MACHINE BUILDING: Cabinet-free automation ‘changes world of machine building’ PRECISION ENGINEERING: Using encoders to close linear actuator feedback loops WATER INDUSTRY: PM-driven mixers slash wastewater plant’s energy bills Drives&Controls AUTOMATION FOR MANUFACTURING INSIDE The next chapter in AC Drives - iC7 iC7.danfoss.com OCTOBER 2024 www.drivesncontrols.com
iC7.danfoss.com iC7-Automation iC7-Marine iC7-Hybrid • Modular and configurable drive • Optimized product for all power conversion applications • Scalable control platform • Powerful hardware-based security including end-to end encrypted data transfer • Built-in cybersecurity for Industrial IoT • Unrivaled power density with new filter technology • Robust performance even in harsh environments • Connectivity with multiple fieldbuses • Industrial IoT-ready • High-torque machine performance • Superior motor control • High power density and small footprint • Reduced OPEX with advanced energy saving features HIGHLIGHTS A new dimension awaits. Where open, connected, and intelligent systems are the new reality The iC7 series from Danfoss Drives is your portal to a new era of opportunities within your industry – in a sustainable and energy-efficient way. The iC7 series of intelligent AC drives puts the power of compactness and integrated intelligence in your hands, so you can boost machine performance in new ways. With the best heat management available anywhere, this drive delivers high torque performance in a small footprint, so you can get much more power into small spaces. Integrated intelligence enables the drive to function as your most powerful sensor meaning you can regulate your process highly efficiently, saving money by reducing external devices. For quick and trouble-free system integration the frequency converter comes with built-in EMC and harmonic filters. Manage your process data in the cloud or your internal network with worldclass stringent security. You get full data traceability with endto-end integrated digitized quality control throughout the drive lifetime from design and testing through to installation and service. Frequency converters in the iC7 series are optimized for wall-mounted, cabinet-mounted or free-standing installation, and meet requirements for operation at ambient temperatures up to 60 °C. iC7 series from Danfoss Drives
50 CONTENTS n Drives & Controls is a controlled circulation publication. If you live in the UK and want to subscribe phone 0333 577 0801 or fax 0845 604 2327. Alternatively for both UK and overseas subscriptions please subscribe online at www.drivesncontrols.com. If you have any enquiries regarding your subscription, please use these numbers . The content of this magazine, website and newsletters do not necessarily express the views of the Editor or publishers. The publishers accept no legal responsibility for loss arising from information in this publication. All rights reserved. No part of this publication may be produced or stored in a retrieval system without the written consent of the publishers. Paid subscriptions UK: £110 per annum Europe: £145 per annum Rest of World: £180 per annum Printing: Warners Midlands PLC., PE10 9PH ISSN 0950 5490 Copyright: DFA Media Group 2024 NEXT ISSUE The November/December issue of Drives & Controls will contain our annual feature on machinery safety, as well as a look at what’s been happening in the world of controlgear and enclosures, and a report on recent developments in controllers, HMIs and software. UPDATE 14 Comment 15 ABB Back to Basics 44 Gambica column 46 New Products 48 Design Data and Multimedia 49 Products & Services IN DEPTH Follow us on X @DrivesnControls Drives Magazine Web site www.drivesncontrols.com Follow us on LinkedIn @ Drives & Controls Join us on Facebook Drives & Controls Drives& Controls REGULARS DfAmedia group 40 34 30 26 5 48 DRIVES & CONTROLS October 2024 Vol 40 No 9 Editor Tony Sacks t: 01732 465367 e: tony@drives.co.uk Consultant Editor Andy Pye t: 07808 137312 e: andy.pye@dfamedia.co.uk Production Manager Sarah Blake t: 01233 770781 e: sarah.blake@dfamedia.co.uk Operations Manager Emma Godden-Wood t: 01732 370340 e: emma.godden-wood@dfamedia.co.uk Marketing Manager Hope Jepson t: 01732 370340 e: hope.jepson@dfamedia.co.uk Financial Finance Department t: 01732 370340 e: accounts@dfamedia.co.uk ADVERTISING Sales Director and DFA Direct Damien Oxlee t: 01732 370342 m: 07951 103754 e: damien.oxlee@dfamedia.co.uk Sales Manager Sara Gordon t: 01732 370341 m: 07505867211 e: sara.gordon@dfamedia.co.uk Italy Oliver & Diego Casiraghi e: info@casiraghi.info t: +39 031 261407 f: +39 031 261380 Managing Director Ryan Fuller t: 01732 370344 e: ryan.fuller@dfamedia.co.uk Reader/Circulation Enquiries Perception-MPS Ltd t: 01825 701520 e: cs@perception-sas.com HEAD OFFICE DFA Media Group 192 High Street, Tonbridge, Kent TN9 1BE t: 01732 370340 f: 01732 360034 e: info@dfamedia.co.uk www.drivesncontrols.com 5 News A round-up of the latest business and industry developments from around the world. 16 Technology Cutting-edge innovations in motion, power transmission, controls and related technologies. 26 Industrial networking Virtual local area networks – or VLANs – are well-established in the IT industry, but do they offer potential benefits to the industrial sector as well? An expert argues that they do, including enhanced cybersecurity and the ability to manage network traffic more effectively. 28 Machine Building A German machine-builder has adopted a cabinet-free form of automation for a profile-processing machine that makes parts for windows. It has found that the new system saves time and space, reduces wiring errors and cuts the number of parts needed. Also, how robots are being used to automate pathology testing. 34 Precision Engineering We report on how fitting a rotary encoder to a linear stepper motor can add a host of benefits, including improving control and load monitoring. Also, a look at how drawing up a correct specification is crucial when using miniature drive systems for precision applications. 40 Water Industry A wastewater treatment plant near Naples has installed 28 submersible mixers in 14 denitrification tanks which are used to remove nitrogen from effluents. The mixers, powered by IE3 permanent magnet motors, have cut the plant’s annual energy costs by up to €45,000. 41 Advanced Engineering Preview A look forward to the Advanced Engineering event which is taking place at the NEC at the end of this month, and will showcase the latest IoT innovations, AI-driven automation and real-time data analytics that are transforming traditional manufacturing into smart, connected operations. 42 SPS Preview The German automation megashow, SPS, returns to Nuremberg next month. The tough economic environment in Germany means that the three-day event will probably remain at a similar size to last year’s show, attracting about 1,200 exhibitors and 50,000 visitors, and drawing more exhibitors than before from outside Germany. 41 Average net circulation January to December 2023 42 47 Subscribe for your FREE copy now 18,942 16
