Engineering Update - April 2021 by jetdigitalmedia

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April 2021

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April 2021

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ENGINEERING UPDATE

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ENGINEERING PDATE

April 2021

CONTENTS Editor

Wendy McManus 01843 267 690 wendy@engineering-update.co.uk

April 2021

At the forefront of digital marketing, Engineering Update strives to bring its readers the latest in industrial engineering, in a format that provides the best usability and ease of use for it’s readers.

Editorial Assistant

Taylor Owens 01843 448 443 taylor@engineering-update.co.uk

Publishing Director

Jodie Little 01843 448 443 jodie@jetdigitalmedia.co.uk

Publication Manager

Tim Johnston 01843 448 443 tim@engineering-update.co.uk

Publishing House

Jet Digital Media Ltd, Suite 1 & 2 Spratling Court Offices, Spratling Street, Manston, Kent CT12 5AN

www.engineering-update.co.uk

April 2021



ENGINEERING UPDATE

esigned by Trotec with Austrian engineering and built to exacting standards, the R400 laser cutter features a 1030 x 630mm working area and CO2 laser power from 60W-100W. It retails from £6,995 (excluding VAT) making it an affordable option for small businesses looking for a productive and reliable laser cutter. Bryan Jater, Sales Director for Trotec UK and Ireland said: "Too often we see businesses buy into cheap laser cutters because the lower initial outlay is attractive to them. Unfortunately, many soon realise that the laser doesn't live up to expectations or the frequent costs and downtime for its upkeep are holding the business back. "The R-series is designed and engineered with the dependability and ease-of-use which is synonymous with Trotec, but the DC laser source enables us to sell it at a lower price point. So, it's accessible for businesses who have a limited budget to start with but don't want to compromise on quality and reliability." The R400 is the latest addition to the R-series of CO2 glass tube laser cutters which already includes the R500 with a 1300x900 mm working area. Trotec has six laser showrooms across the UK and Ireland and also offers online demonstrations for the R-series as well its range of large format cutters, Speedy series engravers and galvo laser markers. For more information on the R-series contact us via www.rayjetlaser.co.uk or call 0191 580 1182.

Trotec launches new affordable laser cutter The new R400 laser cutter from Trotec will enable small businesses to benefit from high-quality cutting technology at an affordable price.

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April 2021

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ENGINEERING UPDATE

Growth Despite Covid in UK’s Gasket & Sealing Sector In a pre-lockdown survey, Members of the UK Gasket & Sealing Association (UKGSA) reported continuing investment and optimism for 2021.

Harrison have invested in topof-the-range CNC machinery for metal machined parts including pump shafts, large leadscrews and brass nuts, which complement their PTFE and plastics machining. They have also invested in a mechanical saw and manual centre lathe. Keith Shepherd, managing director of J A Harrison, said: “The PTFE department has to be a clean environment, so the metal fabrication machines have been located in a new dedicated unit at our Cardiff site. “The expansion at Cardiff required increased power to the building, a new lighting system and connection to our offline CNC programming suite in Manchester, helping eliminate downtime, increasing productivity and reducing costs so we remain competitive.” East Anglian Sealing Co Ltd have been appointed sole UK Distributor for Gambit Lubawka Sp, increasing stock and production by taking on further units at their Bulmer facility. Steve Cant, director at East Anglian Sealing, explains: “New production equipment being installed includes a 2.1mx5.5m bed multi-axis CNC cutter router with automatic saws and sanders. We’re also installing paint and gel coat finishing and non-contact video inspection.

J A Harrison’s new CNC machine “Our production space will increase by 40% and warehousing by 100%! We have also installed our own shredding and crumbing equipment on site to deal with waste. Our plan is to offer this service at cost to other companies in the same position, increasing recycling and reducing landfill.” Flexitallic have moved to larger premises in Aberdeen to support their growing client base which includes offshore oil & gas clients and OEMs. The new 4,600 sq ft site enables them to expand gasket stockholding, workshop capabilities, and host a dedicated Bolted Joint Integrity Training facility. Corseal Ltd, who are a leading manufacturer and supplier of gaskets, seals and associated industrial products, are celebrating 15 years’ of trading and have recently moved to larger premises to hold more stock and materials to meet customer demands. Munsch & Co/PTM have expanded their plastic sheet cutting service with the installation of a Robland panel saw and cutting table, accurately cutting plastic up to 25mm thick to sizes up to 1200mm x 2500mm.

East Anglian Sealing’s new bed multi-axis CNC cutter router 6|

Simon Winfield, chairman of the UKGSA and director of MacLellan Rubber Limited, said: “The gasket and sealing industry is a significant sector in the UK and I’m delighted to see our Members continue to expand and take on more employees during what continues to be, an incredibly difficult time.”

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April 2021

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ENGINEERING UPDATE

Controller for multiple isolation systems

EXKOP EXPRESS

Self-monitoring safety electronics In the event of an explosion, the EXKOP Express controller receives a trigger signal, for example from the signalling unit of a flameless venting device, an explosion vent, a pressure detector or an IR-Flame sensor. The EXKOP Express controller then activates the connected explosion isolation systems, causing adjacent plant components to be isolated within milliseconds and protected against explosion propagation. The EXKOP Express is suitable for the following isolation systems: REMBE quench valves QV II and QV III, the Q-Bic extinguishing barrier and the RSV Slide Valve and REDEX Slide.

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Together with the REMBE iQ Safety Cockpit, a software program to centrally display the explosion safety of your plant, the EXKOP Express offers the complete monitoring of plant components, process sections and statuses of various protective components. As soon as the EXKOP Express receives a trigger signal in the event of an explosion, it passes this information on to the REMBE iQ Safety Cockpit. Due to the direct notification to the desired communication medium, e.g. the mobile

By detecting operationally relevant components for explosion protection or temperature/fire gas detectors and grounding systems for explosion prevention, they can be registered via the REMBE iQ Safety Cockpit and connected to material management. So if a disruptive event such as an explosion occurs, the system detects which areas are affected and provides information about which spare parts are needed to restore the plant to a safe condition as quickly as possible. These functions can be presented in the operator’s system as a “suggestion” or can be sent directly

phone of the person in charge, REMBE has enabled causes to be identified in an optimised and targeted manner, thus allowing downtimes to be reduced.

to the manufacturer as a non-binding request. Continuous optimisation of processes is made possible through detailed documentation and evaluation of all results. |9

April 2021

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ENGINEERING UPDATE

BIG FEATURES MEANS BIG BENEFITS IN MINIATURE LASER DISTANCE SENSORS The development of miniature laser distance sensors which provide exceptional measurement performance are a vital component in today’s more compact machines and systems, helping manufacturers to meet the ever-present demands for optimum efficiency. The new miniaturised OM20 and OM30 laser sensors available from sensing and instrumentation specialist BAUMER are a good example being perfectly suited to handling precise measurement tasks, despite their ultra-compact size. These sensors are distinguished by their ability to provide reliable, surface-independent measurements with a repeat precision of up to 1µm combined with an impressive measurement speed of up to 5 kHz despite their miniature size. They measure just 37mm x 35mm x 13mm. For applications requiring measurements on structured surfaces such as processed metal or wood, the OM30 option is an ideal solution thanks to its line beam shape with a range of up to 550mm. The standardised IO-Link interface allows for easy integration into control systems along with simple parameterisation of the sensor. Apart from providing standard process data, such as the distance value or the signal quality, the sensors offer additional data including the measurement rate and the

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illumination reserve of the sensor. The latter can also be used as an indicator for the soiling of the sensor, helping to support preventative maintenance regimes. The precise and reliable performance characteristics of these new miniature sensors apply across the entire Baumer OM sensor range giving users the confidence of unrivalled measurement, compared to other options available. This is particularly important in applications where the most challenging conditions prevail such as poor ambient light, or involve dusty environments. For example, OM70 sensors have high ambient light immunity up to 28kLux whereas most other options only go up to 7.5kLux. In addition an automatic light adaption function which can power itself up means the sensors can see through dark or dusty environments and receive a stable reflection back. Finally, reliable results and measurements can be achieved, even on demanding surfaces, thanks to the extra fine line beam and stable measurement signals, thanks to functions such as automatic exposure control and adjustable filters. More at: www.baumer.com/opto-distance-miniature Tel: +44 1793 783839 email: sales.uk@baumer.com www.baumer.com/gb/en/

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April 2021

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Cutting We can cut and shape perforated sheet to meet the needs of your final application. Levelling For some applications a high degree of flatness is required, we have processes in place to ensure our perforated coils and sheets meet with your most demanding requirements. Rolling and forming We can roll, bend and form perforated sheets to match your design. Aesthetic finishes and protective coating We can offer powder coating and hot dip galvanizing solutions to meet your specifications.

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April 2021

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ENGINEERING UPDATE

Comparison of INCONEL ALLOY 626 and INCONEL Alloy 725 When you’re looking for a superior material for your next project, a highperformance nickel alloy might be just what you need. However, there are a number of Grades available in the INCONEL range, any of which could suit your requirements and needs.

he flagship INCONEL alloy is INCONEL alloy 625, one of the most versatile materials ever created. With its outstanding corrosion resistance and high strength, it lends itself to a number of applications across a wide range of industries. It’s a hugely popular material of choice that will solve many material problems for design engineers. It’s been doing so for over 50 years now and remains in common usage, which is testament to its quality. However, if high strength is the priority, INCONEL alloy 725 can be a better fit. It is similar to INCONEL alloy 625, especially in terms of corrosion resistance. However, there are notable differences between the two, which can affect the decision of which to use.

Differences in composition INCONEL alloy 625 is a nickel-heavy alloy, with a minimum 58% of nickel in the blend withchromium (20-23%) and molybdenum (8-10%), plus added niobium (3.15-4.15%). The addition of the niobium and molybdenum gives very high strength in annealed condition without the need for strengthening heat treatment. The nickel and chromium together give the material its incredible corrosion resistance, withstanding highly corrosive elements and environments. INCONEL alloy 625 also contains small amounts of cobalt and silver, which are not present in INCONEL alloy 725 which has a higher amount of titanium and balance, as opposed to 5% max in INCONEL alloy 625. These small differences gives INCONEL alloy 725 its hugely increased strength value.

Comparing strength Whilst INCONEL alloy 625 is a very high strength alloy even co it still outperforms many other nickel alloys in this area. However, there are applications requiring higher strength and outstanding corrosion resistance. INCONEL alloy 625 was introduced and marketed as a solid solution strengthened alloy.The addition of titanium in INCONEL alloy 725 fulfils this requirement

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INCONEL alloy 725 is strengthened through heat treatment, not through cold working as INCONEL Alloy 625 and is around twice the strength of annealed INCONEL alloy 625 it also retains high ductility and toughness.

Applications INCONEL ALLOY 625 Marine Propeller Blades Marine Exhausts Sheathing Sub sea Cables Aircraft Ducting and Exhausts Sour Gas Service Nuclear Reactor Components

INCONEL ALLOY 725 High Strength Fasteners Subsea Valves Stem and Gas Turbines Downhole Drilling Accessories Agitators Valve Stems

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April 2021

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ENGINEERING UPDATE

FRESH AIR COOLING Could a ventilation-based cooling system be the key to keeping your factory fully operational all year round?

ver recent months, the role of adequate ventilation in reducing the spread of Covid-19 has been stressed by numerous professional bodies and government advisors. REHVA* describe ventilation as the best engineering control we have for managing the infection. What’s more, UK government advisors have said that “ventilation should be integral to the COVID-19 risk mitigation strategy for all multi-occupational buildings.” So, what steps can you take to mitigate the risk of transmission between your staff and keep your production running at maximum capacity? Evaporative cooling presents a cost effective and smart solution for the ventilation of buildings while simultaneously providing an eco-friendly cooling system for staff and Machinery. Thankfully, the risk of infection through airborne transmission is something that can be managed with adequate ventilation and air distribution, which dilutes the buildup of the virus in the air. What makes an EcoCooling system a safe solution? Ventilation and cooling, all in one box: EcoCoolers are installed as part of a mechanical ventilation system, Cooling boxes with inbuilt fans bring fresh air into your facility; these are paired with extraction systems to remove inside air, creating a ventilated building, which reduces the risk of virus spread. The cooling process works by cooling incoming air, therefore no recirculation of air is required during the summer months, unlike refrigeration based alternatives.

in manual mode with 0% recirculation for 15-minute bursts to purge the room, or in automatic mode, you can reduce the supply temperature set point to boost the quantity of fresh air. Timers can also be adjusted to allow a burst of ventilation before and after the building is occupied. Show your commitment to staff safety: There is no doubt the vital role ventilation will play in the battle against COVID-19, and we here at EcoCooling are proud to have a fresh air system that helps business manage that risk. We are a UK based company with stock held in Suffolk and an established installation network across the country. For further information please contact us on 01284 810586 / sales@ecocooling.co.uk or visit our web site: www.ecocooling.co.uk

Modular and simple: Each EcoCooling system is specifically designed for the size and use of the building so that there is an adequate number of air exchanges per hour, so additional ventilation should not be required. Specially developed controls: The EcoCooling controls can also help you manage the fresh air levels via its automatic and manual modes. For example, you can run the system

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*REHVA is The Federation of European Heating, Ventilation and Air Conditioning associations

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April 2021

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April 2021

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ENGINEERING UPDATE

ondloc is challenging the status quo in the industrial adhesive market by launching its first National advertising campaign, “Let’s Stick Together”. It promotes unity and support for UK manufacturers, suppliers and distributors and reinforces the current social and economic climate as we exit Europe and the Global COVID pandemic.

challenges surrounding new complex substrates and increasing processing costs. Having in-house production means we have the flexibility to tweak our formulations and bespoke manufacture products to the customer’s exact requirements.

