automation feb 2012

7/28/2019 Automation Feb 2012

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FEBRUARY 2012 PRACTICAL SOLUTIONS FOR MANUFACTURING EFFICIENCY

INDUSTRY FOCUS INSIDE THIS ISSUE: MEDICAL EQUIPMENT

DRIVES & CONTROLS

Robust drives keepwater flowing

New low costSCARA robotslose weight and save money

SCADA & DATA ACQUISITION

SCADA virtualisationdelivers real benefits


2/44

Enter 1


3/44

NEWS

4. Connecting Industry website: Re-engineered for 2012 and beyond5. Robot sales grow by 68 per cent in 20116. Bosch research finds engineering is undervalued

INDUSTRY FOCUS: MEDICAL EQUIPMENT

10. Micro product support for medical technology innovators12. Making developing wireless, cloud-connected medical devices easier

FEATURES

Drives & controls...

14. Robust drives keep water flowing16. Positioning drives at heart of carpet recycler17. Sensors specified for precision measurement

18. Industrial automation: the road ahead

Materials handling & conveying...

21. Shuttle storage system keeps fashion logistics on the rails22. Mobile system cuts pallet racking floor space in half24. Vertical conveyor keeps engine production line running smoothly25. Modular wide belt conveyor improves flow efficiency

Tracking & traceability...

26. Labelling system provides food producer with full traceability28. First wireless industrial ID barcode reader with Ethernet29. Metabolising statistical benefits with SPC

SCADA & Data acquisition...

30. Ensuring an environmental success for potato supplier32. SCADA virtualisation delivers real benefits

TECHNOLOGY FILE

33. Infrared system finds fertilised eggs34. Positioner combinations close control loop

Managing EditorNeil Mead Tel: 01622 69 9193

[email protected]

Assistant Editor

Heather Ramsden Tel: 01622 69 9167

[email protected]

Publishing Director

Hannah Dedman Tel: 01622 699175

[email protected]

Publication Manager

Jo Pilcher Tel: 01622 699177

jpi lch er@ dat ate am. co. uk

Advertisement Manager

Kelly Byne Tel: 01622 699 195

[email protected]

Classified Sales Executive

John McIntosh Tel: 01622 6 99126

jmc int osh @da tat eam .co .uk

Studio Manager

Siobhan Nolan Tel: 01622 6 99121

Classified Designer

Kirsty Hood Tel: 01622 699 186

Production Manager

Claire Noe Tel: 01622 69 9164

Circulation Enquiries

Capsule Publishing Services Tel: 0845 602 7390

E: [email protected]

In a quest to build a better mouse-

trap, Toshiba Machine has taken a

long hard look at how to create a

new breed of SCARA robots that

deliver a host of benefits while at

the same time taking a chunk of

costs out of the equation

TM Robotics (Europe) Limited

T: 01707 290370

www.tmrobotics.co.uk

Turn to page 8 for more details

COVER STORY

CONNECTINGINDUSTRY.COM/

AUTOMATION

(incorporating Automation).

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The statements and opinions expressed in

connectingindustry/Automation are not

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ISSN 1472-1244

Total Average Net Circulation forJanuary-December 2008 is 16,986

Datateam Business Media LtdLondon Road

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Contents

Automation

Next month... Features in the March 2012 issue of Automation will include: Machine building & frameworks Machine vision systems PLCs & Industrial PCs Industry focus: Warehousing & logistics Exhibition previews: MACH 2012 and Drives & Controls

Automation FEBRUARY 2012 3

F EB RU AR Y 20 12 P RA CT IC AL S OL UT IO NS F OR MAN UF AC TU RI NG E FF IC IE NC Y

INDUSTRY FOCUS INSIDE THIS ISSUE: MEDICAL EQUIPMENT

DRIVES & CONTROLS

Robust drives keepwater flowing

New low costSCARA robotslose weight and save money

SCADA & DATA ACQUISITION

SCADA virtualisationdelivers real benefits

February 2012


4/44

News Industry

Connecting Industry (www.connectingindustry.com),

the online hub of the UK's leading portfolio of indus-

trial publications has been completely re-engineered

and was re-launched earlier this month.

Connecting Industry is already the UKs largest and

most comprehensive online resource for engineers

and manufacturing professionals, but now it has been

given a complete redesign making it more attractive,

easier to navigate and user-friendly. New search

options, an unrivalled supplier database, interactive

events calendar and rich multi-media content,

together with links to all the major social networks

will ensure that Connecting Industry remains the

number one online source of information for the man-ufacturing industry. Features of the new site include:

Increased Connecting Industry branding of the

home of the UKs largest and strongest portfolio of

industrial magazines.

Each of the Connecting Industry publications

now has a section of its own so that visitors can go

straight to the magazine/story that is of most rele-

vance and interest to them.

The new site offers a fully interactive, user-

friendly search tool for anyone wanting to read the

latest industry news, quality editorial in the form ofapplication articles and case studies, and find the

products and/or suppliers they require. The search-

able database allows users to find companies by

product category, geographical location, alphabeti-

cally or by keyword search - and to do it faster and

more efficiently than ever before.

Built-in web 2.0 functionality so that it integrates

seamlessly with social networks. In this way

Connecting Industry will build a community

between magazines, readers and suppliers.

ConnectingIndustry.com will therefore continue to

be the first website engineers and manufacturing

professionals think of when they require the latest

information.A comprehensive and fully interactive events cal-

endar. Exhibitions, seminars and training events are

a useful way for people in the industry to network

and being able to find them all together in one place

is difficult. ConnectingIndustry.com provides this

service.

The new site makes it even easier to read the latest

digital editions of Datateams industrial magazines,

register to receive printed copies and sign up for

regular e-newsletters.

A brand new and bespoke administration tool

allows our editorial staff to upload the latest news

stories and content quickly and easily keeping the

site up to date and maintaining its position as theleading online industrial news resource.

Many more advertising opportunities, both in

terms of space and interesting and different ways for

companies to get their message across to our dedi-

cated readership.

Bookmark http://www.connectingindustry.com

now and be among the first to experience a new age

in industrial websites.

Connecting Industry website:Re-engineered for 2012 and beyond

CommentAs you can see from our lead story

opposite, the new Connecting

Industry website is now live. This

represents a major investment in time

and resources by Datateam to bring

the site up to date and consolidate itsposition as the leading source of

information for engineers and

manufacturing professionals.

Weve worked extremely hard on

improving the look and feel of the site

in order to make it faster and easier to

use. Each of the Connecting Industry

magazines now have their own clearly

defined sections on the site, so users

can go directly their own particular

area of interest.

A new feature is the site wide

search, so even if youre not exactly

sure where to find the information youneed you can quickly look for it here.

This includes all articles, suppliers and

even events. And that brings me on to

another new feature, the Events

Calendar. With more industry events

being added all the time, this is the

place to find the latest information

about exhibitions, seminars, open

days and other industry networking

opportunities.

The new site also incorporates the

latest Web 2.0 technology which

adds rich multimedia content and links

to all the major social networks.Were really pleased with the end

result and Im sure Automation

readers will find it a very useful tool.

As with any online resource it will

continue to grow and develop and Id

welcome your feedback so please let

me know what you think of it.

Neil Mead - Managing Editor

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5/44

Robot sales grow by 68 per cent in 2011

Schaeffler UKs manufacturing

plant in Llanelli, South Wales hasreceived a national award that

demonstrates the companys com-mitment to manufacturing quality.

At this years Wales QualityAwards 2011, Schaeffler UK

received the Chairmans Prize

for Automotive Excellence, anew category that recognises out-

standing achievements of Welshcompanies operating in this

sector of the economy. The WalesQuality Award is an annual com-

petition based on the EFQMEuropean Excellence Model.

www.schaeffler.co.uk

Plant wins award

For the fifth year in a row, Schunk will host the

'Expert Days on Service Robotics' from February 29to March 1, 2012 at its world headquarters in

Lauffen, Germany. As with all the previous events,globally renowned industry and academic experts

from the field of robotics will meet to discuss the

key issues for the sector in depth.The 2012 event will be titled Service robotics -

Quo vadis? As one of the world's leading communi-cation platforms for applied service robotics, this

event will examine the opportunities and potentialfor this rapidly growing emerging market. The

anniversary event will focus on topics such as per-

ception and learning, marketing, robots and compo-nent design, and robots and people.

