Front cover Revised 25/7/08 10:46 am Page 1 ISSN 0269-0225 ... · In June of this year, Saudi...

Ambassador® Fan Coil Unitschosen for leading hotels.

Find out why on page5

Diagnostic EngineeringISSN 0269-0225 No.161 July/August 2008

T H E J O U R N A L O F T H E I N S T I T U T I O N O F D I A G N O S T I C E N G I N E E R S

Front cover Revised 25/7/08 10:46 am

TO ALL MEMBERSPLEASE NOTE THAT OUR

SUPERB NEW WEBSITE ISNOW UP AND RUNNING.

All the Institution information you need

is right here on

Make sure you visit us soon.If you have forgotten you password

simply follow the on-line instructions.

Document2 web adapt 24/7/08 10:56 am Page 1

www.diagnosticengineers.org

Terex Construction(Coventry) - Venue of

the AGM

13

this issueJuly/August 2008

Apart from any fair dealing for the purposes of research or private study, as permit-ted under the copyright, Designs and Patents Act 1988, no part of this publicationmay be reproduced, stored in a retrieval system or transmitted in any form or byany means without prior permission in writing of the Institution. Single copiesmay be made for the purpose of research or private study. Multiple copying of thecontent of the publication without prior permission is illegal.

Applied MeasurementsSubmersible Load Cell

Schaeffler’s Autobalancer

12

28

The Bridge that’ssmaller than

a pinhead

A Dozen RobotDo’s And Don’ts

20

INSTITUTION OFDIAGNOSTIC ENGINEERS

President: Dr.David Adams PhD., MIPM(SA), FIDiagE

Diagnostic Engineeringis published by

The Institution of Diagnostic Engineers

Registered Office:7 Weir Road, Kibworth,

Leicester LE8 0LQ.

Tel: 44 (0) 116279 6772Fax: 44 (0) 116279 6884

E-mail: [email protected]: www.diagnosticengineers.org

Chairman: Arthur Kennedy,BEng(H), CEng., MIET., FIDiagE.

Institution Officers

Treasurer: Ing.P.Eur, Ray EldersPEng., FIDiagE. MIIE., AFA.

Vice-Chairman: Bill Parker MIDiagE.

Membership Selection Officer:Chris Gilbert MIDiagE., MIOA.

Council MembersSteve Reed MIDiagE., MCMI.

Andy Garnor MIDiagE.

Administrator: Karen SeilesEditor: Dave Mullins CEng., MIMMM,

Design & Print: Tony Kirby

Articles, photographs, manuscripts andother contributions for publication to:

The EditorDiagnostic Engineering7 Weir Road, Kibworth,

Leicester LE8 0LQ.or by e-mail:

[email protected]

Advertising RatesAvailable upon request from Head Office.

ISSN 0269-0225Diagnostic Engineering is free of charge to members

of the Institution of Diagnostic Engineers.

It is also available on subscription.For details contact Head Office.

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The views expressed by contributors are their own and are notnecessarily those of the publishers, the editor or the Council ofManagement of the Institution of Diagnostic Engineers. Whilstevery care is taken to ensure that the contents of the Journalare accurate, we can accept no responsibility for these, or forthe effect of errors or omission. Likewise, while every care istaken when accepting advertisements, we cannot acceptresponsibility for the contents of these or for unsatisfactorytransactions. We will however investigate any complaints.

�

Polar InstrumentsSpeedstack Impedance

Coupon Generator

2 Notice of New Website

4 Objectives of the Institution

5 Diffusion’s intelligent air conditioning units

6 Saudi Aramco Honours

8 A Water Problem Solved

by Eur. Ing. Jeffrey N Cascasiani-Wood C.Eng.FIDiagE

10 Magi’s Stockings... by John Sayer FIDiagE

11 Obsession - The brother of stupidity

Case No. 50 from Douglas Wragg FIDiagE

13 Corporate Members visit us at Maintec 2008

14 Power Supply Harmonics

Bob Liddle discusses

15 Notice of AGM

22 Invitation to become a Council Member

23 Women really are smarter than men!

by Andy Garnor MIDiagE

23 McLachlan Cartoon

24 Your Letters

25 Welcome New Members

26 Top this for a speeding ticket!

29 Membership Application Form

30 Corporate Membership Application Form

31 Corporate Members Gallery

27

7

Contents AW 29/7/08 4:33 pm Page 1

4 Diagnostic Engineering

Institution of Diagnostic Engineers • www.diagnosticengineers.org

1. To promote the education and training of persons whether resident in the United Kingdom or elsewhere in all matters relating to diagnostic engineering and allied technologies.

2. To establish and maintain contacts with persons and/or organisation concerned with the employmentof diagnostic engineers and consultants.

3. To arrange consortia of specialist diagnostic engineers to perform specific advisory/consultancy projects as required.

4. To develop the science, practice and business of diagnostic engineering and allied technologies.

5. To encourage and improve the technical, financial, business, managerial and general knowledge of all persons engaged in the practice of fault andfailure diagnosis, condition monitoring, post-mortemexamination,accident investigation and allied activities.

6. To compile and classify information and particulars relating to the expert services rendered by members of the Institution.

7. To disseminate information and particulars relating to the expert services rendered by members of the Institution.

8. To stimulate efficiency in diagnosis and to elevate the position of those connected therewith in skilled practical employment.

9. To foster intelligent appreciation of the facilities existing for the provision of education and research.

10. To facilitate the exchange of information, ideas and practice by the publishing of such information as shall be of interest to diagnostic engineers.

11. To render advice and aid in the exploitation of inventions and to make known their nature and merits.

12. To assist in obtaining employment and to help engineers and others to find competent staff.

Definition

A ‘Diagnostic Engineer’ shall be any person capableof contribution to the art or science of determining theexistence of a problem in a machine, plant,system or structure and/or appraising the cause(s) ofa failure which may have taken place and/or assessingthe condition or vulnerability of such machine, plant,system or structure either during use or while underdevelopment.

Interpretation

It is accepted that through a diagnostic capability ora special knowledge of a failure and deteriorationmodes, reliabilities and hazards a person will be ableto contribute to a satisfactory assessment of thecauses of a defect and able to contribute to theidentification of remedial action to cure the defectand prevent failure.

Motivation

Employers are invited to recognise that persons whohave joined have shown distinguished interest indeveloping and extending their technical skill.

Rewards

Prizes up to £500 in value are offered annually for thebest brief accounts of interesting diagnostic cases.

Activities

The Institution shall arrange and subsidise:

� Regular Newsletters to members� Regular notices of services available from members

will be (distributed free of charge to members) to interested parties. These notices will also be displayed at times on the Institution’s web page.

CertificateA Membership Certificate is issued to all members.

The Objectives of the Institution

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Diagnostic Pages Not Change 28/4/08 1:03 pm Page 5

Diffusion has supplied morethan five hundred AmbassadorAir Conditioning Units to the

progressive City Inn Hotel. TheWestminster hotel, the fourth in anexpanding network that includesGlasgow, Birmingham and Bristol, is oneof very few entirely new build hotels tobe built in the heart of Westminsterwithin close walking distance of theHouses of Parliament. Faber Maunsellwas the Mechanical and Electricaldesign consultant with Bennett’sAssociates responsible for the architec-tural design

The patented Diffusion AmbassadorR

Hotel system with Systemteq customiseddigital controls is a single integratedslot-in intelligent heating, air condition-ing and reporting unit that allows hotelsto plan maintenance around the roomoccupancy and more importantly allowsthe room temperature, controls andpossible alarms to be viewed remotely,saving time, money and resources.

The Diffusion Ambassador unit is manu-factured and pre-commissioned off-siteand can be installed and running withina few hours, compared with days for tra-ditional systems.

The Ambassador units for the City InnHotel were supplied with fast responseuser friendly wall mounted control plates,

giving guests the ability to control theirown environment. The units are unob-

trusive and can be easily fitted within anormal hotel bedroom lobby.

The Diffusion Ambassador fan coil is theultimate air conditioning unit for hotelsas it is quiet, highly energy efficient andit has lower running costs than othersystems.

The Ambassador unit was runner up atthe H&V awards for best air conditioningProduct of the year and was designedand developed by the same engineeringteam that won this year’s award with theUVGI Nightingale unit. The City InnWestminster project was worth £1.3m toDiffusion.

Heating & Cooling47 Central Avenue, West Molesey,

Surrey KT8 2QZTel: 020 8783 0033

WWW.diffusion-group.co.uk

Intelligent air conditioning units saves City Inn Hotel time & money

Institution of Diagnostic Engineers · www.diagnosticengineers.org

The Diffusion Ambassador is a singleintegrated slot-in intelligent heating, air

conditioning and reporting unit.

The City Hotel, Westminster

Environmentally FriendlyNo refrigerants used in the unit.All materials are CFC and HCFCfriendly. In excess of 90% of the

material can be re-cycled.

