Drives&Controls AUTOMATION FOR MANUFACTURING INSIDE SEPTEMBER 2025 www.drivesncontrols.com ENERGY EFFICIENCY: Making efficiency the cornerstone of the energy transition FOOD AND BEVERAGE: Servos help to produce convincing meat alternatives MAINTENANCE AND REPAIRS: Dairy milks the benefits of AI-driven predictive maintenance
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 October issue of Drives & Controls will contain a special section devoted to developments in machine-building, as well as roundups of recent applications in precision engineering and motion control, and news from the water industry. UPDATE 12 Comment 13 ABB Back to Basics 52 Gambica column 54 New Products 56 Multimedia and Design Data 57 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 46 38 32 24 6 56 DRIVES & CONTROLS SEPTEMBER 2025 Vol 41 No 8 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. 14 Technology Cutting-edge innovations in motion, power transmission, controls and related technologies. 24 Industrial automation As manufacturers seek to achieve more with less, they are exploring advanced automation architectures that balance operational efficiency with sustainability. An industry expert argues that the best way to do this is to embrace open automation. 25 Energy efficiency Are we ignoring the vast potential of increasing the efficiency of existing installations, in favour of investing in new supply technologies such as renewables? Plus understanding emissions standards, how VSDs are helping to cool data centres, and advice on choosing VSD-controlled air compressors. 38 Food and beverage A look at how manufacturers can re-engineer their operations to cater for the growing demand for fresher, healthier and less processed foods. Plus a look at how a linear transport system has helped to design and build a carton-capping machine that operates three times faster than usual. 46 Maintenance and repairs One of Europe’s most modern dairies has implemented an AI-powered predictive maintenance system aimed at ensuring 24/7 operation, 365 days a year. The system has already identified a pump that was about to fail, saving a six-figure sum. Plus what do the new vibration standards mean for industry? 50 Engineering Design Show preview The EDS is gearing up to welcome more than 4,800 mechanical, electronic and embedded design professionals to its Coventry venue next month, making it the biggest edition yet. They will be able to talk to more than 220 exhibitors, and attend more than 50 conferences and workshops. 50 Average net circulation January to December 2024 52 55 Subscribe for your FREE copy now 20,514 14
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NEWS n 5 Support for UK SMEs could close tech gap and add £150bn to GDP A NEW REPORT FROM Make UK and Sage is calling on the Government to provide targeted funding, training and innovation support for SME manufacturers to help close the gap between the UK and its rivals in adopting digitalisation and automation technologies. They say that such backing could add £150bn to GDP by 2035. They point to other countries, such as South Korea, Singapore, Switzerland and Germany, where targeted support has transformed SME manufacturing. In Korea, for example, a programme including tax incentives and training programmes has eliminated skills shortages in digital innovation, boosted productivity by up to 25%, and cut defects by 27%. Make UK and Sage argue that the UK’s target of attaining a digitally literate workforce by 2025 – as laid out in the recent Industrial Strategy – is not ambitious enough. The new report – called Making it Smarter: Global lessons for Accelerating Automation and Digital Adoption in UK Manufacturing – points out that over the past two decades, UK manufacturers have plummeted dramatically down global automation tables. In the past ten years, for example, the UK has slipped from second to fifth place in the in the Global Innovation Index. And Britain is now languishing at 24th position in global robotic density, with just 112 industrial robots per 10,000 workers – half the EU average. In addition, the report says, the training of British people with the relevant digital skills to take advantage of innovative technology is well below what is needed to catch up. The 28-page report reveals that almost half of British manufacturers identify a lack of technical skills as being the biggest hurdle to them improving their use of advanced technologies. Those projects that do start, often stall after the implementation stage, because companies cannot find the help and advice needed to make the technologies work well. Countries where all SME innovation funding and advice is held under an easy-to-access “umbrella hub” have dramatically better success rates. www.drivesncontrols.com September 2025 The Government’s recent Industrial Strategy aims to create a digitally literate workforce by 2035, but “we can’t wait for this to happen”, Make UK warns. It is calling on the Government to embed targeted funding for the digital skills needed in manufacturing and engineering to accompany the £100m it has already set aside for engineering skills. For decades, the report points out, South Korea has been undergoing a successful