MOTORS: How are there IE6 e ciency motors if there is no standard? SAFETY: What does the new Machinery Regulation mean for you? ELECTRICAL: Are you complying with the BS EN 60204-1 safety standard? Drives&Controls AUTOMATION FOR MANUFACTURING INSIDE Y YOUR SAFET toprotec Safety de ct you without com e desig evices that ar Ene promise gned rgy and Automation NOVEMBER/DECEMBER 2024 www.drivesncontrols.com
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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 January issue of Drives & Controls will contain our annual supplement on variable-speed drives, and a look at what’s been happening in the worlds of gears and gearboxes, and packaging, printing and paper. 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 32 30 28 26 5 47 DRIVES & CONTROLS NOVEMBER/ DECEMBER 2024 Vol 40 No 10 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 Electric Motors Some manufacturers of electric motors are already oering “IE6” motors, even though no ocial standard yet exists for this level of eciency. An expert explains how and why this is happening. 28 Logistics The parcels giant Hermes is the rst company in Europe to use a wheeled robot to unload boxes from containers onto conveyors. The robot has relieved human workers of an arduous task, especially in summer when the temperatures inside containers can soar. 30 AI and Robotics Articial intelligence has the potential to change the way that we automate our factories. Universal Robots’ vice-president for strategy and innovation considers some of the far-reaching implications of AI and suggests how it might aect robotics in the future. 32 Controls Generative AI tools are emerging that promise to change the way that controls engineers work. We examine how the shift to these tools will make their lives easier, as well as helping companies to cut costs. Plus, how remote I/Os work and some precautions that you need to take when using them. 36 Safety The EU’s Machinery Regulation will supersede the Machinery Directive that was issued in 2006. An expert explains the implications of the new Regulation, and how its diers from the Directive. Plus a look at how robot safety standards are being updated to take account of the advances in collaborative robots. A member of the BSI’s robot technical committee outlines the changes and how ensure that your applications comply with them. 40 Electrical The BS EN 60204-1 machine safety standard is often not complied with. A pair of safety experts have produced a White Paper designed to help machine-builders and panel-builders to improve their compliance with the standard. Plus a look at the role of mains chokes in VSD applications, their benets, and factors to consider when using them. 36 Average net circulation January to December 2023 40 44 Subscribe for your FREE copy now 18,942 16
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NEWS n 5 Clickable busbar distribution tech ‘will halve assembly times’ RITTAL HAS UNVEILED A new platform for power distribution systems in enclosures, consisting of boards and components that click together, thus simplifying the previously laborious process of assembling such systems. It claims that the RiLineX system could halve assembly times and cut engineering times by up to 30%, compared to conventional busbar systems. The new system also cuts plastic waste by an average of 1.9kg per board, and will reduce the need to ship heavy copper around the world. Rittal says that any organisation that needs fast, reliable power distribution up to 1kV AC or ±1.5kV DC will benet from the new system. It is aimed at panelbuilders and switchgear manufacturers, as well as IT users. It ends the need for complex system dimensioning, the loss of space when components are installed, and the need to cut protective covers to size. The system’s copper bars are integrated directly into the board, allowing components to be mounted anywhere. This eliminates the convoluted process of arranging supports on a project-by-project basis. The complicated cutting of covers is no longer needed, either, reducing trimming waste and plastic refuse. The busbars are covered end-to-end, protecting them against accidental contact. This contact hazard protection is certied to IP2XB, which means that it will prevent penetration by a solid object with a diameter of 12mm or more. The protection at the front can be upgraded to IP4X, resisting penetration by objects with diameters upwards of 1mm. In either case, it is impossible for ngers to touch live parts. The system has been pre-tested for short-circuit resistance up to 52.5kA. Rittal says that the system will reduce the amount of work needed at all stages, from planning and assembly, to maintenance. The click technology ensures simple installation, and means that project-specic modular systems can be implemented at a far lower cost. Depending on the application, there are two ways to use the RiLineX system. In the rst, the platform is available as a complete board including quick-to-install copper bars for Rittal’s AX compact and VX25 bayable enclosures up to 1.2m. It can also be supplied already installed in an enclosure. This approach is ideal for standard applications. It cuts costs and gives users a clearer overview. They can install the system without needing any specialised knowledge. The second option is an open modular version that oers conguration freedom for customised system designs, with baying connections extending to 2.4m or more. Users simply need to know the length of the mounting plate and can then exibly combine modules in 200mm increments. The drilling pattern is identical on every mounting plate, and standard busbars are cut to size. The bars are then xed in the board, ensuring short-circuit resistance at all times. This version is also available as a bar-free kit. For export applications, the need to ship heavy metal can be eliminated, oering both cost and environmental benets. The boards can simply be used on site with cost-eective standard bars made from copper or aluminium. Baying across several enclosures, even retrospectively, is said to be easy. There is a new planning