Magazine 1

The Engineer’s guide to new products & design ideas

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Finishingtouches

Jan2013

21: Energy strategiesPlanning for energy efficiency? Beware'short-termism' says Mike Malina

26: Motor protection Protect your assets with more functions,fewer wires says Stuart Greenwood

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Circulation - CDS GlobalTel: +44 (0) 1858438425Email: [email protected]

18,000Average netcirculationJan-Dec 2010

Energy strategy: the long viewMike Malina's presentation on the financial implications of an en-ergy efficiency strategy, given last year at the MDS 2012 con-ference, provided food for thought on a raft of issues. What isthe best carbon-cutting policy - install renewable generatingcapacity or simply use less energy by being more efficient?How do you convince those holding the purse strings thatROI is just one part of the equation, and that in the long term,sustainability will bring its rewards? In this issue we run anedited version of Mike's paper, which, while concentrating onone particular area - sustainable buildings - is just as relevantto those seeking light on this subject in a wider industrialcontext.

Editor:Les [email protected]

Group Advertisement Manager:Nicole Piesse [email protected]

Classified Executive:Nicola [email protected]

Publisher:Andrew [email protected]

Head Office:IML Group, Blair House,184/186 High Street,Tonbridge, Kent TN9 1BQ

Tel: 01732 359990Fax: 01732 770049E-mail: [email protected]

Copyright in the contents of Design Products &Applications, itswebsites and newsletters is theproperty of the publisher. Thepublisher and thesponsors of this magazine are not responsiblefor theresults of any actions or omissions takenon the basis of information inthis publication. Inparticular, no liability can be accepted in resultofany claim based on or in relation to materialprovided for inclusion.Design Products & Appli-cations is a controlled circulation journal,pub-lished monthly. Completed print or onlineregistration forms will beconsidered for freesupply of printed issues, website access andonlineservices. Annual subscription for non-qualifying readers is UK £121, EU£146, Airmail£212 and single copy price is £12.

January 2013 3

13

16

29

ContentsMaterials & FastenersSpecial Report

05: Alternative automotive finishes Carbon fibre surface texture adds lustre to Noble's M600 supercar

06: Computer aided engineering Modelling the performance of a complex, hydraulically operated offshore crane design

08: Computer aided manufacture Roughing strategy cuts cycle times without compromising product quality or tool life

10: A razor-sharp service A novel unisex travel razor gets the full prototype treatment

12: Getting stuck into the Airbus A350 project Resin helps tooling specialist speed mould creation for composite airframe parts

16: Inserts for clean assembly Tangless inserts don't leave debris behind to end up in critical parts of equipment.

19: Are you sitting comfortably? Thermoplastics make Knoll's 'Generation' work chair responsive to the user

Motors & DrivesSpecial Report

20: Summing up an energy strategy Mike Malina advises taking the long term view when investing

in energy efficiency technologies

24: 'Oversize' isn't everything Stuart Harvey warns that the days of motor oversizing are well and truly numbered

26: Motor protection devices Stuart Greenwood explains how to protect your assets with

more functions and fewer wires

29: Power conditioning pays Rob Morris describes a two-year study of power quality systems

to identify their real ROI performance.

32: Saving energy with PM motors PM synchronous versus standard asynchronous: what is the real gain?

35: ...and what’s more! Les Hunts news & reviews

38: Data Focus Quick guide to new products

40: Buyers Guide Products & Services classified guide

Les Hunt, Editor

Cover Story:Carbon fibre textures are bringingexciting new finishes to the automo-tive sector. On page 5 we discoverhow ARRK's 'lacquered carbonweave' is setting the Noble M600supercar apart from the competition

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Precision engineering, immaculatehandling, real performance, lightningresponse - yes, that's everything theNoble M600 supercar can offer, butARRK also likes to think that this de-scription genuinely reflects the servicesit offers its clients! As one of Noble'skey suppliers, ARRK provides a num-ber of product development services,including prototypes and composites,as well as carrying out low volumemanufacturing of production compo-nents.

The ARRK team, based in Nuneaton,have worked closely with their oppositenumbers at Noble, not just to under-stand their immediate productionneeds, but to offer its expertise in thelatest processes and specialist materi-als that combine to make the NobleM600 such a head-turner. ARRK claimsthat its knowledge of materials, cou-pled with an ability to provide low vol-ume production components to a tightschedule, makes it a perfect partner forclients, like Noble, operating in niche,specialised markets.

The main centre section, rear body,front nose and inner and outer doorpanels are fabricated from carbon fibrecomposites, which reduce the vehicle'sweight, and so improve its responsive-ness and exceptional performance.

The original model was fully painted;however, with an eye to market trendsand through a process of innovationand development, the team tried itshand at producing vehicles with acoloured carbon weave roof, which isthen lacquered and polished, giving ita particularly exclusive and individualappearance.

Such was the impact of the lacqueredcarbon weave effect, that some ofNoble's clients are now choosing tohave the complete vehicle manufac-tured in this way.

Thanks to some pretty deft craftsman-ship that ensures a precision join andbalance of the weave, the Nuneatonteam have managed to make the vehi-cle look as if it has been produced from

a single roll of fabric.

From the moment the carbon fibre ma-terial is cut, through to lay up, the partsare continually checked and validatedto maintain the highest quality of finish.Once produced, the parts are trimmed,drilled and inspected once more to en-sure that they meet the specifications.The components are then assembledto ensure material alignment beforesign off, and from here the sectionsare delivered directly to Noble forassembly.

www.arrkeurope.com

Feature: Carbon Fibre Composites

dpaonthenet.net 5

'Lacquered carbon weave'- a finish to be proud ofNiche automotive manufacturer, Noble gets its prototypes and low volume

composite production parts from materials specialist, ARRK. During the courseof development, the Nuneaton based supplier suggested an alternative to conventionalbody paintwork for its customer's high-performance M600 supercar - a special finishthat took full advantage of the carbon fibre fabric surface texture.

The main centre section, rear body, front nose and inner andouter door panels are fabricated from carbon fibre composites

The Noble M600 supercar

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With offshore oil and gas drilling op-erations costing millions of dollars aday, crews are under pressure to gettheir jobs done as quickly as possible.One of those jobs involves assem-bling the thousands of metres of flex-ible pipe that make up a drill string,

and doing so safely and con-sistently on a remote plat-

form where space is at apremium and weather

conditions are fre-quently chal-

lenging.

Typically, the materials handlingequipment for this is hydraulicallyoperated and, to some de-gree, automated. Thecontrol system design ischallenging; when acrane is in motion its dy-namic behaviour is de-pendent upon manyvariables - the electrical and hydrauliccharacteristics of control valves andhydraulic actuators, the inertia of thecrane's structure and its load, and thecomplex interactions between allthese components.

Moreover, the chosen hydraulic com-ponents must deliver the requiredlevel of responsiveness, or 'band-width', while meeting requirements forbudget, size, weight, long term relia-

bility and ease of main-tenance.

A research project at Norway'sAgder University, currentlybeing carried out in conjunctionwith offshore equipment manu-facturer Aker Solutions,is hoping to simplify thisformidable design chal-lenge by allowing engineers to buildand run detailed simulations of equip-ment before they assemble a singlepart. Morten Kollerup Bak, a PhD re-search fellow in charge of the project,takes up the story:

Feature: Computer Aided Engineering

Simulation liftsdesign exerciseto a higher level

A Norwegian universityresearch project is

using computermodels to predict the

performance of complexoffshore materials handling

equipment. In the short term,the work is helping designerspick the best components for

the job; ultimately, the aim is toautomate more of the design process.

6 dpaonthenet.net

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"Our aim is to use model-based design to pre-dict the behaviour of the finished products andto support key design decisions. For that towork, everything depends on your beingable to model the entire structure andcontrol system in sufficient detail toget a realistic idea of its perform-ance." For this work, Bak isusing the MapleSim simula-tion application fromMaplesoft, which issupported in the UKby Adept Scientific.

"I divide the wholesystem into threedifferent models," hesays. "The mechani-cal structure, the hy-draulic actuationsystem and the elec-trical control system. I'm using MapleSim tomodel the first two parts and in some cases allthree.

"Our aim with this work is build the models ofhydraulics as much as possible from standardcatalogue data. But we quickly found thatcomponent manufacturers don't always pro-vide all the data you need, particularly whenyou are looking at the precise behaviour oftheir components in dynamic conditions."

To obtain the missing data, Bak has built cus-tom models of key components, like controlvalves, and validated their accuracy by con-ducting tests on single components operatingin isolation. Once he has confidence in theperformance of the custom elements, he inte-grates them into the MapleSim system modelsand uses that to evaluate the likely perform-ance of the crane.

"With my industrial partner, we have alreadybuilt a model of one of their existing cranesand demonstrated that it predicts the behav-iour of the real crane accurately. Now we havebegun to use the model in our design work bylooking at the likely impact of substitutions ordesign changes to individual components."

The ability to model such changes beforedoing them is obviously extremely useful forthe Aker Solutions designers, but the nextstage of the project has the potential to fun-damentally change their roles.

"Ultimately, we want to use our models for de-sign automation. In this approach we feed thesystem with the performance requirements ofthe finished product and with a library of op-tions for hydraulic and mechanical compo-nents, then allow it to search for the optimumsolution."

Optimising the simulated model requires anefficient search algorithm and for this Bak isusing the so called 'Complex' method. "In thealgorithm, we populate the simulation with anumber of randomly generated designs and itevaluates the performance of each," he ex-plains. "It then picks the poorest performingdesign and 'mirrors' it across the centroid ofthe remaining designs to produce a solutionthat should work more effectively." Thisprocess is then repeated, with the worst per-forming design substituted each time, until thesolutions converge on the optimum result.

Initially, Bak is using stability and accuracy asperformance criteria, and, consequently, theoptimum solution is the design yielding the

lowest level of oscillations in the hydraulicsystem and with the best ability to follow

the position reference fed to thecontrol system. Later, Bak plansto add other criteria such asprice, robustness and long termreliability.

www.adeptscience.co.uk

Feature: Computer Aided Engineering

dpaonthenet.net 7

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Computer Aided ManufacturingFeature:

8 dpaonthenet.net

"It's exciting when new technologycomes along that changes things somuch for the better," says Mr Bentley."We find it a very powerful tool becauseit enables us to do much deeper depthcuts than before. And because we canalso increase feed and speed rates itreduces our cycle times considerably."

Edgecam's waveform roughing strat-egy is designed to maximise material

removal rates while prolonging bothtool and machine tool life. It producesrough milling toolpaths that delivershorter cycle times, greater tool life,better surface finish and are kinder tomachine tools.

Waveform creates its toolpaths so that,when viewed from above, the distancebetween the roughing passes - alsoknown as stepover - varies, but thisvariation allows the actual width of cutto stay the same and at the optimumlevel, meaning the spikes are removed.Chip load stays constant, and thedepth of cut employs the cutter's entireflute length.

It is proving to be invaluable in MachOne's machining operations for theirbiggest customer base, the satellitecommunications industry. Chris Bent-ley highlights how it reduced the cycletime from two hours five minutes, toone hour 36 minutes, for an aluminium4G broadcast amplifier casing.

"We went from a 4mm depth cut to15mm using a 25mm indexable insertcutter, and we reduced the stepoverfrom 50 per cent down to 20 per cent.

We'd expect even better results fromusing solid carbide, because it wouldgive us more flute length. But we canpush the indexable insert cutter partic-ularly hard, and we ended up movingfrom 2.4m/min to 4.5m/min - just underdouble the feed rate."

Other satellite communications equip-ment that the ISO 9001-accreditedcompany now manufactures withWaveform includes a componentwhich houses electronics for a HD tel-evision broadcasting unit. "Traditionallywe roughed the open pockets with a16mm cutter making 6mm depth cutsat a feed rate of 1,800mm a minute,"says Mr Bentley. "With waveform wewere able to take a 29mm depth cutwith a stepover of 20 per cent."Although they did not increase thefeed rate too much for that particularjob - taking it to 2.5m/min, the feedrate for another component has morethan doubled. An aluminium casing fora person-to-person communicationunit is produced with a feed rate of5.4m/min, up from 2m/min. Prior toWaveform, the 8mm ripper created adepth cut of 4mm. That has now beenincreased to 12mm using the same

Pushing theboundaries

of traditionalmilling

Chris Bentley is managing director of Mach One Engineering, a companythat specialises in the manufacture of precision engineered components andassemblies. A core customer base is the satellite communications business

for whom it manufactures aluminium 4G broadcast amplifier casings. In the fiveyears that he has been using Edgecam CNC software, he has discovered that the

Waveform Roughing Strategy has, in his words, pushed the boundaries of tradi-tional milling, cutting cycle times without compromising product quality or tool life.