transition from legacy production methods to advanced digitalised factories. For example, the government provides SMEs with incentives such as easy-to-access 30% R&D tax incentives for companies investing in semiconductor manufacturing, turning Korea turning into a global leader in this area. The Korean government also committed to training 40,000 people to operate automated production systems and there are now no skills shortages in technical and digital innovation in the country. Firms adopting smart technologies have seen a 25% rise in productivity, and a 27% drop in defects. Switzerland, with a population similar to London’s, has a manufacturing output worth around £150bn – not far off the UK’s £217bn. Its national strategy prioritises advanced technologies, SME competitiveness, and long-term innovation. The Swiss Innovation Agency typically funds up to 50% of eligible project costs for SMEs, while larger firms qualify only if they partner with smaller ones. “Time and again, we hear from small and medium-sized manufacturers that they’re keen to adopt new technologies, but are being held back by fragmented support, complex funding systems, and a lack of accessible, appropriate digital skills training,” says Make UK’s chief economist, Seamus Nevin. “If we want to unlock a £150bn boost to UK GDP by 2035, we must make it easier for SMEs to adopt automation and AI. “Other countries are accelerating ahead by putting smaller firms at the heart of national strategies – with long-term support that’s simple to access, reliable, and rooted in real business needs,” he adds. “From South Korea to Switzerland, governments have created clear, SME-focused strategies that simplify innovation funding, offer long-term tax incentives, and ensure every business can access practical support. “These policies work not just delivering improvements in economic growth, but also in more environmentally friendly processes with fewer defects, higher profit margins, and creating more higher skills, better paying jobs.” https://drivesncontrols.news/un2tllu5 “Other countries are accelerating ahead by putting smaller firms at the heart of national strategies – with long-term support that’s simple to access, reliable, and rooted in real business needs” The Make UK / Sage report suggests ways the UK could close the gap with its high-tech rivals For more of the latest news visit www.drivesncontrols.com
n NEWS September 2025 www.drivesncontrols.com 6 AFTER SPENDING ALMOST six years developing separate versions of Single-Pair Ethernet (SPE), two group of industrial communications companies have decided to join forces to work together on the technology and its promotion. SPE allows industrial data to be transmitted over a single twisted pair of wires, saving space and costs for both cabling and connectors, and simplifying industrial automation installations. Until now, the two groups – the SPE Industrial Partner Network and the Single Pair Ethernet System Alliance – have operated independently with their own members, working groups and areas of interest. With the growing awareness and relevance of SPE, the groups have been moving closer since the Hannover Messe 2025 exhibition and now plan to coordinate their activities to accelerate the uptake of SPE. Members of the SPE Industrial Partner Network include Harting, TE Connectivity, Hirose, Hirschmann, Würth Elektronik, Softing, Amphenol, Lütze, Lapp, igus, Nexans, Molex and Helukabel. Members of the SPE System Alliance include Phoenix Contact, Weidmüller, Rosenberger, Sick, Wieland, Keba, Ilme, Honeywell, Wago, Legrand, Eaton, Werma, Innovance, Kübler, Endress+Hauser, 3M, Advantech and HMS Networks. Murr Elektronik and Hilscher are members of both groups. The two groups say they have been committed to the development of international standards for SPE since the start. They both support the IEC 63171-7 SPE connector standard and have been driving its expansion to include a standard IP20 SPE mating profile. A main focus of their new collaboration will be the further internationalisation of SPE. The groups – most of whose members are German – are aiming to make the advantages of SPE known worldwide and to give users around the globe access to what they see as a powerful, efficient and future-oriented network technology. The IEC 63171-7 standard creates a uniform basis for future-proof industrial communications. Other connector systems and associated international standards are unaffected by the latest developments, and will continue to be valid for the numerous fields of application of SPE. Single-Pair Ethernet groups bury the hatchet p Rockwell Automation plans to spend $2bn over the next five years on its manufacturing plants, staff and digital infrastructure. CEO Blake Moret says that most of the expenditure will be on investments in the US. After cutting its workforce in 2024, Rockwell is taking on new staff again. p The engineering specialist March has launched a digital apprenticeship programme to address the shortage of automation and control systems skills and to create a training path across its business. An initial group of apprentices at four of its offices will work towards an HNC in Instrumentation and Control Engineering from