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Transcript of Automation Feb 2012
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FEBRUARY 2012 PRACTICAL SOLUTIONS FOR MANUFACTURING EFFICIENCY
INDUSTRY FOCUS INSIDE THIS ISSUE: MEDICAL EQUIPMENT
DRIVES & CONTROLS
Robust drives keepwater flowing
New low costSCARA robotslose weight and save money
SCADA & DATA ACQUISITION
SCADA virtualisationdelivers real benefits
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Enter 1
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NEWS
4. Connecting Industry website: Re-engineered for 2012 and beyond5. Robot sales grow by 68 per cent in 20116. Bosch research finds engineering is undervalued
INDUSTRY FOCUS: MEDICAL EQUIPMENT
10. Micro product support for medical technology innovators12. Making developing wireless, cloud-connected medical devices easier
FEATURES
Drives & controls...
14. Robust drives keep water flowing16. Positioning drives at heart of carpet recycler17. Sensors specified for precision measurement
18. Industrial automation: the road ahead
Materials handling & conveying...
21. Shuttle storage system keeps fashion logistics on the rails22. Mobile system cuts pallet racking floor space in half24. Vertical conveyor keeps engine production line running smoothly25. Modular wide belt conveyor improves flow efficiency
Tracking & traceability...
26. Labelling system provides food producer with full traceability28. First wireless industrial ID barcode reader with Ethernet29. Metabolising statistical benefits with SPC
SCADA & Data acquisition...
30. Ensuring an environmental success for potato supplier32. SCADA virtualisation delivers real benefits
TECHNOLOGY FILE
33. Infrared system finds fertilised eggs34. Positioner combinations close control loop
Managing EditorNeil Mead Tel: 01622 69 9193
Assistant Editor
Heather Ramsden Tel: 01622 69 9167
Publishing Director
Hannah Dedman Tel: 01622 699175
Publication Manager
Jo Pilcher Tel: 01622 699177
jpi lch er@ dat ate am. co. uk
Advertisement Manager
Kelly Byne Tel: 01622 699 195
Classified Sales Executive
John McIntosh Tel: 01622 6 99126
jmc int osh @da tat eam .co .uk
Studio Manager
Siobhan Nolan Tel: 01622 6 99121
Classified Designer
Kirsty Hood Tel: 01622 699 186
Production Manager
Claire Noe Tel: 01622 69 9164
Circulation Enquiries
Capsule Publishing Services Tel: 0845 602 7390
In a quest to build a better mouse-
trap, Toshiba Machine has taken a
long hard look at how to create a
new breed of SCARA robots that
deliver a host of benefits while at
the same time taking a chunk of
costs out of the equation
TM Robotics (Europe) Limited
T: 01707 290370
www.tmrobotics.co.uk
Turn to page 8 for more details
COVER STORY
CONNECTINGINDUSTRY.COM/
AUTOMATION
(incorporating Automation).
To ensure that you continue to receive
your free personal copy of this
magazine, please fill in the reader
registration form with this
issue, or register online at
www.connectingindustry.com
Automation is sent free of charge to
individuals who meet the publishers strict
terms of control. Annual subscription rates:
UK 74, Overseas 96, Airmail 118.
The statements and opinions expressed in
connectingindustry/Automation are not
those of the editor or Datateam Business
Media Ltd unless described as such.
ISSN 1472-1244
Total Average Net Circulation forJanuary-December 2008 is 16,986
Datateam Business Media LtdLondon Road
MaidstoneKent ME16 8LY
Tel: 01622 687031
Fax: 01622 757646
www.datateam.co.uk
Registered in EnglandNo 1771113
Members of the Audit
Bureau of Circulations
Datateam Business
Media Limited
The paper used in this magazine is obtained from
manufacturers who operate within internationally
recognised standards. The paper is made from Elementary
Chlorine Free (ECF) pulp, which is sourced from
sustainable, properly managed forestation.
Contents
Automation
Next month... Features in the March 2012 issue of Automation will include: Machine building & frameworks Machine vision systems PLCs & Industrial PCs Industry focus: Warehousing & logistics Exhibition previews: MACH 2012 and Drives & Controls
Automation FEBRUARY 2012 3
F EB RU AR Y 20 12 P RA CT IC AL S OL UT IO NS F OR MAN UF AC TU RI NG E FF IC IE NC Y
INDUSTRY FOCUS INSIDE THIS ISSUE: MEDICAL EQUIPMENT
DRIVES & CONTROLS
Robust drives keepwater flowing
New low costSCARA robotslose weight and save money
SCADA & DATA ACQUISITION
SCADA virtualisationdelivers real benefits
February 2012
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News Industry
Connecting Industry (www.connectingindustry.com),
the online hub of the UK's leading portfolio of indus-
trial publications has been completely re-engineered
and was re-launched earlier this month.
Connecting Industry is already the UKs largest and
most comprehensive online resource for engineers
and manufacturing professionals, but now it has been
given a complete redesign making it more attractive,
easier to navigate and user-friendly. New search
options, an unrivalled supplier database, interactive
events calendar and rich multi-media content,
together with links to all the major social networks
will ensure that Connecting Industry remains the
number one online source of information for the man-ufacturing industry. Features of the new site include:
Increased Connecting Industry branding of the
home of the UKs largest and strongest portfolio of
industrial magazines.
Each of the Connecting Industry publications
now has a section of its own so that visitors can go
straight to the magazine/story that is of most rele-
vance and interest to them.
The new site offers a fully interactive, user-
friendly search tool for anyone wanting to read the
latest industry news, quality editorial in the form ofapplication articles and case studies, and find the
products and/or suppliers they require. The search-
able database allows users to find companies by
product category, geographical location, alphabeti-
cally or by keyword search - and to do it faster and
more efficiently than ever before.
Built-in web 2.0 functionality so that it integrates
seamlessly with social networks. In this way
Connecting Industry will build a community
between magazines, readers and suppliers.
ConnectingIndustry.com will therefore continue to
be the first website engineers and manufacturing
professionals think of when they require the latest
information.A comprehensive and fully interactive events cal-
endar. Exhibitions, seminars and training events are
a useful way for people in the industry to network
and being able to find them all together in one place
is difficult. ConnectingIndustry.com provides this
service.
The new site makes it even easier to read the latest
digital editions of Datateams industrial magazines,
register to receive printed copies and sign up for
regular e-newsletters.
A brand new and bespoke administration tool
allows our editorial staff to upload the latest news
stories and content quickly and easily keeping the
site up to date and maintaining its position as theleading online industrial news resource.
Many more advertising opportunities, both in
terms of space and interesting and different ways for
companies to get their message across to our dedi-
cated readership.
Bookmark http://www.connectingindustry.com
now and be among the first to experience a new age
in industrial websites.
Connecting Industry website:Re-engineered for 2012 and beyond
CommentAs you can see from our lead story
opposite, the new Connecting
Industry website is now live. This
represents a major investment in time
and resources by Datateam to bring
the site up to date and consolidate itsposition as the leading source of
information for engineers and
manufacturing professionals.
Weve worked extremely hard on
improving the look and feel of the site
in order to make it faster and easier to
use. Each of the Connecting Industry
magazines now have their own clearly
defined sections on the site, so users
can go directly their own particular
area of interest.
A new feature is the site wide
search, so even if youre not exactly
sure where to find the information youneed you can quickly look for it here.
This includes all articles, suppliers and
even events. And that brings me on to
another new feature, the Events
Calendar. With more industry events
being added all the time, this is the
place to find the latest information
about exhibitions, seminars, open
days and other industry networking
opportunities.
The new site also incorporates the
latest Web 2.0 technology which
adds rich multimedia content and links
to all the major social networks.Were really pleased with the end
result and Im sure Automation
readers will find it a very useful tool.
As with any online resource it will
continue to grow and develop and Id
welcome your feedback so please let
me know what you think of it.
Neil Mead - Managing Editor
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Robot sales grow by 68 per cent in 2011
Schaeffler UKs manufacturing
plant in Llanelli, South Wales hasreceived a national award that
demonstrates the companys com-mitment to manufacturing quality.