Bondloc UK, based in Worcestershire, has manufactured and supplied adhesives and sealants to the industrial, engineering and automotive sectors for over 28 years. With an international distribution network and product approvals within major OEMs like JCB, Black & Decker, Honda, Bosch, Bombardier and Princess Yachts, they have over 150 adhesive formulations and over 300 active SKU’s sold across 32 countries. This includes a wide range of adhesive chemistries - anaerobic, cyanoacrylates, sealants and structural epoxies, PU’s and MMA’s.

“Our key successes have been through technical support and training of our distributors and end-users. Where specific adhesive brands are already defined on production drawings, our technical team fully supports the switching process. Our chemists work closely with the project teams on sampling and testing to ensure a smooth production transition. ISO 9001:2015 underpins our customers’ confidence in our quality systems to aid this process. The pandemic hasn’t stopped us manufacturing or the support we’ve given to our customers to deliver projects to fruition.”

Warren Wilkinson, managing director of Bondloc said: “Our focus continues to be within the engineering market, with our metal bonding anaerobic products used extensively in this sector. We have an established network of distributors with core competencies within pneumatics, seals, bearings, transmission, pumps and gearboxes, and we continue to supply and support many OEMs directly.”

Improved productivity and financial benefits after reviewing and switching products outweigh the time and costs involved. Bondloc has developed and modified more adhesives in the past 24 months than in the previous 25 years. With the onset of Brexit and various supply issues with imported goods, more and more OEMs are looking to switch their adhesive products for UK made, high-quality but lower-cost local alternatives.

With continued pressure around sustainability and manufacturers investing in greener and more fuel-efficient solutions, the overall demand for high-performance adhesives to bond synthetic materials is increasing. The evolution of new substrates and composites coming onto the market is also spurring additional technical challenges.

The environmental contribution is also key to the ethos of the business. Recycling programmes, plastic packaging reduction initiatives, reduction in the use of hazardous chemicals and plans to extend the Safer Product range of non-hazardous anaerobic products across the next 12 months are key initiatives.

Warren continues: “Traditionally, we’ve supplied structural adhesives for carbon fibre bonding to F1 motorsports, but it now has wider applications across the automotive, construction, aerospace, wind turbine, marine and military sectors. Distributors and OEM’s need to be able to work closely with their suppliers to tackle production

The 5-year growth plan for Bondloc is ambitious but without compromise on quality or service built over the last 30 years.

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“Let’s Stick Together” launches on 1st April. Commercial adhesive users can try and test Bondloc adhesive products using the free sampling service.

Visit www.bondloc.co.uk or call 01299 269269 for more information.

April 2021

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ENGINEERING UPDATE

PushPull offers a secure fit with just one click

eveloped with the user in mind, the PushPull family is available in a range of materials to suit your requirements. From the robust V4 Industrial with a housing that protects from aggressive industrial chemicals to the sleek M12 with its capacity to deliver data transfer rates of up to 10GBit/s, the entire range relies on a simple yet effective connection method. As its name suggests, PushPull incorporates an uncomplicated connection and termination technique that ensures absolute dependency and reliability. The intuitive, tool-free method guarantees an error-free connection as the two sections click into place, the audible feedback indicating the connection is secure. The sturdy housing is also inscribed with pronounced contours, which gives the operator a firm grip on the connector. To further simplify the process and eliminate the possibility of incorrect connections, HARTING has fitted the PushPull range with colour-coded marks. The first is a yellow triangle which appears on both the plug

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Control cabinets often contain a myriad of switches and connections, so the ability to quickly and efficiently disconnect and reconnect the industrial lifelines of data, signals and power are vital if expensive machine downtime is to be avoided. That’s where HARTING’s PushPull technology comes into its own. and socket, meaning it’s incredibly easy to ensure both connections are orientated correctly before they are mated. Secondly, the user has the option to allocate colour codes to each PushPull plug and socket in an installation. For example, they could easily colour code data, signal and power lines to ensure each line can be easily identified; a simple system to help reduce cabling errors. In addition to the audible click, the PushPull range also comes with a spin-lock which firmly secures the

connecter in a mated condition, preventing any inadvertent disconnection. Simply plug in the PushPull then rotate the ring oneeighth of a turn clockwise to lock and secure the connection. Finally, when it comes to variety, the PushPull range can handle all your requirements. Whether you’re looking to transmit data via an RJ45 or 690V / 16A of power via 5 poles, HARTING’s range of interfaces, inserts and housing materials can provide universal solutions for your specific applications.

To learn more about HARTING’s PushPull range, including time savings for installation and termination, please click here or email us via salesUK@HARTING.com .

ENGINEERING PDATE

April 2021

[Click & Safe]

PushPull is completely safe for installation and application.

The robust connection for mechanical engineering. Fast and simple plugging and unplugging delivers time savings of up to 60%. Tool-free, simple installation even in tight spaces thanks to tried-and-tested PushPull mechanism. Acoustic plug-in feedback ensures safe connections even in unfavourable working conditions. Thanks to IP65/67 ratings, dust and water don’t stand a chance. Shock and vibration-resistant for maximum reliability. Find out more:

www.harting.com/UK/en-gb/pushpullconnector

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April 2021



ENGINEERING UPDATE

C.K – Offering High Quality Hand Tool Solutions for Engineers About Us Founded in Germany in 1904, Carl Kammerling International is a leading provider of a wide range of innovative, premium quality Hand Tools, Tool Storage solutions, Power Tool Accessories and Security products designed and developed for industry professionals.

Leading Brands The Company’s leading brands include C.K, C.K Magma, C.K Classic, Avit and Kasp Security, all offering great products with advanced features and benefits, designed to make tasks easier. Constant investment in new products and brand development also creates a pipeline of exciting new products that push the boundaries of performance.

C.K Tools For over 100 years, the C.K brand has been at the forefront of hand tool manufacturing, producing innovative, high quality tools, engineered to offer high performance, durability, accuracy and strength. Driven by research through an extensive panel of cross trade professionals, tools are developed with everyday tasks in mind, an approach that helps to produce products that transform working practices. C.K HD Classic Screwdrivers These premium quality, heavy-duty screwdrivers will tackle the toughest of jobs, and include: Shatter resistant acetate handles, which are wipe clean, oil and acid resistant; Large square shaped handle design for maximum torque; Handle injection moulded directly to blade for ultimate blade to handle bond; Anti-roll flats; Chrome plated toughened alloy steel blade; and precision machined tip for an exact screw fit and damage-free screwdriving. The C.K Redline Pliers and Cutters range offers a great selection of quality products. A two-component ergonomic design, with anti-slip horns provides increased comfort, control and safety; Induction hardened jaws ensure outstanding long-term performance; Cutting jaws with C.K optimised geometry allow superb cutting performance; with special alloy steel, drop forged, hardened and tempered for strength and durability. The new C.K Sure Drive Socket Sets are ideal for professionals who demand high quality, high performance tools. Manufactured from forged chrome vanadium alloy steel for superior strength and durability, and featuring a rust resistant satin chrome finish, each socket features the C.K Sure-Drive design which applies torque evenly to the flat of the nut, to avoid rounding-off.

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Other features include: Dual component, non-slip grip for comfort and control; a Hex and Bi-Hex design to suit a range of fasteners and bolts; with a reversible 72-teeth ratchet mechanism for fine adjustment in confined spaces. A ball bearing locking system with push-button release offers quick interchange of sockets. To find out more about our products contact your local C.K stockist or visit www.carlkammerling.com

April 2021



ENGINEERING UPDATE

Wolf Safety’s bespoke lighting solutions add value and cut costs As world leaders in manufacturing hazardous area portable and temporary lighting, Wolf Safety know that many customers require a bespoke solution which addresses safety, technical and logistical issues raised by a specific project.

o when the Wolf team was asked to propose a lighting solution for the inspection and maintenance of a condensate LNG tank in Norway it was an ideal opportunity to demonstrate the company’s technical expertise and bespoke service. This enhanced capability proved a key factor in Wolf Safety being awarded the contract, following a highly competitive international procurement process. Says Miles Jackson, Sales Director: “We not only came up with a better lighting scheme but also a safer, total solution, delivered at considerably lower cost than our competitors. This addressed all safety aspects, including correct fusing of very long extra-low voltage power cables." Project summary: The LNG (liquefied natural gas) storage tank to be inspected and maintained is 60m in diameter and 45m high. The task required the use of a SELV (Safe

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Extra Low Voltage) power supply and this, combined with limited access to the tank, raised several issues.

from the SELV transformers located on the roof of the tank, out to the perimeter of the tank base.

As different contractors’ teams needed to work on the project at the same time the base of the tank had to be fully illuminated. This objective was achieved using 60 perimeter mounted lights, fewer than the number proposed by other companies.

Emergency LX-400E luminaires (luminaires with an additional battery power source) will provide back-up illumination in the event of a power failure, while a magnet based cable management solution will allow cables to be raised off the tank floor.

Using highly efficient Wolf lights, requiring fewer transformers, led to substantial cost reductions. The lighting solution required 48 mid-power WF-250XL floodlights mounted using magnet fixing kits at a 2m height on the tank wall, projecting light from the perimeter towards the centre. An additional 12 high power WF-300®XL LED floodlights illuminated out from the central tower of the tank. In their blueprint for the project Wolf’s experienced team also met the challenge of getting power safely

For further information about bespoke ATEX temporary lighting solutions for use in hazardous areas, go to: www.wolfsafety.com

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April 2021



ENGINEERING UPDATE

Temperature monitoring and remote monitoring From Ziehl Industrie elektronik TVR Instruments are pleased to announce the addition to the Ziehl Industrie elektronik range of temperature protection relays of the TR640IP and the TR660IP. The two new additions to the Ziehl Industrie elektronik range of temperature measuring and monitoring relays are the TR640IP and the TR660IP. Both units offer inputs for up to 6 sensors, either 6 x Pt 100, Pt 1000, or PTC thermistors. Different sensors can be connected at the same time, e.g. Pt 100 (RTD) and PTC-thermistors. The TR640IP has 4 limit relays and remote monitoring via TCP/IP connectivity, whilst the TR660IP has 7 limit relays, remote monitoring via TCP/IP LAN, and the option of 4 analogue outputs programmable 2 x 0/4 - 20 mA and 2 x 0/2 - 10 V or RS485 RTU. Typical applications are monitoring of motors, generators, or transformers. In applications it can be used as a 2- or more step- controller with additional monitoring of overor under temperature or monitoring of differences in temperatures of 2 sensors. Pre-set programs allow easy setting e.g. monitoring of transformers with/without monitoring of the temperature of core or with/without controlling a ventilator.