It has been almost five years since Schunk recog-

nised the potential for an international servicerobotics market and in response, initiated the Expert

Days on Service Robotics in the spring of 2007. Fortwo days, key note speakers from around the world

will present current trends, the latest research and

promising business models. Two of the honouredguests will be Professor Dr Roland Siegwart from

ETH Zurich and Steve Cousins of the US roboticsfirm Willow Garage. In 2012, the Expert Days will

again serve as an intensive forum for the directexchange of ideas between research, industry, busi-

ness and the trade press.For further information contact your local Schunk

representative or visit www.schunk.com

Schunk hosts fifth Robotics Expert Days

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... youre in safe handsEnter 3

The latest robot sales statistics compiled by the British Robot and

Automation Association (BARA), reveal that sales have increased bya dramatic 68 per cent over the last year. Almost all of the major

robotics suppliers to British Manufacturing have reported this trendwhich is welcome news from the industry.

The most dramatic growth has come from the automotive or auto-motive components sectors with growth of 235 per cent and 176 percent respectively. Surprisingly both the food and drink and pharma-

ceutical, health and medical sectors reported a decrease of 8 per centand 76 per cent respectively.

Mike Wilson chairman of BARA said: We are delighted with such anincrease in industrial robot sales over the year although most of this has

been within the automotive industry. Most sectors have experiencedincreases and this represents the best growth statistics since 1997. Average

growth is nearly 70 per cent year-on-year which represents strong sales for

most of the robot manufacturers."Mike continued "the Government are also putting considerable money behind

the promotion of robotics in UK Manufacturing in recognition that robots actuallycreate more jobs through growth. Currently over 100 companies are making use of the

free automation review open to any UK manufacturer. This in turn should also enhance

growth in robotics over the next couple of years"Companies wishing to make use of the free automation review should contact Grant Collier on

0208 773 8111 or visit the website www.automatingmanufacturing.co.uk

B&R Product of the Month ACOPOSmulti65m

B&R has expanded its line of drives with a series of motor-

integrated servo drives with IP65 protection. The

ACOPOSmulti has always been extremely modular, and it

was the next logical step to merge inverters with the motor

to create servo actuators that can deliver power directly

where it is needed. Configurable modules thus become

easy-to-connect mechatronic units. This not only savesvaluable space in the control cabinet, but also cuts costs

for logistics and commissioning. By combining the latest IGBT technology and

optimized motor types, users profit from the resulting maximum performance. With

three different sizes, the servo actuators cover the entire spectrum, with a torque

range of 1.8 to 10.5Nm and a power range of 500W to 2kW. For applications

that demand more power, an optional fan assembly can be retrofitted for a

performance boost of up to 100 per cent. The ACOPOSmulti65m is fully

compatible with the entire ACOPOS drive series. As a result, it is possible

to utilise all of the tools and features available in Automation Studio as

well as applications created therein. With regard to topology, the new

servo actuator can be employed in either a line or tree structure.

Networking takes place using POWERLINK.

B&R Industrial Automation

T: 01733 371320

www.br-automation.com


6/44FEBRUARY 2012 Automation6

News Industry

In brief

A white paper, based on research

carried out jointly by AC drive tech-

nology company,Vacon and global

computer security provider F-

Secure, provides a detailed insightinto security threats relating to

industrial automation systems. The

paper, which is the result of more

than a years work by Vacon and F-

Secure, identifies and analyses the

nature of the threats as well as

proposing methods for increasing

security. The security in industrial

automation white paper published

by Vacon and F-Secure can be

downloaded free-of-charge from

www.vacon.com

Sato, a specialist in barcode

printing, labelling, and EPC/RFID

solutions, has announced its

acquisition of Argox Information Co,

a manufacturer of barcode printers,

barcode scanners, and portable

terminals, making Argox a member

of the Sato Group of companies.

www.satoworldwide.com

Parker Hannifin Corporation, the

specialist in motion and control

technologies, has signed an

Enterprise Framework Agreement

(EFA) with Shell as a single source

supplier for the provision of instru-mentation valves, manifolds,

process-to-instrument valves, fit-

tings, tubing, protective enclosures

and related products.

www.parker.com

Laser machine specialist and UK

distributor for Mitsubishi laser cut-

ting machines, World Machinery,

has created the website

www.mitsubishilaser.co.uk

featuring information on the LVP

Series and EX Series. UK cus-

tomers can also get information on

performance, installation, service

support and consumables.

Eriks is to move its Slough Service

Centre into its nearby Core

Competence Centre for Industrial

Hose Technology, streamlining cus-

tomer care by bringing two local

engineering services under one

roof. The Slough Service Centre is

a key location for Eriks, serving a

strong customer base in Berkshire

and West London, Hampshire,

Buckinghamshire, Bedfordshire and

Surrey. Eriks will also relocate itsOtley Service Centre to the city of

Bradford, improving customer care

by bringing the operation to a new,

purpose-built facility.

www.eriks.co.uk

One of the largest manufacturing and engineeringevents of 2012 will be taking place at the NEC inBirmingham between 17 and 19 April. Drives and

Controls Show, The Plant and Asset Management

Exhibition, Air-Tech, and the InternationalFluid Power Exhibition (IFPEX) will form

part of the manufacturing and engineeringseries of shows alongside MACH 2012.

Organiser DFA Media believes its seriesof events ensures industry professionals will

be able to gain the broadest insight concerning whatindustry solutions are currently available. The Plant

and Asset Management Exhibition, being launched

by DFA Media, is a new UK event for the mainte-

nance sector, solely concerned with aspects of themanagement and maintenance of physical assets.Organisers are optimistic the Drives & Controls

Show will exceed both the exhibitor and visitornumbers of 2010 which had 103 exhibitors, 16 per

cent more than the previous show in 2008.

The co-location of events attracted more than8,600 visitors in 2010 and Ryan Fuller, exhibitionsales director at DFA Media, believes this figure,

along with visitor numbers will be exceeded asmanufacturing regains confidence.

Next year will include a free highlyfocused seminar programme. New for

2012 is the Energy and Safety seminar the-atre, sponsored by CompAir where themed

panel discussions and seminar presentations

will focus on key energy management topics.Also new is the Motion and Control Industry semi-

nar theatre to include more technical workshop stylepresentations, with practical issues being discussed

concerning the various sectors that makes up Drivesand Controls Exhibition, Air-Tech, and IFPEX.

The Plant and Asset Management Exhibition willalso have two free seminar theatres.

www.drives-expo.com, www.airtech-expo.com,www.ifpex-expo.com, maintenanceuk-expo.com

Manufacturing and engineering showcase at the NEC

Bosch research finds engineering is undervalued

A survey by the Bosch Group, a leading global sup-

plier of technology and services, has found that engi-neering is undervalued and misunderstood by adults

in the UK. The research was carried out amongst1,347 people aged between 18 to 45 years old and in

general shows that many people, particularly younger

adults, see engineering as a back of house function inbusiness that is not critical to the UK economy.

Peter Fouquet, President of Bosch UK, said: Thefindings are concerning given that the engineering

sector in the UK makes up nearly a fifth of the econ-omy and employs over 4.5 million people.

Combined, engineering and manufacturing con-tribute around 800 billion to the UK economy.

The research found that only 45 per cent of people and only 23 per cent of young people thought

engineering was a key industry for the UK economy.Retail, banking and tourism were all seen as more

important. Respondents also did not see engineeringas a frontline role in business, with 92 per cent saying

that they thought engineers have mostly technicalroles in business and less than two per cent thinking

that engineers are involved in running businesses.