tool to help users. Rittal says that the new system takes power distribution in enclosures into the future. Initially, the system will be available as a three-pole version for currents up to 800A. End-to-end fourpole systems will follow. The platform is equally suitable for use in DC (direct current) applications, which are increasingly common in industrial and renewable energy applications. All of the connection adapters, fuses and disconnectors for the three-pole system will be available by the time of the Hannover Messe in April 2025. Rittal is also working with external partners to create an ecosystem based on the RiLineX technology. It is providing device and component manufacturers with the interface data they need to develop products that are “ready for RiLineX”. www.rittal.com www.drivesncontrols.com November/December 2024 NIDEC DRIVES CLAIMS that it the rst VSD supplier to oer a veyear warranty as standard across its complete range of drives, including high-performance and high-power models. It is now oering a ve-year warranty on all Control Techniques global drives, option modules and keypad products. The company rst oered a ve-year warranty for its Commander C general-purpose drives in 2019, and more recently added its specialised Pump Drive F600 and HVAC Drive H300 ranges, as well as its Commander S100 micro AC drive. “We are proud to be the rst global drive supplier to oer a veyear warranty as standard,” says Nidec Drives’ global marketing manager, Sue Clark. “This reects the condence we have in the quality of our products, built on the back of major investments in our design and manufacturing facilities worldwide. “In today’s competitive landscape,” she adds, “this initiative allows us to oer our customers a clear dierentiator – a risk-free investment that lowers their total cost of ownership. Our customers can be assured that their investment is protected, with no extra cost for added peace of mind.” Nidec argues that it is now unnecessary for drives buyers to pay for an extended warranty when it is oering ve-year coverage as standard, without any need for registration or extra fees. Nidec Drives is ‘first’ to offer 5-year warranty for all products Rittal claims that its new RiLineX power distribution system will halve assembly times, and cut engineering times by up to 30%
n NEWS November/December 2024 www.drivesncontrols.com 6 THOUSANDS OF SMALLER manufacturers could bene t from a £16m expansion of the Made Smarter Adoption programme that the chancellor Rachel Reeves announced in her recent budget. The funding will be used to expand the programme to cover the whole of England in 2025-26. The programme oers access to technology advice, leadership, and skills training, as well as grant funding for digital internships and technology projects. The new funding will help to boost productivity, growth, create high-value jobs and decarbonise SME manufacturers across the country. Since Made Smarter was launched in North West England in 2019, around 2,500 manufacturers have bene tted. The scheme has funded 379 technology projects, which are predicted to create more than 1,700 new jobs, upskill 3,200 existing roles, and expand the economy by £267m over the coming three years. In 2022, the programme was extended to four other regions – the North East, Yorkshire and the Humber, the West Midlands and East Midlands – and a locally funded programme was launched in the West of England. Brian Holliday, who co-chairs the Made Smarter Commission and is MD of Siemens Digital Industries, says that the budget announcements on the Made Smarter Adoption and Innovation programmes “are a tremendously positive acknowledgement of the impact that Made Smarter is having on UK manufacturing. Manufacturing leaders need Made Smarter, which has become the bestknown start-point and signposting service for the sector in support of productivity, competitiveness and sustainability improvement at scale.” “Over the last ve years Made Smarter has transformed countless SME manufacturers, introducing them to new technologies and new digital skills,” adds Donna Edwards, director of Made Smarter’s North West adoption scheme. “The programme has proven that by oering businesses specialist advice to help them select the right approach, level of investment and tools for their business, they can grow and build resilience. The Budget also laid out plans for a modern Industrial Strategy, up to £37m of funding to extend the Made Smarter Innovation programme during 2025-26, and long-term funding for growth-driving sectors, including more than £2bn for the automotive sector and £975m for aerospace. Plans to expand the Made Smarter scheme were rst announced by the former chancellor Jeremy Hunt in 2023 as part of £4.5bn of funding for British manufacturing. He also said that the Government was working with the devolved administrations in Scotland, Wales and Northern Ireland to explore making the programme UK-wide from 2026-27. £16m funding will expand Made Smarter to SMEs across England pSiemens is planning to cut up to 5,000 jobs in its global industrial automation business, which employs a total of around 70,000, according to a Reuters report. “Sometimes we have to do some re-engineering because the developments weren't as positive as we expected them to be,” Siemens CEO Roland Busch said after the company had reported a 46% fall in prots in its digital industries business. He added, however, that he saw good long-term potential for the automation sector, because of shrinking populations and the low level of mechanisation in SMEs. pSKF has closed its roller bearing manufacturing plant in Luton with the loss of around 300 jobs after more than a century of production. The closure was announced last year with SKF saying that it was part of a change in strategic direction to ensure long-term competitiveness in the European market, and that there was “no viable alternative”. The plant was opened in 1911 and was the company's rst site outside Sweden. SFK will continue to have a presence in Luton with around 50 non-factory workers. pABB is buying Aurora Motors, the US-headquartered supplier of vertical pump