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Independent finance company, Henry Howard Finance, are reporting a sharp increase in companies
updating their commercial vehicles in the first three months of the London Ultra Low Emission Zone (ULEZ).
Since April 2019, older vehicles that are not Euro 6 compliant face additional or higher charges when they enter London’s latest congestion zone. Birmingham, Leeds, Glasgow and Manchester have also recently announced clean air zone charges.
Unlike current congestion charges, however, these additional charges will operate 24 hours a day, every day.
Marie Dunkley, Head of Hard Asset Finance at Henry Howard Finance, explained: “Even within the first three months of ULEX, these charges are having a massive effect on the bottom line for many couriers and delivery drivers.
“Small businesses with fleets of older vehicles or who regularly used to drive into these cities in the night or early hours to avoid the congestion charge are now finding themselves subject to this extra charge.”
The Euro 6 standard sets out the acceptable limits for exhaust emissions as defined by the European Union, with all new cars sold since September 2015 required to comply.
Drivers whose vehicles are already compliant with Euro 6 therefore need not worry as the exhaust emissions meetULEZ standards – while those with older vans which don’t comply are facing hefty extra charges if they drive into central London regularly.Vehicles which aren’t Euro 6 compliant are being
charged an extra £12.50 a day on top of the congestion charge for a van of £11.50. The ULEZ charge replaced the older T-charge which affected older vehicles that didn’t comply with emission standards.
Since the 8th April, if a commercial van that isn’t ULEZ compliant travelled into the congestion zone three times a week for year, this means they would have to pay £3,744. As the ULEZ charges are in force 24 hours a day, any driver travelling into London before midnight and still working in the congestion zone area after 12am would also have to pay the ULEZ charge twice.
Most commercial vans manufactured post 2015 will now be Euro 6 compliant but, as it is, older vans could well fall foul of these new charges. Those failing to comply with the additional charge or who miss paying the extra charge could also find themselves having to pay a £160 fine as a result.
For more information on Henry Howard Finance please contact 01633 415222 or visit www.henryhowardfinance.co.uk
Tel: 0121 550 2086 – www.industrialprocessnews.co.uk – August – Issue 687
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Inside this issue:
Contents:
DD ScientificSee them on page ........18
British EncoderSee them on page ........24
PalamaticSee them on page ..........7
Drives, Controls & Automation News ............4
Surface Finishing & Grinding News .................8
Machining News ...........12
Test, Measurement & Monitoring News ...........18
Water, Energy & Environment News .........19
Products of the Month .............................24
The trousers feature a smooth, inner-crotch seam panel and patches of highly stretchable and ventilated material at the
backs of the knees and seat areas to help keep the wearer cool and provide increased flexibility whilst bending or kneeling. There are two spacious slanted pockets at the front, two back pockets and a mobile phone pocket with a flap on the right thigh; there’s a standard one on the left which has an extra inner, zipped compartment.
Other useful features include a ruler pocket with extra sections for tools, tool straps and Velcro-fastened, knee-reinforced pockets with two knee pad positions for height adjustment. Reflector strips are built in behind the knees for greater visibility and the trousers have an extra deep hem so the length can be increased if required.
The Engel ‘X-treme’ Slim-Fit Stretchable Work Trousers are made from 65% polyester and 35% cotton and can be supplied with optional clip-on hanging tool pockets. Depending on model, they come in a variety of colour combinations and in all sizes. Item numbers to look out for are: 0360-186, 0361-186, 0362-740 and 0363-740. These and a new ‘4-way stretch’ version of the trousers, together with other Engel Workwear clothing and accessories will be exhibited in conjunction with specialist distributor Workwear Trade Centre (WTC) on stand B50 at the Harrogate Flooring Show, 15-17th September 2019.
M +44 (0)7759 520034 [email protected] www.engel.eu/en
Work trousers designed for flexible comfort
Companies affected by the London Ultra Low Emission Zone
is sponsored by DD Scientific – see them on page 182
Toby Cook’s dedication as a health and safety advisor for Lanes Group plc has
earned him the chance to be named health and safety Rising Star of the year. The 20-year-old has been shortlisted for the award which recognises the talent, hard work and contribution made by young health and safety professionals across the UK.
Toby was nominated for the Rising Star Award in the utility industry category by Health and Safety Manager Kris Taylor. Both work for the Lanes operation delivering the wastewater network maintenance service for Thames Water, the UK’s largest water company.
Lanes is responsible for surveying, cleaning and repairing drains and sewers, as well as wet well cleaning and wastewater tankering, on behalf of 15 million customers across London and the Thames Valley.
Kris said: “Toby came to us with no experience of the water utility industry or health and safety management, but he has
excelled from day one. Despite being the youngest, Toby has shone since he joined us, using his own initiative to introduce ideas that we’ve adopted across our whole operation.”
Toby joined Lanes in April 2018 as a health and safety trainee. While studying for a NEBOSH General Certificate in health and safety, he used his study leave to support colleagues preparing for audits to achieve ISO 45001:2018 accreditation.
T 0800 526 488www.lanesfordrains.co.uk
Since early January 2019,
TC Security Services, part of TC Facilities Management (TCFM), have been providing guarding and mobile patrol services to Avison Young (formerly GVA). The portfolio, covers multiple and diverse locations across London and the South East.
TC Security Services welcomed 20 new colleagues to the business from a number of incumbent suppliers.The contract commenced on 2nd January and client feedback about the mobilisation, led by Patrick O’Sullivan, Operations Manager, is very positive.
Alan Prince, Director, National Strategic FM for Avison Young commented, “We ran a full-blown tender to make sure we appointed the right security specialist to manage this diverse portfolio of properties. Against a wide range of criteria, TC Security Services came out in front. As a new supplier, there was an added element of risk, but nearly four months after go-live, we’re delighted with the decision to appoint them”
In response to the award, Satia Rai, Operations Director of TC Security Services said, “Having been awarded the contract for guarding and mobile patrol services with Avison Young, we committed the resource necessary to ensure the mobilisation was seamless. We’ve implemented best in class technology that will provide TC Security Services & Avison Young with data & analysis to shape better decision making.”
T +44 (0)1737 [email protected]
Editor Recommends
Toby shines in health and safety Rising Star Awards
TC Security Services safeguarding Avison Young
Introducing a new product or technology into a high-integrity market such as oil and
gas can prove challenging. That is why at the University of Strathclyde’s Advanced Forming Research Centre (AFRC), we provide support to firms of all sizes to navigate this complex landscape.
Tapping into our powerful networks, we create collaborations right across the supply chain. We also help de-risk manufacturing innovation by providing practical advice, access to our cutting-edge equipment and support with finding funding.
Working with blue chip oil and gas firms and OEMs, we support growing companies with big ambitions that want to establish and mature technology ready for market commercialisation. Our experienced design engineers will support your product development requirements, offering guidance on qualifying your technology for critical applications and creating virtual and physical concept models.
Working alongside world-class metallurgists, material scientists, process modellers and
manufacturing engineers, our team will verify your product design and validate your components. We can also help if you are looking to introduce Industry 4.0 into your existing operations. We will work with you to identify opportunities and assess the suitability of technologies that will bring about real business benefits.
A centre of excellence in innovative manufacturing technologies, we are based near Glasgow airport in Scotland. Contact us today to develop your products of tomorrow.
ContactT 0141 534 [email protected]
Address challenges & seize new opportunities
is sponsored by British Encoder – see them on page 24 3
Industrial Process News is proud to announce that OEM Automatic Ltd has been selected as our Industrial Automation Company of the Month,
for its dedication to providing a comprehensive range of high quality industrial automation components, fortifying its status as a leading supplier offering unparalleled customer service.
OEM Automatic Ltd was established in 1989 as the UK subsidiary of its Swedish parent company, OEM International. Based in Whetstone, just south of Leicester, OEM Automatic supplies an extensive range of over 8,000 products, which are divided into five automation business areas: panel; pressure and flow; sensors and safety; machine vision and identification; and motors. Each of these areas has its own sales, product and customer support staff, meaning the company can provide complete solutions which are backed by specific industry expertise.
“We provide customers with access to a wide range of high quality products from a single supplier,” explained Richard Armstrong, Managing Director. “We also provide technical knowledge both in house and with our travelling sales engineers.”
Since its establishment, OEM Automatic has seen exponential growth, and is celebrating its 30th anniversary this year. “I am very proud of our
achievements over the last three decades, which are a testament to the commitment and expertise of our staff, both past and present,” said Richard.
“We have cemented our success with loyalty and partnership agreements with many of the industry’s leading manufacturers. These have enabled OEM to build strong, long-term relationships and offer a comprehensive range of products. This has culminated in the company’s unique offer: high quality products sold by technically experienced product specialists, backed by fast and accurate service from UK stock.”
The company’s strong organic growth since its inception resulted in a major turnover milestone of £5m in 2007 and £10m in 2014. Then, in 2013, OEM
Automatic completed a major redevelopment of its 1,000 m2 warehouse. A significant element of this was the introduction of new technology which transformed the storage capability of the facility. The investment in six vertical automated storage systems, which replaced the existing warehouse racking, has facilitated storage of over 8,000 lines. This high tech storage and retrieval solution ensures next day delivery of products to OEM Automatic’s customers if their order is received before 1600 hrs.
New workshops have also been built inside the warehouse to provide a professional environment for the company’s added value section. This has proved to be a big growth area for OEM Automatic, building sub-assemblies and kits of parts to help customers streamline their purchases.
Building on the company’s 30 years of triumphs, OEM Automatic went through a major refurbishment of their office during 2018/19 and established a new product area in Machine Vision. As they company looks to the future, it will continue to invest in its people, product range development and internal process efficiencies.“To maintain our first class customer service, in the near future we plan to invest in further vertical storage machines which will increase our stockholding capacity. We are committed to carrying more stock in our UK Leicester warehouse in order to secure swift, on time deliveries to satisfy our customers.
“We will also be actively investigating the possibility of further acquisitions to drive growth and continue to broaden our product ranges. As we celebrate our 30th year, our goal is to make working with OEM Automatic easy and enjoyable, not only for our manufacturing partners, but also for our customers.”
If you would like to find out more information on OEM Automatic’s full range of products and services, head to the website or get in touch using the contact details below.
ContactT 0116 284 9900www.oem.co.uk
Industrial Automation Company of the Month
Engineering News
OEM Automatic: 30 years of excellence
is sponsored by DD Scientific – see them on page 184
Digitization has fundamentally changed mechanical engineering.
Modern production systems are no longer based purely on mechatronic solutions; instead they employ a combination of electronic components and state-of-the-art IT. However, in the past, the word “digitization” was generally abstract, rather than tangible. PIA Automation has changed that with a practice-oriented symposium featuring prominent speakers on June 6 in Bad Neustadt (Germany).
As part of the official opening of its new Headquarters in Bad Neustadt, PIA Automation demonstrated digital automation in practice, using the concrete examples of PIA machines and solutions, and with the support
of its expert partners: Festo, Siemens, Balluff, Beckhoff, montratec and Viewpointsystem. Along with a professional exhibition and factory tour through the company’s modern premises, more than 200 visitors were treated to a series of exciting technical presentations.
PIA Automation Holding is an international corporate group that offers technically complex, commercially mature automation solutions. Its range of services covers everything from manual assembly workstations to fully-automated production systems with integrated testing technology and data recording. PIA has mastered the interplay of mechanics, electronics, programming,
measurement technology, production systems, documentation, image processing and robotics, along with research and development. It has responded to the trends toward digitization and networking with its own Industry 4.0 solution. ContactT +49 9771 6352 4844 [email protected]
Handling, Storage & Logistics News
Drives, Controls & Automation News
Challenging convention and pinpointing the real barriers to change is continuing to
underpin the success of change management specialist Libra Europe Consulting. As it approaches its 20th anniversary, the progressive consultancy has doubled in size over the past year. According to Chief Executive, Tim Kershaw, the consultancy’s success underlines the importance of fresh thinking and pragmatism as the processing industry faces up to the relentless squeeze on margins, fierce global competition and the constraints of legacy structures and processes.
“Our collaborative and hands-on approach to help clients fulfil their operational and performance objectives clearly resonates with businesses struggling to adapt and identify or to address those factors that are compromising growth, efficiencies and competitiveness.
“There needs to be true engagement and a real commitment to embrace new ways of doing things, new responsibilities and new
mindsets. Showing how to achieve that level of connection and supportive attitude has helped our team of consultants to transform productivity and performance for clients throughout the processing sector. We’re determined to deliver change management solutions that reflect fully the unique parameters, dynamics and market influences of our clients to help them look to the future with confidence rather than trepidation.”
For more information, please contact:
T 0207 290 [email protected]
Dramatic growth attributed to fresh thinking and pragmatism
For a chain to have a long service life without wear-related loss of performance, it needs to be serviced
and lubricated regularly. Maintenance and lubrication intervals should be strictly adhered to: about two thirds of all chain failures can be prevented by suitable relubrication, so selecting the right (re)lubricant is the most important factor in guaranteeing a long service for the chain, since the individual links of a chain act as bearings while the constantly oscillating chain is in operation.
Inadequate lubrication and additional contamination can cause a reduction of chain performance to as little as 20% of its full potential, thereby reducing service life more than any other influencing factors. iwis antriebssysteme produces precision roller and conveyor chains for industrial applications in the field of general machine engineering, plant engineering, the packaging, printing and food industries and conveyor technology. iwis antriebssysteme and its engineers are at your service with help and advice on chain maintenance and lubrication.
iwis also offers solutions for applications that do not permit relubrication. The bushes of maintenance-free JWIS MEGAlife chains are made from sintered material, so the lubricant is retained in the chain joint long-term. Chains stay dry on the outside, but the joint is always well lubricated – and JWIS b.dry stainless steel chains require no lubricant whatsoever.
