Drives&Controls AUTOMATION FOR MANUFACTURING INSIDE Seamless automation, sustainability and digitalisation with Festo electric drives JUNE 2025 www.drivesncontrols.com COMMUNICATIONS AND SECURITY: How to protect your factory against cyberattacks MECHANICAL POWER TRANSMISSION: The pitfalls of shaft-mounted gearboxes – and how to avoid them SMART WAREHOUSES: Why Safety Ethernet networks are essential in intralogistics
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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 2025 NEXT ISSUE The July/August issue of Drives & Controls will contain our annual Buyer’s Guide – the industry “bible” for motion control and power transmission engineers, telling you who makes and sells what in the automation and allied sectors. We will also be looking at developments in the transportation sector, clean energy, and robotics and automated manufacturing. UPDATE 14 Comment 15 ABB Back to Basics 45 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 30 28 26 5 48 DRIVES & CONTROLS JUNE 2025 Vol 41 No 6 Editor Tony Sacks t: 01732 465367 e: tony@drives.co.uk Production Manager Sarah Blake t: 01233 770781 e: sarah.blake@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. 18 Technology Cutting-edge innovations in motion, power transmission, controls and related technologies. 26 UK Industry The UK manufacturing sector is at a pivotal moment. The world is changing, global politics are in flux, and economies are seeing seismic shifts. This unpredictability is an opportunity for a manufacturing renaissance, argues the interim CEO of the University of Sheffield’s Advanced Manufacturing Research Centre. 28 Automation Ethics The integration of AI with automation technologies could revolutionise how we work, manufacture and interact with our environment. Yet, as the boundaries of innovation expand, so too do the ethical and regulatory implications. An industry leader explores the ethical dilemmas and regulatory challenges posed by AI and automation. 30 Communications and Security A cybersecurity expert explains how industrial companies can protect their systems against the wave of cyberattacks that are targeting OT systems. Plus how an automotive supplier is using a gateway to perform tests on components at the end of its production lines. 36 Mechanical Power Transmission Advice on how to avoid some of the common mistakes made when installing shaft-mounted gearboxes. Plus an examination on the current state of play in the global market for industrial gearboxes and geared motors. And news of a project that aims to find ways to recycle highperformance industrial lubricants. 42 Smart Warehouses Traditional approaches to safety do not apply to smart warehouses. An expert explains why Ethernet safety networks are more agile, reduce wiring, improve diagnostics and simplify system integration. Plus advice on avoiding problems when implementing smart warehouse projects. 44 Smart Manufacturing Week June will see the industrial world converge at the Birmingham NEC, as Smart Manufacturing Week 2025, including the Drives & Controls exhibition, will explore the latest developments in drives and technology, IIoT, maintenance, AI and digital transformation. 43 Average net circulation January to December 2023 44 47 Subscribe for your FREE copy now 18,942 18
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NEWS n 5 Yasa’s £12m UK axial-flux motor factory is ‘world’s most advanced’ THE UK AXIAL-FLUX motor developer, Yasa, has opened a £12m manufacturing facility in Yarnton, near Oxford, with the capacity to produce more than 25,000 of its high-efficiency motors every year. The company claims that the 5,574m2 factory is the world’s most advanced axial-flux electric motor manufacturing facility. The operation brings all of Yasa’s production processes under one roof. It also creates a seamless manufacturing ecosystem, with enhanced automation and highly efficient production lines. The facility incorporates cutting-edge technologies including four coil and bar manufacturing cells with state-of-the-art CNC coil winding, assembly and impregnation processes. Other processes performed at the site include: automated laser stripping and brazing; high-accuracy rotor balancing; laser-based stator welding; quality control; and dimensional, electrical and leak testing. Yasa says the plant will enhance its ability to create complete motor sets while improving repeatability and reliability and introducing greater flexibility by overcoming bottlenecks in the component supply chain. “With a multi-million-pound investment into our Yarnton facility, we have transformed our manufacturing capability and significantly accelerated our production capacity,” says Yasa’s founder and chief technology officer, Tim Woolmer. “This latest initiative will enable us to apply our technology with even greater accuracy, pace and scale. “Combined with Yasa’s position as part of the Mercedes-Benz Group, the factory transformation consolidates Yasa’s role as a global leader in developing high-performance, high-efficiency axial-flux e-motors. “As a company, we have come a long way since our humble origin as an Oxford University start-up,” www.drivesncontrols.com June 2025 Woolmer adds. “However, we are still driven by the same passion, spirit and determination to create the world’s most advanced electric mobility technology solutions.” Yasa was acquired by Mercedes-Benz in 2021. Mercedes is also producing Yasa-designed axial-flux motors in Berlin and is expected to start using them in some of its high-performance cars soon. The axial-flux motors are said to deliver up to four times better performance than the radial-flux motors currently used in most vehicles. The compact motors produce high levels of torque and power, and can be used in pure electric or hybrid vehicles. “Each of the numerous technical manufacturing advances we have implemented during the factory transformation consolidates Yasa’s ability to outpace and outperform all existing radial flux technology by