Energy and Automation LOVATO Electric’s Synergy Energy Management software is the perfect starting point for your journey to sustainability. Working with not only our extensive range of products and third-party devices, such as gas and water metering along with support for renewable energy generation, you can identify and automatically report the optimum energy performance measures and determine best practice to reduce carbon footprint and energy costs. 01384 899700 | lovato.co.uk | sales@lovato.co.uk SCAN TO DOWNLOAD YOUR FREE GUIDE WHY INVEST IN ENERGY MANAGEMENT? Your FREE guide to understanding all of the benefits 100 CONTROL % 12 MONTHS ROI < YEARLY SAVINGS LESS CARBON FOOTPRINT
NEWS n 5 Blair and Hague call for UK to spearhead a new era of robotics The former Prime Minister, Tony Blair, and the former leader of the Conservative Party, William Hague, have released a report arguing that the UK should spearhead a new wave of robotics which, they believe, could benefit the British economy and society as a whole. “Failing to act now will result in other countries reaping the largest economic benefits, with the UK having little influence over how the technology is regulated,” they warn. “Lagging behind in robotics would also pose a serious risk to national security.” The report, A New National Purpose: The UK’s Opportunity to Lead in Next-Wave Robotics, is one of a series published by the Tony Blair Institute for Global Change since 2023, arguing that the world is undergoing the fastest technological and scientific revolution in history. The reports call on British political parties to respond to this revolution with “a new national purpose. The challenge of responding is so urgent, the risk of falling behind other countries so great, and the opportunities so exciting, that nothing less will do.” The new paper argues that robotics “will become increasingly central to the future of our country,” with AI-enabled robotics having the potential to transform the economy, public services and daily life. “Robotics is one of the key technologies for which greater state support will be necessary,” Blair and Hague say, pointing out that the UK has the least advanced robotics sector of the G7 countries. “However, the fact that robotics increasingly intersects with AI – where the country does have strengths – gives Britain an opportunity to catch up.”The report sets out how “the new government can seize this opportunity and realise the transformative long-term benefits of robotics by addressing challenges across innovation, commercialisation and governance. “Many countries have woken up to the fact that robotics will become increasingly critical to their place in the world,” the report states. “The UK, meanwhile, has failed to produce a national strategy for robotics and deprioritised the technology to focus on other areas. The new government must avoid the mistakes of previous governments in misunderstanding the importance of robotics to the future of the UK. Instead, it should position the country at the forefront of this emerging wave of technology.” To achieve this, “the government must take action now to help cultivate and drive the innovation required to realise the transformative longer-term opportunities of robotics – and to avoid falling behind other major countries around the world.” Blair and Hague argue that this can be done “through additional investment and action that explicitly addresses the structural barriers to developing and commercialising these technologies in the UK.” Among other recommendations, they are calling for: n The creation of a £100m Robotics Investment Programme providing follow-on funding to support robotics start-ups. n A review of Government investment programmes for robotics research, reallocating some UKRI funding to new approaches, including a network of National Robotariums, and grant funding for creating opensource, modular software and hardware to help researchers and startups to develop more complex robotics faster at lower costs. n Confirmation of a £16m roll-out the Made Smarter Adoption Programme across the rest of England. n Expanding the robotics team at DSIT by hiring more specialists in robotics software and hardware. n Resisting any moves towards a robot tax, even if future automation leads to significant funding pressures and tax disruption. n Supporting more people in gaining expertise in robotics through projects with school children, robotics undergraduate courses, and fellowships for robotics. n Increasing financial support for regulators, and implementing a proposed robotics secondment scheme in the HSE to act as a pilot scheme for bringing experts into regulators. n Addressing societal concerns over robotics and automation by focusing on automating dull, dirty and dangerous tasks, and planning a retraining fund for those whose jobs are displaced by robotics. The report concludes that the Government needs to leverage the UK’s strengths in AI software, while mitigating its relative weaknesses in robotic hardware, through reforms in innovation, pull-through and governance. “This will result in the prospect of leading in robotics and delivering a better future for the country,” Blair and Hague contend. The report can be downloaded from https://drivesncontrols.news/31btk273 “The government must take action now to help cultivate and drive the innovation required to realise the transformative longer-term opportunities of robotics – and to avoid falling behind other major countries around the world” www.drivesncontrols.com October 2024 Tony Blair and William Hague: “Lagging behind in robotics would also pose a serious risk”