Situated within an English HeritageBuilding, the London Marriott Hotelhas 200 rooms and superb leisurefacilities in the heart of London.Almost opposite the Houses ofParliament County Hall was formany years the home of London’sgovernment, in the form of the LondonCounty Council and latterly theGreater London Council (GLC) andInner London Education Authority(ILEA). Designed by Ralph Knott, wasstarted in 1911 but the interventionof two world wars prevented itscompletion until 1958. Duringconstruction a 3rd century Roman shipwas discovered.

Diffusion has supplied the Marriotthotel with two low output singlephase column heaters, which weredesigned to fit into existing architec-tural features. Specially painted blackthese heaters blend perfectly into thedécor so as to remain unobtrusive,whilst giving the hotel closer controlof the entrance doorway temperature.Stand alone, with anoutput of 6kW’s theyrun independently ofeach other and have2 stage speed and fancontrols.

Diffusion provides awarm welcome at theLondon Marriott Hotel

The column heaters werepainted black which enabledthem to be concealed withinthe archetectural columns

each side of the mainentrance.

Diagnostic Engineering 5

Energy Technique/City Inn 24/7/08 11:04 am Page 1

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In June of this year, Saudi Aramco honoured our Treasurer, Ray Elders FIDiagE by awarding him aCertificate of Appreciation for his exceptional service and outstanding contribution to Aramco.

The pesentation was made in Italy when he attended the Aramco Conference and AwardsMeeting in a four Star hotel in Tremezzo on Lake Como.The Conference covered the detailed projects of their next, very busy, five year plan .

During his stay Ray made many contacts and thoroughly enjoyed the appreciation he received.

Congratulations to Ray on this Award. He is a shining example of what can be achieved.The membership of the Institution is spread across the globe. No doubt there are members whohave themselves made significant contributions, at whatever level, to their own profession andhave been similarly recognised, they too would alo be worthy of recording in this journal.

Saudi Aramco HonoursRay Elders FIDiagE the Institution’s Treasurer


BW Cert 24/7/08 11:09 am Page 1

Significantlyreduces impedance

coupon design time and errors

Compatible with SpeedstackPCB stackup systems

User-selectable probe styleand coupon formats

Automatically producesextended RS274x Gerber files

for panelisation

Polar Instruments announce thelaunch of an automatic coupongenerator, which dramatically

reduces the time required to generateimpedance test coupons compared tomanual or scripted systems.

Conventional methods of coupon genera-tion require both skill and time, and evenscripted systems may not be able toproduce complex coplanar or waveguidecoupons. These systems are also prone toerrors, which can result in incorrect linewidths on the finished coupon.

Designed for use with Polar Instruments’industry-leading Speedstack PCB orSpeedstack Si printed circuit board (PCB)stackup design and documentationsystems, the automated CouponGenerator imports complete stack-updesigns directly from Speedstack. Theseare compiled with the user’s preferredcoupon format and the chosen test probestyle, which is selected from a library ofthe most frequently-used IP probes forCITS impedance test systems.

The Coupon Generator automaticallyproduces an RS274x extended gerber fileand drill file which can be exported tothe CAM system.

“The Speedstack automated CouponGenerator provides a break-through forPCB manufacturers by producing couponsin a fraction of the time it would takeusing conventional methods. This helpsto speed the overall turn-round time forthe PCB and increases the accuracy ofthe finished test coupon,” explainsMartyn Gaudion, Polar Instruments’ Sales& Marketing Director.

About Polar Instruments

Polar Instruments is a market leader indesigning and manufacturing tools tosimplify and enhance the design, fabrica-tion and testing of printed circuit boards(PCBs). Their innovative tools include the

industry-standard Controlled ImpedanceTest System (CITS) which provides theglobal PCB industry with an easy-to-usetest system for high-speed digital and RFboards, as well as class-leading tools forfast and accurate design and testing ofcontrolled impedance in PCBs. Polar alsoleads the industry in tools for automatedPCB layer stackup design and documen-tation. Polar Instruments was establishedin 1976 and now has operations in theUS, UK, Europe, Japan and Asia Pacific.

For more information:Martyn Gaudion

Polar Instruments Europe LtdTel: +44 (0) 1481 253081

www.polarinstruments.comE-mail:

[email protected]

Polar Instruments introducesSpeedstack Impedance Coupon Generator


MEMBERS - ADVERTISE YOUR SERVICES FREE!Members can advertise their services in the journal without charge.

Simply e-mail details and we will produce an advertisement to suit available space.


text 24/7/08 11:13 am Page 1

It began simply enough with astandard request to carry out apre-purchase survey. There were no

real problems. It was a standard narrowboat, I’d looked at hundreds of thembefore and the owner already had agreedto dry dock to vessel for the survey.The design of the boat was such that therudder stock passed through a 4” o.d.tube which in turn passed from thecounter plate of the hull to the deckplate inside the fuel oil tank which wasbuilt into the hull across the boat’s stern.Again, a standard arrangement.

Access to the inside of the tank requiredthat a large plate fitted into the bulk-head forming the forward end of thetank and secured thereto be some thirtystuds be removed. I should point out

that it is not incumbent upon thesurveyor to remove such a plate so that,in effect, the interior of the fuel oil tankwas inaccessible.

It was also impractical even with theaid of a lead light and hand mirror toexamine the interior of the tube fromunderneath the boat. After the usualhammer tests, external visual examina-tions and ultrasonic thickness measure-ment of the shell plating we had stoppedfor a cup of tea. The only odd thing thatI had noticed during the inspection waswhat appeared to be oil stains down theline of the rudder stock.

It was then that the bombshell wasdropped. Almost as an afterthought, theowner said to the prospective purchaser

“If you let the fuel oil in the tankdrop too low the engine will be difficultto start and will splutter a lot.”Immediately my ears picked up.The standard pre-purchase surveyrequires that the surveyor carries outonly a superficial examination of themachinery without taking it apart.If practical, it is good practice to carryout a running test of about an hour’slength. The particular installation hadthe machinery cooled by means of skintanks welded inside the swim of theboat. This means that a running test canonly be carried out with the boat afloat.As the vessel was in dry dock such a testwas not possible.

When I went back aboard the boat I tooka quick look into the fuel oil tank via the

A Water Problem SolvedEur. Ing. Jeffrey N Cascasiani-Wood C.Eng.FIDiag.E.



txt 24/7/08 12:39 pm Page 1

filler cap and decided that the oil levelwas low and that, therefore, starting dif-ficulty could be possible as soon as wetried to move the vessel from the drydock.

After some discussion, it was agreed,therefore, that immediately the externalpart of the survey was complete the drydock would be flooded up and a runningtest carried out while the vessel was stillwithin the dry dock environs.Sure enough when attempts were made

to start the engine, despite a wellcharged battery, there was no joy. Itwould spit and splutter for two or threeseconds and then would die.

The prospective purchaser, then asked,“Why is there so much white smokecoming from the exhaust?” Whitesmoke? Usually a sign of fuel trouble.I asked for the engine to be turned overagain while I observed the exhaust but itwas not white smoke, it was steam!

Water in the cylinders!But from where?

A quick removal of the pressure capshowed to sign of water inside the rockercover and an examination of the dip stickgave a similar null result with the lubeoil in the sump. It did not seem likely,therefore, that the head gasket was leaking.

Continued overleaf


4 mm thick deck plate 4 mm thick tank 6 mm thick 6 mm thick bulkhead tube wrapper plate Oil T ank O il T ank

Broken weld here Waterline

C. L. 8 mm thick counter plate Rudder stock 6 mm thick swim plate

Severe corrosion here Cooling tank behind

Rudder not shown for clarity 10 mm thick bottom plate Skeg A. P.

Longitudinal Section through the After End Fuel Tank


txt 24/7/08 1:46 pm Page 2

Examination of the flexible hoses on thecooling system showed them to be ingood order.Then the penny dropped. The problemarose only when the fuel in the tank was

low. The tank itself was leaking hencethe oil stains down the rudder stock.

I requested that the dry dock again bedewatered and the vessel set down onthe keel blocks and that the fuel oil tankbe drained by pumping its contents intoa suitable drum. This clearly showed thatthe fuel tank was badly contaminatedwith dock or river water.When the tank was empty I requestedthat the door be removed so that accesscould be gained to the inside of the tank.It was then that we discovered the causeof the problem.

The weld attaching the rudderstock tubeto the vessel’s counter plate was badlycorroded and fractured. Attempts hadbeen made at sometime to stop the leakby wrapping the heel of the tube withmotorists exhaust gunk with, clearly, nosuccess.

The owner claimed that he had not madethe bodge up and that he had solved theproblem by simply keeping the tank atleast half full.