Ziehl’s electronic devices for industrial systems are innovative, future-oriented, and renowned for top quality. Working to the highest technical benchmarks, Ziehl develops and produce using state-of-the-art systems and under a demanding quality management system. We are pioneers in producing electronic devices for modern and reliable measurement, control, regulation technology to meet every requirement – be it in industrial applications, commercial premises, or residential buildings. Ziehl’s goals are that sustainability, energy efficiency and maximum efficiency can be achieved using their products. Ziehl has the highest of standards when it comes to commitment for our customers making us the ideal partner for business and industry. Our products are made in Germany. Ziehl’s operations are certified in accordance with both ISO 9001:2015 and ATEX directive 2014/34/EU and are subject to regular monitoring for UL-approved devices. For further information, please contact us on 0206 575755 or email us on sales@tvri.co.uk or follow the link www.tvri.co.uk/temperature-relays-for-pt100.html

Designed for DIN rail mounting they add to the range of panel and rail mounting temperature protection devices which Ziehl manufacture.

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TVR Instruments Limited, 143 Butt Road, Colchester CO3 3DP, Essex, United Kingdom

NOW IN ITS 16TH YEAR!

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DUE TO POPULAR DEMAND, LIFTEX - THE LEADING NETWORKING EXHIBITION DEDICATED TO THE LIFTING INDUSTRY - IS COMING TO THE MIDDLE EAST! The 2-day exhibition will be hosted by LEEA (Lifting Equipment Engineers Association), the global representative body for the lifting industry worldwide, under the patronage of Bahrain’s Ministry of Labor at the Gulf Hotel & Convention Centre, Bahrain on 27-28 September 2021.

If you work in the lifting and rigging industry or you want to learn about the latest solutions in the local marketplace, then you can’t afford to miss LiftEx 2021. Network with other like-minded professionals, gain advice on the latest regulations and best practice to save you time and money.

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www.liftex.org

April 2021



ENGINEERING UPDATE

TVision: Delivering integrated business management solutions for the engineering sector TVision Technology is one of the UK’s most experienced providers of Microsoft Dynamics 365 Business Central. Established in 1999, TVision has delivered over 300 successful Enterprise Resource Planning (ERP) software projects in a wide range of sectors, including engineering, drinks production and professional services. Business Central is Microsoft’s leading ERP solution for ambitious organisations. It is a cloud-based, allin-one business management tool that connects sales, service, finance, and operations teams, allowing them to adapt to changing demands and deliver results effectively and efficiently. As part of the Microsoft stack, it also connects seamlessly with Office 365, Microsoft Azure and Microsoft Power BI. TVision has a proven track record in implementing Project Costings. Commonly known as “Job Costings”, “Project Costings” or “Jobs & Resources” to Microsoft Dynamics users, this is a powerful module within Business Central. Aimed at

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businesses that regularly run one or more projects at a time (these can be internal or external), it is a simple and effective way to manage and track project expenditure, costs and resources (hours spent), and allows easy invoicing per project. Collaborative approach equals implementation success TVision has implemented Business Central for RDG Engineering (TW) Ltd, a London-based engineering consultancy providing a full range of specialist design services for public and private clients. RDG chose to implement Business Central to provide the capability to do their full financial reporting from a complete data set

Colin Hollowood, Head of IT, RDG said: “TVision’s collaborative approach to our Microsoft Dynamics 365 Business Central implementation has been invaluable. Their expert team has been on hand at every stage, providing us with knowledge and skills as needed whilst allowing us to a free hand to tailor the system to our own requirements. “The migration to Business Central is a pivotal step for us as a company, allowing data and systems to be harmonised through the fully integrated Microsoft platform of products. With it will come improvements in efficiency, streamlining many disparate processes, alongside full depth reporting of key business metrics. We have exciting plans to further develop these systems and we look forward to working with TVision to help bring them to life.” Contact us on 01483 751888 or hello@tvisiontech.co.uk to arrange a demo and we can show you how Business Central could be the perfect ERP solution for your business. www.tvisiontech.co.uk

Curtiss-Wright Surface Technologies, Everlube products & Coating Services Protection & life extension of your critical components throughout any crisis!

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April 2021



ENGINEERING UPDATE

Thermographic Solutions for Non-destructive Testing – Versatile and Innovative

nalysing the consistency and quality of modern materials and components is becoming increasingly important for high-tech sectors such as the automotive, electronics and aerospace industries. As a result, infrared thermography, as an efficient method of non-destructive testing (NDT), is growing steadily in its numerous applications. It allows the detection of even the smallest defects and anomalies – whether you inspect inline during the production process or in the laboratory. Users benefit from the flexibility thermography offers for the analysis of materials and material combinations by using application-specific components such as infrared cameras, software packages, excitation units and accessories. Efficient non-destructive testing of a wide variety of materials and defect types

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•

Non-destructive testing saves time and costs

•

Pulsing activation allows the detection of below-surface errors

•

Analysation of process immanent temperature differences or externally induced heat streams

•

In-line applications for permanent quality control possible

ENGINEERING PDATE

April 2021

Infrared Camera Systems Minimise Product Waste from Testing Procedures

Passive Thermography as well as Active Heat Flow Thermography Locates Defects

Material tests using thermal imaging save time and costs as test objects will not be destroyed during process. They can be used for further testing or locating quality problems that could be corrected. NDT tests with infrared camera systems provide good solutions with greater applications as they can be used for a wide range of different materials and types of defects. A huge advantage is that thermographic testing procedures can be applied to larger areas at once in comparison to ultrasonic or other methods that focus on smaller zones.

Which method of thermography is used for material testing depends decisively on the question of the origin of the heating of the test object. In one test mode, it could stem directly from heating the test object gains during its production process. This case is referred to as passive thermography. The other possibility is called active heat flow thermography or just active thermography. This is when the test object will be thermally activated by an external energy input for instance by a halogen radiator or a flash lamp.

Automated Thermographic Solutions for NDT – find out more Possible applications of infrared cameras from InfraTec •

Testing of electronics/semiconductor material • during the manufacturing process to detect shunts, oxide defects, transistor and diode defects on integrated circuits

Assessment of impact damages, delaminations, inclusions, curing or adhesive defects in carbon fibre reinforced polymers (CFRP)

•

Quality assurance for glued, welded, soldered and other joints, blowhole detection (for example on automotive interior parts) and detection of defective weld seams / spots in the car body construction

Inspection of solar cells and complete solar modules during the manufacturing process

•

See some of our examples here Do you have questions about non-destructive testing and active thermography? Please contact Shayz Ikram by email on shayz@qd-uki.co.uk

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April 2021

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ENGINEERING UPDATE

Interroll launches new sorting system on the market Sant'Antonino, Switzerland. March 8, 2021. Interroll has added a system for a wide range of potential users to its successful range of automated sortation solutions with the launch of a new drop tray sorter, the Split Tray Sorter MT015S. The new product makes it easier for companies to enter the ecommerce market or can be used as a flexible addition to existing sortation solutions, for example in the fashion industry, the pharmaceutical industry, and for parcel service providers. Based on the proven mechanical design principles of Interroll sorters, the new Split Tray Sorter ensures maximum availability, very long service life, and fast payback times for the automatic sortation of conveyed goods weighing up to 12 kilograms. This makes these compact and flexibly expandable systems particularly suitable for system integrators who want to enable their customers to implement e-commerce or omnichannel strategies that are as powerful as they are economical, for example in the fashion or pharmaceutical industries. In addition, the new Split Tray Sorter in combination with Interroll's crossbelt sorters provides logistics service providers and courier, express and parcel service providers with an ideal solution for making customeroriented distribution centers even more productive by efficiently separating small parts sortation from other transport goods. Very short project runtimes can be realized, ready to start from day one Even during the planning and development of the new Interroll Split Tray Sorter, special consideration was given to efficient manufacturing processes in order to realize optimum benefits for customers and end users. "Because short project lead times give our customers a decisive competitive advantage, we focused not only on technical performance and quality but also on very short delivery times for our customers," says Steffen

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Flender, Managing Director of Interroll Automation GmbH. "This includes the fact that the system already has a modular and configurable machine control system. This allows it to be commissioned easily, quickly and safely and then connected to customers’ respective goods management system," reports Florian Funk, Global Product Manager for Sorters at Interroll. In addition, the systems offer the possibility of recording, visualizing, and processing the operating status in real time and generating helpful operating data— important prerequisites for predictive maintenance and Industry 4.0 applications. Complete automation of upstream and downstream processes Equally future-proof is the ability to flexibly adapt the system to changing

material flow processes thanks to its modular expandability. In addition, the supply of goods to the sorter can be easily automated by the optional Interroll Top Loader, which is based on the proven technology of the innovative infeed conveyors for the crossbelt sorters. In combination with the Modular Conveyor Platform (MCP) and a zero-pressure- accumulation connection to labeling or packaging machines, this solution can even be used to completely automate downstream work processes from picking to shipping, if desired. "With the Split Tray Sorter, we now offer an innovative solution in the basic segment. We will continue to consistently drive the expansion and deepening of our sorter platform," says Flender.

Protecting Your Plant Before

Rotech Motion Sensor’s can be used whenever information or monitoring of shaft rotation, position, direction, speed, slip etc is required! Rotech Motion Sensor’s can be used for indication, control, interlocking, protection, sequencing, alarm initiations and many more functions! Rotech Motion Sensor’s can be used wherever materials are transported or processed By conveyors, elevators, screws, mixers, etc!

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Monitoring the world

April 2021



ENGINEERING UPDATE

AUTOCODING SYSTEMS LTD, GLOBAL LEADER IN PACKAGING LINE AUTOMATION SOLUTIONS, IS ACQUIRED BY JBT CORPORATION, CHICAGO AutoCoding Systems is delighted and excited to announce that they have been acquired by JBT Corporation enabling them to continue with their expansion and growth within the food and beverage industry.

JBT Corporation is a global technology solutions provider to high-value segments of the food and beverage industry. The acquisition of AutoCoding Systems for £12.5 million extends JBT’s capabilities in packaging line equipment and associated devices, including coding and label inspection and verification.

AutoCoding Systems’ world-class packaging line automation software solution integrates all in-line packaging devices such as coders, scanners, labellers, checkweighers and inspection equipment. By automating the set-up and control of the equipment, the need for human intervention is removed thereby reducing manual inspection and downtime for line configuration. Whilst AutoCoding is scalable across JBT FoodTech’s diverse end markets, it provides a particularly strategic fit with JBT’s Proseal business where its tray sealing equipment begins the end-of-line process. Mike Hughes, AutoCoding Systems’ Managing Director said, “This is an exciting time for AutoCoding Systems in the UK, US and Australia. With the support of JBT and their wealth of experience across multiple businesses supplying the food and beverage industry, including Proseal, AutoCoding Systems can expand their reach into previously untapped markets for packaging line automation software.” “AutoCoding’s offering embodies JBT’s broader mission to make better use of the world’s precious resources by providing a solution that substantially enhances our customers’ success. AutoCoding helps its customers reduce food waste, ensures complete and accurate food packaging information, and facilitates traceability and food safety,” said Brian Deck, JBT's President and Chief Executive Officer. “The acquisition also expands our capabilities in the large and growing global market for in-line coding and inspection solutions, which includes hardware and software for food & beverage, pharmaceutical, and nutraceutical customers.” www.autocodingsystems.com

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Smart sensing in 3D

Built-in apps make 3D sensor easy to use

RANTY AR

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ifm’s amazing smart time-of-ﬂight 3D sensor has built-in apps for; • Completeness in packaging or palletising • Checking volumes in materials handling • Levels of bulk material Making it so easy to set up, anyone can do it. You’ll be amazed!

www.ifm.com //uk/o3d uk/o3d ifm Telephone (020) 8213 1111

April 2021



ENGINEERING UPDATE

INDUSTRYEXPO 2021 KEEPS PUSHING THE

BOUNDARIES OF VIRTUAL EVENTS When Industryexpo Virtual Exhibition opened its doors to online visitors in 2018 nobody could have predicted how rapidly the digital events landscape was going to change. The show, which was already hugely popular prior to the Covid-19 pandemic, has gone from strength to strength in 2020. For 2021 it is pushing the boundaries of digital gatherings even further having opened a second hall, networking area and auditorium. All delivered within an industry leading, high resolution 3D environment.

ndustryexpo.online is the world’s first full-scale interactive virtual trade show, dedicated to all things industrial: from design and engineering to processing and manufacturing.