motors, which has an engineering operation in Shanghai, China, and customers in 30 countries. Financial terms have not been disclosed. The deal is part of ABB Motion’s growth strategy, and will allow its Nema motors division to enhance its product oering, expand its supply chain, and improve support to its global customer base. pOxford Metrics, the smart sensing and software company, has acquired the Gloucester-based manufacturing measurement specialist, The Sempre Group, for up to £5.5m, depending on its earnings. The acquisition will strengthen Oxford Metrics’ smart manufacturing division, following its earlier purchase of Industrial Vision Systems (IVS). p The global industrial automation market will grow by $107bn between 2024 and 2028 (a CAGR of 9.45%) according to a new report from Technavio. It detects a trend towards open automation software. In two other recent reports, Technavio predicts that sales of AC motors will grow by $34.9bn (with a CAGR of 6%), and micro-PLCs by $2.4bn (a CAGR of 7%), over the same period. www.technavio.com NEWS BRIEFS Made Smarter Commission co-chair, Brian Holliday: a tremendously positive acknowledgement of the impact that Made Smarter is having on UK manufacturing
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November/December 2024 www.drivesncontrols.com 8 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 Hannover Messe 2025 Hannover, Germany 31 March – 4 April, 2025 The main exhibition areas for the 2025 industrial megashow will be Smart Manufacturing, Digital Ecosystems, Energy for Industry, Compressed Air & Vacuum Technology, Engineered Parts & Solutions, Future Hub and International Trade & Investment. Drive and uid power technologies will be highlighted in the Motion & Drives areas. The conference programme will include around 1,600 speakers. The partner country for 2025 is Canada. www.hannovermesse.de/en 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 UK GOVERNMENT HAS identi ed advanced manufacturing as one of eight key sectors that its industrial strategy – the rst new one for seven years – will focus on in an attempt to deliver long-term growth for the nation. The business and trade secretary Jonathan Reynolds and the chancellor Rachel Reeves have published a green paper designed to kickstart the new industrial strategy. The strategy aims to drive long-term growth that is sustainable, resilient and distributed across the country. Reynolds believes the strategy will put Britain back on the global stage and help to attract investment into the most productive parts of the UK economy. “Our modern industrial strategy will hardwire stability for investors and give them the con dence to plan not just for the next year, but for the next 10 years and beyond,” he says. “This is the next step in our pro-worker, pro-business plan which will see investors and workers alike get the security and stability they need to succeed.” Clare Barclay, CEO of Microsoft UK, will chair the government’s new Industrial Strategy Advisory Council, which will help to guide the development of the new industrial strategy, working with business, trade unions, devolved governments, local leaders, academia and other stakeholders. In addition to advanced manufacturing, the other sectors that have been earmarked for support include clean energy and “digital and technologies”. The government points out that the top 30% of sectors ranked by productivity in 1997 have been responsible for around 60% of the economy’s entire productivity growth over the past 25 years. That’s why the industrial strategy will direct support to those sectors and geographical clusters thought to have the highest growth potential. Make UK CEO, Stephen Phipson, has welcomed the new industrial strategy, saying: “We live in a world which is massively dierent to a decade ago and simply leaving the economy and, industrial strategy, to the free market is an ideology which is long past its sellby date. This is a welcome rst step in addressing the Achilles heel of the economy which has left the UK an outlier among advanced countries. It sets out a clarity of vision for how the resources of Government and, in particular, each department can be convened towards a single objective of long term growth across all regions. With the Advisory Council being put on a statutory footing, he adds, “industry will no longer fear the constant chop and change in policy we have seen over the last decade or so and can focus on the long term – it is important that the Government is delivering on its promises.” Advanced manufacturing is a key sector in new industrial strategy Schneider Electric has appointed Olivier Blum as its CEO, after Schneider’s board dismissed his predecessor, Peter Herweck after 18 months as CEO “due to divergences in the execution of the company roadmap at a time of signicant opportunities”. The change is intended to “accelerate the execution of [Schneider’s] strategy and engage into the next phase of its development”. Blum, 54, is a French citizen who has been leading Schneider’s Energy Management business – its largest – since 2022. Rockwell Automation has appointed Gustavo Zecharies as president of its Emea (Europe, Middle East and Africa) region, succeeding Susana Gonzalez, who is leaving “to pursue other opportunities” after almost six years in the role. Zecharies was previously Rockwell’s vice-president for Latin America and earlier in his 18-year career with the company held roles in its Canadian operation. Zecharies, who will be based in Spain, will report to Rockwell senior VP and chief revenue o§cer, Scott Genereux. Electro Mechanical Systems (EMS) has appointed Mike Davies as managing director, following the retirement of Stewart Goulding. Davies, who has been with EMS for almost 30 years, is moving from his previous role as manufacturing director. Dave Walsha has been promoted to the position of sales and marketing director – a role which Goulding also lled. As MD, Davies will retain his oversight of shopoor operations, while focusing on advancing progress and e§ciency across EMS. Olsen Actuators & Drives has appointed Ian Walch as its new managing director. Founder Piers Olsen has moved to the role of chairman and will continue to focus on business development and strategic markets and applications. Walch was managing director of Sewtec Automation for almost ve years until January 2023. He has worked in sectors including aerospace, defence, and industrial, for companies including Octopus Dynamics, Misas Technology and Stirling Dynamics. UK business and trade secretary Jonathan Reynolds announcing the new industrial strategy at the government’s International Investment Summit in London
