Drives&Controls Individual product transport Free system layout 6D motion Scalable payload kg Levitating planar movers Velocities up to 2 m/s INSIDE FEATURING: DRIVES & CONTROLS 2025/2026 ANNUAL BUYER’S GUIDE ROBOTICS & AUTOMATED MANUFACTURING: Next-gen switches roll off automated assembly lines TRANSPORT: AC drives take to the high seas to propel a variety of vessels CLEAN ENERGY: Record-breaking tidal turbine sets stage for commercialisation AUTOMATION FOR MANUFACTURING JULY/AUGUST 2025 www.drivesncontrols.com
a highly flexible control cabinet-free automation solution robust, water- and dust-proof design (IP67 protection rating) plug-and-play with pluggable function modules for IPC, coupler, I/O, drive, relay and system standardized connectors for transmission of data and power EtherCAT communication tried-and-tested connector for the field level reduces engineering work high time and cost savings integrated diagnostic functions A pluggable system solution for control cabinet-free automation: The MX-System | MX11-01E | Find out about the world of control-cabinet free automation! 2023
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 September issue of Drives & Controls will contain a special section on energy efficiency, as well as a feature covering developments in the food and beverage industry, and a look at what’s been happening in the world of service, maintenance and repairs. UPDATE 14 Comment 15 ABB Back to Basics 56 Gambica column 58 New Products 62 Design Data and Multimedia 185 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 DfA media group 44 40 34 30 12 62 DRIVES & CONTROLS JULY/AUG 2025 Vol 41 No 7 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. 30 Safety and Security Developments such AI and the rise of cybercrime are challenging established concepts of machine safety. An industry leader examines some of these issues and how they are being tackled. He believes an international approach will be needed. 32 Robotics and Automated Manufacturing Examples of industrial automation and robotics in practice, ranging from assembling low-voltage switches to welding wood-burning stoves. Plus a look at how AI is transforming packing and palletising, and a report on a global survey of attitudes to smart manufacturing. 40 Corrosion Corrosion is often overlooked as a failure risk for industrial drives. Traditional corrosion standards can fall short when applied to drives. An industry expert describes a new test method that helps to predict drive lifetimes in harsh environments 42 Transport A novel electric propulsion and steering system for ships delivers higher efficiencies than traditional systems, thus cutting the use of fuel as well as emissions. Plus a look at how VSDs are increasingly being used to propel vessels ranging from navel corvettes to ferries and tugboats. 48 Clean Energy A subsea tidal flow turbine operating off Scotland since 2018 has demonstrated the long-term viability of the technology. It could lead to commercial arrays producing power at competitive costs. Plus reports on two large heat pump schemes, and a hydro plant in the Peak District. 54 Skills Tackling the shortage of suitable skilled personnel is a perennial problem for UK industry. Based on many years of experience, a UK operations director offers suggestions on how UK manufacturers cn combat recruitment challenges. 50 Average net circulation January to December 2024 54 60 Subscribe for your FREE copy now 20,514 18 63 ANNUAL BUYER’S GUIDE This issue contains the 2025/2026 edition of the industry “bible” for power transmission, automation and motion engineers, telling you who sells what and how to get in touch with them.
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NEWS n 5 Industrial Strategy: Made Smarter scheme will help 5,500 more SMEs Around 5,500 SME manufacturers in England will be helped to adopt advanced industrial technologies as part of the government’s long-awaited Industrial Strategy, which was published in June. The 160-page main document lays out a raft of measures aimed at making Britain the best place to invest in, and grow a business. The Strategy sets out a ten-year plan to boost investment and create good skilled jobs in UK industry. It focuses on eight sectors where the UK is already strong and could grow even faster, including advanced manufacturing and digital technologies. Highlights of the plan include: n investing an extra £1.2bn each year in skills by 2028-29, delivering more opportunities to learn and earn in highgrowth sectors, including new short skills courses funded by the Growth and Skills Levy, and skills packages targeted at defence digital and engineering; n supporting 1.1 million new well-paid jobs over the next decade; n slashing the electricity bills of more than 7,000 energy-intensive British businesses by up to 25% from 2027; n unlocking billions in finance for innovative business, especially SMEs, by increasing the British Business Bank’s financial capacity to £25.6bn, attracting tens of billions of pounds more in private capital; n reducing regulatory burdens by cutting the administrative costs of regulation for business by 25% and by reducing the number of regulators; n boosting R&D spending to £22.6bn per year by 2029-30 to drive innovation in the eight chosen sectors, with more than £2bn for AI over the period of the Spending Review, and £2.8bn for advanced manufacturing over the next ten years, potentially attracting billions more from private investors; n attracting elite global talent to key sectors via visa and migration reforms, and a new Global Talent Taskforce; n deepening economic and industrial collaboration with partner countries, building on recent deals with the US, India and the EU, and the UK’s Industrial Strategy Partnership with Japan; n centralising government support in one place through the Business Growth Service; n cutting planning timelines and costs for developers by hiring more planners, streamlining pre-application requirements and combining environmental obligations, and removing burdens on businesses; n revolutionising public procurement and reducing barriers