n NEWS October 2024 www.drivesncontrols.com 6 SALES OF INDUSTRIAL ROBOTS in the UK hit a record high in 2023 with 3,830 new machines being installed – 51% more than the previous year. According to the International Federation of Robotics (IFR), the main driver of the boom was the automotive sector, where the number of new installations jumped by 297% to 1,924 in 2023. But in its World Robotics 2024 report, the IFR warns that the number of new robot installations in the UK is likely to fall sharply in 2024, before recovering slowly and returning to growth from 2025 onwards. “The UK manufacturing industry invested heavily in the installation of robotics in 2023,” reports IFR president, Marina Bill. “A massive tax break for investment in plant and machinery expired after the first quarter of 2023,” she explains. This “super deduction” boosted investment. The automotive sector accounts for around half of all of the robots sold in the UK, which are used mainly for assembly tasks. Since the end of the super deduction tax break, the sector has announced only a handful of investments in robots, which will be delivered in 2025 and 2026. But car-makers were not the only UK sector to have spent money on robots in 2023. The food and beverage industry raised the number of robots it installed by 59%, to 555. And demand from the metal industry was up 20%, with 324 new robots. The UK's uptake of robotics and automation is still low compared to mainland European countries. By the end of 2023, the UK had an operational stock of 28,831 robots – 9% more than in 2023. But Germany, with 269,427 robots had about nine times as many, Italy about three times as many (96,803), and France more than twice as many (58,572). https://ifr.org UK robot sales soared by 51% in 2023 – but it may not last p US-based Automated Industrial Robotics (AIR), which recently acquired Sewtec Automation in the UK, has now bought the Irish industrial automation company, Robotics & Drives (RDS), for an undisclosed sum. RDS, founded in 2005, employs around 50 people. AIR has appointed Vivian Farrrell, CEO of another Irish business, Modular Automation, which AIR acquired last year, as president of its Irish operation. AIR, formed last year by Ares Management Corporation, now has more than 500 employees in the US, UK and Ireland. p Danfoss Drives and Honeywell have agreed to explore automation systems with integrated architectures, with the aim of cutting downtime and engineering costs. They plan to address the limitations of traditional automation systems, which often force operators to choose between integrated, closed architectures that lack flexibility, or open architectures that offer flexibility but suffer from limited data integration and interoperability. The partners hope to resolve the data integration and interoperability issues by offering an open, integrated platform. p Dexory, the UK-based warehouse logistics and robotics company, has raised $80m of funding to drive its global expansion, accelerate deployment of its autonomous robots, enhance its development and production facilities, and develop new technologies and AI-powered functions. Dexory has now raised $120m over the past three years. It launched its first commercial product 18 months ago and its customers already include Maersk and DB Schenker. p The global market for industrial automation will expand with a CAGR of more than 9% in the period 2024–2028, with it value increasing by $107bn over this period, according to a new report from Technavio. More than half of this growth will come from the Asia-Pacific region. The report identifies a trend towards open platform software architectures. www.technavio.com NEWS BRIEFS THE BRAZILIAN MOTOR manufacturer WEG is buying the Turkish motor-maker Volt Electric Motors for $88m. Volt, a subsidiary of the Saya Group, has the capacity to produce 1 million motors per year. Volt was founded in 1966 as a coil winder and in 1987 expanded to produce single-phase motors. It has a strong presence in the Turkish market and also exports, mainly to Europe, the Middle East and central Asia. In 2023, Volt had a net operating revenue of $70m with an EBITDA margin of 18.5%. WEG says that the acquisition will expand its activities in the region and diversify its industrial presence to serve Turkey and Europe WEG will assume full control of Volt, which has a 27,000m2 (290,000ft2) factory dedicated to designing and manufacturing motors with outputs up to 450kW. WEG will take on Volt’s 690 employees. Rodrigo Fumo, managing director of WEG’s industrial motors business, says “Volt has a strong presence in Turkey, where we started our own operation in 2022, in addition to proximity to regions with potential demand for our products and services, such as Eastern Europe, the Middle East, central Asia and North Africa.” Volt’s location in Izmir will facilitate WEG’s access to these markets, both by land and by sea. Last year, WEG opened a plant in Turkey to assemble electric motors and provide technical support for customers in the region. The 7,000m2 facility in Dilovasi offers shorter timesto-market not only for Turkish buyers, but also for those in the Middle East, Eastern Europe, North Africa and central Asia. WEG buys the Turkish motor-maker Volt for $88m The number of industrial robots installed in the UK hit a record high in 2023
A 360° SOLUTION. FOR STRAIGHTFORWARD DECISIONS. Automating and optimizing intralogistics processes is a key success factor in the factory of the future. The product family ctrlX FLOW, with the planar system for contactless high-performance conveying and the linear motion system for high-speed transportation and and positioning, the ctrlX FLOW family offers easy-to-integrate solutions for highly efficient material and goods flows. Learn more about ctrlX FLOW: ctrlx-automation.com/ctrlx-flow