Engineering is also not seen as sufficiently attrac-tive to young people, with less than half of 18-24

year olds associating engineering with the wordresearch and more associating it with the word

geeky rather than exciting. In terms of working inengineering, the research showed that only 11 per

cent overall and only five per cent of 18-24 year oldswould consider a career in engineering and more

men would consider an engineering career (23 per

cent) compared to women (three per cent).

Bosch was founded as the Workshop for PrecisionMechanics and Electrical Engineering in Stuttgart in1886. It is now one of the worlds largest technology

and engineering organisations and leading innovators.Bosch employs over 285,000 employees 34,000 of

whom work in R&D and a significant proportion of its

board of management is made up of engineers.

www.bosch.co.uk

Duke of York attends Manufacturing Technology Centres handover

Ahead of its formal opening laterthis year, the Manufacturing

Technology Centre (MTC) held aweek of handover celebrations

with the bodies that have fundedit since the need for a UK centre

of excellence for high value man-ufacturing was first identified

four years ago. Staff and industry

and academic partners at theMTC were proud to welcome

HRH The Duke of York for a tourof the new facility.

The MTC is the result of a

40.55 million investment by

Advantage West Midlands andthe East Midlands Development

Agency and is housed in a land-mark building located at Ansty

Park near Coventry. There arefour initial research partners:

University of Birmingham, TheUniversity of Nottingham,

Loughborough University and

TWI Limited. There are threefounding industry members:

Rolls Royce, Airbus UK and Aero

Engine Controls.

The MTC supports manufactur-ing businesses and was set up inresponse to the UK Government's

Manufacturing Strategy. This envi-

sions the UK as leading the worldin capturing higher value compo-

nents of the global value chain,whilst consolidating areas of exist-

ing comparative advantage withinhigh technology manufacturing.

www.the-mtc.org


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Enter 4


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Advertisement feature Cover story

T

oshiba Machine has developed a

new range of SCARA robots thatset new benchmarks for price,

performance, mass and lowenergy consumption. The Toshiba

Machine THL models satisfy the grow-ing demand for affordable, flexible

automation in applications outside ofindustries such as packaging, materi-

als handling and welding where robots

have been installed for decades.The THL range represents more than

simply low cost lightweight robots.Rather, they are the result of painstak-

ing research and development leadingto a radical new design.

The mechanical challenge facingrobot designers has always been the

ability to marry low mass and lowinertia with the necessary rigidityfrom which high accuracy is attained.

Almost always this quest leads to com-promise. To ensure rigidity, mass

inevitably increases. To compensatefor that, oversized servo motors may

need to be deployed and positionadjustments made via the servo loops.

By lowering the mass, smaller motors

and simplified gearboxes can be used,which in turn also has the benefit of

reducing power consumption andhence reducing the price of the resul-

tant robot. The trick is to get the opti-mum balance between all of the

mitigating factors to ensure none of the

machines performance is conceded.Much of the reduction in mass is

thanks to the use of lightweight cast

aluminium mechanical componentsthat have a series of ribbed sections to

provide the rigidity required. As aresult of building the body and arm ofthe robot in this manner, smaller servo

motors have been fitted. Moreover,because the lightweight system gener-

ates substantially less inertia, andreduced demand for continuous posi-

tion adjustments, a simplified gearbox

has been able to be used.So, just how successful has Toshiba

Machines design team been in achiev-ing its objective? Well, the THL range is

up to 50 per cent lighter than otherToshiba Machine models and the robots

consume 50 per cent less electricity.Performance compares favourably with

other models and the new robots fea-

ture easier maintenance than previ-ously. The adage might be applied that

if one can make it better and cheaper,it cannot fail.

The benefit to end users, apart fromprice, is that the new THL robots can

be installed with cheaper, less robustsupports with significantly less need

for vibration suppression a major

advantage for systems integrators.Available on 500mm, 600mm and

700mm arm lengths, the next surpris-

ing revelation is that all three modelshave exactly the same price. ToshibaMachine explains that since the only

difference between the three robots isthe length of the extruded aluminium

tube that forms the arms main beam,

the cost difference is negligible.Each robot has four axes of move-

ment including 360 rotational, witha working envelope of 125 on the

first axis and 145 on axis two.Maximum composite speed using axes

one and two is an impressive 6.3m/sfor the THL 500, 7.1m/s for the THL

600 and 7.9m/s for the largest THL700.Cycle time, with a 2kg payload, is0.45s for the THL 500 and THL 600,

while the THL 700 is only half asecond. Maximum payload is a

weighty 10kg for all three models.

The allowable moment of inertia is

just 0.2kg/m2 and thanks to the use of

absolute encoders repeatability in X-Yis a mere 0.01mm.

The new Toshiba Machine THLrobots are distributed and supported

throughout Europe by TM Robotics(Europe) Limited. To suit the European

markets, the THL robots are controlled

by the proven and popular TS3000controller, which features easy pro-

gramming, in-built PLC functions andEthernet connectivity.

An advantage when it comes to inte-grating automation is the fact that the

unit allows complete system control to

be handled from the robot controller.Equipped with 64 I/O as standard, but

expandable up to 166, the TS3000 con-troller satisfies even the most demand-

ing production line or manufacturingcell requirements. Impressive process

speeds can be attained by taking advan-tage of the Toshiba Machine controllers

PASS and NOWAIT commands.Robot programming is simple and

conducted via a series of dedicated

commands. Furthermore, the TS3000sEthernet connectivity makes it simple

to share vision data from a singlecamera across multiple robots, reduc-

ing maintenance overheads and instal-lation costs while increasing efficiency.

TM Robotics managing director

Nigel Smith says: Industry acrossEurope, in these times of manufactur-

ing austerity, is crying out for anythingthat helps it compete. The new low

cost THL range certainly helps satisfythat need.

But, he adds, this range ofmachines is not simply a value engi-

neering exercise to reduce costs.

Rather it is a thoroughly thought outremodelling that has resulted in robots

that meet completely new and verydifferent design specifications.

TM Robotics (Europe) Limited

T: 01707 290370

www.tmrobotics.co.uk Enter 200

New robots lighten the

load on investmentIn a quest to build a better mousetrap, Toshiba Machine

has taken a long hard look at how to create a new breed of

SCARA robots that deliver a host of benefits while at the

same time taking a chunk of costs out of the equation

The new Toshiba

Machine THL robots

are distributed and

supported through-out Europe by TM

Robotics (Europe)

Limited

FEBRUARY 2012Automation8


9/44

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10/44

Industry focus Medical equipment

Reaffirming its commitment to

medical technology innovators as

they design equipment toimprove health and save lives,

Molex Incorporated offers a selectedseries of core micro products, which

will be available for purchase, replace-ment and technical support for up to 10

years, in order to more accurately alignwith medical industry design cycles.

Micro interconnect solutions, including

Molex FFC/FPC, board-to-board, micro-miniature wire-to-board and memory

card connectors, are used in a widerange of medical device applications.

Molex offers one of the most com-plete ranges of microminiature fine

pitch connectors to support designersand manufacturers in the medical

industry, states Anthony Kalaijakis,

strategic medical market manager,Molex. Our micro connector series

now carries a powerful commitment ofongoing product availability and sup-

port to help deliver smooth launchesand long product life cycles for medical

devices and equipment.Molex micro products align with the

trend towards smaller, lighter andintegrated solutions for mobile and

portable medical applications. The

firms core micro products includesome of the smallest and most innova-

tive connector systems available on

the market. For example: SlimStack 0.40mm pitch, board-to-board system provides approximately a

25 per cent overall space savingcompared to competitive styles.

IllumiMate 2.00mm wire-to-board

system supplies the narrowest widthof any similar low-power connector

systems, along with significant costand performance advantages.

FPC 0.30mm pitch dual-contact

connector offers the shortest length and

most secure FPC retention comparedwith similar competitive versions,

while eliminating the need to source atop- and bottom-style connector when

routing an FPC to parallel boards. microSD ultra-small 1.28mm

height memory card connector

reduces memory card fly-out andsticking problems in portable devices

such as mobile phones.From portable electronic defibrilla-

tors and handheld blood glucose mon-itors to drug infusion pumps and

medical imaging equipment, Molex

offers innovative interconnect solu-tions to meet the needs of medical

technology designers today and adecade from now, adds Kalaijakis.