for new entrants and SMEs to bolster domestic competitiveness; and n supporting city regions and clusters by increasing the supply of investible sites through a new £600m Strategic Sites Accelerator, enhanced regional support from the Office for Investment, National Wealth Fund, and the British Business Bank. Up to £99m more funding will be made available for the Made Smarter Adoption programme from 2026 to help a further 5,500 SME manufacturers in England to adopt new technologies. The model will also be applied in a new scheme for the professional and business services sector. The Government will also launch demonstration programmes to enhance technology confidence and use across businesses – for example, by establishing new adoption hubs for robotics. Another announcement is the creation of a Sovereign AI Unit, with up to £500m to boost the UK’s stake in frontline AI. It will work with the British Business Bank to make investments to build the UK’s AI capabilities. An Industrial Strategy AI Adoption Fund will facilitate the development of AI applications in high-growth potential firms in the earmarked sectors. UK Research and Innovation (UKRI) will increase support for the eight chosen sectors by pivoting its programmes and budgets towards research and innovation priorities in those sectors. Innovate UK will play a central role in accelerating the commercialisation of new technologies, and the Catapult Network – which Innovate UK funds – will also focus on the priorities laid out in the Industrial Strategy. According to prime minister, Sir Keir Starmer, the Industrial Strategy “marks a turning point for Britain’s economy and a clear break from the short-termism and sticking plasters of the past. In an era of global economic instability, it delivers the long-term certainty and direction British businesses need to invest, innovate and create good jobs that put more money in people’s pockets as part of the plan for change.” www.drivesncontrols.com July/August 2025 HEPCOMOTION, THE DEVON-BASED manufacturer of linear motion systems and automation components, is investing around £15m on new infrastructure, increased manufacturing capacity, and upgrades to its Tiverton headquarters, including the construction of three new manufacturing and logistics buildings. Two of the planned additions, due to start operating by the end of this year, will increase the company’s footprint by 25–30%, while the third – currently in the planning phase – will add further capacity for future growth. Hepco says that the investment will address a rising demand for its products by expanding its manufacturing capacity, enhancing its operational efficiency, and advancing the development of its core products. It adds that the plans reflect its long-term commitment to growth, innovation and continued investment. One of the new buildings will expand the company’s manufacturing and assembly facilities, including its capacity to produce GFX guidance system for use in Beckhoff’s XTS linear transport system. The second building will act as a logistics and storage hub to streamline HepcoMotion’s material-handling and supply chain operations. The third new building, still in the planning phase, will form part of Hepco’s long-term strategy to accommodate future growth. “This expansion strengthens our operational capability and reinforces Hepco’s role as a global leader in linear motion technology,” says managing director, Peter Fanshawe. “We’re investing in infrastructure that supports innovation and positions us to meet the evolving needs of customers worldwide.” HepcoMotion invests £15m to support its global growth The government’s Industrial Strategy aims to make the UK the best country to invest in and grow a business
n NEWS July/August 2025 www.drivesncontrols.com 6 THE ENGINEERING SERVICES provider, March (formerly the Edwin James Group) has acquired Northumberland-based Quantum Controls (QC) and Q Electrical Industrial Services (QE), together known as Quantum. The move strengthens March’s ability to deliver critical asset care and maintenance services with a focus on energy efficiency and sustainability. Quantum, established in 1989, is said to be the UK’s largest independent provider of turnkey projects in the design, installation and maintenance of VSDs (variable-speed drives), panels and motors. It has customers in sectors including water, manufacturing and infrastructure. Quantum currently employs around 100 people. Its existing management team, led by managing director Dan Fitzsimons and supported by founder Kevin Brown, will stay, helping to ensure continuity for customers and employees. March says that Quantum’s expertise is highly complementary to its own offerings, particularly in asset care, energy management and decarbonisation. It supports all major VSD brands. The acquisition also strengthens March’s position in the water utility sector, supporting its ability to deliver engineering services under AMP 8 frameworks. “Integrating Quantum into March expands our capabilities in servicing critical assets,” says March CEO, Christopher Kehoe. “Quantum’s broad capabilities and support for all major equipment brands align with March’s focus on energyefficient, sustainable solutions, enhancing our asset care services, especially in sectors where downtime is costly.” “This deal provides an opportunity for Quantum to accelerate growth and broaden our service offerings,” adds Quantum MD, Dan Fitzsimons. “As part of March, we can access additional resources and expand our reach while continuing to deliver the service our customers rely on.” March now has team of more than 1,300 people, and operates a network of 24 offices and service centres across the UK. It focuses on regulated, asset-rich industries, offering them a single point of contact for managing assets in managing complex, environments, across their entire lifecycle. In early 2024, the then Edwin James Group bought Burton-on-Trent-based Automated Control Solutions Holdings and its subsidiaries Automated Control Solutions and ACS Electrical Engineering (together trading as ACS), for an undisclosed