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NEWS n www.drivesncontrols.com November/December 2024 11 AT THE SPS SHOW IN Germany, Beckho unveiled a new generation of its TwinCat PLC technology that speeds up both engineering and runtime operations, and can execute control code up to 1.5 times faster. Beckho describes the new TwinCat PLC++ controllers as “a real leap in automation technology performance”, resulting in faster throughput times from development and commissioning, to machine lifecycles. Project loading times are shorter and translation processes have been improved. Shorter lead times will cut costs and allow machine-builders to launch new machines faster. The controllers are a new development based on the IEC 61131-3 languages. Familiar functions have been kept, while editors and compilers have been redeveloped. DevOps principles can be used to implement continuous integration and deployment. A new compiler makes it possible to enhance control codes in terms of execution times. This option – already familiar in the IT world – increases execution speeds further, and means that industrial PCs with less computing power may suce, cutting hardware costs. Alternatively, freed-up computer resources can be used to implement more control functions or to increase the machine productivity by cutting cycle times. The new PLCs were one of a slew of products that Beckho launched at SPS. The others included: n A variable-speed drive for applications such as conveyors, pumps and fans, that is integrated into the TwinCat system via EtherCat, o ering similar commissioning and diagnostics to Beckho ’s servodrives. The AF1000 VSD is available in a version that can drive two motors simultaneously. It covers a single-phase range of 0.37-1.5kW for 230V supplies, and a three-phase range of 0.372.2kW for 400V AC supplies. Both are available as one- or two-axis modules, and support synchronous servomotors, asynchronous and reluctance motors without feedback, in V/f or vector modes. n An “economy” servodrive in two versions: a low-power singlephase model, and a three-phase version for currents from 1.65-6.9A. The compact AX1000 servodrives integrate with the TwinCat system and all tools for the larger AX5000 and AX8000 drives can also be used with the AX1000. They incorporate a power supply, DC link capacitors, ballast circuit and – in most variants – a ballast resistor. Supported motors include AM8000 synchronous servomotors with One Cable Technology, as well as asynchronous and reluctance motors with or without feedback. n A range of low-cost linear motor modules for Beckho ’s XTS transport system, said to o er 95% of the technical abilities of earlier modules at 55% of the cost. The 500mm XTS EcoLine motor modules are twice as long as standard modules, yet ¢t in the same grid dimensions. They support speeds up to 4m/s and accelerations up to 10g. They o er initial forces up to 30N and peak forces up to 80N per mover, with 0.70mm absolute accuracy and 0.075mm repeatability. n IP67 I/Os with simple identi¢cation and addressing via ID switches. The EtherCat and EtherCat P Box modules have three hexadecimal rotary addressing switches, allowing them to be identi¢ed regardless of their installation position. n Embedded PCs for BACnet/IP and Pro¢net RT applications. The compact (71 x 100 x 73mm) CX7000 embedded PCs are said to open up the TwinCat 3 world to small controllers too, providing a high level of computing power for the small controller sector. The CX7293 has a Pro¢net RT interface, while the CX7291 is suitable for BACnet/IP. www.beckho .com Beckhoff unveils next-gen PLCs, VSDs, servodrives and I/Os at SPS SCHAEFFLER HAS ANNOUNCED plans to deploy Digit humanoid robots from the US ¢rm, Agility Robotics, in its manufacturing plants around the world. Schae§er is also making a minority investment in Agility. “In disruptive times, implementing innovative manufacturing solutions is crucial to be successful. Here, humanoids play an important role,” says Schae§er’s chief operating ocer, Andreas Schick. “We will integrate this technology into our operations, and see the potential to deploy a signi¢cant number of humanoids in our global network of 100 plants by 2030. We look forward to the collaboration with Agility Robotics which will accelerate our activities in this ¢eld. Earlier this year, Agility claimed to be the ¢rst company to deploy humanoid robots commercially after GXO, the world’s largest contract logistics provider, started to use Digit in its logistics operations. The agreement also marked the industry’s ¢rst Robots-as-a-Service (RaaS) deployment of humanoid robots. Agility describes Digit as “a bipedal mobile manipulation robot”. The 1.75m-tall machine can carry loads of up to 15.9kg. “We are excited to welcome Schae§er as a customer and investor, and look forward to delivering value in their operations with Digit,” says the company’s CEO, Peggy Johnson. “Scaling the use of humanoid robots will require them to work cooperatively with humans and outside of the safety cages they are in today. I am con¢dent that in the next 24 months, Agility will be the ¢rst company to deliver a safe humanoid robot that will be able to work alongside people.” n Schae§er is cutting 4,700 jobs in Europe to bolster its ¢nancial position which has been hit by the downturn in the automotive sector, as well as a drop in demand for its industrial products. Schaeffler to use humanoids at sites around the world Beckhoff’s new VSDs are available in versions that power two motors. They use the same commissioning and diagnostics tools as its servodrives.
