.Cure – with materials which curequickly or are easily catalysed, considerusing a valve with a disposablefluid path (pinch tube valve) orone which is both chemicallyinert and very low wetting(diaphragm valve). Light sensitivematerials (such as UVcurable adhesives)will require light-tightvalves, fittings andhoses.Reactivity – withhigh solvency or corrosivematerials, metal partsmight need to be stainless steel.Polymer partslike seals,valve seatsand O-ringsmight need to bean ultra high molecular weight (UHMW)plastic, synthetic rubber or fluoropolymerelastomer like Viton.Abrasiveness – any fillers that areused to increase conductivity (thermaland/or electrical), chemical resistance,physical robustness or even simple bulk,may also be abrasive, so do considerease of component replacement.We can see then that there are quitea few options when it comes to choosinga dispensing valve, and a plethora ofmaterials which might be dispensedthrough them. Finding the optimalmatch is quite complicated – materialrheology and reactivity needs to beunderstood, valve capability identifiedand proven, and the final outcomedefined.MORE INFORMATION:Enter G445 on the card, or visit ‘latest issuestories’ at www.industrialtechnology.co.uk forfurther details from Intertronics44INDUSTRIAL TECHNOLOGY • July 2008

Seeing the lightwith UV curingWe take a look at a new UV curing systemthat provides an alternative to conventionalMercury Arc Lamp based equipmentIt is no exaggeration to say thatultra violet light curing adhesivesare widely used in industry. Thisis especially true of the medicalindustry, where adhesives provide avery real alternative to theconventional methods, such assolvent welding. Where UV adhesivesare cured by exposure to UV sourcestransmitted via flexible light guides,the most frequently used systems arebased on Mercury Arc lamps. Thesetransmit a broad range of UVwavelengths and intensities, makingthem an excellent choice in a widerange of applications and with manytypes of UV adhesives.However, there is now analternative approach; LEDtechnology. This method centreson a light emitting diode sourcethat has been developed throughthe integration of lamp andsemiconductor technologies. Thetechnology enables high UVAintensity up to 4.6W/cm² to beachieved at a very focussed wavelength.As such, the matching ofadhesive to light source becomes acritical decision.UV curing systemTo handle this advancement in curingtechnology, Henkel has introduced theLoctite 97059 LED UV cure system.Technically, the unit, which isequipped with one LED driver, oneLED head and one condenser lens,emits nearly monochromatic light at365nm. As an option, the unit can beequipped with three additional LEDdrivers and heads.“As the wavelength is accuratelyfocused, it means that minimal heat isradiated onto the componentsurface,” explains Steve Ginger,equipment manager at Henkel’sHemel Hempstead facility. “This hasthe effect of reducing the potential forheat damage. In addition, the LEDtechnology means that the unit doesnot require a warm-up/warm-downperiod during use. This is a significantbenefit as mercury lamp systems aregenerally ‘on’ continuously – withexposure being guarded andJuly 2008 • INDUSTRIAL TECHNOLOGYcontrolled by an integral shutter.”The LED system has been createdto provide a very long working life –around 20,000 hours. Ginger pointsout that it will readily be appreciatedthat this factor reduces the cost ofproviding replacement lamps.The LED system also offersenvironmental benefits through itssignificantly lower power usage. Evenwith the four head operation, theconsumption is less than 80VA.Indeed, the estimated powerconsumption with four headsoperating for 24 hours a day, 365days a year is less than 700 kilowatthours.Just as important, there are nomercury filled lamps for disposalwhen the light sources are replaced.“To meet the many differing needsof our customer base, the unit isdesigned so that it can be used atmanual workstations or beincorporated into automaticproduction lines,” states Ginger.The radiation can be activated inone of three ways: the start button inthe front panel, with the footswitch orvia the PLC connection. Other featuresinclude a programmable intensityprofile, locking key and a connectionfor external emergency stop. The unitis compact, measuring just 150mmwide by 142mm high and 196mmdeep, and weighing 2.3kg. Gingerconcludes: “This new unit is animportant addition to our existingrange of dispensing equipment andwill be of considerable benefit toour customers.”MORE INFORMATION:Enter G455 on the card, or visit ‘latest issuestories’ at www.industrialtechnology.co.ukfor further details from HenkelMore details: Write in 450 on the free information cardEPOXIES • SILICONES • CYANOACRYLATESURETHANES • UV CURES • ANAEROBICSWidest selection of formulations ■ Deal direct withmanufacturer ■ Latest technology ■ Environmentallyfriendly ■ Convenient packaging in small to large quantitiesPrompt Technical AssistanceGrades Available Which Meet NASA,UL and USP Class VI SpecificationsTECHNICAL SALES REPRESENTATIVES:Tel: +44-(0)207-039-0034 ■ Fax: +44-(0)207-060-0628www.masterbond.com ■ eutech@masterbond.comMore details: Write in 451 on the free information card45

MECHANICAL JOININGFasteners & AdhesivesCompression latch deliverscompression of 10-12mmThis new compression latch from Dirak is easyto install with a roller cam designed to minimisescrape damage caused by traditional camsThe Dirak 1-081SL CompressionLatch offers a compression rangeof up to 12mm, significantlygreater than other compressionlatches on the market today, says thecompany. The compression range can bemodified depending on the length of thecam. Standard cam heights are 22 and28mm with other cams available uponrequest.The innovative use of a planetary gearfor actuation gives significantcompression at extremely low torquewhile ensuring strength and durability.The use of a roller at the end of the camminimizes scrape damage to panels oftencaused by traditional cams, and alsoreduces the required closing force.In addition, the 1-081SL CompressionLatch incorporates two of Dirak’sinnovative technologies, D-SNAPTechnology and Design Symmetry.D-SNAP Technology provides fast andsimple installation without hardware ortools. All components of the latch arepre-assembled making installation intosandwich type panels easilyaccomplished from the front of the panel.Application flexibilityDesign Symmetry allows the same latchto be installed on both right- and lefthanddoors. The 180° rotation range ofthe cam eliminates the need to re-installfor a rotation of door to/from right- andleft-hand doors giving flexibility inapplications and reducing inventory.The latch can be actuated withstandard inserts, double bit 3 and 5mmand square 8mm with others available onrequest. The latch also meets IP65requirements for water and dustresistance.MORE INFORMATION:Enter G465 on the enquiry card, or visit ‘latest issuestories’ at www.industrialtechnology.co.uk forfurther details from DirakScrews gostainlessPerfect stainless steel hasboth the equivalence instrength and toughness ofSUS410 and corrosion resistanceequivalent to or better thanSUS630, says Rino Industries,launching a new range offasteners.They may be used in anyapplication which necessitateshigh strength and high corrosionresistance. They may also be usedin applications that utilisemagnetic sensors due to theirmagnetic properties.For now, only socket headcap screws are available asstandard in this material andsizes range from M3 to M10threads with lengths varyingfrom just5mmincreasing to50mm.Mini drains suitmarine tasksAsleek design of marine-grade MiniCompartment Drains in threecompact sizes offers boat-buildersand boatyards cost-effective and easy-toinstalldrainage solutions for hatch-covergutters, small compartments, tightcorners, and other isolated deck areas.Available to fit standard 12.7mm,15.9mm and 22.2mm ID drain tubing,these fixtures expose only a low-profilepolished stainless steel flange above thedeck surface, matching the appearanceof other Southco Marine designs for acoordinated look throughout a vessel.MORE INFORMATION:Enter G466 on the enquiry card, or visit ‘latest issuestories’ at www.industrialtechnology.co.uk forfurther details from Southco MarineAnaerobic gasket offershigher vibration toleranceThreeBond has announced thegeneral release of its TB1133Enext generation anaerobic gasket.Building on the benefit of anaerobics tobe dispensed and then permitcomponent placement at leisure,TB1133E offers enhanced vibrationtolerance and user-friendlycharacteristics. This enables greaterconfidence in established applicationssuch as gearboxes and cam covers,while opening up uses in sealing ofcomplex areas. In particular, it is screenprintable and so offers significant timesavings against robotic dispensing onintricate 2D shapes proving especiallyvaluable where elimination of potentialoil gallery blockage is paramount.ThreeBond TB1133E features highelongation versus traditional anaerobicgaskets and superior gap filling capacity,so is compatible with reduced machinerytolerances. It is a solventless, onecomponent,liquid gasketing material. Itwill cure when compressed between twometallic surfaces and isolated fromoxygen, and an elastic gasket is formedwithin a very short time. The curedgasket exhibits superior chemicalresistance, flexibility comparable to thatof silicone based gaskets, excellentadhesion to substrates, high temperatureresistance and high strength.MORE INFORMATION:Enter G464 on the enquiry card, or visit ‘latestissue stories’ at www.industrialtechnology.co.ukfor further details from ThreeBondMORE INFORMATION:Enter G468 on the enquiry card, or visitwww.industrialtechnology.co.uk forfurther details from Rino IndustriesInstant cureadhesivesNew from Master Bond is ahigh strength ‘instant cure’cyanoacrylate adhesivecalled MB297. In addition to highstrength bonds as high as 2800psiin shear, it provides better generalresistance to effects of extremehumidity.MB297 is supplied as aviscous liquid adhesive with aviscosity of 2000-2400cps (at20°C). Its appearance iscolourless. Its service operatingtemperature range is from –55°Cto +85°C. The cures are moistureactivated and bonds are almostinstantaneously formed. Theadhesive creates excellent bondsto metals, ceramics, plastics andelastomers.MORE INFORMATION:Enter G467 on the enquiry card, or visitwww.industrialtechnology.co.uk forfurther details from Master Bond46INDUSTRIAL TECHNOLOGY • July 2008