Teesside University via flexible open learning, with options to progress to higher qualifications. p Klüber Lubrication has acquired TriboServ, a German company specialising in automatic lubricators and customised lubrication systems, for an undisclosed sum. The acquisition expands Klüber’s portfolio to secure further growth. p Around 1,600 products from the connector manufacturer binder are now available in the Eplan Data Portal, simplifying their integration into electrical and mechatronic projects. The portal gives direct access to standardised CAD and product data, embedded in an engineering environment. It will make it easier to integrate the connectors into circuit diagrams, wiring schematics, and bills of materials. p The global services company Accenture has acquired Systema, the German-based supplier of software and consulting services for manufacturing automation. The terms of the deal have not been disclosed. p Zebra Technologies and its distributor, Clearview, have set up an Industrial Automation Centre of Excellence in Oxfordshire, offering training, advice and demonstrations for manufacturers, logistics organisations, and machine vision users in EMEA. The centre will support end-users, machine-builders and systems integrators looking for machine vision, 3D and AI systems. www.clearview-imaging.com/coe p RARUK Automation has formed a partnership with Grip, the German specialist in intelligent tool-changing systems for collaborative robots. The deal will bring Grip’s portfolio to UK manufacturers, enhancing the flexibility, safety and efficiency of cobot cells. The tool-changers integrate with Universal Robots cobots, with a URCap for easy set-up and programming. Manual and automatic options available, allowing a robot to perform multiple tasks by switching between tools. NEWS BRIEFS The Stoke-on-Trent based transformer manufacturer Electro-Wind has designed, built and delivered a bespoke 500kVA 3-phase 415V/690V transformer to power one of the world’s largest land-based cranes, which is being used to build the Hinkley Point C nuclear power station. The robust transformer, designed for outdoor use, will operate on a raised platform. It is providing temporary power to the Unit 2 reactor polar crane during the commissioning phase of the station. A major challenge was achieving IP55 protection, while minimising the transformer’s size and weight. This was achieved by incorporating forced air cooling, ensuring compliance with environmental standards while maintaining performance and efficiency. Electro-Wind delivered the transformer in eight weeks. Single-Pair Ethernet has the potential to simplify industrial automation connections
NCC 8-pole bayonet locking > 5000 mating cycles Panel mount parts unplugged IP67 Solder and dip solder contacts www.binder-connector.co.uk
n NEWS NIDEC DRIVES HAS INTEGRATED its servomotor business Control Techniques Dynamics (CTD) into its operations, thus unifying the company’s servodrive and motor offerings. Founded in 1962, Control Techniques Dynamics was a pioneer in the design and production of high-performance servomotors. It was one of the first companies in the world to specialise in brushless servomotor technologies. The business now delivers precision motion systems to industries ranging from robotics and automation, to aerospace and medical devices. The integration is intended to realign Nidec Drives’ strategic goals, enhance collaboration, and streamline operations across both organisations. By allowing cross-functional teams in sales, product management, engineering, operations and supply chain, to collaborate more closely, Nidec is aiming to redefine its servodrive and motor portfolio, boosting efficiency and cutting costs. The move is expected to result in a more compelling and competitive servo offering, positioning Nidec Drives for future growth. Work is underway on joint product and sales initiatives. “Integrating Control Techniques Dynamics within Nidec Drives allows us to serve our customers better than ever,”says Nidec Motion Platform president, Anthony Pickering. “By driving this collaboration and growth – we can offer better value servo solutions and support, as part of our ongoing strategic initiative as one Nidec.” “Integrating Control Techniques Dynamics into Nidec Drives marks an exciting milestone,”adds Randy Guzman, global vice-president of product management and marketing, and commercial leader of the integration project. “By combining Control Techniques Dynamics’s proven innovation in our servodrive technology with our global reach and support network, we’re delivering even greater value, service, reliability and performance to customers worldwide.” CTD started life as Moore Reed & Co, which was established in 1962 by six engineers in South London to produce precision servo elements, mainly for aircraft applications. In 1964, the business moved to Andover, in the South of England, and added AC and DC motors, as well as encoders, to its portfolio. In 1972, Moore Reed merged with the motormaker Newman Industries, giving it access to global markets and widening its expertise. In 1976, the business was bought by an electronic components manufacturer, Kode International. This relationship