sum. Last September, Edwin James rebranded itself as March in a move aimed at supporting its growth ambitions, simplifying its market presence, and enhancing its ability to deliver complete engineering packages to customers. March buys Quantum to boost engineering services p India’s Amber Group is taking a controlling stake in Unitronics, the Israeli manufacturer of industrial controls including PLCs, HMIs, PLCs/HMIs, motion controls and drives. Amber plans to use its IL JIN Electronics India division to accelerate innovation in Unitronics and to strengthen its position in India, as well as exploiting synergies. p IntelliAM, a UK technology company specialising in AI and machine learning technologies for manufacturing, has formed a partnership with the US sensormaker, Connection Technology Center (CTC), to co-develop smart sensing systems. The collaboration brings together IntelliAM’s AI platform with CTC’s sensing devices to create dual-branded hardware. p The Swedish industrial group Dacke Industri has acquired 80% of UK-based BTL-UK, which manufactures and distributes ball and roller bearings, power transmission components, and motion transfer linkages. BTL’s management will keep the remaining 20%. BTL-UK will join Dacke’s Fluid Power Technology Division. BTL-UK is based in Ashford Kent. It has around 64 employees and an annual turnover of £11m. p Smart Manufacturing Week 2025, the UK’s largest event for advanced manufacturing and engineering, attracted 13,319 visitors to the NEC across two days in early June – similar to the 2024 figure of 13,428. There were 456 exhibitors (down slightly from 470 in 2024). In 2026, Smart Manufacturing Week will take place on 3 and 4 June. p Siemens has completed its acquisition of ebm-papst's Industrial Drive Technology (IDT) division, announced in March 2024. Siemens says the acquisition complements its Xcelerator portfolio, strengthening its position as a supplier of flexible manufacturing automation systems. IDT has around 650 employees at sites in Germany and Romania. Its portfolio includes intelligent mechatronic systems, as well as driving systems. ebm-papst will now focus on fans and blowers. p B&R, ABB’s machine automation division, has entered into a strategic agreement with RS to distribute B&R’s products via its online and offline channels. B&R says the deal marks a significant milestone in expanding access to its technologies, initially in Europe, with later expansion to other regions. The collaboration also expands RS Group’s footprint in the industrial automation sector. NEWS BRIEFS THE JAPANESE motors and drives manufacturer Nidec has opened a huge plant in China capable of producing 18 million motors and more than 20 million inverters every year. The Nidec Qingdao Industrial Park, located in Jiaozhou, covers an area of 108,000m² – equivalent to 15 football fields – and contains 75 production lines. The project was completed in just 18 months. The site integrates two long-standing Nidec facilities. It will be operated by Nidec’s Appliance, Commercial and Industrial Motors (ACIM) business. The campus incorporates real-time digital monitoring and an automated warehouse. There is also a 8,500m² R&D centre which includes eight laboratories. By integrating the production of motors and electronics under one roof, the site has been designed to create strong synergies across processes, enabling faster execution and stronger support for customers. Appliance, Commercial and Industrial Motors is one of Nidec’s largest businesses, with around 18,000 employees and more than 30 manufacturing sites in 25 countries. Its portfolio includes motors for commercial and domestic applications, as well as drives for industrial, commercial, residential and utility applications. Nidec’s Chinese super-plant will make 18 million motors a year March CEO, Christopher Kehoe: acquisition enhances asset care services
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n NEWS July/August 2025 www.drivesncontrols.com 8 The US National Electrical Manufacturers Association (Nema) has announced enhanced efficiency specifications for its Nema Premium class of electric motors. Nema calculates that its Premium motors will save 5,800GW of electricity capacity over the next 10 years – equivalent to preventing almost 80 million tonnes of carbon dioxide from entering the atmosphere. The new specification will help purchasers to identify higher efficiency motors that could save them save money and improve their system reliability. It covers three-phase motors from 1-500hp (0.75-1,850kW), operating at up to 600V. “We’re excited Nema’s programme recognises recent innovations in motor technology,” says Ben Hinds, executive vice-president of climate and commercial solutions at ABB. “The updates to Nema’s programme will help drive adoption of advanced motors that reduce losses by up to 20%. These updates couldn’t come at a better time as cities and utilities struggle to keep up with increased power demand from AI and data centre installations.” “The Nema Premium program was originally developed before DoE efficiency regulations to provide confidence to buyers that they would get the savings they paid for,” adds Dale Basso, product manager for low-voltage motors at WEG Electric Corp. “The programme has now been enhanced to provide that same level of confidence, as motor efficiencies once again run ahead of the DoE regulations. The Nema Premium programme ensures all certified manufacturers are tested and verified to the same standard.” Electric motors consume more than half of all of the electricity used in the US. Enhanced Nema Premium efficiency motors could save 5,800GW in 10 years RITTAL HAS FORMED A technology partnership with Lenze aimed at shaping the future of power distribution and intelligent drive technologies. They will work together on joint developments based on a combination of Rittal’s RiLineX clickable busbar system, launched last year, and Lenze’s compact inverter technologies. “With the RiLineX system platform, Rittal is defining new standards for power distribution in the enclosure,” says Lenze SE CEO, Dr Marc