Torque multipliergives accuratesubsea actuationNorbar Torque tools hasdeveloped an innovativetorque multiplier for thesubsea tools market.Designed as an adapter to allow API17D Class 4 intervention torque toolsto generate the torque required tohandle Class 7 applications, the newtorque multiplier delivers a higherlevel of accuracy than alternativesolutions, and increased flexibility inuse through its added-value featuresand its ability to be configured in twostandard lengths.Gear adapters have becomepopular as a means of extending aClass 4 tool (which would generateup to 2,700Nm of torque) up toClass 7 (34,000Nm). To date, thetrade-off for this added conveniencehas been accuracy, with extendedClass 4 tools failing to offer theprecise torques of dedicated Class 7tools. But Norbar’s innovative designhas overcome this problem, enablinga Class 7 torque to be generatedfrom a Class 4 torque input to anaccuracy of better than ±5%.The function of the gear is tooperate as a torque multiplier, butthe ratios have to be exactly right toachieve the correct torque and thespecified speed from the Class 4 tool.At the same time, the gear has to beable to function reliably in a subseaenvironment at extreme temperaturesand pressures. It also has to be easyto handle. Norbar was able to meetall of these requirements.The company’s newly developedtorque multiplier is designed towithstand the corrosive environmentand is pressure compensated to allowoperation at typical subsea pressures.It is designed to be suitable for usewith the standard Class 4 torquetools that, operated by ROVs, areused to remotely actuate the wetvalves. There is also a restriction onthe weight that ROVs can manipulateso considerable design work has gonein to keeping the tool weight down toan acceptable level.MORE INFORMATION:Enter G475 on the enquiry card, or visitwww.industrialtechnology.co.uk for furtherdetails from Norbar Torque ToolsPortable clinchingsolutionsUnit 5C, Quinn Close • Seven StarsEstate • Whitley • Coventry CV3 4LHTel +44 (0)24 7630 7555Fax +44 (0)24 7630 2777Email sales@eckold.co.ukIdeal for sheet metal,tubes and profiles •Joins materials ofdifferent thicknesses •Joins dissimilar andcoated materials •Offers significant costsavings• Easy to useExpert applicationadvice readily availableMore details: Write in 470 on the free information cardRivet nut setting tool is aforce to be reckoned withBollhoff Fastenings hasannounced the introduction ofa new pneumatic setting tool,to a market where many millions ofblind rivet nuts arebeing used toplace areinforcedthreadintosheetmetals,profilesandhollowsections. Now usingautomatic forcecontrolwhen ‘pulling-up’ the fastenerfrom one side of the workpiece, thenew design employs a pressuresensitivity on the tool stoke, in orderto ensure a totally consistent setting,even when faced with a variablematerial thickness.The P2007 from Bollhoff, is astylish hand-held tool, operated by asingle trigger movement andengineered for speed, reliability andergonomic use.MORE INFORMATION:Enter G476 on the enquiry card, or visitwww.industrialtechnology.co.uk for furtherdetails from Bollhoff FasteningsJuly 2008 INDUSTRIAL • TECHNOLOGYMore details: Write in 471 on the free information card47

SENSORS & SYSTEMSWater Detection SensorsInnovative sensing solution tothe detection of water presenceA unique product line in Idec’s portfolio is a range of sensors that canreliably detect H2O molecules, offering a dramatically simpler solutionto problems of liquid detection in a host of demanding applications.Now the company has extended its range with a new modelIt’s funny how the problems that seem the leastdemanding are often to the most difficult to solve.Take, for example, checking the fill level in bottle. Ifyou use level sensors overhead to look down into thebottle, then you create difficulties for yourself in ensuringthe bottles are properly positioned under the sensor. If youtry checking side on, you can have problems with thelabel or the bottle material or a myriad of other issues.Applications such as fill level control in a bottlingplant, glue detection in packing and carton formingmachines, or even the safe detection of chemical in thebottom of a medical file are all notoriously difficult tosolve, with the likes of ultrasonic, capacitive andphotoelectric sensors, vision systems or moisture metersall creating problems of their own as part of the solution.Surely there must be a better way. And there is, in theform of Idec’s SA1W moisture detector. This uniquedevice has the capability to detect the presence of H2Omolecules in any liquid, paste or glue. The sensor useslaser technology where the device is tuned to the resonantfrequency of the H2O molecule, ensuring reliable noncontactdetection. Due to the technology employed thissensor is able to see through any container which is clearor translucent such as a wine bottle or medicine jar, evenwhen the labels are applied. An additional benefit,especially for the bottling industry, isthat this sensor has the capabilityto detect through variouscolours of container.As easy to use asa standard photoelectric sensor,the SA1W rangehas been on themarket for a couple of years now, quietly solving problemsthat seemed unsolvable. For example, when a customerin the packaging industry wanted to detect breaks in aline of glue laid down for sealing packing material, hefound he had a problem. Similarly, a contact lensmanufacturer wished to detect if solution had failed to beimpregnated in contact lens blister packs. In both casesthere didn’t seem to be a readily available solution, but inboth cases the SA1W was able to provide one.To date there have been two versions of the SA1W: alow cost, LED-based product suited to close machineinstallation, and a higher powered device using a Class 1laser to give reliable sensing even through opaque orlabelled bottles. They feature housing dimensions13x23x46mm for both transmitter and receiver, with theoption for through beam or diffuse reflective operation.Now, for applications where mounting a standard sensorhead simply isn’t an option because of spaceconstraints or difficulties with access, Idec hasintroduced a new fibre-based version, with a smallsensing head connected to an associated amplifier usingfibre-optic cable. The new fibre model offers a high speedresponse time of just 0.5msec and sensing ranges of upto 800mm, with a small diameter laser beam for preciselevel detection. Set up of all the devices in the range issimplified by a visible red light, and the devices canprovide either light ON or dark ON operation.Enabling flexible manufactureNot only do the devices provide simpler and more reliabledetection of liquids in challenging manufacturingenvironments, they also play a key role in increasingmanufacturing flexibility. If a single production line wasworking with different bottle materials or colours, or withdifferent versions of the liquid itself, you could findyourself have to retune a conventional sensor at eachproduct changeover. The SA1W, by contrast, is unaffectedby container colour or liquid colour or even changes in thelabel type and position, offering a vastly more flexiblesolution.Idec sees a host of possible applications for the newmodels of the sensor. As well as a standard liquid fillchecking type application, the SA1W could be used tocheck water levels where there is oil sitting on top of thewater. Here, the sensor would see the water, but ignorethe oil. The sensor might also find uses in looking at waterlevels in a cross section of pipe. In the carbonated drinksindustry, the SA1W offers a level detection solution whereother technologies might struggle due to the CO2 bubblesrising to the top of the container. With a special lensattachment, the SA1W can even detect liquid sealedinside an aluminium can.Outside of water level checking, the SA1W might beused in glue-related applications, for example on anenvelope production line to check that the glue paste hasbeen put on the flaps, or has been applied to the clearfilm window.MORE INFORMATION:Enter G486 on the enquiry card or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for further details. You can also findmore stories from Idec48INDUSTRIAL TECHNOLOGY • July 2008