The corroded tube was cut out and anew length installed and fully welded allround. This time with the tube extend-ing below the counter plate and weldedon the outside.

The sad thing about this experiencewas that I found on board the boatcopies of reports issued by two otherzsurveyors neither of whom haddiscovered a problem.

Subsequent close up examination of thesection of tube cut out showed that itsinterior was badly corroded withhaematite rust and there was no sign ofinternal painting.

So often in these boats the fuel tankbulkhead is not fitted with a door whichleaves one wondering about how manyof the rest of them are a disaster waitingto happen.


The corroded 6mmm thick tube

How often an embarrassed newrecruit found himself waiting atthe big Scotsman’s door I will

never know? It had long been a traditionto send ‘new boys’ to ‘take a look atMagi’s stockings!’ ... Magi was in fact achap by the name of Magnus, he lookedafter the companies spares and stockroom and likewise looked after the stock-book; a book that came to be known as‘Magi’s stockings!’

Magnus was like every other ‘StoresController’ I have ever met was like aselfish child who jealously guarded everyitem as though it was his own personalproperty, to draw a spare component wasalways a daunting ordeal! But Magnushad one trait that could be classed ashelpful in that being so zealous herecorded the location of every item andevery stock level in meticulous detail inthat renowned book known as ‘Magi’sstockings!’ What I doubt that Magnusrealised was that by keeping such recordshe was actually recording trends in faults

that engineers could detect by doinglittle more than using the book like anhistorical record of previous repairs.Not, I might add, the way in which it hadever been intended that the book shouldbe used?

Bearing in mind that Magnus was ofan era long before the introduction ofpersonal computers it was all the moresurprising that his book was so easy touse! It was after all a database thatcovered not only the issue and distribu-tion of items but also the reason whysuch items were being issued in the firstplace? Originally the book had no doubtbeen a management project or tool usedto justify stock levels and staff. ButMagnus, once let loose on this personalcrusade that so strongly justified his veryexistence, proved without a shadow of adoubt that such a book, kept regularly upto date, it was in fact a very powerfultool in its own right!

Today trend analysis has become animportant analytical tool normally asso-

ciated with huge computer databasesand system tools, no doubt this evolvedfrom the frustration of the likes ofDiagnostic Engineers who themselvesstarted to log trends of failures that inturn developed into stock faults?

I can still hear the gruff Scottish voice ofMagnus reverberating in the echoes of adistant memory,

‘You make sure you bring ma book backlad, I do’ not want to have to come look-ing for it, you hear?’

I wonder if he ever realised what animportant contribution he made, overand above the one that he assumed hemade, to the smooth running of thatengineering workshop? In fact Magnushimself was, without ever realising it, agenuine diagnostic tool in his own right!

John Sayer FIDiagE

Magi’s Stockings...

�


txt 24/7/08 12:26 pm Page 3

Obsession-The brother of

stupidityCase No.50 from the files of

Douglas Wragg FIDiagE

Following on from the case ofMr. Worthington and Am-Cars(Obsession – The Mother of

Irrationality) comes a case which israther difficult to write about, as itwould be easy to for some to recognisethe car and thus the participants in thestory.

Perhaps you will forgive me if I tell youthat the vehicle in question was CrudleySuper Nine convertible.

The facts of the case are as follows;Daniel Brixton was an expert on Crudleycars, and in particular, the Super Nine. Hehad sold them for a number of years, andin his words, “many of my customershave become good friends.”

All well so far, and then arrives on thescene one Justin Cruikshank who wishesto purchase a rather rare version of theSuper Nine – the Super Nine Victory. Veryfew of these were produced and theycommanded quite a seller’s premium.

An agreement was reached, the priceagreed and Mr. Cruikshank became theproud owner of a rare and rather lovelycar.

I am not entirely sure how the nextchapter of events really occurred, as theyare lost in the red mists of irrationalityand time; however, shortly after takingdelivery of his car, Mr. Cruikshank per-ceived that there were faults with thevehicle, and so he returned it to Mr.Brixton for rectification.It was about this point that Mr.Cruikshank conceived the idea that Mr.Brixton was a crook and a rogue who hassold him a car that had been involved ina serious collision and had a forged logbook!

From then on, all hell broke loose. Thelist of perceived defects on the car grewon a daily basis, as did the blackening ofMr. Brixton’s character.

Mr. Cruikshank instructed a firm of solici-tors with the aim, no doubt, of wipingMr. Brixton off the face of the earth. The

solicitors in turn instructed me, butbefore I could start work, Mr. Cruikshankhad “de-instructed” them as they hadhad the temerity to suggest that hisbehaviour and attitude was less thanreasonable!

Mr. Cruikshank then decided that he didnot need any solicitors, as he would con-duct his own case – you can see wherethis is heading can’t you?

My initial instruction was to carry out afour wheel alignment check on the steer-ing geometry, and if that showed prob-lems, an alignment check on the body.

Simple enough, you would have thought.Yes, and like me you would be wrong. Anunholy war ensued as to who was tocarry out the work. Mr. Cruikshank wasinsistent that it should not be a garageanywhere near Mr. Dixon, as he wouldhave bribed them to say that the car waswithout blemish or fault! In the end, I put my foot down with afirm hand and said that the choice ofgarage would be mine – it was nowherenear either of them and thereforeunknown to them.

Before we could proceed any further, Ireceived a list from Mr. Cruikshank offurther checks that he wanted carriedout, and these included things likechecking forged signatures on the V5 logbook and a whole host of other quiteirrelevant items!!

Having pondered this for a while, I thenwrote to both parties saying that I wasnot qualified to comment on many of theitems which had been added to the list,and would they now release me from anyfurther involvement in this case.

I sent a copy of the letter to the CountyCourt Judge for good measure.Back came a reply that I was notreleased; however, the Court had now setout the items to be checked – not Mr.Cruikshank!

I then went ahead and made all thearrangements and we met at theappointed place and time.

As with all these single joint expertcases, I laid down a few ground rulesbefore we started – any questions andcomments must be directed to me, asthat way we can keep the heat out ofthe situation.It will come as no surprise to you tolearn that our two protagonists had metin court on several occasions before this

investigation, and it was evident that theJudge was less than amused by thebehaviour of Mr. Cruikshank.It will also come as no surprise to learnthat there was absolutely nothing wrongwith the steering geometry of the vehi-cle, and that a body alignment check wasnot required.

I tried to explain to Mr. Cruikshank thatif there were any distortion in the bodythat this would have showed up in thesteering geometry check – you cannotalter steering geometry to cover up errorsin body alignment.

You would have thought that I had triedto disprove Einstein’s Theory of Relativitygiven the response from Mr. Cruikshank!!

Following the investigation I wrote myreport which basically said that therewere no defects found in the steeringgeometry or the bodywork. The vehiclehad not been involved in a serious colli-sion; however, there had been a veryminor repair to the front bumper as aresult of somebody parking by ear!

You may imagine how thrilled with myreport Mr. Cruikshank was! Mr. Dixon wasquite happy as it exonerated him fromthe rather nasty accusations which hadbeen levelled at him.

I had a long list of rambling questionsfrom Mr. Cruikshank which I did my bestto answer – all to no avail, as he keptasking more questions.

Just to give you a further flavour of theobsession of Mr. Cruikshank, he hadasked the Court to rule that Mr. Dixonshould give his evidence using a liedetector!

The case duly came to Court; however, Iwas not required to attend as the Courthad accepted my report in evidence.

Sometime later, I had a telephone callfrom Mr. Dixon who informed me thatthe Judge had thrown out all ofMr. Cruikshank’s claims. He then wenton – at some length – to explain toMr. Cruikshank why vexatious litigationis rarely successful in English Courts.Without any prompting from Mr. Dixon,he then said “Now turning to costs…”Mr. Dixon was awarded all of his costsand Mr. Cruikshank was left with a heftybill to pay – Court costs, solicitors andthe like.Strangely, I never heard another wordfrom Mr. Cruikshank.



Wragg article no.2 24/7/08 11:29 am Page 1

Designed for underwater tensionmeasurement applications, forhigh humidity conditions and for

applications in which occasional submer-sion due to flooding is likely, a range ofminiature, compact, low profile load cellsis now available, which can be cus-tomised to suit specific applications.

The DDEN Series of load cells fromApplied Measurements Ltd measure ten-sile or compressive forces in underwaterlocations to a depth of up to 10 metres,although the unit can be customised tooperate in even greater depths. The unitis unique in its compactness over a widecapacity range. Even at the top end ofthe capacity rating of 50kN, the unitdimensions do not change – with adiameter of just 44mm and a length of65mm.

The DDEN is protected to IP68 and is veryrobust, being constructed from stainlesssteel. Operating temperatures are from–20°C up to +80°C and measurementcapacities are from 250N up to 50kN.With its low deflection and high naturalfrequency, the DDEN is particularly wellsuited to cable tension monitoring,marine and offshore applications, moor-ing lines and material testing.