The show, which is live year-round, has daily footfall in the thousands and offers visitors the opportunity to chat directly with exhibitors or register their interest for oneto-one meetings. Recent visitors include representatives from companies including Princes Foods, Severn Trent Water, Jaguar Land Rover, Nestle, Pernod-Ricard, Honda, Allied Bakeries, Thames Water, Arla Foods, Anglian Water, Dover Port, Halo Foods, Pirelli, PepsiCo, Toyota, Merlin Entertainment, Veolia, Tata Steel. With such a pedigree of visitor it’s no surprise that the concept has been popular with businesses of all sizes. Show Directors Nigel Borrell and Sara Gordon comment, “The launch cycle of the virtual show is more frequent than a traditional physical show. We are open and live 24hrs a day, so we set a quarterly renewal date when the latest floor space goes live and we issue e-Tickets to our registered visitors. This way new exhibitors are always able to join the show and existing partners can make changes to their stand and keep their content current. This in turn ensures the show benefits from continuous high footfall as there is always something new for visitors to see. “Exhibitors can further boost traffic to their stand through VIP invitations or by hosting a duplicate of their stand on their own website at no extra costs. Additional leads and enquiries can be generated by taking advantage of the auditorium to host live webinars or supply on-demand content. A networking area in Hall 1 also extends the opportunity for visitors and exhibitors to engage.” With over 10,000m2 of virtual floorspace, the top priority of the platform is to introduce a user-friendly interface that allows visitors to experience all the benefits of a ‘real’ event, with fewer of the drawbacks. Each stand can feature Super-HD 3D products, offer downloadable pdf literature, host company videos or live presentations and even support one-to-one video meetings with a sales representative. Visitors won’t have to face rush hour traffic or parking fees to attend. In fact, visitors will be able to

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register to the platform and save their favourite stands or materials to their browser to make return visits even more efficient. As its name suggests, Industryexpo.online is an industrial trade fair built using high-res CGI and dynamic rendering that hosts a wide range of exhibition stands from SMEs to market leading brands. With a truly multi-national audience, the emphasis is on promoting the global capabilities of the exhibitors. The show is open all year-round with the stands being constantly updated to promote the new products, services, and solutions; registered visitors can access the platform using a PC, laptop or mobile device without having to download any specialist software or apps. Of course, virtual exhibitions are unlikely to replace the social aspect of attending live trade shows when they return. Industryexpo serves to bridge the gap that exists between live events and traditional digital media. It’s a platform that allows visitors to see what’s out there, at their convenience, 24/7 365. Visitors to the platform will be able explore the everincreasing number of exhibitors. Who include – AEMT, Abloy, Altra Motion, Baumer, Burkert, BWB Technologies, CC-Link Partner Assoc, CD Automation, Dugard, , Elmo Motion Control, EMAS, Excel Redstone, Fulton, Hansa-TMP, HT Servo, IFM, IKO, Infologic Design, Inovo Robotics, KEB, Keyence, Kinetic-ID, KMT, Kodenshi, Lafert Electric Motors, Lamonde Automation, Leuze Electronic, Megger, Mitsubishi, Moore International, Motion Control Products, Nvent Hoffman, NS Tool, Optimal, Panduit, Products 4 Automation, Radwell, Rebo Systems, Rift, Routeco, Spelsberg, Sulzer, TEC Motors, Three High Co, WEG, Weidmuller

April 2021

INTERACTIVE. ACCESSIBLE. ONLINE.

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ENGINEERING PDATE

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Virtual Exhibition 2021

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Case Studies “Since launching at Industryexpo we’ve had almost 6,500 people from over 80 countries visit our stand. This is a platform that allows us to present our smart sensor portfolio 24/7 globally, I’m overwhelmed by the interest it has generated” – Karsten Just, Chief Marketing and Sales Officer, Baumer

“Moore International has been part of Industryexpo since the show’s launch. We decided to extend the size of our stand to enable us to introduce a wider range of products – including our brand-new series of high precision planetary gearboxes from Apex Dynamics. Just imagine how many miles and resources this has saved us.” - Mark Moore, Managing Director, Moore International Ltd.

“We are really excited by this novel concept. Of course, the current situation with global travel restrictions has further strengthened the argument to augment our online presence. The platform is an excellent solution for showcasing our products to a global audience and allowing us to interact with potential customers without attending physical meetings.” – Carl Knight, Managing Director, Fulton Boiler Works |35

April 2021

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ENGINEERING UPDATE

Low dew point climate control for battery research at University of Birmingham Munters, global leaders in energy efficient climate control solutions, was approached by the University of Birmingham to build a bespoke turnkey battery dry room and HVAC plant for their vital battery research. Munters has extensive expertise in this field, with dehumidification solutions installed in approximately half of the world’s lithium-ion battery production facilities.

The Energy Materials Group at the University of Birmingham works with moisture sensitive materials such as lithium-ion, sodium-ion, and solid-state chemistries. All of these materials require very dry climate conditions to prevent damage, explosive reactions, and to ensure product integrity. Munters agreed to be principle contractor for this project, and as the research team had worked in existing Munters low dew point facilities installed in other industry and academic settings in the past, expectations of a comparable facility here were extremely high. One of the key challenges encountered during this project was working within a grade II listed building. “The added complexity of working within a listed building presented a number of challenges throughout the project, including working around pillars, matching existing building louvers that were over 20 years old, and complying with increased planning and building regulations” says Paul Richards, Munters Project Manager. The 50m² dry room consistently maintains conditions to around -40°C dew point at a temperature of 20°C, with capacity for approx. 6 people. These conditions are created and maintained by the Munters desiccant dehumidification solution installed in the adjacent plant room. “Having the dry room has certainly opened up new opportunities for us," says Scott Gorman, Research Fellow and the Dry Room Manager. "Around half of the projects

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that are carried out each year will use the dry room regularly. It gives us a unique selling point (USP), and the ability to offer certain things that other groups can’t. The dry room allows us to bridge that gap between industry and academia.” Munters and the University worked together to optimize the dry room design and ensure reliable climate control performance. The Munters system is high performing yet energy-efficient, which results in a cost effective solution for the University. Low leakage wall panels and ductwork and a positive pressure in the room are all also critical. Munters optimized the room and ductwork designs using CFD modelling to ensure it would meet target dew point in all areas of the room. For the full story or for more information, visit https://bit.ly/3cdGZW0

Benefits: •

Create and maintain precise and consistent control of low dew point conditions to -40°C (less than 1% relative humidity)

•

Turnkey solution

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Ensure full compliance of regulations within grade II (2) listed building

For more information, please visit munters.com

ENGINEERING PDATE

April 2021

> Corrosion resistant for up to 1000 hours in salt spray > Manufactured from a premium alloy with less than 0.1% copper content for corrosion resistance > IP tessng performed aaer impact tessng to verify the seal is maintained when the enclosure is treated roughly > Impact resistant up to 7 Joules > Reusable seals (Up to 200 compressions)

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April 2021



ENGINEERING UPDATE

INNOVATIVE VIBRATION SENSOR FOR LOW SPEED ROTATING MACHINERY Effective monitoring of slow speed rotating industrial applications, such as wind power generation and hydro-electric turbines is a critical requirement, just as it is on standard speed applications, especially given the increasing importance of ‘greenenergy’ alternatives. Reliable and effective vibration measurement of low speed machinery (typically less than 300 RPM) helps to ensure that machinery and plant is functioning at optimal levels and is one of the areas that Condition Monitoring specialist SENSONICS provides effective solutions.

if left unchecked, has the potential to result in more serious damage affecting overall performance.

In all situations the focus should be; understand the dynamic behaviour, establish a baseline vibration performance and then detect the early onset of failure in rotating parts, which

The VEL/GLF is an electro dynamic sensor which has become established as the preferred option for measuring vibration on slow speed rotating machinery. It offers a

While using accelerometers is commonplace on standard speed machinery (usually 1500 RPM) this becomes problematic at lower speeds as the absolute accelerations measured are much smaller in value for similar vibration displacements. In recognition of the need for a sensor to meet these specific requirements Sensonics developed its low frequency velocity vibration sensor the VEL/GLF.

superior performance compared to piezo-electric devices by combining high measurement sensitivity with a frequency response down to 0.5 Hz making it ideally suited to measuring velocity vibration on equipment with speeds below 300 RPM. The sensor offers a standard IEPE type interface to enable easy integration with existing plant protection and monitoring equipment. Furthermore, the VEL/GLF provides advantages over traditional piezoelectric based velocity vibration sensors which are susceptible to many forms of interference in low frequency applications that can result in spurious readings and alarms. Typical causes of these unwanted readings and alarms include; base strain effects due to temperature changes amplified through the internal signal processing, high frequency and high g vibration events caused by auxiliary machine items resulting in transducer saturation. Also mains voltage interference due to a combination of a poor local plant earth and insufficient transducer internal isolation. Thanks to its robust design, the VEL/ GLF combats these effects, offering high noise immunity due to the low impedance electro dynamic nature of the sensor assembly. In addition to the filtering of high frequency events and since no electronic integration is required, the design is immune to the saturation problems that impair the reliability of piezoelectric devices. Typical applications for the VEL/ GLF will be found in wind power generation, hydro-electric plants and cooling towers, on slow speed pumps and also structural monitoring. ENDS

Further details on VEL/GLF sensors are available from: Russell King, Sensonics Ltd, Berkhamsted, Hertfordshire UK. Tel: +44 (0) 1442 876833.

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Email: sales@sensonics.co.uk www.sensonics.co.uk

ALL OF YOUR TEMPORARY RENTAL NEEDS COVERED 24/7 IN ONE PLACE Our hire services give you fast access to our broad range of wellmaintained, market leading ABB & Schneider Electric Drives and application engineering expertise. You get solid engineering advice and hire equipment for emergency, temporary bypass or semi-permanent application within hours. Services include round the clock access to over 1500 Weatherproof VSDs up to 4.5MW power rating ensuring a first time fix for any drive failure. Our engineers can deliver and install a suitable temporary drive to your site anywhere in UK within hours. As well as Weatherproof Variable Speed Drives, we have a range of Ancillary Products to support your full temporary solution Electric Motors

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April 2021



ENGINEERING UPDATE

Radiation Resistant Lens for Low Light Applications Manufactured from specially selected non browning glass – the Model 313-000 fixed focus lens from Resolve Optics has an aperture of f/1.4 to enable as much light as possible to be gathered and transmitted to the sensor.

esign optimised for use with 2/3-inch image format radiation resistant CID cameras, this radiation resistant lens is the perfect choice for low light applications in space exploration and in the nuclear industry. The optical glass selected for use in the Model 313-000 lens is proven to withstand long-term exposure to radiation up to a dose of 100,000,000 rads and temperatures to 55 °C without discoloration. The Model 313-000 delivers high image resolution and minimum geometric distortion from 400 to 770 nm. For further information on the Model 313000 non-browning lens please click here

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or contact Resolve Optics on +44-1494777100 / sales@resolveoptics.com. Nuclear industry and spaceborne applications require lenses and optical systems that can withstand exposure to high levels of radiation and sometimes endure extreme temperatures. Resolve Optics has considerable experience of developing lenses and optical systems for these environments. Drawing upon nearly 30-years’ experience - Resolve Optics has built a strong reputation for design and manufacture of production quantities of non-browning fixed focus and zoom lenses on time to strict quality and target price guidelines.

JOC_1098 KRUK Automation Half H-A.pdf 1 24/09/2015 18:09:43 April 2021 ENGINEERING PDATE

Setting the benchmark... Faster, compact, energy saving and affordable...

Kawasaki’s latest robots increase one of the largest robot ranges available today. They are more compact, provide smooth control and give increased all round performance. For assembly the new collaborative duAro; for palletising the CP Series; the general purpose CX Series and the high-speed spot welding BX Series. Check out the new robots and see just how affordable they can be....

info@kawasakirobotuk.com kawasakirobot.co.uk +44 (0)1925 713000

Kawasaki Robotics (UK) Ltd

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April 2021



ENGINEERING UPDATE

hen covid eventually relents, customers’ expectations for fast, accurate and on time delivery will remain. Manufacturers and distributors are focused on improving fulfilment processes to meet these expectations without adding labour costs

2021 The Year of Inventory Classification Customer demand for fast order delivery has increased exponentially since the start of the Covid-19 pendemic.