delivering more compact, lightweight electric propulsion systems,” says the company’s commercial director, Andy North. “Yasa is now better placed to meet the needs of our OEM customers, such as Ferrari and Lamborghini, and new customers on a global scale than ever before.” The high-tech expansion at Yarnton has been funded privately. Yasa is continuing to work closely with the UK’s Advanced Propulsion Centre (APC), which helped with to develop its original facility, and will collaborate with the APC on future generations of its axial-flux technology, ensuring that cutting-edge motor innovation remains in the UK for years to come. Yasa’s new facility has the capacity to produce more than 25,000 axial-flux motors every year “Yasa is now better placed to meet the needs of our OEM customers, such as Ferrari and Lamborghini, and new customers on a global scale than ever before” THE LOGISTICS GIANT DHL has agreed to buy more than 1,000 of Boston Dynamics’ Stretch box-handling robots for use in its facilities around the world. The companies have signed a strategic Memorandum of Understanding under which DHL will also take an active role in shaping, directing and testing robotics developments at BD. DHL has been using Strech robots in North America since 2023, and more recently in the UK and Europe. The robots have achieved unloading rates of up to 700 cases per hour and reduced the need for demanding work in trailers and containers. Looking ahead, DHL plans to use the robots for case-picking – its most labourintensive activity – thus extending the use of the wheeled Stretch robots beyond container loading and unloading . Boston Dynamics and DHL plan to jointly develop, test, and scale technologies for real-time operations. They have already developed end-to-end automation systems that integrate conveyors and palletisers, and demonstrated this in a project in the UK. Over the past three years, DHL has invested more than €1bn in automation for its contract logistics division. Globally, it now uses more than 7,500 robots, more than 200,000 smart handheld devices, and almost 800,000 IoT sensors to optimise its operations and enhance working conditions for its employees. DHL plans to buy more than 1,000 box-handling robots
n NEWS June 2025 www.drivesncontrols.com 6 THE UK’S £37.6m Digital Twin Centre has opened in Belfast, with the aim of driving the next wave of industrial transformation by accelerating the adoption of digital twin technologies across critical UK sectors, potentially delivering 230 new jobs and £62m in GVA for the Northern Ireland economy over the coming decade. The Centre will help businesses across the UK to demonstrate and deploy digital twins. It brings together capabilities in six areas – intelligence, data services, immersive end-user experiences, cyberphysical systems, integration and security – to make the emerging technology more accessible and interoperable across sectors and suppliers. The Centre is funded by the £850m Belfast Region City Deal and Innovate UK, and delivered by the Digital Catapult. There are three co-investing industrial partners: Artemis Technologies, Spirit AeroSystems and Thales UK. Since the project was announced last year, the Digital Catapult has brought industry and other interested parties together to identify barriers to adopting digital twins and possible strategic interventions. At the Centre’s opening, the industrial partners used its facilities – including a 360degree immersive space and an advanced technology lab – to demonstrate how digital twins can solve complex challenges. The earlystage use cases emphasise how cross-sector collaboration can help to create scalable, practical systems, while building expertise that can be shared across industries, ultimately improving product design, building supply chain resilience, and decarbonising industrial operations. The Centre’s first six-month accelerator programme will support partnerships between technology SMEs and industry to fast-track digital twin adoption in the maritime, aerospace and defence sectors. As well as funding from Innovate UK, participants will also receive mentorship, workshops and support to develop proofs-of-concept for technologies such as IoT, data integration, and simulation tools, bringing their systems closer to real-world deployment. SMEs and others interested in taking part in the accelerator programme can apply online at https://digicat.org.uk/UK-Digital-Twin-Centre “The UK Digital Twin Centre brings together our technical expertise, facilities and networks to unlock the power of deep technologies,” says Digital Catapult CEO, Susan Bowen. “By connecting industries with cutting-edge technology through our programmes, we are enabling businesses to harness the full potential of digital twins – driving operational efficiencies, advancing sustainability, and sharpening the competitive edge of UK businesses.” www.digicatapult.org.uk UK’s £37m Digital Twin Centre opens to drive digitalisation p More than 200 companies have registered for the £1.55m Government-backed Made Smarter South East programme which will help manufacturing and engineering SMEs in the region to adopt cutting-edge manufacturing technologies. It will offer advice, training, student placements, and match-funded grants of up to £20,000 to help improve productivity, competitiveness and sustainability. The programme is being delivered by Surrey County Council in partnership with 11 local authorities and LEPs. The programme is open to SMEs with fewer than 250 employees and an annual turnover of less than £44m. https://bit.ly/MadeSmarterSouthEast p ABB has been chosen by the energy company Eni to be the main automation contractor for the HyNet project which will transport CO2 emitted by industrial plants in the North West of England and North Wales for storage in four depleted gas fields in the Irish Sea. The project aims to cut CO2 emissions by 10 million tonnes a year by 2030 – a quarter of the CO2 emitted in the region. ABB’s Ability 800xA control and safety system