n NEWS SIEMENS IS BUYING the industrial simulation and analysis software developer Altair Engineering for around $10bn. It says the acquisition will strengthen its leadership in industrial software, and create the world’s most complete AI-powered design and simulation portfolio. By adding Altair’s simulation portfolio, which is strong in mechanical and electromagnetic applications, Siemens is enhancing its digital twin capabilities to oer a physics-based simulation portfolio as part of its Xcelerator platform. Altair's data science and AI-powered simulation capabilities allow anyone to access simulation expertise, and to accelerate timeto-market and design processes. In addition, Altair's data science capabilities will unlock Siemens’ industrial expertise in product lifecycle and manufacturing processes. “Acquiring Altair marks a signicant milestone for Siemens,” says Siemens’ president and CEO,” Roland Busch. “This strategic investment aligns with our commitment to accelerate the digital and sustainability transformations of our customers by combining the real and digital worlds. “The addition of Altair’s capabilities in simulation, high-performance computing, data science, and articial intelligence, together with Siemens Xcelerator, will create the world's most complete AI-powered design and simulation portfolio,” he adds. “It is a logical next step: we have been building our leadership in industrial software for the last 15 years, most recently, democratising the benets of data and AI for entire industries.” The acquisition will boost Siemens’ revenues by 8%, adding €600m to its digital business revenue of €7.3bn in 2023. Siemens expects to achieve signicant synergies, especially from cross-selling of the complementary portfolios and giving Altair access to Siemens’ global customer base, with a projected impact on revenues of more than $500m a year in the medium term, growing to more than $1bn in the longer term. n Siemens is selling its Siemens Logistics business to Vanderlande, a company owned by Toyota Industries, for €300m. Vanderlande specialises in logistic process automation in the warehouses, airports and parcelhandling facilities. “By selling Siemens Logistics, we’re taking another important step in sharpening our portfolio as a leading technology company,” says Siemens’ chief nancial ocer, Ralf Thomas. “In Vanderlande, we have found the best future owner for our airport logistics business.”The transaction expected to close during 2025. Siemens buys Altair for $10bn to create ‘AI-powered portfolio’ Siemens says that Altair’s simulation capabilities will enhance its digital twin portfolio RGH RS *OUFMMJHFOU $PNQBDU s3RVLWLRQLQJ(& %UXVKOHVV RU$FWXDWLQ s6DIHW\7RUTXH2II 672 RU6DIH6WR s %URDG 5DQJH RI 0RWRU DQG *HDU 0R HOV 66 2SWLRQDOO\,QWHJUDWHG : %SJWFT GPS :PVS "QQMJDB QJ'& %UXVK 'ULYHV BUJPOT DIHW LP s $ $EVROXWH 3RVLWLRQ $YDLODEOH DW $Q\WL s (DV\ ,PSOHPHQWDWLRQ RI 0DFKLQH 6D s 9'& RU 9'& 6XSSO\ s 6LPSOH :LULQJ s 0DGH LQ *HUPDQ\ W\ H HOHFWURQL - ZZZ WU )RU PRUH LQIRUPDWLRQ 7HO RU HPDLO LQIR#WU-HOHFWURQLF FR XN F FR XN
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THE GREENING OF A MODERN UK INDUSTRIAL STRATEGY The government’s Green Paper on its proposed Modern Industrial Strategy sets out a 10-year plan intended to deliver the certainty and stability that businesses need to invest in high-growth sectors. It argues that “the case for governments to roll up their sleeves and shape markets, rather than step back in the face of the challenges [in the global economy], is stronger than ever. To capture the growth the UK so desperately needs, we need a modern industrial strategy to share in the next decade’s growth opportunities. “This industrial strategy will provide a launchpad for businesses,” the Paper continues. “It provides the rm foundation for investment that businesses have told us they need. This government believes it is our role to provide the certainty that inspires condence, allowing businesses to plan not just for the next year, but for the next 10 years and beyond. “We will not repeat the mistakes of the past, with policy changing as fast as decision-makers,” it adds. “To put an end to the policy merry-go-round, we are going to establish a statutory Industrial Strategy Council, hardwiring stability and long-termism into our plan from the start.” Encouraging words, but at this stage the Industrial Strategy is short on detail. The esh will be put on the bones after a period of consultation and the subsequent publication of a fuller document. But even before the Green Paper had been published, the prospect of a new industrial strategy appeared enticing to UK manufacturers. A survey conducted by Make UK and RSM UK prior to the publication revealed that most UK manufacturers (70%) believe that a long-term industrial strategy could lead to a surge in previously oshored manufacturing being brought back to the UK. The survey of 209 companies found that half of UK manufacturers would increase investment in their UK facilities in response to a new