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

SENSORS & SYSTEMSRemote ConnectivityRemote monitoring and controlof important systemsYour machines are talking, but are you getting the message?SeNd Technology now offers an updated version of its GSMAlarm intelligent monitoring device – the new GSM Alarm+Manufactured by Italian specialist Contrive, andsold in the UK through SeNd Technology, theGSM Alarm+ is a self contained intelligentmonitoring device which can inform you of thealarm states of remote, unmanned equipment. You can thenremotely control your process via your mobile phone or overa landline, and receive a confirmation text by return.The GSM Alarm+ provides eightdigital (volt-free) inputs with variableinput delay, and one relay output.When it detects an alarm one ofits inputs, it can send an email,an SMS text message, or simplyring your phone, and it can send itsalarm signal to up to 100 recipientsper event. It can also report itsstatus via SMS text message.Consider a typical application scenariofor the GSM Alarm+ at a remote pumpingstation. When a flow meter detects no flow, it triggers anSMS message such as ‘Site 10 – pump failed’ to be sent toa local engineer. At same time an email is sent the centralmonitoring station confirming the fault.The local engineer can then decide on the best courseof action. One option might be to visit the site, but anotheroption might be to call the GSM Alarm+ and request ‘pump2 start’. The remotely controlled relay output is energised,starting the pump. The flow meter resets, which triggers the‘pump working’ SMS to confirm all is ok. Allthis has been accomplished for just the costof a couple of SMS messages, and thereare still a further seven inputs to use forother alarms, as well as battery-backedversions you can ensure your wholecontrol system can let you knowwhen any event occurs.The eight digitalinputs on the GSMAlarm+ providesimple connectionto varioussensors andalarm contactson remote processes ormachines, and the unit canbe programmed to send aunique text message on both theclosing and opening of each input, givinga possible 170-message capability.Applications include remote, unmanned machinesor processors across all sectors of industry.MORE INFORMATION:Enter G505 on the enquiry card or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for further details. You can also findmore stories from SeNd TechnologyPutting cyber security in your sightsThe Crossbow Secure Access Manager delivers an integrated solutionto cyber security threats to facilities and other critical infrastructureGarrettCom Europe has expanded its portfolio ofsolutions offering protection against threats tocyber security. With the introduction ofCrossbow Secure Access Manager, users canbenefit from user-friendly access to plant floor, field andremote devices via PC-based client or web interface,whilst unauthorised attempts to access the network aresecurely locked out.The Crossbow Secure Access Manager is based onproven remote access software solutions from BowNetworks, and integrated with the security andmanagement features of GarrettCom’s hardened remotenetwork and security devices. This combination providesan electronic security perimeter for the network, andprovides auditable secure remote access to devices onthat network.In 2007 GarrettCom introduced the Magnum SecureNetworking Framework (MSNF) – an initiative topromote best practice for industrial network security,constructed around consisting of functional buildingblocks and secure networking protocols. MSNF providesnetwork-centric solutions for cyber security protection,while providing a framework for the overall control andinformation systems infrastructure.Now the company has extended cyber securityoffering with Crossbow, which integrates seamlessly withGarrettCom DX and DynaStar routers and serial deviceservers to add a comprehensive electronic securityperimeter.GarrettCom Europe also offers professional services toassist customers in implementing effective cyber securitysolutions. Targeted industries include power utilities,transportation, water treatment and pipelines, energy,other critical industries as well as generalmanufacturing.MORE INFORMATION:Enter G506 on the enquiry card or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for further details. You can also findmore stories from GarrettCom Europe50INDUSTRIAL TECHNOLOGY • July 2008

GEInspection TechnologiesMeasure materialthickness fromone side onlyPortable thickness gauges from GEbring you compact, accurate,easy-to-use and affordableinstruments for measuringwall thickness of tubes, pipes,vessels, boilers, tanks orcomplex sections. Digital displaygives instant test results in seconds.To discover how we can measure upto your quality control standards,contact us today or visitwww.ge.com/inspectiontechnologiesGE imagination at workGE Inspection Technologies • Coventry CV4 8AF • tel: 0845 6015771More details: Write in 510 on the free information cardMore details: Write in 511 on the free information cardMore details: Write in 512 on the free information card 51

SENSORS & SYSTEMSNew ProductsDimensionalmetrologyinstrumentNewly appointed as distributorfor CEJ from Sweden, SussexSensors is proud to offer theCEJ Mikrokator dimensionalmetrology length measuringinstrument. The device isunsurpassed in terms of accuracy,despite being able to measuredown to 1 micrometer. It isextremely rugged and cansurvive tough workshopenvironments.The measuring system ispurely mechanical and iscompletely free from friction orbacklash. Full scale measuringranges of 400 micrometersto 6 micrometers with scaledivisions of 0.1 micrometers areavailable.MORE INFORMATION:Enter G526 or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for furtherdetails from Sussex SensorsPressure sensor is poweredthrough computer USB portUSB pressure sensor offers fast system set-upHamersham is offering a solutionto simplify and speed upsystem pressure sensing. It is aUSB powered pressure sensorthat plugs directly into your PC. Gone arethe days where the sensor had to behooked up to an interface box andpressures were monitored via a smallinstrument display. Taking the HamershamHT100 route to pressure testing truncatesthe process to three easy steps. Onceyou’ve installed the sensor, you simplyconnect the communication cable to thePC. Then you start the PC softwareand begin measuring pressureimmediately.The product evolved by reasoningthat service engineers generally use aPC laptop as a resource for diagnostictools, service manuals and reporting.Logic dictates that the service engineershould be able to plug all of his servicetools into the laptop. The obviousquestion was: why can’t we do thiswith a pressure sensor? After carefulresearch, design, field testing andcertification, the Hamersham HT100range of USB pressure sensors wascreated.There is a pressure test range tosuit most applications from a low of25bar to a high of 800bar. Individual,multipoint dead weight testercalibration means an excellent degreeof accuracy is achieved (±0.25% offull scale over the rated temp span andin the zone 5-95% of full scale).Much consideration has been givento both mechanical and softwareinterfacing. A compact, instrumentgrade push-click connector has beenselected as the electrical interface. Nolocating screw threads have to beturned and a mechanical ID means thesensor can be installed blind ifrequired. An integrated dust covermeans the communication cable canbe removed and the sensor left on themachine.Smart sensor technology meansthe sensor keeps its calibration data onboard together with fault records,serial number and recommended datefor recalibration. And the easy-to-usePC software ensures that when thesensor is plugged in, it is immediatelyrecognised and starts to measurepressure straight away. The pcsoftware allows the test engineer to dosimple static visual pressure tests orlog individual pressure samples over atime base.MORE INFORMATION:Enter G525 or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for furtherdetails from HamershamProximity switches forextreme temperaturesSensors UK has announced thelatest in its MI range of hightemperature proximity switchesdesigned for use in extremetemperature applications – theMI-400. These silicon free inductiveswitches are suited for use whereobject and position detection must becarried out in areas of hightemperature such as steel works,paint ovens or manufacturingprocesses where dirt, heat and anaggressive environment are present.The MI-400 has a workingtemperature range of 350ºC, withshort excursionsup to 400ºCwheremany conventional switches wouldjust burn away or fail. The MI-400has been designed to survive thesearduous conditions for extremely longperiods of time, thus delivering majorcost savings in terms of plantmaintenance.The MI-400 design allowsmeasurement to these hightemperatures due to the use of aspecial carrier for the inductive coils,a new ceramic enclosure and heatresistant cables. The sensor headconnection cable employs Tefloninsulated with metallic over sheath togive the full 400ºC protection, andthis can be specified in lengths of 3,5 or 7m.MORE INFORMATION:Enter G527 or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for furtherdetails from Sensors UK52More details: Write in 520 on the free information cardINDUSTRIAL TECHNOLOGY • July 2008