Peter Lewis, Managing Director atApplied Measurements Limited com-ments: “The DDEN Series was originallydeveloped for a marine customer in Italy,who needed to measure the precisemooring tension of buoys in the sea, aspart of a wave energy research project.With a small, quick and cost effective re-design of our existing DDE style load cell,we changed the construction to stainlesssteel, with the two halves lockingtogether with a seal. Internally, the unitwas further protected by back-fillingwith an inert waterproof gel. The electri-cal termination is a tough IP68 multicore

cable that is connected through anIP68 cable gland in order to providefully-submersible sealing.”The company envisages a diverse rangeof other applications for the DDEN. Maststays on racing yachts, for example, mustbe kept tuned to a very high level at alltimes. Also, in the water industry, under-ground pipes need to be cleared of anyobstacles or blockages. Therefore a ‘pig’is often sent down the pipe and pulledthrough on a line to clear the obstacles.The tension of this line is critical and soload cells are required here.

Peter Lewis continues: “We can cus-tomise the DDEN Series for specificapplications, whilst still offering thecustomers the same lead time as ourstandard range.”

The DDEN Series comes with integralmale threads for in-line mounting.This enables the load cell to be mountedin a wide variety of applications whereconventional load cells such as S-Beamswill not fit.

The DDEN can be supplied complete withmonitoring and control electronics andcalibrated as a system. Other optionsavailable include non-standard sizes,spherical seating rod end bearings,female adapters and compression fittings.The DDEN comes with a three-yearwarranty.

Company Profile

Applied Measurements Limited offers acomprehensive selection of transducersbased on strain gauge technology.The company’s product range includessensors to measure load, pressure, torqueand displacement. In addition, a customtransducer design service and straingauge bonding facilities are available.

To support the transducer range, avariety of analogue and digitalinstrumentation is available, includinghigh resolution, high speed andRS232/485 equipped signal conditionersand indicators, as well as portable bat-tery powered indicators with integraldata logging, enabling the company tooffer complete systems with calibrationtraceable to UKAS standards.

In addition to the standard transducerrange, the company also has the capabil-ity to design, develop and manufacturecustom devices to meet specific needs.Expertise is based on bonded straingauge technology, which is carried acrossthe company’s complete line of transduc-ers. Involvement in customer projects canbe at any stage, from development anddesign, through prototyping, testing andinto full production.

Submersible LLoad CCell fforTensile aand CCompressive FForces

is uultra ccompact


For more informationon the DDEN range of submersible

load cells, please contact the

Sales Department

Applied Measurements Ltd

Mercury House , Calleva ParkAldermaston, ReadingBerkshire RG7 8PN.Tel: 0118 981 7339

email: [email protected] visit our website

www.appmeas.co.uk


Applied Measurements 24/7/08 11:32 am Page 1

Terex Construction (Coventry) have very kindly offered to hostour AGM this year and the formalities of the meeting will befollowed a buffet lunch and then a very interesting tour of theworks as seen in the photograph above.The programme will be as follows:10.30am – Meet and greet, coffee on arrival 11.00am – AGM12.30pm – Lunch (Free to members) £3.95 for guests.1.30pm – Factory Tour. Terex Construction(Coventry)2.30pm – Close

The factory tour will last approx 30-45 minutes. It will startoutside the Engineering Dept going onto the factory goingthrough processes, continuous improvement processes and howengineering is built into the machines and future product lines and finishing in the Quality Audit area.

The address of the venue:Terex Construction (Coventry)Central Boulevard, ProLogis ParkCoventry CV6 4BX UKwww.terexce.com

The factory of our host Terex Construction (Coventry)


Corporate Members visit us at the MAINTEC Exhibition 2008

The Venue of this years AGM

Our stand at the Maintec Exhibition this year was visited by a number of our Corporate Members including the abovepictured with Council Members: Left to right they are Steve Reed Institute Council Member, Dennis Ballard (Cobas),

Ken West (Fluke), Mike Herring (Whitelegg Machines Ltd), Michael Windsor (Rewinds & J Windsor Engineers Ltd),Geoff Smith (Hawk IR), Colin Picket (Pruftechnik), Bill Parker Institute Vice Chairman.


24/7/08 11:40 am Page 1

Bob Liddle, Managing Directorat Block UK, provides useful

advice on how industrial companiescan reduce the effects of harmonicdistortion from their power supply

lines, thereby eliminating equipmentfailures and cutting production

downtime, repair andreplacement costs

Power supply networks are the lifesupport of modern industry, buttheir quality and reliability are

rarely questioned. Manufacturers arebasically interested only in whethercurrent is flowing or not. The majority ofcompanies never question how good orbad the quality of the power source theyare using actually is. However, on closerexamination, the destructive effects ofdistortion sources, such as harmonics,can be seen. But with the help ofsuitable harmonic filters, the effects ofharmonic distortion can be practicallyeliminated.

Although the power supply grids inEurope are amongst the most reliable inthe world, this does not guarantee thequality of the power they deliver.Unfortunately, machinery and equipmentcan fail with no apparent reason, or canshow signs of failure with expensiverepairs. In these cases, an analysis of themains supply is critical.

A Pure Sinusoidal VoltageWaveform is Rare

A pure sinusoidal voltage waveform forwhich most equipment is designed tooperate on is very rare these days inmains supplies. Harmonics that distortthe waveforms have been on the increasein power supply grids for many years.There are many sources of these harmon-ic distortions. One of the first was themercury steam rectifier, which was used

to transfer AC to DC for operating elec-tric train engines and for adjusting thespeed of industrial DC motors.

Today, equipment such as variable speedmotors, large uninterruptible power sup-plies (UPS), computers, discharge lampsand B6 bridge rectifiers used in powerelectronics, are the primary cause of har-monic distortion.

Knowing the Weak Points

Harmonic distortion on modern powergrids can harm equipment in differentways. For example, vibration and noiselevels are annoying symptoms, but theireffect on the operation of machines isminimal. Another is the harmonic distor-tion present in communication lines andin electronic circuits, which can causemalfunction and fault conditions.

Overheating of transformers, cables,motor windings and in capacitor bankscan also be caused by harmonic distor-tion. These faults can reduce the lifeexpectancy of machines and equipment,causing unnecessary expense and pro-duction downtime for a company.

Harmonic distortion is also a cause forcost explosions in power distributioncompanies. On their highly distortedpower supply grids, the harmonic distor-tion can cause up to 300% of the totalcurrent in neutral lines. Mathematically,it is not difficult to prove that harmoniccurrents have a large proportion of RMScurrent. Practically, this effect can alsobe easily proved. A first clue is the tem-perature measurement of the neutralwire. Only a small proportion of currentshould be flowing in the neutral wire,however, in many industrial plants andinstallations, an increase in the tempera-ture of the neutral wire can be seen,which is a definite indication of highharmonic currents.

How does Harmonics Arise?

Rectifiers, frequency inverters, UPSdevices and electronic power supplies aregenerally found as loads in all modernpower grids. The current that they drawis not sinusoidal but pulsating. One causeof this is the pulse current drawn forcharging smoothing capacitors.Inevitably, this results in a reverse cur-rent flowing back into the supply grid.There are numerous national and inter-national standards limiting these har-monic levels to certain values. For exam-ple, DIN EN 61000-4-2; DIN EN 61000-3-12 and IEEE 519-1992.

Unfortunately, in industrial everydaypractice, these standards are not alwaysbeing adopted. For reliable industrialpower distribution, having in the mainthree phase loads, the fifth harmonic at250Hz and the seventh harmonic at350Hz are of primary concern.Three phase systems such as variablespeed drive units and large UPS systemsutilise three phase rectifiers (6-pulsebridge). The order of the harmonicsdepends on the number of pulses therectifier has. For a B6 bridge circuit, theresulting harmonics has the order ofV=K*P±1 (where K = integer number i.e.1,2,3,4 etc. and P = Pulse Number i.e. 6Pulse bridge). This means that harmonicswith the number five, seven, eleven, thir-teen, etc. are present. Single phase loadssuch as computers and monitors inadministration buildings generally onlyproduce the third harmonic, which if leftundetected could cause fires.

Losses are Hidden CostsIn every electrical system, losses arecaused by current flowing and magnetis ing currents. These are taken intoaccount when calculating the gauge ofcables and the size of transformers anddrives equipment.

Continued on page 19

POWER SUPPLY HARMONICSPay Attention or Pay the Price



Power supply harmonics 29/7/08 4:41 pm Page 1



SOCIETY OF DIAGNOSTIC ENGINEERSNOTICE OF ANNUAL GENERAL MEETING

NOTICE is hereby given that the Annual General Meeting of the Society will be held at TerexConstruction (Coventry), Central Boulevard, Prologis Park, Coventry CV6 4BX, on Friday 12thSeptember 2008 at 10.30 a.m. to transact the following business:-

1. To receive the Chairman’s report.

2. To receive the Report of the Directors and the Financial Statements for theyear ended 31st March 2008.

3. To re-appoint Messrs Berry & Co as auditors of the Society and authorisethe Council of Management to fix their remuneration (Resolution No. 1).