October 2024 www.drivesncontrols.com 8 Digital Manufacturing 2Day 30 October, 2024 MTC, Coventry This one-day event will cover technologies and topics that are transforming UK manufacturing, such as AI, data transformation, cybersecurity, and the industrial metaverse. The event will include presentations, panel discussions and hands-on workshops. https://digitalmanufacturing2day.com Advanced Engineering 2024 30–31 October, 2024 NEC, Birmingham Advanced Engineering UK returns to the NEC, showcasing innovation from the UK’s manufacturing and engineering sector. More than 85% of the available floor space has already taken. In 2023, more than 400 companies exhibited at the show, with a further 202 at the colocated Lab Innovations event. www.advancedengineeringuk.com The Manufacturer Live 26-27 November, 2025 Titanic Hotel, Liverpool The annual gathering of the manufacturing industry will include the MX Awards, The Manufacturer Director’s Forum, and the Manufacturing Leaders’ Summit – a two-day conference during which experts and influential discussion leaders will share ideas, innovations and real-world experiences. https://themanufacturerlive.com SPS (Smart Production Solutions) 2024 12-14 November, 2024 Nuremberg, Germany The German automation mega-show is expected to attract around 1,200 exhibitors to its 16 exhibition halls, covering a total area of 125,000m2. Last year’s show drew more than 50,000 visitors. The event spans the spectrum of smart and digital automation, from simple sensors to intelligent systems, offering a vision of a digitalised industrial world. https://sps.mesago.com/events/en Southern Manufacturing & Electronics 2025 4–6 February, 2025 Farnborough, UK The annual regional event returns to Farnborough, aiming to attract people involved in design, engineering production and procurement. They will be able to see the latest in production hardware, components, consumables and other technologies. The organisers are expecting more than 500 exhibitors and 9,000 visitors. https://www.southern-manufacturingelectronics.com Smart Manufacturing Week 4–5 June, 2025 NEC, Birmingham More than 450 exhibitors and 13,500 visitors are expected at the two-day event that includes the Drives & Controls show, Smart Factory Expo, Maintec, the Air-Tech exhibition, Fluid Power & Systems and the Design+Engineering Expo. Running concurrently are the Manufacturing Digitalisation Summit, the Industrial Data and AI Summit, and the Automation & Robotics Accelerator Symposium. www.smartmanufacturingweek.com n NEWS THE ENGINEERING PLASTICS specialist igus is looking for new UK headquarters about twice the size of its existing site in Northampton, which it has outgrown. The company wants to stay in the area but hasn’t decided whether to move to an existing building, which it could do in about a year, or to construct its own dedicated premises, which would take longer. Igus has occupied its current site since 2006 and currently employs 115 people, as well as eight apprentices and some agency staff. It has already implemented some space-saving measures such as installing four Kardex storage machines at a cost of around £750,000, but still needs extra space – partly to display and demonstrate its extensive portfolio of products, which range from plastic bearings and energy chains, to cables and electric motors. The company stores more than six million parts and 200km of cables in Northampton. To give potential customers a better idea of its range, igus has transformed part of its office to create a series of displays and demonstrations showing hundreds of items from its portfolio. This initiative – which igus is calling its “enjoyneering experience” – includes demonstrations of its ability to manufacture cables with customised connections. It produces around 250 of these readycables every week on semi-automated machines, usually shipping them within 24 hours of an order being placed. Igus’ fastest-growing business is its low-cost automation operation, focused on robots with high levels of plastic components, many of them existing igus products such as linear slides. The portfolio includes gantry, delta, Scara and collaborative robots with up to six axes. The cobots, which can carry payloads of up to 3kg, have starting prices of less than £4,000 – compared to around £19,000 for conventional cobots with similar capabilities, according to managing director, Matthew Aldridge. The slight sacrifice is that the plasticsbased cobots are less precise than traditional designs. Igus has also developed food-safe delta robots, currently going through certification, which it expects to sell for around £15,000. Potential robot-buyers can either visit the Northampton site to see them in action, or view them remotely via a webcam link Recently, igus has entered a new market by developing the first of a series of lubrication- and maintenance-free bicycles made largely from plastic waste recovered from the ocean. The first model of the lightweight Rcyl bike is a basic single-speed version, but the company has plans for geared and electrically-powered versions. Igus UK plans to double in size with new headquarters Andy Mills has succeeded Colin Green as managing director of Phoenix Contact UK. Green has retired at the after 16 years with the company. Mills, who joined Phoenix in 2005, was previously the company’s sales and marketing manager for industrial components and electronics. The Telford control and automation specialist, iconsys, has promoted Andy Bunce (left) to technical sales director, and has recruited Andrew Rushton as its group sales director. The changes aim to build on a record year for the company, which has seen its orders rise by £5m to £14.5m, and the opening of two new technical offices in Cheshire and Scotland. Bara (the British Automation and Robotics Association) has named Oliver Selby, head of sales at Fanuc UK, as its new chair, succeeding George Thompson. Selby will be supported in his new role by vice-chair Rosie Davies from Reeco Automation. Selby plans to drive Bara’s activities forward, supporting its aim to increase automation uptake while placing members’ needs “front and centre”. Igus’ enjoyneering experience allows visitors to its Northampton headquarters to sample its wide-ranging portfolio
A variety of modules for your automation solution: The MX-System a highly flexible control cabinet-free automation solution robust, water- and dust-proof design (IP67 protection rating) plug-and-play with pluggable function modules for IPC, coupler, I/O, drive, relay and system standardized connectors for transmission of data and power EtherCAT communication tried-and-tested connector for the field level reduces engineering work high time and cost savings integrated diagnostic functions | MX11-02E | Find out about the world of control-cabinet free automation! 2023