A major area that Is not properly managed is classifying inventory. Exactly how a facility’s inventory shoud be catergorised depends on many factors, including the types of products and picking sizes common to the business. At the highest level classiftying inventory based on picking size (by pallet, case or piece) and also by frequency of picking/velocity of movement (fast, medium, slow or very slow). During the classification process, certain shared attributes will appear. For example when comparing pick velocity, group fast, medium, slow and very slow movers together. By crossreferencing the time associated with picking each of these parts against their order frequency, a cost-to-pick graph can be created. The most dramatic improvements in order fulfilment optimisation will come from applying the Pareto Principle (also known as the 80/20 rule) For example, 80% of a warehouse’s picks frequently come from 20% of its inventory (the fast movers) Most companies focus their picking optimisation efforts soley on their fast movers – which comprise just 20% of their inventory. Applying the Pareto Principle, however, tremedous gains in efficiency throughput and cost savings remain to be exploited in medium and slow movers, which likely represent nearly 80% of a facility’s floor space and picking labour efforts. Kardex as a world-leader in automated storage and handling solutions and has put together six steps to optimise order fulfillment, which covers all you need know about clasifying inventory, Matching SKU’s with technology, The fulfilment process, sloting your inventory, mapping workflows and integrating systems to maximise visibility. Click here to download the free white paper or contact us at info.remstar.uk@kardex.com

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April 2021

MetLase challenges the manufacturing sector to go digital MetLase, one of the UK’s leading specialists in tooling, intelligent fixturing and components, is launching a new range of ‘digital’ solutions that will connect manufacturing processes and enable easier, faster automation. Manufacturers are increasingly looking towards digital transformation and how Industry 4.0 technologies can be embedded in all processes. However, the big question remains… in the formative stages of the roll-out, how does a business ensure it gets a return on its investment, whether that is increased efficiency, cost savings or reduced lead times?

Human error remains a leading cause of machine downtime in factories

Through innovation and advanced technologies, the Rotherham-based company is scaling up the production of a suite of disruptive smart solutions that can deliver this crucial competitive advantage. Richard Gould, Business Development Manager at MetLase explains…

Design engineers are equipped with digital skills to offer advanced solutions to manufacturing problems. But nonhuman error, such as equipment moving out of tolerance, can also cause massive production problems - our technology can also detect this failure before it becomes an issue.

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We offer process solutions that have no room for error. Using a variety of sensor technology, our experts have designed and built a series of smart products that can be customised to suit the manufacturing process.



ENGINEERING UPDATE

‘Factory of the Future’ The ‘Factory of the Future’ is a more efficient factory that always delivers products to its customers on time… but how can businesses implement this concept? MetLase products can be introduced at different stages of the production process, with our most recent launch being the Smart Gauge, which was developed to solve the complex production issues of one of our customers. Imagine a production line where an existing 90-minute quality check can be achieved by simply using a 4-second quality check carried out by a MetLase Smart Gauge. That’s the transformation that MetLase’s smart product has delivered. In the current climate, waste in any business is a cost that needs to be avoided, so when one of the UK’s largest plastic fuel system manufacturers challenged us to fix a production problem we jumped at the opportunity. Using our multidisciplinary team of engineers we were able to design and build the right solution.

ENGINEERING PDATE

And the solution didn’t only rectify the problem, it also delivered extra functionality that transformed the process. On this specific occasion, with around 49 points of data to inspect, the manual inspection process can take around 40 to 90-minutes to complete. If the production line stops due to a fault, a substantial amount of scrap can occur. Turning to a digital solution that automates the inspection process would provide an instant assessment of the fuel tanks.

Rapid 4-second Quality Check A Smart Gauge, which has over 50 different sensors, was the solution and can inspect the fuel system instantly, reducing the time taken from potentially 90 minutes to just four seconds. MetLase engineers developed the technology to include a ‘plug and play’ feature, which integrates into the Smart Gauge fixturing system.

April 2021

of the manufacturing process, sensors have been embedded in workstations to guide workers to the next step in assembly or alert workers if the wrong part is picked, providing Standard Operating Procedures at every stage.

Building the Factory of the Future MetLase’s strategic plan will see the development of a suite of digital technologies, including digital twins, process modelling and simulation, control automation, industrial robotics, artificial intelligence, software programming, sensing, 3D printing, machine learning and augmented/ virtual reality systems. All of these can be sold into key markets like automotive and aerospace, as well as emerging sectors such as off-site modular construction and renewable energy. We are investing £1m - backed by £400k of funding from the Sheffield City Region LEP’s Business Investment Fund - to roll out our standardised Industry 4.0 digital products to customers both in the UK and overseas.

Challenge us with your problems Going forward, we are looking for businesses to work with us to further develop these solutions. If you have a problem with your manufacturing or feel that there must be a better way to run a process, then challenge us! We’ve created a simple form to capture these challenges - or you can always email me direct at richard.gould@metlase.com

Future Masterclasses Following the recent success of our online Digital Masterclass, we will also be hosting a number of Smart Product manufacturing webinars to help UK industry embrace new processes and technology. All of these webinars will be free to attend and further details will be announced shortly. Click here to view our previous webinars…

Smart Assembly Also in development is our Smart Bench. Recognising the benefits of using digital sensors at different parts

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April 2021



ENGINEERING UPDATE

MARKATOR® specializes in marking systems and is a pioneer in the field of mobile dot peen marker with its battery-powered FlyMarker® mini models. With their light weight and compact design this marking units are mainly suitable for durable markings of big and unmovable work pieces directly on-site. MARKATOR® is constantly working to optimize its marking systems and to meet the marking requirements of its customers. The focus is on achieving a continuous simplification in permanent marking of different kind of workpieces and materials. The latest development is the new version of the battery-operated hand-held marking system FlyMarker® mini 85/45 plus. A wide range of extensions and accessories are available for this model, tailored to a wide range of possible applications. An optional extension is the adjustable and removable aluminium positioning plate. This positioning plate makes it easy and flexible to adapt the FlyMarker® mini 85/45 plus to customer-specific requirements and devices. In addition, the stable design of the aluminium positioning plate ensures optimal positioning and precise marking results even on hot surfaces. As a new feature the FlyMarker® mini 85/45 plus can also be equipped with an optional 2-point touch. The positioning plate with 2-point touch has two point touch supports instead of a flat positioning plate. Through the vertical adjustment possibility, a more comfortable positioning is given. This accessory is used when space for positioning on the component is limited or when marking in depressions is required. The non-slip rubber coating on the 2-point touch prevents slipping and provides a stable working position. For other applications, the FlyMarker® can be equipped with an integrated barcode scanner. With this optional scanner it is possible to scan 1D, 2D-codes (e.g. barcodes, QR-codes, marked Codes, etc.) without any external accessories. The scanner is integrated directly on the front face of the marking unit therefore both hands remain free to operate the marking system. With this, barcodes can be scanned quickly and the content can then be marked in characters directly on a work piece. Equipped with all the general functions of the FlyMarker® mini basic unit, the FlyMarker® mini 85/45 plus portable marking system with its numerous extension possibilities becomes a professional partner for permanent and tamperproof markings.

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THE FUTURE OF DIGITAL PRESSURE MONITORING The GD4200-USB

April 2021



ENGINEERING UPDATE

We keep our customers connected Established in January 2009, Industrial Communication Products (ICP) is a leading distributor of industrial communication products to the water, transportation, military and marine, power, and industrial automation sectors.

ts product offering enables the transmission of a wide range of industrial protocols (Ethernet, Fieldbus, RS232, RS422, RS485, Audio and Video) over many different types of ‘media’ (Cat5, Fibre, Twisted pair, Coax and Wireless). The company also offers protocol conversion/gateway products allowing conversion between one protocol and another. ICP’s chief executive officer, Graham Bull has been in the industrial communications market for over 20 years and states that the company’s expertise is, “technology, which nowadays, is getting even more complicated." ICP is both a Hirschmann specialist and a master distributor for RUGGEDCOM, which means it is entrusted with supplying other distributors. “Our combination of products and technical background is what sets us apart from our competitors,” says Graham.

Factory and Process Automation ICP has a great deal of experience in the factory automation sector working with many leading UK SIs and end users. It offers a wide range of communication and computing products for this sector, compatible with all leading automation protocols such as Profibus, CANbus, Profinet, EtherCAT and Ethernet/IP.

fibre-optic transmission products for 4-20mA and 0-10V analogue signals which are suitable for process automation applications. It also offers Industrial PC products with IP69K stainless steel housings for specialised food and beverage applications.

The company also has a strong expertise in PoE based products and technology and has supplied equipment for a number of more general CCTV projects for large industrial premises and manufacturing facilities.

In recent years it has expanded it has product offering of both communication and computing products to include even more products with ATEX approvals.

As a leading supplier to the process automation sector, ICP offers Gateway products for Profibus PA, FF and HART and has a range of

ICP has been involved in a number of projects supplying equipment for nuclear attack submarines, frigates, amphibious assault ahips

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Military & Marine

and land- based fighting vehicles. It is able to offer high reliability COTS (Commercial Off The Shelf) industrial grade communication equipment and more specialised, military grade equipment with MIL-STD approvals. “We have supplied products for both military and commercial shipping including FPSOs and super yachts,” says Graham. “Our range of industrial fibre-optic products including Ethernet switches, Profibus DP repeaters and compact fibre patch panels are ideal for marine applications.” The company also offers marine grade computer products. More information about ICPs products and services is available at www.industrialcoms.co.uk.

April 2021



ENGINEERING UPDATE

Get ready for LiftEx 2021 in Bahrain LiftEx 2021, the free-to-attend flagship event of LEEA (The Lifting Equipment Engineers Association), takes place in Bahrain on 27-28 September 2021, at the Gulf Hotel Bahrain & Convention Centre. “Holding this year’s exhibition in Bahrain gives LEEA members a post-lockdown chance to meet with new customers and partners and we expect the 250 members in the Middle East to really support the show,” said Ross Moloney, CEO of LEEA. “If you're looking to do more business in the Middle East, this will be a key opportunity. Bahrain offers a central location for the Middle East and good connections for visitors from Europe, Australasia, South East Asia and America, with accommodation available on-site in the Gulf Hotel, where the event is being held.” The Lifting Equipment sector is involved in a broad array of end-user markets including: oil and gas, offshore engineering, construction, civil engineering, entertainment, renewable energy, road, rail & maritime transport, health & safety, utilities, logistics and manufacturing. LiftEx provides a dedicated event to address the many different challenges, solutions, regulations and best practice advice for these sectors under one roof – providing an ideal networking forum for industry peers. Exhibits will include lifting, height safety and load monitoring equipment as well as solutions for materials handling, machinery moving, IT, inspection services and training. New sponsorship packages are available this year to suit a variety of budgets, with a particular focus on encouraging more digital connections before and during the event, along with brand exposure and lead generation. Exhibitors can be safe in the knowledge that a range of Covidsecure measures are planned to ensure everyone involved is able to enjoy a hygienic, productive and high-quality organised event experience, including a brand new event app will allow all participants to connect and interact in a safe and effective manner. For further information on LiftEx, as well as sponsorship opportunities, please contact Leah Phelps on +44 (0) 203 488 2865 or email: enquiries@L2Events.com or visit www.liftex.org.

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ENGINEERING PDATE

April 2021

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April 2021

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ENGINEERING UPDATE

Liquids and bulk solids remote inventory: IIoT monitoring sensors you can stick with!

t’s no secret. The bulk logistics and purchasing sectors are always looking for simple, streamlined ways of remote monitoring of their stocks. Successful implementation of ‘remote/vendor inventory management’ can deliver myriad direct benefits; perfectly timed logistics, CO2, fuel and time savings, optimised stocks, avoiding returned loads or emergency deliveries, less stress and process shutdowns. There are also strategic gains through streamlined purchasing and ordering, improved supplier-customer partnerships, and retention of supply contracts.

Fast payback The applications for bulk liquids and solids are many: Sites populated with fixed silos and tanks, mobile tanks and IBC’s, on road or rail transport, waste-collection containers, silos at temporary or semi-permanent sites. All offer different challenges; site access, product compatibility, container and infrastructure tracking. While many are based on just in time supply and delivery, others are operating removal and disposal services. Because of the size and weight, speciality and often ‘dedicated’ nature of bulk shipping, an effective stock management overview has the capability for fast payback.

One single device, simpler to implement Up until now, the implementation of remote monitoring has involved complex internal and external engineering, multiple crossdepartment planning, programming, external cabinets, power supplies, cabling and sensor installation, followed by often complex commissioning and integration into software systems. This is a new technology emerging from the field of process and control, and it offers a greatly simplified solution in a single, battery powered wireless sensor.