At this years Wales QualityAwards 2011, Schaeffler UK
received the Chairmans Prize
for Automotive Excellence, anew category that recognises out-
standing achievements of Welshcompanies operating in this
sector of the economy. The WalesQuality Award is an annual com-
petition based on the EFQMEuropean Excellence Model.
www.schaeffler.co.uk
Plant wins award
For the fifth year in a row, Schunk will host the
'Expert Days on Service Robotics' from February 29to March 1, 2012 at its world headquarters in
Lauffen, Germany. As with all the previous events,globally renowned industry and academic experts
from the field of robotics will meet to discuss the
key issues for the sector in depth.The 2012 event will be titled Service robotics -
Quo vadis? As one of the world's leading communi-cation platforms for applied service robotics, this
event will examine the opportunities and potentialfor this rapidly growing emerging market. The
anniversary event will focus on topics such as per-
ception and learning, marketing, robots and compo-nent design, and robots and people.
It has been almost five years since Schunk recog-
nised the potential for an international servicerobotics market and in response, initiated the Expert
Days on Service Robotics in the spring of 2007. Fortwo days, key note speakers from around the world
will present current trends, the latest research and
promising business models. Two of the honouredguests will be Professor Dr Roland Siegwart from
ETH Zurich and Steve Cousins of the US roboticsfirm Willow Garage. In 2012, the Expert Days will
again serve as an intensive forum for the directexchange of ideas between research, industry, busi-
ness and the trade press.For further information contact your local Schunk
representative or visit www.schunk.com
Schunk hosts fifth Robotics Expert Days
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The latest robot sales statistics compiled by the British Robot and
Automation Association (BARA), reveal that sales have increased bya dramatic 68 per cent over the last year. Almost all of the major
robotics suppliers to British Manufacturing have reported this trendwhich is welcome news from the industry.
The most dramatic growth has come from the automotive or auto-motive components sectors with growth of 235 per cent and 176 percent respectively. Surprisingly both the food and drink and pharma-
ceutical, health and medical sectors reported a decrease of 8 per centand 76 per cent respectively.
Mike Wilson chairman of BARA said: We are delighted with such anincrease in industrial robot sales over the year although most of this has
been within the automotive industry. Most sectors have experiencedincreases and this represents the best growth statistics since 1997. Average
growth is nearly 70 per cent year-on-year which represents strong sales for
most of the robot manufacturers."Mike continued "the Government are also putting considerable money behind
the promotion of robotics in UK Manufacturing in recognition that robots actuallycreate more jobs through growth. Currently over 100 companies are making use of the
free automation review open to any UK manufacturer. This in turn should also enhance
growth in robotics over the next couple of years"Companies wishing to make use of the free automation review should contact Grant Collier on
0208 773 8111 or visit the website www.automatingmanufacturing.co.uk
B&R Product of the Month ACOPOSmulti65m
B&R has expanded its line of drives with a series of motor-
integrated servo drives with IP65 protection. The
ACOPOSmulti has always been extremely modular, and it
was the next logical step to merge inverters with the motor
to create servo actuators that can deliver power directly
where it is needed. Configurable modules thus become
easy-to-connect mechatronic units. This not only savesvaluable space in the control cabinet, but also cuts costs
for logistics and commissioning. By combining the latest IGBT technology and
optimized motor types, users profit from the resulting maximum performance. With
three different sizes, the servo actuators cover the entire spectrum, with a torque
range of 1.8 to 10.5Nm and a power range of 500W to 2kW. For applications
that demand more power, an optional fan assembly can be retrofitted for a
performance boost of up to 100 per cent. The ACOPOSmulti65m is fully
compatible with the entire ACOPOS drive series. As a result, it is possible
to utilise all of the tools and features available in Automation Studio as
well as applications created therein. With regard to topology, the new
servo actuator can be employed in either a line or tree structure.
Networking takes place using POWERLINK.
B&R Industrial Automation
T: 01733 371320
www.br-automation.com
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News Industry
In brief
A white paper, based on research
carried out jointly by AC drive tech-
nology company,Vacon and global
computer security provider F-
Secure, provides a detailed insightinto security threats relating to
industrial automation systems. The
paper, which is the result of more
than a years work by Vacon and F-
Secure, identifies and analyses the
nature of the threats as well as
proposing methods for increasing
security. The security in industrial
automation white paper published
by Vacon and F-Secure can be
downloaded free-of-charge from
www.vacon.com
Sato, a specialist in barcode
printing, labelling, and EPC/RFID
solutions, has announced its
acquisition of Argox Information Co,
a manufacturer of barcode printers,
barcode scanners, and portable
terminals, making Argox a member
of the Sato Group of companies.
www.satoworldwide.com
Parker Hannifin Corporation, the
specialist in motion and control
technologies, has signed an
Enterprise Framework Agreement
(EFA) with Shell as a single source
supplier for the provision of instru-mentation valves, manifolds,
process-to-instrument valves, fit-
tings, tubing, protective enclosures
and related products.
www.parker.com
Laser machine specialist and UK
distributor for Mitsubishi laser cut-
ting machines, World Machinery,
has created the website
www.mitsubishilaser.co.uk
featuring information on the LVP
Series and EX Series. UK cus-
tomers can also get information on
performance, installation, service
support and consumables.
Eriks is to move its Slough Service
Centre into its nearby Core
Competence Centre for Industrial
Hose Technology, streamlining cus-
tomer care by bringing two local
engineering services under one
roof. The Slough Service Centre is
a key location for Eriks, serving a
strong customer base in Berkshire
and West London, Hampshire,
Buckinghamshire, Bedfordshire and
Surrey. Eriks will also relocate itsOtley Service Centre to the city of
Bradford, improving customer care
by bringing the operation to a new,
purpose-built facility.
www.eriks.co.uk
One of the largest manufacturing and engineeringevents of 2012 will be taking place at the NEC inBirmingham between 17 and 19 April. Drives and
Controls Show, The Plant and Asset Management
Exhibition, Air-Tech, and the InternationalFluid Power Exhibition (IFPEX) will form
part of the manufacturing and engineeringseries of shows alongside MACH 2012.
Organiser DFA Media believes its seriesof events ensures industry professionals will
be able to gain the broadest insight concerning whatindustry solutions are currently available. The Plant
and Asset Management Exhibition, being launched
by DFA Media, is a new UK event for the mainte-
nance sector, solely concerned with aspects of themanagement and maintenance of physical assets.Organisers are optimistic the Drives & Controls
Show will exceed both the exhibitor and visitornumbers of 2010 which had 103 exhibitors, 16 per
cent more than the previous show in 2008.
The co-location of events attracted more than8,600 visitors in 2010 and Ryan Fuller, exhibitionsales director at DFA Media, believes this figure,
along with visitor numbers will be exceeded asmanufacturing regains confidence.
Next year will include a free highlyfocused seminar programme. New for
2012 is the Energy and Safety seminar the-atre, sponsored by CompAir where themed
panel discussions and seminar presentations
will focus on key energy management topics.Also new is the Motion and Control Industry semi-
nar theatre to include more technical workshop stylepresentations, with practical issues being discussed
concerning the various sectors that makes up Drivesand Controls Exhibition, Air-Tech, and IFPEX.
The Plant and Asset Management Exhibition willalso have two free seminar theatres.
www.drives-expo.com, www.airtech-expo.com,www.ifpex-expo.com, maintenanceuk-expo.com
Manufacturing and engineering showcase at the NEC
Bosch research finds engineering is undervalued
A survey by the Bosch Group, a leading global sup-
plier of technology and services, has found that engi-neering is undervalued and misunderstood by adults
in the UK. The research was carried out amongst1,347 people aged between 18 to 45 years old and in
general shows that many people, particularly younger
adults, see engineering as a back of house function inbusiness that is not critical to the UK economy.
Peter Fouquet, President of Bosch UK, said: Thefindings are concerning given that the engineering
sector in the UK makes up nearly a fifth of the econ-omy and employs over 4.5 million people.
Combined, engineering and manufacturing con-tribute around 800 billion to the UK economy.