Modular level sensorscan be easily adaptedBurkert is introducing a newrange of intelligent levelsensors with a modularstructure and IP67 protection,making it easy to adapt the sensorsto the widest range of requirements.The new range is a single conceptwith many variants. It enablesseveral different measuringtechnologies to be integrated into onetype of housing, including: tuningfork for ON/OFF monitoring or overfillprotection; ultrasound for continuousmeasurement, using a 2-wire circuit,guided microwave; and radar.The launch of the new sensors isthe latest stage in Burkert’s strategyof providing system solutions usingintelligent process valves andsensors. The combination of theseelements creates systematicallyoptimised control loops, whichdeploy state-of-the art technology.The communication techniqueemployed is centred on sensorsintegrating with intelligent valvecontrol heads. This enablesimplementation of low-cost localcontrol loops, which cancommunicate with supervisorysystems such as PLCs and DCSsystems via standard interfaces.MORE INFORMATION:Enter G535 or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for furtherdetails from BurkertMore details: Write in 530 on the free information cardPressure sensor technology from 1 mbar … 1000 barPressure TransmitterType 694Mechanical pressure switchType 604Pressure transmitterOEM Type 511Relative and differential–0.5 … 0.5 – 50 mbarThe pressure transmitters of type 694 seriesincorporate a proved ceramic cantileveredbeam technology. They deliver adjustedtemperature-compensated sensor signals(voltage or current outputs). They are idealfor registering low air flow in air conditioningsystems and for the measurement offine pressures in environmental, laboratoryand cleanroom applications.Relative and differential0.2 … 50 mbarThe type 604 pressure switch is used as a Pflow switch in ventilation ducts for thecontrol of filters and fans, and in primaryand secondary control systems for thecontrol of air dampers. The 604 pressuremonitoring switches are also ideally suitedto protect heating coils from overheatingand for monitoring industrial air coolingcircuits.Relative –1 … 0 – 600 bar,absolute 0 … 1 – 25 barType 511 pressure transmitters meetthe highest specifications for longevity,accuracy, temperature stability and EMCcharacteristics, making them suitable foran extremely wide range of demandingindustrial applications.Huba Control AGUnit 3 Network PointRange RoadWitney Oxfordshire OX29 0YDTel +44 (0) 1993 776667Fax +44 (0) 1993 776671info.uk@hubacontrol.comwww.hubacontrol.comMore details: Write in 531 on the free information card53

FLUID POWERHydraulics & PneumaticsThe changing shape of pneumaticsThe pneumatics market is becoming increasinglypolarised by the demand for high technologyproducts at one end, and basic low-cost productsat the other. Steve Sands of Festo examinessome of the key market driversUntil recently, the bulk of thepneumatics market was formedium performance, mediumtechnology products. But thereis a clearly emerging trend that favourseither higher technology or basic, low-costproducts. This is squeezing the traditionalmiddle sector of the market dramatically,and the pressure looks set to mount.A trend which is worth looking at indetail concerns the growing focus on lowercost components, with technopolymersreplacing metal components in pneumaticvalves and cylinders. Injection mouldedplastic might seem an obvious contenderfor replacing some of the more complexmetal parts in pneumatic valves andcylinders, but it is only recently that theadvent of advanced CAE tools and thefurther development of technopolymers hasenabled manufacturers to seriouslyconsider this option. In the past, severallow price pneumatic manufacturersexplored the use of plastic pneumaticcomponents. This led to a poor reputationfor these components in the market,because the manufacturers were unable topredict and control the mechanicalcharacteristics of the materials they wereusing. But Festo has conducted a rigorousmaterials R&D programme to develop themodelling and analysis tools to ensure thatit can utilise the right materials in theoptimum way.For example, thermal stability is criticalin the performance of a valve housing, asdistortion in either the solenoid pilotsection or the main spool area quicklyFor more information, contact Lee ProductsInnovation in Miniature Tel: 01753 886664Fax: 01753 889588www.industrial-microhydraulics.co.uke-mail: sales@leeproducts.co.ukLee Products Limited, 3 High Street, Chalfont St Peter, Bucks SL9 9QEFesto’s new technopolymer-based VB12valves undergoing thermal analysisdegrades performance and reliability.Festo is selecting materials such asIXEF 1022, which is a 50%glass-fibre reinforced polyarylamidecompound that can be readilyprocessed in conventional screw-typeinjection moulding machines. Withcareful design these materials can becombined effectively with metalcomponents to offer the samereliability as all-metal alternatives yetwith cost savings of 30%.Excellent alternativeFinished technopolymer parts exhibitvery high strength and rigiditycombined with superb dimensionalstability, have a high surface qualityand gloss, and provide excellent creepresistance at high stress levels. Thiscombination of attributes make thematerial an excellent replacement formetal; it has a tensile strength aboutsame as mild steel, and a coefficientof thermal expansion of 15 x 10-6K-1. And unlike metal, it also has themajor advantages of being a goodelectrical insulator, with excellentenvironmental resistance characteristics.Clearly polymers don’t rust, butsome have far better chemicalresistance than others.The first technopolymer-basedproducts that Festo is introducing aredesigned specifically for high volumemarkets, where price/performance isa key factor. The product line-upincludes air preparation units,compact and ISO cylinders, one-wayflow control valves and a series ofelectrically-operated valves and valveterminals. All of these products havesignificant cost advantages over theirall-metal counterparts.The DSNUP series of pneumaticcylinders, for example, featuretechnopolymer end caps, stainlesssteel piston rods and aluminiumbarrels, and have a list price which issome 30% less than the identicallyconstructedall-metal versions. Festohas also introduced the ADNP ISOcompact cylinder with technopolymerend caps incorporating push-in tubefittings, which costs 20% less than itsequivalent all-metal version. Theirhigh chemical resistance makes thememinently suitable for food processingand packaging applications, and theirlow weight will prove particularlyadvantageous to OEMs developinghandling automation technology.Another example of the benefits oftechnopolymers will be provided byFesto’s new VB12 valves and valveterminals. The entire body of eachvalve is moulded from IXEF 1022glass-filled polyamide, resulting in avery cost-effective, low weight design.Festo has performed extensive X-rayanalysis of the valves to determine theoptimum technopolymer design. Itwas important that the chosenmaterial provided a similar modulusof rigidity to metal, to ensure goodleakage values and to prevent anymisalignment of embedded contacts.Thermal analysis has confirmed thatthe valves provide 100% reliability atambient temperatures to 50°C.Festo believes that theintroduction of technopolymer-basedpneumatics products represents amajor opportunity for UK-basedOEMs and systems integrators. Untilnow, the absence of high quality, lowcostcomponents has made it verydifficult for these companies tocompete with lower cost imports. Soalthough the shape of the pneumaticsmarkets is changing, it looks like achange for the better.MORE INFORMATION:Enter G545 on the card, or visit ‘latest issuestories’ at www.industrialtechnology.co.ukfor further details from Festo54More details: Write in 540 on the free information cardINDUSTRIAL TECHNOLOGY • July 2008

ADVERTISEMENT FEATUREIntegrating particle analysishelps hydraulic systemdesigners cut end user costsTogether, we canRising energy costs, growing awareness of environmental issues,and the need for ever greater system uptime means that integratingon-line particle and moisture analysers into new hydraulic systemsis now cost effective for OEMs and adds real long term benefits fortheir customers – the end users.In particular, a new generation of on-line particle analysers fromParker Hannifin makes it simple for design and production engineersto specify and install instruments at the build stage. Just asimportantly, these analysers enable OEMs to offer added valueto customers, giving them the ability to improve still further theperformance and reliability of hydraulic systems, and to reduceoverall maintenance costs. This is especially true in modern highperformance systems with tight tolerances, and where equipmentis used in critical industrial, process and mobile applications.The new and innovative IcountPD contamination monitoringtechnology from Parker has been developed to measure the size andconcentration of particles in oils and lubricants. IcountPD is basedon the company’s 20 years experience of particle analysis, and ofworking with designers and engineers to reduce production costsand increase the performance and reliability of hydraulic systems.IcountPD is designed as a simple to fit and operate instrument, thatcan be designed into new equipment or retro-fitted to existing plant,as a permanent on-line instrument.IcountPD uses proven laser detection technology, for precise andrepeatable particle detection, and to provide a continuous indicationof the quality of oils or lubricants. An easy to read digital statusdisplay, backed by appropriate alarms, confirms that operatingconditions are within safe parameters or are changing due tofluctuations in contamination levels.IcountPD can operate at flow rates from 6 to 380 l/min, (whenconnected to a Parker in-line System 20 sensor), and at linepressures from 2 to 420bar; it offers a choice of output signals,including 4-20mA, 0-5V, CANBUS, J1939 and RS232, and canbe supplied with an optional moisture sensor. Just as importantly,IcountPD is easy to integrate into hydraulics systems and is backedby Parker’s comprehensive technical support services and rangeof filtration, hydraulics, pneumatics and drive technologies.@More details: Write in 551 on the free information cardTo learn more about IcountPD and other Parkerfluid contamination monitoring productsemail filtrationinfo@parker.com.55