NEWS n www.drivesncontrols.com October 2024 11 ADVANCED ELECTRIC MOTOR AND inverter technologies are set to benefit from £88m of joint funding that the UK government has announced for 46 projects designed to boost zero-emission vehicle technologies, create thousands of skilled green jobs, and deliver long-term growth for the UK economy. The government is providing £44.5m of investment for the projects, with a further £43.5m coming from industry. Among other things, the projects will work on electric trucks for the NHS and Royal Mail, electric motorcycles, and wireless charging technologies. The government says it has a mission to create a strong, stable and pro-business economy, with the UK remaining an attractive destination for investment for the automotive industry. One of the chosen projects is a £11m initiative, led by the led by the in-wheel motor developer Protean Electric, that brings together five industrial partners, together with Coventry University and the Warwick Manufacturing Group, to industrialise the assembly and manufacture of inverters and converters. The Pulse (Power electronics Upscale for Localisation and Sustainable Electrification) project aims to accelerate the development and industrialisation of in-wheel motors and fuel cells. One of the project’s partners, Unipart, will establish a flexible power electronics manufacturing capability in Coventry to support the development and production of high-power DC-to-DC converters and inverters, using advanced vision systems, flow management, and end-of-line testing to enhance efficiency and quality. The project is expected to create or safeguard 159 jobs in the UK and to save 1.2million tonnes of CO2 every year by 2030. Other organisations to benefit from the new funding are: n Microchip Technology Caldicot, which is developing high-efficiency power modules for next-generation inverter systems, and addressing gaps in the UK’s power electronics supply chain; n Ram Innovations, which will demonstrate high-efficiency power electronics systems and sub-systems that use GaN (gallium nitride) devices with enhanced thermal performance; n Magtec, which is prototyping nextgeneration drivelines for electric trucks to be trialled by NHS Wales and Royal Mail; n Electric Green, which is developing smart wireless technologies for charging EVs without needing to plug in cables; n Muon Tech, which is marketing an integrated electric drive and vehicle control system designed to fit in tight packaging volumes, with high levels of functional safety, reliability and functionality; n Equipmake, which is creating a “daisy chain” energy management system for batteryelectric fire engines; and n Flit, which is developing lightweight folding electric bikes for urban commuters that “even people who don’t ride bikes will want”. Sarah Jones, the minister for industry and decarbonisation, says: “Labour is committed to boosting the jewel in the crown of our manufacturing base – the automotive industry. Working in partnership with industry this funding will drive innovation and propel the development of next-generation zeroemission vehicle technologies. £88m of funding will back 46 EV technology projects PLYMOUTH-BASED APPLIED AUTOMATION (UK) has acquired the brand, intellectual property and assets of Somerset-based CME Automation Systems, following its liquidation. Details of the transaction have not been released. Administrators were appointed at CME in May, despite it having received “significant” private equity backing in 2023. CME (Colin Mear Engineering) specialised in automated lines for packaging applications in the tobacco, pharmaceutical and food and beverage sectors. It will now be known as Applied Automation – CME Solutions, and will move from its original location in Combe St Nicholas, near Chard, to Applied Automation’s 140,000ft2 (13,000m2) Plymouth site. Several key members of the CME team have joined Applied. “It’s always sad to see a business that’s been trading for over 40 years end up in administration and it’s even sadder when they are based, like ourselves, in the South West of England,” says Applied Automation’s MD, David Rowe. “However, we’re very much looking forward to working with CME customers in the future and we believe that by running the business as an entity within our existing engineering division it will provide us with some exciting new possibilities. “We see this acquisition as an opportunity to increase our sales in the FMCG packaging sector and to expand our services to existing CME markets in both North America and Europe,” he adds. Applied Automation (UK) has been trading for more than 38 years and currently employs more than 170 people. It designs and manufactures automation and control systems for industrial and marine applications. Applied Automation acquires assets of CME Automation Systems As part of the £11m Pulse project, led by Protean Electric, Unipart is developing power electronics manufacturing capabilities CME Automation Systems specialised in producing packaging machinery
n NEWS THE GOVERNMENT HAS announced a new growth and skills levy which will replace the existing apprenticeship levy and include new foundation apprenticeships. The new apprenticeships, announced by the Prime Minister Sir Keir Starmer and the Education Secretary Bridget Phillipson, will give young people a route in to careers in critical sectors, allowing them to earn a wage while developing vital skills. The new levy will also allow funding for shorter apprenticeships, giving learners and employers more flexibility over their training than under the existing system, where apprenticeships must run for at least 12 months. The training eligible for funding under the new levy will develop over time, guided by Skills England’s assessment of the priority needs for skills. To fund the new scheme, employers are being asked to rebalance their apprenticeship funding, and to invest in younger workers. This will also have to fund more of their level 7 apprenticeships – equivalent to a master’s degree, and often accessed by older or already well-qualified employees – outside of the levy. There have been reports of top executives using the scheme to fund masters-level courses for themselves. Skills England, the government’s new body for the skills system, has also published its first report, providing an initial assessment of the nation’s skills, as well as future skills needs and gaps which employers are facing. The report says that employer investment in training has been falling steadily over the past decade, with training expenditure now at its lowest level since records began in 2011. Investment per employee has fallen by 19% in real terms. The report also shows that, across the UK, almost one in ten – or more than 2.5 million – roles are in critical demand, with more than 90% of these requiring training or education. The government launched Skills England in July to help identify skills needs. It will determine which