The research found that only 45 per cent of people and only 23 per cent of young people thought
engineering was a key industry for the UK economy.Retail, banking and tourism were all seen as more
important. Respondents also did not see engineeringas a frontline role in business, with 92 per cent saying
that they thought engineers have mostly technicalroles in business and less than two per cent thinking
that engineers are involved in running businesses.
Engineering is also not seen as sufficiently attrac-tive to young people, with less than half of 18-24
year olds associating engineering with the wordresearch and more associating it with the word
geeky rather than exciting. In terms of working inengineering, the research showed that only 11 per
cent overall and only five per cent of 18-24 year oldswould consider a career in engineering and more
men would consider an engineering career (23 per
cent) compared to women (three per cent).
Bosch was founded as the Workshop for PrecisionMechanics and Electrical Engineering in Stuttgart in1886. It is now one of the worlds largest technology
and engineering organisations and leading innovators.Bosch employs over 285,000 employees 34,000 of
whom work in R&D and a significant proportion of its
board of management is made up of engineers.
www.bosch.co.uk
Duke of York attends Manufacturing Technology Centres handover
Ahead of its formal opening laterthis year, the Manufacturing
Technology Centre (MTC) held aweek of handover celebrations
with the bodies that have fundedit since the need for a UK centre
of excellence for high value man-ufacturing was first identified
four years ago. Staff and industry
and academic partners at theMTC were proud to welcome
HRH The Duke of York for a tourof the new facility.
The MTC is the result of a
40.55 million investment by
Advantage West Midlands andthe East Midlands Development
Agency and is housed in a land-mark building located at Ansty
Park near Coventry. There arefour initial research partners:
University of Birmingham, TheUniversity of Nottingham,
Loughborough University and
TWI Limited. There are threefounding industry members:
Rolls Royce, Airbus UK and Aero
Engine Controls.
The MTC supports manufactur-ing businesses and was set up inresponse to the UK Government's
Manufacturing Strategy. This envi-
sions the UK as leading the worldin capturing higher value compo-
nents of the global value chain,whilst consolidating areas of exist-
ing comparative advantage withinhigh technology manufacturing.
www.the-mtc.org
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Advertisement feature Cover story
T
oshiba Machine has developed a
new range of SCARA robots thatset new benchmarks for price,
performance, mass and lowenergy consumption. The Toshiba
Machine THL models satisfy the grow-ing demand for affordable, flexible
automation in applications outside ofindustries such as packaging, materi-
als handling and welding where robots
have been installed for decades.The THL range represents more than
simply low cost lightweight robots.Rather, they are the result of painstak-
ing research and development leadingto a radical new design.
The mechanical challenge facingrobot designers has always been the
ability to marry low mass and lowinertia with the necessary rigidityfrom which high accuracy is attained.
Almost always this quest leads to com-promise. To ensure rigidity, mass
inevitably increases. To compensatefor that, oversized servo motors may
need to be deployed and positionadjustments made via the servo loops.
By lowering the mass, smaller motors
and simplified gearboxes can be used,which in turn also has the benefit of
reducing power consumption andhence reducing the price of the resul-
tant robot. The trick is to get the opti-mum balance between all of the
mitigating factors to ensure none of the
machines performance is conceded.Much of the reduction in mass is
thanks to the use of lightweight cast
aluminium mechanical componentsthat have a series of ribbed sections to
provide the rigidity required. As aresult of building the body and arm ofthe robot in this manner, smaller servo
motors have been fitted. Moreover,because the lightweight system gener-
ates substantially less inertia, andreduced demand for continuous posi-
tion adjustments, a simplified gearbox
has been able to be used.So, just how successful has Toshiba
Machines design team been in achiev-ing its objective? Well, the THL range is
up to 50 per cent lighter than otherToshiba Machine models and the robots
consume 50 per cent less electricity.Performance compares favourably with
other models and the new robots fea-
ture easier maintenance than previ-ously. The adage might be applied that
if one can make it better and cheaper,it cannot fail.
The benefit to end users, apart fromprice, is that the new THL robots can
be installed with cheaper, less robustsupports with significantly less need
for vibration suppression a major
advantage for systems integrators.Available on 500mm, 600mm and
700mm arm lengths, the next surpris-
ing revelation is that all three modelshave exactly the same price. ToshibaMachine explains that since the only
difference between the three robots isthe length of the extruded aluminium
tube that forms the arms main beam,
the cost difference is negligible.Each robot has four axes of move-
ment including 360 rotational, witha working envelope of 125 on the
first axis and 145 on axis two.Maximum composite speed using axes
one and two is an impressive 6.3m/sfor the THL 500, 7.1m/s for the THL
600 and 7.9m/s for the largest THL700.Cycle time, with a 2kg payload, is0.45s for the THL 500 and THL 600,
while the THL 700 is only half asecond. Maximum payload is a
weighty 10kg for all three models.
The allowable moment of inertia is
just 0.2kg/m2 and thanks to the use of
absolute encoders repeatability in X-Yis a mere 0.01mm.
The new Toshiba Machine THLrobots are distributed and supported
throughout Europe by TM Robotics(Europe) Limited. To suit the European
markets, the THL robots are controlled
by the proven and popular TS3000controller, which features easy pro-
gramming, in-built PLC functions andEthernet connectivity.
An advantage when it comes to inte-grating automation is the fact that the
unit allows complete system control to
be handled from the robot controller.Equipped with 64 I/O as standard, but
expandable up to 166, the TS3000 con-troller satisfies even the most demand-
ing production line or manufacturingcell requirements. Impressive process
speeds can be attained by taking advan-tage of the Toshiba Machine controllers
PASS and NOWAIT commands.Robot programming is simple and
conducted via a series of dedicated
commands. Furthermore, the TS3000sEthernet connectivity makes it simple
to share vision data from a singlecamera across multiple robots, reduc-
ing maintenance overheads and instal-lation costs while increasing efficiency.
TM Robotics managing director
Nigel Smith says: Industry acrossEurope, in these times of manufactur-
ing austerity, is crying out for anythingthat helps it compete. The new low
cost THL range certainly helps satisfythat need.
But, he adds, this range ofmachines is not simply a value engi-
neering exercise to reduce costs.
Rather it is a thoroughly thought outremodelling that has resulted in robots
that meet completely new and verydifferent design specifications.
TM Robotics (Europe) Limited
T: 01707 290370
www.tmrobotics.co.uk Enter 200
New robots lighten the
load on investmentIn a quest to build a better mousetrap, Toshiba Machine
has taken a long hard look at how to create a new breed of
SCARA robots that deliver a host of benefits while at the
same time taking a chunk of costs out of the equation
The new Toshiba
Machine THL robots
are distributed and
supported through-out Europe by TM
Robotics (Europe)
Limited
FEBRUARY 2012Automation8
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Industry focus Medical equipment
Reaffirming its commitment to
medical technology innovators as
they design equipment toimprove health and save lives,
Molex Incorporated offers a selectedseries of core micro products, which
will be available for purchase, replace-ment and technical support for up to 10
years, in order to more accurately alignwith medical industry design cycles.
Micro interconnect solutions, including
Molex FFC/FPC, board-to-board, micro-miniature wire-to-board and memory
card connectors, are used in a widerange of medical device applications.
Molex offers one of the most com-plete ranges of microminiature fine
pitch connectors to support designersand manufacturers in the medical
industry, states Anthony Kalaijakis,
strategic medical market manager,Molex. Our micro connector series
now carries a powerful commitment ofongoing product availability and sup-
port to help deliver smooth launchesand long product life cycles for medical
devices and equipment.Molex micro products align with the
trend towards smaller, lighter andintegrated solutions for mobile and
portable medical applications. The
firms core micro products includesome of the smallest and most innova-
tive connector systems available on
the market. For example: SlimStack 0.40mm pitch, board-to-board system provides approximately a
25 per cent overall space savingcompared to competitive styles.
IllumiMate 2.00mm wire-to-board
system supplies the narrowest widthof any similar low-power connector
systems, along with significant costand performance advantages.