Get it right first time VEGAPULS Air is the first IIoT level sensor range of its kind, designed and manufactured for all types of vessels storing or transporting bulk liquids and solids; from waste water to chemicals, fine powders to plastic pellets, animal feeds to aggregates. It has wireless communication, stand-alone battery power for up to 10 years, vessel measurement ranges up to 30m, ready to locate via GPS, communicate and provide your data - in one compact sensing device. Simple to install, easy to set up and quick to deliver stock management information

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No cables, wires or boxes, capable of battery power for 10 years, level sensors for remote inventory, waste or environmental monitoring

in the format you need. VEGA are the world leaders in non-contact radar level-sensing technology, with 30 years’ experience. Easy, reliable and cost effective, it means you can be confident in the accuracy of your inventory, waste collection, or environmental monitoring data, that you base logistics decisions on.

Stick with it Combined with VEGA ‘SaaS’ (Software as a Service) VEGA Inventory System (VIS), to install at your monitoring point it can be as simple as stick it to an IBC, or install it onto a tank or silo, and activate at the press of a button – then all you need is a login to see your data and begin managing your logistics/

supply-chains effectively, whether on the desktop or mobile App, using tables, maps and predicted usage. VEGA offer truly visible, global inventory management, connecting you to the finished product tank outside your door, waste collection depot in your city, national plastic powder supplies, or an animal feed silo on the other side of the world. From Sensor to Server, and to your Screen, VEGA take care, service and responsibility, for it all. To discuss your requirements, ideas and explore solutions, or make a test to see its capabilities, please contact VEGA Controls Ltd.

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April 2021



ENGINEERING UPDATE

New date set for PROFINET, PROFIBUS and IO-Link Birmingham seminar 17th November at the National Conference Centre. This free-to-attend seminar organised by PROFIBUS & PROFINET International (PI UK) addresses the key practical issues arising from the use of digital communications technologies in automated manufacturing and process industry applications, with particular attention being paid to Industry 4.0 and the Industrial Internet of Things (IIoT). Covering key application areas such as control systems and energy management, pulp & paper, chemical, utilities, pharmaceutical, packaging and printing, mechanical handling and logistics, robotics, automotive engineering, electrical and electronics assembly, it focuses on the practical aspects of using PROFINET, PROFIBUS, and IO-Link, from system design and safety & security considerations through to fault-finding and maintenance.

Live Demonstrations Supported by an exhibition with demonstrations of actual tools used in configuration and maintenance, the seminar will be of great value to Designers, Production/System Engineers, Instrument Technicians/ Engineers and C&I Engineers involved in the design, operation and maintenance of modern automated factories and process plant.

Abstracts Introduction to PI Group and its technologies An overview of PROFIBUS & PROFINET International and the group’s supported technologies, its protocol basics and their significance in the global automation market.

demonstration, will take a “how it’s done” approach and will include PROFINET to PROFIBUS DP and PA, CANOpen, IOLink and OPC UA.

PROFINET Network Design This presentation examines the fundamental principles of good network design for PROFINET and other networking systems. It will discuss the main factors that must be considered at the design stage of an automation system with practical examples showing how facilities for health checking, faultfinding and maintenance can have a crucial impact on plant availability, plant up-time and profitability.

Network gateway technology

Industrial network commissioning & testing

A vendor-independent overview of how to connect PROFINET networks to existing fieldbuses and expose the data to IOT technologies using OPCUA. This presentation, including live

Take a walk through the process of certifying a new PROFINET installation against the standards and see how easy it can be, then look at a few gotchas that can easily be avoided by

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careful planning. Learn how to simplify the process of testing both cabling and networks in Industrial Ethernet networks that utilise the PROFINET protocol, how to prevent network failures and resolve cable and network issues faster.

PROFIBUS and PROFINET device configuration tools. A look at the available device configuration tools and their development including the move to unify the different types into one format – FDI. This will be followed by a live demonstration of PROFIBUS and PROFINET device configuration using an existing open platform and web browser option.

Industrial networks safety & security What does this greater acceptance of Industry 4.0 mean for Functional Safety and Cybersecurity in Industrial Automation and Control Systems

ENGINEERING PDATE

April 2021

(IACS)? This presentation will discuss the basics of Functional Safety and Cybersecurity for PROFI based applications and then will consider the impact on these areas from Industry 4.0. What should System Integrators and Product Manufacturers be doing now and what can you expect to be seeing from PI in the not too distant future? We will also consider the impact of open architectures/systems, common technology, international standards and trust in technology.

Industry 4.0 and the Industrial Internet of Things (IIoT) A short journey to explain IIoT, The Industrial Internet of things, IND4.0 from IND1.0 and Big Data. How PROFINET is placed as the ideal Industrial Fieldbus to fulfil the above, how it is implemented and why you should consider it. Some of the myths explained.

PI’s Technologies With over 80 million nodes installed worldwide, PROFINET, PROFIBUS and IO-Link are truly market leaders, providing state of the art digital communications addressing all the needs of manufacturing and process industries, significantly lowering capital expenditure on installation, commissioning and maintenance. They offer unprecedented integration of automation, control, monitoring and safety systems using standardised and widely supported communications and networking solutions. This seminar is ably presented by specialists from PI UK member companies. Attendance is free of charge to pre-registered delegates from the User community, i.e. companies that own, operate, design, build or maintain automated process plant and manufacturing facilities. The event will provide delegates with an excellent networking opportunity and the ability to speak to experts.

Sign up here for more information and to be kept updated: Birmingham - https://bit.ly/PiUKBirmingham or Belfast or Scotland, exact dates TBA: Belfast https://bit.ly/PIUKBelfast2021 Scotland - https://bit.ly/PIUKScotland2021 Note: all dates are of necessity provisional, but registered delegates will be kept informed of changes and will be assured of a place at the event of their choice. Places are limited so don’t delay - book today! Contact Details: PROFIBUS & PROFINET International (PI UK) uk@profibus.com www.profibusgroup.com +44 208 144 9597

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April 2021

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ENGINEERING UPDATE

Three outstanding women celebrated nationally as Young Woman Engineers of the Year Three young women engineers have been recognised at the Institution of Engineering and Technology’s (IET) Young Woman Engineer of the Year Awards for their work in engineering.

IET

Yo u n g Woman Engineer of the Year: Ella Podmore (25), is a Materials Engineer for luxury British supercar maker McLaren Automotive. Ella is responsible for all the material investigations in the business across the development phases of the company’s supercars; from concept drawings, all the way to customers in the field. Balancing her time between experiments and leading technical meetings, Ella created this department from the ground-up and plans to demonstrate the importance of materials in the automotive industry even further. IET Mary George Memorial Prize for Apprentices: Denize Ivy Pilatra (21), is an Apprentice Non-Destructive Examination Engineering Technician at BAE Systems Submarines. Denize is responsible for ensuring the structural integrity of submarines, working alongside technicians confirming critical components are free from unwanted defects. As a passionate STEM ambassador, Denize supports many educational events and has been awarded for her dedication to continuously improve and actively promote the endless possibilities within STEM to young girls. Women’s Engineering Society (WES) Prize: Shrouk El-Attar (28), is an Electronic Engineer at Elvie. Shrouk engineers smart tech that improves the lives of cis women and trans men, whilst breaking down barriers and smashing taboos. Shrouk has been a STEM Ambassador since 2011, teaching children about engineering solutions and most recently headed up a project, teaching maths to children of refugees. On winning, Ella said: “I am absolutely honoured to have been chosen by the IET and the judges to be this year’s winner. Those who know and work with me recognise how passionate I am about my science and being able to talk about

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that and the amazing supercars I get to work on at McLaren. I want to encourage the next generation of engineers and scientists to push the boundaries of what’s possible.” Finalists Bethany Probert, Melanie Jimenez and Neera Kukadia were all highly commended. All winners and finalists will play an ambassadorial role for the engineering and technology professions in the forthcoming months, promoting engineering careers to girls and young people. Now in its second year, the Gender Diversity Ambassador Award, which recognises an individual’s hard work in achieving gender equality within the engineering industry, was awarded to Pam Wilson. The award aims to showcase innovation and good practice to compliment the YWE Awards, by recognising the support and encouragement of women in STEM careers. Pam is passionate that engineering is seen as a rewarding and enjoyable career and she supports the promotion of STEM whenever she can. She actively mentors within her own company and externally and sees key skills for all future engineers to be problem solving, knowledge sharing, balancing risks, process improvement and a continuous desire to learn and evolve in what is an ever-changing environment. These prestigious engineering industry awards celebrate women working in modern engineering – and aim to help change the perception that engineering is predominantly a career for men by banishing outdated engineering stereotypes of hard hats and dirty overalls. As well as highlighting female engineering talent, the IET Young Woman Engineer of the Year Awards seek to find role models who can help address the UK science and engineering

skills crisis by promoting engineering careers to more girls and women. Just 12% of those working in engineering and technical occupations are women (source: Engineering UK). Jo Foster, Equality, Diversity and Inclusion Manager at the IET, said: “I’d like to congratulate our fantastic winners and highly commended recipients of this year’s awards. They are inspirational and a real credit to the engineering profession and will play a huge part in altering the perception of what a career in engineering and technology can look like. “It’s vital that we champion engineering careers to the next generation – it’s a diverse, creative and exciting career, which offers the opportunity to do something life – or even – worldchanging.” The winners were announced at the IET Young Woman Engineer of the Year virtual awards ceremony on 4 March. British Astronaut, Tim Peake made a surprise appearance at the end of the ceremony with a video message congratulating the winners and finalists and talking about the importance of the awards. The YWE Awards are sponsored by BAE Systems, Boeing, BP, Collins Aerospace, Frazer-Nash, GCHQ, Leonardo UK, MBDA, Ofcom, Royal Air Force, Royal Mail, Teledyne e2v, Thales and Wiley. To find out more information, please visit the IET YWE website. You can also find out more about the awards and this year’s virtual ceremony by listening to the latest edition of our Engineering a Better World podcast, featuring our winner, Ella Podmore! Available to listen to here.

ENGINEERING PDATE

April 2021

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April 2021



ENGINEERING UPDATE

UNIVERSAL ALLOY TURNS TO FULTON FOR STEAM AS OPERATIONS EXPAND With a requirement for new steam boilers with increased capacity, higher efficiency and more eco-friendly emissions when expanding their operations at a second facility in Romania, Universal Alloy Corporation had no hesitation in turning to heat transfer specialist Fulton, the supplier of steam boiler solutions already installed at its facilities in Romania and Vietnam.

eat transfer specialist Fulton has supplied, assisted with installation and commissioned two gas-fired, horizontal RBC3000 steam boilers for Romania-based Universal Alloy Corporation (UAC), a manufacturer and fabricator of high-strength, hard alloy extrusions for aircraft structures or where precisionengineered products are critical. This is UAC’s second Fulton installation in Romania – at an all-new facility built to cope with increased demand from the airline industry – and third installation across its sites in Europe and Vietnam.

In accordance with strict Romanian regulations on the installation of new plant equipment, including steam boilers, as the OEM Fulton had to be in attendance at the system testing stage, ensuring reliable, maintainable steam could be provided ahead of a planned visit by several prestigious UAC customers. This meant that Fulton’s engineering services supplied support from the UK and, in line with current COVID-19 guidelines, had to self-isolate for two weeks following the test-fire visit. Under normal operating conditions, the two RBC steam boilers at the new Romanian facility are setup for N+1, with steam being used to heat water in several large vessels via coils, with the water being used for quenching purposes during component processing. Steam is also being passed through coils for a heaterdryer system at the end of the same processing line. For the steam boilers supplied to UAC, Fulton partnered with renowned burner manufacturer Weishaupt and supplied the RBCs with two low-NOx, fully-modulating burners and reconfigured the boiler steam outlet nozzles to run at just 2 bar. The use of a Siemens high integrity digital burner management sytsem means the boilers are capable of achieving at least 7:1 turndown, something not always achievable from large horizontal firetube boilers.