FLUID POWERHydraulics & PneumaticsModularising machinedesign and buildRay Barnes of Hoerbiger-Origa explains how mechatronicsubsystems, modular design and intelligent controls can beused to ensure machines have a long, productive working lifeThe European market for packaging machineryis forecast to grow at an olympian 8% perannum to reach €13m in 2008. And withdeveloping nations coming on-stream asproducers, but still looking to Europe for machinedesign and build, some analysts put the figure higheryet. This is in contrast to growth of 1.6%predicted for the UK economy as a whole.So packaging machinerywould seem to be a goodmarket to be in,especially as otherengineering sectors donot appear to be in suchgood shape. However there are some significantbarriers to entry, most notably the level of expertise thatis needed. Designing a packaging machine is not easy.Packaging machines need to be very efficient (and thatusually means high speed) to safeguard the slimmargins in which food processors operate. They alsohave to be long-life machines, robust enough to runand run, often with low maintenance for many years.And they have to be very flexible so that they are ableto accommodate the constantchanges driven bysupermarkets and theircustomers, including thesteady stream of temptingspecial offers, free gifts attached tothe packaging, requirements for multi-packs, anddifferent packaging for different customers.There are new reasons emerging at quite analarming rate too. For instance, new materials areconstantly coming to the market. To date these havetended to be multi-material high performancelaminates that may need special handling. But moreand more ‘green’ materials are emerging, for instancestarch-based plastics replacements that have differenttolerances to temperature and may be less pliable. Soa packaging machine needs to be robust, high speed,ultra reliable, energy efficient flexible and easilyadaptable. To accommodate these requirements, fourkey technologies are emerging in mechatronic design;linear motion, servodrives and programmable control.All have been around for some time, but continue toevolve.Simpler machines are typically controlled by a small‘brick-style’ PLC. But the performance level of theseincreases year on year, allowing ever greater control ofmachines. Additionally fieldbuses and industrialEthernet are making ‘wiring up’ far less daunting andencouraging greater take up of comprehensive controls.Similarly servo drives are getting faster, morecontrollable, more powerful and more compact as timegoes on.Linear motion technologyPerhaps surprisingly, the greatest advances are beingmade in linear motion technology. The need for linearmotion has existed as long as there has been machines,but for a long time this was generated using bespokesolutions. The first linear actuators were probablyhydraulic and pneumatic cylinders, which becamestandardised engineering components in the 1960s(and have evolved considerably since then). The 1980s56INDUSTRIAL TECHNOLOGY • July 2008

Hydraulics & Pneumatics FLUID POWERsaw the development of the rodless pneumatic cylinder,which was soon finding uses way beyond thosenormally associated with pneumatics, encouraging.Several variations of the concept emerged, and featuressuch as guides, sensors, encoders and controls wereincorporated, such that they became integratedstructural and actuation elements within a machine.Demands for ever greater positional accuracy andthe very compressibility of air meant that a practicallimit was reached for some packaging applications,which spawned the birth of electro-mechanical linearactuators.Modern machine requirementsThe greatest positional accuracy is achieved with linearactuators based on ballscrews or lead screws. Thesealso have good load carrying capacity. But there aredownsides too, most notably with regard to weight, unitcost and limited high end operating speeds. But formany packaging machinery applications, a moreeffective, faster and lower cost solution is achieved withbelt-based linear actuators. These are able to satisfythe levels of precision, flexibility, robustness andreliability demanded, particularly for longer strokeapplications .However machine design is not only about speedand throughput. There are also growing demands forshorter stroke applications that do not require highspeeds and cycle rates, but provide for the flexibilityrequired to adapt to constant change. And this is wherespindle (screw) drive actuators can be indispensable. Atypical applicationmay be a machine fillingindividual containers of varioussizes and involving frequentbatch changes. In this case, ascrew driven linear actuator could be used toautomatically make the necessary machine adjustmentsto accommodate the changes in container size.Similarly demands for multi-packing flexibility, forvarying pack sizes and special offer runs will alsonecessitate machine settingadjustments that may readily beautomated with linear actuators.Programmable changeover using the memory of a PLCand the precision of a linear actuator has replaced stockholding with short run flexible working, enablingmachine designers to meet the evolving needs ofmachine users, who in turn then have the tools tomeet the changing demands of their customers.MORE INFORMATION:Enter G565 on the card, or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for further details fromHoerbiger-Origa and more news on linear actuatorsAlliance Plastic Parts Centre, Unit 2A, Shepcote Way, Tinsley Ind. Estate, Sheffield S9 1THTel: 0114 244 6614 Fax: 0114 244 6615 email: sales@alliance-plastic.co.ukwww.alliance-plastic.co.uk www.spiralguard.comMore details: Write in 570 on the free information card57

FLUID POWERHydraulics & PneumaticsPneumaticcalibrationpumpsAmetek Calibration Instrumentshas further enhanced its range ofpressure generation productswith the launch of the T-960, T-970and T-975 pneumatic calibrationpumps. The T-900 series calibrationpump is used to generate pressure andvacuum (specific models) for checking,adjusting and calibrating mechanicaland electronic pressure measuringinstruments by comparativemeasurements. These pressure testsmay be carried out in laboratories,workshop or on site at the measuringpoint.The new calibration pumpscomplete a range of 18 pressuregeneration solutions offering anoperating capability from vacuum up to1000 bar (15,000 psi).MORE INFORMATION:Enter G586 or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for furtherdetails from Ametek Calibration InstrumentsFast-fit valve reduces powerand increases performanceAn innovative ISO Valve from Parker is quick to fitwith integrated fast serial bus communicationsParker Hannifin has launched arange of innovative pneumaticvalves that meet ISO standard15047 parts 1 and 2 (ISO sizes02, 01, 1, 2 and 3). Called the IsysNet,the new valves combine exceptionalpneumatics performance, with 20% lesspower consumption and claimed lowerbreakaway forces than competingproducts, with integrated and fast serialbus communications that enable valves tobe installed quickly and easily in a widerange of industrial applications.The IsysNet system is based on amodular construction, using robust quickfitlatching mechanisms that enable valve,I/O and communication modules to beinstalled on common manifold units inseconds and without the need for extraconnector plates that are typically requiredwith other ISO valves. In addition,modules can be reconfigured on site, whileserial modules canbe changed evenwhen the systemis powered upand withoutaffecting the controllingsoftware;I/O modules arealso colour coded for quickidentification. The serial modules use afast backplane with the latest changeof state (COS) connections foroptimum performance, and allow anIsysNet manifold unit to be linkeddirectly to sensors, limit switches andencoders, and to remotely operatedsolenoid valves or other pneumaticdevices. The IsysNet system providesa choice of digital, analogue and highwattage I/O, with individual modulesincorporating comprehensive safetyfeatures such as short circuit and opencircuit detection. The system can beextended considerably by the use ofcommunication modules, whichsupport upto 62 I/O modules and upto 252 inputs and 252 outputs. Bothelectronic and pneumatic connectionsare built into a single manifoldmounted end plate.Mechanically, the new IsysNetvalve modules are compact, with a lowprofile and are available as single ordouble solenoid modules, with internalor external pilots, Cv ratings of 0.6 to6.0 and a choice of NPT or BSpp Gstandard ports. Perhaps as importantly,the solenoid valves use up to20% less power than conventional ISOdevices of the same size.MORE INFORMATION:Enter G585 or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for furtherdetails from Parker HannifinMore SMC parts from RSRS Components is pleased toannounce the availability ofover 12,500 new productsfrom SMC. These new additions buildon the existing range of over 2,000SMC products already available fromRS, meaning you can now go to oneplace for all your SMC pneumaticneeds. The extended range coverscomponents from regulators, filters,valves, silencers, cylinders, manifoldsand fittings through to spares andaccessories.MORE INFORMATION:Enter G588 or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for furtherdetails from RS ComponentsCountdown markings takethe guesswork out of tubesCountdown markings nowprinted on Legris’s pneumatictubing ranges allow users todetermine the precise quantityremaining in a Tubepack dispenser.The markings – at one-metre intervals– also help to reduce wastage.The new system is being appliedto 100 and 25 metre rolls of Legris’most popular tubing ranges.Polyamide provides high pressure,temperature and chemical resistance,polyurethane polyester is ideal forcompressed air applications becauseof its low bend radius, whilepolyurethane polyether, offers lowbend radius and high chemicalresistance.The tubing, including crystal clear,is also available in a range of coloursfor ease of circuit identification.MORE INFORMATION:Enter G587 or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for furtherdetails from Legris58More details: Write in 580 on the free information cardINDUSTRIAL TECHNOLOGY • July 2008