FPC 0.30mm pitch dual-contact
connector offers the shortest length and
most secure FPC retention comparedwith similar competitive versions,
while eliminating the need to source atop- and bottom-style connector when
routing an FPC to parallel boards. microSD ultra-small 1.28mm
height memory card connector
reduces memory card fly-out andsticking problems in portable devices
such as mobile phones.From portable electronic defibrilla-
tors and handheld blood glucose mon-itors to drug infusion pumps and
medical imaging equipment, Molex
offers innovative interconnect solu-tions to meet the needs of medical
technology designers today and adecade from now, adds Kalaijakis.
By blending proven commercialtechnologies, cost-effective modified
off-the-shelf and custom products,Molex is helping to lead the way in the
integration of commercial electronics
into medical applications. Molexworks in conjunction with its medical
equipment manufacturer customers todevelop solutions that economically
support industry compliance andhealthcare needs.
More information
For more information about micro
interconnects for the medical industry,
please visit the website below. Toreceive information on other Molexproducts and medical industry solu-
tions, readers can sign up for the regu-lar Molex e-nouncement newsletter at
www.molex.com/link/register
Molex
T: 01252 720720 Enter 201
www.molex.com/industry/medical.html
Molex delivers complete interconnect
solutions for a number of markets
including data communications,
telecommunications, consumerelectronics, industrial, automotive,
medical, military, lighting and solar.
Established in 1938, the company
operates 39 manufacturing locations
in 16 countries.
Micro product support for
medical technology innovatorsMolex is offering a 10-year commitment to micro product
availability and technical support reflecting lengthier design
and product life cycles for medical devices and equipment
Molex works in
conjunction with its
medical equipment
manufacturer
customers todevelop solutions
that economically
support industry
compliance and
healthcare needs
Customised float switches for medical use
Customised float switches from elobau, for medical applications, are configured with thecustomers application in mind. A typical use in the medical industry would be a dialysismachine where the cleaning cycle is an essential part of the systems function. This part of
the process proves the biggest challenge for elobaus component - after one patients
treatment water is pumped through the machine and heated to a high temperature, this
heated water flushes through the system and the clean system is ready for the
next patient to begin treatment.
A miniature float switch was designed to suit this application and
the customers functional and material specifications. Special
temperature shock testing was completed by the engineering
department at elobau to validate the correct design. Creating a
reliable product for this application is difficult - the specific design
meant that the miniature float switches were created without any epoxy in
the stem of the float to ensure reliable function of the reed switch during the
challenging temperature cycle. These products can be manufactured using one type of plastic like PP or PVDF and a
correctly specified elobau float switch will not contaminate fresh water and has no issue with harsh chemicals. elobaus
flexibility means that a solution can be found for all medical level measurement applications.
elobau UK T: 0161 2661180 www.elobau.com Enter 202
FEBRUARY 2012Automation10
Float switches from
elobau can be
customised for
medical
applications
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Industry focus Medical equipment
The kit includes the Freescale
Semiconductor Home HealthHub (HHH) reference circuit
board which enables wired andwireless connectivity to medical
devices like blood pressure monitors,
blood glucometers, pulse oximetersand scales. It also features the iDigi
Device Cloud, allowing medicaldevices to easily and securely inte-
grate patient data into new, existingand custom healthcare applications.
Cloud-connected medical devices
help patients get out of the hospitalfaster by allowing doctors to monitor
patient status remotely, says LarryKraft, senior vice president of global
sales and marketing, DigiInternational. This kit makes it easy
to create cloud-connected medicaldevices to improve quality of care.
Through the iDigi Device Cloud,doctors can easily access and analyse
patient data, set up alarms and alerts
and store information.Telehealth is a growing technology
that allows patients to be monitored
remotely, says Steven Dean, globalhealthcare segment manager atFreescale. According to a Continua
Health Alliance study, remote moni-toring for individuals with chronic
conditions can reduce office visits by
65 per cent, shorten the length of hos-pital stays by up to six days on aver-
age, and most importantly, reducemortality anywhere from 35 to 56 per
cent. We are excited to work with Digito help enable this growing trend.
In addition to allowing management
of remote patient data, the iDigi Device
Cloud enables centralised control ofmedical device configurations, set-tings, firmware updates and device
groups. With iDigi Manager Pro, iDigisdevice network management software,
healthcare institutions can rollout largeinstallations of cloud-connected med-
ical devices in a simple, secure and
cost-effective manner.Based on the Freescale i.MX28
processor, the HHH reference platformincludes the hardware and software
components necessary for connectinghealthcare devices and user interfaces.
It includes pre-validated secure con-
nectivity with USB, Bluetooth,
Bluetooth Low Energy and ZigBeemedical-class grades, WiFi, sub-1GHz
and Ethernet. Medical device manufac-
turers can use the kit to develop proof-of-concept prototypes of network
connected medical devices.Design experts from Spectrum
Design Solutions, a subsidiary of DigiInternational, are also available to pro-
vide complete design and developmentservices, including assistance with
product development and certification
based on the HHH reference design.The iDigi Telehealth Application Kit
is now available. For more informationabout the iDigi Device Cloud, a leading
platform for connecting any applica-tion to anything, anywhere, visit the
website below.
Digi International is aiming to makewireless M2M easier by developing
reliable products and solutions toconnect and securely manage local or
remote electronic devices over the net-work or via the Web. Digi claims to
offer the highest levels of performance,flexibility and quality, and markets its
products through a global network of
distributors and resellers, systemsintegrators and original equipment
manufacturers (OEMs).
Digi International T: 01943 605055
www.idigi.com Enter 203
Making developing wireless, cloud-
connected medical devices easierDigi International has launched the iDigi TelehealthApplication Kit a development kit that allows customers
to create cloud-connected medical devices
The Digi Telehealth
Application Kit from
Digi International
allows customers
to create cloud-
connected medical
devices. These canthen integrate
securely with
patient data via the
iDigi Device Cloud
Sensor manufacturer expands to meet medical demand
Gems Sensors & Controls (Gems), the global manufacturer ofcustomised, application engineered sensors, controls,solenoid valves and sub-assemblies has expanded its facilities
for the development and manufacture of specialised medical
products. Increased demand from around the world has led the
company to open a new Medical Processing Area at its
headquarters in Plainville, USA; together with a recently
completed expansion of its sensor and controls production
operation this adds a further 1,858m2 of manufacturing space.
Gems has experienced continued growth over the past 10
years, particularly in the medical sector. The new Medical
Processing Area will allow the company to improve its product
development and manufacturing layouts, providing better
material and product workflow to address the specific needs of customers in the
medical sector, while ensuring safer working areas for employees. The additional
space will also allow Gems to expand its workforce.
Gems has served the medical sector for more than 20 years,
providing ISO13485 certified products for the specialised fluid control
and handling requirements of the medical device, diagnostic, life
science, and biotechnology market segments.
We are delighted with the expansion of our manufacturing
facility, says Patrick Murphy, VP and general manager for Gems
Sensors & Controls. The additional space will allow us to continue to
grow our product offering and serve the unique needs of our
customers around the world. I am particularly excited about the
addition of a dedicated processing area to accommodate the exacting
requirements of our customers in the medical sector, as it will
increase our ability to design new and innovative solutions that are
purpose built for each application.
Gems Sensors & Controls T: 01256 320244 www.gemssensors.com
FEBRUARY 2012Automation12
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Feature Drives & controls
In water works and waste water
treatment facilities, pumps often
have to process great amount ofliquid. High-performance drives
are therefore necessary for smoothoperation. In such applications, drive
units are often subject to extreme envi-ronmental conditions, and must be
designed accordingly. But in additionto climatic conditions, other factors
also play a great role in the choice of
the drive technology supplier. Thetotal cost of ownership needs to be
taken into account and savings in thewrong place can result in considerable
additional efforts and expenses.The waster water treatment plant in
Tunis, which is operated by publicenterprise ONAS (Office National de
lAssainissement), has eight pools in
which mixers powered by two largegeared motors ensure steady circula-
tion. Thereby, the waste water is oxy-genated, enabling the decomposition
of dirt particles through bacteria.The plant supplies Tunis and its
metropolitan area with process water,covering the needs of approximately
2.5 million people. It features drive
technology that is nearly 30 years oldand must be replaced step by step.