Chris Bentley: in some cases we've increased thedepth cut five times from the depth we used to have

3402 - DPA Jan13 Edn_DPA 08/01/2013 12:25

An innovative solution, to a simple problemSpirolox Retaining Rings provide a shoulder to rely on

360o technology strong and durableno lug interferenceno tooling costs

www.tfc.eu.com+44 (0)1435 860333 call now to speak to our expert team

Feature: Computer Aided Manufacturing

tool, with a 20 percent stepover.

With many of Edgecam's waveformroughing parameters being outsidethe traditional machining comfortzone, Mach One's machinists wereunsure originally that the processwould work without damaging thetools.

"In some cases we've increased thedepth cut five times from the depth weused to have," says Chris Bentley."And even though we were reducingfrom a 50 per cent stepover to 20 percent, the confidence just isn't there at

first to start pushing the feed ratehigher as well. But I've put some rad-ical programs in place, and they've allworked.

"Your instincts as a skilled miller tellyou combining these depths of cutwith the amount of stepover and in-creased feed and speed rates is goingto go badly wrong. But it doesn't.Waveform is real, it does work, and isactually pushing the boundaries of tra-ditional milling.

"The quicker cycle times are increas-ing our capacity. Quality and service is

always ournumber onepriority, andE d g e c a m ' sW a v e f o r mR o u g h i n gStrategy willd e f i n i t e l ymake a majorcontr ibut iontowards that."

Having usedEdgecam forfive yearsnow, ChrisBentley says itis an integral

part of their manufacturing process,driving three XYZ mills, aCincinnati Arrow and DugardEagle. The 3,500 square footfactory, which machines a varietyof materials as well as providinganodising services, also benefitsfrom an unexpected side-effect ofWaveform roughing: it's noticeablyquieter. The machines don't 'squeal',making it a more comfortable workingenvironment for the machine opera-tors.

www.machoneengineering.netwww.edgecam.com

the Waveform Roughing Strategy in Edgecam CNC

the Waveform Roughing Strategy in Edgecam CNC

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3402 - DPA Jan13 Edn_DPA 08/01/2013 12:26

Designed by Mario Cormier, the ownerof Canada-based Cormia Design, thePocket Razor is TSA approved meaningit is ideal for men and women on the go,and can also be used on an everydaybasis. It is manufactured in high qualityaluminium, comes with a cover and key-chain and accepts all popular twin bladecartridges.

Cormier said: "Since I started shavingback in 1980 I've experimented with vir-tually every kind of razor imaginable, butnever found the perfect travel one. Sowith the intention of developing a solu-tion that ticked the boxes the othersfailed to satisfy I set about creating thePocket Razor."

"Of course the job of taking these de-signs and developing a working productout of them is a huge challenge, and Icouldn't have picked a better partnerthan Star Prototype.

"They were a great company to do busi-ness with. Their service was always fastand efficient and the quality of both their

work and communication was excellent.I'm certainly looking forward to workingwith them again."

Star's brief was to develop the toolingand parts for the Pocket Razor. A jobthat included producing a cover made ofAluminium 6063, which was createdusing extrusion processing. The teamalso developed 15 samples of the differ-ent cover finishes available so thatCormia was able to select the right op-tion for them. The chosen satin finishwas then cleaned and coated in order toprotect its surface and prevent oxidisa-tion. Star also made the razor by diecasting with ADC12.

Prior to delivery, all 500 parts developedby Star were put through a rigorous in-spection process to ensure every-thing was the correct shape, the rightmaterial and that it passed the Farotest.

Gordon Styles, managing directorof Star Prototype, said: "While wepride ourselves on the speed of our

service, we will never allow the quality ofour work to suffer as a result of trying tocomplete a project in the quickest pos-sible time.

"Everything we do undergoes a full in-spection prior to delivery. We checkeverything from size, shape and finish tothe exact content of the metallic materialused and only when everything haspassed every test do we allow the prod-uct to leave our factory."

To find out more about Cormia Designand the Pocket Razor visitwww.cormia.ca

www.star-prototype.com

Feature: Rapid Prototyping

10 dpaonthenet.net

Star deliversa close shave forunisex travel razor

Star Prototype has helped turn an innovative idea for a unisex travel razor into acommercial product for the discerning traveller by delivering the key elements

of Cormia Design's new Pocket Razor.

Shaving on themove: CormiaDesign's newPocket Razor

3402 - DPA Jan13 Edn_DPA 08/01/2013 12:26

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Originally founded in1988 under the nameLoire Modelage,Loiretech designs and manu-factures tooling for large, complexthermoplastic and composite parts,serving customers primarily in theaerospace, automotive, defence andrail industries. One of the company'sspecialities is resin infusion.

On the Airbus project, Loiretech wassubcontracted by airframe manufac-turer and Airbus partner, Aerolia, todesign and produce moulds for theEuropean aerospace giant, working toa demanding schedule.

The new Airbus 350 is the latestin a family of long range, wide-bodiedjet airliners developed by the Euro-pean aircraft manufacturer. Capableof carrying between 250 and 350 pas-

s e n g e r s ,depending on the speci-fication, it is the first aircraft of its kind

which has wings and fuselage madeprimarily of carbon reinforced poly-mer.

Step 1: master model milling operations Step 2: the resin infusion process set-up

Airbus A350 XWBpassenger aircraft

Feature: Carbon Reinforced Polymer Composites

12 dpaonthenet.net

Tooling specialistgets stuck intoAirbus projectFrench tooling specialist, Loiretech is using Araldite 8615 resin in the manufacture

of prototype lower front panels for Airbus' new A350 passenger airline,which is expected to go into service with launch customer,Qatar Airways in approximately two years time.

3402 - DPA Jan13 Edn_DPA 08/01/2013 12:26

Feature: Carbon Reinforced Polymer Composites

Loiretech chose Araldite 8615 for thisparticular application primarily for itsvery low viscosity, which delivers op-timum impregnation of the carbon fi-bres during the infusion process. Italso offers a long pot life that facili-tates the very large tooling capabilityrequired in aircraft manufacturing;parts typically up to 20m in length arenot uncommon. The Araldite systemwas supplied by DiL France, a Hunts-man Advanced Materials' area distrib-utor.

Working with productsand technical support

supplied by Huntsman Ad-

vanced Materials, the team fromLoiretech completed the project injust 16 weeks. Loiretech president,Marc Moret, takes up the story:"With a customer such as Airbusand an application of this kind,there can be no compromise in thequality of the manufacturingprocess. The mould was createdusing resin infusion on a CNCmilled master model. Araldite8615's high Tg is an importantparameter for such moulds. With itsability to withstand 300 curing cy-cles at temperatures up to 180ºC, itfulfils critical performance criteriaand we have al-

ready used this type of system tomake large composite moulds for theaerospace industry in serial produc-tion."

In August 2012 Airbus successfullypowered up the flight deck of theA350 for the first time. The A350XWB (extra wide body) will featurelarge carbon reinforced polymerpanels for the fuselage skin andcomposite fuselage frames for theaircraft structure.

www.huntsman.com/advanced_ma-terials

Step 3: the mould structure assembly Step 4: the final mould

3402 - DPA Jan13 Edn_DPA 08/01/2013 12:27

Monitor efficiency in the workshop

with WERMA's data collection

package,"WIN", now including a

new piece part counting module

WERMA has an extremely innova-

tive solution for the wireless moni-

toring of machinery in the

workshop. The system – WIN –

Wireless Information Network – is a

simple yet proven product which

can improve efficiency and produc-

tivity in the workshop and lead to

greater transparency of the manu-

facturing process. The low cost

system can monitor wirelessly up to

50 machines irrespective of age or

type of the machine.

A new development – piece part

counting module

The Southern German manufac-

turer WERMA has now introduced a

new development to the WIN sys-

tem called “WIN slave perform-

ance” The new software developed

for this module also includes many

other new features. In addition to

the existing monitoring functions

the new software can monitor the

piece part count of the machine

and analyse the progress of a job

on the machine. The new hardware

monitors up to six different machine

status conditions as well as count-

ing the piece part production output

signal of the machine.

Simple and quick to install

WIN is an inexpensive piece of kit

which is very easy to install. The

system is “plug and play”, that is;

the transmitter accessory, WIN

slave performance” is added to an

existing WERMA KombiSIGN sig-

nal tower which transmits data

collected to the receiver “WIN

master” connected to a PC with

a USB cable. There is no li-

cence restriction to the number

of users permitted to use the

system software.

Intuitive software developments

As well as a new piece of hardware,

the “WIN slave performance” the

new WIN software contains many

new functions, features and new an-

alytical tools. In addition to the ex-

isting WIN functions now details of

the job in hand can be put into the

system and monitored. The moni-

toring of specific job performance

criteria can contribute to improve

machine utilisation and help reduce

idle time in the production process.

A further feature is the display of the

“fulfilment” level of a job in hand on

the machine. Any time frame, for

example the shift yesterday or last

week can be viewed retrospectively

at the touch of a button. The clear

and concise notification and display

of monitored condition changes on

the machine

can make a big differ-

ence to reducing down time in the

value added process chain.

Keep in touch with the job – no

matter where you are

It is no problem for WIN to keep you

informed, no matter where you

might be. If the status condition of

the machine should change an

Email can be generated automati-

cally and sent to a PC or smart

‘phone. This notification can also

be time delayed if the user so

wishes.

Advertorial: Werma

3402 - DPA Jan13 Edn_DPA 08/01/2013 15:20

Good transmission range

The transmission distance given an

unobstructed line of vision is 300m,

but the construction and layout of a

workshop may influence this. How-

ever as each WIN slave acts as a

“repeater” one to another the net-

work distance capability is in fact

considerably greater.

Convenient starter kits available

Two different starter kits are offered

which allow the user to set up and

start monitoring and counting with-

out a complicated installation

process. With the all round starter

kit WIN complete with WIN slave

performance for KombiSIGN 71 the

user can set up monitoring three

machines and comes with three

signal tower kits as well. A second

starter kit, WIN system with WIN

slave performance is designed for

an existing WERMA KS70/71 instal-

lation and contains just the ele-

ments required to be added onto

the existing WERMA signal tower to

allow monitoring to take place. Ad-

ditional accessories can be se-

lected at any time from the

extensive range available.

Both starter kits allow a network

containing up to 50 machines to be

built up and monitored. Further in-

formation on WERMA’s “Lean Pro-

duction” solutions can be found on

www.werma.co.uk.

WERMA (UK) Ltd.

Linnell Way

Telford Way Industrial Estate

Kettering

Northamptonshire

NN16 8PS

Tel: +44 (0) 1536 486930

Fax: +44 (0) 1536 514810

www.werma.co.uk

[email protected]

Advertorial: Werma

3402 - DPA Jan13 Edn_DPA 08/01/2013 15:21

Tangless Kato CoilThread insertsfrom Advanex have all the character-istics of tanged threaded inserts,without the need for tang break-offand retrieval; moreover, they areeasily adjusted or removed afterinstallation. This ensures significanttime savings on each installation,especially in applications thatusually require the counting ofeach removed tang.

Additional time savings are madebecause of the bi-directional designof tangless threaded inserts whichavoids having to ensure that eachpart is correctly orientated, and theavailability of special tools to speedinstallation. These benefits are obvi-ously multiplied for high volumeusers.

There is, however, a problem withstainless steel inserts when theyare used with mating stainlesssteel fasteners: they can be suscepti-ble to galling, a cold welding processwhich can occur when pressurebuilds between the contactingthread surfaces of male and

female fasteners during assembly.