will manage the project’s automation, comms and cybersecurity. p The Italian automation and robotics company, Comau, is buying another Italian business, the warehousing and intralogistics automation specialist Automha, from its owner Trasma, for an undisclosed sum. The deal will open up new opportunities in the expanding warehousing and logistics sector. Comau hopes that synergies will help to create an Italian automation hub that competes globally. p The Japanese-headquartered bearings and linear motion company, NSK, is combining its industrial and automotive operations in Europe in a move designed to improve its efficiency and enable collaboration between functions including manufacturing, engineering and sales. Matthieu Lavieuville has been appointed chief operating officer to oversee the merger. p Mitsubishi Electric has bought the Irish elevator company, Ascension Lifts, via its Swedish subsidiary, Motum. The move is part of an expansion of Mitsubishi’s activities in elevator maintenance and renewal, with demand for these services expected to grow against the backdrop of ageing elevators and escalators, and heightened environmental awareness. p The global market for industrial controls was worth $157.3bn in 2024, and will reach $321.6bn by 2034 – a CAGR of 7.6% from 2025 to 2034 – according to a new report from Allied Market Research. The survey covers PLCs, DCSs, Scada systems, industrial Ethernet, power supplies and other technologies. DCSs accounted for more than 40% of the market in 2024 and are expected to retain this dominance. www.alliedmarketresearch.com NEWS BRIEFS The UK Digital Twin Centre will allow industry and innovators to embrace, explore and realise the power of digital twins. For more News visit www.drivesncontrols.com
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n NEWS OMRON HAS CREATED a dedicated robotics organisation in Europe that will operate alongside its automation business. It says that the strategic step reflects its commitment to robotics as an essential pillar of its end-to-end automation offering. The organisation will ensure quick decision-making and strengthen Omron’s specialised expertise. The operation will consist of dedicated teams of sales, application and services engineers. They will operate at both regional and country levels, and will work closely with Omron’s global robotics business. The new set-up will allow Omron to respond faster to customer needs. The new organisation also strengthens ties with Omron’s global R&D and robotics teams, as well as its new European R&D team. “Robotics plays a vital role in our vision for the future of automation,” says Fernando Colás, CEO of Omron’s Industrial Automation business in the EMEA region. “This investment reflects our strong focus on building expertise, quality of service, and helping our customers stay competitive. We are putting the optimal structure in place to ensure continued excellence in innovation and customer satisfaction.” “I’m excited to kick off this new initiative, which is all about helping our customers get the most out of their robotics investments,” adds Vincent Nabat, general manager of Omron Robotics EMEA. “With a dedicated robotics organisation, we’ll be able to respond faster to local needs, offer more direct access to technical expertise, and collaborate even more closely with our customers on co-development projects with fixed, mobile and collaborative robots.” The robotics organisation is part of an investment by Omron in Europe that includes its Automation and Robotics Centres of Excellence in France, Spain and Germany, and a recently opened Automation Centre in Stuttgart, as well as it network of Proof of Concept (PoC) laboratories. https://industrial.omron.eu/en/products/robotics Omron sets up dedicated robotics organisation Omron’s robotics portfolio includes Scara and Delta models, as well as AMRs (autonomous mobile robots) June 2025 www.drivesncontrols.com 8 OMRON HAS LAUNCHED a compact inverter for low-end applications where space, reliability and price are key factors. The J1 inverter provides essential motor control capabilities and is particularly suitable for applications such as conveyors, mixers, small fans, pumps and material-handling systems. Despite its compact size and accessible price point, Omron says that the J1 delivers functions typical of higher-tier models. It controls single-phase 220V motors from 0.4– 2.2kW, and three-phase 400V motors from 0.4– 3.7kW. It offers V/f control, dynamic torque vector control, PID control and overload protection. It also supports automatic deceleration, a sleep mode for pump and fan applications, and slip compensation to ensure stable torque, even at low speeds. The inverter has a max output frequency of 400Hz, and an overload capability of 150% of the rated output current for one minute. A compact IP20 housing allows side-by-side mounting to save cabinet space. Communications are handled by Modbus RS485, and the J1 includes both digital and analogue I/O (0-10V DC and 0-20mA). The J1 can be programmed using Omron’s Sysmac Studio software, or a new, free configuration tool called J1 Editor. https://industrial.omron.eu/en/products/j1 Small drive focuses on price and performance EVENTS CWIEME Berlin 2025 Berlin, Germany 3-5 June, 2025 The exhibition for the coil winding, electric motor, transformer and generator industries, returns to its Berlin venue and is expected to attract more than 550 exhibitors and around 6,500 visitors. Last year’s Start-Up Zone brought together fledgling companies and their latest technologies. This year’s Innovation Zone will expand on this and provide a platform for cuttingedge technologies, including AI and machine learning, predictive maintenance and monitoring, IoTenabled tools, smart sensors and data analytics. https://berlin.cwiemeevents.com/home 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 2025 OT Cybersecurity Summit 17-19 June, 2025 Brussels, Belgium This event, organised by ISA, will focus on strategic OT (operational