4. To elect the Directors. (Resolution No. 2)

5. To elect the Chairman and Vice Chairman. (Resolution No. 3)

On behalf of the Council

Karen SeilesOffice Manager/Administrator

3rd July 2008

Any member of the Society, entitled to attend and vote at the meeting, may appoint one ormore proxies to attend and vote on his behalf A proxy need not be a member.

There are three ways that a member’s vote can be cast:

(a) Use Form A to appoint the Chairman as your proxy and post the form to theSecretary, to be received not later than 4.30 p.m. on 10th September 2008.

(b) Use Form B to appoint a proxy to attend the meeting and vote on your behalf(c) Attend the AGM and vote yourself

Registered Office: 7 Weir Road, Kibworth, Leicester, LE8 0LQ. A Company limited by guaranteeand registered in England and Wales number 3390130.

AGM AW 1/8/08 9:57 am Page 2



SOCIETY OF DIAGNOSTIC ENGINEERSFORM A

USE THIS FORM ONLY IF YOU WANT THE CHAIRMAN TO BE YOUR PROXY(*Strike out whichever is not desired)

1. RE-APPOINTMENT OF AUDITORS - RESOLUTION NO 1

To re-appoint Messrs Berry & Co as auditors of the FOR/AGAINST *Society and authorise the Council of Management to fix theirremuneration.

2. ELECTION TO THE COUNCIL OF MANAGEMENT - RESOLUTION NO 2 FOR/AGAINST *

3. ELECTION OF CHAIRMAN & VICE CHAIRMAN - RESOLUTION NO 3

ELECTION OF CHAIRMANIn accordance with the Constitution, on the retirement of the currentChairman the current Vice Chairman will assume the Chairman’s position FOR/AGAINST *

ELECTION OF VICE CHAIRMANThe vacant Vice Chairman’s position, should the Vice Chairman’sposition be vacated, Council Member Steve Reed, nominated bythe Council Members will adopt this role. FOR/AGAINST *

Post this form to the Office Manager/Administrator of the Society of Diagnostic Engineers,7 Weir Road, Kibworth, Leicester, LE8 OLQ, to arrive not later than 4.30 p.m. on 10th September 2008.-----------------------------------------------------------------------------------------------

FORM BUSE THIS FORM ONLY IF YOU WANT TO APPOINT A PROXY TO ATTEND THE MEETING AND VOTEON YOUR BEHALF.YOUR PROXY MUST BRING IT WITH HIMI, ................................................................of ................................................................Membership No...............................being a member of the Society of Diagnostic Engineers, herebyappoint.......................................................................................................................................of.............................................................as my proxy to vote in my name and onmy behalf at the Annual General Meeting of the Society to be held on 12th September 2008 andat any adjournment thereof.

Signed: .....................................................................................Dated: ...............................................

✃

AGM AW 1/8/08 9:58 am Page 3



I will be attending the Annual General Meeting only

I will be attending the AGM and Lunch - Free to Members

or I will be attending the AGM and Buffet Lunch and will be bringing a guest.

I enclose my payment of £3.95 for lunch

Please debit from my Visa/Mastercard/ Delta/Electron/Switch/Solo/ account Number

Card Security Code (last 3 digits on the signature strip)

Expiry Date:.....................................................

Post to: Office Manager,Society of Diagnostic Engineers, 7 Weir Road, Kibworth,Leicester LE8 OLQ

Tel: 0116 279 6772 ª Fax: 0116 279 6884 ª Email: [email protected]

SOCIETY OF DIAGNOSTIC ENGINEERS AGMAND VISIT TO TEREX CONSTRUCTION

DAY AGENDA1) 10.30am Meet & Greet, coffee on arrival

2) 11.00am AGM

3) 12.30pm Lunch (Free to members) £3.95 for guests

4) 1.30pm Factory Tour. Terex Construction (Coventry)

5) 2.30pm Close

IF YOU WILL BE ATTENDING THE AGM AND/OR THE TOURPLEASE COMPLETE AND RETURN THIS FORM TO THE SECRETARY

BEFORE 22nd AUGUST 2008

Surname .................................................. First Name ................................ Membership No ....................................

Address .................................................................................................................................................................................

....................................................................................................................... Post Code...........................................

Telephone No ........................................................................ Fax ....................................................................................

Email................................................................................................

AGM AW 1/8/08 9:58 am Page 4



AGM AW 1/8/08 9:58 am Page 1

All of these losses have to be accepted,because they cannot be completely elimi-nated, even with modern technology. Butharmonics cause other losses, includingcopper and iron losses in transformersand copper wires. Adding all these lossestogether means that for a typical indus-trial company, around 5% of its totalelectricity bill is comprised of losses.

Until now, very little attention has beenpaid to these cost factors, mainly due tolack of knowledge or lack of adequatemeans of monitoring. Modern supplyanalysing equipment makes these prob-lems more transparent. With these aids,

it is easier to track down the source ofdistortion, which is the first step insolving the problem. Block UK assists itscustomers, analysing the line supplyvoltage, and helping to decide whichharmonic filter is best suited for theapplication.

Effective Line ProtectionThrough Filters

Up to now, industry has used reactors oractive filters to protect the line supplyfrom harmonic distortion. With bothsystems, a reduction in the level ofdistortion can be achieved. However,both methods have distinct disadvan-

tages. The effectiveness of a reactor isnot always adequate, so reactors onlyhave a limited implementation.Active filters, however, eliminateharmonic distortion almost completely;the drawback being that the technicalexpenditure is comparatively high.

The Block SolutionBlock has developed a third method ofdealing with these harmonic distortions -the ‘harmonic filter module’ (HFM).During development of the filter module,priority was given to the fifth andseventh harmonics, which cause mostproblems in industrial applications.With the harmonic filter the proportionof THD (total harmonic distortion) forany frequency inverter and intermediatecircuit using B6 input bridges is reducedsignificantly, typically by 84% up to 95%.

Customised Filter Module

Depending on the application, a filter canbe used either directly in front of thesource of the harmonic distortion or as acomplete system filter in the distributioncabinet. Typically, filters are designed forthe individual equipment and its har-monic distortion level, which means thedesign is relatively straightforward.

Normally, a filter is designed for thepower rating of the equipment that iscausing the harmonic distortion. In orderto optimise the design of the requiredfilter, Block offers an on-site analysisof the power quality. This informationof THD current levels enables a moreeffective design of the required filtermodule.

Block’s family of harmonic filtermodules range from 7kW up to 800kW.Larger power ratings can be achieved byconnecting modules in parallel. Due tothe very high production quality and theuse of only high quality components, thesystem loss caused by the filter module isvery low (HFM efficiency is higher than98%). A comparison between industrialapplications with and without the har-monic filter module, show the advan-tages of the system with a filter.

The primary advantage of these filters isthat they need no servicing and are rela-tively easy to install. Practical experience

has shown that far fewer fault conditionsor equipment failures caused by harmon-ic are present when harmonic filter mod-ules are installed. The thermal stress on atransformer and motor windings, instal-lation wiring and premature ageing ofelectronic circuits, is reliably prevented.

For more information on Block UK’srange of harmonics filter modules,

please visit

www.blockuk.co.ukor telephone the sales department on

01621 850 666.


Company profileBlock Transformatoren-Elektronik GmbH& Co. KG (www.block-trafo.de ) productsoffer a virtually seamless system for yourmain network interface. From researchand development to production and finalcertification, all Block products aredeveloped in-house, so the company canreact quickly and flexibly to a customer’srequirements. Since the company wasestablished almost 70 years ago, Blockhas become a global operator in thefield of electrical engineering. As a DINEN ISO 9001:2000 certified company,Block is also well equipped to face thefuture: week in, week out, thanks to ourmajor development centre in Germanyand accredited EMC test laboratory, wedeliver innovative products to a satisfiedcustomer base.


Power supply harmonics 24/7/08 11:48 am Page 2

At first glance, industrial robotspecification sheets look fairlystraightforward. Typically, there’s a

picture of the particular model, lookingsleek and stylish, unblemished by exter-nal cabling, end-of-arm tooling, feedmechanisms and safety guards.Then there are the quoted figures: num-ber of axes, maximum payload, reach,repeatability, maximum speed, cycle timeand installation footprint. All these speci-fications seem comparable, manufacturerto manufacturer, so it’s like buying a caror a TV, surely…

Actually, it’s not. During my many yearsdesigning and commissioning robotworkcells, I’ve encountered many mis-takes and oversights when specifying arobot for a particular task. Some I mademyself, in the early days when roboticswas still an unfamiliar technology; most Ihad to fix for frustrated robot buyers,whose machines wouldn’t do what theywere supposed to do. So I have assem-bled a dozen of the most common robotdo’s and don’ts, partly to help those newto robotics avoid the worst pitfalls, butmainly to emphasise that specifying andbuilding robot workcells is a specialistjob, best left to specialists. It’s what I do.