Wucherer. “Through the incorporation of Lenze inverters, we can now extend the benefits to drive technologies and create more compact solutions for our customers.” For example, Lenze’s i550 cabinet frequency inverter – which, the company claims, is the smallest in its class – and its fuses, can be mounted onto a RiLineX board via a single adapter using a “clickand-work” principle. This will guarantee the highest possible packing density, say Lenze and Rittal. The slim inverters allow inline mounting on the boards, which themselves allow unrestricted top mounting. The risk of cabling mistakes is eliminated and users will be able to cut engineering times by up to 30% and assembly times by up to 75%, compared to traditional busbar systems, according to Rittal and Lenze. A Wi-Fi data connection to the inverter also helps to accelerate commissioning. Rittal launched the RiLineX enclosurebased power distribution system at last year’s SPS show in Germany. It consists of boards and components that click together, simplifying the previously laborious process of assembling such systems. It uses copper bars 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. Rittal and Lenze have a similar approach to high-quality data which, they say, is “a prerequisite for efficient planning and designing and configuration”. For example, Rittal’s RiPower system integrates closely with software from its sister company, Eplan. Lenze is an Eplan technology partner and also uses its data. “Lenze sets the pace in the field of automation,” says Rittal’s chief business units officer, Ulrich Engenhardt. “By integrating electromechanical, electronic and software expertise they demonstrate an understanding of the customer’s processes far beyond the functions of individual components. That aligns perfectly with Rittal’s approach and makes the company an excellent technology partner within the RiLineX ecosystem.” Lenze and Rittal team up on power distribution and drives Rittal’s chief business units officer, Ulrich Engenhardt (left), with Lenze SE CEO, Dr Marc Wucherer
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n NEWS July/August 2025 www.drivesncontrols.com 10 EVENTS UK MANUFACTURERS ARE leading Europe in their adoption of AI (artificial intelligence) and digital twins, according to a new global survey conducted by Rockwell Automation. The company’s annual State of Smart Manufacturing Report reveals that 53% of UK manufacturers are already implementing machine learning or AI (compared to the European average of 47%), and 94% are either using, or planning to implement, generative AI. Digital twin adoption in the UK has jumped from 21% to 37% in just 12 months, with 35% more planning to adopt digital twins in the next 12 months – the highest rate in Europe. The survey of more than 1,500 manufacturing leaders in 17 countries – 13% of them located in the UK – also reveals that: n 81% of UK manufacturers rate AI/ML as very or extremely important to their future. n 56% of UK manufacturers have already invested in GenAI or causal AI tools (up from 41% last year), with a further 42% planning to do so. n 15% of UK firms say that generative AI delivered the highest ROI of any technology in the past year. Rather than using AI to replace workers, UK manufacturers are using it to enhance their roles and address labour shortages, with 81% seeing AI as a key to recruitment. n 45% of UK firms say they are adopting automation to ease labour shortages (up from 35% last year) and 40% are turning to AI/ML tools to augment existing roles (up from 31%). A further 39% are using technology to design more engaging jobs that attract and retain top talent. n 38% percent of UK manufacturers are planning to upskill their existing workforce – up from 30% last year, and well ahead of the European average. n 97% of UK firms are already investing or planning to invest in cybersecurity platforms, with 21% citing it as their top ROI driver, and 32% seeing cyberattacks as their top external threat – up from 28% last year. n labour shortages are easing, with 19% of manufacturers citing it as a top issue, down from 23% in 2024. n 89% of UK manufacturers now have formal ESG (environmental, social and governance) policies, with 56% citing efficiency as being the main driver, ahead of compliance with regulations (cited by 43%). Almost a third (32%) are using AI/ML to track ESG. Rockwell says that in a single year, GenAI has gone from a curiosity to a priority in the UK, and is being deployed rapidly in applications such as writing code, generating training content and documentation, compliance reporting, cybersecurity and customer communications. Quality control is the most common use for AI/ML, cited by 50% of manufacturers (up from 38% last year). This is in line with the global trend, but slightly ahead of the European average (48%) and well behind that in the Middle East (68%). But the UK still trails behind Europe in its use of digital twins, and they are not yet perceived as high-impact technologies by most UK manufacturers. When asked which tools had delivered the biggest business value over the past year, only 3% of UK respondents cited digital twins or simulation – down from 7% in 2024. This reflects a lag between adoption and realised returns, Rockwell suggests. It argues, however, that digital twins are becoming an essential layer in the UK’s smart manufacturing stack. For the results of Rockwell’s global survey of manufacturers, see pages 36-37. UK manufacturers lead Europe in adopting AI and digital twins Generative AI tools can help manufacturers to eliminate unplanned downtime EMO Hannover 2025 22-26 September, 2025 Hannover, Germany Around 1,500 exhibitors from 40 countries are expected at the biennial metalworking show which covers areas including production systems, measuring technologies, machine tools, and software. Focus topics for 2025 include automation, AI and digitalisation, and sustainability. https://emo-hannover.com PPMA Total 2025 23-25 September, 2025 NEC, Birmingham The UK’s largest exhibition dedicated to processing and packaging machinery returns to the NEC for