technology) cybersecurity based on the ISA/IEC 63443 standards. It will include various technical tracks, training courses as well as a cyberescape room. https://otcs.isa.org Automatica 2025 24–27 June, 2025 Munich, Germany The smart automation and robotics show will be bigger than in 2023, with more than 500 exhibitors from more than 30 countries expected, a third of whom will be exhibiting for the first time. There will be more exhibitors from China than ever before. For the first time, there will be a pavilion devoted to laboratory automation and clinical robotics. https://automatica-munich.com SPS 2025 25-27 November, 2025 Nuremberg, Germany The SPS (Smart Production Solutions) automation show returns to its traditional late November slot following several years of taking place earlier in the month. Last year, the event attracted 51,291 visitors and 1,114 exhibitors. The organisers are expecting an increase in UK visitors this year, pointing out that many of the exhibitors are multinationals that are already active in the UK. https://sps.mesago.com/nuernberg/en
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n NEWS June 2025 www.drivesncontrols.com 10 THE WELSH DRIVES-MAKER Invertek Drives has been awarded a 2025 King's Award for International Trade, in recognition of its continuous growth in overseas sales. Exports account for 95% of the company’s sales and grew by 149% over a six-year period, despite challenges such as Covid, Brexit and electronics supply chain disruptions. Invertek, owned since 2019 by Sumitomo Heavy Industries, has doubled the workforce at its Welshpool, Powys headquarters to 420 since 2018. Invertek CEO Adrian Ellam says that the King’s Award “validates our international business strategy and commitment to creating innovative, energy-efficient solutions for global markets. Our VFDs play a crucial role in helping industries worldwide to reduce energy consumption, optimise processes, and minimise environmental impact – all increasingly important as businesses focus on sustainability and operational efficiency.” Other winners of 2025 King’s Awards for International Trade include: n Createc, a Cumbrian R&D business working on sensor technologies, robotics and AI; n Datum Electronics, a manufacturer of sustainable torque and shaft power sensors, based on the Isle of Wight; n FB Chain, located in Hertfordshire, which supplies leaf and conveyor chains; n Antrim-based InspecVision, which manufactures 2D and 3D measurement systems for inspecting components; n Lund Halsey Console Systems; which manufactures control room systems; n Worcestershire-based Seada Technology, which also supplies advanced control room technologies; and n Somerset-based Wittenstein High Integrity Solutions, which provides RTOS (real-time operating system) and related services, and specialises in safety-certified software. King’s Awards for Sustainable Development have gone to the Yorkshirebased seals manufacturer AES Engineering, and the Leicestershire producer of LV switchgear and control panels, Michael Smith Switchgear, which halved its emissions in five years, while achieving a 64% growth in revenues. Inductosense, A Bristol-based business that develops battery-free wireless sensors for non-invasive monitoring of corrosion in industrial equipment, has received a 2025 King’s Award for Innovation. Invertek Drives wins 2025 King’s Award for trade with a 149% spurt SCHNEIDER ELECTRIC has developed an industrial Copilot with Microsoft with the aim of boosting productivity and enhancing efficiency. The generative AIpowered assistant will simplify application development, speed coding, help users to collaborate, improve efficiency and cut time-to-market. The Copilot integrates Microsoft’s Azure AI Foundry with Schneider’s industrial automation portfolio. It builds on Schneider’s expertise in open, software-defined automation. The Copilot will be available as part of Schneider’s EcoStruxure Automation Expert Platform. This integrates hardware and software, enhancing collaboration between Copilots, operators and engineers by providing access to realtime data which it uses to generate accurate recommendations, predictive maintenance and troubleshooting. “We are at a pivotal moment where industry must achieve unprecedented levels of flexibility and efficiency with generative AI,” says Aurelien LeSant, Schneider’s chief technology officer for industrial automation. “Our Copilot, developed in collaboration with Microsoft and leveraging our deep domain expertise, is designed to improve industrial competitiveness by boosting worker confidence, simplifying processes and bridging skills gaps.” It “proactively assists engineers in adding complex functionalities, such as new production lines, with simple steps by pre-generating code, checking for errors, and improving the re-use of existing libraries,” LeSant adds. “It allows engineers and operators to leverage Schneider Electric's industrial datasets to bring systems online faster and optimise them for long-term success.” Invertek CEO Adrian Ellam: the Award validates our international strategy Schneider and Microsoft develop gen AI Copilot to lift productivity SEW-Eurodrive has promoted Andy Turner to UK operations director after 17 years with the company. Turner joined the company in 2008 as an area sales manager before becoming sales and marketing manager in 2021, and sales and operations manager the following year. In his new role, Turner will oversee the sales and production teams at the company’s Normanton HQ, working with MD, John Pickup, to drive the company forward. Apex Dynamics UK has appointed Andrew Parsons as general manager, promoting him from national sales manager after six years at the gearbox specialist. In his new role, Parsons takes on a broader role, overseeing Apex’s daily operations and its growth plans. His appointment comes at a pivotal moment, following Apex’s 20% growth in 2024, and its recent move to larger premises to meet growing demand for its portfolio of more than 50,000 gear products.