types of training will be eligible for the expanded growth and skills levy, and will set out shortly how they will work with stakeholders to inform their advice to DfE. Stephen Phipson, CEO of Make UK, has welcomed the apprenticeship announcement, saying that it “demonstrates real intent from the Government to fix England’s broken apprenticeship system. For too long, manufacturers have been held back from investing in critical trade and technical skills by a chronic lack of funding and industry will applaud the Government’s determination to start putting this right. It is clear the Prime Minister has listened to businesses across the country and taken decisive action on apprenticeships. “Manufacturers are clear that a successful, long-term industrial strategy depends on employers being able to invest in the skills they need to create jobs and deliver growth,” he adds. “This new approach to Foundation apprenticeships, focused on making highquality training for crucial job roles available and, accessible to the businesses developing the next generation of talent, is central to making this a reality. Industry stands ready to work with Government to take this positive announcement forward.” New apprentice scheme aims to boost chances for young people The Manufacturing Technology Centre is a leading provider of apprenticeships
ifm.com/uk/vision Combined vision technology for next level quality control. The new 2D-Vision Sensor Dualis. Analysis of surfaces and contours in one device. The new 2D vision sensor, Dualis, analyses object surfaces and contours taking 2D quality control to the next level. The powerful onboard algorithms are easily mastered using ifm’s intuitive, user friendly software. Whether you’re a vision expert or a beginner your next inspection task will be set up in minutes. Our vision: cutting-edge technology available to everyone!
ADOPT ROBOTS, OR PERISH? The perennial, and apparently insoluble, issue of the UK’s poor take-up of industrial robots is back in the news. First, there were glimmers of hope when the International Federation of Robotics (IFR) revealed that the UK installed 51% more robots (3,830) last year than it had the year before. Had Britain’s manufacturers at long last seen the light and realised that robots were key to their future – perhaps even their survival? Unfortunately not. It turned out that the surge in sales was largely a blip resulting from car-makers taking advantage of the super-deduction tax break before it ran out. The IFR expects UK robot sales to fall “sharply” this year, before possibly starting to recover next year. But even if you remove the distortions resulting from the large automotive orders, there were some positive indicators in the 2023 installation figures, with the food and beverage sector commissioning 59% more industrial robots than in 2022 (to reach a total of 555) and the metals industry raising its number of installations by 20% (to 324). Whether these increases were also driven by the super deduction incentive is not clear. We will have to wait for next year’s figures to see. The fact remains that the UK lags far behind its European rivals in the number of robots that it uses. In 2023, our robot population reached a grand total of 28,831 machines. Germany has about nine times as many (269,427), Italy three times as many (96,803), and France twice as many (58,572). The reason for this lag has been discussed widely by panels of experts and in numerous papers. There seems to be combination of reasons including: a reluctance by many British manufacturers to invest in cutting-edge hardware and software; a pride in “sweating” existing assets rather than upgrading to the latest technologies; and worries about antagonising workers by appearing to replace them with machines. Whatever the reason, the result is that productivity in the UK is falling even further behind levels in other industrialised countries. According to a recent report by Citi, growth in output per UK worker is at its slowest pace since the Victorian era, with output 36% lower than it would have been if growth continued at that same pace that it did from 1997-2008. It is now 24% lower than the US and 31% below that in the Eurozone. Against this background, the intervention by two former politicians, Tony Blair and William Haigh (see page 5), is fascinating. Aided by a team of experts, they have declared that if UK industry does not embrace robotics more enthusiastically, it risks falling even further behind rival economies. Failing to act now could “pose a serious risk to national security”, they warn. Blair and Haigh argue that the UK needs to use its strengths in AI to develop a new generation of AI-enabled robotics with “the potential to transform the economy, public services and daily life”. Achieving this will need buy-in from the government as well as industry, but the risks of not making better and wider use of robots are so high that we cannot afford to do nothing. Tony Sacks, Editor n COMMENT
Drives&Controls & BACK TO BASICS n SPONSORED BY G99: what you need to know When connecting generating equipment, such as regenerative drives, in parallel with a public distribution network, the installation must comply with the G99 engineering recommendation to maintain the integrity of the distribution network in terms of safety and supply quality. Liam Blackshaw, ABB’s product manager for LV drives, examines what G99 means in practice. The G99 engineering recommendation replaces the earlier G59 and details the requirements for generation equipment connected to distribution networks. It has evolved to protect the grid from sudden increases in electricity being exported back onto it. DNOs (distribution network operators) need to ensure that they can distribute electricity safely and maintain a high quality, while accepting the increasing power being generated by generators, regenerative drives, generator modules and renewable sources over 16A per phase. Furthermore, as the grid becomes increasingly decentralised, keeping operations stable and secure while managing constant fluctuations from intermittent power sources, becomes an increasingly delicate balancing act. The G59 standard was established in the 1990s to ensure that all new energy generating installations would be safe and would not compromise wider grid operations. By essentially vetting what comes onto the grid, DNOs are thus able to manage their networks more effectively. G99 superseded G59 in 2019. The