At the least this may cause somedamage to thread forms or, in severecases, prevent disassembly of thethreaded joint. To lessen the effectof galling, some users apply lubrica-tion before joint assembly. However,this can lead to unreliable torque/tension results in the joint andalso have FOD issues that maynot be acceptable for a criticalapplication.

For applications where galling ormagnetic permeability is an issue,tangless inserts made from an anti-galling wear resistant austenitic stain-less steel, comparable with materialslike Nitronic 60 (UNS S21800) areavailable. The gall resistant stainlesssteel material has strength propertiessimilar to the standard stainless steelmaterial, providing galling preventionwithout the need for lubrication orplating.

Combining the benefits of a tanglessinsert with a special anti-galling ma-terial, customers with critical applica-tions finally have a truly FOD freesolution. This material is also non-magnetic and can be used in manu-facturing facilities that have a vacuumprocess environment or equipment.

For high temperature (550ºC) applica-tions, tangless Inconel X750 inserts(AS7246) are now available. InconelX750 is a non-magnetic, high corro-sion resistant nickel based super-alloywith excellent heat resistance andstrength characteristics. And for saltwater and electrical applications, aslong as you don't need the strength ofstainless steel or Inconel, tanglessphosphor bronze inserts (PB102) arealso available.

These Advanex Kato Precision prod-ucts and associated tooling are avail-able in the UK from ASM Fastenerswww.asmfasteners.com

Feature: Threaded Inserts

16 dpaonthenet.net

Stainless steel fasteners are usedin many applications where zero

foreign object debris (FOD) isessential. Such applications includethe food industry, clean rooms,electronics, aerospace, satellites,safety critical applications, spaceand other vacuum environments.The tangless insert was developedto eliminate the potential problemof tangs being broken off afterinstallation and being left behind,or ending up in critical parts ofequipment.

Tangless insertssave time in criticalassembly

Advanex tangless Kato CoilThread inserts are available in a variety of materials.The standard insert range is made from 304 stainless steel (Material Spec:AS7245), meeting most application requirements. Inset: tangless Inconel X750 in-serts (Material Spec: AS7246) are also available for high temperature applications

3402 - DPA Jan13 Edn_DPA 08/01/2013 12:27

Standards are important. So is quality.We specialise in manufacturing small, high precision components and assemblies.Our components range from simple helical springs to complex multi-stage pressings with precious metal contacts.We also offer a design and technical service.

AerospaceAutomotiveDefenceElectricalElectronicsMedicalSecuritySport & LeisureHobbies & ToysMarineISO/TS16949 automotive accreditationAS9100 Aerospace accreditation

Victoria Works, 30 Victoria Rd, London E17 4JUTel: 0208 527 5599 Fax: 0208 527 1142Email: [email protected]

www.goss-springs.com

3402 - DPA Jan13 Edn_DPA 08/01/2013 12:27

• 100% Performance Tested

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Why fuss with the in-house approach when Lee Chek Valves install in less time, work more reliably, last longer, and cost less? Lee Chek features include:

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Lee Products Limited3 High Street, Chalfont St PeterGerrards Cross, Bucks. SL9 9QE.

3402 - DPA Jan13 Edn_DPA 08/01/2013 12:27

"By getting DuPont involved earlyin the design process, we were ableto evaluate a huge variety of materialideas to achieve our comfort andperformance targets," says Knoll'sNicole Mirchandani "The use of renew-ably sourced materials also enablesus to deliver a pace setting designthat reinforces our commitment tosustainability."

According to Rick Tobar, DevelopmentPrograms Manager at DuPont: "As wellas introducing lots of different samples,we demonstrated how the different ma-terials could be used and how the de-signers could extract the maximumvalue out of them in terms of balancingfunctional attributes against designneeds... such as increased supportwhile maintaining the necessary flex."

Designed by Formway Design of NewZealand, Generation uses high per-formance DuPont materials in a waythat is quite new to the furniture indus-try. The 'Flex Back Net' and 'Dy-namic Suspension' control worktogether to give the chair itsflexibility and structure - al-lowing it to move to suit theextended range of motionrequired in a contemporaryworking environment - andyet still retain the mem-ory of its originalposition.

The Flex Back Net, which deploys re-newably sourced Hytrel, supportsmany different postures and facilitatesa wide range of multi-dimensionalmovement - not just from front to back,but also from side to side. Users canalso push against the Flex Top of thebackrest and it will bend over to sup-port their arm as they turn in the chair.

The chair's innovative Dynamic Suspen-sion control, which uses Hytrel thermo-plastic polyester elastomer and CrastinPBT polyester, is a simple, non-me-chanical control concept that providesa smooth, weight-compensated ride.Without the complexity of metal links orsprings, it uses one-third the number ofparts of a traditional ergonomic chairmechanism - helping to ensurethat it is also 20 percent lighterthan most other high per-formance chairs.

Generation was the first product in thefurniture industry to be rated Sustain-able Platinum by the SMaRT Sustain-able Product Standard, whichmeasures a product's environmental,economic and social benefits over itslife cycle and throughout its global sup-ply chain, from raw materials extractionthrough reclamation or re-use.

www.dupont.com.

Feature: Performance Thermoplastics

Are you sittingcomfortably?Knoll's 'Generation' work chair embraces the idea of elastic design - where a product

rearranges itself in response to its user. Key to the chair's flexing and supportivefeatures is the use of high performance thermoplastics supplied by DuPont.

dpaonthenet.net 19

Using the inherent propertiesof DuPont high performance

thermoplastics and particularlyits Hytrel RS TPC-ET for the

Flex Back Net, Knoll's 'Genera-tion' work chair literally flexes

as you change position

3402 - DPA Jan13 Edn_DPA 08/01/2013 12:27

Feature: Energy Efficiency

20 dpaonthenet.net

The current financial system is gearedto short-termism. To demonstratethis, we only need to look at thevolatility of the stock markets. Itseems to be human nature to meas-ure only up to the horizon. In busi-ness, we seem to concentrate onlooking at annual budgets rather thanover the long term. There needs to bea total culture change, as sustainabil-ity is for the long term. But the wholeeconomic system, from stocks and

shares to commodities, continues tobe driven by speculation and senti-ment.

What will hopefully focus minds, how-ever, is the significant pressure on en-ergy and commodities prices, as theincentives will be greater than ever tomake sure that savings are made. Butto achieve this, investment will haveto be made; as the old saying goes,you have to speculate to accumulate.

Efficient technologies

To meet environmental and businessobjectives for the future, energy effi-cient technologies will be a mainstayfor economic survival for all busi-nesses. This will be coupled with widerefficiency programmes. The key will bethe communication of our solutionsand technology developments to amuch wider audience than we haveconsidered before.

Developing a way to integrate widersustainable engineering and financewill be the big challenge. How can wedefine sustainable building servicesand buildings in such a way that en-ables investors; developers; and fi-nance professionals, including valuersand occupiers, to measure and attrib-ute a financial value to sustainability?

The answer must be to change the waywe conventionally measure finance.How we construct longer term meas-ures will be the big question. A goodexample of how measurement is beingchanged would be the introduction ofcarbon accounting and the CRC en-ergy efficiency scheme (formally knownas the Carbon Reduction Commit-ment).

This involves measuring the price ofcarbon, which is obviously adding acompletely different dimension to theconventional way of measuring financein relation to energy consumed. So aswell as paying for the energy, businessis also paying a carbon tax on the use

The financialimplications of anenergy strategyShort termism damages sustainability, says Mike Malina, founder and director of

Energy Solutions Associates, and award winning building engineering servicesconsultant. Here, we present an edited version of a presentation he made at theMotor Driven Systems conference last year, in which he makes the case for takingthe long term view when investing in energy efficiency technologies.

Figure 1: a traditional financing model

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of energy. In the future this may be ex-tended in some form to cover the do-mestic energy market, but has so farbeen held off due to the likely unpopu-lar reaction to this at a time of signifi-cant energy price rises and recessionaltimes.

When the CRC was first introduced,the idea was geared to a performancetable where the top performers wouldget a rebate and gain financially inorder to incentivise the process. How-ever, many companies were shockedwhen the scheme changed in 2010,when the coalition government de-cided to keep all the payments, so thatthe CRC in effect became a carbon tax.

Industry and building owners were upin arms. It seems they didn't realisethat the situation created an even big-ger incentive to save, offset and reducetheir energy consumption. The effect ofthe CRC seems to have been verymuch about concentrating people'sminds on the price of carbon per ton.In this process, they seem to have for-gotten about the initial cost of energy.

By reducing their payment of the car-bon tax, they would at the same timebe reducing their energy bills by savingtheir energy resources, so creatinga double benefit on energy use.People become obsessed withthe politics and the tax, but theyneed to see the CRC as an exam-ple of integrating a financial mech-anism to incentivise sustainability.

Funding for sustainable buildingprojects

Finding the finance in difficult eco-nomic times can be a challenge, not tomention attitudes to payback. Many

companies seem not to want to borrowmoney to fund what others would con-sider a good return on investment(ROI). Especially if the debt chargeswould cover the on-going cost of theloan repayments, gained from the en-ergy savings. This is very much a con-vention in finance where the funds maybe available but the company doesn'twant to accept any risks.

There are a number of establishedways companies appraise investmentpotential, but the majority will be con-cerned at how long it will take to breakeven. With current investment ratesand financial uncertainties it surprisesme that so many good energy effi-ciency projects are held back, becauseeven with return on investments withinfive years (which can cover a wholerange of energy saving technologies)these projects do not get approval forfunding.

All sorts of accounting techniques areused to measure tradi-tional financialmodels. All rely ona capital sum tofinance theproj-

ect, which means many projects willneed the total cost as up front capital.This can be illustrated as a graph (Fig-ure 1) showing traditional ROI.

An alternative model (Figure 2) devel-ops a system of financing a project thatdelivers a much shorter payback - ROIfunded in stages by a finance provider.This commercial model is potentiallysimilar to how the Green Deal may befinanced over the term of many proj-ects, small and larger scale.

To achieve an integration of financeand sustainability, and break down thebarriers that currently exist, I believethat there has to be a significant andserious discussion between finance in-stitutes and their equivalents in the en-gineering and sustainability fields tocreate a mutual understanding of theissues on both sides. Experienceshows that, currently, finance peopledon't really have a grasp of sustainabil-ity issues and vice versa. Once weachieve this, integration can easily be-come the norm.

The cheapest kWh is the one younever use!

The reduction in energy use should bethe priority issue, although many peo-ple and companies are looking at theinstallation of low carbon and renew-able technologies as well. The bigdilemma people are facing is when ex-actly to make the decision to install re-newables, as there is so muchconflicting information regarding theirperformance and the financial returnson different technologies. What is clearis that energy prices will inevitably con-tinue to rise over the longer term.

An analogy might be deciding when tobuy a new computer or

upgrade an exist-ing one. Ide-ally, it is bestto buy a ma-chine that is

Figure 2: an alternative financing model

dpaonthenet.net 21

Page 22

3402 - DPA Jan13 Edn_DPA 08/01/2013 12:27

upgradable - the same goes for renew-able and low carbon technologies.

However, this could be very difficultwith photovoltaics for instance. Thepanels are manufactured, sealedand installed for a 25 year life, so itwould be very hard to make themupgradable. During the 25 years of aphotovoltaic panel's life, technologywill undoubtedly develop and futurepanels will become more efficient. Atpresent, the conversion rate from sun-light to electricity is just 12-18%,but there is the possibility that this willhave increased to about 25% in a fewyears. This will improve still further astime goes on.

Faced with this fact, the incentive forearly adopters was the feed-in tariff(FiT), which was really the only incen-tive to invest in current technology.Without this, it would be totally uneco-nomic to buy now. Those that took upthe FiT in 2010-12 were guaranteed 43pence per unit generated. At the time,the early adopters had to use the levelof technology that was available. If theywaited however, in the same way thatone might wait to upgrade a computer,then they received a diminishing FiT, soit was clearly designed as a reward forearly adopters, which of course wouldstimulate and create a market. On theother hand, as the technology devel-ops and becomes more efficient, thephotovoltaic panels will generate moreelectricity as the conversion ratio fromsunlight to electricity will have im-proved.