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NEWS n THE AEMT (Association of Electrical and Mechanical Trades) has introduced its first Codes of Practice, intended to support its members in delivering a high-quality service, while reassuring customers that the members maintain and repair electromechanical equipment to the highest standards. The codes, which come into effect in late 2025, set out standards that the AEMT’s members are expected to meet in areas such as quality, expertise, integrity, sustainability, stability and safety. The aim is to set a benchmark for the industry to work against, providing trust and a mark of quality. Any members that do not currently meet the standards will be classified as “working towards” and will be able to access resources and support from the AEMT to help them comply. Members who meet the standards can self-assess their organisations as being “compliant”. On-site assessment will be required for members to gain a “verified” status. The AEMT will carry out spot check visits to ensure that standards are being maintained. “We are delighted to have formed our Codes of Practice as a key milestone in our 80th year, and I'm extremely grateful for all the effort that our members and team have put into their creation,” says the AEMT's general manager and secretary, Thomas Marks. “I believe this demonstrates that the Association and its members are aligned in the quest to deliver exceptional services wherever possible. I also believe it will give our members confidence in knowing they are running their businesses to the highest standards, and that support is there from the AEMT with any areas they are looking to develop. The AEMT, established in 1945, is an international association representing companies that manufacture, distribute, install, service, maintain, and repair, electric motors, drives, pumps, fans, gearboxes, generators, transformers, switchgear, and ancillary equipment. The new Codes of Practice can be downloaded from the AEMT’s Web site. www.theaemt.com AEMT’s new codes of practice aim to set a benchmark for electromechanical services Marks: new codes will reassure customers that an AEMT member is a sound choice
TACKLING THE CYBER CRIMEWAVE The well-publicised ransomware attacks on Marks & Spencer and the Co-op have emphasised how vulnerable organisations of any size are to determined cyberattackers. While the attacks on retailers may have generated a lot of publicity, manufacturing remains the sector that has been the most targeted by cybercriminals in recent years. According to a new analysis by the IT consultancy, IDS-Indata, an alarming 42% of UK manufacturers were affected by ransomware attacks in 2024 – up from 34% in 2023. The figures reveal that cyberattacks of all types are rising, with “spearfishing” (the most common form of attack) affecting 88% of manufacturers in 2024 (up from 84% the previous year). Reports of malware attacks on manufacturers rose from 45% in 2023, to 50% last year. According to the analysis, the fastest-growing mode of attack comes via third-party suppliers and vendors (the route reportedly taken by M&S’s attackers). In 2023, supply chain attacks affected just 20% of manufacturers. By last year, that figure had risen to 30%. The interconnected nature of supply chains creates cascading vulnerabilities, according to IDS-Indata. What’s more, some cybercriminals are now using AI tools to automate the identification of weak points, accelerating the pace of attacks. The growing use of AI is one of the most worrying aspects of the cyber crimewave. In ransomware attacks, for example, cybercriminals are using AI to create malware that can adapt itself in real time to avoid detection. AI is also being used to create deepfakes and automated scams for phishing and impersonation attacks. Cybercriminals can create highly personalised attacks that exploit human error – one of the weakest links in manufacturing cybersecurity. In spearphishing attacks, for example, AI can help cybercriminals to customise emails for specific individuals, using personal information obtained from public sources. Many manufacturers are particularly vulnerable to cyberattacks because their OT (operational technology) systems are integrated with IT networks, with unmanaged or legacy systems acting as weak links that offer entry points to sophisticated AI-powered cyberattackers. According to IDS-Indata, hackers are exploiting these gaps in security with alarming speed, using AI to automate and adapt their tactics. So, what – if anything – can be done to thwart these attacks? The risk will never be eliminated entirely, especially when ransomware attacks, in particular, are so potentially lucrative. Also, cybercriminals are continually innovating, as can be seen by their increasing adoption of AI and other advanced technologies. Finally, they only need to find one vulnerability to worm their way into a system. The usual advice applies about keeping your systems separated from the Internet (as far as possible) and ensuring that security patches are up-todate. Consulting with cybersecurity experts might reveal potential vulnerabilities that you are not aware of. If your system proves too challenging for hackers to penetrate, they might move on to easier targets. Tony Sacks, Editor n COMMENT Follow us on LinkedIn @Drives & Controls Follow us X Drives&C Controls & rives Join us Facebo Drives & C on X @Drivesn Forthe D on ok Controls Controls latest news visit Controls the Driv www.driv ves & Controls we vesncontrols.com