strategy, 30% would adopt more automation, 29% would boost exports to the EU, while 26% would raise their R&D budgets. Contrary to a widespread belief, the survey also found that UK-owned companies invest more than foreign-owned companies operating in the UK in both plant and machinery (8.7% compared to 4.7%) and R&D (5.5% compared to 5%). According to Make UK, this shows the potential benets of an industrial strategy that creates growth among UK businesses, which then scale up. The survey also shows that plant and machinery (53%) and sta (52%) are the top two investment priorities for UK manufacturers. Almost two-thirds of manufacturers (64%) say that they invest up to 10% of their turnover in plant and machinery, with a further 26% investing 10-50% of turnover. The government has picked eight sectors which it believes have the highest growth potential. One of them is advanced manufacturing, which suggests that if your manufacturing activities are not “advanced”, you might not warrant future government support. Obviously, the government cannot back every sector of industry, but even traditional – or “non-advanced” – sectors could have an important role to play in the UK’s industrial future. Tony Sacks, Editor n COMMENT Ǖ Ǒ ǒ Lj ť Lj ƪ Lj Ǜ ǒ Ǖ Ǒ ǒ Ǖ ǒ įĦ Ơ Ĩĭ ĦĦĦĶ ħĦĨĨ Ǖ Ƭ ĶĪĪ ƮĦƯĨĦ ĩħįĬ ĪĪħĪ ĬĦĦĶ Ǒ ĭ Ǒ
Drives&Controls & BACK TO BASICS n SPONSORED BY Codesys eases programming It can take weeks to produce a PLC program from scratch for complex processes with many I/O points and HMIs. Carl Eely, an industrial automation product manager at ABB, explains how the use of open protocols can speed up the process signicantly. A PLC is – in theory, at least – a relatively simple device. It turns things on (1) and o (0). Of course, in practice, a PLC can also do much more than that, which is why programming one for complex industrial automation systems and processes can be labourintensive and time-consuming. The complexity levels ramp up even further when you start adding di erent communications protocols into the mix. This presents additional challenges, chie y because not all devices from all manufacturers will always play nicely together. A PLC from one vendor may not communicate easily with a drive, HMI, electrication product, or even a robot, from another. Additional licenses for other protocols – for example, IEC 61850, KNX, BACnet, EtherCat or Pronet – can be purchased, but these are often expensive and may require extra hardware, as well as additional time and programming knowledge to implement. Learning to program in a new language takes time, and so it’s understandable that integrators often prefer to stick with what they know. The problem is that this e ectively locks you into a single vendor, forcing you to either spend additional money on licenses, or change your PLC to match whatever other devices you’re using around it. Alternatively, you can attempt to master a new programming language, but this will typically take even the most capable and fast-learning engineer several weeks at a minimum – which is time you typically won’t have. Codesys PLCs can provide an answer here. The Codesys programming platform supports all ve major PLC programming languages as dened by IEC 61131-3 (LD, IL, FBD, ST and SFC). In practice, this means that a Codesys PLC can be congured to communicate with other devices using multiple protocols – for example, CANopen, J1939 or Modbus – without having to purchase additional licenses. Additional hardware can also open up Extra Ethernet, Probus, Pronet, EtherCat and CanOpen 2A/2B, while additional software licenses add capabilities for IEC 61850, KNX, BACnet, EtherCat and Ethernet/IP. This compatibility means that one code can be ported easily across to other Codesys PLCs without having to rewrite it entirely, saving vast amounts of training, programming and debugging time. ABB is one of several manufacturers that o er Codesys-based PLCs. For more information, visit https://new.abb.com/plc/programmablelogic-controllers-plcs/ac500 igus® Caswell Road Northampton NN4 7PW Tel 01604 677240 sales@igus.co.uk motion plastics® Perfect for robots igus® the-chain ... moving energy made easy ... Save time & increase reliability ... triflex® TRCF for maximum robot reliability: 3-chamber system for large hoses and cables. Easy to open using a screwdriver and easy to vary the length. Now 25% more push-pull strength. Available in sizes 65, 85,100 Ø, and in dresspack modules. More at www.igus.co.uk/triflex