KOENIG SEALING PLUGSAEROSPACE AND AUTOMOTIVE APPLICATIONSPneumatic and hydraulic low and high pressure plugsEasy to install, reliable and clean to fitA quick and effective method of sealing drilled holesin castings and machined componentsFor a catalogue please contact:T: +44 (0)1623 445 450 F: +44 (0)1623 445 451E: sales@boneham.co.uk or visit: www.boneham.co.ukMore details: Write in 590 on the free information cardMore details: Write in 591 on the free information cardMore details: Write in 592 on the free information card 59

MACHINERY SAFETYAir MotorsBrake air motor systemmeets ATEX standardsfor explosion protectionAir motor specialist Deprag has developed an innovative drivesystem consisting of a motor, brake assembly and gears.Constructed in stainless steel, the system is certified to ATEXstandards for use in potentially explosive environmentsExplosion prevention is a hot issue within thefield of systems engineering, where friction,overheating or sparks could lead to a horrorshow in potentially explosive environments. Butnow air motor specialist Deprag has risen to challengewith the development of an air-motor holding and brakedrive-systemthat guarantees explosion prevention inpotentially explosive environments according to ATEX.The system was developed as a drive for vatdrainage equipment from Beer-Fördertechnik. Based in Bad König,Germany, the company has beeninvolved with batching, conveyingand transportation since 1976. Itis a renowned manufacturer ofcustom-made system components for bulk goodstechnology, and had been searching for a drive-solutionusing an integrated brake assembly to optimise thesafety of its vat drainage equipment that is primarilyused in the chemicals industry.Integrated brakeThe drive system that Deprag developed is based aroundan innovative air motor with integrated brakes andplanetary gear works. In operation, the vat is movedusing the power of the air motor to begin a tilting anddraining procedure. At the highest point, the deadcentre, the motor switches off and the brakes areapplied, holding the current position. The integratedholding brake comprises three brake disks, a pressurespring and a piston. They are controlled separatelyusing an airline. When the pressure in the controlline is over 3bar and the spring load is less thanthe compression force, then stress is taken offthe brake disks and the motor can turn. If thepressure in the control line is below 3bar andthe spring load is greater than thecompression force, then the brake disksare forced together and the motor isblocked.To produce a motor, which couldbe certified for use in potentiallyexplosive environments, Depragengineers had to think outsidethe box. If an air pressure ofover 3bar remained in thelines that control thebrakes, then the brake disks couldconstantly rub against each other and causeexcessive temperature increases. This wouldof course elevate the risk factor in potentiallyexplosive areas. Gerd Zinn, manager of theserial machine developmentdepartment comments:“By implementing asafety valve, we haveminimised this risk.” Thevalve turns the air feed offautomatically when the pressure fallsunder 5bar, causing the pressure appliedto the brake to become zero. The brakes are then forcedtogether fully and the motor is blocked. Product managerDagmar Hierl adds: “With this entirely new type of drivesystem we have been successful in launching anattractive complete system on the marketaccording to ATEX guideline 94/9/EG,corresponding with EX II 2GD c IICT5 (95°).”Because of the way they areconstructed, air motors are ideallysuited for use in potentiallyexplosive environments.Operating principleThe principle is simple, withthe motor rotation driven by airpressure from a compressor. Themotors are vane motor designs.The rotor, which revolves in aneccentrically set cylinder, is setin motion. There are vanes inits slots, which are pushed outwardsagainst the cylinder wall through centrifugalforce. Working chambers are created for theexpanding air pressure. Through theexpansion of this restricted supply-air, thecompression energy changes to kineticenergy and the rotary motion iscreated.Wilfried Beer, managing partnerof Beer Fördertechnik, isunderstandably enthusiasticallyabout the advantages of thisnew type of brake motor. “By usingDeprag stainless steel air motors with integral brakes conform toATEX requirements, are corrosion-free, reversible and fully sealed,and can be used oil-free without needing any modificationsthis complete system for my vat drainageequipment, I can save myself enormousadditional construction and manufacturingexpenses because the brakes, whichprovide the safety for my mechanism,are already integrated.”Extensive rangeThe newly developed brakemotors are now available aspart of Deprag’s stainless steelmotor program. They are offeredin various torque ranges, in powersto from 20W to 1.2kW. The stainlesssteel product line contains a large rangeof fully-sealed, corrosion-free air-motorswith oil-free capability. Basing the design ona flexible kit-system enables Deprag to offer avariety of possibilities (including different drivespindles, motor mounting options, etc) for an extremelyattractive price-to-power ratio.Stainless steel motors are generally used inapplications where a high grade of hygiene is required orwhere steam- and acid-resistance are required. Themotors are full sealed, and reversible.MORE INFORMATION:Enter G605 on the card, or visit ‘latest issue stories’ atwww.industrialtechnology.co.uk for further details from Deprag andmore news on ATEX certified motors and drive systems60INDUSTRIAL TECHNOLOGY • July 2008