three days. More than 350 exhibitors and 7,500 visitors are expected to attend. There will be guided tours of the hall, hosted by industry experts. www.ppmashow.co.uk Engineering Design Show 2025 Coventry Building Society Arena, Coventry 8–9 October, 2025 Claimed to be the UK’s biggest event for design engineers, the show is expected to attract more than 200 exhibitors and 4,500 visitors. It is dedicated to mechanical, electronic and embedded design. In addition to the exhibition, there will be more than 50 conferences and workshops. www.engineeringdesignshow.co.uk MachineBuilding.Live 2025 15 October, 2025 National Agricultural Exhibition Centre, Stoneleigh Park This one-day event moves to a new venue this year. Its organisers describe it as “a unique opportunity to meet face-to-face with the largest array of machine-building, systems integration and factory automation technical experts ever assembled in one place at one time in the UK”. https://machinebuilding.live Digital Manufacturing 2Day 22 October, 2025 MTC, Coventry A one-day event at the Manufacturing Technology Centre dedicated to the technologies, strategies, and people driving the digital transformation of manufacturing. The theme is: Navigating and Mastering Digital Transformation. In addition to presentations by expert speakers and panel sessions, the event will include an exhibition. https://mtcevents.co.uk/ upcoming-events/digital-manufacturing-2day/ Advanced Engineering 2025 29-30 October, 2025 NEC, Birmingham The organisers says that Advanced Engineering is the only UK event connecting all industrial ecosystems, driving high-value manufacturing and supply chain solutions. There will be more than 400 exhibitors, and five forums hosting talks by more than 150 speakers. Additions this year include an SME village, an electronics zone and an expanded composites pavilion. www.advancedengineeringuk.com
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n NEWS THE LOGISITCS GIANT DHL Supply Chain is investing £550m to deploy more than 1,000 new robots and to accelerate the rollout of automation across its operations in UK and Ireland. The investment will support a growing demand for its services in the e-commerce and life sciences / healthcare sectors. The new investment builds on the €1bn that DHL has already spent on more than 3,200 automation and digitalisation projects across the UK, Ireland and EMEA region over the past three years. DHL’s contract logistics business plans to increase its operations “significantly” in UK&I, as well as globally, over the next five years, with automation, robotics and digitalisation being key enablers of this growth. DHL is co-developing, testing and scaling robotics technologies through strategic partnerships with technology suppliers. This has already resulted in more than 2,000 robots in the UK, Ireland and EMEA, including more than 750 picking robots from Locus Robotics and 6 River Systems. DHL recently deployed the first Boston Dynamics Stretch robot for container unloading in the UK. These robots can unload up to 700 boxes per hour, significantly reducing physical strain on warehouse staff and enhancing productivity. “At DHL, we’re driving the next wave of automation, not as a one-size-fits-all approach but as a set of intelligent, adaptive technologies tailored to the specific needs of individual sectors,”says the company’s global head of digital transformation, Tim Tetzlaff. “In ecommerce, for example, where the market is evolving and demand is growing, we’re expanding our fulfilment capabilities to support that shift with automated solutions that significantly simplify high-volume operations. “Meanwhile, in the growing life sciences sector, we’re leveraging automation to respond faster to demand and manage complexity at scale with end-to-end visibility, amid a larger focus on patient-centric approaches and differentiated routes to market.” As part of its expansion, DHL is opening a health logistics facility in Derby, designed to support growth in the life sciences and healthcare sector, which it expects to experience double-digit expansion in the UK over the next five years. “Our investment reflects the growing opportunities across the UK market,” explains Saul Resnick, CEO of DHL Supply Chain in the UK and Ireland. “Customers are increasingly recognising the benefits of digitalisation and, to date this year, we’ve already surpassed the number of deployments achieved last year.” More News reports on our Web site We post many more news reports on our Web site than we have space for in the magazine. Often our Web site also carries longer, more detailed versions of reports in the magazine. Here are some of the stories that we have posted since the last issue of Drives & Controls appeared. n World’s first industrial AI cloud plant will boost European manufacturing https://drivesncontrols.news/0crsduwk n Lightweight motor uses carbon nanotubes instead of metal windings https://drivesncontrols.news/pa80s6hd n Single-Pair Ethernet groups bury the hatchet to promote the technology jointly https://drivesncontrols.news/06ogym04 n ABB unveils three robot families including a faster, lighter IRB 1200 https://drivesncontrols.news/1dldnecf n Scottish group aims to revolutionise farming with robots and 5G networks https://drivesncontrols.news/yb7airby n Remote I/O system frees engineers from constraints of central controls https://drivesncontrols.news/3hg3jk7r n Firm offering capex-free energy-saving for motors attracts £20m to drive expansion https://drivesncontrols.news/fqb7pqph n Robotic start-up with $8.5m of backing, cuts deployment to ‘weeks’ https://drivesncontrols.news/1f00n8q7 n Edge gateway ‘revolutionises’ data processing, saving time and costs https://drivesncontrols.news/boeztyyk YBDU DBC "SFZPV GB F MF MFOHUIT BDJOH DIBMMFOH C HFT XIFO EFUUFSNJOJOH 1MVH 1 &1-"/ *OUSPEVD MBZ $BCMF 1MBO /$BCMFQ DJOH OOJOH QSP% DHL invests £550m to deploy 1,000plus robots in UK and Ireland Tim Tetzlaff, DHL’s global head of digital transformation and Saul Resnick, CEO of DHL Supply Chain in the UK and Ireland, with a Boston Dynamics Stretch robot.