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ENGINEERING PDATE

April 2021

Additionally, unlike typical gas pressures in the UK of approximately 20 mbar or 60 mbar on the continent, the supply at UAC’s site in Romania was 1.6 bar, so Fulton and Weishaupt provided an over-protection rig for the gas components in the gas train. While the gas supply to the gas train is now regulated to 95 millibar, the over-protection rig ensures that a slam-shut system is enabled should the gas pressure exceeds 180 millibar, completely negating any possible component damage. In addition to November’s test-firing visit, two of Fulton’s engineers visited Romania in September to service the RBC boiler at UAC’s original facility and commission the two boilers at the new plant. Again, both engineers followed COVID-19 guidelines on self-isolating when returning to the UK. Both visits also provided an opportunity for the training of key boiler operators at UAC’s new manufacturing facility which, as well as the usual instruction and guidance, also ensured that operators were educated on the start-up procedures in both low fire hold and auto modulation modes for these particular boilers. Offering higher capacities than the 2500 kg/h maximum for its VSRT range of vertical boilers, with outputs to 4787 kg/h and a maximum working pressure of 10.34 bar, Fulton’s RBC range can be specified with matched multi-stage oil, modulating gas or dual-fuel burners as standard, with other burners available on request. The boilers are constructed to BS12953 standard, meet current and anticipated legislation and have been engineered to provide a substantial performance margin. For further information on Fulton’s horizontal RBC and vertical VSRT steam boilers, call +44 (0)117 972 3322, email sales@fulton.co.uk or visit www.fulton.co.uk.

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April 2021



ENGINEERING UPDATE

Covid shines light on efficiency in water asset management is By Matt Hale, International Sales & Marketing Director, HRS Heat Exchangers

The water industry in England and Wales is almost twelve months into the current Asset Management Period, (AMP7) which determines price settlements, management priorities and infrastructure investment for the sector until March 2025. Normally this stage of the five-year cycle would be marked by a step-up in investment and engineering activity as capital projects are approved and construction begins. However, with the global Coronavirus crisis coinciding with the start of AMP7, what is the current state of play, and how should water companies prioritise their spending and investment in the circumstances?

Covid-19 means that a more flexible approach will be needed to investment projects during AMP7

Efficient equipment solutions, such as the use of corrugated tube heat exchangers, are important where capex projects are going ahead

Asset Management Periods

investment which repeats every five years. Within these five-year periods, spending peaks typically during the central 12-18 months of the period before tailing off again, with activity resembling a typical bell curve. To try to overcome some of these peaks and troughs in activity, at the beginning of AMP6, the Cyclicality Working Group was formed. This which brought together the regulator OFWAT, the water companies, trade unions and supply chain workers to try to find solutions to this ‘boom & bust’ cycle of investment, although the initial optimism seen in 2014 appears to have evaporated long ago.

Asset Management Periods (AMPs) were introduced following the privatisation of the water industry in the UK. The five-year timeframe is designed to allow the regulator to review prices and evaluate key performance indicators (KPIs), while providing structure for the water companies to meet the priorities set out by the regulator and government. As a result, not only do AMPs set allowable price increases, but water companies align to their contract and investment framework to the same timetable.

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AMP periods last for five years and begin on the 1 April, with the corresponding Price Review (PR) carried out by the regulator in the preceding year. The current PR19 and AMP7 took effect on 1st April 2020 and runs until 31st March 2025. Four water companies: Anglian, Bristol, Northumbrian and Yorkshire appealed their PR19 determinations to the Competition and Markets Authority (CMA), although the investment priorities under AMP7 will not be affected by the outcome of any appeals process. The cyclical nature of the AMP model leads to a ‘boom and bust’ cycle of

ENGINEERING PDATE

April 2021

Heat regeneration is one area where equipment choice can help deliver operational savings

Management priorities for the current AMP AMP7 focuses on several priorities, including ensuring the long-term resilience of both infrastructure and operations, and has a total approved budget around £50 billion, representing a 13 per cent increase on AMP6. Another area of focus is the environment, with proposals designed to improve the quality of 8,000 km of rivers and reduce the number of serious pollution incidents by 90 per cent by 2025. Ofwat has said that it wants to see significant changes in the way that water companies engage with their customers, and PR19 requires companies to improve customer service while also reducing prices: delivering outcomes that customers and society value at a price they are “willing to pay.” To measure this, Ofwat has introduced 14 performance commitments (PC’s) which will allow it to compare the performance different companies using common methodology across the sector, to ensure that they continue to manage their assets well and for the future, with long-term strategies not just for water supply, but also for drainage. The regulator is also taking a more indepth and holistic view of environmental performance, including financial, operational and corporate resilience. It will also consider areas such as

Evaporation is an efficient method for handling sludges

environmental pressures, demographic change, changing customer behaviour, and climate change. To deliver these sometimes-contradictory objectives Ofwat has stressed the need for innovation and had encouraged the water sector to look to introduce best practice from other industries. As a result, one leading consultant to the industry has said that, ‘Water companies will need to focus on getting the basics right.’

The effect of Covid-19 on AMP7 Normally, after twelve months the sector would be starting to see the results of planning and investment for the current Management Period, with projects starting to take shape, however Covid-19 has changed what is and is not possible. In many cases companies have refocused their efforts on maintaining water flows and sewerage systems and helping customers, with strategic longer-term investments taking a back seat. Such behaviour is completely understandable and logical given the circumstances, particularly given potential changes in customer behaviour and monetary status, which will impact their ability to pay bills at both a domestic and industrial level. However, there may also be some unexpected positives. Reduced activity

Environmental measures, such as sludge and effluent management, are a key priority under AMP7

may reduce pressure on the system, reducing leaks or environmental pressures, both of which may make routine repair or upgrading systems easier to timetable. However, reduced activity will impact on previous demand and growth projections for the current period – plans which looked viable or essential at the planning stage of AMP7 may no longer be possible to justify. This means that managers and planners in the water industry must adopt an increasingly flexible approach, and this should also be reflected in the projects which to get taken forward, and the technology which is specified and used. Energy efficiency and system flexibility will be more important than ever, as will design features such as energy regeneration and low temperature evaporation. With the prospects for longer-term economic recession increasing, the long-term costs and payback periods of projects will become more important in relation to upfront capex. With forty-years’ experience, HRS Heat Exchangers have a wide range of heat exchangers and environmental systems for the water supply and wastewater sectors. Our corrugated tube technology improves efficiency, while our systems for handling sludge and digestate have been proven to be reliable, long lasting and energy efficient.

www.hrs-heatexchangers.com |61

April 2021

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ENGINEERING UPDATE

Torque sensor with separate sensing head can probe deep into machinery Sensor Technology has extended its new range of torque sensors with a model that has the sensing head and electronics in separate housings. This has two advantages: the sensing head can fit into very confined spaces, and the electronics can be located in a position where they are protected from physical damage, dust, dirt, moisture, electromagnetic forces, etc. 62|

ENGINEERING PDATE

April 2021

he new TorqSense SGR530/540 series operates on the same principle as all the other SGR510/520 units, namely a full four element strain gauge bridge. This uses four individual stain gauges affixed to the drive shaft; each measures the deflection of the shaft in a different direction as it rotates under load. The electronics collects readings from all four gauges and calculates the torque value. Sensor Technology launched the TorqSense SGR510/520 range in 2020 as the successor to its RWT range which worked on surface acoustic wave (SAW) measurement and detection. It has specialised in real-time torque measurement for over forty years, and pioneered the development of wireless technologies that use radio frequency pickups rather than hard-wired solutions involving delicate and unreliable slip rings. Initially launched in sizes up to 500Nm, interest in the SGR sensors was so high that the introduction of larger sizes up to 13,000Nm was brought forward 6-12 months to December 2020. “Because of our experience with the RWT, we have been able to compress the development times for the new SGR models considerably,” says Sensor Technology’s Mark Ingham. “So, we have been able to react to specific enquiries from individual users and bring forward model launches “ The new range is designed to meet emerging user requirements, notably accurately recording transient

torque spikes. In the past transducers didn’t have the bandwidth to capture these spikes, so they were ignored. However, advances in automation, continuous operation and the increasing need for accurate track and trace data has led to the need for more detailed measurement and analysis, as Mark explains: “A single spike could indicate say the wrong amount of an ingredient being added to a compound or an oversized workpiece, both of which could affect product quality. A series of spikes would probably suggest the beginnings of a problem within the machinery, so their detection gives the plant engineers an early warning”. In use, a rotor mounted ultra-miniature microcontroller, powered by an inductive coil, measures the differential values in each strain gauge and transmits them back to the stator digitally, via the same coil. The SGR510/520 series transducers then use state of the art strain gauge signal conditioning techniques to provide a high bandwidth, low cost torque measuring solution with high overrange and overload capabilities. An advantage of the design of the SGR torque sensors is that they automatically compensate for any extraneous forces, such as bending moments, inadvertently applied to the sensor. They also offer high sensitivity and have a wide temperature tolerance, attributes that are required more and more and production machinery becomes more and more sophisticated and performance demands increase. Other advantages of the SGR range include: elimination of noise pickup and signal corruption associated with slip rings and hard wired solutions, a 400% mechanical overload limit with accurate torque measurement even at these extremes, and multipoint calibration to eliminate linearity errors within the sensor. All units are accurate to +/-0.1% and resolution to +/0.01% of the transducer’s full scale. Other features include an adjustable moving average filter, power supply range from 12VDC to 32VDC, user settable analogue output voltages, and RS232, USB, CANbus and Ethernet comms options. “Like the RWT sensors the new SGRs can integrate digitally with TorqView software and LabView virtual instruments,” says Mark.

For more information contact Sensor Technology on Tel: +44(0)1869 238400

Email: info@sensors.co.uk

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April 2021

ODU-MAC® PUSH-LOCK

Modular connectors with top packing density

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ENGINEERING UPDATE

space, so several connectors can be mounted very close to each other – an advantage that is inextricably linked to its locking principal. This, combined with low mating and de-mating forces, means the connector can be used intuitively with just one hand. ODU-MAC® PUSH-LOCK is just one of the locking options available in the ODU-MAC® Blue-Line range, which is setting new standards with manual connector solutions that can be configured for the smallest installation spaces – giving an impressive, custom-fit end result.

Unique hybrid rectangular connectors with simple push-pull locking. Modules are assembled and removed without tools, while a special coding function ensures no mistakes can be made when clipping them in. Contacts are replaced from the mating side, so the crimp-clip contacts are easy to release even after connector assembly.

Summary

When panel space is at a premium, then the maximum possible connector density needs to be achieved. That’s what ODU offers with their push-lock option for rectangular connectors. ODU have created a hybrid rectangular connector, incorporating expertise from its range of pushpull locking circular connectors into their ODU-MAC® Blue-Line product range. The resultant PUSH-LOCK creates an even more compact ODU-MAC® modular connector with a design that makes these innovative hybrid connectors stand out from the crowd.

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The goal was to offer a connector that was ergonomic, easy to use, and highly flexible – in a style as small as possible. The size was incredibly important to meet the growing trend for miniaturization. The result is a sleek hybrid IP67 connector capable of over 5,000 mating cycles, equipped with various module inserts and yet with a large M25 cable outlet. The plastic housings come in white or black as standard, with the white version fitting perfectly into the design of medical devices. Push-pull locking is incredibly simple and reliable. This locking style saves a huge amount of

• Over 5,000 operations • Easy handling - clip-in modules & contacts – no tools • 6 Coding options on the clip modules to prevent incorrect mating • Range of transmission types: signal, power, high current, coax, compressed air, fluid coupling, high-speed data transmission and fibre-optics. • IP 67 when mated [dust covers available for when unmated] • With a maximum of 740 contacts, the most compact hybrid connector in the market. • Separate PCB-termination module option • Over 5,000 mating cycles

Learn more about the ODU-MAC® PUSH-LOCK here sales@odu-uk.co.uk

www.odu-uk.co.uk

April 2021

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ENGINEERING UPDATE

Re-fueling and re-charging business with FLEETMAXX SOLUTIONS fuel cards We can all agree; it has been quite a balancing act for fleet managers during this pandemic to improve fuel efficiency when the pump costs have been spiralling out of control.

uel cards are an exceptionally convenient way to manage your fleet’s fuel consumption. Another advantage of a fuel card is that all the transactions can get registered on a single invoice, saving time chasing staff for receipts and having to input data. These invoices are also recognised and approved by the HMRC. Now that’s efficiency.