lasted for more than 10 years, during which Moore Reed expanded its expertise in precision motion control systems. In 1989, Moore Reed was bought by Control Techniques. The following year, it added Evershed and Vignoles’ Powerotor division, thus uniting two of the UK’s leading servo component companies. In 1993, Moore Reed & Co was renamed Control Techniques Dynamics (CTD). In 1995, Control Techniques and CTD were bought by Emerson which, in turn, sold them to Nidec in 2017. The addition of CTD to Nidec Drives follows the earlier integration of KB Electronics, strengthening Nidec’s ability to deliver unified, highperformance systems for global markets. www.ControlTechniques.com Control Techniques Dynamics joins Nidec Drives to unify servo portfolio September 2025 www.drivesncontrols.com 8 The AEMT (Association for Electrical and Mechanical Trades) has appointed Mark Brady, MD of Hayley 247 Dexis, as its honorary President, succeeding James Stevens, CEO of Preformed Windings. Andy Patten from ADC Electrical is the AEMT’s new vice-president, Kirstie Davies from Solutions in IT is junior vice-president, and George Knowlton from Knowlton & Newman is junior vicepresident elect. Ray Penny has been appointed president of the metrology specialist, Mitutoyo Europe – the first non-Japanese national to fill this role in 57 years of Mitutoyo in Europe. He started his career with the company as a service technician in the UK in 1986. In 2017, he was appointed MD of Mitutoyo UK, and sat on the board of Mitutoyo Europe. His new responsibilities span the entire EMEA region. Control Techniques Dynamics’ servo portfolio has joined the Nidec Drives operation EVENTS 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/upcomingevents/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
Quality in repair Quality in repair uksales@unisgroup.com www.unisgroup.co.uk + 44 1604 499 777 Are you using Control Techniques drives? Get in touch to discuss your requirements. NO FIX, NO FEE FIXED REPAIR PRICES UP TO 2 YEARS WARRANTY FREE PICKUP SERVICE EMERGENCY REPAIR 24/7 SERVICE UNIS GROUP IS APPOINTED BY NIDEC GERMANY AS CERTIFIED REPAIR CENTRE
n NEWS September 2025 www.drivesncontrols.com 10 A GERMAN DEVELOPER of high-performance electric motors that it claims are lighter, smaller and more efficient than rivals, has raised €3m in an oversubscribed round of pre-seed funding. Munich-based Hyperdrives’ motors use a hollow-conductor cooling technology that results in record power densities at a “dramatically lower cost”, without needing exotic materials, novel motor layouts, or new production processes. Hyperdrives, founded in 2021, will use the new funding to convert its “strong customer pipeline” into commercial projects, validate the durability of its motors, and prepare its manufacturing processes for an industrial rollout. Most motors are cooled indirectly via water jackets or oil spray, leaving hot spots in the windings that limit their currenthandling capabilities and compromise their efficiency. Hyperdrives cools the insides of the copper conductors using a low‑viscosity dielectric that flows through channels in the hollow hairpins, removing heat at its source. According to the company, this enables continuous current densities up to three times higher than today’s series-produced motors. The lower motor temperatures also help to reduce material degradation and extend motor lives. Hyperdrives compares the effect of its technology to that of a turbocharger on a combustion engine – you get a higher output from the same hardware, without fundamentally new designs or production concepts. Previous attempts at using hollow‑conductor cooling have been complex, expensive, and prone to reliability issues. Hyperdrives claims that its patented design and manufacturing processes are robust, leak‑proof, and compatible with existing hairpin production lines. “Our breakthrough is making hollowconductor cooling work for mass production,” says Hyperdrives’ co-founder and CTO, Michael Numberger. “By cooling directly inside the copper conductor, we achieve up to three times higher current density than today’s motors – more power in the same space, or the same power in a smaller, lighter package. “Hyperdrives is turbocharging electrification with the best performanceto-cost electric motors on the market, designed for industrial-scale production,” adds co-founder and CEO, Robin Renz. “Over the past years and through three product generations, we have proven that breakthrough motor performance doesn’t require exotic materials or new production concepts. With this new funding, we will expand our team to validate lifetime durability to automotive standards, accelerate our go-to-market, and prepare for industrial-scale production.” Replacing jackets and oil sprays with hollow hairpins delivers benefits such as: n Direct coolant-to-copper contact Dielectric oil contacting the inner channel surface of each copper hairpin extracts heat immediately (without needing a double‑walled cooling jacket). n Hollow-pin topology The 1–2mm channels maximise the wetting area, achieving cooling claimed to be more than ten times better than conventional stators. n Turbulent high-velocity flow This boosts convective