The choice: renewables or efficiency

This argument, for both efficiencyfrom technological development andcosts, has also been made to me onthe issue of fitting technology such asvariable speed drives or EC fans. Icounter this with the fact that the effi-ciencies and paybacks for motor drivensystems far exceed any renewabletechnologies and don't require anysubsidies or special financial treatment,such as FiTs or renewable heat incen-tive payments.

People tend to like new technologiesand want to be part of their develop-ment in society. Nevertheless, this candistract our attention from the fact thatthe cheapest kilowatt of power is notsolar: it's the kilowatt we never use inthe first place. I would maintain that thekey is still to focus on the energy hier-archy (Figure 3) since the financial andenvironmental impact is far betterserved by reducing energy in the firstplace. Perhaps another way of lookingat this is to combine the hierarchy withfinance.

Whilst reducing energy usage is key,that is not to suggest that I'm notkeen to see further investment inrenewable energy. Once we'veachieved the first steps on the energyhierarchy we must ultimately invest inrenewables, perhaps by ring-fencingthe savings from energy use reduction.That way, we could fund ourphotovoltaic panels from the energyhierarchy savings made earlier by

reducing the energy demand.

We have to look at energy and all theother resource issues and impacts,from cradle to grave, for all activitieswe employ inside and outside ourbuildings and all the associated activi-ties. Most importantly, there needsto be a simple process for the enduser and/or consumer to evaluateand understand the true impact, bothfinancially and from a sustainabilitypoint of view.

I propose we adopt the tried andtested 'A to G' rating method, whichgives everyone a good understandingof what is efficient and what isn't.Complex arrangements for makingsure that a universal and robust sys-tem is put in place can take place be-hind the scenes; for the decisionmaker, the simpler the system, the bet-ter. A-G can be used universally to labelall products on a common measurablescale of energy with the cost and life-cycle data.

Ultimately, any energy efficiency meas-ure to improve building performance,which can be financed from the sav-ings on energy bills, should be consid-ered.

The key to a universal and a muchwider adoption of a motor driven sys-tem technology efficiency programmewill be the education, training andawareness of not only the end users,but even more crucially of the industryitself.

Mike Malina is author of DeliveringSustainable Buildings: An Industry In-sider's View published by Wiley-Black-well this month. For details copy thisURL into your browser: goo.gl/vbZX6.DPA readers can obtain a 20 percentdiscount on the price of this title byusing the discount code VBB09 at theWiley.com checkout

www.energyassociates.co.uk


22 dpaonthenet.net

Mike Malina

Figure 3: the energy hierarchy - what delivers a low carbon energy efficient building?

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Precision engineering

Call or visit our web-site to fi nd out about this revolutionary concept produced with engineers in mind.

Light as a FeatherInspired design using today’s materials means that you can generate 4.4Nm from 62g

3402 - DPA Jan13 Edn_DPA 08/01/2013 12:27

Electrical engineers have had a com-mon thread running through theirwork for the last five or ten years, re-ducing energy consumption to cutcarbon emissions. This has the veryuseful additional benefit of cuttingelectricity bills. Not surprisingly, newregulations and guidelines haveemerged to encourage this drive, thelatest of which is the EU's MinimumEnergy Performance Standard(MEPS). This is being phased in, withthe first part already a legal require-ment and the last part due to be en-acted in 2017.

Under MEPS the current Eff1 and Eff2efficiency classification will be discon-tinued. Indeed Eff2 rated motors willbecome illegal. Also a new testingprocedure that gives highly accurateefficiency figures will be introduced. Itis expected that the increased pur-chase price of the new high efficiencymotors will be recouped many timesover by the energy savings.

However, in the past designers rou-tinely oversized motors by 10-20 per-cent. And these motors may havebeen driving equipment via equallyoversized and therefore inefficientgearboxes, lead screws, belt or chaindrives, clutches or couplings. Addedto this is the fact that motors have afairly narrow optimal efficiency bandof typically 80-85 per cent full load,and many will not be running withinthe range.

Feature: Motor Driven System Design

24 dpaonthenet.net

Engineers:you no longer needto oversize motors

The water industry has long understood theenergy saving benefits of drives and soft starts

For generations engineers happily oversized electric motors to allow for worsecase working conditions, plus an extra margin of comfort. But what made good

sense then is something of an anathema to today's energy conscious engineers,claims Stuart Harvey

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The new MEPS addresses this bymeasuring the efficiency level ofthe whole drive system ratherthan just the motor on its own.This means every installationhas to be assessed individually,whereas in the past motorscould be bought with anefficiency rating.

All systems go

Fan systems are already subjectto MEPS, and pumps will be from2013. These are by far the twobiggest user groups for motors,so OEMs need to make sure theyare up to speed and comply withrequirements. Over the subse-quent four years all motor drivesystems will be drawn into thesystem, but it is likely that endusers will start specifying compli-ance to their OEMs rather sooner.

Thus engineers of a certain agewho were brought up over-spec-ifying motors, need to move to anew paradigm. This may simplybe a matter of changing habitsand assumptions, but it may alsomean getting company policiesand design procedures changed.Established OEMs may need toinform their regular customers ofthe changes.

End users are not obliged tochange existing equipment, but itmay be worth modernisingequipment in line with MEPS inorder to improve their own en-ergy efficiency and enhance theirgreen credentials.

Significantly if a motor is used inconjunction with a soft start orvariable speed (VS) drive, theelectronic component is alsoconsidered to be part of the sys-tem for which overall efficiency iscalculated. This means mains-borne harmonics and power fac-tor correction will have to bebrought into the efficiency calcu-lations, as will filters and otherassociated line equipment.

It is also notable that a drive maymake a significant contribution tooverall efficiency by allowing asmaller motor to be specified.The motor would be sized for'normal' duty, but the drive canpush through a bit more powerwhen required for short-lived un-usual circumstances. The net re-sult could be a significant energysaving, with a payback period ofjust a few months, leading to a

positive contribution to the over-all bottom line within the first fi-nancial year.

It should also be understood thata variable speed drive can be agood investment for a fixedspeed application. If the load isto run at a different speed thanthe output speed of the motor,the speed shift can be achievedwith a gearbox, belt/chain drive,mechanical variator or an elec-tronic VS drive. Each of these willcost something, and the advan-tage of a drive is that it can easilybe reset if requirements change.

However it must be made clearthat a drive will not improve theefficiency of the motor it is feed-ing. Thus if a low efficiency motoris specified, it cannot be mademore efficient by the addition ofa drive.

The advantage of lower efficiencymotors is that they are cheaper tobuy, so may be suitable for dutycycles that have low overall run-ning times. As a rule of thumbthere are 9,000 hours in a yearand if a motor is expected to runfor less than 2,000 hours a year,the total running cost of a highefficiency motor won't be signifi-cantly below those of a lowercategory motor.

Before MEPS is fully imple-mented the EU intends to intro-duce a similar scheme for VSdrives. Hopefully the twoschemes will be so similar thatthey will mesh together seam-lessly rather than burdening engi-neers with even more paperwork!

Stuart Harvey is managing direc-tor of Softstart UK

www.softstartuk.com

Feature: Motor Driven System Design

dpaonthenet.net 25

Harvey: It is no longer accept-able to waste energy by over-

sizing motors. A variable speeddrive on a right-sized motor is a

far greener solution

3402 - DPA Jan13 Edn_DPA 08/01/2013 12:27

The key tasks of motor-protective cir-cuit-breakers include the switching,protecting and disconnection of currentcircuits primarily for motor loads. At thesame time they protect motors frombeing destroyed by overloads andguarantee safe disconnection in theevent of a short-circuit. They are alsosuitable for the operational switching ofmotor loads with a low switching fre-quency, and safe disconnection fromthe supply for maintenance or modifi-cation work.

While development in the past primarilyfocused on the mechanical side ofthings, today's development increas-ingly comes from the field ofelectronics and

automation with regard tocommunication and fieldbustechnology.

Motor-protective cir-cuit-breakers withelectronic wide-rangeoverload protectionoffer several key ben-efits compared to devices withthermal releases. These include largesetting ranges, low heat dissipation,tripping classes above Class 10, pre-cise and exceptionally long-time stabletripping characteristics, as wellas the possibility

Feature: Motor Protection

26 dpaonthenet.net

Protect your assetswith more functions,fewer wiresFor the majority of processes, motors have a significant

influence on production efficiency, so motor protectionis of central importance. Stuart Greenwood reviews thelatest developments and describes how motor-protectivecircuit-breaker technologies are increasingly being mergedwith electronics and lean automation technologies

Eaton's PKE motor-protective circuit-breaker in combination with the SmartWire-DT bus-based lean panel wiring system

3402 - DPA Jan13 Edn_DPA 08/01/2013 12:28

to read parameter data.

Illustrative of these advances is Eaton's PKEmotor-protective circuit-breaker with electronicwide-range overload protection. This devicemeasures the current rise via an integrated cur-rent transformer in the trip block, and evaluatesit using a special electronic circuit which, in theevent of an overload, sends a pulse via an actu-ator system to the switch mechanism. PKE cir-cuit-breakers operate with a larger currenttransfer ratio and the device has a wide currentsetting range in the ratio 1:4 (conventionalbimetal motor-protective circuit-breakers have aratio of 1:1.6).

Wide current setting ranges also reduces thenumber of product variants needed - reductionsof up to 75 percent are possible, compared withbimetal trip type devices. This has a positive im-pact on both inventory costs and maintenancelogistics.

Energy consumption is also important whenconsidering the life cycle costs of an industrialinstallation. PKE motor-protective circuit-break-ers with electronic wide range overload protec-tion feature low heat dissipation (up to 85percent less than a bimetal alternative), limitingtemperature rise in the switching cabinet andoften eliminating the need for forced cabinetventilation.

Smarter wiring

As well as the purely basic functions of on/offswitching under normal operating conditions,and the basic protective functions available froma circuit-breaker, users also want additional in-f o r m a t i o n

from these devices in order to maximise opera-tional and maintenance efficiency.

While it was previously only possible to evaluateswitch states or differentiate overload or short-circuit trip indications, motor-protective circuit-breakers with electronic overload protectionoffer rather more, including diagnostics, statusor overload messages, and even the actual cur-rent flow.

The necessary data transmission platform isprovided by the SmartWire-DT wiring and com-munication system, which offers an alternativeto point-to-point control wiring, and avoids thelaborious process of setting up device ad-dresses via DIP switches. In place of multi-wirecontrol lines there's a single bus cable.

Data from networked motor starters are trans-ferred directly to the controller and made avail-able over the entire system. Indeed, adoptingthe lean panel wiring capability of SmartWire-DTgreatly improves the transparency of the au-tomation system. Since fieldbus and networkbased field wiring already supports informationexchange, the addition of lean panel wiring sys-tems means, in essence, that any informationabout any aspect of the automation system'soperation and status can be made availablewherever it is needed.

Stuart Greenwood is with Eaton's ElectricalSector

www.moeller.co.uk

Feature: Motor Protection

dpaonthenet.net 27

The author, Stuart Greenwood

3402 - DPA Jan13 Edn_DPA 08/01/2013 12:28

Drives Datafocus: To advertise here please callNicola Crawley on 01732 359990 or

email [email protected]

28 dpaonthenet.net

MAYR TRANSMISSIONS LTDINTRODUCES NEW SOFTWARE FOR

2D AND 3D CAD MODELS

Mayr Transmissions Ltd has installed newsoftware allowing them to produce 2Dand 3D CAD models of all of Mayr’sstandard products in just a few seconds.

Rather than a catalogue drawing or ageneric model, Mayr can now supplydetailed drawings and models reflectingtheir customers’ requirements.

Details including bore sizes, couplingsleeve lengths, hub designs or braketorques are programmed into the packageand an e-mail containing a set of approvaldrawings is immediately generated.

This saves Mayr’s OEM customers hoursrecreating designs that already exist,allowing them to simply drop Mayr’smodels straight into their own design.

For more information contactMayr Transmissions Ltd

Tel: 01535 663900Email: [email protected]

Web: www.mayr.co.uk

ABB INTRODUCES NEW 8 MW HIGHVOLTAGE FLAMEPROOF MOTOR

The new motor offers considerablebenefits for the chemical, oil and gasindustries, including low vibration levelsincreasing reliability, and reducedmaintenance requirements for lowercost of ownership.