1. Don’t overestimatespeed performance

Although manufacturers’ speed data isusually honest, a robot won’t operate atfull speed throughout its work cycle, norwill it interact with the workpiece atmaximum speed. You also need to allowfor the gripper to secure and release theworkpiece, which slows the cycle time.True, some manufacturers do quote cycletimes, based on a benchmark function,but this relates to a simple pick & placeoperation, not necessarily your applica-tion. No, the only way to get an accurateestimate of speeds and cycle times is topre-design an actual workcell simulation,which I’ll come to later.

2. Do make allowancesfor the end-effector

The end-effector is the end of arm tool-ing that grips the workpiece, usually bymeans of grippers, suction or magnetics.The gripper or vacuum cup needs to pickup the workpiece with sufficient force forthe weight of the object, but without toomuch aggression that it marks or dam-ages the object. You also need to takeinto account the robot’s accelerationforces during a high speed work cycle,which can actually lever open grippers orpeel the workpiece straight off the vacu-um cup. The weight of the end-effector,together with its cable or hose, needs tobe added into the equation, when speci-fying the machine, which leads to…

3. Don’t underestimatepayload requirements

A common specifying error is to omit theweight of the end-effector and associat-ed cabling when calculating payload. Arobotic gripper, which employs jaws orfingers to hold the workpiece, can weighseveral kilos, which is why lighter vacu-um cups are often specified, althoughthey require vacuum generators and hosethat must also be factored into the pay-load. Kinetic forces generated by off-cen-tre payloads, as well as torsional forcescreated at the extreme end of the robotarm’s travel, should also be accommodat-ed in your calculations. Remember toothat the maximum payload is just that,an occasional maximum limit, not thenormal operating capacity.

4. Do take the robot arminto account

If you’ve ever played snooker in a roomthat was too small or tried to saw woodtight against a wall, you’ll appreciatewhat I mean. A robot, especially a 6-axisarticulated robot, has an arm mechanismvery similar to a human arm, complete

with jointed elbow. It has a large workenvelope, almost spherical in shape, andthe end-effector can be manipulated toany position or orientation within thatenvelope. However, when laying out theworkcell, many people focus solely on theend-effector, forgetting the rest of thearm and particularly that flying elbow.Given the speed of movement, there isgreat potential for mechanical damage ifthe rest of the arm is overlooked.

5. Don’t overlookcable management

Cable management is a major installationissue that’s often forgotten. Although itis possible to channel cables and pneu-matic hose internally through the robotbase and arm, in most cases some levelof external cable routing is required.Here, the very flexibility of the robot armand its high speed movement pose aproblem, since you need to plan the cablerouting to avoid snagging, tangling andstressing sensitive connecting wires.Designing cable runs to allow unrestrict-ed movement of the robot manipulator isquite an art and happily there are flexiblecable carrying systems available, whichare able to withstand the twisting move-ment, high-speed friction, and harshoperating environments associated withsuch applications.


A DDozen RRobot DDo’s AAnd DDon’tsStirling Paatz, of robot integrators Barr & Paatz,

provides tips for avoiding specifying mistakes


Robots 24/7/08 11:54 am Page 1

6. Do provide foroperating conditions

The conditions in which the robotwill be operating, whether it’s a dusty,greasy shop floor or a pristine cleanroomenvironment, is an important considera-tion when specifying the IP rating, oringress protection. Levels of protectionextend from a basic IP54, through themore standard water- and dust-tightIP65, which is ideal when installing nextto a machine or workstation, through tospecial versions equipped with gaitersand external coverings for laboratory,cleanroom paintshop or hazardous appli-cations. Enhancing the IP rating adds tothe cost, so consider the applicationcarefully; just because it’s food process-ing, the robot might be handling productthat is already wrapped, so advancing thespec may not be necessary.

7. Don’t forgetworkcell safeguarding

Often overlooked in the initial specifyingand costing, yet absolutely critical from a

safety compliance angle, are themechanical and electronic safeguards.Robots are virtually silent and extremelyfast in operation and unlike conventionalautomated machinery, in which the oper-ating envelope is clearly defined, mostrobotic workcells are individual in config-uration, so bespoke safeguarding is usu-ally required. HSE guidelines providestandards for perimeter fencing, inter-locking devices, opto-electronic systems,safety light curtains and emergency stopactuators, which we adhere to whenbuilding highly sophisticated workcellsafeguarding.

8. Do factor in theperipheral costs

Far be it for me to dissuade potentialrobot buyers by pointing out hiddencosts, because robotic applications can,and usually do, justify themselves onfinancial grounds alone. But don’t over-look peripherals, like teaching pendants,interface boards and software licenses,when budgeting for an installation.Because if you omit these from your ini-

tial order, then run over budget and incurdelays awaiting delivery, question marksare likely to be raised. Teaching pendantscost a grand or so and you require themfor programming purposes, but you don’tneed one for every machine. Softwarelicenses are often required for everymachine and you’ll need plug-in cards fornetwork communications, so be sure tocompare competitors’ pricing.

9. Don’t confuse accuracywith repeatability

Repeatability data always looks impres-sive at ±0.02mm or so and, indeed, it is.But don’t confuse accuracy withrepeatability and expect the same preci-sion, because repeatability figures arealways better than those for accuracy.Repeatability refers to how precisely arobot can return repeatedly to a givenposition, following the same approachvector. Accuracy relates to how closely arobot can move to a specified X-Y-Zposition in the work envelope. If, say, arobot gets to within 0.5mm of that spec-ified position, that would be its accuracy;



Robots 24/7/08 11:54 am Page 2

however, once that position is pro-grammed into the controller memoryand, each time the robot is sent there, itreturns to within 0.02mm of its taughtposition, that would be its repeatability.

10. Do exploit the robot’sfull capabilities

Current trends toward shorter productlife cycles and more versatile manufac-turing mean that when selecting anindustrial robot, it pays to bear in mindpossible future duties. Unlike fixedautomation, robots offer inherent flexi-bility and can be re-programmed andredeployed any number of times, over anaverage 15 year life cycle. Also, modernrobots, especially 6-axis models, arecapable of so much more than simplepick & place duties, since the arm’s abili-ty to reach over and around obstructionsand twist or tilt the end-effector make itideal for complex functions. The exten-sive command sets embedded into therobot controller and pre-written subrou-tines also make programming easier andmore economical.

11. Don’t buy a robotsolely on price

The fact that a modern robot costs aquarter what it did a decade ago, meansthat the technology is already moreaccessible and affordable. So don’t be

tempted to buy solely on price, but lookinstead for best-value performance. Thevarious manufacturers have differentstrengths in different robot classes, socheck out their credentials in the payloadcapacity you’re buying. Equally, it doesn’tmake financial sense to over-engineerthe solution by specifying functionalityyou don’t need. A 6-axis robot is highlycapable, for instance, but for many rou-tine pick & place tasks a 4-axis machinewould be equally capable and consider-ably cheaper.

12. Do request a robotworkcell simulation

When planning and specifying a newproject, we invariably use an advanced3D design package to simulate the entireworkcell and verify that our initial calcu-lations and specifications are correct. Inmost cases, we use a simulation, notleast because it demonstrates graphicallyto the client that our proposed solutionwill work. It allows us to check thereachability of all positions, optimisecycle times, and generally observe thedo’s and don’ts I’ve covered in this arti-cle. So convinced are we that this is theway forward for those new to robotics,that we offer a 3D workcell simulation ofany prospective application for just£1,500, including a video. Then if you goahead with the project, we’ll discountthat figure off the final project price.

Further enquiries to Barr & Paatz, FordRoad, Totnes Industrial Estate, Totnes TQ95LQ, telephone 01803 869 833, [email protected].

Stirling Paatz: Biography

Stirling Paatz is MD and joint founder ofTotnes-based robotics integrator Barr &Paatz, a high technology company withan 18 year track record of automatingproduction processes across a wide cross-section of industry sectors. He is a quali-fied Engineering graduate, specialising inelectronics and software, and is experi-enced across all mechanical, electricaland IT disciplines, with in-depth knowl-edge of the design, programming, buildand implementation of robot work cells,automated assembly lines and materialshandling systems. His company is an offi-cial integration partner for such leadingedge technology brands as Mitsubishi,Stäubli and Festo, positioning itself as anearly adopter of advanced automationproducts and bringing state-of-the-artideas to its client base.