A robust design is a must for newdrive solutions, since the units are
installed outdoors and operate non-stop while the temperature fluctuates
considerably. In winter, the tempera-ture can drop to -5C, while up to 45C
is possible in summer.
Up to now this has frequentlyaffected the lubrication of the origi-
nally installed gear units, requiringmaintenance to a problematic extent.
The goal was therefore to implementlower-maintenance drive solutions
which are well-suited for extreme
environmental conditions.
Avoiding false economiesThe original drive technology equip-
ment in the Tunis waste water treatmentplant was supplied by manufacturers
from South and West Europe. However,the units that needed replacing have
now been discontinued, which meansthat spare parts were becoming increas-
ingly scarce and lead times longer. Thisfact contributed to the decision to find a
new supplier, which is where Nord
Drivesystems came into play.The company has been operating a
sales office in Tunisia since 2003,which had already successfully imple-
mented some smaller-scale projects.Drive technology from Nord, which is
slightly more costly than comparableproducts, is said to require less main-
tenance, thereby minimising operating
costs and optimising the availability ofthe plant. ONAS wished to benefit
from these advantages. During thecourse of 2009, Nord delivered two
combinations of helical shaft gearunits and Siemens motors which have
since proven themselves during con-tinuous operation.
Getting a grip on heatNord uses a high-quality syntheticlong-life lubricant for the helical shaft
gear units. It withstands the ambienttemperatures considerably better than
mineral oil with the latter, the oil filmwould break down at high tempera-
tures, resulting in increased wear andtear. Each gear unit requires 210l of oil
which has to be changed after approxi-
mately 20,000 hours of operation.Other manufacturers often stipulate
shorter maintenance intervals, whichmakes a considerable difference at a
price of 10-18 euros per litre. An oilcooling system additionally increases
operational safety in the Nord gearunits: a temperature sensor constantly
monitors the temperature of the lubri-
cant and activates the cooling systemas soon as a configurable limit is
exceeded. In this application, the limitis 60C. Heated oil is then pumped out,
cooled by an oil cooler and returned to
the gear unit. When the temperaturefalls below 40C, the cooling systemswitches off automatically.
Drive technology in detailCurrently, two helical shaft gear unitswith a 132kW performance from
Nords SK 12382VZ series are installedat the waste water treatment plant.
They are combined with Siemensmotors via IEC adapters. Nords helical
shaft gear units are available as two- orthree-stage basic types with hollow or
solid shafts, in foot mounted, flange
mounted, or face mounted versions
each with the same housing. Suitablefor integration into limited installationspaces, they can be combined with
many components from the modularNord system. ATEX models and
models with IP55 or IP66 protectionare available on request for all types.
All gear units are manufactured
according to the UNICASE concept,originally developed by Nord in 1981,
which enables maximum performancefor small gear dimensions and ensures
operational safety, high efficiency, highoutput torques, high resistance to axial
and radial loads, low-noise operation,low maintenance and a long lifetime.
Nord Drivesystems
T: 01235 534404
www.nord.com Enter 205
Robust drives keep water flowingRobust gear units from Nord Drivesystems
are ensuring smooth operation at a wastewater treatment facility in Tunis
In the Tunis waste
water treatment
facility, the con-
tents of eight poolsare stirred by
robust drive units
FEBRUARY 2012Automation14
Nords low-
maintenance
helical shaft gear
units are operated
with a synthetic oil
lubricant and
thereby resist even
high ambienttemperatures
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Feature Drives & controls
The Fibrebak pile removal system
separates the fibres from the back-ing and gives separate outputs
suiting both carpet factories andpost-consumer waste. An infeed con-
veyor is manually fed with carpets orcarpet tiles. The carpet is brought to a
horizontal saw blade that is finely
adjustable to the heights of the pile andbacking. Vertical motion is achieved
through 10KN screw jacks and posi-tional accuracy is achieved with the
aid of motor-mounted 2048 pulseencoders. Separate out-feeds deliver
fibres to the side of the machine and
backing material to the rear. A touchscreen operator panel is positioned to
the front and side of the machine,easily accessible for the operators.
One of the advantages offered by theLenze system is the way 10 inverter
variable speed drives have integratedpositioning functionality. On the
Fibrebak machine, positioning is
required to set the height of the blade
head, the tracking and the blade grind-ing wheels. The Lenze 8400 HighLine
inverters feature point-to-point posi-
tioning with the associated travel pro-files and 100kHz evaluation of encodersignals, all without need for external
control. Set-up is made simple with L-force engineer software, and a plug-in
memory module allows drives to be
exchanged without reprogramming.The Lenze solution ranges from the
motors right up to the screw jacks andthe inverter drives. CAN is the chosen
field bus as it is standard at no extracost in the 8400 inverter drives. The
CAN network covers the 10 HighLineand a further two 8400 StateLine
inverters. The remaining five motorsare fixed speed.Further system simplification and
cost reduction is achieved by the SafeTorque Off (STO) option on the Lenze
inverters. This is certified to ISO 13849-1 Performance Level e meaning that
after a safety stop signal the machine
can be worked on without fear of
uncontrolled movement. The STOoption means that a safety contactor
between the drive and the motor is notrequired. Furthermore there is no need
to disconnect the power to the drives sorestart can be instantaneous without
waiting for the drives to boot up. SafeTorque off is a popular option on all
8400 drives that invariably reduces cost
through system simplification.A mix of motors and geared motors
is supplied by Lenze. For intermittentduties such as adjustments, worm
gearboxes are suitable as they are lowcost and the energy losses through
inefficiency are insignificant. The
same applies to the screw jacks whichhave short running times. Where the
duty approaches 100 per cent, forexample on the feeds, high efficiency
geared motors are supplied such as thetype GKR, a bevel helical design with
wear-free efficiency at around 96 percent. Power ranges from 90W for the
blade tracking up too 11kW for the
blade drive.
Positioning drives at heart of carpet recyclerSellers Engineers of Huddersfield manufacture carpet
finishing machinery for markets across the world. Its new
patent-protected Fibrebak machine, aimed at the North
American market, processes waste and used carpet,
recovering the reusable fibres. It uses 17 axes of Lenze
drives and 10 of these have built-in positioning functionality
capable of achieving precise machine settings.
Using Lenze drives
has allowed Sellersto produce a simple
automated system
that reduces costs
through a reduction
in components and
faster build times
Lenze
T: 01234 753227
www.lenze.co.uk
Enter 206
POWER DISTRIBUTIONENCLOSURES CLIMATE CONTROL
We are inventing the future.Benefit from Rittal The System. with its system solutions tailored precisely to the needs of your industry.
Experience a whole new dimension in customer benefits with our globally available product diversity, now
summarised for you in the latest edition of our Catalogue 33. Order your copy of the Catalogue now, either
from www.rittal.com/HB33 or by using the adjacent QR code.
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Feature Drives & controls
I
t could be claimed, with consider-able validity, that as soon as remote
I/O modules became available, theprocess of convergence between
PLCs and DCSs was underway. Withthis in mind, its hard to see the con-
vergence of PLCs and DCSs as a newtrend since its already been with us
for at least a couple of decades.
But, of course, convergence continuesto spread and most modern automation
systems of any size now incorporateintelligent devices such as variable-
speed drives with built-in intelligence,and electronic operator interface panels
in the field. With all of these devices
linked to the central controller via net-work or fieldbus connections, it does
indeed become difficult and even, per-haps, almost meaningless to distin-
guish between the PLC and theremainder of the automation system.
Except, that is, within the controlpanel itself. It is astonishing to realise
that, although conventional hardwiring of field devices has virtually
disappeared in all but the smallest of
installations, traditional hard wiring isstill very much the norm inside most
control panels.The wiring runs are, of course,
much shorter inside the panel thanoutside, but thats no longer a valid
reason to ignore the benefits that bus-
based panel wiring which is perhapsbetter described as lean panel wiring
can provide. This surprising omissionin automation technologies has, how-
ever, finally been addressed, and atleast one bus-based lean panel wiring
system SmartWire-DT from EatonsElectrical Sector is now available.