A network of fuel card options We are FLEETMAXX SOLUTIONS. Our fuel cards can save up to 10p per litre on diesel and petrol, and are valid to use at BP, Esso, Shell, Texaco sites and supermarkets (Fuelgenie), independent retailers and specialist diesel networks, such as Keyfuels and UKfuels. We are a wholly-owned subsidiary of Oilfast Ltd, a substantial bulk fuel, lubricant and licensed Adblue® manufacturer and distributor. We have brought fuel costs down for more than 50,000 customers during this pandemic, including HGV operators, transport managers, hauliers, couriers, PSV and many more organisations that rely on vehicles to get the job done and keep the country going during this uncertain time.

Electric vehicle fuel card We can also announce that drivers can now re-charge electric fleet vehicles with our Shell Fuel Card from FLEETMAXX SOLUTIONS. It gives fleets access to NewMotion’s interoperable network, where the use of one card can charge across 16 different networks. As the network grows, fleets will access an even more extensive network with no extra admin

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Figure 1 CHARGE YOUR EV WITH A SHELL FUIEL CARD FROM FLEETMAXX SOLUTIONS

required. The Shell and NewMotion networks are conveniently placed across the UK to allow your drivers to charge wherever they are.

Compare fuel cards Whether you have one or thousands of vehicles on the road, FLEETMAXX SOLUTIONS can help reduce your running costs with discounted diesel and petrol fuel cards. We offer many options to suit how your business runs.

Esso Maxx fuel card is exclusive to FLEETMAXX SOLUTONS with savings of up to 10p per litre on diesel. It has access to 1,100+HGV friendly pump locations, 130+ Motorway service areas and 1,900+ 24-hour sites. If your fleet runs predominantly on diesel and your priority is to secure the best rates this card guarantees saving on every litre at any Esso pump all day, every day this really is a great option for businesses with all kinds of vehicles on the road.

ENGINEERING PDATE

April 2021 - PC, Laptop, Tablet, or Mobile App. FLEETLOC8 allows you to monitor expenditure and validate timesheet and fuel expenses based on how, why, and when the vehicles were on the road. Identify Drivers, zones, and critical locations. Other areas where our solutions can impact risk and time management, employee schedules, challenges to fines, minimising mileage, and cutting CO2 emissions. This visibility better informs productivity and the way your business serves your customers.

Figure 2 PENNY SAVINGS ON PETROL QUICKLY ADD UP TO POUNDS WITH ESSO MAXX

FuelGenie card gives competitive diesel and petrol pricing at supermarket forecourts, including Tesco, Morrisons and Sainsbury’s. Drivers can still collect loyalty points each time they fill up, or you can allocate the card to a specific vehicle. Keyfuels card gives weekly fixed pricing on diesel at all fuelling stations across the market-leading UK Fuels network. Drivers will have access to an extensive network of truck stops and HGV friendly fuel stations strategically placed on all major trunk roads and near major ports. Texaco Fastfuel fuel card is a petrol or diesel fuel card offering flexibility for your car and van fleet; this fuel card has excellent nationwide network coverage with competitive fixed wholesale pricing.

Tracking solutions and dashcam combos Managing the logistics of your team may be more of a priority right now. We know, once your team leave early in the morning, or the last thing at night and throughout the day, keeping an eye on fuel expenditure and the company vehicles can be a struggle remotely. Our telematics solutions FLEETLOC8 gives complete visibility with accurate live and historical data of every journey made for just £9.95 a month. Our tailor-made solutions’ recording capacity can continuously record for up to three days driving (128GB) or a working week (256GB) or more subject to individual requirement. Fleet managers can access realtime information from any device

Combining our tracking and forwardfacing fleet cam FLEETVISION will provide professional insights into how drivers conduct themselves on the road. The camera also provides clear proof in the event of accident claims, protection against crash-for-cash scams and evidence of dangerous driving. Its wide-angle lens can record in both dark and light conditions at all angles of the road. Using FLEETVISION as a training tool can help your drivers change their driving habits and improve overall performance and prevent future incidents from occurring. It also safeguards deprecation as it monitors how drivers drive the vehicles. A camera and tracking combo are less than £15 to run a month after installation.

Covering all eventuality While we have everything covered, recording, and fuelling every move you make, we can cover every accident with our commercial insurance solutions. Our dedicated team of experts can provide a no-obligation quote right for your business covering insurance or liability insurance. Our experts will find a cover for every eventuality, and some you might not have considered. Contact FLEETMAXX SOLUTIONS Tel: 01367 704 910 Email: info@fleetmaxxsolutions.co.uk

www.fleetmaxxsolutions.co.uk

Figure 3- COMBINED TRACKING & DASHCAM ONLY £14.95

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April 2021

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ENGINEERING UPDATE

A closer look at our Altivar Process Modular hire panels. We recently launched the new generation of hire panels, utilising the latest variable speed drive technology from Schneider Electric as the only authorised Altivar Process Modular (APM) panel builder in the UK.

hese new Hire Panels are completely weatherproof for outdoor use and suitable for indoor too, up to 500KW/880A rating at 400V. The new unique design allows for additional modules, each at 160KW rating. So your power requirements can be matched using the same panel design by simply adding the number of modules to obtain your required design power output. This panel is unique at this power rating as it is small enough (with the rain hood removed) to fit through a standard doorway! Enabling access to areas which would have previously been unreachable! This is the first design of its kind in the UK VSD rental market but also first for having an outdoor rated unit, up to 500KW and without the need for an additional enclosure or container to house it in. They come with our previous easy to install, cable and set up options and with a genuine 24/7/365 engineer support throughout the whole of the UK. This truly is a market leading design, with added features created by our in-house Control Panel manufacturers which no other hire VSD has:

Built in 3 phase line choke. Each drive module has a 3-phase line choke built in for harmonic mitigation, this allows for operation on either the customers own mains supply or mains supply from a diesel generator source without the need for further harmonic filtering.

Built in dv/dt filter.

induced circulating currents and associated heating of the gland plate with single core cables. The different gland plates are all the same size so can be interchanged as required. They can also be mixed and matched as required so you could have quick connect for the mains and a plain gland plate for an armoured motor cable, as an example.

Each drive module has a dv/dt filter built in allowing up to 300m motor cables without any external components required, this allows for not only long cable runs but also offers further motor winding protection.

We also have cable entries at the top, side and bottom of the panel for both mains and motor connections. The top ones would be for indoor use only as the rain hood needs to be removed to access these.

Variable Gland Plate Options

Door mounted controls with lockable transparent cover

Hire panel available with either plain gland plate, brush or quick connects depending on your requirements: Quick Connect – suitable for indoor or outdoor use with appropriate cables, simple plug and play type connections to allow for ease and time saving connections. Brush - suitable for indoor use with flexible single type cables Plain Aluminium – suitable for indoor or outdoor use with armoured or flexible single cables and appropriate glands. Aluminium to prevent

All door mounted controls located behind a lockable transparent cover (except E-Stop). This gives added security when operating on site and allows for authorised only access to door controls. The cover allows for a water / weatherproof option whilst maintaining a clear view to the variable speed drive keypad for operating data.

Recessed door mounted controls All door mounted equipment is recessed to reduce the overall depth of the panel and reduce the risk of damage during transport or whilst in situ on site. These Hire Panels are available now, get in touch at rental@quantum-controls.co.uk for your no obligation quote and receive a FREE Easy Guide to Rental Drives.

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Claim your FREE VSD Guide!

Email us at rental@quantum-controls.co.uk

Any Time | Any Place | Any Weather Drive breakdown is a disastrous situation - lost production costs on average £12,000 per hour. That means you need a back up plan. Thankfully Quantum Controls has the largest stock of Weatherproof Variable Speed Drives for rental in Europe - our team of engineers are available 24/7, 365 days a year to get you back up and running quickly and efficiently if you suffer a drive breakdown. We have over 1500+ Weatherproof VSDs, up to 4.5MW, a perfect solution for any application.

IN THE EVENT OF A DRIVE BREAKDOWN CALL OUR 24/7 DRIVE EMERGENCY HOTLINE

0330 9000 247 www.quantum-controls.co.uk | 01661 835 566

April 2021



ENGINEERING UPDATE

Traco Power medical power solutions

ne of the key safety concerns with respect to medical devices is, that the patient is often electrically connected to the medical device. Since a medical device must be absolutely safe for both, the patient and the operator, all electronics including components must meet strict requirements according to IEC/EN 60601-1.

The AC/DC products range from small 5W PCB-mounting modules, a range of mid-power open frame designs, and enclosed power supplies offering power levels of up to 850W.

As an example: AC/DC power supplies and DC/DC converters for medical and healthcare applications, need to fulfill much stricter requirements compared to power supplies for the industrial market. Some of the main technical differences are additional requirements on the isolation system (2xMOPP), the leakage current, the isolation capacitance and EMC limits.

Features

A comprehensive product offering Traco Power offers both AC/DC and DC/DC solutions for medical applications, all of which fulfil the 2xMOPP requirement. Compliant with the EMC. requirements of the 4th edition of IEC/EN 60601-1, they are suitable for all patient connected, body floating rated applied parts medical devices.

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Traco Power’s DC/DC converter range comprises PCBmounting modules with power levels from 1W to 60W.

• IEC/EN/ES 60601-1 3 rd Edition for 2 x MOPP • Risk Management ISO 14971 • IPC-A-610 Class 3 High Performance Acceptability • EMC Emission compliant according to IEC 60601-1-2 ed. 4 • Quality Management ISO 13485 • 5-years warranty For more information, videos, documents, articles and datasheets, go to: www.tracopower.com/medical-campaign

ENGINEERING PDATE

April 2021

NEW INDUCTIVE SENSORS ARE MORE COMPACT AND OFFER HIGH ACCURACY AND TEMPERATURE STABILITY FOR CONTINUOUS MONITORING OF TOOL CLAMPING POSITION

recision sensor manufacturer MicroEpsilon has introduced a range of inductive displacement sensors that monitor the clamping position in machine tools. The sensors are extremely compact and robust (IP67), while providing high temperature stability and high repeatability, even in harsh machine tool environments. When developing new machine tools, key requirements include faster machining speeds, higher precision and higher productivity. However, if the cutting tool is incorrectly positioned in these high performance machines, this can lead to machining errors, damage to the machine or personal injury. The new induSENSOR LVP/LDR range of inductive displacement sensors The new induSENSOR LVPmonitor the clamping position in machine tools. 25-Z20 and induSENSOR LDR14-Z20 from Micro-Epsilon are requirements for high precision and availability of available with measuring ranges of 25mm and 14mm, machine tools. respectively. The cylindrical sensors are integrated into the release device to detect the clamping stroke of the Glenn Wedgbrow, Business Development Manager at drawbar (i.e. shaft, spindle), which passes through the Micro-Epsilon comments: “The induSENSOR LVP and centre of the sensor. The measuring object is a target LDR sensors measure on a continuous, non-contact ring which is attached to the drawbar. This ‘throughbasis and are therefore wear-free. The sensors also bore’ sensor design requires the minimum amount offer large measuring ranges [25mm and 14mm] relative of installation space compared to more traditional to their short design, which simplifies their integration clamping position sensors. into release devices on clamping systems where space Due to their extremely compact design – the LDR-14-Z20 can be limited. Also, compared to alternative methods has a diameter of just 13mm and a length of 26mm of measuring the clamping stroke – which often – the sensors can be integrated to a wide variety of comprise of multiple proximity sensors and complex different tools. The sensors provide an analogue output mechanical control disks of various shapes and sizes – based on the target ring position that corresponds to our solution is a much more elegant one that consists the stroke movement of the drawbar when clamping of an individual measurement sensor, which simplifies the tool. The sensor provides continuous monitoring of integration and significantly reduces the rotating the drawbar position and therefore removes the need mass on the drawbar. The sensors also offer higher to mechanically set the switching point and eliminates temperature stability and higher resolution, linearity complex, time-consuming adjustments when changing and repeatability than competing clamping stroke the tool. measurement systems.” The miniature sensor controller can either be For more information on the induSENSOR LVP/LDR accommodated at the point of measurement or mounted range, please visit in a control cabinet. Due to their high resolution (6-7µm), www.micro-epsilon.co.uk or call the Micro-Epsilon thermal stability and operating temperature range, up sales department on +44 (0)151 355 6070 or email to 125°C as standard (higher on request), the sensors contribute significantly to meeting the ever-increasing info@micro-epsilon.co.uk

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