Stirling can be contacted on 01803 869 833, at

[email protected] or via his firm’s website at

www.barr-paatz.co.uk


IMPORTANT NOTICE TO ALL MEMBERSAn Invitation to become a Council Memberof the Institution of Diagnostic Engineers

At a recent Council of Management meeting it was decided that the number of

Council Members should be increased. Additional members would bring wider and

differing experiences which would greatly assist in the furtherance of the Institution

throughout the various fields of diagnostic engineering.

If you would like to take a more active part in the Institution please

write to the Office Administrator with your details at Head Office

7 Weir Road, Kibwoth, Leicester LE8 OlQ

Telephone: 0116 279 6772

or email [email protected]


Robots 29/7/08 4:55 pm Page 3

Three women and three men are travel-ling by train to the football game.

At the station, the three men each buy aticket and watch as the three women buyjust one ticket.

‘How are the three of you going to travelon only one ticket?! asks one of the men.

‘Watch and learn,’ answers one of thewomen.

They all board the train. The three mentake their respective seats but all threewomen cram into a toilet together andclose the door.

Shortly after the train has departed,the conductor comes collecting tickets.

He knocks on the toilet door and says,‘Ticket, please. The door opens just acrack, and a single arm emerges with aticket in hand.

The conductor takes it and moves on.

The men see this happen and agree itwas quite a clever idea; so, after thegame, they decide to do the same thingon the return trip and save some money.

When they get to the station they buy asingle ticket for the return trip but see,to their astonishment, that the threewomen don’t buy any ticket at all!!

‘How are you going to travel without a

Watch and learn,’ answer the women.

When they board the train, the threemen cram themselves into a toilet, andthe three women cram into another toi-let just down the way. Shortly after thetrain is on its way, one of the womenleaves her toilet and walks over to thetoilet in which the men are hiding.

The woman knocks on their door andsays ‘Ticket, please.’

(I’m still trying to figure out why menever think they are smarter than women.

Andy Garnor MIDiagE Council Member


Women really are smarter than men!


Cartoon & Joke 24/7/08 11:57 am Page 1

ticket?’ says one perplexed man’.

Dear Sir,

Hands up those of you who think youwill never grow old - good there’s oneamong you.The rest will have to learn theimmense pleasures of ageing.

One 'pleasure' is to receive a letter fromthe DVLA, saying that you now need aphotocard licence. When I received myletter, I thought it was an insult. It waslike asking a medical doctor after 50years of practice, if he knew how to takea patient's temperature!

I'm no mean driver - having retained myvarious work records of mileage, andknow that I have done well in excess of1,000,000 miles - without EVER causingan accident. There are thousands moreprivate miles that I didn't record, and Ididn't cause any accidents during thosemiles, either!

I was, however, involved in one accident.I was moving slowly through a privateestate (speed below 10mph) looking forthe name of a house. I thought I saw itahead on the right, and slowed down,almost to a halt. Suddenly, there was onehelluva bang at the passenger side. Thedoor bent inwards and its glass shat-tered and spread all over me. Quick-as-a-flash (because I was quick in those faroff days), I radioed back to base andasked them to send the police immedi-ately.

I then shot out of the car and racedaround to see what had happened. Those of you who love cars, would havewept if you saw the wreckage that I saw.First, there was a young woman ballingher eyes out, but obviously not hurt in

any way (which she later confirmed tothe young Bookalot, who arrived veryquickly).

But what would have made you car-lovers weep? Smashed into my car, as ifit was trying to get into the passengerseat, was a sparkling, BRAND-NEWItalian-red open-topped Ferrari.A gorgeous car, even though it had beensadly scrunched!

Apparently, it had been delivered to thehouse just minutes before. The husband, who'd ordered it, was atwork, but the wife (a non-driver, as shecoyly admitted to the Bookalot) couldn'tresist the temptation to sit in its plush-ness. The key was in the ignition, so sheturned it and, as she said her husbandalways did, she put her foot on theaccelerator.

"It sped down the driveway and justTOOK-OFF!" she wept to the Bookalot.Me, being quick (as I said), immediatelysaid, "yes, and it LANDED in my car!"The Bookalot smiled, and said I'd bettergo back to my depot and get a replace-ment car, and he would attend to thedetails.

I have never heard another word aboutthe event, but I wish I'd been aroundwhen the husband turned up!

Ray Pressnell MIDiagE

On the dangers of counterfeitelectrical products

Fake eelectrical pproductscan bbe rreal kkillers

Dear members,

The topic of counterfeiting in consumerindustries has been properly highlightedover the years – largely thanks to lobbiesfrom powerful global brands. Less opaqueis the fact that the same thing goes on intechnical equipment markets but with fargreater potential consequences.

If a fake Nike tee shirt fades prematurelyit is annoying but no more than that. If acounterfeit circuit breaker fails, it couldliterally kill someone.

We have seen products coming mostlyfrom the Far East, that are seriouslyand potentially life threatening – andwe purchased them in the UK from alegitimate established trader. In the worstexample, we found a so called ResidualCurrent Circuit Breaker that had nosafety components at all within it.A single copper wire breached the twopoles – effectively rendering the deviceas a mere switch!

The worry is that counterfeit productsenter the UK marketplace in a variety ofguises. There are three obvious ways inwhich goods are imported – as greyimports (not technically illegal, but rarelywith manufacturer’s warranties); legal orillegal copies that perform less well thanthe legitimate originals; and the down-right dangerous fakes that make noattempt to even provide something thatworks at all. While not all products areunsafe as such, none carry the qualityand certification standards that responsi-bly made goods carry from legitimatemanufacturers.

The call is therefore for everyone inthe trade – wholesalers and stockists;contractors and electricians – to verycarefully check the origins of anyequipment they purchase.

Remember, cheap fakes could lead tohighest possible price being paid.

Paul CanningSchneider Electric Building Systems

and SolutionsStafford Park 5, Telford,

Shropshire, TF3 3BL

Your letters are alwayswelcome on any topic youconsider of interest to our

readers and your fellowmembers.

Please let us have yourcomments and anecdotes

on your experiences inwhatever field of

diagnostics you work in.


�


letters 24/7/08 12:01 pm Page 1


Please tick boxes as required and we willdespatch to your address stated below.

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Welcome New Members

The Chairman and the Council of Management are pleasedto welcome our new members. We hope that theirmembership will assist them in reaching their aspirationsand add to their knowledge from contact with othermembers as well as through the medium of the Journal.

Nigel EllisNo. 10219 Member. Area: PlymouthGarage proprietor/Vehicle Technician

Brian WilkinsonNo.10220 Member. Area: Berkshire

Reservoir Engineering Manager

Adrian CollinsNo. 10221 Member. Area: West Sussex

Mechanical Engineer

Call for yourContributions to the Journal

If you have, in your work or profession,an experience that you would like to

share with fellow members please forward it tothe editor together with any photographs etc.,

Case studies from members are also ratherthin on the ground and we would

like to include more of these in futureissues. Please dig into your memory bank.

Please forward you material to:The Editor, Diagnostic Engineering,

7 Wier Road, KibworthLeicester, LE8 OLQ

or by email:[email protected]

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Institution of Diagnostic Engineers

NEW MEMBERS ETC 24/7/08 12:11 pm Page 1

Membership recommendationPlease list potential member(s) below stating yourname using the form overleaf.

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Tick the box if you require an upgrading form.

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A copy of the Journal for a friendWe will be pleased to send a free current copy ofDiagnostic Engineering to any person in a positionof influence you would like to nominate.

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Two British traffic patrol officers from North Berwick, eastof Edinburgh, were involved in an unusual incident, whilechecking for speeding motorists on the Al Great NorthRoad.One of the officers (who are not named) used a hand-heldradar device to check the speed of a vehicle approachingover the crest of a hill, and was surpnsed when the speedwas recorded at over 300mph. The machine then stoppedworking and the officers were not able to reset it. Theradar had in fact locked on to a NATO Tornado fighter jetover the North Sea, which was engaged in a low-flyingexercise over the Borders district.Back at police headquarters the chief constable fired offa stiff complaint to the RAF Liaison office. Back camethe repay in true laconic RAF style. “Thank you for yourmessage, which allows us to complete the tile on thisincident. You may be interested to know that the tacticalcomputer in the Tornado had automatically locked on toyour hostile radar equipment and sent a jamming signalback to it, Furthermore, the Sidewinder air-to-ground mis-siles aboard the fully-armed aircraft had also locked on tothe target. Fortunately the Dutch pilot flying the Tornadoresponded to the missile status alert intelligently and wasable to override the automatic protection system of theTornado jet fighter.

Top this for aspeeding ticket!