Designed for fixed speed applicationsfrom 375 to 3,000 rpm, it is especiallysuitable for driving pumps andcompressors.

ABB has launched a new high voltageflameproof induction motor certified toIEC frame size 900 and rated to 8 MW.

Ms Karita Forss of ABB’s high voltageinduction motor product managementsaid, “Higher output motors are neededto drive bigger machines, and our newflameproof motor will be ideal for theseapplications.”

For more information contactABB Limited

Email: [email protected]: www.abb.co.uk/energy

COST-EFFICIENT AND COMPACT,THE PIEZOMOVE® LINEAR

ACTUATOR P-604 FOR OPEN-LOOPOPERATION FROM PI

The immensely cost-efficient andcompact P-604 lever actuatorsupplements the PI’s PiezoMove® seriesportfolio.

The linear actuator achieves a travel rangeof 300 µm and is exclusively designed foropen-loop operation.

The P-604 features properties that makeit ideal for OEM applications in optics,medicine, biotechnology andmicrofluidics: It is designed particularlyfor cost-effective production of largequantities with installation space kept toa minimum (19.5mm x 13mm x 4.1mm).

PICMA® multilayer piezo actuators arethe driving force of the P-604-type leveractuators.

They have an all-ceramic encapsulationthat makes them extremely robust anddurable.

Information on the P-604 andPI’s other products available online at:

www.pi.wsor call 01234 756369.

SIEMENS TECHNOLOGY IN WORLD’S FIRST COMMUNITY TIDAL DEVELOPMENT

Siemens is supplying specialised gear and control technology to growing UK tidal powergeneration company Nova Innovation, for the world’s first community tidal power project.Siemens Industry’s Mechanical Drives has supplied a planetary unit plus IE2 electric motor,along with inverter drive and control system through Siemens specialist technology partnerHMK. The Siemens technology features in the world’s first community-owned tidal power project,based in the Bluemull Sound in Shetland, between the islands of Yell and Unst, the two mostnortherly inhabited islands in the UK. It is a 30kW unit with horizontal axis and three-bladedrotor, and is being deployed in early 2013 to provide power to a local ice-house and industrialestate. The local community will reap the benefits of the project, safeguarding jobs andproviding valuable income.

For more information contact Siemens Web: www.siemens.co.uk/drives

ROCKWELL AUTOMATION BUNDLES KEYS TO MACHINE CONTROL DESIGN INONE-STOP SOLUTION

Rockwell Automation introducesthe Connected ComponentsAccelerator Toolkit (CCAT), abundled, one-stop solution thatsimplifies and expedites complete,cost-effective, small-machinecontrol design andimplementation. The CCATcombines a simple, yet powerfulcontroller with a full suite ofcompatible components andclass-leading applicationdevelopment tools that enableOEMs to focus engineering anddevelopment resources oncreating compelling anddifferentiating machine features.The CCAT speeds the basic,common design functions thatevery machine design requires. Byproviding this functionality, theCCAT allows the OEMs to investtheir design work in developingbetter, more competitivemachines.

For more information contact Rockwell Automation LtdTel: 0870 242 5004

Email: [email protected]

PLANETROLL® THE UNIQUE VARIABLE SPEED ATEX DRIVE

planetroll® is a leader in the field of drive technology with an extensive technical know-howin developing and manufacturing of variable speed gearboxes. planetroll® variable speedgearboxes are wet running transmissions. There is no friction inside the gear resulting in along service life and high levels of reliability.

The outstanding characteristics of the planetroll® variable speed gearbox is the result of anextraordinary system of torque transmission. The basis for this is the interaction of a perfectgeometrical body incorporating 4 rings, the ball and a traction fluid with an appropriatecoefficient of friction - This is elasto-hydrodynamic power transmission

Contact: Labtex Ltd01484 600200

3402 - DPA Jan13 Edn_DPA 08/01/2013 14:41

The benefit of installing powerconditioning equipment to manageand eliminate power quality issuessuch as those described abovehas long been clear. However, it hasnot always been easy to quantifywhether improving the power qualitysupply has a significant effect on thebottom line.

With the state of the economy contin-uing to make headline news and thefuture uncertain, businesses are look-ing to make their assets work harderfor longer. They also have to justifyevery penny of spending.

With that in mind, my company re-cently undertook a two-year study,which looked to better understandhow improving power quality affectedthe bottom line. Put simply is there areturn on investment when installingpower conditioning equipment?

Variable power quality

While there are only around ninehours of power outages on averageeach year in developed countries, thequality of the power produced by thegrid does not meet desired standardsfor around 79 hours per year. Gener-ally speaking, the power that comesfrom the grid still meets the standardsthat were set out in the early days ofelectricity. This was more or less ac-ceptable up until a few years agowhen hi-tech equipment with sensi-

tive components was introduced. Thisequipment requires good qualitypower if it is to perform correctly.

These irregularities can cause sys-tems to fail, crash or lock up suddenlyand without warning, leading to cu-mulative damage to integrated cir-cuits and electrical systems. Failureslead to down-time, lost production,lost customers - possibly even lostlives where medical devices are con-cerned - and it can take days for sys-tems to recover.

Feature: Power Quality

dpaonthenet.net 29

Power conditioningdelivers proven ROIProblems

associated withpower quality cantake a huge toll oncompanies, withinterruptions to thepower supply suchas impulses, noise,sags, surges,brownouts andoutages causingsensitive electronicand computingequipment to fail.Rob Morris describeshis company's two-year study of powerquality systemsinstallation to identifytheir real return oninvestment (ROI)performance.

Page 30

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In manufacturing, if computers andother sensitive electronic equipmentthat control processing lines areknocked out, production can behalted entirely. In retail, problems caninclude failure of point-of-sale sys-tems and other back-office systemsessential for successful day-to-daybusiness. Equipment failures such asthese inevitably lead to call-outs andservice visits, which can come at sig-nificant cost. We call this on-goingcost the 'service burden rate' and itcan often be very high for bespoke orcritical systems.

To find out whether the financial ben-efits of cutting the service burdenwould outweigh the capital expendi-ture of a power management system,we set out to measure our customers'service burden rate before and afterinstalling our equipment and compareit with the cost of power manage-ment. This enabled us to identify thetrue ROI of power conditioning equip-ment.

Our extensive research found that thetypical service burden rate for a pieceof commercial electronic equipment isin the region of 4 - 8 per cent of itsoriginal price. Taking into account thehigh capital cost of specialist equip-ment, and this service burden rate be-comes a significant factor. When wecompared the results gathered frommore than a thousand pieces of in-stalled power conditioning equip-ment, customers reported asignificant fall in service costs of be-tween 43 and 88 per cent. Taking intoaccount the cost of buying the powerprotection equipment, we found theROI in these applications varied from154 per cent to a staggering 1,148 percent.

For high value electronic equipment,a service burden at four per cent, thelower end of the spectrum, representsa large ongoing cost to a business,meaning that a reduction in costs of43 to 88 per cent can represent a sav-ing of hundreds of thousands or evenmillions of pounds.

The research found that the benefitswere not just financial. There is asofter side to consider, such as im-proved customer satisfaction, greatercustomer loyalty, less downtime andfewer call-outs to manufacturers. Forexample we found that calls to helpdesks decreased by an average of 60per cent, which can represent a sig-nificant saving to an OEM in clientservicing. The service burden ratealso includes software training, hard-ware and staffing issues; so, address-

ing the 'hidden' problems caused bypower fluctuations frees up time andresources to focus on the business inhand.

ROI in practice

In theory, therefore, the researchshowed that businesses that installpower-conditioning equipment canexpect a minimum ROI of around 154per cent - but what is the reality? Oneexample is James Hall & Co, a majorSpar Group wholesaler that installedpower quality equipment to protect itselectronic point-of-sale equipmentand back office systems in shops andpetrol forecourts.

At outlets where the power condition-ing equipment was tested, staffreported an 80 percent fall in harddisk failures and data corruption,a figure which prompted thecompany to invest in power condi-tioning equipment across all 500 of itsretail stores.

James Hall & Co currently rents retail

systems to its outlets for five yearsbut is confident that an investment ofaround £130,000 in power condition-ing equipment would make it possibleto extend the trouble-free life of frontand back office systems by 20 percent and deliver additional rental in-come of more than £2m.

With pressure on budgets, the powerquality market is having to evolve anddemonstrate the financial benefit ofinstalling power quality managementequipment and associated UPS.

Our recent study proves that there isa strong financial case for investing inthis type of equipment as it candemonstrate savings from the meas-urable areas of service and warrantycosts with proven ROI as well as thesofter benefits of improved customersatisfaction and retention.

Rob Morris manages the UK basedoperations of the US power condition-ing specialist, Powervar

www.powervar.com

Feature: Power Quality

30 dpaonthenet.net

Morris: research found that the benefits were not just financial

3402 - DPA Jan13 Edn_DPA 08/01/2013 12:28

T: 01256 365 605E: [email protected]

make it how you want it*profile assembly solution fast. versatile. simple.

*we mean MiniTec solutions as well as sandwiches

www.minitec.co.ukvisit us and see the versatility of MiniTec

»freesamples

design advice

& design tools

» machine guards» workstations» conveyors» customised enclosures

3402 - DPA Jan13 Edn_DPA 08/01/2013 12:28

Feature: Permanent Magnet Motors

32 dpaonthenet.net

Bauer believes the market is graduallycoming round to the fact that energyefficiency has to be one of the key de-termining factors when specifying amotor. Energy prices are only going togo one way, so it is important that amotor's lifelong running costs are con-sidered, rather than simply the cost ofprocurement. The company developedthis new range of super premium effi-ciency permanent magnetic synchro-nous motors (PMSM) in anticipation ofthe new IE4 classification and cus-tomers' needs for higher efficiencydrives.

The PMSM series features an efficientdesign of rotor with embedded rareearth magnets that replaces the squir-

rel-cage construction of conventionalLV induction motors. The design offersa number of key benefits; it eliminatesheat losses from the rotor, while totallosses are reduced by approximately25 percent to give an overall improve-ment in total efficiency of 10 percent ormore. This translates into a lower totalcost of ownership, a reduction in CO2emissions, and ongoing savings thatbuffer against future increases in en-ergy costs.

PM motors have been much in thetrade news of late, but there is still re-luctance in the market to buy them, asthe purchase cost is higher than that ofstandard motors. In some light duty ap-plications, where the motor is rarely on,

it is still more economical to specify astandard motor, but if the duty cycleis high then a PM motor can quicklydeliver a satisfactory return on invest-ment and then go on to achieve oper-ational savings for a long time tocome.

The test

The disc thickenermentioned in the in-troduction to thisarticle is in contin-uous operation forseven hours perday, seven days aweek, so it providedan excellent opportu-

Saving energy wsynchronous m

Adirect product comparison test was recentlyconducted to see how a Bauer Gear Motor

IE4 rated, super premium efficiency permanentmagnetic (PM) synchronous motor performed

against a standard asynchronous motor. The testwas carried out on a Huber disc thickener, at a

waste water treatment plant in Germany, in part-nership with inverter drive specialist Danfoss.

In order to ascertain that any differences in efficiency could be attributed to the motors, eachdrive used the same Bauer gearbox with a reduction ratio of 381:5 and an efficiency of 94 percent

3402 - DPA Jan13 Edn_DPA 08/01/2013 12:28

nity to test the PMSM against astandard asynchronous motor(ASM). Prior to the test the exist-ing ASM was controlled by astandard inverter, so prior to thePMSM being installed, a Danfossinverter drive was retrofitted tothe original system to achieve afair comparison.

The frequency inverter was pro-grammed to monitor the loads oneach motor to ensure that theyran at optimum efficiency. Inorder to ascertain that any differ-ences in efficiency could be at-tributed to the motors, each driveused the same Bauer gearboxwith a reduction ratio of 381:5and an efficiency of 94 percent.