new recommendation applies to all new equipment connecting to the grid since then. It brought with it changes to the application process, as well as new commissioning requirements, and new definitions for how generators are classified. The requirements of G99 are generally more onerous than G59, particularly for larger generation schemes, with new requirements for frequency response, voltage control, fault ride-through, fast fault current injection, and variable reactive power. As we move away from large centralised power stations to smaller scale decentralised generation, this allows any new generation coming online to play its part in keeping the grid safe and secure. Regenerative drives are covered by G99, and any regen drive over 16A per phase must comply. ABB’s ACS880 regenerative drive, for example, is certified as being G99-compliant when used with an appropriate and correctly configured interface protection device. It's down to the end-user and the DNO to ensure that compliance is achieved. A formal application is submitted outlining the nature of the project, and testing must be undertaken by the installer to ensure that the installation meets all of G99’s requirements. In some cases, the DNO may wish to observe the testing. The National Grid offers helpful resources explaining the application process and what you need to do, while ABB can advise on G99 matters relating to its drive packages. If you have any queries about G99 and ABB drive packages, please contact Liam Blackshaw at liam.blackshaw@gb.abb.com. applicat for ov reliable Super r f rmo tions ving cables online stock, p huge UK pricing K tions,
n TECHNOLOGY October 2024 www.drivesncontrols.com 16 ABB ROBOTICS HAS developed a technology that, it says, gives its GoFa collaborative robots (cobots) more than 10 times better path accuracy than any other cobot on the market. The Ultra Accuracy function delivers a claimed path accuracy of 0.03mm, ensuring precision in tasks such as gluing and sealing, laser welding, layering of composite materials, and precision laser-cutting. It can also be used for accurate positioning of additive layers in 3D-printed prototypes, and to perform precision quality checking. Ultra Accuracy has been developed to meet the demands of applications where precise positioning is crucial for product quality and operational efficiency. It can achieve absolute position accuracies of 0.1mm, providing the reliability needed for maintaining tight tolerances. Cobots with the function combine precision with speed and a full range of motion. Unlike 2D gantry systems, the cobots offer full 6D motion across their entire workspace, without needing additional calibration work, providing the flexibility and mobility to handle a broad range of tasks. “As industries look to automation to enhance product quality and achieve tighter tolerances – continuously decreasing the maximum allowable deviation from the standard in quality control – there is a growing need for robots that can perform tasks with exceptional precision,” explains ABB Robotics’ global head of collaborative robots, Andrea Cassoni. “By combining ultra-accurate path performance with GoFa's inherent simplicity, safety, and flexibility, ABB’s new Ultra Accuracy feature opens a wide range of possibilities for the use of cobots in businesses including electronics, automotive, aerospace, and metal fabrication.” The compact, portable cobots can be integrated easily into production lines without needing expensive customisation, offering an advantage over gantry-based systems. They can be added to production lines with minimal installation and deployment time, because the calibration is done in the factory before delivery. Combining the new function with ABB’s RobotStudio software allows applications to be programmed offline, with a claimed 99% match between simulation and reality, eliminating the need for touch-ups and guaranteeing precise implementation, says ABB. The Ultra Accuracy function is available for new GoFa cobots, and as a retrofit for existing GoFas. www.abb.com KOLLMORGEN HAS ANNOUNCED a programmable motion controller based on a 1.5GHz quad-core processor that, it claims, delivers industryleading cycle times. The PCMM2G controller supports applications from simple machine modules, to complex automation systems with up to 64 axes of synchronised motion, including S-curve and other complex paths. The controller is compatible with Kollmorgen’s earlier PDMM and PCMM models, offering a simple migration path, while delivering greater flexibility and fieldbus cycle rates that are 1.5 to 3.5 times faster. There is a simple upgrade path with step-by-step migration assistance. The controller has 16GB of internal flash memory, six digital inputs, two digital outputs, functional safety modules and an onboard HMI. “It’s exceptionally fast and powerful. It’s fully featured and versatile,” says Kollmorgen’s product management senior director, Chris Cooper. “And it’s an easy way to bring advanced automation capabilities to practically any industrial application.” The scalable controller offers simple integration with systems based on Kollmorgen’s Automation Suite and supports most third-party automation systems. Integrated tools simplify and speed network configuration, servo tuning and machine optimisation. 100Base-T connections support UDP, HTTP, Modbus, Ethernet/IP and Profinet for fast integration. Dual Ethernet ports allow systems to be configured while connected to a network. An uninterruptible real-time clock with battery backup, plus support for an external time-keeping server via NTP (network time protocol), ensures precise timing and synchronisation across axes. www.kollmorgen.com 64-axis controller promises ‘industry-leading cycle times’ Collaborative robots are ‘10 times more accurate’ than any rivals ABB claims that its GoFa collaborative robots equipped with the Ultra Accuracy function are at least ten times more accurate than any other cobot on the market
iC2-Micro Performance that pays off iC2-Micro is the compact drive that gives you a convenient way to optimize efficiency and cost. Run it with your preferred IM, PM or SPM motor. Save up to 40% on energy consumption, while enjoying highly reliable performance. What’s more, it’s easy to commission. Ratings 1-phase 200–240 V AC: 0.37–2.2 kW 3-phase 380–480 V AC: 0.37–22 kW 1-phase 100–120 V AC: 0.37–1.1 kW* 3-phase 200–240 V AC: 0.37–3.7 kW* *Available 2024 What are you waiting for? Run reliably at full load for ambient temperatures up to 50 °C