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MACHINERY SAFETYNew ProductsSafety sensors – simplified andwithout limitationsDew pointtransmitterFM certifiedSpecifying, ordering, fitting and setting up lightguard installations for virtually every applicationare easy tasks with the new all-in-oneMS28/MS48 safety light curtains from OmronUnlike conventional light curtaindesigns that make it necessary forspecifiers to choose from a widerange of potentially confusing options, theMS28/MS48 range features a smallnumber of products, each of which canbe easily and quickly configured by theuser to suit the needs of the application.MS28 light curtains are suitable forType 2 applications, while MS48 productsare designed for Type 4 applications,complying with EN 61946 Part 1. Theseries includes 14mm finger protectionmodels, with a maximum operating rangeof 7m, covering protection heights from280mm to 1800mm. Also available are30mm hand protection models with amaximum range of 20m, coveringprotection heights from 240mm to2120mm. Rapid alignment is ensured byan innovative alignment aid that usesintuitive LED indication and instantlyshows whether adjustment is correct orincorrect.The light curtains incorporate a simpleswitch arrangement that allows them tobe set up and put into operation withoutthe need to use any external programmingequipment. Standard models featureoptions for external device monitoring,restart interlock, range reduction and ascan code selection option. Fordemanding applications, a multifunctionalversion adds facilities for muting and forfixed and floating blanking.Up to four M28/48 light curtains canbe cascaded for segmented guardingapplications. Housings up to 9mm thick,making them suitable for use in even thetoughest of industrial environments. Thesame accessories fit all models, cuttingthe investment needed in design andmaintenance.MORE INFORMATION:Enter G624 on the enquiry card, or visit ‘latest issuestories’ at www.industrialtechnology.co.uk forfurther details from Omron ElectronicsMichell Instruments hasreceived confirmation ofthe accreditation by FMApprovals for the intrinsically safeversion of its Easidew Transmitter.In addition to its ATEXcertification, this allows theEasidew TX I.S. to be used inhazardous area applicationswithin the USA.The Easidew TX I.S. iscertified by FM Approvals for usein hazardous areas toIS/I/1/ABCD/T4 when used with agalvanic isolator for signal powerAdaptability iskey strengthCompliant with international safetystandards and easy to adapt toindividual applications, the Falk‘Orange Peel’ rotating machinery guardfrom Rexnord offers engineers a costeffectivesolution for original and retrofitinstallations that is backed by a 3-yearwarranty.The Orange Peel rotating machineryguard (couplings, pumps etc.) complieswith OSHA, ASME and ANSI standards. Itis available in a number of differentdesign configurations, all of which can betailored on site to fit applications. Thedesign options and adaptability of theguards ensure all the problems associatedwith custom fabricated alternatives areeliminated.MORE INFORMATION:Enter G626 on the enquiry card, or visit ‘latest issuestories’ at www.industrialtechnology.co.uk forfurther details from RexnordReplacing the rotary switchwith a ‘program-in-a-plug’The UE410 FlexiSOFT from Sick is aDIN-rail mounted, software-basedmodular safety controller forapplications that require moresophistication than basic safety relays butdo not require the complexity of a fullscalesafety PLC.The UE410 FlexiSOFT is adevelopment of the well establishedUE410 Flexi Classic. Where the UE410Flexi Classic was programmed by meansof rotary switches, the Flexi Soft comeswith a software configuration tool, whichallows safety engineers to configurecomplex safety systems – from simplelogic gates like AND, OR, etc, to moreadvanced functions such as safe on/offtimers and set/reset function blocks.Iain Smith, Product Specialist forIntegration Technology at SICK, explains:“The UE410 Flexi Classic is designed forusers who want to manipulate safety logicwithout going through PC software andthis is still the best solution for customersnot wanting to adopt a software safetysolution. The UE410 FlexiSOFT units are22.5mm wide, and programming isachieved through a small M8 connectorport on the CPU from a serial cableconnected to a PC’s RS232 connectorport. The program is in the plug. If thesystem needs replacing for any reason,you just take the plug out, put a new unitin and put the plug back in. You do nothave to worry about re-programming orforming links between terminals.”The UE410 Flexi Soft seriescomprises a number of DIN-rail mountedunits: a CPU control unit, eight singlechannelsafety input module, mixed eightinput four output module, one dualchannelsafety relay output module(2N/O) and a two dual-channel safetyrelay output module (4N/O). Diagnosticdata can be obtained from the RS232port on the main CPU, and diagnosticmodules can interface to standardnetwork topologies.MORE INFORMATION:Enter G627 on the enquiry card, or visit ‘latest issuestories’ at www.industrialtechnology.co.uk forfurther details from Sicksupply connections. The newTransmitter can be safely used invirtually all industrial gasmeasurement applications. Thecertification lists five differentgalvanic isolators.MORE INFORMATION:Enter G628 on the enquiry card, or visitwww.industrialtechnology.co.uk forfurther details from Michell InstrumentsSafer testingin the labThe fast and safe testing ofhigh voltages up to 5kV ACand 6kV DC is provided bythe portable bench-top SentinelHiPot/flash/dielectric tester nowavailable from Clare Instruments.Product features one touch testing,selectable ramp and dwell periodsfor accurate test control. Safeprogrammable test sequences areprovided by the inclusion of an arcdetection feature capable ofmonitoring low energy dischargesin equipment under test.MORE INFORMATION:Enter G629 on the enquiry card, or visitwww.industrialtechnology.co.uk forfurther details from Clare Instruments62INDUSTRIAL TECHNOLOGY • July 2008

1998 - 200810 Years of IndependentMachinery Safety AdviceRisk AssessmentCE MarkingPUWER AssessmentsOnsite EMC TestingTrainingTel +44 (0) 8700 111375Fax +44 (0) 8700 111395Web www.laidler.co.ukeMail enquire@laidler.co.ukMore details: Write in 630 on the free information cardMore details: Write in 631 on the free information cardMore details: Write in 632 on the free information card 63

product and service factfindersAIR CONTROL INDUSTRIES LtdSilver Street, Chard, Somerset TA20 2AEe-mail: sales@aircontrolindustries.com www.aircontrolindustries.comFree Airknife DemosACI Ltd is currently offering customer-on-site Free Demos of their Airknife Drying Systems.For any process requiring the removal of surfacemoisture, coatings, dust or contamination from awide range of materials and shapes, ACI Airknifesystems provide clear performance and efficiencyadvantages over other methods.Email sales@aircontrolindustries.com to arrangeyour visit.More details: Write in 640 on the free information cardONDRIVES LtdFoxwood Industrial Park, Foxwood Road, Chesterfield, Derbyshire S41 9RNe-mail: sales@ondrives.com www.ondrives.comPrecision Oil FilledWorm Gear Reducers fromOndrivesNewest gear unit available from gearbox specialistOndrives Ltd is the OFG40 – a precision oil filled wormgear reducer. These are unique to Ondrives and madein-house to exacting specifications – please visitwww.ondrives.com for further details or speak to ourexperienced technical team who will be happy to assistyou.More details: Write in 644 on the free information cardCOTEL MOULDINGSJG Coates (Burnley) Ltd, Trafalgar Street, Burnley, Lancashire BB11 1THe-mail: sales@cotel.co.uk www.cotelmouldings.comNew Products 2008from Cotel MouldingsPlease request the new Cotel Mouldings catalogue featuring thelatest additions to our comprehensive range of industrialproducts:• New Design Bridge Handles & Wing Knobs• Rubber Dampers • Cam Locks & Latches• Nylon Bushes & Insulation Sleeves • Industrial CastorsFor fast, reliable service please contact us today, and please also visitwww.cotel.safetychannel.com for over 23,000 safety signs and related products.More details: Write in 641 on the free information cardRELIANCE PRECISION MECHATRONICS LLPRowley Mills, Lepton, Huddersfield HD8 0LEe-mail:sales@rpmechatronics.co.uk www.reliance.co.ukNEW Reliance Planetary GearboxesReliance is pleased to announce a new range of planetary gearboxes; with both NEMA 17and 23 interface availability, the gear heads can be coupled to the Reliance Cool Muscle toprovide a high torque intelligent drive system.The gearboxes feature 96-98% efficiencies, lowest backlash(