T 0121 521 [email protected] www.iwisuk.com
For longer chain service life: relubricate – and prevent wear
The hr342 with CoaXPress interface is SVS-Vistek’s latest industrial camera. Its features predestine it for many
demanding applications in quality control. SVS-Vistek’s cutting-edge technology enables the highest speed with the best image quality.
Excellent sensorThe Sony IMX342 sensor with 31 megapixels captivates with an image quality far above standard in this resolution. Fixed-Pattern-Noise and Signal-to-Noise Ratio are at the highest level. The result is excellent flatness and a very convincing dynamic range of more than 70 dB. The basis of this high performance level is the outstanding pixel architecture of the very light-sensitive Sony Pregius 2 sensor. For the pixel size of 3.45 µm, there is a good selection of high-quality, but
inexpensive lenses on the market.
Fastest IMX342 camera on the marketWith a frame rate of 35.4 fps, the hr342 from SVS-Vistek is currently the fastest camera on the market with the high-quality Sony IMX342 sensor. This is made possible by the sensor’s new Sony SLS-EC protocol and the CoaXPress interface. A clever implementation of the interface and a housing design with outstanding heat dissipation ensures a low operating temperature, which in turn enables low image noise.
CoaXPress in the High EndThe CoaXPress interface is not only fast, it also offers long, thin data lines and a power supply for the camera via the
data cables. Thus, CoaXPress offers many advantages. But if you can live with a 10% lower frame rate and need the flexibility of GigE, the hr342 is also available with a 10 GigE interface. This model combines the flexibility of GigE with nearly the speed of CoaXPress. The CoaXPress variant is already available as a sample for customers; the 10 GigE version will be available soon. With both a CoaXPress and 10 GigE interface, the hr342 always offers cutting-edge technology in camera construction.
ContactT +49 8152 9985-0 F +49 8152 [email protected] www.svs-vistek.com
Fast with CoaXPress and High Resolution
Meachers Global Logistics, one of the UK’s leading
independent providers of transport and logistics services has announced it has purchased yet another 12 tractor units at a price tag of over £750k, 25 trailer units at a price tag of nearly £500k and will take delivery of five more tractor units later this year to total nearly £2m in investment.
The investment by the Southampton and Derby based business, will provide the Company with significantly increased capacity to supply its current growing operation across both locations.
Meachers has taken delivery of both Volvo DHs’ and new DAF’s, which significantly strengthens its fleet. The purchase follows Meachers Global Logistics recently securing a number of high profile
contracts as well as extending existing contracts. The vehicles will be predominantly based out of the Southampton facility which has grown in staff members yet again at the start of the year.
Jamie Terris, Meachers Global Logistics, Fleet Director said: “We have experienced a strong period of growth already in 2019 and this is reflected in our fleet replenishment programme. The move reflects a desire to strengthen and grow our fleet and this strategy is expected to produce significant operational benefits to the business.”
Meachers Global Logistics is one of the UK’s leading independent providers of logistics services. For 60 years, the company has built an enviable reputation by providing customers with complete solutions to their
Freight Forwarding, Supply Chain Management, Warehousing, Distribution, Logistics and Contract Management requirements.
T 023 8073 [email protected]
Meachers Global invests nearly £2m in additional vehicles
Digitisation in automation: great response at PIA event
is sponsored by British Encoder – see them on page 24 5
Established in 1989 by Professor Peter Andresen, LaVision is a leading supplier of integrated imaging systems. The
company headquarters is based in Goettingen, Germany, however as a result of substantial growth it has developed subsidiaries in the UK and the US as well as a worldwide distribution network. The expansion that the company has seen over the last 30 years is demonstrative of the intuitiveness with which it develops its products. LaVision maintains partnerships with some of the most globally renowned academic and industrial companies.
LaVision aims to provide reliable photonic measurement solutions to both the scientific and the industrial markets that exceed the realms of what can be defined as simply adequate. With LaVision’s state of the art technology and constant strive towards bettering end user experiences through research and development, the company has produced a broad and effective range of imaging systems. The company is heavily involved in ongoing development processes; innovating (laser) imaging systems, smart optical sensors, measurement technologies and software tools.
One (of several) notable mentions from LaVision’s product range is the StrainMaster. StrainMaster
systems offer turnkey imaging solutions for a variety of material testing applications. All systems include high resolution scientific grade cameras, illumination units, synchronisation electronics, mounting mechanics and software for recording and Digital Image Correlation (DIC) computation. Unlike other systems of a similar nature, StrainMaster can observe the deformation of materials under loading without contacting the material’s surface. StrainMaster provides a map of data over the whole surface of the sample providing accurate and detailed results can be achieved.
LaVision also produces a ground breaking particle, droplet and bubble imaging system.
The ParticleMaster imaging systems simultaneously measure size, shape and velocity of individual particles, droplets or bubbles when dispersed in gas, liquid or multiphase flows. The systems use eye-safe LEDs or ultra-short laser pulses as their measurement methods which allow the user to directly see the results of the process being observed. The ParticleMaster inspex system is built to be reliable and provide reproducible results and is used predominantly on industrial applications such as fuel sprays, paint sprays, particle deposition, and pharmaceuticals.
LaVision offers demonstrations of all of its products to new and existing customers. It’s this kind of attentiveness towards ensuring that
its customers have a full understanding of its products that puts LaVision above the heads of its competitors. The company has recently seen its products become increasingly popular among industrial practices and as a result has gained ISO9001 certification. LaVision plans on expanding its distribution network broadening its range of partnerships. The company will be exhibiting at the EMex Show at the BSSM Conference in Belfast this year, showcasing its vast product line and developing relationships with new companies. The company also plans on attending the K Fair in Dusseldorf, Germany.
For more information on LaVision see the details listed below.
T 0870 997 6532www.lavision.com
Company of the Month
Gas Transportation Company of the Month
Industrial Process News is pleased to announce as this issue’s Gas Transportation Company of the Month,
Hexagon Composites. Hexagon Composites, a world leading provider of clean energy solutions, was established in Norway in the early 1990s by visionary Knut Flakk, and has been providing the Gas Industry with innovative gas storage and transportation solutions for nearly 30 years. The company has become known as a leading figure in developing and supplying more efficient products than those already on the market. The company is split into four business segments: Agility Fuel Solutions, Hexagon Purus, Hexagon Ragasco and Hexagon Mobile Pipeline®. Each segment brings its own team and ideas to the table, subsequently the Hexagon Group is capable of catering to a global market.
Hexagon offers safe and innovative solutions that adapt to meet a wide range of mobility
and storage applications for compressed gases, in particular compressed natural gas (CNG), renewable natural gas (RNG), hydrogen and propane (LPG). With its headquarters is Aalesund, Norway and further facilities in Germany, Norway, USA, Canada and Russia, the company’s solutions are evidently renowned internationally. Hexagon is the world’s leading manufacturer of fibre composite lightweight components and systems, with over 500,000 high-pressure cylinders installed and more than 1,600 operating Hexagon Mobile Pipeline® units spanning more the 40 countries.
A Mobile Pipeline® works in a relatively simple cycle: an empty container travels to its mother station where it is filled with natural gas. The full container then travels to an offloading station and is then offloaded at the client’s decompression station.
Being 70% lighter than the equivalent steel ones, Hexagon tanks allow to transport
three times as much of gas. The carbon fiber composition makes the product stress and corrosion free; hence inspection is also less costly. The production units for Mobile Pipeline® are in Kassel, Germany and in Lincoln, Nebraska. While the first is specialized in building ADR (EU approved) and ISO 11349 containers (X-STORE®) with vertically arranged Type 4 cylinders, the second is manufacturer of long (40ft and 53ft) Type 4 tubes and related modules/trailers with American Bureau of Shipping (ABS) and American DOT approval (TITAN®).
Hexagon´s TITAN® solution offers the largest Type 4 cylinders available on the market, available from 30 ft up to 53 ft. The cylinders can be offered in a trailer solution for ease of transportation. Along with the TITAN®, Hexagon Mobile Pipeline® offers the X-STORE® solution. Unlike the TITAN®’s horizontally assembled tanks, the X-STORE®’s tanks are assembled vertically, and are available from 10 ft up to
53 ft. Together, both strong brands have been distributed to North America, Latin America, Europe and Russia and Asia.
The company’s future plans are to expand even further than it already has. It aims to penetrate the Asian, African and Middle Eastern markets as well as stepping further into the hydrogen market. As well as broadening the markets it reaches, the company plans on broadening its product range to further develop as a systems supplier and keeping its focus on gas transportation.
For more information see the details listed below.
Efficient gas transportation with Hexagon Mobile Pipeline®
Imaging made clear with LaVision
is sponsored by DD Scientific – see them on page 186
Established in 1976 – packing over 40 years of
experience and expertise in their field – Cap Coder are based in Oxfordshire, and has been a family run business ever since its inception. Founded on trust and integrity, it truly is a company that cares, driven by a strong ethical code to do right by the customer. This is one of the many benefits of using Cap Coder, you’re guaranteed to have your needs put first by a team of technical experts eager to create a bespoke solution for the customer.
Cap Coder specialise in the design and manufacture of bespoke and standard machines for capping, coding, and filling applications. Cap Coder is well established in its field, serving a wide range of industry sectors, including: toiletries, cosmetics, pharmaceuticals, complimentary medicines, chemical, food and beverages. Within these sectors there is a wide range of products Cap Coder’s machines can be designed for use with, from nail varnish to nasal spray, from tomato sauce to paint – Cap Coder have it covered.
All products can be handled by Cap Coder’s machines, including all shapes and sizes of bottles, jerry cans and other bottles, tamper evident caps, pump action spray caps and trigger spray caps.
Aside from the versatility and adaptability of Cap Coder’s machines to suit customer’s specific needs, Cap Coder also offer customers unparalleled customer service. Offering a proactive and supportive
service, once the client has bought a machine, the customer’s experience does not end there.
Offering an excellent technical support service, experts from Cap Coder will be at hand to service machines and provide and change spare parts.
The team at Cap Coder pride themselves on getting to know the customer, gaining a deep understanding of their needs before undertaking any project. Delivering first class and flexible results, Cap Coder has its finger on the pulse when it comes to the latest technological developments in the industry. Seeking to continually adapt and respond to changes in the engineering and packaging industries, Cap Coder is constantly developing new products.
Its machines are ideal for a wide range of industries, and are all accredited to 9001-2008 build standard and come supplied with a
Certificate of Conformity/Incorporation. The array of machines is impressive, meaning there is no company too big or too small for Cap Coder, and no project too specific. From screw cap tightening (to a desired torque), press on capping, plug insertion (including brushes, roll-on deodorant balls and dispensing nozzles), liquid filling, agitator ball insertion, conveyor, and ATEX zone 1 and 2 compliance; Cap Coder have it covered.
Moreover, all of the machines are made in England and designed in-house, with this ensuring the team have complete control over the entire manufacturing process. The end result? Capping, coding and filling machines which are second-to-none in quality.
ContactT +44 (0)1865 [email protected]
Print & Packaging News
Suppliers of food processing machinery, weighing scales, vacuum pouches, thermal labels and food packaging
Introducing the Ishida WM Nano
Automatic Wrapper •The most compact,
affordable table top semi-automatic wrapper in the world
•Weighs, wraps and labels up to 15 packs per minute
•Scale, software and set up included
• Innovative packaging technology award 2012
•Use Foil, Polystyrene, PSP and PP Trays
Shop On-Line: www.pfmplus.co.uk
Call: 0330 058 4650 - Email: [email protected]
Experts in labels, labelling and label printing, Datamark supply and manufacture a varied range of labelling
solutions to a wide range of customers spread across various industries. Enlisting in the services of Datamark, customers can enjoy numerous benefits, for example gaining from the years of knowledge and experience amassed by Datamark.
Constantly innovating and seeking to add new products to their already extensive range, Datamark truly are the one stop shop for all of your labelling needs. Moving from strength to strength since its inception in 1995, Datamark offers customers competitive pricing, unparalleled customer service, reliable deliveries, rapid quote turnaround, and an extensive product range.
Datamark’s product range includes: Plain and Colourwashed Labels, Flexographic Printed Labels, A4 Sheeted Labels, Fanfolded Labels & Tags, Own Brand Thermal Transfer Ribbons, Thermal Transfer Ribbons, Thermal Transfer Bureau Print Solutions, GoDex and other brand Thermal Transfer Printers, Thermal Transfer and Direct Thermal Print Solutions, and TT Printers Service and Maintenance. Driving the company forward, aside from their extensive product range, is their continued emphasis on providing the best customer service possible. It is no wonder that Datamark supply such a wide variety of industries, including; food, distribution and logistics, storage and contract packers, electronics, homecare, automotive and industrial.
One stop shop for all of your labelling needs
Signs and labels in multiple colours in one passRebo systems has introduced its new, multi-colour Kodiak in-house
safety sign system and will be featuring it at Safety & Health Expo 2019.
The Kodiak has two print heads for multi-colour printing and can print from 10 to 20cm wide, giving fast, single pass printing for everyday signage, labels, GHS chemical labels and more.