Trafalgar page 24/7/08 12:14 pm Page 1

Anyone working with electrical toolswill be familiar with the highvibrations that are transmitted

from the tool to the body. These vibra-tions impede work, have a negativeeffect on quality and represent a healthrisk when used frequently. The poweredrotating disc in angle grinders, for exam-ple, creates imbalance that causes theseundesirable vibrations.

The Schaeffler Group’s application engi-neering team has developed a solution tothis problem – the Autobalancer – aproduct that reduces vibration in anglegrinders by more than 50 per cent, whichmakes working more comfortable, moreproductive and improves the health andsafety of users. AEG Milwaukee (part ofthe TTI group of companies) is alreadyusing the Autobalancer on its anglegrinders on an OEM basis.

The Autobalancer is a compact sealedunit that is mounted onto the anglegrinder’s drive shaft. The device is simply

slid onto the shaft, where it replaces thedriving plate. The cavity between thesolid plate and the drawn sleeve is par-

tially filled with oil. The ballsinside the oil can move freelyand create a counterforce to anyimbalance. For this reason, the shaft hasto be manufactured to very tighttolerances. All outside surfaces of the Autobalancer are protected by

Schaeffler’s Corrotect® coating.

The Autobalancer reduces the vibrationof angle grinders by more than 50 percent, resulting in much more comfortableoperator handling. At the same time, dueto easier handling of the tool, productivi-ty and quality are increased. Since limit-ing guidelines and values are not exceed-ed, it is no longer necessary to documentusage times.

Strict guidelines in the EU

The EU Directive 2002/44/EC, which mustbe complied with throughout Europe,defines the maximum permissible thresh-old values for electrical tools. Both thevibration intensity and the exposure timedetermine the daily vibration level. Thedirective stipulates that an electrical toolis considered to be critical from a vibra-

tion value of 2.5m/s2 upwards if it is usedcontinuously for more than eight hours.In such cases, the risks must be evaluat-ed more precisely and the employeesmust be notified. If a threshold value of5m/s2 is exceeded, working hours withthe tool must be reduced. This requirestraceable documentation of usage times.Employers are obliged to assess thevibration exposure of their employeesand to reduce it as soon as the limitingvalues are exceeded.

Improved health and safety

The health hazards arising from constantexposure to vibration should not beunderestimated, since these can, insome cases, lead to employees beingunable to work. Schaeffler Group hastherefore made a decisive contributionto improving industrial health and safety.

For more information on Schaeffler’sAutobalancer, please visit

www.schaeffler.co.uk or contact

Schaeffler (UK) Ltd,Forge Lane, MinworthSutton Coldfield

West Midlands B76 1AP

Tel: 0121 351 3833Fax: 0121 351 7686

e-mail: [email protected]

Autobalancer iimproves ssafetyand ccuts vvibration bby mmore tthan

50 pper ccent oon aangle ggrinders

The latest EU Directive2002/44/EC stipulates the

maximum permissible vibrationthresholds for operators of

electrical power tools.Schaeffler’s new Autobalancer

for angle grinders cuts vibrationby 50 per cent, improving

operator handling and safety,whilst reducing grinding

disc wear.



Schaeffler 24/7/08 12:17 pm Page 1

Two major UK landmarks now countamong the world’s smallest objectsthanks to a team from the University

of Newcastle upon Tyne.

Scientists & engineers specialising inminiaturisation technology have recreat-ed North East England’s Angel of theNorth and the Tyne Bridge so they aresmaller than a pinhead and invisible tothe naked eye.

The team used a combination of chem-istry, physics and mechanical engineeringtechniques to create the tiny structures.Both are created out of silicon, the mate-rial used to make microchips. They arearound 400 microns wide and theirdetails can only be seen through a micro-scope.

The technology used to develop thebridge and the angel could be used tomake miniaturised antennae for next-generation mobile phones. These so-called chip antennae will significantlyreduce the power consumption and costof production of mobile communicationdevices.

The fact that these structures can bemade in silicon is an important feature asthis allows the integration of movingmechanical parts and smart materialswith standard components used in themicroelectronics and semiconductorindustries.

The scientists, who are based at INEX(Innovation in NanotechnologyExploitation), the engineering & commer-cialisation arm of the Institute forNanoscale Science & Technology at theUniversity of Newcastle upon Tyne,undertook the project to showcase theirexpertise in an emerging technologicalfield, micro electro mechanical systems(MEMS), in an interesting way.

The techniques are now being used byINEX to develop a number of applicationson behalf of industry.

The applications range from accelerome-ter devices used in the automobile andmedical markets; biosensors for rapid &cheap point-of-care diagnostics that arefinding novel application in the health-care sector; through to making groovesand channels 1/10th the width of ahuman hair to transfer picolitre (which is0.0000000000001 litres) volumes ofchemicals and biological materials forlab-on-a-chip applications that isenabling the generation of new and bet-ter drugs at a much faster pace than pre-viously possible.

The business director of INEX, RichardCarter, said: “Newcastle is already knownfor creating some of the UK’s largeststructures - and now the region is build-ing a global reputation for making someof the smallest.

“These are not just gimmicks. The workwas performed as part of a technologydevelopment programme looking at newways to make very small structures anddevices.

“The North East is a UK leader for thistype of advanced technology and we areworking hard to make sure that weremain on top of the market, whichshould ultimately boost the region’seconomy and create more jobs.”

For further information contact.Richard Carter,

business director, INEX.Tel: + 44 (0) 191 222 5477.Email: [email protected]

INEX is the business & commercialisationarm of the Institute for Nanoscale

Science & Technology at the Universityof Newcastle. INEX operates some of

the best public-sector micro- andnanofabrication facilities in the UK andruns projects on behalf of its industry

clients. More about INEX can be found atthe following website:

http://www.inex.org.uk

The Bridge that’ssmaller than a

pinhead


Quotable QuotesThe major difference between a thing thatmight go wrong and a thing that cannotpossibly go wrong is that when a thing thatcannot possibly go wrong goes wrong, itusually turns out to be impossible to get atand repair. Douglas Adams

There are three possible roads to ruin -women, gambling and technology. The mostpleasant is with women, the quickest is withgambling, but the surest is with technology.Georges Pompidou

One has to watch out for engineers - theybegin with the sewing machine and end upwith the atomic bomb. Marcel Pagnol

The joy of engineering is to find a straightline on a double logarithmic diagram. Koenig

Science is the study of what Is, Engineeringbuilds what Will Be.The scientist merelyexplores that which exists, while the engineercreates what has never existed before.Theodore VonKármán

What you need to invent, is an imagination and a pile of junk.Thomas Edison,


The Bridge 24/7/08 12:20 pm Page 1

To: The Society of Diagnostic Engineers.7 Weir Road, Kibworth, Leicester LE8 OLQ. England.

I submit herewith my application for membership inthe following Grade:

Surname:

Form of address: Mr/Mrs etc.

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Enclose copies with this application

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Submit any additional or supporting information on a separate sheet

Hobbies and other interests

Declaration: I declare that the information containedwithin this application is, to the best of my knowledge andbelief, true and correct in every particular. If admitted tomembership I agree to be governed by the Rules andRegulations as they now exist and as they may hereafterbe altered.

Signed

Date

Fees * The relevant total of Application Fee and first Annual Subscription must accompany this form.

Grade App Fee Annual Subs *Total

SlDiagE £15.00 £31.50 £46.50

AMIDiagE £25.00 £31.50 £56.50

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Please make cheques payable to:

SOCIETY OF DIAGNOSTIC ENGINEERS

Our Central Bank Account is held byNational Westminster Bank plc.5 The Parade, Oadby, Leicester LE2 5BB

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It would help us if you could advise us how you knew of us or who suggested us:

Membership ApplicationPrivate & Confidential

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To: The Institution of Diagnostic Engineers.Society of Diagnostic Engineers · Registered Charity No.1082206

Registered Office: 7 Weir Road, Kibworth, Leicester LE8 OLQ. England.

Chairman: Mr Arthur Kennedy BEng(H), CEng., MIET., FIDiagE.

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SKF CONDITION MONITORING CENTRE(LIVINGSTON) LTD

AMEC GROUP LIMITED

FLIR SYSTEMS LIMITED

ACOUSTIC ASSOCIATES

WHITELEGG MACHINES LIMITED

SECURITY & SURVEILLANCE LIMITED

HARWELL MAINTENANCE AUTHORITY

HAWK IR INTERNATIONAL LTD

FLUKE®

FLUKE (UK) LIMITED

HEATHGATEKNOWLEDGE

ENGINEERING

ROCHE PRODUCTS LIMITED

Roche

PRUFTECHNIK LIMITEDTYCO ELECTRONICS UK LIMITED

PRUFTECHNIKII

®

Corporate Members

MFH GROUP

REWINDS & J WINDSOR& SONS (ENGINEERS) LTD


SCHAEFFLER (UK) LTD

COBAS UK LIMITED

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32 AW 24/7/08 1:53 pm Page 1

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