John Richardson’s ENGINEERING DIARYIt feels to me as though manufacturing in the UK is onthe cusp of something great. The rest of the economymay be struggling, but the manufacturing sector isenjoying its longest period of sustained growth formany a year. Over the last twelve months, I have visited manycompanies and spoken to them about their forecasts for thefuture. A year ago, they were saying they’d enjoy it while it wasgood, but that they all expected to hit a wall soon. Today, almostuniversally, they seem surprised that they still haven’t hit thatwall, and that orders are still looking good.I would have expected the government to be latching ontoany bit of good news about the economy it could find, and doingeverything it its power to nurture successful and growingsectors. But as ever, it seems content instead to ignoremanufacturing and let the sector do its own thing. There aremoments when you think the government is taking an interest,but then you realise that it’s only lip service.Take the issue of corporation tax for example. What the UK’srevitalised manufacturing sector could really do with to give itthat little bit of extra impetus is a cut in corporation tax. And theChancellor has hinted at as much. But you get the feeling thatit’s just not going to happen.Corporation tax backlashI was saddened by the backlash of opinion against AlistairDarling’s promise to further cut the headline rate of corporationtax, following the 2p cut that took it down from 30% in 2007 to28% in 2008. If a survey carried out by the TUC isrepresentative of wider public opinion, fewer than one in fivevoters back his promise to cut tax further as soon as he can findthe funds.The Chancellor has repeatedly made it clear that reducingbusiness taxes will be a priority, just as soon as he has the fiscalroom to do so. But the TUC argues that the Treasury has fallenvictim to a concerted lobbying campaign by multinationals. In asurvey of more than 2,000 people, carried out by YouGov, just18 per cent of respondents agreed with the statement ‘thegovernment is right to reduce tax on the profits of largecompanies’.Brendan Barber, the TUC’s general secretary, said: “CorporateBritain is waging a big campaign to pay less tax. But the rest ofus should be on our guard. If business gets its way it will meanhigher taxes for the rest of us, cuts in public services or a retreatfrom anti-poverty targets. Big companies are playing the samecard across the world – threatening to quit countries unless theirtax is slashed. The UK should stop pandering to this cynicalgame and start working with other governments to call thecorporations’ bluff.”Commenting on the TUC report, the CBI’s Deputy Director-General, John Cridland said: “Last year, the amount UKbusinesses paid in tax ran to almost £150 billion – equivalent tothe NHS budget one and a half times over and twice theeducation budget. Since new taxes were introduced in thisyear’s Budget, firms are paying an additional £4 billion. So let’sdispel the notion once and for all that business is ‘getting out of’paying its way on tax.“Recent research showed 92% of any increase in corporationtax is passed onto workers in lower wages and hits the economythrough less investment and reduced productivity,” he continued.“There’s no point in pretending we don’t all feel the impact ofhigher business tax. What’s more, with businesses becomingincreasingly mobile there’s a real risk that firms will simply votewith their feet if they see the UK becoming any less competitive– costing more jobs and hurting the economy at a time when itdoesn’t need it. As a nation, we can choose whether or not wewelcome high earners who generate wealth, make investmentsand create jobs. In a global economy, they too can vote withtheir feet.”That’s fighting talk from two opposing camps, and you cansee the points of view each. The profits announced by the big oilcompanies, for example, at a time when the rest of us are beingpriced off the roads and wondering whether we can afford tostay warm this winter certainly don’t engender any feelings ofempathy. If you’re a company making more than £1.5 million anhour, and registering annual profits of over £13 billion, then isn’tit only fair that you should be paying more tax? Well, maybe so,but the problem is that most companies don’t make anythinglike that sort of money, and the headline rates of tax for theUK’s smaller businesses have actually gone up since 2007.If the UK’s manufacturing sector is to grow and thrive, then itis the SMEs that would we should be nurturing. Thesecompanies will be hit hard by the increase in tax that they willhave to pay in 2008 through the increased corporation taxrates, as well as all the other new taxes that the Chancellor haspushed through. Tax, we are constantly told, doesn’t have to betaxing; but it does have to be fair.feedback@itmagazine.uk.comJuly 2008 • INDUSTRIAL TECHNOLOGY65

EAR TO THE GROUND • Becky Silvertonbecky@itmagazine.uk.comBalancing the conflictsin industrial design...Whichever way you’ve turned thissummer, it’s been all but impossibleto avoid sports in the TV scheduling.I can’t say that’s really my thing,although I have to confess a certain fascination thisyear... with the men’s shorts. I reckon that that onesimple garment embodies the thin line betweensuccess and failure in industrial design.When you see snippets of archived footballfootage from, say, the 1930s or ’40s, the players’shorts were probably mid-thigh length. They weren’texactly baggy, but at the same time they were along way from clingy. Fast forward to the 1970s,and the shorts were so short andso tight and if you happened toflick through a TV replay it wouldbe difficult to tell at first glancewhether you were watching a realfootball match or soft porn thinlydisguised as sport.From my studying of men’sshorts during the Europeanchampionships, I can see thatfashion has reverted to a stylemore akin to the 1930s. And it looks to me asthough shorts reached this length in gradualincrements through the 1980s and ’90s. So where,I wonder, might shorts design be headed in thefuture? Well, if you’d flicked over to the BBC duringthe first week of July, you couldn’t fail to have seenRafael Nadal at Wimbledon, playing in a pair ofshorts that seemed to me to be ludicrously long.That’s quite a fashion statement. At the same time,if you caught Maria Sharapova before her untimelyexit, you’ll have noticed that her top seemed to bemodelled on a dinner jacket – again a seriousfashion statement. I bet you feel great wearingsomething like that when you’re winning, but just atouch self-conscious if you lose somewhatunexpectedly.But what, you’re asking me, does all this have todo with industrial design? Well, contemporarydesign is a balance between two conflicting issues:finding an area of differentiation between yourproduct and your competitors’, but strenuouslyavoiding reinventing the wheel. The shorts worn byNadal and the top sported by Sharapova seem tosuggest that if you try to achieve real definitionwithout some reinvention, then you end up withsomething so extreme as to be a pastiche of adesired product rather than something which isdesirable in its own right. Extremes polariseopinions, and that puts you into the realms of nichemarkets – not somewhere you want to end upunless it’s where you’re specifically aiming.But if we don’t want to constantly reinventtechnologies to achieve differentiation, and if wedon’t want to resort to extremes, then do we have toaccept that ultimately there are no genuinely newideas? And if that’s so, how do we really defineinnovation? I’m not sure I have the answer, butperhaps asking the question is a good place to start.Instrumentation ScotlandSeptember 3-4, 2008Aberdeen Exhibition & Conference Centrewww.instrumentation.co.ukTrident Exhibitions (01822 614671)EtherNet/IP SeminarSeptember 16, 2008, ParisSeptember 19, 2008, BarcelonaSeptember 24, 2008, Bolognawww.odva.orgODVA (+1 734 975 8840)Wireless TechnologiesSeptember 27-29, 2008Bochum, Germanywww.mesago.deMesago Messe Frankfurt(+49 711 61946-0)Northern ManufacturingOctober 1-2, 2008Hallam Arena, Sheffieldwww.industry.co.ukEtes (01784 880890)Sealing, Adhesive, ElastomerOctober 21-23, 2008Nuremberg, Germanywww.mesago.deMesago Messe Frankfurt(+49 711 61946-0)EMS Summit 2008European Manufacturing StrategiesOctober 6-9, 2008Düsseldorf, Germanywww.ems-summit.comWTG Events (020 7202 7547)SPS/IPC/DrivesNovember 25-27, 2008Nuremberg, Germanywww.mesago.deMesago Messemanagement(+49 711 61946-0)Index to Advertisers July 2008Air Control Industries ................................ 24-25Air Control Industries ..................................... 64Alliance Plastic Parts Centre ..................... 56-57Asco Numatics ........................................ 34-35Associated Spring ......................................... 41Autodesk ...................................................... 19Automation Supplies ..................................... 43M Barnwell .................................................. 58Boneham & Turner ......................................... 59Bosch Rexroth .............................................. 15Bürkert Fluid Control Systems ........................ 59JG Coates .................................................... 64Components 4 Machinery .............................. 13E2S ............................................................. 61Eckold ......................................................... 47George Emmott ............................................. 37EMS ............................................................ 23ETA Enclosures ............................................. 29Expert Tooling & Automation Products ............. 33Futek Advanced Sensor Technology ................. 52GE Inspection Technologies ............................ 51Heidenhain .................................................. 63Henkel Loctite ................................................ 7HepcoMotion ................................................ 33Huba Control ................................................ 53Huco Dynatork ............................................. 23Idec ............................................................... 3Impac Infrared .............................................. 53Industrial Gas Springs ................................... 41Interpower Components ................................... 5Interpower Components ................................. 64Interpower Components ................................ IBCAlbert Jagger ................................................ 41JBJ Techniques ............................................... 9Jokab Safety ................................................. 63Kingston Engineering ..................................... 30Kobold Instruments ....................................... 49Lafert ............................................................ 6Laidler Associates ......................................... 63Land Instruments .......................................... 49Lee Products ................................................ 54Lee Spring ................................................... 39Lenze .......................................................... 10Machine Building Systems ............................. 43Master Bond ................................................ 45Mayr Transmissions ....................................... 11Micro-Epsilon ............................................... 14MK Profile .................................................... 43Moog .......................................................... IFCMotion Control Products ................................ 64Ondrives ...................................................... 64Parker Filtration ............................................ 55Penny & Giles Controls .................................. 51Rino Industries ........................................... OBCReliance Precision Mechatronics LLP .............. 64Rittal ........................................................... 27Rotaflow FV ................................................. 64Schaeffler ..................................................... 64Sensors UK .................................................. 32SEW-Eurodrive ............................................. 31SKF ............................................................. 11Spelsberg ..................................................... 28Spirol Industries ............................................ 39Spirol Industries ............................................ 45Spirol Industries ............................................ 47Springmasters ............................................... 39Tapeswitch ................................................... 51Trident Exhibitions ........................................ 49Turton Springs .............................................. 41Welser Sections ............................................ 15The West Group ............................................ 59Wittenstein ................................................... 2166INDUSTRIAL TECHNOLOGY • July 2008

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