By blending proven commercialtechnologies, cost-effective modified

off-the-shelf and custom products,Molex is helping to lead the way in the

integration of commercial electronics

into medical applications. Molexworks in conjunction with its medical

equipment manufacturer customers todevelop solutions that economically

support industry compliance andhealthcare needs.

More information

For more information about micro

interconnects for the medical industry,

please visit the website below. Toreceive information on other Molexproducts and medical industry solu-

tions, readers can sign up for the regu-lar Molex e-nouncement newsletter at

www.molex.com/link/register

Molex

T: 01252 720720 Enter 201

www.molex.com/industry/medical.html

Molex delivers complete interconnect

solutions for a number of markets

including data communications,

telecommunications, consumerelectronics, industrial, automotive,

medical, military, lighting and solar.

Established in 1938, the company

operates 39 manufacturing locations

in 16 countries.

Micro product support for

medical technology innovatorsMolex is offering a 10-year commitment to micro product

availability and technical support reflecting lengthier design

and product life cycles for medical devices and equipment

Molex works in

conjunction with its

medical equipment

manufacturer

customers todevelop solutions

that economically

support industry

compliance and

healthcare needs

Customised float switches for medical use

Customised float switches from elobau, for medical applications, are configured with thecustomers application in mind. A typical use in the medical industry would be a dialysismachine where the cleaning cycle is an essential part of the systems function. This part of

the process proves the biggest challenge for elobaus component - after one patients

treatment water is pumped through the machine and heated to a high temperature, this

heated water flushes through the system and the clean system is ready for the

next patient to begin treatment.

A miniature float switch was designed to suit this application and

the customers functional and material specifications. Special

temperature shock testing was completed by the engineering

department at elobau to validate the correct design. Creating a

reliable product for this application is difficult - the specific design

meant that the miniature float switches were created without any epoxy in

the stem of the float to ensure reliable function of the reed switch during the

challenging temperature cycle. These products can be manufactured using one type of plastic like PP or PVDF and a

correctly specified elobau float switch will not contaminate fresh water and has no issue with harsh chemicals. elobaus

flexibility means that a solution can be found for all medical level measurement applications.

elobau UK T: 0161 2661180 www.elobau.com Enter 202


Float switches from

elobau can be

customised for

medical

applications


11/44

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elobau has over 35 years of experience inmagnetically actuated sensors. With more than 20different product groups, our expertise allowsus to offer a wide range of standard and bespokeolutions for machine safety, automation and levelensing applications.

eloProgconfigurable safety control unit

safety sensors

IP67 / IP69K

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Enter 7

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12/44

Industry focus Medical equipment

The kit includes the Freescale

Semiconductor Home HealthHub (HHH) reference circuit

board which enables wired andwireless connectivity to medical

devices like blood pressure monitors,

blood glucometers, pulse oximetersand scales. It also features the iDigi

Device Cloud, allowing medicaldevices to easily and securely inte-

grate patient data into new, existingand custom healthcare applications.

Cloud-connected medical devices

help patients get out of the hospitalfaster by allowing doctors to monitor

patient status remotely, says LarryKraft, senior vice president of global

sales and marketing, DigiInternational. This kit makes it easy

to create cloud-connected medicaldevices to improve quality of care.

Through the iDigi Device Cloud,doctors can easily access and analyse

patient data, set up alarms and alerts

and store information.Telehealth is a growing technology

that allows patients to be monitored

remotely, says Steven Dean, globalhealthcare segment manager atFreescale. According to a Continua

Health Alliance study, remote moni-toring for individuals with chronic

conditions can reduce office visits by

65 per cent, shorten the length of hos-pital stays by up to six days on aver-

age, and most importantly, reducemortality anywhere from 35 to 56 per

cent. We are excited to work with Digito help enable this growing trend.

In addition to allowing management

of remote patient data, the iDigi Device

Cloud enables centralised control ofmedical device configurations, set-tings, firmware updates and device

groups. With iDigi Manager Pro, iDigisdevice network management software,

healthcare institutions can rollout largeinstallations of cloud-connected med-

ical devices in a simple, secure and

cost-effective manner.Based on the Freescale i.MX28

processor, the HHH reference platformincludes the hardware and software

components necessary for connectinghealthcare devices and user interfaces.

It includes pre-validated secure con-

nectivity with USB, Bluetooth,

Bluetooth Low Energy and ZigBeemedical-class grades, WiFi, sub-1GHz

and Ethernet. Medical device manufac-

turers can use the kit to develop proof-of-concept prototypes of network

connected medical devices.Design experts from Spectrum

Design Solutions, a subsidiary of DigiInternational, are also available to pro-

vide complete design and developmentservices, including assistance with

product development and certification

based on the HHH reference design.The iDigi Telehealth Application Kit

is now available. For more informationabout the iDigi Device Cloud, a leading

platform for connecting any applica-tion to anything, anywhere, visit the

website below.

Digi International is aiming to makewireless M2M easier by developing

reliable products and solutions toconnect and securely manage local or

remote electronic devices over the net-work or via the Web. Digi claims to

offer the highest levels of performance,flexibility and quality, and markets its

products through a global network of

distributors and resellers, systemsintegrators and original equipment

manufacturers (OEMs).

Digi International T: 01943 605055

www.idigi.com Enter 203

Making developing wireless, cloud-

connected medical devices easierDigi International has launched the iDigi TelehealthApplication Kit a development kit that allows customers

to create cloud-connected medical devices

The Digi Telehealth

Application Kit from

Digi International

allows customers

to create cloud-

connected medical

devices. These canthen integrate

securely with

patient data via the

iDigi Device Cloud

Sensor manufacturer expands to meet medical demand

Gems Sensors & Controls (Gems), the global manufacturer ofcustomised, application engineered sensors, controls,solenoid valves and sub-assemblies has expanded its facilities

for the development and manufacture of specialised medical

products. Increased demand from around the world has led the

company to open a new Medical Processing Area at its

headquarters in Plainville, USA; together with a recently

completed expansion of its sensor and controls production

operation this adds a further 1,858m2 of manufacturing space.

Gems has experienced continued growth over the past 10

years, particularly in the medical sector. The new Medical

Processing Area will allow the company to improve its product

development and manufacturing layouts, providing better

material and product workflow to address the specific needs of customers in the

medical sector, while ensuring safer working areas for employees. The additional

space will also allow Gems to expand its workforce.

Gems has served the medical sector for more than 20 years,

providing ISO13485 certified products for the specialised fluid control

and handling requirements of the medical device, diagnostic, life

science, and biotechnology market segments.

We are delighted with the expansion of our manufacturing

facility, says Patrick Murphy, VP and general manager for Gems

Sensors & Controls. The additional space will allow us to continue to

grow our product offering and serve the unique needs of our

customers around the world. I am particularly excited about the

addition of a dedicated processing area to accommodate the exacting

requirements of our customers in the medical sector, as it will

increase our ability to design new and innovative solutions that are

purpose built for each application.

Gems Sensors & Controls T: 01256 320244 www.gemssensors.com


Enter 204


13/44Enter 10


14/44

Feature Drives & controls

In water works and waste water

treatment facilities, pumps often

have to process great amount ofliquid. High-performance drives

are therefore necessary for smoothoperation. In such applications, drive

units are often subject to extreme envi-ronmental conditions, and must be

designed accordingly. But in additionto climatic conditions, other factors

also play a great role in the choice of

the drive technology supplier. Thetotal cost of ownership needs to be

taken into account and savings in thewrong place can result in considerable

additional efforts and expenses.The waster water treatment plant in

Tunis, which is operated by publicenterprise ONAS (Office National de

lAssainissement), has eight pools in

which mixers powered by two largegeared motors ensure steady circula-

tion. Thereby, the waste water is oxy-genated, enabling the decomposition

of dirt particles through bacteria.The plant supplies Tunis and its

metropolitan area with process water,covering the needs of approximately

2.5 million people. It features drive

technology that is nearly 30 years oldand must be replaced step by step.