n TECHNOLOGY October 2024 www.drivesncontrols.com 18 THE GERMAN CAD SOFTWARE developer WSCAD had announced what it describes as “the world’s first AI-powered electrical CAD solution”, which, it believes, will be “a gamechanger”. The Electrix AI package eliminates many of the usual steps and can complete tasks in seconds, slashing design times by up to 99%, according to the company. With smart errorchecking, intuitive guidance, and the ability to tackle complex tasks with simple commands, the software boosts productivity, and frees up users’ time. “Electrix AI is revolutionising how electrical design is done,” declares WSCAD CEO, Axel Zein. “We’ve seen massive time savings, and the streamlined process unlocks major productivity gains.” At its core is the AI Copilot. With a click on a button, a chat window opens up to help users. It can review designs, find errors and adapt to users’ needs. “Instead of manually searching for components, or designing from scratch, you just ask the AI Copilot, and hand over the tasks,” Zein explains. WSCAD says that when using other electrical CAD software, it can take more than 20 clicks to create a BOM (bill of materials). In the new software, this happens in seconds using a “create a bill of materials” command. Similarly, AI Copilot takes 15 seconds to place four macros on a new page, down from around five minutes that it took previously. To check for design errors, users can ask: “Find the errors in this project,” and the software will scan a schematic in seconds, pinpointing any open connections, missing assignments, or misplaced components. A quick request such as “Give me a copper wire, blue, 24V DC, 64A”, delivers a wire with a 16mm2 cross-section to the cursor. The software is said to be easy to use. It delivers electrical CAD expertise while learning continuously from user inputs, becoming more efficient with each task. Novice users can tackle jobs that were previously restricted to experts, while experienced designers can focus on complex projects and complete them faster. “This new division of labour supercharges productivity, enabling companies to handle growing demands more efficiently,” says Zein. “By integrating AI into our electrical CAD software, we are unlocking new possibilities and paving the way for enhanced productivity.” p Hilscher has collaborated with a German electronics specialist, Promwad, to develop a platform that addresses a compatibility issues faced by industrial robot manufacturers using platforms from Nvidia, Qualcomm and others. Integrating these with existing networks and components can require extra technologies to bridge the gaps, raising hardware and software costs and potentially affecting performance. The new platform supports EtherCat, Profinet and EtherNet/IP, and allows manufacturers to integrate modules and servodrives with robots without needing extra technologies. p A Swiss firm, Naviq, has patented a magnetic sensor for guiding mobile robots, which can measure angles with 1-degree precision and positional accuracy to within 1mm. It says the development will improve mobile robot navigation “significantly”. Unlike magnetic line-following sensors that only detect position in one dimension, the MTS160 sensor allows robots to assess track curvatures and to distinguish between minor adjustments on straight paths and more active steering for curves. The improved path-tracking will allow robots to follow paths more accurately at higher speeds. https://naviq.com/product/mts160 p Sick is integrating its Tag-Loc wireless tracking technology with the cloud-based RobOps platform developed by California’s InOrbit.AI, to enhance the safety and efficiency of mobile equipment. In addition to InOrbit’s support for AMRs and AGVs, it is now possible to track and orchestrate the movement of manually-operated vehicles and equipment such as forklifts, pallet jacks and carts. The development will support hybrid fleets that combine autonomous, guided and manual vehicles. It unlocks realtime analytics across vehicles, as well as complex workflows following traffic rules. p ABB has demonstrated a technology, developed in collaboration with BHP, Komatsu and Boliden, that charges electrically-powered mining vehicles automatically and safely without human intervention. The eMine Robot Automated Connection Device is designed to withstand harsh mine environments. It is regarded as an important step towards allelectric mines. After testing at an ABB lab in Sweden the technology will undergo field trials in a mine. p The Digital Twin Consortium (DTC) has expanded its scope to include the development of advanced digital engineering methodologies throughout the digital twin lifecycle. By integrating advanced methodologies and leveraging industry-wide adoption of DTC frameworks and new products, the consortium hopes to drive the adoption of leading practices for digital engineering ecosystems. www.digitaltwinconsortium.org TECHNOLOGY BRIEFS First AI-powered electrical CAD software is ‘up to 99% faster’ WSCAD has embedded AI into its Electrix AI electrical CAD software, cutting design times by up to 99%. WEG HAS LAUNCED a software tool that simulates energy efficiency projects, allowing users to analyse the energy impact of changes to motors, drives and gearboxes. By comparing equipment configurations, The WEGSee+ tool provides KPIs on energy consumption, return on investment, and CO2 emissions, helping users to make informed decisions to enhance operating performance and sustainability. The tool displays detailed insights into potential energy savings using simulations of motors, drives and gearboxes. It enables users to analyse the feasibility and potential of energy-saving projects and evaluates the potential ROI before implementing changes. “The launch of WEGSee+ marks a significant step forward in energy management for industrial applications,” says Marek Lukaszczyk, WEG’s marketing manager for Europe and the Middle East. “By simulating the impact of different equipment configurations, WEGSee+ reduces time and energy consumption during the planning phase, optimising resources and maximising benefits. “The launch of WEGSee+ enables our customers to take energy management into their own hands and optimise resources in an intelligent way,” he adds. https://www.weg.net/seeplus/en/calculator Tool analyses energy impact of changes to motors, drives and gearboxes
RkJQdWJsaXNoZXIy MjQ0NzM=