The stand-alone system has an integrated touch screen and in-built applications for fast sign and label production. In addition the Kodiak can be connected to a PC if required, having its own print driver available.
One system can create all your signs and labels in 10-year-durable outside vinyl, complete with graphics, custom texts and with more than
one colour. Sign templates are in-built for ease of design and a full GHS database is integrated into the system, complete with layouts, to create fast, effective warning labels.
Having a range of material widths means no wastage and greater versatility, including pre-printed materials that will boost the effectiveness and usefulness of the system. Changing ribbons and supplies is fast and effortless, and creating and printing are said to be virtually seamless.
T +31 35 60 169 [email protected]@rebo.nlwww.rebosystems.com
High quality coding, capping and filling machines designed and built in England
is sponsored by British Encoder – see them on page 24 7
Industrial Process News is proud to announce that Palamatic Ltd has been chosen to receive our Materials Handling Company of the Year
Award. For nearly 35 years, Palamatic has been at the forefront of innovation in the design and production of lifting and handling solutions for an extensive range of manufacturing industries. Since its inception, it has completed over 10,000 projects and is now active in over 50 countries, establishing itself as a global leader in materials and powder handling solutions.
Established in 1985 by Stewart and Sue Bennison, Palamatic’s Headquarters are based in Chesterfield, with an additional American location in North Carolina. These are also complemented by a worldwide distribution network covering Africa, Europe, Asia, North America and South America.
Boasting unparalleled expertise in all areas of handling solutions, Palamatic offers a wide range of equipment which includes vacuum tube lifting systems, support gantries, and automatic sack opening machinery. What’s more, Palamatic also offers cGMP hygienic handling systems under its PalPharma Handling Solutions brand, which are ideal for handling products within controlled environments, as well as keeping a stock of spare parts for standard systems.
We had the pleasure of speaking to Andrea Fincham, Business Performance Manager, who told us about Palamatic’s impressive achievements over the last year. “The last 12 months have been extremely positive for Palamatic. Our sales figures have fared well against the targets set, and we have exhibited at eight trade shows taking place in
the UK, USA and Europe. These covered all aspects of our product portfolio, which has generated an increase in brand awareness, labelling us as the go-to brand for materials handling solutions. We learn so much more about our customers from talking face to face, such as new handling issues, and this organically expands our solutions and understanding of the issues our customers face.”
The past year has also witnessed some notable developments for some of Palamatic’s product ranges. “We have undergone a standardisation project for our Uni-LITE range meaning that the product can now be sold as a complete solution and rolled out to our distribution network. This is very exciting for Palamatic because the demand is high and we have a great product to supply.
“We have also developed a new range of mobile
handling units that are suitable for cleanroom environments and rated to IP65, which in real terms means the unit can be jet washed clean without compromising the internal battery and components. Furthermore, we have made developments to our cGMP pneumatic PalPharmAssist range for lifting weights up to one tonne.”
As well as these advancements, Palamatic maintains its industry-leading standard equipment range for sack lifting, box lifting, drum lifting and pallet inspection. Its S-LINE vacuum tube lifter series is ideal for streamlined robust effortless lifting, perfect for cardboard box lifting and carton handling, palletising and depalletising. It is also designed for use with paper and plastic sack lifting and steel drum lifting. What’s more, Palamatic’s full range of pallet lifters and inspectors can cut down the time taken to load and offload commercial vehicles, offering speed and efficiency and reducing the risk of fatigue, injury or repetitive strain for the user.
Determined to remain as leaders in innovative solutions, Palamatic has been committed to advancing other essential areas of the company. “We have been on an intensive recruitment drive,” explained Andrea, “covering roles throughout the whole organisation. We have also continued to invest in training, development, and our IT infrastructure.”
In the present ambiguous climate surrounding Brexit and its possible repercussions, Palamatic is ensuring it remains steadfast in the face of these difficulties. “It has been a period of steady growth amid the uncertainty of Brexit, so pushing forwards by positioning ourselves in front of our customers and developing new products
has been a successful strategy for us. We have close relationships with Europe and our distribution network. Having spoken to many people, they do not appear fazed by Brexit but more interested in the difference it may make. We are obviously concerned about what may or may not lie ahead, but as a global company with strong partnerships in all continents, we are confident that we will embrace the challenges we may face.
“We have found that our UK customers are less committed to raising the final system order, but are insistent that the projects are live. I think there has been a shift in mentality to mend and make do as we have found an increase in business from our existing customers to move existing systems and make upgrades to alter their
use. When the country knows what is happening, we are confident that things will reset back to normal.”
With a positive 12 months to build upon, Palamatic is constantly working on improving both its products and
its brand image to further its impressive successes. “In the short-term, we are pushing our standard ranges of products for vacuum lifting. Looking further ahead, we aim to grow the business and as best as possible standardise all of our solutions, endeavouring to be the go-to brand for materials handling solutions worldwide. We are also undergoing a lean manufacturing restructure of our production facilities and will soon be launching our new website.”
Finally, we asked Andrea about her thoughts on receiving our Company of the Year Award. “We are very proud to be selected. We have been in business for almost 35 years and genuinely are experts in helping our customers solve their manual handling problems. Simply put, our solutions keep our customers’ operators safe and happy while improving productivity.”
Palamatic will be exhibiting at a wide selection of trade shows this year, including the AWFS Woodworking Show, Las Vegas in July; ISPE, Singapore in August; IMHX, UK in September; PPMA TOTAL show, UK in October; and the ISPE Europe Pharma 4.0 Conference in November. If you would like to find out more information on Palamatic’s full range of products and services, use the contact details below.
T 01246 [email protected]
Materials Handling Company of the Year
Leaders in quality materials handling equipment
is sponsored by DD Scientific – see them on page 188
Surface Finishing & Grinding News
Curtiss-Wright have a commendable history behind them, having been founded by three of the world’s most
celebrated aviation pioneers, Orville and Wilbur Wright and Mr. Glenn Curtiss, one of the forerunners of naval aviation. Their companies, the ‘Curtiss Aeroplane and Motor Company’ and ‘Wright Aeronautical Corporation’ merged in 1929 in order to create Curtiss-Wright. Today Curtiss-Wright is one of the world’s leading advanced engineering companies, having diversified and branched out into numerous different technologies across multiple sectors, including commercial and industrial, defence, power, metals, aerospace and much more.
At the turn of the 21st century, Curtiss-Wright had grown into a multi-national company, with global sales of over $2 billion and having acquired almost 60 businesses. Many of these companies still operate under their original name, such as Metal Improvement Company, Bolt’s Metallizing, IMR Test Labs, Component Coating and Repair Services and more who now are part of Curtiss-Wright Surface Technologies. These various divisions offer a wide variety of different specialised surface treatments such as thermal spray coatings, solid film lubricants, shot peening technology and much more.
Curtiss Wright Surface Technology, one of their most well-known and international subsidiaries, specialises in providing material surface treatment solutions, focuses on enhancing the performance of critical materials and components. As many of their clients are in heavy engineering based industries, critical components are often of vital importance.
Not only do they need to be specially designed to precision specifications, but they need to be long lasting and properly maintained too. Curtiss Wright Surface Technology can offer clients a comprehensive material treatments service that covers silicone, plastic and electronic components, coatings, shot and laser peening, material analysis, testing, repair and maintenance.
Curtiss Wright Surface Technology can provide mechanical and metallurgical testing services for a range of different materials and components through IMR Test Labs. Curtiss-Wright Surface Technologies uses only the most advanced technology and methods in order to conduct fatigue testing, thermal spray coating analyses, metallurgical and failure analyses, accelerated weathering and corrosion testing, weld testing and much more.
When it comes to engineered coatings, Curtiss Wright Surface Technologies have a wide scope of services, including providing thermal management, corrosion and erosion, and protection and repair of turbine components. Curtiss-Wright Surface Technology can provide protective engineered coatings or metal
coatings to protect components from the environment, corrosion, heat, and wear.
As they can ensure protection for components of any size or complexity, they have a vast client base made up of those seeking their protective coating services, including the aerospace, oil, gas, automotive and medical industries. Their range of coating solutions includes
thermal spray/HVOF coatings, solid film lubricants, liquid coatings, and parylene conformal coatings. Not only that, but Curtiss Wright Surface Technology also offer repair and overhaul for gas and steam turbine components, as well as laboratory testing and process verification for: salt spray corrosion testing, U.V testing and development of their own bespoke coating systems such as Everlube®, Microseal, and Flurene Lube-Lok®, sacrificial aluminium coatings, diffusion coatings and pre-treatments.
Metal and material surface solutions are a huge part of why Curtiss Wright Surface Technology has become such an internationally recognised name. In addition to their famous controlled shot peening process, the company can provide highly effective and controlled Laser Peening for components in turbine engines, aircraft structures, wing skins and more.
This specialist process puts exceptionally deep residual compressive stress in certain parts of a component to prevent crack initiation and fatigue. Not only does this allow the component to resist damage from erosion, strike damage, fretting, and corrosion, but
it can also better withstand pressure from both low cycle/high stress and high cycle/low stress situations. Better yet, their laser peening ensures quality control, precise application and poses no risk of process contamination.
Preventing the failure of critical components is a huge concern for clients, and is one of the most highly sought after services from Curtiss Wright Surface Technologies. Problems can be caused due to any number of reasons throughout the component design process, whether it’s the choice of materials used, incorrect assembly, or damage to the parts caused by bending, rolling or forging. Components of any type can be damaged, such as blade roots, rotating rings and tie wire holes used in Aero-Engines, fasteners & stringers used in Airframes, and torsion bars, gears & keyways, which are used to make Crankshafts and more.
Thankfully Curtiss Wright Surface Technology have a large array of solutions, including but not limited to: C.A.S.E. isotropic superfinishing, Parylene coating, Thermal barrier coatings, Cathodic protection and much more.
If you would like to find out more about Curtiss Wright Surface Technologies and their many specialised, services and solutions, then be sure to get in contact with the company today. Alternatively, you can find out more about the company by visiting the website below, where information, animations case studies and links to their many services can also be found.
Come and see CWST at Engineering Materials Live on Thursday 19th September 2019 at The National Conference Centre, Solihull.
T 01635 279621www.cwst.co.uk
Experts in life extension of materials & critical components
is sponsored by British Encoder – see them on page 24 9
Master Abrasives is offering a limited number of grinding machines from its Midlands-based
showroom at a special rate.
Following the release of its new machinery and equipment brochure, Master Abrasives has launched a new initiative to offer its stocked grinding machines for sale this summer. This special showroom offer will run until the end of September 2019 with limited availability and includes free abrasives up to a set value, such as grinding wheels and dressing tools. Further details can be requested from Martin Stevens, Applications Engineer.
The first machine available is the Micromatic eco 200 universal, a Cylindrical, Semi-Automatic grinding machine ideal for external, internal or face grinding of small
components up to 200mm diameter in low to medium production batches.
Alex Machine Tools’ NH-500 surface grinding machine is the second machine in Master Abrasives’ summer sale. This machine has a grinding area of 500mm long x 250mm width and comes with PLC control and auto lubrication already fitted, a magnetic chuck with built in De-magnetiser, 200mm diameter grinding wheel and coolant tank (30LPM) with magnetic separator.
Master Abrasives’ visitors can also view and try out a range of metrology equipment from the Innovative Automation Products brand. The selection of measuring equipment available onsite for the grinding process includes a height gauge, air gauge and optical and digital profile projectors.
T +44 (0)1327 [email protected]
Surface Finishing & Grinding News
Grinding machines available
Take a look at our photos from RK-System’s recent visit to give our applications team training on
their balance and vibration measurement system!
We can offer technical advice for applications through our experienced representatives or our agent in Poland, Slawomir Klisiewicz.
VibroDAQ System SoftwareThe system can be used for measuring vibration and balance of grinding wheels and parts in a range of applications, including aerospace. For example, RK-System has produced a new design that uses 4 vibration sensors and 1 laser sensor for measurement so that the balance can be restored to the part by adding or removing mass in the identified area.
T +44 (0)1327 [email protected]
RK-System’s training session for our team
Romford based Coborn Engineering Company Limited, a global provider of engineered solutions
for the diamond industry, and Berlin located relayr, a specialist for industrial solutions in the field of Internet of Things (IoT), have formed a strategic alliance. The purpose of this long-term partnership is to develop Coborn’s diamond grinding machines into smart equipment by installing digital services in their products.
Thanks to anomaly detection through relayr’s AI-based analytics, data collected from Coborn’s machines will allow them to determine and resolve failures in advance. Delivering pre-emptive service to each diamond customer will enable Coborn to offer machines with guaranteed performance and availability targets. Each machine will also come with an insurance policy to support these guarantees.
As an additional feature, Coborn will be offering a pay per use business model for its equipment, also known as an Equipment as a Service (EaaS) model. EaaS is an innovative business model in which Coborn‘s diamond grinding machines are not sold but made available for a usage fee. Coborn will remain responsible for maintenance, service, repairs and spare parts. This model makes Coborn’s products easier to finance for companies in the diamond industry, especially in emerging markets.
ContactT +49 162 258 86 [email protected]
Diamond Processing Industry Goes Digital
CWST is exhibiting at Engineering Materials Live on 19th September 2019
is sponsored by DD Scientific – see them on page 1810
The AMO M10 is a new low cost industrial pressure transmitter designed for general
purpose pressure measurement. This sensor is rugged and durable, providing accurate measurement even under harsh conditions, available in gauge, absolute and sealed gauge versions. The MPM489 model is the ATEX approved version certified to ATEX Exia IIC T4 Ga .