A robust design is a must for newdrive solutions, since the units are

installed outdoors and operate non-stop while the temperature fluctuates

considerably. In winter, the tempera-ture can drop to -5C, while up to 45C

is possible in summer.

Up to now this has frequentlyaffected the lubrication of the origi-

nally installed gear units, requiringmaintenance to a problematic extent.

The goal was therefore to implementlower-maintenance drive solutions

which are well-suited for extreme

environmental conditions.

Avoiding false economiesThe original drive technology equip-

ment in the Tunis waste water treatmentplant was supplied by manufacturers

from South and West Europe. However,the units that needed replacing have

now been discontinued, which meansthat spare parts were becoming increas-

ingly scarce and lead times longer. Thisfact contributed to the decision to find a

new supplier, which is where Nord

Drivesystems came into play.The company has been operating a

sales office in Tunisia since 2003,which had already successfully imple-

mented some smaller-scale projects.Drive technology from Nord, which is

slightly more costly than comparableproducts, is said to require less main-

tenance, thereby minimising operating

costs and optimising the availability ofthe plant. ONAS wished to benefit

from these advantages. During thecourse of 2009, Nord delivered two

combinations of helical shaft gearunits and Siemens motors which have

since proven themselves during con-tinuous operation.

Getting a grip on heatNord uses a high-quality syntheticlong-life lubricant for the helical shaft

gear units. It withstands the ambienttemperatures considerably better than

mineral oil with the latter, the oil filmwould break down at high tempera-

tures, resulting in increased wear andtear. Each gear unit requires 210l of oil

which has to be changed after approxi-

mately 20,000 hours of operation.Other manufacturers often stipulate

shorter maintenance intervals, whichmakes a considerable difference at a

price of 10-18 euros per litre. An oilcooling system additionally increases

operational safety in the Nord gearunits: a temperature sensor constantly

monitors the temperature of the lubri-

cant and activates the cooling systemas soon as a configurable limit is

exceeded. In this application, the limitis 60C. Heated oil is then pumped out,

cooled by an oil cooler and returned to

the gear unit. When the temperaturefalls below 40C, the cooling systemswitches off automatically.

Drive technology in detailCurrently, two helical shaft gear unitswith a 132kW performance from

Nords SK 12382VZ series are installedat the waste water treatment plant.

They are combined with Siemensmotors via IEC adapters. Nords helical

shaft gear units are available as two- orthree-stage basic types with hollow or

solid shafts, in foot mounted, flange

mounted, or face mounted versions

each with the same housing. Suitablefor integration into limited installationspaces, they can be combined with

many components from the modularNord system. ATEX models and

models with IP55 or IP66 protectionare available on request for all types.

All gear units are manufactured

according to the UNICASE concept,originally developed by Nord in 1981,

which enables maximum performancefor small gear dimensions and ensures

operational safety, high efficiency, highoutput torques, high resistance to axial

and radial loads, low-noise operation,low maintenance and a long lifetime.

Nord Drivesystems

T: 01235 534404

www.nord.com Enter 205

Robust drives keep water flowingRobust gear units from Nord Drivesystems

are ensuring smooth operation at a wastewater treatment facility in Tunis

In the Tunis waste

water treatment

facility, the con-

tents of eight poolsare stirred by

robust drive units


Nords low-

maintenance

helical shaft gear

units are operated

with a synthetic oil

lubricant and

thereby resist even

high ambienttemperatures


15/44

Enter 11

Enter 12

Enter 13


16/44


The Fibrebak pile removal system

separates the fibres from the back-ing and gives separate outputs

suiting both carpet factories andpost-consumer waste. An infeed con-

veyor is manually fed with carpets orcarpet tiles. The carpet is brought to a

horizontal saw blade that is finely

adjustable to the heights of the pile andbacking. Vertical motion is achieved

through 10KN screw jacks and posi-tional accuracy is achieved with the

aid of motor-mounted 2048 pulseencoders. Separate out-feeds deliver

fibres to the side of the machine and

backing material to the rear. A touchscreen operator panel is positioned to

the front and side of the machine,easily accessible for the operators.

One of the advantages offered by theLenze system is the way 10 inverter

variable speed drives have integratedpositioning functionality. On the

Fibrebak machine, positioning is

required to set the height of the blade

head, the tracking and the blade grind-ing wheels. The Lenze 8400 HighLine

inverters feature point-to-point posi-

tioning with the associated travel pro-files and 100kHz evaluation of encodersignals, all without need for external

control. Set-up is made simple with L-force engineer software, and a plug-in

memory module allows drives to be

exchanged without reprogramming.The Lenze solution ranges from the

motors right up to the screw jacks andthe inverter drives. CAN is the chosen

field bus as it is standard at no extracost in the 8400 inverter drives. The

CAN network covers the 10 HighLineand a further two 8400 StateLine

inverters. The remaining five motorsare fixed speed.Further system simplification and

cost reduction is achieved by the SafeTorque Off (STO) option on the Lenze

inverters. This is certified to ISO 13849-1 Performance Level e meaning that

after a safety stop signal the machine

can be worked on without fear of

uncontrolled movement. The STOoption means that a safety contactor

between the drive and the motor is notrequired. Furthermore there is no need

to disconnect the power to the drives sorestart can be instantaneous without

waiting for the drives to boot up. SafeTorque off is a popular option on all

8400 drives that invariably reduces cost

through system simplification.A mix of motors and geared motors

is supplied by Lenze. For intermittentduties such as adjustments, worm

gearboxes are suitable as they are lowcost and the energy losses through

inefficiency are insignificant. The

same applies to the screw jacks whichhave short running times. Where the

duty approaches 100 per cent, forexample on the feeds, high efficiency

geared motors are supplied such as thetype GKR, a bevel helical design with

wear-free efficiency at around 96 percent. Power ranges from 90W for the

blade tracking up too 11kW for the

blade drive.

Positioning drives at heart of carpet recyclerSellers Engineers of Huddersfield manufacture carpet

finishing machinery for markets across the world. Its new

patent-protected Fibrebak machine, aimed at the North

American market, processes waste and used carpet,

recovering the reusable fibres. It uses 17 axes of Lenze

drives and 10 of these have built-in positioning functionality

capable of achieving precise machine settings.

Using Lenze drives

has allowed Sellersto produce a simple

automated system

that reduces costs

through a reduction

in components and

faster build times

Lenze

T: 01234 753227

www.lenze.co.uk

Enter 206

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from www.rittal.com/HB33 or by using the adjacent QR code.


17/44


18/44


I

t could be claimed, with consider-able validity, that as soon as remote

I/O modules became available, theprocess of convergence between

PLCs and DCSs was underway. Withthis in mind, its hard to see the con-

vergence of PLCs and DCSs as a newtrend since its already been with us

for at least a couple of decades.

But, of course, convergence continuesto spread and most modern automation

systems of any size now incorporateintelligent devices such as variable-

speed drives with built-in intelligence,and electronic operator interface panels

in the field. With all of these devices

linked to the central controller via net-work or fieldbus connections, it does

indeed become difficult and even, per-haps, almost meaningless to distin-

guish between the PLC and theremainder of the automation system.

Except, that is, within the controlpanel itself. It is astonishing to realise

that, although conventional hardwiring of field devices has virtually

disappeared in all but the smallest of

installations, traditional hard wiring isstill very much the norm inside most

control panels.The wiring runs are, of course,

much shorter inside the panel thanoutside, but thats no longer a valid

reason to ignore the benefits that bus-

based panel wiring which is perhapsbetter described as lean panel wiring

can provide. This surprising omissionin automation technologies has, how-

ever, finally been addressed, and atleast one bus-based lean panel wiring

system SmartWire-DT from EatonsElectrical Sector is now available.