Drives&Controls & BACK TO BASICS n SPONSORED BY Has the ‘everything protocol’ finally arrived? Proprietary standards and competing communications protocols have created an ecosystem where integrating different automation technologies is not always as easy as it might be. However, with the emergence of OPC UA, that might be about to change, argues ABB’s Industrial Automation product manager, Carl Eely. Everyone wants more data about their plant operations. The more data you have, the more you can analyse and optimise. IoT devices are everywhere, and are only going to become more ubiquitous in the future. Meanwhile, advances in cloud computing are opening up almost limitless opportunities to leverage data across plant operations. However, building such an architecture can present obstacles, particularly with the vast array of different communications protocols that each device, or group of devices, uses. Even if your field devices can talk to each other, they may not be able to communicate seamlessly up the hierarchy to PLCs, Scada systems and beyond. This could be about to change with the emergence of OPC Unified Architecture (OPC UA). This communication protocol for industrial automation is designed specifically to be cross-platform and opensource, allowing integration from field-level devices, all the way up to cloud applications. This brings some significant advantages. Not only can devices using OPC UA talk to each other at a local level, but they can also communicate all the way up and down the chain using the same protocol. In practice, this enables more reliable control networks, and allows secure data collection from multiple systems at the same time. Consider, for example, a system where you have a robot with a PLC sitting above it, a Scada system above that, a Manufacturing Execution System (MES), an Enterprise Resource Planning (ERP) system, and then up to the cloud. Previously you might have needed different protocols all the way up the chain, but with OPC UA you just need the one protocol. Of course, there is still a place for other protocols, especially in point-to-point communications, but anything that makes adoption of automation easier generally has to be a good thing. Crucially, OPC UA has widespread industry support. At ABB, we include it as standard in our PLCs, and plenty of other vendors do so too. OPC UA is not the first attempt to unify under a single standard, but it is the most widely adopted of any to date. This has been the holy grail of automation products for years – moving away from proprietary protocols and needing to buy additional protocols for every point-to-point, towards a single unifying architecture. OPC UA also includes certificate-based encryption, which can provide more robust security compared to patching several different protocols together. For more information, search for “ABB OPC UA”. applicat for ov reliable Super r f rmo tions ving cables online stock, p huge UK pricing K tions,
Seamless automation, sustainability and digitalisation with Festo electric drives Whether to use a stepper or a servo drive can be a tricky decision for machine builders and design engineers. The high dynamics and controllability of servo control loops are useful in many automation applications. On the other hand, there are times when the pulse, lock, stay and cost characteristics of a stepper are the better choice. The development of a new range of extra-low voltage servo drives means that this dilemma is now easily solved. Innovation in stepper motor technology means the gap between stepper and servo technology is narrowing. In applications where the performance of a servo motor is not required, the stepper (with its choice of battery-less encoders and motor brakes) offers closed loop positioning performance and is particularly suited where high dynamic loads or speed demands aren’t required. These new devices are described as ‘extra-low’ voltage because they work at 24 or 48V DC offering open or closed loop positioning, they effectively bridge the gap between stepper and servo drives. Several new features distinguish this new generation of controllers from previous drives on the market to offer multiple benefits for users. Today, the humble stepper can offer surprising cost effectiveness with uncompromised performance at Automation lines and machinery are an amazing feat of integration of components and sub-systems from a vast range of suppliers. They meet ever increasing demands for lower cost, higher performance, sustainability and provide the capability of being incorporated within digital factories. Festo is making this task faster, easier and cheaper by focusing on Performance, Seamless Automation, Digitalisation and Sustainability. Ben Lloyd, Festo Electric Automation Product Manager looks at the latest developments. Highlighting the benefits with the CMMT-ST extra low voltage servo drive extra low voltage. The CMMT-ST servo drive maybe the smallest of the Festo electric drives range at just 27mm wide and only needing a 24 or 48V DC power supply, but it epitomises the approach of increased performance, seamless automation, sustainability and digitalisation. Higher performance Significant performance improvements have been achieved because the new servo drives are equipped with a microcontroller, which is three times more powerful than previous models. This delivers a number of performance enhancements, including: multi-protocol fieldbus compatibility, field weakening, energy management, auto-tuning, and U/f open loop control. Field weakening enables the