NEWS n THE NUMBER OF NEW industrial networking nodes installed around the world dropped by 10-11% in 2024, compared to 2023, according HMS Networks’ latest annual analysis of the global industrial networking market. It attributes the dip – which follows an “exceptional” surge in 2023 – to a more challenging economic environment, political and other uncertainties, and excess production capacity in highly automated sectors such as automotive and manufacturing, especially in Europe. Despite the overall slowdown, the study confirms that industrial Ethernet continues to strengthen its grip on the market, accounting for 76% of new nodes installed during 2024, up from 71% in 2023. Traditional fieldbus technologies are declining at an accelerating pace and now represent just 17% of new nodes, down from 22% in 2023. During the previous two years, component shortages sustained the demand for serial-based fieldbus systems. However, with components now being more readily available and economic pressures mounting, the focus has shifted toward more costefficient and scalable Ethernet-based communications. HMS’ latest analysis shows that Profinet strengthened its global lead among Ethernet-based industrial networks from 23% in 2023 up to at 27% in 2024. EtherNet/IP also increased its market share from 21% to at 23%, while EtherCat grew slightly from 16% to 17%. Modbus TCP, Powerlink, CC-Link IE and other Ethernet networks remained stable, each with 4% or less of the market. In the fieldbus segment, Profibus remains the leader, but the number of nodes installed dropped from 7% in 2023 to 5% in 2024. DeviceNet, CC-Link, and Modbus RTU each declined by about 1%, while CAN/CANopen held steady at 2%. Other fieldbus protocols together make up 4% of the market. Wireless technologies accounted for 7% of new node installations in 2024, remaining at a similar level to 2023. Wireless continues to be an important complement for non-real-time critical communications, mainly for applications requiring mobility or flexible networking, or for hard-to-reach areas. Take-up of 5G wireless technology is still slow. HMS says this is due to the complexity of infrastructure management, high implementation costs, and challenges in achieving affordable realtime performance in cellular chips. However, despite these barriers, early industrial deployments are already underway, particularly in Asia, and “the technology holds exciting potential for the future of industrial communication”. HMS predicts that, following the slowdown in 2024, the industrial network market will return to growth, averaging 7.7% over the coming five years, despite short-term political and economic uncertainties and upcoming cybersecurity regulations that will force automation companies to rethink the way they connect automation systems. Industrial networking installations dropped by more than 10% in 2024 HMS Networks analysis of the industrial networking market reveals the growing dominance of industrial Ethernet technologies, and the decline of traditional fieldbuses
A STRATEGIC BREAKTHROUGH? Since our previous issue, the Government has published its highly anticipated Industrial Strategy. It’s a substantial document. If you include its various annexes, it runs to more than 600 pages. It ranges far beyond manufacturing into areas such as the creative industries, financial services, and professional services – three of the eight sectors identified by the government as being potential “winners” for the UK economy over the coming decade. Another of those sectors is advanced manufacturing, to which the government is pledging £4.3bn in funding – including up to £2.8bn in R&D programmes over the next five years – to spur innovation, automation, digitisation and commercialisation. Sarah Jones, minister of state for industry, describes advanced manufacturing as “the backbone of our economy, directly supporting around 760,000 jobs and contributing more than £82bn gross value added to the UK economy every year. This is an industry that strengthens our national resilience, and drives prosperity across every region of our country.” But, she adds, “we must recognise the urgent need to maintain a competitive edge in an era of global competition and rapid technological change… Our vision is bold. By 2035, the UK will be recognised as the best place in the world to start, grow, and invest in advanced manufacturing.” Bold indeed! We have summarised some of the highlights of the Strategy on page 5 of this issue. And on page 56, Gambica’s Nikesh Mistry digs deeper into the Strategy and its implications. A cornerstone of the Strategy are its measures designed to tackle two of the biggest barriers facing UK industry – high electricity prices, and the long wait for grid connections. Under the proposals, more than 7,000 energy-intensive British businesses will see their electricity bills slashed by up to 25% from 2027. These businesses, which are said to support more than 300,000 skilled jobs, will be exempt from paying certain electricity industry levies, helping to level the playing field and make them more internationally competitive. The government is also increasing its support for the most energy-intensive firms – in sectors such as steel, chemicals and glass – by covering more of the electricity network charges that these businesses normally have to pay through the British Industry Supercharger. They currently get a 60% discount on those charges. From 2026, that will rise to 90%. This is certainly good news if your company is a “energy-intensive” business, or you are active in one of the eight favoured sectors. However, if you are not a big energy