The Diaphragm is the sensing element in these pressure sensors comprised of multiple layers including a silicone substrate which has excellent piezoresistive properties. When pressure is applied, the diaphragm flexes and causes a deformation in its crystal lattice which modifies
the band structure placed on the diaphragm and changes the resistivity of the material. Semiconductor resistors on the front side transduce this tension into resistance changes by means of the piezoresistive effect. Silicone has Young’s Modulus of about 2*105 MPa, which is same as that of steel, but silicone is as light as aluminium, with a mass density of about 2.3 g/cm3 . Its melting point of about 1400°C makes silicon dimensionally stable even at elevated temperatures. It has a thermal expansion coefficient 8 times smaller than that of steel, and more than 10 times smaller than aluminium. It is an elastic material with no plastic or creep below 800°C. The major advantage of this fabrication technique guarantees high precision and large volume production at low costs.
Both models are constructed from stainless steel with a choice of grades to ensure application suitability. Process connections and operating
pressure ranges can be specified as can options for signal output type, diaphragm material and electrical connections. Every device is temperature compensated and calibrated and supplied with a traceable serial number and calibration certificate. The electronics incorporate a microprocessor based amplifier which means that there are no adjusting pots and therefore the electronics are very stable, especially in high vibration and high shock applications.
For further information, contact: [email protected] or call us on 01280 817304.
Electric vehicles are gaining momentum around the world, with more and more major
cities increasingly switching to electric buses for public transport. The global Dürr Technik Group devotes itself to all aspects of “e-mobility” and has developed oil-free compressors that are powered by their own electric motor(s). These compressors offer energy savings with fewer pollutants in the “Automotive” sector.
For vehicles over 3.5 tons, a reliable and robust compressed air supply is essential – for applications ranging from brake release air to door opening to air suspension. Instead of mechanically connecting the existing compressors with the vehicle engine in a conventional manner, the newly developed and efficient Dürr Technik compressors have their own electric motor(s). These are extremely environmentally friendly, run independently of the vehicle engine and only draw power when needed, meaning there is very low energy consumption.
The compressors that we manufacture are oil-free meaning oil control or oil changes are a thing of the past. Coupled with their compact and robust design, very low noise/vibration, low whole life costs, ease of installation and the fact that they are almost completely maintenance free, they can be installed into many positions within the vehicles that would have been impossible in the past. Depending on the product selected our compressors can achieve temperature ranges of between -40 and +400C and can be operated with a duty cycle of 100%.
The compressor B-304 WR from Dürr Technik is especially suitable for vehicles with a total mass of up to 13.5 tonnes. With a centralised air intake system, this allows flexibility of installation to suit the manufacturers’ requirements.
For vehicles over 13.5 tonnes, the E-Bull-300 from Dürr Technik is the ideal choice. At 400 V and 50 Hz, the compressor delivers 280 I/ min at 10 bar – at a sound pressure level of 72 dB (A), similar to a vacuum cleaner. With the E-Bull-300 weighing in at only 45kg, with dimensions of 474 x 286 x 496mm and an IP67 rating it is suitable for all types of vehicle. In addition, Dürr Technik can make individual adjustments to suit specific customer requirements. Durr Tecknik pride themselves by offering complete solutions with dryers, after coolers, ambient cooling fans, support brackets and enclosures as required.
T 01761 422944
Hydraulics, Pneumatics, Pumps & Valves News
New low cost range of safe and hazardous area pressure transmitters
Manuli Hydraulics assembly machines are part of an integrated product
range, designed to ensure users get the best results from their Manuli products.
The latest evolution of this range are the EVO crimping machines, including the MRB 137 EVO R.
Designed specifically for maintenance workshops and on-site repairs, the MRB 137 EVO R is a compact, ergonomically designed crimping machine which features an adjustable head for maximum ease of use. The rotating crimping head can be positioned vertically, horizontally or any position in between thanks to its innovative design and tool-free locking mechanism.
Features n Ergonomically positioned adjustable crimping head
n Axis of crimping head oriented perpendicular to the operator
n Compact design n Includes quick change tool for dies n Range of standard dies available n Optional die storage panel available
Manuli Hydraulics is focused on achieving excellence in the design, manufacture and supply of fluid conveyance solutions, components and associated equipment for high pressure hydraulics, refrigeration and oil and marine applications.
Manuli Hydraulics has over 2,000 employees, with manufacturing and logistics facilities located in 14 countries throughout the world.
For more information about the MRB 137 EVO R visit the Manuli Hydraulics website, www.manuli-hydraulics.com.
New Manuli Hydraulics MRB 137 EVO R Rotational Head Crimper
Explore an Ecological Future
is sponsored by British Encoder – see them on page 24 11
Machinery can be hazardous, hence the legal requirement for periodic PUWER
inspections to ensure the safety of workers and compliance with health and safety regulations. Procter Machine Safety’s experts understand the regulations and standards, plus they have extensive knowledge of machinery across many different industries. They can therefore inspect your machines in the knowledge of what safety measures should be present and when any residual risks are ‘as low as reasonably practicable’. The TUV-certified machinery safety specialists can inspect individual, linked or multiple machines at one or more sites. At the end of the PUWER inspection an illustrated report is presented, showing any non-compliances.
If requested, advice and support can be provided to help make machines PUWER-compliant.
T 02920 882222www.machinesafety/puwer
Machining News
Deep holes in stainless steelCrazyDrill Cool SST-Inox is a carbide drill,
available in diameters from 1 to 6 mm, developed for machining stainless steels, superalloys and chrome-cobalt alloys. This tool is now available for holes up to 40xd. With this the Swiss tool manufacturer Mikron Tool is boosting deep hole drilling in stainless steels.
How is it done? A “chip breaking profile” at the tip of the tool creating short chips and an enlarged flute profile in the rear section providing massive, constant cooling and chip evacuation. However, for drilling deeper than 10xd, an additional feature was required: The fine polishing of the flutes creating an extremely smooth surface of the spiral flutes makes a significant difference in flushing out chips. The other important element to machine stainless materials fast and reliable is the efficient cooling. The new drill has spiralized integrated cooling ducts up to the drill tip. Their cross section has a “drop-shape” which is different from usual round cross section. The distinct advantage is a 4 times higher coolant volume. Hence this cooling performance prevents overheating and subsequent chipping of cutting edges and build-up of material.
These features are the key to success when drilling deep. And all this results in reaching the full drilling depth in one single feed stroke; no need for pecking!
T 0041 [email protected]
PUWER inspections by machinery safety experts
New Automated Filters at EMO Exhibition 2019Eclipse Magnetics is launching
its new range of cost effective, automated filters at EMO Exhibition in Hannover, Germany from 19–21 September 2019. The new Autofiltrex range is the latest generation in cost-effective, high performance filtration, with features including fully automated cleaning and a magnetic reclaim unit. Available in 3 different sizes, the Autofiltrex range is ideal for most ferrous machining applications such as grinding, honing, lapping, forming and quenching.
Visitors will have the opportunity to find out more about how Eclipse’s high performance magnetic filtration products can significantly improve process efficiencies for precision metal finishing processes. Also on display will be Eclipse’s full range of high performance magnetic filters, which includes the recently launched FiltraMag+ Mobile Unit. As an off-line filtration system, it is perfect for cleaning oils and coolants. Simple and versatile, it features the high performance FiltraMag+ magnetic
filter in a convenient “plug and play” unit, offering effective sub-micron filtration with the huge advantage that it can be moved easily from machine to machine. In addition, Eclipse Magnetics range of magnetic workshop tools, welding aids, workholding and lifting products will be showcased at the exhibition.
Visit Eclipse Magnetics in Hall 7, stand A59.T +44 (0)114 225 [email protected]
is sponsored by DD Scientific – see them on page 1812
Machining News
Multitasking machining centresIndustry: MouldmakingCustomer Product: Complex MouldsUNISIG Solution: USC-M38+M50 Deep Hole Drilling and Milling Centres
Purchasing one, then two more, multitasking machining centres has transformed the way Concours Mold Inc
builds moulds.
Concours Mold Inc (Lakeshore, Ontario, Canada) makes it a priority to keep its machinery and equipment up to date to ensure competitiveness. From its enterprise resource planning (ERP) system and advanced scheduling system, to its radio frequency identification (RFID) tool management system, to rigorous quality-check procedures, not to mention five-axis machining centres, the company does whatever it can to continually improve its processes. In fact, the company recently invested millions of dollars in new equipment, but one machine, the UNISIG USC-M, has so improved Concours’ machining processes that, according to Ed Ergun, corporate sales manager, it has been a game changer.
Concours Mold Inc. n Problem: The efficiencies in standard machining
processes at Canada facility due to multiple setups required on each of two machines (boring mills and gundrills) necessitated more outsourcing of work to keep up with deliveries.
n Solution: Addition of a UNISIG USC-M50 and two UNISIG USC-M38 multitasking machining centres.
n Results: Significant reduction in setups, virtually eliminating down time between setups. Faster machining, better accuracy and fewer mistakes reduced lead times, allowed first-time quality and enabled more time to handle more work coming through the machines.
Concours specialises in building small to very large injection, compression and hydroforming moulds
as a primarily Tier-One supplier to the automotive industry and has additional locations in Cullman, Alabama, and Puebla, Mexico. All locations run 24/7. Moulds built for interior automotive parts produce instrument panels, door assemblies, A, B, C and D pillars/assemblies and much more, while moulds for exterior parts produce such items as fascias, grilles, spoilers and rockers. The balance of the company’s business encompasses building moulds for heavy-truck parts and consumer products.
Still, it is the automotive OEMs that dominate Concours’ customer list and, as anyone who has experience with serving the automotive industry knows, high quality is expected, and mould deliveries are tight. “As our company announcement said when we launched our third UNISIG USC-M in February 2018, the USC-M series brings unmatched capabilities in a single, game-changing machine,” Ergun says. “This is our tomorrow.”
It’s about throughput gainedBoring Mill. Gundrill. Before purchasing its third UNISIG in February 2018, Concours utilised these machines every day, repeatedly, during the mould building process. “Anything that came into our facility basically hit these machines at one time or another,” Ergun says. He adds that each machine would need to be reserved in the schedule as
needed to complete that portion of the build, to keep blocks and components moving and on schedule. If any issues arose that prevented movement of the workpiece, then the scheduling would be off, and machining delayed till the next available slot opened up. It was a constant struggle to update and revise the schedule to remain current.
This is our tomorrow“Now, instead of reserving a boring mill for three days, and then the gundrill another three days, we can take care of all the boring and high-speed gundrilling on the UNISIG,” Ergun says. “The USC-M Series machine is very much a multitasker and has reduced our lead times by roughly 30%.”
It’s about reducing costsConcours regards the time spent setting up jobs
as throw-away costs. “There are so many setups involved on just a boring mill alone, it adds up to costs that we have to absorb, plus a crane and any employees required to work on it,” Ergun says.
For example, to set up a block in the boring mill, he says it would take half an hour to an hour, depending on the setup, to bore/drill five holes, then lay it down and set it up to complete another series of holes and so on.
Our setup time has decreased by more than 50%“Now we have the five-axis positioning capability of the Unisigs and FCS clamping systems along with automatic pallet changers on each machine, which is a 100% time-saver when it comes to switching a tool from one setup to the next,” Ergun says.
Concours now sets up one pallet while the other is being worked on. When setups are required on the original block, the pallets are shuttled so machining can begin on the other job while the first block is being set up. “Because of these new improvements, the Unisigs stay in production mode with minimal down time. I can honestly say that our setup time has decreased by more than 50%.”
Ergun says that as Concours purchased its first, second and eventually its third UNISIG USC-M Series multitasking machining centre, the company was able to eliminate other machinery and significantly reduce outsourcing work. “When we bought the first UNISIG USC-M50, we were able to eliminate two boring mills right off the bat,” he says. The USC-M50 features a 120-position toolchanger. In addition, it has a 25-ton capacity table for work pieces as large as 3,000mm, 50mm diameter capacity for both BTA drilling and gun drilling up to a depth of 1,830mm, and dedicated 5,000rpm, 24/30kW drilling spindle power.
Then Concours purchased the first UNISIG USC-M38, which features a rated gundrill diameter of
is sponsored by British Encoder – see them on page 24 13
Machining News
50mm and a BTA drilling diameter of 38mm. With dedicated drilling spindle power of 4,500rpm, 22kW, drilling depth capability is 1,500mm. The M38 also features a 120-position toolchanger and a 15-ton table-weight capacity. “That eliminated our need for another boring mill and one of the two gundrills we had, but we were still outsourcing a large amount of work plus using our remaining gundrill,” Ergun says. Since purchasing a third UNISIG, another M38, Concours has eliminated its gundrills, and outsourcing has become an ‘only as-necessary’ option that is rarely used. “It’s about the throughput that we have gained by having these machines,” he says.
It’s about quality controlErgun explains that Concours was outsourcing work due, in part, to tight timelines from customers and being limited as to how much work could get through the older machines with their limited capabilities. “We also feel at risk when outsourcing because of supplier limitations with regard to quality and their capabilities,” he says. “We spend much of our own resources managing vendors to ensure we get the quality we need in the timeframe required. Keeping jobs in house is definitely the best option to get the quality we need, complete the work on time & keep costs down.”