connected motors to achieve higher maximum speeds or torques. For example, at low torques the maximum speed increases from 1,600 to 2,300 rpm – an increase of 44%. This presents the opportunity to select a smaller, lower cost motor to perform the same task. The CMMT-ST also features an integrated web server, an advanced feature for a low-cost device. This enables the easy transfer of data to and from the servo drive for fast, simple set-up, diagnostics, and file transfers. In addition, safety functions such as Safe Torque Off and Safe Stop 1 are also catered for. Seamless Automation Seamless Automation means that throughout the machine life cycle the CMMT-ST is easier, faster and cheaper to use. In the design phase simple software tools enable it to be quickly and easily selected, designed and documented. Festo online selection and configuration tools, such as the Electric Motion Sizing Tool, mean that specifiers can select the right drive package quickly and reliably. Faster and easier commissioning is also possible using Festo’s Automation Suite (FAS) software. In build, the drives connect seamlessly from set-up to commissioning – to the controls and software world ‘above’ and has a perfectly matched range of motors, mechanics and sensors ‘below’. The CMMT-ST range incorporates (just like its larger family members) multi-protocol connectivity. The new servo drives have the integral capability to communicate instantly to more than 75% of major fieldbus systems (including PROFINET, EtherCAT, EtherNet IP, and Modbus), either through simple DIP switch settings, software setup, or auto-recognition.
Contact Festo Ltd www.festo.co.uk Tel: 0800 626 422 Email: info.gb@festo.com Starter Kit Offer Festo offers a starter kit for only £390 containing a CMMT-ST controller with multi-protocol function, an EMMT-ST stepper motor and matching motor/encoder cables with OCP technology as well as application support. It can be used to develop solutions for individual automation tasks and to test possible applications. The kit is easy to use and intuitive to install with the Festo Automation Suite software and provides the full range of functions. Also included is an hour of remote support from Festo’s expert applications team to give you a head start. Energy and cost reduction The drive is capable of automatically detecting the fieldbus comms from the attached PLC or controller, recognising and initiating communications. This eliminates the need for any changes to electrical designs, cabinet layout, or wiring when swapping between control architectures – this saves time and reduces costs for special purpose machine builders adapting to enduser specifications. With fewer stocked or service parts required, and fewer parts for installers and service technicians to become familiar with, these devices streamline BoM and reduce training requirements. Supporting sustainability goals The CMMT-ST controller features energy management functions that can make the most ordinary positioning system more sustainable. Connectivity for braking resistors enables efficient energy management, soaking up the energy spikes and increasing the drive’s peak performance characteristics. A further useful energy saving option is to use the DC link, sharing energy peaks between different drives within a system. This dissipates heat, reduces peak energy demand and can allow smaller power supplies to be selected. Extra-low voltage servo drives are very mechanically efficient, featuring advanced electronics within a robust enclosure with good EMC protection. Digitalisation Festo is a leading player in the digitalisation of factory automation. It has grouped its digital product portfolio under the Festo AX (Automation Experience) banner. For example Festo provides standardised digital twins according to the AAS (Asset Administration Shell) for easy gathering and exchange of machine-readable data for more than 19,000 components including the CMMT-ST range. There is also the possibility to implement predictive maintenance functions from integrated estimation of the total mass and friction in the drive train without any additional sensors. Aggregating this data internally allows resource efficient calculations. The Festo AX Motion Insights is a further enhancement applying machine learning algorithms in docker based apps that can be easily implemented in a few minutes, at a truly minimal cost within the standard PLC program function block program. The recently launched Festo AX Controls automation hardware platform further enables users to pick-and-mix their apps based software to suit their application, experience and preferences. Utilising open standards such as the PLCnext platform and in the future the Nexeed platform, users have the power to choose and always remain open to future trends. Conclusion Recent developments in the Festo CMMT servo drives range are offering improved performance at lower cost. The smallest, the CMMT-ST, bridges between servo and stepper technology offering a high performance closed loop control drive option. Its easy integration into the control and mechanical worlds also saves time and cost savings. To experience the advantages of the CMMT-ST see the special Starter Kit offer, complete with free online set-up support. Festo AX Automation Platform Drives perfectly partner with EMMB “basic” or EMMT “technical” motor series