heat transfer, keeping copper temperatures around 80°C lower than conventional designs with equal loads, preventing hot‑spots and degradation. n Hydraulic-electrical decoupling Cooling paths are optimised independently from the electrical winding layout. n Low-viscosity fluids and low pressure drops Less than 1 bar of pressure drop across the system allows use of low‑cost, low‑power pumps. n Distributed windings Compatibility with multiple rotor topologies including designs such as synchronous reluctance motors, that don’t need rare-earth magnets. The motors are capable of continuous current densities of up to 75A/mm2 (about three times higher than usual), and system power densities (including the motor, inverter and housing) of more than 12kW/kg continuous (15kW/kg peak) – comparable to the best electric aviation systems. Hyperdrives claims that its technology will cut energy consumption by up to 10% in typical duty cycles, and reduce bills of materials by up to 40% through downsizing and eliminating costly alloys and magnets. Last year, Hyperdrives generated more than €1m in revenues without any external funding. It is currently operating two commercial models: offering turnkey systems (motor, SiC inverter and cooling) to customers with low‑to‑medium volume projects; and licencing high‑volume customers to use its technologies to produce motors using their existing hairpin stator production lines. Hyperdrives is focusing initially on transport applications, but the technology could be applied to other sectors. It is offering an 350kW peak (260kW continuous) automotive system called Hyperdrive One, with an integrated SiC drive, that weighs 36.1kg and operates at 17,000 rpm / 800V, with an efficiency of more than 96%. There is also a 19.6kg aviation variant, called Hyperdrives Ultra, that delivers 320kW peak (250kW continuous) and operates at 24,000 rpm / 800V. Matching 7kg SiC inverters can deliver 500A continuously at 800V, and can drive SynRM, PSM and IPM motors. www.hyperdrives.de €3m funding will turbocharge low-cost hollow-conductor motors Two versions of Hyperdrives’ integrated motor-drives: the 36.1kg One (left) for automotive applications; and the 19.6kg Ultra for aviation duties.
NEWS n www.drivesncontrols.com September 2025 11 NEW RESEARCH HAS revealed a huge untapped potential for tackling the UK manufacturing sector’s 47,000-person skills gap, with employers missing the opportunity to harness crossgenerational learning. The research, conducted for the Manufacturing Technology Centre (MTC), shows that 41% of the “baby boomer” generation (those aged 60–66) working in manufacturing say their skills are going unused. At the same time, 91% of “Generation Z” (those aged 18-27) say they are willing to learn from their older colleagues. According to the MTC, these findings point to a clear opportunity for industry to embrace cross-generational learning and unlock the knowledge already within their workforce, before workers with decades of experience retire. Doing so can accelerate the adoption of technology to improve resilience and boost productivity – both of which are vital to supporting the ambitions of the UK’s recently published Modern Industrial Strategy. The study reveals that the opportunity to pass on knowledge is largely being overlooked by manufacturers. Around 60% of both younger and older workers report that they are not involved in crossgenerational skills-sharing activities. The survey of 1,000 manufacturing workers aged from 18-66, conducted by Censuswide, also challenges common assumptions about digital learning preferences. Just 11% of Gen-Z workers prefer digital-only training, signalling a clear preference for hands-on, people-focused learning. On a broader issue, only 35% of the manufacturing workers surveyed report that their training includes both technical and interpersonal skills. This gap is felt most by younger employees, with 28% of Gen-Z workers and 16% of 28–43–year– old Millennial workers saying their development lacks training in soft skills such as communications, resilience and strategic thinking. “There is a wealth of knowledge already embedded in the UK’s manufacturing workforce, but too often it goes untapped,” says David Grailey, managing director of MTC Training. “At a time when the sector is facing a significant skills gap, we need to realise the benefits of many different ways of skilling, upskilling and reskilling workers – not just on bringing in new talent. Creating the conditions for employees of all ages to share knowledge on how to make the most of technological developments, and communicating the benefits is crucial. “Our research highlights just how much potential exists within crossgeneration collaboration – and how the workforce is ready to embrace it,” he adds. “Through MTC’s training programmes, we’re helping our partners to build inclusive, future-ready teams. The wider sector has the opportunity to do the same by recognising the value in every generation and the distinctive ways in which they prefer to learn. “Generational diversity is a significant strength for every manufacturer. When manufacturers invest in training that connects people – blending technical and soft skills and encouraging