This allows all of the devices
within a control panel, such as motorstarters, HMI panels and even conven-
tional pushbuttons and indicatorlights, to be connected to the central
controller, whether its a PLC or asmart relay, via a simple daisy-chain
connection. Conventional controlwiring is eliminated.
Its important to note that with thebest lean panel wiring systems, special
components are not needed. Instead,inexpensive interface units are added
to standard components in exactly the
same way that an auxiliary contactblock is added to a contractor.
Benefits of lean panel wiring
Some of the benefits of this technologyare instantly apparent. It cuts panel
wiring time, for instance and, since itvirtually eliminates the possibility of
wiring errors, the time needed to testpanels is also greatly reduced, as is the
risk of problems during commission-
ing. It is also clear that modificationsto the panel can be made much more
easily instead of having to carry out
extensive wiring changes for even thesimplest modification, all thats
needed is to daisy chain the new com-
ponents to those already there.
Possibly the biggest benefit, how-ever, is that the use of lean panelwiring facilitates the flow of informa-
tion between components mounted inthe panel. A suitably equipped motor
starter could, for example, report therunning current of the motor and the
status of the protection device to the
central controller, where this informa-tion could be processed and used to
initiate further actions, such as sendinga message to the HMI panel alerting the
operator to an impending overloadcondition before a trip actually occurs.
Put simply, adopting lean panelwiring can greatly improve the trans-
parency of the automation system.
Since fieldbus- and network-basedfield wiring already supports informa-
tion exchange, the addition of lean
panel wiring means, in essence, that
any information about any aspect of
the automation systems operation andstatus can be made available whereverits needed.
This transparency is one of the keyelements needed for lean automation,
which is one of the reasons that thedescription lean panel wiring for the
new bus-based panel wiring systems is
preferred. The growing uptake of leanautomation is arguably a much more
significant trend than PLC/DCS con-vergence. Lean manufacturing is a
well-known concept that is based onidentifying all sources of waste and
inefficiency in a process and eliminat-ing them. Lean automation extends
this concept to automation systems,
slimming down control panels, simpli-fying wiring, increasing data trans-
parency and enhancing performancewhile reducing overall costs.
With the introduction of lean panelwiring, lean automation can now
cover every facet of manufacturing
processes, from the ERP system rightdown to an emergency stop button,
and from the SAP package down toindividual sensors.
Trend for converganceIn summary, there certainly is a trendfor PLCs and DCSs to converge and
this trend is continuing because con-
vergence has already been shown timeand again to deliver excellent results.
This much is hardly news.What is news, however, is the emer-
gence of lean control panel wiring sys-tems that mark one of the final stages in
the transition from traditional controlsystem technologies to modern net-
work- and bus-based technologies. This
greatly facilitates the implementation of
transparent automation, and that mostdefinitely is a trend worth watching.
Eaton Electric
T: 08700 545 333
www.eaton.com Enter 208
Industrial automation: the road ahead
A recent Frost & Sullivan report highlights the convergence
of programmable controllers (PLCs) and distributed control
systems (DCSs) as an important market trend, but also notes
that this is a technical strategy that has yet to demonstrate it
can yield the expected results. Stuart Greenwood of Eaton
Electrical argues that this trend is, in fact, well advanced and
is already delivering excellent results
Stuart Greenwood
of Eaton Electrical
FEBRUARY 2012Automation18
Put simply, adopting lean panel wiring can
greatly improve the transparency of the
automation system
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Feature Materials handling & conveying
Automation FEBRUARY 2012 21
The first Knapp Fastbox has beeninstalled at the site of third-party
logistics supplier, JCL Logistics,in Werndorf, Austria.
Fastbox is essentially a tall storage
tower for containers, trays or cartons,served by the ultra-rapid lift module
from Knapps OSR Shuttle storagesystem. Any number of these Fastbox
buffers can be located directly adja-cent to the order picking stations and
used to store fast-moving products,
such as lines that are included incurrent promotional campaigns.
The short transport distance fromthe picker and the ultra-fast handling
combine to ensure maximum pickingspeed for these frequently required
goods. Fastbox modules can also act as
a buffer for order containers or as ameans of sequencing containers ready
for robotic palletisation or route-opti-mised vehicle loading. The Fastbox
towers can be up to 12 metres inheight, with the number of levels
variable according to container height.Craig Rollason, head of sales and
marketing for Knapp UK, explains:When combined with the random
storage of the OSR Shuttle system, the
Fastbox solution allows the needs of amuch wider range of customer appli-
cations to be met. In other words,Fastbox makes the OSR Shuttle suit-
able for fast-movers, as well asmedium-movers and slow-movers.
The solution is therefore attractingconsiderable interest in the market.
The solution supplied by Knapp to
JCL Logistics allows both hanging andflat-packed garments to be handled
with ease. JCL Logistics has more than60 sites across 25 countries and pro-
vides distribution services for anumber of clients including a majorSwiss fashion retailer. The company
recently invested over 18 million eurosin its 45,000m2 Werndorf facility.
The distribution centre accommo-dates some two million hanging gar-
ments, 15,000 containers and 10,000pallets. Designed to use automation to
meet both B2B (retailer) and B2C(online consumer) demands in a flexi-
ble way, the site features not onlyKnapps proven OSR Shuttle solution,
but also the overhead conveyor sys-
tems of Knapp subsidiary, DrkoppFrdertechnik.
Shuttle-based storage
At the heart of JCLs order picking opera-
tions lies Knapps shuttle-based storage
system. The OSR Shuttle system fea-tures an independent shuttle on every
level of the storage cube, served by ded-icated lifts at the aisle ends. This system
is said to achieve up to six times the rate
of totes in/out than a traditional auto-mated storage and retrieval system
(ASRS), while having about 20 per centless footprint and using less than 10 per
cent of the energy consumption. Thispower saving is achieved through
energy recuperation from the braking
process, the use of sophisticated soft-
ware to optimise power requirementswithout loss of performance and intelli-gent design to minimise shuttle weight.
Ergonomic picking
JCL placed great emphasis on the
design of the new facilitys worksta-tions to ensure that they would be as
ergonomic as possible. This not onlyshows consideration for the physical
needs of workers but also ensures
maximum productivity. As well asallowing plenty of natural light in the
work area, user-friendly materials
such as warm-to-touch wood andcushioned fascias were incorporatedinto the design of the picking stations.
Knapp UK
T: 01844 202149
www.knapp.com Enter 211
Shuttle storage system keeps
fashion logistics on the railsLeading warehouse automation supplier, Knapp, recently
handed over the first installation of its Fastbox solution,
designed to speed up the picking of fast-moving products
Knapp Fastbox
system installed at
JCL Logistics in
Werndorf, Austria
Video system helps resolve service issues
Warehouse automation supplier, Knapp has launched a video-based t roubleshooting servicefor its customers. Available as an addition to any service contract, Knapps KiSoft Web Eyeallows live, bi-directional video and voice transmission to identify and resolve service issues at
the customers site. Wearing the fully mobile kit, a client employee or a Knapp engineer can
transmit live images and sound from the actual location of any problem to Knapps customer
service experts at the companys headquarters in Graz, Austria. This 24-hour service uses WLAN
technology to connect with the customer network and allows hand-drawn sketches, videos orinstructions to be sent quickly and easily, directly to the operators display on-site.
Ebb Kretschmer, head of customer services for Knapp UK, comments: KiSoft Web Eye is a
really clever piece of kit that results in clearer communication of service problems and, consequently, much faster
resolution of any issues. As well as being used for real-time scenarios, the equipment can also be used for long-term
monitoring. With the record function, users can perform time-delayed analyses that help to pinpoint trouble spots.
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Feature Materials handling & conveying
Often seen as a system only
required by large companies,
Komori, a small to mediumsized manufacturer and sup-
plier of printing production equip-ment and machinery, recently
purchased a mobile racking systemfrom SSI Schaefer that has now been
installed within its new premises inLeeds, Yorkshire.