n TECHNOLOGY June 2025 www.drivesncontrols.com 18 FANUC AND THE 3D machine vision specialist Inbolt have announced a “manufacturing breakthrough” that allows robots to tackle one of the most complex challenges in industrial automation: performing tasks on parts as they move along a production line at speed. It will allow manufacturers to automate precision tasks such as inserting screws, applying glue and tightening bolts on parts as they move along lines, without costly investments in infrastructure or having to compromise cycle times. Until now, automating moving lines was considered almost impossible, requiring massive infrastructure upgrades, expensive fixtures and constant maintenance. The new development allows Fanuc robots, including its CRX models, to work with real-time 3D vision and adaptive trajectory correction, even if parts vary in shape or size, or if the environment is imperfect. The system is claimed to operate up to 100 times faster than conventional techniques, and is designed to work in a variety of production scenarios, such as systems integrators wanting quick and easy installations, or manufacturers concerned about line throughputs. The developers say that the technology will lower the barriers to high-performance automation by eliminating the need for specialised lighting or custom jigs, making it easier to deploy robots in complex, real-world environments. A single robot can now handle more than 100 part models with real-time accuracy, even on continuously moving lines. General Motors is the first manufacturer to adopt the technology which is aimed, in particular, at automotive companies. “This new collaboration between Inbolt and Fanuc gives car manufacturers a new level of automation – precision tasks, performed by robots, on lines that never stop,” says Inbolt CEO, Rudy Cohen. “No more expensive indexing. No more undue complexity and maintenance challenges. Just robots operating in a continuous motion environment and a huge leap forward for automakers’ general assembly shops.” The technology combines Fanuc’s streaming motion capabilities, which enable realtime trajectory inputs via Ethernet, with Inbolt’s lightweight, robot-mounted vision system and ultra-fast AI model. It offers: n Real-time 3D guidance Inbolt’s proprietary localisation AI refreshes at a high rate, identifying object orientations continuously and adapting robot paths on-the-fly, allowing tasks such as highspeed screwdriving and part insertion to be performed without indexing n Flexible deployment The system does not take up much space and does not need fencing. The technology supports tasks such as bolt rundown, screw insertion and filter installation, that are challenging for traditional robotics. It handles real-world constraints such as crowded stations, variable parts, limited floor space, and moving lines with variable parts positions. “Our primary goal is to reduce the complexity of automation,” says Inbolt’s chief operating officer, Albane Dersy. “With Inbolt’s guidance system and Fanuc’s native motion control, robots can now think and act on-the-fly.” The new system is deployed using the Inbolt Studio software that allows users to import CAD files, train the AI model, validate tracking in real time, and launch a program on a line. The technology is available now for Fanuc’s CRX robots and for others that use Stream Motion. Leading manufacturers that already use Inbolt’s vision technologies include Stellantis, Ford, Whirlpool, ThyssenKrupp Automotive and Toyota. www.inbolt.com www.fanucamerica.com ELMO MOTION CONTROL, the Israeli controls developer owned by Bosch Rexroth, has announced a next-generation multi-axis motion controller that, it says, redefines motion control, achieving an “industry-leading” 100μs EtherCat cycle time for 16 axes. The Titanium Maestro controller is suitable for applications with up to 256 axes. It offers real-time EtherCat communications and has been designed to meet the demands of machine-builders requiring high performance, speed, accuracy and robustness. A quad-core 1.9GHz CPU, with dedicated cores for real-time tasks, powers the fanless, passively cooled controller. With graphical capabilities, C++ and Python programming, and realtime programming support, the controller “stands in a league of its own”, according to Elmo. “Software in the loop” support further streamlines development and accelerates validation of complex automation systems. www.elmomc.com/product/titanium-maestro Next-gen motion controller delivers 100μs EtherCat cycle times for 16 axes ‘Breakthrough’ allows robots to work on items moving on production lines Inbolt and Fanuc claim that their technology can automate “previously impossible” tasks, working on items as they move along production lines.
UNPARALLELED COMPACTNESS could reduce footprint by up to two sizes. MAX TC EVEN AT HIGH SPEED can perform in formerly unreachable operating points. CONTINUOUS TORQUE up to 120% higher than previous generation. ETEL is 100% dedicated to direct drive technology. Our wide range of linear and torque motors, position and motion controllers and high-end motion system products provides a portfolio to meet your needs. www.etel.ch Get an edge with the best torque motor in the market ETEL Torque Motors are distributed in the UK by HEIDENHAIN GB Limited • T: 01444 247711 • sales@heidenhain.co.uk Lamonde Automation Limited Quality Products: Expert Advice sales@lamonde.com | www.lamonde.com | +44 (0)20 3026 2670 4, 5 & 8 Industrial Ethernet Switches Din Rail & Surface Mounting Options Rugged Aluminium Housing PoE Devices Available Plug & Play half_A4_hor_dandc_jun25_teltonika_switches.pdf 1 15/05/2025 16:28:43
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