user, or your operate in a sector that has not been earmarked for success, the benefits may not be so clear. Still, there are other measures – such as the extension of the Made Smarter technology assistance scheme to an extra 5,500 SME manufacturers, and the creation of a series of robotics adoption hubs – that could prove attractive. Up to £99m of new funding will be made available for the Made Smarter Adoption programme from 2026 to help a further 5,500 small and medium-sized manufacturers in England to adopt new technologies. The robotics hubs are part of a new Robotics and Autonomous Systems (RAS) programme, which is promised an initial investment of £40m. They will offer the experts, equipment, and the connections needed to accelerate firms’ take-up of robots. The hubs will provide a one-stop-shop to help manufacturers to invest in RAS technologies. They are a welcome addition and might help to improve the UK’s dismal record so far in terms of its take-up of robots, compared to other industrialised nations. But how far will £40m go to change things? Stephen Phipson, CEO of of the manufactrers’ organisation, Make UK, has described the publication of the Industrial Strategy as “one of the most important days for British industry in a generation”. He adds that its publication demonstrates the government’s commitment “to honour its promises and tackle the major structural problems that have blighted UK manufacturing for so long”. The Government must be thrilled to receive this reaction. But, as with all wide-ranging programmes of this sort, only time will tell how many UK manufacturers will really benefit from the new Strategy. Tony Sacks, Editor n COMMENT Make it flexible. Make it sustainable. Make it OMRON. #MakeitOMRON Make the world better through creative manufacturing With our range of integrated manufacturing solutions, scale your business faster and sustainability.
Drives&Controls & BACK TO BASICS n SPONSORED BY Why it pays to be proactive You wouldn’t run your car without regular servicing, so why would you take a similar risk with critical assets such as drives, motors and generators? Rebecca Brannelly, ABB’s OneCare service agreements manager, explains the importance of having more permanent maintenance arrangements in place. When drives, motors and generators are operated in optimal conditions, they can often provide years of incident-free operation. For the first few years of their life, they typically need little in the way of servicing beyond checking their connections, keeping the area free of dust and debris, and ensuring that the surrounding environment is suitable for effective operation. SLAs (service-level agreements ) are a way of making sure that your drive remains fighting fit throughout its lifecycle. Where SLAs differ from warranties is that they are tailored specifically to the operation, condition, age and criticality of the asset(s). An SLA can include preventive maintenance checks throughout the asset’s lifetime, at appropriate intervals based on how and where the drive is being used. This will allow the vast majority of potential faults to be identified and mitigated, to prevent them from turning into failures, helping you to protect your investment, extend the life of your asset, and reduce downtime. In the event of a sudden and unexpected failure, an SLA can also include provision for emergency response from the manufacturer or through service partners. Think of this like roadside repair for a car. Hopefully, you’ll never need it, but when the day comes that you do, you’ll be glad it’s there. Moreover, having this covered within an SLA will invariably be less stressful and more cost-effective than having to arrange repairs or replacements at short notice. Investing in resilience and reliability is never money wasted. Downtime can cost thousands of pounds per hour, and so any proactive action you can take to avoid it, is ultimately money saved. In ABB’s case, its OneCare SLA provides a range of conventional and data-driven services, including technical support, onsite and off-site maintenance, lifecycle assessments, and digital monitoring services, among others, to keep your drive in optimal condition throughout its operational life. Each agreement is bespoke to the customer, so you only pay for what you need, and spread the cost of maintenance over a longer and more predictable timeframe. For more on ABB’s SLA for drives, motors or generators, search for “ABB Motion OneCare”. When the sensing challenges become more demanding Baumer HOG800 Series Encoders deliver a robust and reliable performance. These uncompromisingly robust encoders are perfect for monitoring demanding applications, such as; • Materials Handling • Aggregates & Mining • Ports & Cranes • Steel & Paper Mills Key features include: enhanced protection against corrosion, shaft currents, overvoltage and mechanical stress. Combining ‘smart’ functions with over 70 years of experience in position and speed measurement for large engines, generators, machines and plants, Baumer are a global market leader for Heavy Duty encoders. Find out more at: https://www.baumer.com/HOG800 T: 01793 783 839 E: sales.uk@baumer.com