Reduced spend
The reduction in pallet racking floor
space in Komoris case 372m2 (floorfootprint of existing pallet racking
layout) less 195m2 (floor footprint of a
mobile pallet racking layout) equals180m2 floor space saved also meant
that the company was able to reduce its
required spend when looking at newpremises to move its operational facility.
Darren Etherington, parts manager,
Komori, says: We have achieved sig-nificant space and cost savings as a
result of Schaefers mobile pallet rack-
ing system which is good news for thebusiness storage capacity is often
scarce and expensive but this systemhas allowed us to gain high density,
easy to access storage space withouthaving to pay out for larger premises
than necessary.Stewart Hardy, area manager, SSI
Schaefer, says: Mobile racking sys-
tems are the ideal alternative for usingexisting space more cost-effectively
whilst storing manifold or varyinggoods. Our systems consist of rack
units mounted on a carriage; hence therack units are mobile and save the
space which a conventional rackingsystem would require for aisles.
He continues: According to the
requirements of the customer, ourracking systems are designed for vari-ous weights and heavy load mobile
racking systems move on rails, pow-
ered electrically. Racks for light andmedium loads can be operated manu-
ally and without tracks.
Mobile racking advantages
In direct comparison with traditionalcompact warehouse systems, the
advantages of mobile racking systems
include: Space utilisation - for the same
volume of warehoused goods, mobileracking systems require 40 percent less
space than stationary racking systems. Warehouse volume - in the same
amount of space, up to 85% morewarehouse volume can be stored using
mobile racking systems instead of con-
ventional systems. Building planning - with a space
utilisation percentage of 65 85 percent, the use of mobile racking systems
can have a positive effect on the over-all costs of a warehouse building.
SSI Schaefer
T: 01264 386600www.ssi-schaefer.co.uk Enter 212
Mobile system cuts pallet
racking floor space in halfKomori UK has achieved a 50 per cent
reduction in pallet racking floor space thanks
to the installation of a more cost-effective
mobile system designed by SSI Schaefer
Komori UK has
made a 50 per cent
saving in required
pallet racking
space thanks to a
mobile solution
from SSI Schaefer
Semi-automated cart improves battery changing efficiency
Arecent innovation from motive power specialist,
EnerSys is a four-tier battery handling system.
This is said to reduce significantly the footprint of
lift truck battery change and charge operations,
facilitate easy maintenance and maximise opera-
tional safety. Four-high battery banks are a natural
development for larger operations which demand
maximum flexibility and allow extra capacity through
modular expansion as the business grows.
The configuration of the installation allows main-
tenance engineers to work safely and without
disrupting normal warehouse operations while a
proportion of the battery bank is taken offline. All-
electric drives for lift and travel eliminate the use of
hydraulics used in previous models. This simplifies
service and maintenance.
The Pro-Series BBE-QS is a semi-automated
electric powered change cart which runs on con-
cealed rails alongside the rows of chargers. When a
battery change is required, the truck approaches the
changing area, its battery disconnected and a trained
member of staff completes the change. The BBE
extracts the battery from the truck onto its on-board
roller bed and then pushes the battery into place for
charging. Changing a battery is a quick and simple
one-man job with no manual lifting or handling
which can be accomplished in around two minutes.
Enersys Motive Power T: 0161 727 3800
www.enersys.com Enter 213
FEBRUARY 2012Automation22
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R. A. RODRIGUEZ (UK) Ltd.TURNING IDEAS INTO
ENGINEERING SOLUTIONS
Tel: 01462 670044 Fax: 01462 670880Email: [email protected]
Compact Power
Weightand space saving
linear/rotary actuators+ custom drive solutions
www.rarodriguez.co.uk
I D E N T IB A D G E20 Year Anniversary Celebration
20% O F FyourFIRST FEBRUARY O R D E Rwhen you quote discount code:AF20
w w w. i d e n t i b a d g e . c o m T: 020 8645 2555 F: 020 8645 2333
Applicable to new and existing customers. Once only use.
Enter 18 Enter 19
Enter 17
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Feature Materials handling & conveying
The new facility at Ricardos
Technical Centre in Shoreham,West Sussex provides a near clean
room production environmentand has the capacity to produce 4,000
engines annually across two dailyshifts. Its core is a 10-station vertical
conveyor mini-line supported by
incoming materials inspection andline-side delivery of components. Each
station is equipped with a sophisticatedMacDonald Humfrey Human Machine
Interface (HMI) providing guidance toeach operator on the precise sequence
of operations required at each stage of
assembly. The tools and assemblyequipment used at each station are
instrumented, and provide datadirectly into a central warranty data-
base for each engine built, providingcomplete finished product traceability.
Each line station is interlocked viaits HMI to ensure that all operations
and checks have been successfullycompleted and recorded before the
line can be indexed and the engine
moved forward to the next station. Inaddition to the main production line,
the facility includes a cylinder headsub-assembly line, dress area and an
end-of-line hot test cell that enablesthe performance of every engine pro-
duced to be fully tested and validated.
The brand new facility was speci-fied, designed, constructed and com-
missioned in just 18 months.
No Fault Forward assembly
This is the first time Ricardo has man-ufactured an engine, so Exmac
Automations previous experience of
No Fault Forward (NFF) assembly ona similar engine build project for
Harley Davidsons V-Rod engine was
invaluable. The V-Rod line was a fullyautomated EMS-driven loop systembut, as there was less space in the new
Shoreham facility, Exmac worked withRicardo to determine the number of
stations required and understand the
various processes they would need for
engine assembly, how engine blockswould be loaded and unloaded from
the line, the type of DC-tooling, andthe level of control required, etc.
The design of the Exmac handlingsystem allows Ricardo to load engine
blocks onto the line and rotate them atany of the 10 assembly stations. The
system is also indexed manually to
allow greater control over the assemblyprocess, provide the flexibility to
accommodate long cycle times andenable Ricardo to achieve batch produc-
tion of single engines or different
engines as required. To meet the specifi-cation within the space available Exmacdesigned a compact 10-station back-to-
back manual line that takes up very
little floor space in the new building.Engine blocks are fixed to light-
weight trolleys using a verticallymounted slew ring and quick release
plate, which mates with a bracketlocated on the engine bell housing.
Whilst the engine block is locked inplace, it can also be rotated through
360 degrees to allow complete access
for operators. An engine starts its buildsequence at station one and when all
assembly functions at that station arecompleted the control system allows a
stop to retract, enabling the operator topush the trolley to a holding position
until station two is clear. The system
then allows the trolley to be pushed to
station two where the same stop and
lock procedure holds it in place forthat stations assembly functions to be
carried out and so on to station 10.Trolleys run in a steel track to facili-
tate manual handling by operators; anda latched turn-post at each end of the
line (providing a swing-gate effect)allows trolleys be re-directed to the
opposite side of the line after assembly
operations at station five are completed.When a trolley reaches station 10 the
engine block has been transformed intoa fully assembled, complete engine.
Bespoke HMI
Exmac-designed mechanical lockingsystems accurately locate and secure
trolleys in position at each station,
whilst also ensuring that they cannotbe released unti l the MacDonald
Humfrey HMI system confirms that
operators have completed all requiredtasks at each station, and assembly cancontinue on a no-faults-forward basis.
The bespoke HMI system developedfor the Ricardo engine line takes oper-
ators step-by-step through the process
of building an engine, providingdetailed on-screen information and
visual aids at each of the 10 stations,and even including instructions for
every bolt to be tightened and its par-ticular torque and angle.
In order to optimise the two-hourengine build sequence, Ricardo also
uses the HMI system to monitor thelines indexing against real-time opera-tor performance.