collaboration between age groups – they unlock greater productivity, resilience and long-term competitiveness.” One company that is embracing generational diversity in its workforce is the robotics and automation supplier, Fanuc. Through an MTC apprenticeship programme, a 20-year-old Fanuc engineer, Jack Leonard, has been working side-by-side with a 62-year-old colleague, John Strisino, for the past four years, focusing on robotics and automation. This collaboration has enabled Leonard to gain deep technical insights, while giving him fresh perspectives on problem-solving. “Learning from other generations has been a game-changer,” he says. “Their deep understanding of robotics systems, control architectures and integration workflows goes far beyond what you get from textbooks. “Working in parallel with the team has sharpened my ability to design and troubleshoot complex automation systems, all while making me more confident, technically capable and curious about pushing the boundaries of what our systems can do.” www.the-mtc.org Study reveals untapped resource for tackling UK’s skills shortage Passing on knowledge: Jack Leonard (left) and John Strisino (right) with a Fanuc controls engineer colleague, Neil Weaver (centre)
AUTOMATING APPLE’S FUTURE Apple has reportedly told its suppliers around the world that they will need to increase their investments in robotics and automated systems or risk losing their contracts. This will apply to companies involved in the manufacturing of Apple products such as iPhones, iPads, Apple watches and Mac computers. In the past, Apple has helped its suppliers financially and technically to automate their production lines; now, they will have to bear the costs themselves. Several reasons have been suggested for this change in policy. One is that it would make Apple less vulnerable to major disruptions such as pandemics. Covid had a serious effect on Apple’s operations because of problems staffing production facilities, especially in China. Automation also makes it easier to standardise production, and to implement similar manufacturing facilities in different countries. This has become an important requirement with President Donald Trump wanting American companies to carry out more of their manufacturing activities in the US. It will be easier to replicate highly automated production plants in America if they have been established elsewhere first. What is unlikely is a future as envisaged by the US commerce secretary Howard Lutnick earlier this year, when he talked about an “army of millions and millions of human beings screwing in little screws to make iPhones” in America. The only way that it would make sense for Apple to produce more in the US is if the manufacturing operations are highly automated. With labour costs in the US being much higher than in Asia, where Apple has traditionally done much of its manufacturing, higher levels of automation are obviously attractive. It also means that Apple will be less vulnerable to skills shortages in North America. In addition, President Trump’s wholesale expulsion of undocumented US residents means that there will be fewer of the immigrants who have traditionally been a key element of the workforce in many American factories. Where Apple leads, others are likely to follow, which is good news for the robotics and automation industry, especially in the US. Rockwell Automation has already announced that it is planning to invest $2bn over the coming five years in its plants, staff and digital infrastructure – mainly in North America. One factor behind this decision is no doubt that it is anticipating an increase in automation spending as manufacturers ramp up their US investments in response to pressure from the Trump administration. And as manufacturers – especially in the US – invest more in automation, their rivals will be forced to follow suit to remain competitive. The effects could reverberate around the industrialised world. The UK will not be immune from these pressures. Manufacturers here are probably going to have to invest more in automation than they have done in the past. All of this points to a rosier future for robotics and automation suppliers globally. Tony Sacks, Editor n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ÐÕÍÖÓÖÎÐÊ ËÌÚÐÎÕ ÐÕÊÌ ¯´²³ XN
Looking to source automation, power transmission and motion engineering equipment? www.drives-guide.com Drives& Controls Interactive Buyer’s Guide website Drives&Controls & BACK TO BASICS n SPONSORED BY Are you lubricating your motors properly? An estimated 51% of motor failures are a result of bearing problems. The most common issue is insufficient lubrication. ABB’s David Blissett explains where motor users are going wrong, and how to keep your motors well lubricated and running smoothly. Lubricating bearings is one of the most important jobs when it comes to motor care. Yet I’m increasingly seeing motors being sent back to us with bearing failures caused by insufficient lubrication, which suggests that too many users simply aren’t lubricating properly. Back in my day, plants would have what we’d call a “grease monkey”, who would go around once a month and lubricate every motor. As maintenance teams get