Since launching the second M38 last February, we have reduced outsourcing costs by 20-30%“Our Unisigs are extremely fast, accurate and have made it possible to keep previously outsourced work in-house,” Ergun says. “Since launching the second M38 last February, we have reduced outsourcing costs by 20-30%.”
He adds that the speed and accuracy of the Unisigs, as well as fewer required setups, has reduced the risk of mistakes in-house, too. Concours opted to equip its Unisigs with Renishaw RMP600 wireless probes for on-machine inspection to verify work, further reducing instances of rework due to error. “The old technology was sometimes unpredictable, and surprises would come up. For example, if we drilled a water line 40 inches deep and expected it to hit an existing water line but it didn't because the drill wandered, we went into rework mode,” he says. “Where did the drill wander and how much did it wander and so on? We must gather the facts and get that information to the engineering department to fix this issue and then back on the machine for added drilling to make the circuit work.” Ergun admits that would
be the best-case scenario. “If our drill hit another line, or worse, came too close to the cavity face, we could be forced into a full replacement of the block, which could cost us about $80,000-$100,000 plus the cost of all the work that was completed that now we have to scrap. Every time you move the tool from one setup to the next, you risk accuracy, bottom line.”
“With the old technology, we used to accept large
tolerances and could do nothing about it. Now we work within fractions of those tolerances and will accept nothing less,” he continues. “The ability to catch any potential issues on the machines enables us to deliver first-time quality in our moulds. Nothing helps our business more than that.”
Ergun points out one more thing, “Yes, we’re paying a lot of money for this new technology, but the accuracy and throughput will pay for
that additional cost with every job we do moving forward.”
Further information on all machines of the B series and the complete UNISIG machine programme is available at: www.unisig.com or follow the company on LinkedIn and Twitter (@UNISIG). You can also meet us at the EMO show in Hannover, Germany in Hall 15, D34 from 16.–21.09.2019.
double throughput, cut costs
is sponsored by DD Scientific – see them on page 1814
Eriez Europe takes pride in providing a personal service to their customers. Therefore, when a customer requested
a higher strength RF Cartridge Magnetic Separator, applications engineer Doctor Nick Lewis set about seeing if this was possible.
The RF Cartridge is the ideal magnetic separator for removing tramp iron from dry free-flowing food products conveyed in pneumatic pipelines. Ferrous contamination is attracted and held by the magnet while the separated product continues past the magnet and out of the housing. The ferrous contamination remains on the magnet until the cartridge is removed and cleaned.
Doctor Nick Lewis utilised skills developed during his PhD researching modelling magnetic properties of electrical steel. The experience of using FEM Modelling allowed Nick to successfully implement RF Cartridge strength increases. The upgraded RF Cartridge will incorporate two further pickup points and the field of strength has increased two and half times over. This will bring immense value to installers as a clean product can be guaranteed.
Eriez Europe will be launching the upgraded RF Cartridge at PPMA 2019 at the NEC in Birmingham. Visitors to stand J48 can see the RF Cartridge up close and the Eriez team members present will be happy to answer any questions.
T +44 (0)29 2086 [email protected] www.eriez.eu
Machining News
Food Processing & Manufacturing News
Procurement of new machines is not the only way of increasing production capacity. The right tools and suitable software can also generate up to 85
percent gains in productivity. What if the order book is full and the company has reached the limit of its capacity? When a company finds itself in this situation, the question that arises is: Whether to procure new machines or to explore how to make better use of the existing stock of machine tools. There are ways of doing this. For instance “Parabolic Performance Cutting” (PPC) is a production technique that can accelerate the finish machining process by a factor of nine. By Hoffmann Group.
Expand the existing capacity or start to turn down orders? Many companies find themselves in this dilemma: Every time a company turns down an order there is the risk the customer may not consider this company for future orders. So essentially there is no alternative but to continue to accept every new order. However at some point the existing stock of machine tools will reach its limits. What then? Is it justifiable to procure an additional machine when it is uncertain how long the surge in orders will be sustained? Moreover there is a time lag of several months between ordering and receiving a new machine.
So how can the new machine address the current production bottleneck? Many Production Managers suffer sleepless nights wrestling with such questions. Indeed, new machines represent substantial investment, often a seven-figure sum – they need space, personnel to operate them, and are not immediately ready for productive use. Alternatives by which a relatively small investment and no loss of time can achieve significantly more from existing productive resources are therefore very attractive. PPC milling is one such technique. The success story is already well established. For instance, Koller Formenbau GmbH of Dietfurt in the Altmühltal, Germany, has used PPC milling cutters supplied by the Hoffmann Group to reduce the finish machining time for geometrically ruled surfaces from 100 hours to 15 hours.
Massive reductions in finish machining timesPPC is also called barrel milling. Similarly to that of a ball-nosed slot drill, the main cutting edge of a PPC milling cutter is curved as an arc of a larger radius circle. Whilst for a classic ball-nosed slot drill the effective radius of the tool is only half the diameter, a PPC milling cutter has a much greater effective radius, up to 1000 millimetres, thus permitting a significantly greater engagement length on the workpiece. A barrel milling cutter achieves a line skip up to nine times greater than that available using a ball-nosed slot drill of the same tool diameter, thus placing less stress on both the tool and the machine. If on the other hand the same line skip is maintained a surface quality up
to 80 times better can be achieved. The Hoffmann Group is currently offering a portfolio of tools with effective radii up to 1000 millimetres. Even larger radii are conceivable and could be implemented as tools, but the very long engagement length would demand very high contact pressures. The resulting displacement of the tool would have a negative effect on precision, which of course in a finishing process cannot be compromised.
The Hoffmann Group also offers special solutions with effective radii different from those in the catalogue, to allow the customer to gain the optimum benefits from PPC for specific applications. In order to fully exploit the advantages of PPC, a radius in the range of 700 or 800 millimetres has generally been found to offer the best solution. Very often the best solution depends not only on the component but also on the machine tool in use.
Different profiles and approach anglesPPC is particularly effective when the tool profile is exactly suited to the workpiece surface contour. Therefore, depending on the application, up to four different tool profiles are necessary for optimum machining of workpieces and free-form surfaces with highly complex surface geometries. This is because surfaces with interference contours, large areas, deep cavities or flat faces each demand different tool profiles. The Hoffmann Group therefore currently offers the following principal cutting edge profiles: “straight”, “tangential”, “conical“ and “stub point conical”; each representing a specialised solution for machining particular types of surface. For all profiles except for the straight profile the tool is also mounted at an oblique angle – and the selected approach angle also makes a difference.
Therefore the Hoffmann Group offers conical and stub point conical PPC milling cutters with three different approach angles. These allow the programmer to use the optimum type of milling cutter for the specific application. Depending on the component, for instance steeper approach angles allow interference contours to be avoided. Or the use of a machine tool that has a large headstock may require the choice of a tool with a larger approach angle.
CAD/CAM with tooling databaseIn contrast to ball-nosed slot drill cutting, PPC is more dependent on software. For classic ball-nosed slot drill cutting the CAM software requires only a small amount of information to calculate an appropriate milling strategy: It is sufficient to declare the tool diameter, tool length and the information that the relevant tool is a ball-nosed slot drill. These data can also be processed manually. The more complex tool profiles of PPC on the other hand can be calculated only in combination with CAM software that
offers “barrel milling” as a strategic option. In addition the software must have available a tooling database which holds the exact geometries of the PPC milling cutters.
Furthermore, because for PPC the tools are aligned obliquely to the workpiece, this process can be employed only in conjunction with a 5-axis milling machine. As 5-axis machines come increasingly into use, PPC milling is now really taking off. In any case it is not always necessary to control all 5 axes simultaneously. Often, once the tool has been set up, the draft angles can be machined with 1 or 2 axes clamped, in order to achieve even better results.
At one time there were only a few software programs that offered “barrel milling” functionality. That too has changed in recent years. Koller Formenbau for instance already had a 5-axis machine in use and operated Hypermill software, and only then did it seek suitable barrel milling cutters. At a moderate expense the company has been able to achieve up to 85 percent gains in productivity thereby significantly increasing the productive capacity without having to procure new machine tools.
Increasing areas of applicationA classic area of application for PPC is finish machining of complex components and free-form surfaces in machine tool manufacture and in tool and die production. In medical technology, turbine technology and aerospace, PPC is attracting increasing interest. A relatively new
area of application for instance is the finish machining of workpieces produced by additive manufacturing. 3D printing permits particularly complex workpieces to be produced in a single production operation. However, workpieces produced on a 3D printer fall well short of the surface quality required for contact faces. Such workpieces must be finish machined. PPC was conceived for exactly such applications. And not least because a variety of different materials are often used for the 3D printing process, the Hoffmann Group has extended its PPC milling cutter family to cater for machining a wide range of materials. PPC milling cutters for machining aluminium were demonstrated for the first time at AMB 2018. The new milling cutters are particularly sharp-edged and can also be used for machining plastics. This significantly extends the existing portfolio over a wide range of applications.
PPC as a productivity solutionCompanies which direct their investment into alternative paths can achieve substantial increases in productive capacity at a relatively small outlay, without adding to their existing stock of machine tools. CAM-controlled production using PPC is such an alternative. PPC permits genuine step function gains in productivity with a relatively modest investment in software and tools.
ContactT +44 (0)8704 1761 [email protected]
Directing investments in the right way
RF Cartridge features
is sponsored by British Encoder – see them on page 24 15
After the event, the delegates were asked to complete an online survey to provide feedback on what they
thought of the event, and if they would be more likely to use PROFIBUS, PROFINET or IO-Link.
85% of the responders said “yes” when asked: “Are you now more likely to go ahead or extend your use of PROFIBUS, PROFINET or IO-Link?”
Of these positive responses, quite a few stated they would be going for two or more of these technologies with 70% saying they’d be going ahead with PROFINET, 70% with IO-Link and 40% going for PROFIBUS.Positive Approval
All of the comments made were complimentary, including the following:
“Very well structured and enjoyable. More integrated demonstrations would have made some material more engaging.” Dan Harris, Cummins Generator Technologies “The event was good, but coming from an environment where we have little knowledge of these protocols, was a little hard going.” “A very informative day, good speakers and pace.” Mark Binks, Manchester Metropolitan University “Very useful for keeping up with current topics and technology.”
More about the eventThe event covered key application areas such as control
systems and energy management, pulp & paper, chemical, utilities, pharmaceutical, mechanical handling and logistics, robotics, automotive engineering, electrical and electronics assembly, packaging and printing. It focused on the practical aspects of using PROFINET, PROFIBUS and IO-Link, from system design and safety considerations through to fault-finding and maintenance.
T 020 8144 9597www.profibus.comwww.profibusgroup.com
Online survey shows more will be using PI’s technologies
With energy conservation being one of the UK’s hottest topics today, Forteq UK has been working closely with
the Carbon Trust to gain accreditation and access grant funding to upgrade its existing compressor system.
For Thorite, the UK’s largest distributor of compressed air products and systems, this is all familiar territory as energy efficiency is taken increasingly seriously by senior managers. Additionally, energy efficiency is the main reason for companies gaining Carbon Trust accreditation and in the case of Huddersfield based Forteq UK, they received a capital contribution via the Carbon Trust Green Business Fund scheme to support them in becoming more energy efficient, with Thorite being in a position to supply and install on this project as a Carbon Trust Accredited supplier.
Forteq UK is a precision injection moulding company with major clients in the automotive, pharmaceutical, consumer and electronics industries. Leighton Harris, Thorite’s Key Account Manager for the Huddersfield area, offered to investigate the savings available by replacing their old 30kw HPC fixed speed air compressor with a new energy efficient variable speed version. A data logging exercise took place for seven days to establish an air demand profile and highlight possible energy savings.
By replacing the old 30 kW fixed speed compressor with a new 30 kW HPC variable speed air compressor model ASD60T SFC, annual savings of just over £4,000 are expected. New compressors are not an impulse purchase, they are expensive. But faced with these savings and a grant from the Carbon Trust, the decision to go ahead with the purchase was easy to take.
Contact : 0800 034 5850 or visit www.thorite.co.uk
Industrial Process Technologies News
World-leading spring, wire form and assembly specialist William Hughes has expanded its
range of specialist services for the manufacturing industry with the acquisition of JK Metrology & Quality Services of Liskeard, Cornwall. JK Metrology is a well-established metrology and quality consultancy for ISO 17027, ISO 9000 etc. and offers a UKAS calibration service to ISO 17025.
With a worldwide portfolio of customers, JK Metrology is one of only three UK laboratories offering UKAS Calibration of Gauge Blocks by Interferometry (Class A). ‘By comparison’ calibration is also offered and in the future William Hughes plans to offer a rapid turnaround service. Interferometry is the highest level of accuracy for length measurement and JK Metrology can also measure items up to 1 metre long at 20°C ± 0.05ºC. The scope of services includes Tungsten Carbide, Steel and Ceramic, Long Slip Gauges, Length Bars, Long Series Gauge Blocks, Surface Tables (including refurbishment), Gauge Block and Length Bar Accessories, Optical Flats and Parallels.
The company is also a supplier of the highest
quality metrology equipment, from Micrometers and Verniers, Gauge Blocks and Angle Gauges, to Coordinate Measuring Machines (CMMs) and a wide range of other metrology equipment. JK Metrology continues to supply and service the metrology equipment previously manufactured by Select Gauges Ltd following its closure. T 01963 363377 F 01963 [email protected] www.wmhughes.co.uk
Metrology services for high precision manufacturing following the acquisition of JK Metrology Applied Rubber Linings has been supplying abrasion
and chemical resistant rubber linings for 45 years. Within many industries including water, waste and effluent treatment, chemicals, mining, quarrying and aggregates, manufacturing, and metal finishing, we provide protective linings and coatings for all types of process plant.