It was found that with the fre-quency inverter installed the ASMcreated 2.62Nm torque at1,350rpm, achieved 61.5 percentefficiency and consumed0.26kWh. Following its installa-tion, the Bauer PMSM created3.5Nm at 1,500rpm, delivering87.7 percent efficiency and con-suming just 0.16kWh.

Thus the energy savings from in-stalling the PMSM yielded a 40percent saving in energy use overthe ASM, both motors being con-trolled by the same inverter.

Over a four year period it was es-timated that, with an inverterused in both cases, an ASMwould consume 2,657kWhwhereas Bauer's PMSM wouldconsume 1,635kWh - a total sav-ing of 1,022kWh.

Bauer head of R&D, Jens Gabelsays the aim of this developmenteffort was to give customers veryreal savings in terms of their en-ergy costs. "We are very happywith the results of the test as theyshow that super premium effi-ciency motors do deliver a reallife measurable benefit and inmany higher demand applica-tions should certainly be consid-ered both by design engineersand maintenance engineersalike."

www.bauergears.com

Feature: Permanent Magnet Motors

with PMmotors

dpaonthenet.net 33

3402 - DPA Jan13 Edn_DPA 08/01/2013 12:29

Driven By Quality Tel: +44 (0) 1707 28 31 00

Stock Products

Approved Distributor for: SDP/SI | HYDRO.MEC | POGGI | GATES | CGI | FRANCIA

Contact us now with your enquiry or for your free catalogue

www.davall.co.uk

Spur | Helical | Bevels | Splines | Spiradrive Racks & Toothed Pulleys | Gearboxes | Couplings

Worms & Wheels | Timing Belts

Standard parts or modified to your requirements

KELLER (UK) Ltd.Dorset Green Technology ParkWinfrith Newburgh, Dorchester, DT2 8ZB

UK and Ireland: T. 0845 643 2855UK and Ireland: F. 0845 643 2866E-Mail: [email protected]: www.keller-pressure.co.uk www.keller-druck.com

KELLER pressure sensors

PRECISION PRESSURE TRANSMITTER SERIES 33X

- Ranges: 0…0.2 to 0…1000 bar, adjustable- Output: 4…20 mA, 0…10 V, RS485 Digital

- Mathematical, on-board error correction

- Flexible and modular mechanical construction

OEM PRESSURE TRANSMITTERS SERIES 4 LC…9 LC

with embedded electronics

- Ranges 0…1 bar, thru to 0…1000 bar- Signal 0.5 V…4.5 V, Supply 5 Vdc

- Electronics hermetically sealed inside

3402 - DPA Jan13 Edn_DPA 08/01/2013 12:29

As preparations for the 2013 show

move into high gear, it is becoming

clear that it is heading towards yet an-

other record-breaking year. Confirmed

exhibitor bookings are already well

over the final total for 2012 and as a

result, the total floor area of the show

has been increased by over 35 per-

cent, bringing it to a decidedly roomy

5,350 square meters - larger than five

of the halls at the NEC. The exhibitor

list continues to grow in both length

and stature as befits an event which

has long-outgrown its provincial roots

to become a show of national impor-

tance.

Visitors to FIVE, Farnborough on Feb-

ruary 13 and 14 2013 will meet with

the largest and most diverse gather-

ing of manufacturers and equipment

suppliers, covering everything from

major international machinery makers

to purveyors of packing materials.

The show's increasing gravity within

industry is pulling in not just the big-

ger names, but companies from fur-

ther afield. In 2013, visitors will be

able to meet companies from the

USA, Germany, Netherlands, Italy and

Latvia, alongside firms from every

corner of the UK, from Scotland to

Somerset.

One of the strongest indications of

this growth can be seen in the impres-

sive roll-call of big international

names that are now regularly exhibit-

ing at Farnborough; names such as

Mazak, Haas Automation, Fanuc,

Renishaw, Faro, Amada Machine

Tools, igus (UK),EAO, Finder and Agie

Charmilles are just a sample. Joining

this year, for the first time, are Amphe-

nol, the Paragon Electronics Group,

Fronius, Farsound Engineering, TTI

Inc and Salvagnini, amongst many

others.

An enlarged Electronics Pavilion will

host a variety of component suppliers

and sub-assembly specialists. First-

time exhibitors REO(UK), Manutech

Europe, Merit Plastic Mouldings and

membrane keyboard specialists,

Mekall join an impressive list of well-

established names, such as RS Com-

ponents, Anixter Component

Solutions, Ambersil, Electrolube,

Brady, Bulgin and Goepel Electronics.

Together, these companies bring liter-

ally thousands of parts, components,

consumables, sub-assemblies, pro-

duction aids and design tools to a sin-

gle, easily accessible venue.

The show's location close to the con-

...and what’s more

dpaonthenet.net 35

SouthernManufacturing &Electronics 2013If variety is the spice of life, get ready for a vindaloo you won't forget at

Southern Manufacturing & Electronics, returning to FIVE, Farnboroughon February 13 and 14 2013.

Certification specialist TUV Rheinland exhibits for the first time in 2013

Page 36

3402 - DPA Jan13 Edn_DPA 08/01/2013 12:29

centration of technology, aerospace

and automotive engineering busi-

nesses around the south and the

M3/M4 corridors makes it an impor-

tant annual showcase for designers

and design-led businesses. BitBox

Limited exhibits for the first time; Hot-

house Design, the multi-award win-

ning design firm responsible for the

Yoomi self-heating baby bottle, and

ByteSnap Design both return for

2013, together with a number of firms

that specialise in taking design ideas

from the drawing board to the pro-

duction line. Briton EMS, with its

clever electronic linesman's flag and

Heber Electronics with its long track-

record of success with global names

like Dyson and Electrolux, are just two

of them.

The show organiser claims that, what-

ever your requirement, there will be

subcontractors waiting to speak to

you at Southern Manufacturing &

Electronics 2013.

There are also hundreds of companies

able to help with essential services,

from outsourcing to compliance, fi-

nance and training. Certification spe-

cialist TUV Rheinland exhibits for the

first time in 2013, alongside EMC

Specialists such as Hursley EMC and

Kemtron, training services such as

STEM and Electronics Yorkshire, and

even accountancy and business fi-

nance firms specialising in manufac-

turing industry.

But hardware and services are only

part of the story. Southern Manufac-

turing is also a good place to see ad-

vanced manufacturing in action.

Additive manufacturing specialists 3T

RPD and Laser Lines both return for

2013 alongside companies such as G

English Electronics, able to provide

rapid prototyping services.

Composites, engineering plastics and

components from firms like K D Fed-

derson, Broanmain, igus (UK), FB

Avak, Andel Plastics, Rose Plastics,

Cotswold Plastic Parts are also well

represented. Advanced production

methods are also much in evidence,

with companies like Tesa, Henkel Loc-

tite and Lohmann Adhesives tapes

among others providing alternative

assembly ideas.

No preview could be complete with-

out mention of the ever-popular free

technical seminar programme, featur-

ing 24 sessions over both days of the

show in two lecture theatres. High-

lights of the 2013 programme include

the return of Bang Creations' Stefan

Knox with an update if his extremely

popular Designing for Commercial

Success and New Product Develop-

ment.

Meanwhile, Sergey Putintsev from

TUV Rheinland will give a presentation

on selling to emerging markets - in

particular, the BRIC countries and the

Middle East. Bob Willis presents two

sessions on how to stop counterfeit

components and a look at package-

on-package assembly techniques.

For a full list of sessions - and to pre-

register for the show - visit www.in-

dustrysouth.co.uk.

FIVE, Farnborough is easily accessi-

ble by road and public transport. On

site car parking is also free, and a free

shuttle bus service operates daily be-

tween the show and both North Camp

and Farnborough Main railway sta-

tions. Visitors can keep up with all the

latest news on the show blog site,

http://blog.industrysouth.co.uk or by

joining the Southern Manufacturing &

Electronics group on LinkedIn.

...and what’s more

36 dpaonthenet.net

Trumpf will be showing its solid statelaser range, including the TruDisksystems for high performancewelding and soldering, and thinsheet metal cutting

3402 - DPA Jan13 Edn_DPA 08/01/2013 12:29

3402 - DPA Jan13 Edn_DPA 08/01/2013 12:29

PCB PIEZOTRONICS ANNOUNCES LOW COST ICP® DYNAMIC FORCE SENSORSAVAILABLE FROM STOCK

PCB Piezotronics, a world leader in vibration, acoustic, pressure,force and torque sensors, offers a wide range of ICP® quartzpiezoelectric force sensors. These durable measurement devicespossess exceptional characteristics for the measurement ofdynamic force events and typical of the range is the 208 seriesoffering low cost solutions available for UK delivery in under a week. The 208 series dynamicforce sensors feature a female thread in top and bottom and are capable of measuring intension and compression modes making them ideal for an extensive range of applications,including tensile testing, fatigue testing, drop and impact testing.

For more information contact PCB Piezotronics LtdTel: +44 (0) 1462 429710 Email: [email protected] Web: www.pcbsensors.co.uk

Datafocus: To advertise here please callNicola Crawley on 01732 359990 or


38 dpaonthenet.net

LOW COST HIGH SPEED IMAGERECORDING

STEMMERIMAGING hasannouncedGecko, alow costapplicationthat capturesandcompressesvideo streamed directly from GigEcameras onto a standard PC in real time.The latest version of Gecko supports fastuncompressed ring buffers for capturingshort high speed events plus an incrediblyfast JPG RAM compressor capable ofrecording to memory at high rates for longdurations. Events may be triggered bymouse, keyboard or camera digital I/Owith pre and post event recording buffer.Gecko is designed for applicationsrequiring a digital video recorder forprocess monitoring and event capture andrecords video to standard formats.

For further information contactSTEMMER IMAGING Ltd

T: +44 1252 780000E: [email protected]: www.stemmer-imaging.co.uk

NEW ROTOR INSERTIONFLOWMETER CAN BE INSTALLED‘HOT’ INTO LIVE PIPEWORK TO

CUT INSTALLATION ANDOPERATIONAL COSTS

Spirax Sarco haslaunched its RIM10rotor insertionflowmeter for steam,gas and liquidsfeaturing rapidinstallation in livepipework. The RIM10 can be fitted directlyinto operational pipework using standardhot-tapping techniques, eliminatingproduction disruption for installation andsaving substantial costs by keepingproductivity high. The hot tapconfiguration allows sites to install theflowmeter when needed instead of havingto wait for planned plant shutdowns, andenables the easy withdrawal of the metershould the rotor need changing formaintenance or re-ranging. Its suitabilityfor a wide range of liquids, gases andsteam also saves costs.

For more information contactSpirax Sarco

Email: [email protected]: www.spiraxsarco.com/uk

CUT TIME – CUT WASTE –CUT COSTS

The new Kistler Stasa QC software forinjection moulding requires fewer physicaltrials to increase process stability and partquality whilst optimizing cycle and set-uptimes. With the help of a statistical Designof Experiments (DoE), it determines theeffect of relevant machine parameters onpart quality and optimizes the operatingpoint. A stabilized process, high partquality and short cycle times translate intohigher output rates and significantsavings. The primary advantage is thatrunning the initial tests on a PC allow awide variety of parameters to be changedinteractively by clicking and dragging withthe mouse.

For more information contactKistler Instruments Limited

Tel: 01256 741550Email: [email protected]

Web: www.kistler.co.uk

EFD® AUTOMATED FLUIDDISPENSING SYSTEMS OFFERRELIABLE OPERATION WITHEXCELLENT REPEATABILITY

• Precise and consistent application ofadhesives, sealants and lubricants

• Three- and four-dimensional motioncontrol for dispensing of dots, stripes,arcs, compound arcs and patterns ondifferent planes

• Quick set up and easy programmingthanks to specialized PC dispensingsoftware and CAD download capabilities

• Flexibility of working either as a stand-alone system or a key part of anautomated solution

EFD International, Dunstable, Beds. UKPhone (0)1582 [email protected]

www.nordsonefd.com

LEISTER LHS INTEGRATEDINDUSTRIAL AIR HEATERS

The established range of LEISTER airheaters for production processes hasreleased a new series of process heatunits for connectivity directly into a PLCcontrol system enabling better control andfunctionality for systems designers andline production managers alike. Designedfor professional integration directly intomachine systems, the new LHS seriesenables many applications includingsterilisation, drying, welding, cleaning,shrinking, shaping, curing, deburring andactivation. Operating from temperaturescontrolled to 650 degrees, the Systemrange can be controlled by a PLC orstandalone controller using a 4-20mAsignal or 0-10V allowing for easyintegration into a control system.