stretched ever thinner, it seems that this job is in danger of being overlooked. Bearings that are approaching failure give off a distinctive rumble or high-pitched sound as the motor’s ball-bearings pass over the worn spot. In years gone by, an experienced engineer would stick a screwdriver on the motor frame and, just by listening to the vibrations, would be able to tell if the bearings were about to fail. In these times of leaner maintenance teams and remote monitoring, this is a skill that’s dying out. If a motor has regreasable bearings, then it should also have a lubrication plate or O&M manual. This shows how frequently you should lubricate the bearings in duty hours, depending on how and where the motor is operating. It also sets out how much grease to use, and of what grade. When regreasing, it’s important to follow these instructions closely. Just like the engine oil in your car, grease wears out over time. It’s therefore no good just pouring more in. You have to let the old grease out first. Overfilling will smother the bearings and cause them to overheat, so the top-up must be carefully measured out and performed with grease relief valves open. Using the wrong grade – one not specified on the lubrication plate – will invalidate the warranty and could damage the motor. Actual duty hours will vary from motor to motor, so the easiest way to ensure that you’re lubricating at appropriate intervals is to have an effective preventative maintenance program, or to use smart sensors to measure running hours and provide you with a reminder when it’s time for regreasing. Ideally you would have both. Sensors have the added bonus of being able to monitor vibrations and provide early warnings of bearing failures as well as other problems. A lot of motor users don’t realise that bearings are responsible for such a high proportion of motor failures. But remember, five minutes spent regreasing using 20 pence worth of grease, is much cheaper than letting the bearings fail and having to replace them, or spending thousands of pounds on a new motor. For more information, search for “ABB Motion Service”.
n TECHNOLOGY September 2025 www.drivesncontrols.com 14 SIEMENS CLAIMS THAT it going to transform shopfloor CNC programming with software that combines 3D analysis with the ability to program directly at CNC control panels, thus improving production efficiency, precision and quality. The Optimize MyProgramming /3D Scanner software is designed to be integrated into Siemens’ Sinumerik Operate CNC programming platform, allowing users to create and optimise programs at the controller without needing extra training. Siemens says the software will set new standards in CNC programming, and will allow manufacturers to create higher-quality products and more efficient production processes. The software transfers geometric information from 3D CAD models into CNC programs, eliminating the need for cumbersome and errorprone manual input. As well as saving time and costs, this also allows better parameterisation of machining cycles, prevents programming errors, and ensures consistently high production quality. The 3D Scanner will offer customised suggestions for manufacturing strategies based on an application’s geometric features. Siemens says that by integrating the software into their machines, builders will be able to make their products more attractive and win customers through measurable efficiency and quality improvements. It has piloted the software with the machine tool manufacturer DMG Mori, demonstrating how it can improve manufacturing processes and be integrated into existing systems. The software will be offered as an option for all DMG Mori machines equipped with Siemens’ Sinumerik One CNC system. The Optimize MyProgramming /3D Scanner will be offered as a perpetual license for machine tools, and also as an option for Siemens’ digital twin systems based on its Run MyVirtual Machine platform. The software is part of the Siemens’ Xcelerator portfolio, enhancing it with advanced technologies for optimising manufacturing processes. www.siemens.com AN AMERICAN CONTROLS SPECIALIST, Helios Technologies, has launched a gateway that allows OEMs to connect their equipment to devices and systems which may not normally be compatible. Helios says that its Atlas Connect Gateway – developed by its Enovation Controls subsidiary – is designed for demanding applications, providing secure connections, remote diagnostics, and real-time intelligence. The gateway allows equipment manufacturers and operators to monitor critical data, send remote commands, and update software on equipment in the field, without needing to be on site. Its powerful processing capabilities are said to enable fast, reliable performance, even in the field, making it easier to keep machines running smoothly and efficiently. “The launch of the Atlas Connect Gateway marks a major step forward in Helios Technologies’ vision for intelligent machine connectivity,” says Helios’ president, CEO and CFO, Sean Bagan. “We’re proud to deliver this rugged, future-ready solution to customers around the world, helping them stay connected, informed, and in control.” The gateway integrates with Helios’ broader ecosystem called