Our aim is to provide cost-effective solutions to the problems
of corrosion, abrasion, noise, and product protection that occur when process plant is operating in extreme conditions. We focus on building strong relationships with our customers that are based on reliability, quality, integrity and trust.
For further information visit the website at: www.applied-rubber.co.uk or phone 01452 381849 or email [email protected]
45 years of Process Plant Linings from ARL
On the 11th & 12th September, Birmingham’s NEC will play host to the UK’s leading
international showcase of fastening and fixing technologies - The Fastener Exhibition & Conference.
Under one roof, the event will boast over 100 suppliers, including market leading brands such as ZaGO Manufacturing Co, ARaymond, Simpson Strong-Tie & Rotor Clip Ltd, all displaying their latest innovations designed to help your business grow.
There will also be industry giants like BUFAB, Cirteq, A3L and Altimex speaking in over 50 seminars, allowing you to gain priceless insight from the industry’s biggest and most influential figures as they cover the hottest topics directly affecting the industry today.
Not only that, but your free ticket also grants you access to the UKs most comprehensive environmental exhibitions running alongside Fasteners Exhibition & Conference. Discover the RWM exhibition, Future Resource Expo and the Contamination Expo Series and meet over 18,000 like minded professionals, looking to grow their business.
So don’t wait around, order your Free Ticket now from www.thefastenexpo.co.uk
The Fastener Exhibition & Conference
Little help from the Carbon Trust
is sponsored by DD Scientific – see them on page 1816
A UK based company, Homechip Ltd specialises in products based around the
Dallas/Maxim 1-wire protocol. Whether you are looking for iButtons® (used in a myriad of applications: security, EPOS, environmental monitoring, data storage) or any of the equipment needed to read and program them: probes, adapters, readers and software, then Homechip can advise and supply.
We also supply easy to use RFID readers and cards which will interface with existing 1-wire solutions and allow you to add RFID without changes to hardware or software.
Finally, we supply a range of wireless environmental monitoring equipment which lets you measure and control temperature, humidity, lux and barometric pressure. Battery life is up to 6 months and range is up to 500m.
Give our friendly technical team a ring on +44 1908 410175 or send us an email at [email protected] and we’ll show you how to benefit from our range of solutions.
Find us at: www.homechip.com
Test, Measurement & Calibration News
Monitoring compressed air usage within industrial applications has become increasingly important as
the associated costs continue to rise dramatically.
Compressed air systems are often the largest excess user of electricity for a business, with air leaks or poorly performing components contributing to a significant amount of wasted energy. In this age of energy efficiency to ensure a greener footprint, it is becoming more important for all business’s to identify and rectify any potential energy wastage situations. Problem areas in compressed air systems can be identified by fitting thermal mass flow meters, strategically positioned to calculate outflow generated air with downstream usage.
Thermal mass flow meters are an ideal solution for compressed air measurements as they measure the mass flow of the air directly, removing any need to monitor the pressure and temperature separately. Compressed air thermal mass flow meters are great tools to monitor and manage your energy consumption. They can detect leakages much faster than a pressure sensor, they can be used for cost allocation and they can be used for efficiency monitoring and maintenance management.
Why Thermal Mass?There are many advantages to this method of air flow measurement. These type of sensors feature zero moving parts in a nearly unobstructed straight through flow path, which facilitates extremely low pressure drop measurement. Maintenance costs are low and this type of meter is very sensitive at low flow rates, which allows for a high turn-down ratio whilst remaining accurate over a wide measuring range. Insertion style models can also be used in larger pipe sizes, with the option to install via a Hot-tap kit under full system pressure. We recommend placing thermal mass flow meters in dry air downstream of all air treatment filters to prevent sensor degradation. If temperature changes rapidly, this can affect the accuracy of the flow meter and can shorten its service lifetime as well. Large temperature variations, which can be found downstream of malfunctioning desiccant dryers, should be avoided
Thermal Mass from Bell Flow SystemsBell Flow Systems offer a range of thermal mass flow meters designed for measurement of compressed air and Nitrogen. The TGF200 series are a smaller bore inline range starting at DN8 up to DN50 in size and the TGF450 and TGF600 series are supplied as flanged or insertion style units designed for pipes form DN25 to DN500. All these models have digital and analogue 4-20mA outputs with optional communication outputs such as Modbus RS485 and HART. Bluetooth is available with complimentary mobile phone app allowing the user to check and set meter parameters. It is also ideal for when the operator needs to view readings in hard to reach locations, and provides efficient viewing when multiple meters are installed.
The TGF200 has four flow ranges with a 100:1 turndown ratio for each of the eight sizes, designed to suit the requirements of a variety of applications. This rugged unit is ideal for various industrial applications in factories, workshops and garages as it can be constructed from aluminium or stainless steel. With a fast response time of 160ms, this flow meter has a high accuracy level of +/-0.3% F.S and the meter can handle temperatures up to 100 °c
The TGF450 and TGF600 flanged and insertion models are ideal where the supply cannot be turned off or delayed in terms of installation and maintenance. These can be installed and removed via hot-tap connection if required, reducing costs and production delays. These models feature simple operator programming and it is also possible to adjust the flow calculation. These both have a two line LCD display which can show both the rate of flow and total volume. The display can show volumetric and mass flow in kg or ton with the addition of programming options for alternative gas densities.
Please contact us at [email protected] or call us on 01280 817304.
Managing losses in compressed air systems with thermal mass flow technology
Spectrum Instrumentation has used its modular design philosophy to
create a unique solution for customers wanting multi-channel AWGs: Having 8 AWG channels on a single PCIe-card only 168 mm in length offers great new opportunities for very compact and affordable test systems. The addition of the two new 8-channel-cards to Spectrum’s latest “65” series of PCIe Arbitrary waveform generators means that, using Spectrum’s Star-Hub, up to 80 channels can be fully synchronized in a single PC! As standard, all cards of the “65” series offer a huge on-board memory of 512 MSamples to store and replay lots of waveforms. Using the PCIe-x4 platform, these AWGs provide a data transfer speed which is 5 to 10 times higher than in other solutions, offering 700 MByte/s of FIFO streaming speed. This is ideal for automated testing when customers need to replay lots of different test signals over many channels to accurately recreate real world test conditions. Applications include component testing, automotive, robotics, aerospace, medical and industrial ultrasound, LIDAR, radar and sonar.
“This family of AWG cards has the lowest
noise of any AWGs that we have so far designed, being more than 20% lower when compared to our predecessor AWG families” said Oliver Rovini, Spectrum’s CTO. “In addition, these cards now have 16-bit resolution and a clock being twenty times more accurate at only ±1 ppm. We already have a university research department using an AWG to control the placement of individual atoms.”
Offering up to 8 channels per card, the cost per channel is cut dramatically. This makes Spectrum’s high-performance test solutions really affordable and opens up new application areas that were restricted due to the high costs of multi-point, dedicated AWG solutions.
Contactwww.spectrum-instrumentation.com
16-bit AWGs with 8 channels per card, up to 80 synchronized AWG-channels in one PC
Based around the Dallas/Maxim 1-wire protocol
is sponsored by British Encoder – see them on page 24 17
The new droppers in the PETTE series from IKA were announced at the last ACHEMA
and are now available. A total of 18 models combine all the most popular features of the laboratory classic. Their large displays, durable construction and ergonomic handles make the PETTE fix and vario ideal for frequent pipetting.
IKA PETTE unites everything lab technicians can expect for reliable metering in a single instrument. All models are fully autoclavable and can be easily sterilised. This ensures accuracy, precision and safety when metering.
The large mechanical volume display is also easy to read as you perform the metering. The lightweight droppers are particularly pleasant
to hold thanks to three interchangeable ergonomic grips. The geometry of the receptacle is designed so that it is suitable for all commercially available tips.
IKA PETTE fix and vario are also shock-resistant, UV and chemical resistant. Calibration and maintenance is user-friendly and can be done yourself or with the help of IKA Service.
Laboratory staff are invited to order the droppers for testing from the IKA Application Center.
More information online: ilmt.co/PL/R4Q4T +49 (0)76 33 831 236
Test, Measurement & Laboratory News
Since 1995, JTS Ltd has been designing and building reliable, high-performing environmental test chambers for a
wide variety of industries. The company is an independent specialist UK manufacturer, with design and build undertaken inhouse by a team of skilled engineers and technicians.
Environmental testing is an essential process in the research and development of new products, and the maintenance of quality and reliability of established product lines. Using the right environmental test
chamber to simulate given conditions, such as heat, cold, humidity, dust, vibration and pressure, ensures products meet industry standards, improving quality and minimising failures.
JTS Ltd specialises in designing and building systems for temperature, humidity, rain, dust and vibration testing, with units ranging from small benchtop chambers to walk-in rooms, and air conditioning units to supply independent test rigs.
Operating from a modern purpose-built factory unit in Mid-Wales, JTS engineers will work with you, from initial enquiry through quote, design and delivery to training and after sales support and service. Backed by 40 years of experience in the design and manufacture of test chambers, our aim is to ensure that the system you order is right for your project.
One such project, currently, is for the Centre for Automotive and Power Systems Engineering (CAPSE) at the university of South Wales. The team there are working with major companies to test new battery technologies, not only for the automotive industry but for National Grid and renewable energies too.
JTS has converted eight 30 ft shipping containers into specialist self-contained ‘test cells’ for temperature and humidity testing at CAPSE’s Pontypridd site.
Battery testing can be highly volatile and to minimise risk in this case, JTS engineers designed an innovative CO2 cascade system, capable of achieving a range of +80 / -40c at high rates of temperature change. As an inert gas, CO2 has a major advantage in this application over alternative refrigerants which are either highly flammable, less efficient or have a far higher GWP (Global Warming Potential).
Working closely with clients ensures the best outcomes for individual test needs, whether the requirement is for standard or bespoke chambers, containerised systems, or walk-in rooms. With experience across a wide range of industries, and a
client base including manufacturers such as Dyson, BAE Systems, TRW Automotive and Red Bull, we are ready to help you achieve the best environmental test solutions for your products.
T 01874 711209www.jts-test-chambers.co.uk
High-performing test chambers
Air Science has introduced a selection of mail handling fume hoods designed to improve user safety in handling
and screening of envelopes and packages.
Despite shipping regulations, fentanyl and other substances that are harmful when ingested, inhaled or absorbed are often sent, both legally and illegally, via mail. In addition to potential attacks through the shipment of anthrax and explosives, the shipment of fentanyl, drugs and pharmaceuticals puts mail handlers at risk when packaging is compromised. The Purair SafeSEARCH complies with best practices recommended by the US Department of Homeland Security (DHS). DHS recommends that handling and opening of mail be done in filtered exhaust hoods or containment receptacles as an added layer of protection.
Features & Benefits: n SafeSEARCH reduces the risk of releasing chemical vapors
and harmful particulates (like synthetic opioids, anthrax, etc.) into the environment
n Ductless technology is energy efficient and does not put additional strain on existing facility HVAC systems
n Ductless design eliminates HVAC construction and saves on utility costs
n The SafeSEARCH cabinet design eliminates bypass leakage that could blow back to the operator
n Electronic monitoring ensures continued performance and safety.
n HEPA/ULPA filters provide additional safety layer against biologicals
n Easily installed in existing or new facilities without HVAC changes.
n Standard sized turnkey models are self-contained, selected models are portable.
For complete information and specifications go to:www.airscience.com/purair-safesearch-ductless-fume-hoods
Package and mail inspection workstation
A new dropper for every hand
As specialists in interfacial chemistry and the world’s leading supplier of measuring instruments for surface
and interfacial tension, KRÜSS not only provides high quality product solutions – our offer is a combination of technology and scientific consulting. These include seminars and technical service as well as our Applications & Science Center for trainings and professional measurement services. Our exclusive distribution network and our locations in Hamburg (Germany), China, the US, Great Britain and France allow us to provide fast, flexible support for R&D labs and in quality control throughout the world. Our expertise, precision and passion have already convinced many prestigious companies in countless industries.
The DSA Inkjet is designed for easy, versatile, and safe use. Inserting the print head and focusing on individual nozzles is a matter of a few simple steps thanks to the 3D fine positioning. The instrument is also equipped with a storage tank to supply the print head with ink during long-term measurements, whereby the drops are collected in a waste container. A suction device prevents exposure to harmful vapors. Thanks to a UV protection cover, UV-curing inks such as those used for 3D printing can also be examined.
ContactT +49 40 [email protected]
Real-time drop analysis for inkjet printing
DD-Scientific is a fast growing electrochemical sensor manufacturer. Founded in 2011 by Daniel Davies, we are now producing nearly 1 million sensors per year in our factory on the South coast of the UK.
From the start our goal has been to provide high quality and performance sensors to the market at competitive prices. We have achieved this by investing in new technologies and manufacturing equipment to build sensors with low variability and high reliability.
T +44 (0)2392 [email protected]
Lab automation achieves improved levels of accuracy, repeatability and provides confidence in results. Allow us
to introduce solutions that tackle Temperature, Static and Handling within your process.
Small variations in temperature can be the difference between a successful and failed batch. Temperature monitoring and control with stability of +/- 0.01°C, ensures you have complete control of your process temperatures, from lab scale research to full process applications.