n TECHNOLOGY November/December 2024 www.drivesncontrols.com 16 ABB HAS ANNOUNCED AN open software platform that is integrated into its drives’ operating systems, allowing users to create, validate and implement customised control and analysis applications in programming environments such as Matlab/Simulink or C++. Called the ABB Crealizer, the platform can access high-resolution real-time data for analytics and other applications. “The ABB Crealizer is able to accelerate digitalisation processes in companies,” says Daniel Wyss, ABB System Drives’ digital lead. “The software platform oers customers the possibility of exible programming, easy testing, prototyping, and quick and easy integration. “Companies today must be able to adapt quickly to changing conditions,” he adds. "The ABB Crealizer integrated into our drives is a software platform that supports this by reducing risk, lowering system costs, and shortening time-tomarket. And all of this while protecting the systems and processes through high cybersecurity.” The Crealizer is said to oer a more powerful variant that complements existing approaches to customisation, adaptive programming and IEC programming. The use of exible programming environments, rapid prototyping and short iteration cycles will enable the rapid launch of innovative applications, ABB says. These applications can be validated using simulations. Users will be able to work together with other experts to solve challenging problems at the system level, or adopt ready-made applications from ABB and its partners. ABB says that the platform will simplify supervisory PLC systems, with advanced control logic implemented on the drive. Fieldbus and OPC UA models can be customised to allow data interoperability. Users will also be able to create their own test applications to speed up commissioning. One potential use for the new platform is to dampen vibrations in drivetrains in real time. This will allow drives to be used across their entire speed ranges, and because vibrations are reduced, service lives will be extended. New functions can also be implemented to detect anomalies, or for predictive maintenance. For example, the ageing of crane ropes could be mapped based on high-resolution torque and other stress factors, allowing the ropes to be replaced only when necessary. Other potential applications suggested by ABB include: nsaving energy by implementing noload detection on conveyors; nreplacing old drives without needing to touch the overriding PLC system; ncreating automated test sequences to tune machines; nusing the drive as a sensor and performing Fast Fourier Transformations on the signals; nmonitoring motor eciency and tuning systems in real time; ndetecting anomalies in drive cooling systems; nusing adaptive vibration control to extend operating ranges and prolong system lives; and nimplementing advanced energy management systems. https://new.abb.com/ about/our-businesses/motion WEG has launched an axial-ux motor that will allow OEMs and systems integrators to implement innovative applications with small footprints. Available in frame sizes 250–400 (10125hp), the modular W80 AXgen motor, lets manufacturers downsize systems, cut logistical costs and lower carbon footprints. The Nema motor is said to “set a new standard” by reaching eciencies of up to 96.9%. An advanced cooling system supports the use of fresh or deionised water and oil. With ow rates of 5-15 litres per minute, and inlet pressures of up to ten bar, the motor provides reliable performance in challenging conditions. The motor operates with a constant torque range of 1,000:1 and a constant power range of 1.3 times the nominal speed of 1,800 or 3,600 rpm. For applications needing speeds outside of this range, WEG oers tailored versions. “The W80 AXgen is our rst motor of this type,” says Marek Lukaszczyk, WEG’s marketing manager for Europe and the Middle East. “With this launch, we are enabling OEMs to explore new possibilities, oering them a scalable, reliable and highly ecient motor solution for both today's challenges and future demands.” www.weg.net Compact axial- ux motor delivers e ciencies of up to 96.9% Drives-based platform will allow users to create custom applications ABB’s Crealizer platform will allow drives users to users to create customised control and analysis applications
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n TECHNOLOGY November/December 2024 www.drivesncontrols.com 18 SIEMENS SMART INFRASTRUCTURE HAS announced its rst fully electronic motor starter which, it says, oers short-circuit protection that is 1,000 times faster than conventional devices such as circuit breakers or fuses, and is almost wear-free. This ensures optimal protection for motors and their loads. The compact Simatic ET 200SP e-Starter requires minimal space in control cabinets, and is expected to be attractive to sectors such as food & beverage and intralogistics, where higheciency motors are used in demanding applications such as driving pumps and conveyors. Malfunctions and failures in these sectors can quickly lead to considerable damage and costs. The electronic starters will not only switch motors reliably, but also protect them against overloads and short circuits. The starters use SiC Mosfets (silicon carbide metal-oxide semiconductor eld-eect transistors) for ultra-fast, wear-free switching. Conventional feeders with short-circuit protection devices have relatively slow response times. When a short circuit occurs, they often need to be replaced. By contrast, the e-Starter detects short circuits extremely quickly and switches