This allows all of the devices

within a control panel, such as motorstarters, HMI panels and even conven-

tional pushbuttons and indicatorlights, to be connected to the central

controller, whether its a PLC or asmart relay, via a simple daisy-chain

connection. Conventional controlwiring is eliminated.

Its important to note that with thebest lean panel wiring systems, special

components are not needed. Instead,inexpensive interface units are added

to standard components in exactly the

same way that an auxiliary contactblock is added to a contractor.

Benefits of lean panel wiring

Some of the benefits of this technologyare instantly apparent. It cuts panel

wiring time, for instance and, since itvirtually eliminates the possibility of

wiring errors, the time needed to testpanels is also greatly reduced, as is the

risk of problems during commission-

ing. It is also clear that modificationsto the panel can be made much more

easily instead of having to carry out

extensive wiring changes for even thesimplest modification, all thats

needed is to daisy chain the new com-

ponents to those already there.

Possibly the biggest benefit, how-ever, is that the use of lean panelwiring facilitates the flow of informa-

tion between components mounted inthe panel. A suitably equipped motor

starter could, for example, report therunning current of the motor and the

status of the protection device to the

central controller, where this informa-tion could be processed and used to

initiate further actions, such as sendinga message to the HMI panel alerting the

operator to an impending overloadcondition before a trip actually occurs.

Put simply, adopting lean panelwiring can greatly improve the trans-

parency of the automation system.

Since fieldbus- and network-basedfield wiring already supports informa-

tion exchange, the addition of lean

panel wiring means, in essence, that

any information about any aspect of

the automation systems operation andstatus can be made available whereverits needed.

This transparency is one of the keyelements needed for lean automation,

which is one of the reasons that thedescription lean panel wiring for the

new bus-based panel wiring systems is

preferred. The growing uptake of leanautomation is arguably a much more

significant trend than PLC/DCS con-vergence. Lean manufacturing is a

well-known concept that is based onidentifying all sources of waste and

inefficiency in a process and eliminat-ing them. Lean automation extends

this concept to automation systems,

slimming down control panels, simpli-fying wiring, increasing data trans-

parency and enhancing performancewhile reducing overall costs.

With the introduction of lean panelwiring, lean automation can now

cover every facet of manufacturing

processes, from the ERP system rightdown to an emergency stop button,

and from the SAP package down toindividual sensors.

Trend for converganceIn summary, there certainly is a trendfor PLCs and DCSs to converge and

this trend is continuing because con-

vergence has already been shown timeand again to deliver excellent results.

This much is hardly news.What is news, however, is the emer-

gence of lean control panel wiring sys-tems that mark one of the final stages in

the transition from traditional controlsystem technologies to modern net-

work- and bus-based technologies. This

greatly facilitates the implementation of

transparent automation, and that mostdefinitely is a trend worth watching.

Eaton Electric

T: 08700 545 333

www.eaton.com Enter 208

Industrial automation: the road ahead

A recent Frost & Sullivan report highlights the convergence

of programmable controllers (PLCs) and distributed control

systems (DCSs) as an important market trend, but also notes

that this is a technical strategy that has yet to demonstrate it

can yield the expected results. Stuart Greenwood of Eaton

Electrical argues that this trend is, in fact, well advanced and

is already delivering excellent results

Stuart Greenwood

of Eaton Electrical


Put simply, adopting lean panel wiring can

greatly improve the transparency of the

automation system


19/44Enter 15


20/44

Enter 16


21/44

Feature Materials handling & conveying


The first Knapp Fastbox has beeninstalled at the site of third-party

logistics supplier, JCL Logistics,in Werndorf, Austria.

Fastbox is essentially a tall storage

tower for containers, trays or cartons,served by the ultra-rapid lift module

from Knapps OSR Shuttle storagesystem. Any number of these Fastbox

buffers can be located directly adja-cent to the order picking stations and

used to store fast-moving products,

such as lines that are included incurrent promotional campaigns.

The short transport distance fromthe picker and the ultra-fast handling

combine to ensure maximum pickingspeed for these frequently required

goods. Fastbox modules can also act as

a buffer for order containers or as ameans of sequencing containers ready

for robotic palletisation or route-opti-mised vehicle loading. The Fastbox

towers can be up to 12 metres inheight, with the number of levels

variable according to container height.Craig Rollason, head of sales and

marketing for Knapp UK, explains:When combined with the random

storage of the OSR Shuttle system, the

Fastbox solution allows the needs of amuch wider range of customer appli-

cations to be met. In other words,Fastbox makes the OSR Shuttle suit-

able for fast-movers, as well asmedium-movers and slow-movers.

The solution is therefore attractingconsiderable interest in the market.

The solution supplied by Knapp to

JCL Logistics allows both hanging andflat-packed garments to be handled

with ease. JCL Logistics has more than60 sites across 25 countries and pro-

vides distribution services for anumber of clients including a majorSwiss fashion retailer. The company

recently invested over 18 million eurosin its 45,000m2 Werndorf facility.

The distribution centre accommo-dates some two million hanging gar-

ments, 15,000 containers and 10,000pallets. Designed to use automation to

meet both B2B (retailer) and B2C(online consumer) demands in a flexi-

ble way, the site features not onlyKnapps proven OSR Shuttle solution,

but also the overhead conveyor sys-

tems of Knapp subsidiary, DrkoppFrdertechnik.

Shuttle-based storage

At the heart of JCLs order picking opera-

tions lies Knapps shuttle-based storage

system. The OSR Shuttle system fea-tures an independent shuttle on every

level of the storage cube, served by ded-icated lifts at the aisle ends. This system

is said to achieve up to six times the rate

of totes in/out than a traditional auto-mated storage and retrieval system

(ASRS), while having about 20 per centless footprint and using less than 10 per

cent of the energy consumption. Thispower saving is achieved through

energy recuperation from the braking

process, the use of sophisticated soft-

ware to optimise power requirementswithout loss of performance and intelli-gent design to minimise shuttle weight.

Ergonomic picking

JCL placed great emphasis on the

design of the new facilitys worksta-tions to ensure that they would be as

ergonomic as possible. This not onlyshows consideration for the physical

needs of workers but also ensures

maximum productivity. As well asallowing plenty of natural light in the

work area, user-friendly materials

such as warm-to-touch wood andcushioned fascias were incorporatedinto the design of the picking stations.

Knapp UK

T: 01844 202149

www.knapp.com Enter 211

Shuttle storage system keeps

fashion logistics on the railsLeading warehouse automation supplier, Knapp, recently

handed over the first installation of its Fastbox solution,

designed to speed up the picking of fast-moving products

Knapp Fastbox

system installed at

JCL Logistics in

Werndorf, Austria

Video system helps resolve service issues

Warehouse automation supplier, Knapp has launched a video-based t roubleshooting servicefor its customers. Available as an addition to any service contract, Knapps KiSoft Web Eyeallows live, bi-directional video and voice transmission to identify and resolve service issues at

the customers site. Wearing the fully mobile kit, a client employee or a Knapp engineer can

transmit live images and sound from the actual location of any problem to Knapps customer

service experts at the companys headquarters in Graz, Austria. This 24-hour service uses WLAN

technology to connect with the customer network and allows hand-drawn sketches, videos orinstructions to be sent quickly and easily, directly to the operators display on-site.

Ebb Kretschmer, head of customer services for Knapp UK, comments: KiSoft Web Eye is a

really clever piece of kit that results in clearer communication of service problems and, consequently, much faster

resolution of any issues. As well as being used for real-time scenarios, the equipment can also be used for long-term

monitoring. With the record function, users can perform time-delayed analyses that help to pinpoint trouble spots.


22/44


Often seen as a system only

required by large companies,

Komori, a small to mediumsized manufacturer and sup-

plier of printing production equip-ment and machinery, recently

purchased a mobile racking systemfrom SSI Schaefer that has now been

installed within its new premises inLeeds, Yorkshire.