Troublesome static can cause mayhem with filling applications, even more so where electronics are involved. However, this can be measured and eliminated through the use of Ionizers and sensors, whether for a point of use problem or along a conveyor belt, there’s a solution that fits.
With temperature and static under control, the introduction of automation can fill, handle and cap the finished product seamlessly, completing your process in an accurate and repeatable fashion. The fluid being transferred can be handled with integrated sterile filtration final fill solutions and TFF skids.
Measure, Control and Automate. At BioPharma Dynamics we offer technologies to do all three.
Would you like to discuss your next project or learn more, why not get in touch?
www.biopharmadynamics.co.uk
Are you looking for more control and repeatability in your process?
is sponsored by DD Scientific – see them on page 1818
Test, Measurement & Monitoring News
DD-Scientific was founded in 2011 by
Daniel Davies, a leading expert in electrochemical electrode design and manufacture. Boasting a team with unrivalled expertise, DD-Scientific manufactures electrochemical gas sensors for the detection of potentially hazardous gases, with an acute focus on industrial safety, industrial emissions, domestic safety, and medical breath analysis.
Since its inception, DD-Scientific has seen exponential growth and now produces a potentially lifesaving gas sensor every seven seconds. With a manufacturing facility in Portchester near Portsmouth, DD-Scientific also has sales offices in Shenzhen, China and Chicago, USA, proof that their leading skillset is recognised worldwide. Its team has over 100 years of experience between them in gas sensors and gas detection instrumentation, and these dual credentials ensure DD-Scientific has a sound understanding of what their clients need.
The company’s products convert a physical property, gas concentration, into a measurable electrical signal. When incorporated into suitable detection systems, this can then be used to warn employees if they are at risk of poisoning or asphyxiation.
As well as producing sensors to measure a range of common industrial hazards, such as carbon monoxide, hydrogen sulphide, oxygen, chlorine and many others, DD-Scientific also manufactures products suitable for the measurement of industrial or domestic combustion processes, such as in boilers or burners. This is so that
the burning process can be tuned to provide optimal fuel efficiency. We had the chance to speak to Rob White, Global Sales Manager, who told us more about some of the benefits DD-Scientific can offer its customers. “At the heart of every electrochemical gas sensor is an array of high performance catalytic electrodes. Our expertise is in the high volume manufacture of such electrodes with low variability and high robustness. As a result, our products deliver a very reliable performance over their entire working lifetime. Also, since our products are designed ab initio with high volume in mind, our customers benefit from highly competitive price positions.”
To add to its impressive portfolio of industry-leading products, DD-Scientific has recently launched a range of high performance sensors for the emissions market, optimised for the rigorous demands of monitoring flue gas. These sensors are primed for the unique demands of this market, and have high poison resistant and active catalysts combined with large electrolyte reservoirs and high capacity filters. What’s more, the sensors are also designed to meet the statutory performance requirements of EN50379, parts 1, 2, and 3. Most notably, this range includes the S+5OX, a robust oxygen sensor, and the GS+A5CO, an innovative hydrogen immune carbon monoxide sensor.
The S+5OX is a heavy duty sensor designed for the measurement of oxygen in flue gas applications. It is pin and package compatible with industry standard 5 Series and provides reliable sensing in the dirtiest of environments. The electrolyte reservoir is optimised to cope with the challenging humidity conditions of this application, and the high activity catalysts will provide very low drift and fast response times throughout the device’s working lifetime.
The GS+A Series is a range of high performance
carbon monoxide sensors which are optimised for the measurement of flue gas containing high levels of carbon monoxide, where hydrogen may also be present. The sensors contain two sensing electrodes, one which measures both carbon monoxide and hydrogen, and one which measures only hydrogen. By subtraction, the concentration of both gases can then be calculated.
As well as its impressive product portfolio, DD-Scientific is dedicated to its customers, striving to support them as much as possible with fast, honest and collaborative assistance. Whether the company is small or large, DD-Scientific treats each of its customers in the same way, ensuring they are fully assisted throughout the entire process, from an initial enquiry to finding the most appropriate solution for their needs.
Recently, DD-Scientific has extended its manufacturing facility and it is currently expanding the building to incorporate a new Research and Development facility. With a strong foundation upon which it can build, DD-Scientific has some aspirational future goals with ambitious product development plans. In order to support this, the company has invested heavily in Research and Development scientists and engineers, and DD-Scientific is planning to release between 7–10 new products in 2019 alone. DD-Scientific is often in attendance at trade shows in the US and China, and their latest one was Sensor+Test in Nuremberg, Germany. This was a highly successful three-day event for the company, with numerous existing and new clients visiting its stand.
With a remarkable array of accolades since its inception eight years ago, the future remains bright for DD-Scientific, as the company cements itself as a leading expert in manufacturing lifesaving electrochemical gas sensors. If you would like to find out more information on DD-Scientific’s full range of products and services, head to the website. Alternatively, get in touch using the contact details below.
ContactT 02392 [email protected]
DD-Scientific: Making sense in an unsafe world
is sponsored by British Encoder – see them on page 24 19
Lab Innovations Preview
Water, Energy & Environment News
Explore new and innovative technologies reshaping the laboratory industry at Lab
Innovations 2019. The event is the UK’s largest annual trade exhibition focused solely on the laboratory industry, showcasing over 3,000 industry experts with over 150 suppliers and manufacturers spanning all industry sectors.
As a hub of industry figures, the event is ideal for those looking to network with piers and
further their own business and industry ideas. There is a free to attend conference programme supported by some of the UK’s most significant scientific institutions that is integral to developing the future of UK science.
The event hosts 35 hours of free to attend seminars, each one centred on new ideas and concepts introduced to the laboratory industry. Lab Innovations is ideal for anyone looking
to future proof their laboratory, or designing products that help others future proof theirs. Lab Innovations will be held at the National Exhibition Centre, Birmingham from 30–31 October 2019. If you’re involved in the laboratory industry, it is not an event to be missed. For more information visit the website listed below.
www.easyfairs.com/lab-innovations-2019
Explore the future of the laboratory industry at Lab Innovations 2019
As seasoned attendees, the Cole-Parmer team are excited to attend
Lab Innovations on the 30th to 31st October 2019, to demonstrate their flagship products in the Masterflex®, Jenway® and Stuart® ranges, alongside their other laboratory equipment and consumables.
The team invite you to explore the world’s only remotely controlled MasterflexLive™ Peristaltic Pumps bringing the Internet of Things to pump applications and giving operators the ability to adjust critical processes 24/7.
Also, on display are the new intuitive and user-friendly Jenway® 76 Series Split-Beam Spectrophotometers, equipped with CPLive™ technology that gives users remote access to lab results and method files with a click of a button.
Last but not least, Cole-Parmer are stirring up the scientific community with their NEW innovatively customisable Stuart® Hotplate Stirrers. For the very first-time users can customise their own colourful, sleek and technology rich units with their choice of; model type, interface, surface, and colour. Each unit can be designed to bespoke specifications, built for its specific application, and is personal to the owner.
To learn more about these products find the team on stand G6 in Hall 12, and view the full range of products in the new EMEA Catalogue https://cms-resources.coleparmer.com/cr/p/emea-catalogue2019.pdf.
Cole-Parmer is getting ready for Lab Innovations 2019!
is sponsored by DD Scientific – see them on page 1820
Electrical, Electronics & Enclosures News
CHEMUK2019 Review Top 40
This year’s CHEMUK show took place on 1–2 May at the Yorkshire Event Centre, Harrogate in
Yorkshire. It is the UK’s only trade show dedicated to bringing together multi-layer chemicals/chemical product development, specification and processing/manufacturing communities with crucial supply chain supplier groups.
With over 2,500 specialist businesses contributing to the UK’s chemical industry, CHEMUK is the unmissable event where the UK’s chemical industries meet. 2019’s event saw over 170 specialist exhibitors, showcasing the latest plant equipment, materials, and services, making it an exciting and diverse experience for those who attended.
Taking place over two days, the event was a comprehensive supply chain sourcing, business networking, intelligence gathering, best practice and strategy development experience, boasting an outstanding speaker programme featuring over 90 speakers. These experts delivered the latest intelligence, best practice and technological insights, addressing significant topics which are influencing the chemical industry both today and in the future.
Next year’s event will be taking place on 13–14 May 2020 at EventyCity, TraffordCity in Manchester, UK.
This is our pick of the best exhibitors from this year’s show. Further details can be found on this page
T 0203 829 [email protected]
CHEMUK – where the UK’s chemical industries meet
Since its establishment in 1962, GPE Scientific has become a leading distributor and manufacturer
of laboratory equipment, glass blowing products and specialised glass components. The company’s products are used predominantly in the industrial, laboratory and research markets. GPE Scientific is based in Leighton Buzzard, Bedfordshire from which its operations are orchestrated.
The company prides itself on providing the highest quality technical solutions and offering a fully comprehensive selection of laboratory equipment. GPE Scientific’s laboratory equipment is sourced from its Chemistry and Life Science suppliers which include (but are not limited to) Chemglass Life Sciences & Process Chemistry Reactors, Mettler Toledo RX-10 automation, Norell NMR Tubes and accessories and Nanalysis NMReady Benchtop Spectrometers.
GPE Scientific offers a solution for all of your glassware needs. The company offers a host of services, from centreless ground/polished tubing and rods to optical windows to OEM custom components. GPE Scientific has it all.
In 2004, the company was awarded its Certificate of Registration (ISO 9001:2015) for Quality Management Systems, a testament to how seriously the company takes health and safety. All of the company’s tools are checked continuously to ensure that all regulations are met without fail. For more information on GPE Scientific see the details below.
T 015253 82277www.gpescientific.co.uk
Chemistry, Life Science, Sustainable & Glass products
Although there is no industry definition for what a “critical valve” in a process system is, it is commonly
accepted that a critical valve is one which, if left in the incorrect position, or inadvertently operated during routine operations, could result in a significant loss.
So how do operator’s control critical manual valve movements? Some do through key interlocking systems, others solely by procedure, and some through both.
Controlling by procedure? Then the following statement could make you think twice about how you control critical manual valves, “Operating procedures may not be the best
way of controlling hazards, at least not as the sole defence against human error.” UK HSE
A procedure is a document which must be interpreted by the operator. Misinterpretation (human error), or violation of the procedure could result in critical manual valves being left in the wrong position or being inadvertently operated, potentially resulting in significant loss. To eliminate human error / violation in critical valve operations safe operator’s use mechanical interlocking systems. Mechanical interlocking systems eliminate against human by dictating the sequence of valve operation through a trapped key system which only allows
a key to be released in a pre-determined sequence.
For more information on mechanical interlocking systems contact Avenium Engineering
ContactT +44 (0)1642 [email protected]
Eliminating human error in critical manual valve operations to mitigate loss
is sponsored by British Encoder – see them on page 24 21
To help engineers and buyers in the electronic components industry with End-of-Life (EoL) issues and
getting round today’s long lead times for current products, BEC Distribution has announced the availability of direct alternatives to TOKO/Murata, Coilcraft, Vishay and Sumida lines, with short lead times of 6-8 weeks, where most manufacturers are currently working on 16-30 weeks.
BEC’s range of EoL replacements and pin-for-pin replacements for current passives include: shielded power inductors, multi-layer ceramic chip inductors, radial peaking coils, open wire-wound chip inductors and then-film chip inductors.
Background to EoL and current component supply issuesTypically, large component manufacturers discontinue product lines after 5-10 years. This can have a potentially
disastrous impact on customers whose products have longer than expected lifetimes e.g. aerospace, medical, surveillance or defence industry equipment. The availability of BEC’s component replacements will far exceed 10 years.
BEC Distribution’s EoL component supplies will be a lifeline to R&D engineers and buyers, where components have been designed into their product lines.
With a stock of 15m passive components and franchised distribution agreements with quality alternative component manufacturers, BEC can provide high quality, pin-for-pin direct replacement or alternatives.
If the required components are not in stock, then BEC will track down and source matching alternatives, ensuring that EoL issues will not hinder customer’s projects.
T 08454 900405 www.bec.co.uk
Electrical, Electronics & Enclosures News
Problem solved: discontinued passives & long lead times with current components
Bring your latest research to over 450 experts in Power Electronics, Machines and Drives
at #PEMD2020. PEMD delivers the very latest in practical innovations, technical developments and new theoretical research across the breadth of power electronics, machines and drives.
Authors also benefit from: n Indexing on IET Inspec - with 17 million records
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Key conference themes are power electronics, machines, drives and control, transportation, energy systems and advanced manufacturing.
Submit your paper by 13 September at www.theiet.org/pemd
Power electronics, machines and drives experts wanted!
Powersolve’s new PSICL series is a low-cost peak inrush current limiter designed for capacitive and inductive
loads in a variety of applications. these include installations across complex automation systems and machinery as well as isolation transformers or LED lighting applications where they are particularly useful because you can have a large number of LED driver power supplies operating in parallel and all taking high peak currents together on switch on.
The PSICL series is a true current limiter and cuts off all peak currents when starting loads under practically every AC condition. Extreme conditions can occur on AC lines in the event of a break in the supply and when power returns, high current peaks can often cause havoc and will trip circuit breakers. In decentralised areas, this will often lead to increased maintenance costs as the breakers require re-setting. The PSICL current limiter prevents this happening and can result in reduced cable cross section used and smaller and faster circuit breakers.