o in less than 4µs, making it around 1,000 times faster. It oers unlimited short-circuit shutdowns and does not need to be replaced after being tripped, increasing availability and cutting storage costs for replacement parts. High inrush currents are typical for higheciency motors and this can lead to unintended trips of protection devices. The phase-optimised switching and “Smart Start” capabilities of the new starter neutralise the inrush currents, reducing starting currents and therefore the electrical load on the grid during start-up. In addition, the torque surges that occur during a direct start are much smaller, reducing mechanical wear. “Our fully electronic e-Starter is a real innovation that oers many bene ts over traditional electromechanical or hybrid motor starters,” says Andreas Matthé, CEO of Electrical Products at Siemens Smart Infrastructure. “We developed it in close consultation with potential users. That is why it responds to their challenges exactly as needed. It makes demanding motors and applications more available, durable, and user-friendly than ever before. “Siemens is the rst manufacturer with a fully electronic starter that is completely integrated into ET 200SP and TIA Portal and speci cally addresses two challenges in the industrial sector – applications prone to short circuits, and high current peaks when starting high-eciency motors,” he adds.The e-starter will typically be used in areas where short circuits occur frequently. In the food industry, for example, the high-pressure liquids used to deep-clean conveyor systems can cause short circuits on worn cables between starters and conveyor motors, resulting in costly downtime. The new starter detects short-circuit currents extremely quickly and switches them o immediately, avoiding potentially damaging currents. Once the cause of the short circuit has been eliminated, the device ican be switched on again immediately. Procuring spare parts or replacing devices – as has previously often been needed after short circuits – is no longer required. www.siemens.com/global/en/products/ automation pBoston Dynamics and Toyota Research Institute (TRI) have formed a research partnership to accelerate the development of humanoid robots using TRI’s Large Behaviour Models (LBMs) and Boston Dynamics’ Atlas robots. TRI pioneered the application of generative AI to dexterous manipulation in robotics. The partnership will deploy Boston’s new electric Atlas in a variety of tasks and collect data on its performance. This will support the training of advanced LBMs. The joint teams will also conduct research on training of humanoid robots, and understanding human-robot interactions. www.bostondynamics.com http://tri.global pCambridge GaN Devices (CGD), the UK semiconductor company developing high-eciency GaN-based power devices, is partnering with the US connectivity specialist Qorvo to oer an evaluation kit (EVK) for motor control and power eciency applications. They are combining Qorvo’s PAC5556A 600V BLDC/PMSM motor controller/driver with CGD’s ICeGaN ICs in a board that they say improves motor control applications “signicantly”, achieving 400W peak performance without a heatsink. The kits oer precise control and high torque at low speeds for industrial and other applications. https://camgandevices.com p The world’s rst commercial manufacturing facility for rare-earth-free permanent magnets has opened in Minneapolis in the US. The 6,500m2Niron Magnetics plant is producing an alternative to the rare-earth magnets used in high-eciency motors. The Clean Earth magnets are made of iron and nitrogen – two abundant, safe and non-toxic materials that can be sourced sustainably in the US. The pilot facility has can produce more than 5 tonnes of magnets a year. Niron’s rst full-scale facility is due to open in 2026 and will produce 1,500 tonnes a year. pODVA has announced that the CIP Safety on EtherNet/IP technology now allows the use of Concurrent Connections for applications requiring high availability and functional safety. Concurrent Connections allow redundancy between multiple producing and consuming devices for critical processes. CIP Safety provides failsafe communications between nodes such as safety I/O blocks, interlock switches, light curtains and safety controllers up to SIL 3. pHoneywell and Google Cloud are collaborating to connect AI agents with assets, people and processes, to accelerate safer, autonomous industrial operations. The partnership brings together the multimodality and natural language capabilities of Gemini on Vertex AI (Google Cloud's AI platform) with the large data set on Honeywell’s Forge industrial IoT platform. Honeywell says it will cut maintenance costs, boost productivity and upskill employees. TECHNOLOGY BRIEFS Wear-free solid-state motor starter is ‘1,000 times faster’ Siemens’ new solid-state starter oers short-circuit protection 1,000 times faster than conventional technologies, cutting downtime and maintenance costs
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