Reduced spend

The reduction in pallet racking floor

space in Komoris case 372m2 (floorfootprint of existing pallet racking

layout) less 195m2 (floor footprint of a

mobile pallet racking layout) equals180m2 floor space saved also meant

that the company was able to reduce its

required spend when looking at newpremises to move its operational facility.

Darren Etherington, parts manager,

Komori, says: We have achieved sig-nificant space and cost savings as a

result of Schaefers mobile pallet rack-

ing system which is good news for thebusiness storage capacity is often

scarce and expensive but this systemhas allowed us to gain high density,

easy to access storage space withouthaving to pay out for larger premises

than necessary.Stewart Hardy, area manager, SSI

Schaefer, says: Mobile racking sys-

tems are the ideal alternative for usingexisting space more cost-effectively

whilst storing manifold or varyinggoods. Our systems consist of rack

units mounted on a carriage; hence therack units are mobile and save the

space which a conventional rackingsystem would require for aisles.

He continues: According to the

requirements of the customer, ourracking systems are designed for vari-ous weights and heavy load mobile

racking systems move on rails, pow-

ered electrically. Racks for light andmedium loads can be operated manu-

ally and without tracks.

Mobile racking advantages

In direct comparison with traditionalcompact warehouse systems, the

advantages of mobile racking systems

include: Space utilisation - for the same

volume of warehoused goods, mobileracking systems require 40 percent less

space than stationary racking systems. Warehouse volume - in the same

amount of space, up to 85% morewarehouse volume can be stored using

mobile racking systems instead of con-

ventional systems. Building planning - with a space

utilisation percentage of 65 85 percent, the use of mobile racking systems

can have a positive effect on the over-all costs of a warehouse building.

SSI Schaefer

T: 01264 386600www.ssi-schaefer.co.uk Enter 212

Mobile system cuts pallet

racking floor space in halfKomori UK has achieved a 50 per cent

reduction in pallet racking floor space thanks

to the installation of a more cost-effective

mobile system designed by SSI Schaefer

Komori UK has

made a 50 per cent

saving in required

pallet racking

space thanks to a

mobile solution

from SSI Schaefer

Semi-automated cart improves battery changing efficiency

Arecent innovation from motive power specialist,

EnerSys is a four-tier battery handling system.

This is said to reduce significantly the footprint of

lift truck battery change and charge operations,

facilitate easy maintenance and maximise opera-

tional safety. Four-high battery banks are a natural

development for larger operations which demand

maximum flexibility and allow extra capacity through

modular expansion as the business grows.

The configuration of the installation allows main-

tenance engineers to work safely and without

disrupting normal warehouse operations while a

proportion of the battery bank is taken offline. All-

electric drives for lift and travel eliminate the use of

hydraulics used in previous models. This simplifies

service and maintenance.

The Pro-Series BBE-QS is a semi-automated

electric powered change cart which runs on con-

cealed rails alongside the rows of chargers. When a

battery change is required, the truck approaches the

changing area, its battery disconnected and a trained

member of staff completes the change. The BBE

extracts the battery from the truck onto its on-board

roller bed and then pushes the battery into place for

charging. Changing a battery is a quick and simple

one-man job with no manual lifting or handling

which can be accomplished in around two minutes.

Enersys Motive Power T: 0161 727 3800

www.enersys.com Enter 213



23/44

R. A. RODRIGUEZ (UK) Ltd.TURNING IDEAS INTO

ENGINEERING SOLUTIONS

Tel: 01462 670044 Fax: 01462 670880Email: [email protected]

Compact Power

Weightand space saving

linear/rotary actuators+ custom drive solutions

www.rarodriguez.co.uk

I D E N T IB A D G E20 Year Anniversary Celebration

20% O F FyourFIRST FEBRUARY O R D E Rwhen you quote discount code:AF20

w w w. i d e n t i b a d g e . c o m T: 020 8645 2555 F: 020 8645 2333

Applicable to new and existing customers. Once only use.

Enter 18 Enter 19

Enter 17


24/44


The new facility at Ricardos

Technical Centre in Shoreham,West Sussex provides a near clean

room production environmentand has the capacity to produce 4,000

engines annually across two dailyshifts. Its core is a 10-station vertical

conveyor mini-line supported by

incoming materials inspection andline-side delivery of components. Each

station is equipped with a sophisticatedMacDonald Humfrey Human Machine

Interface (HMI) providing guidance toeach operator on the precise sequence

of operations required at each stage of

assembly. The tools and assemblyequipment used at each station are

instrumented, and provide datadirectly into a central warranty data-

base for each engine built, providingcomplete finished product traceability.

Each line station is interlocked viaits HMI to ensure that all operations

and checks have been successfullycompleted and recorded before the

line can be indexed and the engine

moved forward to the next station. Inaddition to the main production line,

the facility includes a cylinder headsub-assembly line, dress area and an

end-of-line hot test cell that enablesthe performance of every engine pro-

duced to be fully tested and validated.

The brand new facility was speci-fied, designed, constructed and com-

missioned in just 18 months.

No Fault Forward assembly

This is the first time Ricardo has man-ufactured an engine, so Exmac

Automations previous experience of

No Fault Forward (NFF) assembly ona similar engine build project for

Harley Davidsons V-Rod engine was

invaluable. The V-Rod line was a fullyautomated EMS-driven loop systembut, as there was less space in the new

Shoreham facility, Exmac worked withRicardo to determine the number of

stations required and understand the

various processes they would need for

engine assembly, how engine blockswould be loaded and unloaded from

the line, the type of DC-tooling, andthe level of control required, etc.

The design of the Exmac handlingsystem allows Ricardo to load engine

blocks onto the line and rotate them atany of the 10 assembly stations. The

system is also indexed manually to

allow greater control over the assemblyprocess, provide the flexibility to

accommodate long cycle times andenable Ricardo to achieve batch produc-

tion of single engines or different

engines as required. To meet the specifi-cation within the space available Exmacdesigned a compact 10-station back-to-

back manual line that takes up very

little floor space in the new building.Engine blocks are fixed to light-

weight trolleys using a verticallymounted slew ring and quick release

plate, which mates with a bracketlocated on the engine bell housing.

Whilst the engine block is locked inplace, it can also be rotated through

360 degrees to allow complete access

for operators. An engine starts its buildsequence at station one and when all

assembly functions at that station arecompleted the control system allows a

stop to retract, enabling the operator topush the trolley to a holding position

until station two is clear. The system

then allows the trolley to be pushed to

station two where the same stop and

lock procedure holds it in place forthat stations assembly functions to be

carried out and so on to station 10.Trolleys run in a steel track to facili-

tate manual handling by operators; anda latched turn-post at each end of the

line (providing a swing-gate effect)allows trolleys be re-directed to the

opposite side of the line after assembly

operations at station five are completed.When a trolley reaches station 10 the

engine block has been transformed intoa fully assembled, complete engine.

Bespoke HMI

Exmac-designed mechanical lockingsystems accurately locate and secure

trolleys in position at each station,

whilst also ensuring that they cannotbe released unti l the MacDonald

Humfrey HMI system confirms that

operators have completed all requiredtasks at each station, and assembly cancontinue on a no-faults-forward basis.

The bespoke HMI system developedfor the Ricardo engine line takes oper-

ators step-by-step through the process

of building an engine, providingdetailed on-screen information and

visual aids at each of the 10 stations,and even including instructions for

every bolt to be tightened and its par-ticular torque and angle.

In order to optimise the two-hourengine build sequence, Ricardo also

uses the HMI system to monitor thelines indexing against real-time opera-tor performance.

Exmac Automation T: 01905 721500

www.exmacautomation.co.uk Enter 214

Vertical conveyor keeps engine

production line running smoothlyMacDonald Humfrey Automation (MHA) and sister company

Exmac Automation have joined forces to help automotive

engineering specialist Ricardo create a state-of-the-art 600

square metre assembly facility to build a new high

performance engine for the new McLaren MP4-12C road car

A Siemens PLC

drives the

mechanical

operation of the

line. It is backed up

by a server-based

PC system that

drives the build

instructions


Whilst this is a

manual system and

trolleys are pushed

to each of the 10

stations, they are

locked and

released by key

switches at each

station; enablingRicardo production

engineers to verify

the status of every

aspect of the build


25/44



Everything in the wide belt con-veyor, from the smallest compo-

nent to horizontal plain bendsand fully functioning conveyor

modules, is standardised for easierengineering, simple maintenance and

trouble-free operation. The modularity

in design is said to make assembly andmodifications effortless and the

system can be adapted to many differ-ent requirements.