For more information contactWelwyn Tool Group Tel: 01707 331111


WEIDMÜLLER’S DC-UPSSAFEGUARDS AGAINST MAINS

POWER FAILURES FOR UP TO 30MINUTES AT 40 A

Weidmüller's uninterruptible power supply(DC-UPS) ensures a highly available 24VDC power supply for automationapplications. The maintenance free buffermodule is perfect for short interruptions inthe range of several 100 milliseconds;depending on usage, customers can get alife time of up to 10 years from the device.The UPS controller, in connection with abattery module, bridges longer mainspower failures safely and reliably. Thismodule provides power up to 40 A for 30minutes or 1 A for 30 hours, depending onthe requirement.

There are four finely graded batterymodules between 3.4 and 17 Ah. TheDC-UPS controllers can be installedadjacent to one other, so they take up only66 mm of width in the cabinet.

For further information visit:www.weidmuller.co.uk

INNOVATIVE FASTENING SOLUTIONS AND LOWER ASSEMBLY COSTS

The complete range of engineered fastening solutions available fromSpirol Industries is featured in a new eight page overview brochure.The publication provides specifiers with information on the features andbenefits of all Spirol products including Coiled & Slotted Spring Pins,Spacers, Rolled Tubular Products, Solid Pins & Drive Studs, Inserts forPlastics, Ground Hollow Dowels, Dowel bushings & Spring Dowels, shimsand Compression Limiters. The brochure also provides information on theApplication Engineering Services and examples of potential applicationsof Spirol products within markets as diverse as aerospace, agriculture,automotive, cosmetics, electronics, defence, power tools, medical andmany others.

For more information contact Spirol Industries LtdTel: +44 (0) 1536 444800 Email: [email protected]

FREELINE STANDS FOR DEAD ZONE-FREE CONNECTIONS MADE OF HIGH-QUALITY STAINLESS STEEL

Eisele uses stainless steel grades 1.4307 or higher for the FREELine series. As a threadedfitting with a hose they offer a maintenance-friendly, flexible alternative to classic pipeworkand are just as easy to clean. The dead zone-free construction means that no residueremains in the fittings. Outer diameters up to 22 mm allow even liquid foods to flow throughthe lines at the required pressure. While product purity is decisive for paints and lacquers,hygienic aspects are another important factor for foods and pharmaceuticals. In all cases,easy and extremely thorough cleaning of the media circuit is necessary, to enable fastchanging of media. Residue must be absolutely eliminated. The design of these fittingswithout an additional seal ring is another advantage, especially when used with aggressivecleaning agents.

For more information contact EiseleWeb: www.eisele.eu

NEW PRODUCT LITERATURE: FREE BULLETIN FROM PENNENGINEERING®PROFILES COMPLETE LINE OF MICROPEM® FASTENERS

A new comprehensive product bulletin available free fromPennEngineering® profiles the complete line ofmicroPEM® fasteners ideally suited for attachmentapplications in compact electronic assemblies. Theseextremely small fasteners can serve as practical, cost-effective, and permanently secure solutions enablingquicker assembly of devices ranging from hand-heldconsumer electronics including tablets, phones, andlaptops to medical equipment, among others.

Bulletin MPF includes all specifications and installationand performance data for the entire microPEM productfamily. Solutions include self-clinching pins with threadsas small as M1 for positioning and alignment applications,self-clinching and surface-mount standoffs and nuts inlengths as short as .040” / 1mm for mounting and/orspacing requirements, TackPin™ fasteners in a variety ofstyles enabling sheet-to-sheet attachment, insertsproviding strong metal threads in plastic assemblies, andscrews available in sizes as small as M0.8 and as short as .040” / 1mm.

Bulletin MPF can be downloaded at http://www.pemnet.com/fastening_products/micro.html,where free part drawings (PEM CAD Library) for these RoHS-compliant fasteners additionallycan be accessed.

All microPEM products are manufactured by PennEngineering®, founded in 1942 and thisyear celebrating 70 years of excellence in fastening technology.

For sales or marketing information, contact Liam Foy, Director of Marketing EMEA,PennEngineering, Tel: +353 91 7471186 email: [email protected]

3402 - DPA Jan13 Edn_DPA 09/01/2013 09:25

Datafocus: To advertise here please callNicola Crawley on 01732 359990 or


dpaonthenet.net 39

WEIDMULLER LAUNCHES NEW,COMPACT OMNIMATE® SIGNAL LMFPCB TERMINALS WITH INNOVATIVE

PUSH IN CONNECTION SYSTEM.

Weidmüller’s new,compact OMNIMATE®Signal LMF PCBterminals with theinnovative PUSH INconnection systemmeet the stringentdesign requirements ofindustrial devices needing a reliable powersupply connection system. Theserequirements include a 250V voltagesupply, high electrical safety for theinsulation material and access to cablewiring to suit the relevant application.

The PUSH IN connection system results invaluable time savings and features anintegrated test point and variants with 90°and 180° conductor outputs, allowing fordesigns with different wiring directionconfigurations. The LMF PCB terminalsare available with 5.0mm and 5.08mm griddimensions and as 2 to 24 pole versions.

For further information, visit us athttp://tinyurl.com/d6gn75r or email us

at [email protected].

AFFORDABLE DEW-POINTTRANSMITTER DESIGNED FOR OEM

DRYER MANUFACTURERS

The SF52dew-pointtransmitterfrom MichellInstrumentsprovides aheavy-duty,cost-effectivesolution to monitor moisture content inindustrial dryers. The easy to installinstrument has an exceptionally low costof ownership with no maintenancerequired during its lifetime use of typicallyfive to seven years. Its robustness gives a‘fit and forget’ solution with benefits thatmake this a smart and appealing choicefor use in industrial dryers. The SF52offers an affordable solution for dew pointmeasurement for harsh environments. TheSF52 transmitter covers the key dew-pointmeasurement range of -40 to +60°C formost common industrial dryingapplications.

For more information contactMichell Instruments

Tel: +44(0)1353 658 000Email: [email protected]

GILL SENSORS LAUNCH THEIRSMALLEST, FASTEST, HIGHEST

RESOLUTION POSITION SENSORTO DATE

Gill Sensors, a UK company and specialistmanufacturer and supplier of positionsensors has announced the launch of thenew Blade20 non-contact position sensor.This latest addition has been developed inresponse to customer demand for asmaller, faster and higher resolutionposition sensor able to withstand to harshindustrial environments in applicationssuch as process control machinery,materials handling equipment and roboticsystems. The Blade20 features Gill’spatented induction technology principleand represents a significant breakthroughin position sensing, with a single productallowing the measurement of linear andshallow-arc motion and long-strokemeasurement with a single micro sensor.

For more information contactGill Sensors Ltd

Tel: +44 (0) 1590 613400Web: www.gilltechnology.com

AMPHENOL LAUNCHES NEWHERMETIC CONNECTOR AT

SOUTHERN MANUFACTURING 2013

Amphenol is oneof the leadingmanufacturers ofinterconnectionproducts in theworld servicingcustomers at anational and aninternational levelto provideinnovative solutions across many marketsectors. As a global leader in hermeticglass-to-metal seal interconnecttechnology, Amphenol has the expertiseto offer connectors to support manydemanding applications. On show will bethe latest hermetic technologies andproduct ranges optimised for hightemperature sensors and pressure feed-throughs, and other high end applications.Also exhibited will be the latest Heavymate F Series, a modular-based systemintermateable with other brands ofrectangular modular-format connectors.

For more information contactAMPHENOL at STAND NO. 270

Web: www.industrial-amphenol.com

WEIDMÜLLER’S OMNIMATE® PGK 4FEED-THROUGH TERMINAL FOR

TIGHT SPACES

Weidmüllerhas developedthe newOMNIMATE®PGK 4 through-panel terminalwith PUSH INconnectionsystem, for times when space forapplications is limited, and flexible, space-saving connection systems are needed,enabling simple and secure installation inhousing walls. Incorporating Weidmüller'sPUSH IN connection system means aconductor connection is provided on theinside and outside of the device which iseasy to operate, without tools. Theconnection blocks enable a large numberof poles to be quickly and simplyassembled, without taking up valuablespace, whilst the terminal blockengagement mechanism is suited topanel thicknesses of between 1.50mmand 3.00mm.

For further information, visithttp://www.weidmuller.co.uk/ or

www.push-in.com or [email protected].

EMPARRO – THE POWER SUPPLYUNIT WITH MAXIMUM EFFICIENCY

Murrelektronikpresents Emparro,a highly innovativepower supply unitwith maximumefficiency andminimum powerloss. Thecombination ofthe Power Boostfunction with apower limiteroutput allows large loads to be startedeasily. The wide input voltage rangemakes Emparro a global player. Modernmachine builders and users are payingattention to power consumption. Ournew power supply units put the focus onefficiency because energy is a preciouscommodity and unused machine energyincreases costs. Emparro has aninnovative circuit concept and anefficiency rating up to 95% - so only5% of the energy remains unused.

For more information contactMurrelektronik Ltd

Email: [email protected]: www.murrelektronik.co.uk

MULTI-ANGLE LED LIGHT TUBES FROM OMC ARE BRIGHT,ROBUST AND LONG LIFE

OMC, the pioneer in optoelectronics, has announced a new version of their rugged, robustand high-brightness multi-angle LED light tube range which can be used to replacetraditional light sources in hundreds of applications, saving power and lasting longer thanfluorescent products. These compact, low voltage linear LED lighting fixtures featureadvanced lens/reflector assemblies that provide extremely bright and uniform illuminationacross a broad and well-defined target illumination area, with a power consumption of just2.9W per foot of tube. With a slim profile and robust metal housing, the new light tubes areeasy to install and require no additional fixtures or fittings. The adjustable mounting bracketsallow the light to be directed as needed, and low voltage 24V DC operation ensures they aresafe and simple to power electrically.

For more information contact OMCWeb: www.omc-uk.com

ANDON LIGHT WIRELESS MONITORING

Quick and easy to install without hard-wiringor complex programming, the WIN systemfrom WERMA provides a simple low costmeans of monitoring shop-floor efficiency.

Use as a means to monitor idle time andrunning time of a machine, or as a “call toaction” system for workstations. The kit canbe fitted to existing WERMA signal towers (KS71/70 series), or it can be installed as a standalone device without lights.

A transmitter unit fitted to the signal towersends any signal light status changeimmediately to a wireless receiver pluggedinto the USB port of your pc.

This data is presented as different visuals withwhich allows you to monitor the operation andperformance of the machine or workstationbeing guarded by the signal tower.

WERMA (UK) Ltd.Linnell Way

Telford Way Industrial EstateKettering, Northamptonshire

NN16 8PSTel: +44 (0) 1536 486 930Fax: +44 (0) 1536 486 810

[email protected]

HANDLES TYPE PF

Bülte Plastics have added two new references PF150 and PF180 to its productrange “Handles Type PF”. Bülte handles are easily and quickly assembled for aperfect finish. These polyamide (Nylon) handles are resistant to corrosion, impactand common chemicals; they have good dimensional stability and high thermalresistance. our “Handles” are suitable for applications such as gates, guards,cabinets and caravans, as well as industrial applications in general. Handles (flat profile) can beattached with M6 (only for PF94) or M8 hex head screws. Available in two heights (36 and 45 mm)and lengths from 110 to 201 mm. Standard colour is black but other colours are available, on request.A catalogue detailing our full range of products is available free, on request, or visit our web site.