Exmac Automation T: 01905 721500
www.exmacautomation.co.uk Enter 214
Vertical conveyor keeps engine
production line running smoothlyMacDonald Humfrey Automation (MHA) and sister company
Exmac Automation have joined forces to help automotive
engineering specialist Ricardo create a state-of-the-art 600
square metre assembly facility to build a new high
performance engine for the new McLaren MP4-12C road car
A Siemens PLC
drives the
mechanical
operation of the
line. It is backed up
by a server-based
PC system that
drives the build
instructions
FEBRUARY 2012Automation24
Whilst this is a
manual system and
trolleys are pushed
to each of the 10
stations, they are
locked and
released by key
switches at each
station; enablingRicardo production
engineers to verify
the status of every
aspect of the build
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Feature Materials handling & conveying
Automation FEBRUARY 2012 25
Everything in the wide belt con-veyor, from the smallest compo-
nent to horizontal plain bendsand fully functioning conveyor
modules, is standardised for easierengineering, simple maintenance and
trouble-free operation. The modularity
in design is said to make assembly andmodifications effortless and the
system can be adapted to many differ-ent requirements.
This is what our customers demand a standardised, modular plastic belt
conveyor that is quiet, sturdy, safe andwith high reliability, says Gran
Abbestam, product manager at FlexLink
for aluminium and pallet conveyors.FlexLinks new conveyor system
meets the highest standards inreliability and safety we have looked
into every detail with regards to
operator safety and workingenvironment. adds Abbestam. Wehave worked hard to eliminate
potential pinch points and obtain very
low noise level. The flat, smooth beltsurface minimises the risk of scratches
and the sturdy guide rails preventitems from falling off, allowing for the
safe handling of sensitive products.The conveyor is available as
components, modules or a complete
system. The three widths, 322, 424and 626mm make it suited for
handling cartons, bundles, bags andother large individual items that
require the stable support of a widechain. Equally important, it allows
large flows of smaller products.The vertical bends and length up to
15m allows efficient and simple
layouts in three dimensions withoutadditional elevators in constant flow.
With a maximum conveyor speed of40m/min, the capacity is setting new
standards for modular belt conveyors.We have reached 100 per cent
modularity and new capacity levelswith regards to the conveyor speed.
Last but not least, the design solution
opens the door for futuredevelopments, concludes Abbestam.
FlexLink Systems UK
T: 01908 327 200
www.flexlink.com Enter 215
Modular wide belt conveyor
improves flow efficiencyA modular plastic belt conveyor system from FlexLinkis said to be an efficient solution for thetransportation of large individual items and flows of smaller products
FlexLink is a world leading supplier of production logistic solutions and have a long
history serving companies of all sizes, in the UK and around the world.
Our fully compatible range of modular conveyors are flexible enough to be re-configured,
expanded and rebuilt with minimum production stoppage for total cost effectiveness.
From stainless steel to aluminium and pharmaceutical to FMCG we have experience
in improving production efficiencies in any environment, without compromising quality
or knowledge.
Contact us, FlexLink Systems Ltd, today at [email protected] or call on 01908 327200.
Endless possibilities
www.flexlink.com
Enter 20
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FeatureTracking & traceability
Currently all butter manufacturersin Ireland are required to assign
every pallet of butter produced
with a unique label combininginformation including the manufac-
turer, weight, lot number, palletnumber and best before date.
Zetes is internationally recognised asa leading expert in the field of print and
apply and was a natural choice of sup-plier. The company currently works
with manufacturers from all sectors of
industry to provide effective printingand labelling solutions, including
advanced serialised labelling solutionsfor the pharmaceutical sector to combat
counterfeiting. It was as a result of thisexpertise that Glanbia decided Zetes
had the right skills to implement aunique labelling solution for its butter
division.We were concerned that this new
customer requirement would have an
impact on our production costs and so
looked for a solution that requiredminimal levels of human intervention.Our IT department initially recom-
mended we work with Zetes as local
specialists in automated identificationand data capture, says Gerry Warren,
butter store manager at Glanbia.Glanbias application has been
installed at the end of each butter pro-duction line and works in conjunction
with their existing pallet wrappingsystem. Pre-loaded pallets of butter are
placed onto a wrapping turntable
ready for shrink-wrapping and a trace-
ability label is affixed after this stageonce the correct pallet is automaticallyidentified. The print and apply solu-
tion developed by Zetes uses wirelesstechnology and MCLNet as its commu-
nication and dispatching programme.This directs the Motorola wireless
handheld scanner, Datamax A Class
printer hardware and a Zetes dedi-cated print and apply applicator unit.
Using the MCL programming lan-guage, Zetes has effectively turned an
ordinary industrial printer into anintelligent device able to capture infor-
mation from a variety of different data-
bases and combine the results to createa unique number for each pallet, with-
out the need for additional PCs. The
unique pallet number is produced by
combining both the lot and best beforedate information.
After loading, the pallets existing
barcode label is scanned and a newlabel combining any additional pro-
duction and traceability informationrequired is generated automatically. To
complete this stage, the printer effec-tively recognises individual pallets
before they are shrink-wrapped on theproduction line and is able to generate
the correct label for application after
wrapping.By integrating the label printer with
Glanbias product database, detailsrelating to lot number and expiry date
can be captured and combined withmanufacturer information in a single
label. The label is then transferred tothe applicator pad ready to be affixed to
the pallet following shrink-wrapping.
Glanbia estimated that without theprint and apply solution from Zetes,
they would require extra staff to manu-ally produce labels and apply them to
the finished pallets.The solution is completely auto-
mated and our only involvement is toreplace label rolls when they run out
says Warren. It has eliminated theneed for additional staff to manuallyproduce labels and there has been no
impact to the volumes of finishedgoods we can dispatch each day. We
are delighted with Zetes solution, itdoes exactly what we require and
always runs smoothly.Robert van Vliet, managing director
of Zetes Ireland says, This is a mis-
sion critical solution for Glanbia. Theadvantage of Zetes approach using
MCL to create intelligent print andapply devices, is that the solution is as
robust and reliable as possible to dealwith Glanbias busy and demanding
customer requirements.
Zetes T: 0845 520 0180
www.zetes.co.uk Enter 216
Labelling system provides food
producer with full traceability
Glanbia estimated
that without the
print and apply
solution from Zetes,
it would require
extra staff tomanually produce
labels and apply
them to the finished
pallets
Wireless chip tracks beverage dispensing
IDCs ZigBee wireless mesh technology is playing a major role in tracking - in real time - thedispensing of beverages in the hospitality industry. The ZigBee low power wireless technologymakes it possible to track when, where, what and how much beer or spirit is dispensed. The
resulting data is then routed to a back office PC, or direct to the web via IDCs ZB104 Ethernet
Gateway, for analysis. IDCs ZigBee chip is a key element in the Bonzi wireless beverage
metering system, which provides a control system for the hospitality industry. Bonzi comprises
a family of wireless products that delivers control solutions for every aspect of beverage
dispensing that integrate with most major point-of-sale (POS) systems. IDCs ZigBee chipintegrates snugly into the Bonzi pouring head; the chip in no way impinging on the pouring
process: it transmits each pour wirelessly for comparison with registered sales, improving stock
and cost control and highlighting any discrepancies. Any number of the ZigBee-equipped pouring heads can be used at any
one time, each providing specific and accurate pour information to a secure onsite PC,via a IDC ZB104 Ethernet Gateway.
IDC T: 01332 604030 www.zig-bee.co.uk Enter 217
FEBRUARY 2012Automation26
Glanbia, one of Irelands largest food manufacturers, has implemented a
print and apply solution from Zetes. The solution developed enables
Glanbia, whose famous butter brands include Kerrygold and Avonmore, to
comply with a new customer requirement for full product traceability and
the highest possible quality standards
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17-19 APRIL 2012 NEC BIRMINGHAMHalls 3 & 3A
organised in association with
The event is co-located with Plant and Asset Management,Air-Tech, IFPEX (the International Fluid Power Exhibition),
MACH, Electrex, National Electronics Weekand
PE&E (Independent Power Energy & Electricity). Together, the
eight shows provide an integrated networking and exhibition
platform for engineering decision makers.
Running alongside the exhibition will be a comprehensive
FREE seminar programme.
You will need to pre-register to ensure places on the seminars
of your choice.
Pre-register as a visitor, and book your places on the freeseminars, by going to
www.drives-expo.comFor information about exhibiting contact:
Doug Devlin t: 01922 644766
m: 07803 624471 e: [email protected]
Simon Langston t: 01353 863383
m: 079000 95826 e: [email protected]
The Perfect Fit
The following c