This is what our customers demand a standardised, modular plastic belt

conveyor that is quiet, sturdy, safe andwith high reliability, says Gran

Abbestam, product manager at FlexLink

for aluminium and pallet conveyors.FlexLinks new conveyor system

meets the highest standards inreliability and safety we have looked

into every detail with regards to

operator safety and workingenvironment. adds Abbestam. Wehave worked hard to eliminate

potential pinch points and obtain very

low noise level. The flat, smooth beltsurface minimises the risk of scratches

and the sturdy guide rails preventitems from falling off, allowing for the

safe handling of sensitive products.The conveyor is available as

components, modules or a complete

system. The three widths, 322, 424and 626mm make it suited for

handling cartons, bundles, bags andother large individual items that

require the stable support of a widechain. Equally important, it allows

large flows of smaller products.The vertical bends and length up to

15m allows efficient and simple

layouts in three dimensions withoutadditional elevators in constant flow.

With a maximum conveyor speed of40m/min, the capacity is setting new

standards for modular belt conveyors.We have reached 100 per cent

modularity and new capacity levelswith regards to the conveyor speed.

Last but not least, the design solution

opens the door for futuredevelopments, concludes Abbestam.

FlexLink Systems UK

T: 01908 327 200

www.flexlink.com Enter 215

Modular wide belt conveyor

improves flow efficiencyA modular plastic belt conveyor system from FlexLinkis said to be an efficient solution for thetransportation of large individual items and flows of smaller products

FlexLink is a world leading supplier of production logistic solutions and have a long

history serving companies of all sizes, in the UK and around the world.

Our fully compatible range of modular conveyors are flexible enough to be re-configured,

expanded and rebuilt with minimum production stoppage for total cost effectiveness.

From stainless steel to aluminium and pharmaceutical to FMCG we have experience

in improving production efficiencies in any environment, without compromising quality

or knowledge.

Contact us, FlexLink Systems Ltd, today at [email protected] or call on 01908 327200.

Endless possibilities

www.flexlink.com

Enter 20


26/44

FeatureTracking & traceability

Currently all butter manufacturersin Ireland are required to assign

every pallet of butter produced

with a unique label combininginformation including the manufac-

turer, weight, lot number, palletnumber and best before date.

Zetes is internationally recognised asa leading expert in the field of print and

apply and was a natural choice of sup-plier. The company currently works

with manufacturers from all sectors of

industry to provide effective printingand labelling solutions, including

advanced serialised labelling solutionsfor the pharmaceutical sector to combat

counterfeiting. It was as a result of thisexpertise that Glanbia decided Zetes

had the right skills to implement aunique labelling solution for its butter

division.We were concerned that this new

customer requirement would have an

impact on our production costs and so

looked for a solution that requiredminimal levels of human intervention.Our IT department initially recom-

mended we work with Zetes as local

specialists in automated identificationand data capture, says Gerry Warren,

butter store manager at Glanbia.Glanbias application has been

installed at the end of each butter pro-duction line and works in conjunction

with their existing pallet wrappingsystem. Pre-loaded pallets of butter are

placed onto a wrapping turntable

ready for shrink-wrapping and a trace-

ability label is affixed after this stageonce the correct pallet is automaticallyidentified. The print and apply solu-

tion developed by Zetes uses wirelesstechnology and MCLNet as its commu-

nication and dispatching programme.This directs the Motorola wireless

handheld scanner, Datamax A Class

printer hardware and a Zetes dedi-cated print and apply applicator unit.

Using the MCL programming lan-guage, Zetes has effectively turned an

ordinary industrial printer into anintelligent device able to capture infor-

mation from a variety of different data-

bases and combine the results to createa unique number for each pallet, with-

out the need for additional PCs. The

unique pallet number is produced by

combining both the lot and best beforedate information.

After loading, the pallets existing

barcode label is scanned and a newlabel combining any additional pro-

duction and traceability informationrequired is generated automatically. To

complete this stage, the printer effec-tively recognises individual pallets

before they are shrink-wrapped on theproduction line and is able to generate

the correct label for application after

wrapping.By integrating the label printer with

Glanbias product database, detailsrelating to lot number and expiry date

can be captured and combined withmanufacturer information in a single

label. The label is then transferred tothe applicator pad ready to be affixed to

the pallet following shrink-wrapping.

Glanbia estimated that without theprint and apply solution from Zetes,

they would require extra staff to manu-ally produce labels and apply them to

the finished pallets.The solution is completely auto-

mated and our only involvement is toreplace label rolls when they run out

says Warren. It has eliminated theneed for additional staff to manuallyproduce labels and there has been no

impact to the volumes of finishedgoods we can dispatch each day. We

are delighted with Zetes solution, itdoes exactly what we require and

always runs smoothly.Robert van Vliet, managing director

of Zetes Ireland says, This is a mis-

sion critical solution for Glanbia. Theadvantage of Zetes approach using

MCL to create intelligent print andapply devices, is that the solution is as

robust and reliable as possible to dealwith Glanbias busy and demanding

customer requirements.

Zetes T: 0845 520 0180

www.zetes.co.uk Enter 216

Labelling system provides food

producer with full traceability

Glanbia estimated

that without the

print and apply

solution from Zetes,

it would require

extra staff tomanually produce

labels and apply

them to the finished

pallets

Wireless chip tracks beverage dispensing

IDCs ZigBee wireless mesh technology is playing a major role in tracking - in real time - thedispensing of beverages in the hospitality industry. The ZigBee low power wireless technologymakes it possible to track when, where, what and how much beer or spirit is dispensed. The

resulting data is then routed to a back office PC, or direct to the web via IDCs ZB104 Ethernet

Gateway, for analysis. IDCs ZigBee chip is a key element in the Bonzi wireless beverage

metering system, which provides a control system for the hospitality industry. Bonzi comprises

a family of wireless products that delivers control solutions for every aspect of beverage

dispensing that integrate with most major point-of-sale (POS) systems. IDCs ZigBee chipintegrates snugly into the Bonzi pouring head; the chip in no way impinging on the pouring

process: it transmits each pour wirelessly for comparison with registered sales, improving stock

and cost control and highlighting any discrepancies. Any number of the ZigBee-equipped pouring heads can be used at any

one time, each providing specific and accurate pour information to a secure onsite PC,via a IDC ZB104 Ethernet Gateway.

IDC T: 01332 604030 www.zig-bee.co.uk Enter 217


Glanbia, one of Irelands largest food manufacturers, has implemented a

print and apply solution from Zetes. The solution developed enables

Glanbia, whose famous butter brands include Kerrygold and Avonmore, to

comply with a new customer requirement for full product traceability and

the highest possible quality standards


27/44

17-19 APRIL 2012 NEC BIRMINGHAMHalls 3 & 3A

organised in association with

The event is co-located with Plant and Asset Management,Air-Tech, IFPEX (the International Fluid Power Exhibition),

MACH, Electrex, National Electronics Weekand

PE&E (Independent Power Energy & Electricity). Together, the

eight shows provide an integrated networking and exhibition

platform for engineering decision makers.

Running alongside the exhibition will be a comprehensive

FREE seminar programme.

You will need to pre-register to ensure places on the seminars

of your choice.

Pre-register as a visitor, and book your places on the freeseminars, by going to

www.drives-expo.comFor information about exhibiting contact:

Doug Devlin t: 01922 644766

m: 07803 624471 e: [email protected]

Simon Langston t: 01353 863383

m: 079000 95826 e: [email protected]

The Perfect Fit

The following c

automation feb 2012

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