Bülte Plastics UK (Ltd), 13 John Street, Stratford-upon-Avon, Warwickshire CV37 6UBTel.: +44 1789 263 753 – Fax: +44 1789 264 015

E: [email protected] W: www.bulte.com

NEW SITE FOR SURFACE ENGINEERING SOLUTIONS

For more than 50 years, Henkel solutions have been essential tomaintenance personnel involved in rebuilding, repairing and protectingindustrial equipment. Carrying the Loctite® Nordbak® and Hysol® brands,these innovative products have helped to extend equipment life, improveefficiency and minimise downtime in the harshest industrial environments.Now this range has been given its own section on the Loctite® website.Visitors to www.loctite.co.uk/surface-engineering will see a complete overview of theproducts that broadly cover cleaning, metal-filled compounds, protective coatings andcompounds. Collectively the products address problems caused by wear, abrasion, chemicalattack, erosion, corrosion, impingement and mechanical damage.

For more information contact Henkel LtdWeb: www.loctite.co.uk/surface-engineering

3402 - DPA Jan13 Edn_DPA 09/01/2013 10:38

Buyers Guide: To advertise here please callNicola Crawley on 01732 359990 or


40 dpaonthenet.net

A full range of Engineering Adhesives,Sealants, Fillers, Lubricants and

Dispensing Equipment

t: 01256 365605e: [email protected]

Modular aluminiumprofile system.Ideal for Safety Guards,Conveyors, Workstationsand special purposemachinery.

M O T I O N controlComponents, systems and support.

Motion products and systems for scientific, industrial and defence organisations.

Engineering excellence - by design

LG Motion Limitedt: +44 (0)1256 365600 www.lg-motion.co.uk

Axair Fans UK LimitedLowfield Drive - Centre 500Wolstanton - Newcastle-u-LymeStaffordshire ST5 0UU - UKT: 01782 349 430 F: 01782 [email protected]

Murrelektronik - one the of the world's leadingconnector manufacturers. • M12 leads and self wire • M8 leads and self wire • Valve connectors • Distribution systems • in IP67,IP68 & IP69KMurrelektronik Ltd Albion St, Pendlebury Ind.Est. Swinton, Manchester, M27 4FG Tel: 0161 728 3133 www.murrelektronik.co.uk

COMPONENT SOLUTIONSUnit A Nimrod Way,East Dorset Trade Park,Wimborne, Dorset BH21 7HYTel: +44 (0) 1202 865222Fax: +44 (0) 1202 [email protected]

Henkel LimitedTechnologies House, Wood Lane End.Hemel HempsteadHertfordshire HP2 4RQ

Technical Helpline: 01442 278100Fax: 01442 278071


www.loctite.co.uk

Precision Miniature BearingsPrecision AssembliesPrecision BallscrewsTel: 01908 227123 Fax: 01908 310427www.myonic.comE: [email protected]

• well-established planetarygearheads planetdrive® PD

•stainless-steel planetarygearheads planetdrive® VPD

• low-backlash planetary gearheadsplanetdrive® PDH

•geared motors and special gearboxes forcustom-designed solutions by planetroll®

planetroll is one of the world's leading manufacturersof variable-speed gearboxes for use in explosion-proof

areas according to ATEX 95.

Power transmission by planetroll®

[email protected] www.labtex.co.ukTel: 01484 600200

DisplaysTouchscreensIndustrial Pc’sDisplay systems

01959 563345www.review-displays.co.uk

Review Display Systems Ltd

To advertise herecontact

Nicola Crawley onTel: 01732 359990

or [email protected]




Displays

Coolings Systems

Batteries

Batteries & Chargers

BrakesAdhesives

Connectors

Bearings

Automation & Control

Ball Screws

Aluminium Framework

Control Panels

Drives / Gearboxes

Cable Accessories& Plastic Fasteners

3402 - DPA Jan13 Edn_DPA 08/01/2013 16:58



dpaonthenet.net 41

•Tappex Thread Inserts Ltd –54 years of UKmanufacturing excellencein Threaded Inserts forPlastics, Composites &Light Metal alloys

•Tappex provide an Applications technical service,prototyping and bespoke installation tooling historicallyacross multiple industry sectors: OEM/Automotive/Medical & Industrial Equipment manufactures

•Tappex offer fastening solutions produce from Brass,Steel & Stainless Steels with both Metric, Unified andBritish Standard threads

Contact details:Tappex Thread Inserts Ltd Tel: +44 1789 206600 Email: [email protected]; New Website: www.tappex.co.uk Downloadable catalogues and applications advice on the website.

Offer Truly Economical Solutions To driveapplication problems with a comprehensive

range of motors, geared motors andaccessories. Hybrid solutions also available at

moderate cost.

Our products are widely used in industry,education and R&d markets, with some of the

following as typical applications.

Robotics, laboratory equipment, surveillancecameras, slot machines, shop displays,vehicleequipment, telecoms equipment,lighting and

ventilation control. Locking mechanisims,machinery activators, shop displays etc etc.

MFA/Como Drills Felderland Lane, Worth, Deal

Kent CT14 0BTTel: 01304 612132 Fax: 01304 614696

www.mfacomodrills.com

ab

www.rutlandplastics.co.uk

Design and Tooling Latest Moulding Technology inc Gas Injection

Machining and Assembly

Tel: 01572 723476

Plastic Mouldings

Hot Air Sources

Geared Motors

Fasteners & Fixings

Enclosures Lead Screws

Linear Motion

Geared Motors –12mm / 90mm dia

EnvironmentalTest Chambers

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Sensors

Unimeasure Pull Wireswww.unimeasure.com

SE Systems LtdTel: 01702 530174 Fax: 01702 530200

[email protected] www.sesystems.co.uk

• Pull-Wire Displacement sensors • Easy Installation• Compact-Low Cost from £99.00

• Where small size is required • Ranges to 2000”(50m)• Repairs to any manufactures

Systems

position and motion sensorsAssemtech Europe Ltd

Rice Bridge Industrial EstateThorpe Le SokenEssex CO16 0HL

T: 01255 862236 F: 01255 [email protected]

Bosch Rexroth, formerly known as Indramat and Bosch offer:

• Local repairs

• Genuine spare parts

These services are available for control systems, servo drives, servo motors & PLC’s

Contact Service on:

Freephone: 0800 169 6624

Telephone: +44 (0)1285 863049

www.boschrexroth.co.uk

• Field service

• Warranty up to 5 years


Service from Bosch Rexroth

Servo Motor& Drive Repairs

3402 - DPA Jan13 Edn_DPA 09/01/2013 09:15



42 dpaonthenet.net

Transformers

New and refurbished standard range chambers.

Specials manufactured to customers requirements.

Chambers for hire.

Service and Calibration.

James Technical Services LimitedTel: 01874 711209 Fax: 01874 712010Email: [email protected]

www.jts-test-chambers.co.uk

The Unique IndependentSupplier of Temperature &Humidity Test Chambers,Laboratory Ovens,Drying/Curing Ovens &Associated Equipment &Services.

Tel: 01772 600771E-mail: [email protected]: www.teslatest.co.uk

Blackfast Chemicals Ltd462 Ewell Road

SurbitonSurrey

KT6 7EL

Tel: 020 8339 7370Fax: 020 8339 7371

[email protected]

MANUFACTURERS OF SPRINGSPRESSINGS • WIRE FORMS

Unit 1, Latimer Road Industrial EstateLatimer Road, Wokingham

Berkshire RG41 2YDT: 0118 978 6573 F: 0118 989 4434E: [email protected]

www.simpsonsprings.co.uk

Test Chambers

Temperature Measurement

Surface TreatmentsSprings




Goss Spring components Ltd,30 Victoria Works,LondonE17 4JU Tel: +44 (0) 208 527 5599Fax: +44 (0) 208 527 1142 Email: [email protected]

www.goss-springs.com

CABLE ACCESSORIES & PLASTIC FASTENERS

Anixter Ltdwww.anixtercomponents.com

AUTOMATION

ABBwww.abb.co.uk

MOTORS & GENERATORS

ABBwww.abb.co.uk

BATTERIES

Creasefield Ltdwww.creasefield.co.ukDMS Technologieswww.dmstech.co.uk

IEC Ltdwww.iecltd.co.uk

BEARINGS

Gesipa Blind Riveting Systems Ltdwww.gesipa.co.uk

BLIND FASTENING TOOLS

JBJ Techniques Ltdwww.jbj.co.uk

COUPLINGS

Cell Pack Solutionswww.cellpacksolutions.comCreasefield Ltdwww.creasefield.co.uk

CUSTOM BATTERY PACKS

Trident Engineering Ltdwww.tridenteng.co.uk

DC MOTORS

Axair Fans UK Ltdwww.axair-fans.co.uk

FAN BLOWERS & AIR KNIVES

OKW Enclosures Ltdwww.okw.co.ukRittal Ltdwww.rittal.co.ukRolec Enclosureswww.rolec-enclosures.co.uk

ENCLOSURES

DRIVES

ABBwww.abb.co.ukBosch Rexrothwww.boschrexroth.co.ukLenze Ltdwww.lenze.co.uk

Alcoa Fastening Systemswww.afshuck.netBigHead Bonding Fasteners Ltdwww.bighead.co.ukTFC Plcwww.tfcplc.com

FASTENERS

GRIPPING SYSTEMS & ROBOT ACCESSORIES

Schunk Intec Ltdwww.gb.schunk.com

HEAT SHRINK PRODUCTS

CPL ness heatshrinkwww.nessheatshrink.co.uk

LINEAR MOTION

Oriental Motorwww.oriental-motor.co.uk

Chell Instrumentswww.chell.co.uk

INSTRUMENTATION

MINIATURE MOTORS & GEARBOXES

Mfa/Como Drillswww.mfacomodrills.com

PLASTICS & RUBBER MOULDINGS

Applications Engineering Ltdwww.appeng.co.ukRutland Plastics Ltdwww.rutlandplastics.co.uk

PROCESS LEVEL &PRESSURE INSTRUMENTS

Vega Controlswww.vegauk.net

SEALS - PTFE

Moontown Ltdwww.moontown.co.uk

SENSORS & TRANSDUCERS

Keller UK Ltdwww.keller-pressure.co.uk

SENSORS

Sensor Technologywww.sensors7.co.ukLabfacilitywww.labfacility.co.uk

SPRINGS

Goss Springswww. goss-springs.comSimpson Springs & pressings Ltdwww.simpsonsprings.co.ukAssociated Springwww.assocspring.co.uk

KNF Neuberger UK LTDwww.knf.co.uk

VACCUM PUMPS

Howdon Power Transmission Ltdwww.howdon.com

TORQUE LIMITERS

Mayr Transmissionswww.mayr.co.uk

TRANSMISSIONS

TEST CHAMBERS

TeslaTest Systems Ltdwww.teslatest.co.uk

THREAD FASTENERS

Tappex Thread Inserts Ltdwww.tappex.co.uk

Sitefind: To advertise here please callNicola Crawley on 01732 359990 or


3402 - DPA Jan13 Edn_DPA 09/01/2013 09:16

ifm electronic now has an extensive range of sensors to solve machine vision applications. The O3D is the first industrial 3D sensor that can detect objects in three dimensions at a glance; the O2D dualis object recognition sensor is perfect for orientation-independent contour verification and the O2V object identification sensor or ‘pixel counter‘ allows checking of presence, size, position or completeness of objects.

All units are simple to set up and combine sensor, processing and lighting in one robust industrial housing.

QualityA passion for

QualityA passion for

Visionary

ifm electronic – close to you!www.ifm.com/uk/vision

3402 - DPA Jan13 Edn_DPA 08/01/2013 16:21

– THE PLUS FOR ADDED FLEXIBILITY

The next generationThe innovative multi-protocol fieldbus system from Murrelektronik,

which has radically simplified and modernized decentralized

installation has taken a step further with a plus.

The single bus node can support up to 20 I/O modules

in a 30m circumference and with a reduced number

of cables. The range of I/O modules continues to

grow and includes digital and analogue ports,

safe outputs, logic, counter, valve island,

temperature, I/O link etc. Both IP67 or IP20

are available.

Cube67+ : a truly flexible system.

Murrelektronik Ltd

5 Albion St, Pendlebury Ind.Estate,

Swinton, Manchester, GB

M27 4FG

Phone 0161 728 3133

www.murrelektronik.co.uk

[email protected]

Cube67 – the modular bus system

3402 - DPA Jan13 Edn_DPA 08/01/2013 12:29

Magazine 1

Documents

Transcript of Magazine 1