The PSICL series is available in three 230VAC single phase models with continuous operating current rating of 12A, 16A and 25A. Current limiting time is 100-500mS repeat intervals of 1000mS. They have an operating temperature range of -40°C to +70°C and conform to EN60950-1 and EN61000-6-20-3 standards and are CE and RoHS. MTBF figures are 300,000 hours.
The PSICL is housed in a low profile V0 flammability rated plastic case measuring 91H x 71W x 57Dmm. The same design designated PSESB series is also available in a very slim width enclosure with measurements of 100H x 22.5W x 112Dmm. Both items are DIN Rail mounted and internal circuitry is identical for both versions.
www.powersolve.co.uk/product-category/inrush-current-limiters/
New Din Rail AC Inrush Current Limiter
is sponsored by DD Scientific – see them on page 1822
Electrical, Electronics & Enclosures News
Automotive News
As manufacturers within the automotive industry strive to meet the challenges of a highly competitive global marketplace – particularly within the realms of fuel
efficiency and environmental impact – the die casting industry is undergoing a period of change and development. Time Butler at Ultraseal International discusses these trends and how Lubrolene water-free die-release technology can bring about significant quality, cost, productivity and environmental benefits for manufacturers.
In recent years we’ve seen a shift towards lightweighting in the automotive industry with increasing use of aluminium for powertrain components and a rapid growth in aluminium structural components such as shock towers, rails and torque boxes. In fact, structural casting is now being adopted in higher volume, mid-sized vehicle platforms that need to be manufactured to a consistent quality in multiple global locations.
Fundamental in delivering that functionality is the process of die-casting. Supporting manufacturers to move away from multi-component welded assemblies for vehicle structures, high pressure vacuum die-casting technology is able to provide a complex, one-piece structural component, significantly reducing the assembly, number and weight of components in a vehicle. In practice, substituting traditionally steel components with lightweight, one-piece structures contributes significantly to reduced vehicle weights. That means greater efficiency, reduced fuel consumption and lower
levels of CO2 emissions – all key focuses for automotive manufacturers as legislation around the world places greater emphasis on fuel efficiency, emission and the environmental impact of vehicles.
Further to this, lightweight structures, and the weight reduction associated, are essential for the increasing adoption of electrified vehicles. A segment of the market forecast to grow strongly in the medium, major OEMs are investing significantly to develop the necessary technology cost-effectively.
Developments in die-casting technology have facilitated the design of larger, more complex, structural components which assist the automotive industry with its weight reduction goals. This approach accommodates larger components such as door and window frames, instrument panels and cross members to be produced by die-casting, and has led to a trend toward larger die-casting machines and increasing shot weights.
However, the complexity of large one-piece components makes it difficult to design internal cooling which successfully reduces the temperature of all parts of the die uniformly. This can lead to localised hot spots and solder problems.
Overcoming challengesTo avoid compromising quality and increasing costs in the creation of large, complex components, specifying the correct die-casting lubricant is essential to ensure an adequate release lubricant film is formed over the die surface. However, the surface temperature of the die makes this difficult with water-based lubricants. To ensure the oil film is successfully formed on the die surface some water-based lubricant will remain in the die cavities. This may cause porosity problems and water stain on the casting surface. While residual water on the die surface can be dried using compressed air, this extends cycle times and is a costly consumer of electrical energy, increasing processing costs.
For an industry looking to cast larger components with higher process temperatures and also meet the challenges of maintaining product quality, improving productivity and reducing costs, Lubrolene WFR provides the best solution. Significantly reducing the quantities of lubricant required, Lubrolene negates the need for die cooling by lubricant and delivers a high adhesion efficiency for thicker and more effective film formation. Quality is improved through better molten
metal flow and reduction of the quantity of trapped gases due to no external water-cool, as well as the fact that WFR can be applied at higher temperatures than conventional water-based lubricants, meaning there is less thermal stress on dies. The avoidance of heat cracks extends the service life of the dies significantly – the major source of savings.
With cavities increasingly present in complex pieces, Lubrolene WFR-EC – which features an electrostatic charge – ensures an effective and efficient release. Creating a wrap-around effect, the electrostatic charge delivers consistent, uniform coverage, irrespective of die complexity. Using a specially developed electrostatic spray gun, the application of Lubrolene WFR further reduces soldering problems, providing full, unrivalled coverage. Once the practicalities of complex, one-piece die casting are resolved through the implementation of new technologies and solutions, the benefits for automotive manufacturers begin to emerge fully.
Reduced spray time, increased die life and a low reject rate all lead to enhanced benefits and cost savings for manufacturers. Combine that with zero wastewater from the process and reduced CO2 emissions, as a result of reduced air blow, and the environmental impacts of utilising an efficient casting die release lubricant cannot be ignored.
ContactT 024 7625 8444www.ultraseal-impregnation.com
Increasing die-casing productivity and reducing costs
By Michaël Uyttersprot, Market Segment Manager Artificial Intelligence and Vision at Avnet Silica
There’s a gap between the technology that today’s self-driving cars use to steer along well-lit, well-marked highways and that needed
to drive along an unlit, unmarked country lane at dusk. Many companies are addressing this issue by developing sophisticated embedded-vision systems that can capture scene data and then apply machine-learning strategies to plan a vehicle’s route through such complex environments. Creating such systems requires a development toolchain that enables rapid experimentation, systemic optimisation, and a fast route to commercialisation.
The hardware challengeOne of the main hardware challenges is handling the very large amounts of data created by multiple cameras and sensors. An advanced driver assistance system may have multiple cameras, radar and LIDAR sensors, as well as in-vehicle cameras to sense driver alertness. It’s a similar story for drones and autonomous guided robots, which both use multiple cameras to sense their environments.
Autonomous vehicle vision systems must offer high reliability and functional safety, real-time execution with low latency, minimal power consumption, the flexibility to work with different camera configurations, and extensive capabilities to implement computationally intensive vision
processing algorithms.
Vision systems for cars also need to achieve stringent automotive qualifications, which means that developers must ensure that there’s an easy route from the systems upon which they validate their hardware and software choices to a qualified commercial system.
The software challengeSoftware challenges include processing very large amounts of data, and coordinating the work of heterogeneous multiprocessor system architectures. Machine-learning algorithms are also evolving quickly, so the development environment must allow for late changes to core code. Reliability and safety issues are further complications.
One of the key tasks in developing vision systems for autonomous vehicles is sensor fusion. This involves correlating inputs from multiple sensors of different types, often with very low latency, to correct deficiencies in individual sensors and enable more accurate position and orientation tracking.
Another major software task is to implement efficient machine-learning algorithms, usually some form of neural network, to do object recognition, classification & verification. These machine-learning strategies have become more accessible thanks to the steady rise in general computing power, the development of graphics processing units (GPUs), & field programmable gate arrays (FPGAs), and the availability of very large training datasets.
A development solutionCreating a vision system for autonomous vehicles means exploring trade-offs among the hardware, software, computer-vision & machine-learning aspects of a design. The development solution presented here is for an embedded vision system using multiple cameras, and includes a design methodology, hardware platform, software environment, drivers, and access to worked examples.
The hardware architecture (see Figure 1) supports four 2Mpixel cameras, and will be upgraded to support an additional two 8Mpixel cameras. It uses a Xilinx Zynq UltraScale+ MPSoC, which has multiple ARM Cortex-A53 processors and a programmable logic fabric. The cameras connect over coaxial cables to a multi-camera deserialiser on an FPGA mezzanine card (FMC) plugged into a board that carries the MPSoC.
The Zynq UltraScale+ MPSoCs (see Figure 2) are available with a variety of CPUs, GPUs and video codecs. Their programmable logic fabrics can be configured as hardware accelerators for computationally intensive algorithms.
The design methodologyThe design methodology is based on a set of software resources for developing algorithms, applications & platforms (see Figure 3). The development toolchain supports GStreamer, a multimedia framework for linking media-processing subsystems to complete complex workflows. Its pipeline-based design is well suited to analysing streaming media data using machine-learning techniques.
The programmable logic fabric on Xilinx MPSoCs can provide the computing power needed to run machine-learning algorithms. Toolchains from companies such as DeePhi – acquired by Xilinx – help users apply these resources effectively. The DeePhi Deep Neural Network Development Kit uses the output from the most popular deep-learning algorithm exploration toolkits, such as Google’s TensorFlow or Caffe, as its input. The DeePhi toolkit includes a graph compression tool, a deep neural network compiler, assembler, and a neural
network runtime. DeePhi has also developed hardware architectures optimised for video and image recognition, which can be instantiated on the programmable fabric. The toolchain includes simulators and profilers for these architectures.
ConclusionDeveloping autonomous vision systems for vehicles involves a lot of experimentation and systemic optimisation. Avnet Silica offers embedded-vision solutions bundled with tools and reference designs that enable this experimentation and optimisation, as well as making it simple for developers to access the benefits of hardware acceleration and other, more advanced techniques such as model compression.
For more information go to https://avnet-silica.com/ai4cameras, email [email protected], or contact your local Avnet Silica offices.
Developing multicamera vision systems for autonomous vehicles
is sponsored by British Encoder – see them on page 24 23
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The UK’s Largest Heating Element Manufacturer
Please telephone 029 2077 8727Email: [email protected] | www.elmatic.co.uk
Leading the wayElmatic (Cardiff) Ltd is the largest manufacturer of Industrial Electric Heating Elements in the UK. Elmatic Ltd have the widest product range to meet our customer’s requirements.Our product range includes:
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Industrial Process News is proud to feature British Encoder Products Company (BEPC) for our Products of the Month profile.
BEPC is the European branch of the Encoder Products Group, which is a worldwide manufacturer of motion sensing and control devices. As a customer driven company, BEPC is highly responsive in the areas of customer service and technical support, with an acute focus on high performance, excellent delivery and competitive pricing. These values work together to ensure BEPC provides products and services of the highest quality to guarantee great value for money for every customer. Indeed, BEPC prides itself on building long-lasting relationships, a principle which has facilitated the company’s impressive growth since its inception.
Established in 1969 by Bill Watt, the Encoder Products Group is celebrating its 50th anniversary this year. In the sixties, Bill invented an encoder to provide an output to feed directly into the growing number of counters and PLCs which were being used at the time. His invention, the ‘cube encoder’, revolutionised the encoder world and is now an industry standard.
Recently, BEPC released its new range of absolute encoders, which provide a unique code for each increment of shaft rotation. This means that the encoder indicates both that the shaft position has changed, and the absolute position of the shaft. The company now offers a higher resolution of 16 bits for single turn resolution and 43 bits for multi-turn resolution, meaning the encoders can measure with greater resolution and have a longer run-time before reset.
We had the pleasure of speaking to Stephen Evans, General Manager, who told us more about the advantages of BEPC’s absolute encoders. “This range is ideal for systems which need exact position information in order to prevent damage to machinery and its operators. This is particularly valuable
during power loss, when the absolute encoder will
maintain its value without being powered, so any movement during the loss of power is tracked and
retained for immediate transmission once power is
restored.”
The absolute range has been offered with SSI and CANopen
protocols for years, and BEPC has recently added encoders with EtherCAT
capabilities, with more protocols to follow as the range is developed and expanded. BEPC’s A58HE (hollow bore) and A58SE (shaft) models are EtherCAT ready and designed for harsh factory and plant environments. Suitable for a variety of applications, these encoders plug directly
into a network with minimal prerequisites, working in various configurations with the
ability to continue communication in the event of a line break. Furthermore, these models work
with CANopen over EtherCAT, so implementation remains straightforward for those who are familiar with CANopen.
One of BEPC’s strongest ranges is their programmable incremental encoders, which have been specifically designed for the challenges of an industrial environment. Within this robust casing is a selection of advanced electronics which allow the encoders to be programmed to precise application needs. The optional programming module means users can select from six different output types, choose from 32 different waveforms, and program any resolution from 1 to 65,536 PPR. This means that a single encoder can be configured for multiple applications, making it possible to replace numerous different part numbers with one encoder, thus saving inventory and down time replacement costs. What’s more, these programmable incremental encoders can be shipped with specifications pre-programmed, meaning there is no need for onsite programming.
It is evident that BEPC has remained up to date with the changing needs of the market place since its innovative beginnings. Their absolute encoder range has been expanded in the last year, with further additions to follow in the near future. To ensure its finger is on the pulse of the industry’s evolving
requirements, BEPC’s essential engineering division, based in the US, looks at the market and produces what it demands, working hard to develop products which solve real problems that are surfacing within automation. “We are leading the way, maintaining our position at the forefront of new developments in the encoder world,” said Stephen. Indeed, with further innovations on the horizon, BEPC will be attending the Engineering Design Show at the Ricoh Arena, Coventry on 16–17 October 2019 where the company is hoping to showcase its new range of products.
“We are doing extremely well,” expanded Stephen. “We are growing exponentially, with further growth in the pipeline as we move forward. We are maintaining and growing our market share worldwide, and it’s fair to say we possess a significant share of the encoder market in the UK. Things are definitely moving in the right direction for us, and I would just like to take this opportunity to say a huge thank you to our customers and suppliers, without whom we would never have had the success we have achieved over the last 50 years.”
Indeed, BEPC is cementing its status as an industry leader, offering unparalleled expertise in the development of ground-breaking encoders for all sectors of automation, ensuring they are staying ahead of the game to address the industry’s constant progression. If you would like to find out more information on BEPC’s full range of products and services, head to their website or get in touch using the contact details below.
T 01978 [email protected]
Products of the Month
BEPC is at the forefront of innovation in worldwide encoder market