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Remote monitoring for ABB inverters AND their environment The problem: Five significant VSD breakdowns within 1 year. DART was installed to find out why by monitoring the inverters & their environment. A fault alarm was triggered when H2S levels exceeded the preset safe value programmed in DART of 10 ppm, an email was sent to the on-call engineer automatically from DART. Values peaked at 32 ppm H2S on Jan 21st 2025: proving conclusively that a high level of H2S and the subsequent corrosion were the cause of the failures. ... DART case study - corrosion in a WWTW … DART had identified (and verified) the cause of the plant's numerous breakdowns and information could now be provided on how to improve the situation, aiding efficiency, cutting repair costs and downtime and significantly extending the life of the asset. Protect your plant. Scan the QR code below to see DART's website
n TECHNOLOGY July/August 2025 www.drivesncontrols.com 18 ABB HAS ANNOUNCED A variable-speed motor that combines an high-efficiency permanent magnet motor with a VSD (variable-speed drive) in a compact, customisable, plug-and-play package that allows users to cut energy consumption and reduce their carbon emissions. The IE5-efficiency LV Titanium Variable Speed Motor can be used as a drop-in replacement for existing, inefficient DOL (directonline) induction motors, offering an easy upgrade to a VSD-driven motor with a rapid payback. Thanks to its compact design and high power density, the variable-speed motor is at least two frame sizes smaller than comparable induction motors, making it ideal for installations where space is at a premium. The package is not simply a drive bolted onto a motor. ABB has engineered it as an integrated assembly, with a drive module purpose-designed for optimal performance, combined with a highefficiency motor. The axial drive is mounted on the end of the motor, saving space and making the motor ideal for applications such as vertical pumps. The customisable motor can be tailored to suit pump, compressor and other industrial applications with power ratings from 1.5–30kW, and nominal speeds from 1,500–4,500 rpm. It can operate over a wide range of speed and torque requirements, and deliver high torque at low speeds. It is said to operate quietly. The plug-and-play capability means that the motor needs no on-site commissioning – the motor and drive are set up to work together before leaving the factory. This, combined with the reduced need for cabling, makes installation quick and simple, with low set-up costs and a reduced need for materials. There is no need for cabinets, electrical rooms, or specially trained installation personnel. The motors can be fitted by one person. ABB says that comparing the variable-speed motor with a conventional fixed-speed motor in a 7.5kW centrifugal pumping application, the annual electricity savings will be more than €4,000, based on a typical energy cost in Europe of €0.21/kWh. At the same time, there will be an annual reduction of six tonnes in CO2 emissions, based on the average European carbon intensity factor of 0.3kg CO2/kWh. “We developed the LV Titanium in collaboration with customers who asked us to help them achieve energy savings and reduced carbon emissions without installation complexity,” says Stefan Floeck, president of ABB’s IEC Low Voltage Motors division. “This variablespeed motor delivers just that – advanced performance in a compact, user-friendly and speed-controlled motor package that draws on our decades of application expertise.” The integrated motor has an intuitive control panel with a simple built-in PLC. It offers analogue and digital I/Os (inputs and outputs), and supports the Modbus RTU communications protocol for easy integration with PLCs and other devices. The LV Titanium variable-speed motor is currently available in sizes from 1.5kW, and will be expanded later to cover applications up to 30kW. In addition to being available in off-the-shelf versions, the motor can be customised to meet specific customer requirements. https://new.abb.com/motors-generators A US SPECIALIST IN AI-driven condition monitoring, Waites Sensor Technologies, has announced a technology that enhances machine health monitoring by sending sensor data to the cloud for processing, display and alerting – without having to overhaul existing sensor infrastructures. Waites’ Universal Adapter suite allows users to connect almost any off-the-shelf industrial sensor – including those with 0–5V, 0– 10V or 4–20mA outputs, as well as current transformers and RTDs – directly to one of the company’s nodes. This transmits the sensor data simply and reliably to the cloud, where it can be analysed using Waites’ own AI software, or be integrated with other systems for further processing. Factories have previously faced limitations when trying to unify a variety of sensors that use different platforms. The new suite is claimed to eliminate these constraints, offering wide compatibility, and reducing the need for custom wiring or specialised devices. The result is lower deployment costs, increased system flexibility, and faster access to operational data. “For years, industrial operations and facilities have struggled with incomplete sensor systems, requiring costly workarounds to access critical data. Waites’Universal Adapter suite removes those barriers,”says the company’s co-founder and CEO, Rob Ratterman.“It reflects our commitment to unlocking actionable insights from any sensor, on any platform, as simply and reliably as possible. This launch is a major step forward in manufacturing intelligence, ease, and efficiency.” Waites has recently established a subsidiary in Poland, from which it is selling directly to end-users in the UK and Europe. https://waites.net Adaptors link existing sensors to the cloud, simplifying access to data Plug-and-play IE5 motor-drive replaces DOL motors directly ABB’s LV Titanium motor-drive reduces energy consumption and saves money by delivering IE5 efficiency
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