Cygnus Reach. “By pairing the Atlas Connect Gateway with Cygnus Reach, Helios’ patented remote troubleshooting platform, we’re delivering a powerful new advantage to OEMs by enabling remote support capabilities,” explains Billy Aldridge, senior vice-president and managing director of Helios’ electronics business. “For organisations operating customer support centres or field service teams, this integrated solution streamlines diagnostics, reduces downtime, and elevates the overall service experience. It’s a major step forward in connecting people, machines, and data in smarter, more efficient ways.” The gateway can be wired into any Can-enabled system in a matter of minutes. Users can monitor the Can bus, take recordings, and share data, via cellular mobile devices. The IP67-rated gateway can operate in temperatures from –20°C to +70°C. It has an operating voltage of 6–36V DC. www.heliostechnologies.com www.enovationcontrols.com Gateway allows OEMs to diagnose their machines remotely Software will transform shopfloor CNC programming, cutting costs and errors Siemens says that its new software will transform shopfloor CNC programming
We have the solution. Position. Transport . Rotate Oriental Motor (UK) LTD www.oriental-motor.co.uk – info@oriental-motor.co.uk – 01256 347 090
n TECHNOLOGY September 2025 www.drivesncontrols.com 16 Rockwell Automation has launched an edge gateway that, it says, will revolutionise data processing for industrial users. The OptixEdge gateway processes information where it’s created – at the machine – in real time. It connects to the user’s control system via Rockwell’s FactoryTalk Optix software to collect and analyse data, and send it to the cloud, allowing them to monitor and analyse machine or system data from multiple locations, resulting in faster insights, lower costs and smarter decision-making. The gateway’s capabilities include: n A built-in wizard app This simplifies data collection and allows easy configuration via a Web browser, thus cutting down on engineering time. It also allows users to deploy custom applications. n Efficiency The gateway allows lightweight applications to run in tandem with included software. n Secure remote access and troubleshooting Remote assistance is available via FactoryTalk Remote Access, allowing engineers and maintenance teams located remotely to program, configure and troubleshoot systems over a secure VPN connection. n Openness and flexibility The gateway can be used with a plant or machine’s existing Rockwell hardware, or third-party graphics terminals and controllers. n Cost savings and improved network performance The gateway allows users to send less data to the cloud, helping to save on storage costs, and improve network performance. "OptixEdge empowers customers to take control of their data like never before, providing powerful edge computing capabilities with flexibility, security and ease of use,” says Rockwell Automation software product manager, Jessica Morell. “By processing data at its source, OptixEdge enables customers to unlock valuable insights, improve efficiency, and drive innovation across their operations.” www.rockwellautomation.com p The lift-maker Kone is developing a proof-ofconcept for a DC-powered elevator system, to demonstrate the potential improvements in energy efficiency, durability and reliability. By recovering and reinjecting energy generated while braking, DC-powered lift systems cut losses and electricity consumption. They are also more suitable for renewables and energy storage systems, reducing the energy drawn from the grid. Also, unnecessary AC/DC conversions are avoided, making electrical distribution more stable, reducing breakdowns and making systems more resilient and secure. Kone has joined the Current/OS Foundation which champions DC power. p Fluke Reliability has integrated its eMaint CMMS (computerised maintenance management system) with its Watchman Services AI vibration condition-monitoring system, allowing maintenance personnel to bridge the gap between asset condition-monitoring and maintenance, improving uptime, and cutting costs. When Fluke bought Azima in 2023, eMaint users started to use its diagnostics and AI-driven fault detection to improve maintenance decisions. Now, with the platforms connected, real-time vibration data and recommendations from Watchman Services can go directly into eMaint work order management. https://reliability.fluke.com/azima-dli p Mujin, a Japanese pioneer in intelligent robotics for logistics, manufacturing, and supply chains, has developed a robotic operating system called MujinOS that eliminates the need for custom programming, manual calibration and rigid system design. At its core is a real-time digital twin that perceives, plans and controls robotic systems, enabling consistent performance even in high-variability environments. At least eight systems integrators in North America are planning to use the OS to design applications such as palletising, bin picking and mobile robot coordination, while expanding into more complex and dynamic use cases that were previously too difficult or timeconsuming to automate. www.mujin-corp.com p ABB says it has achieved an industry first by gaining Environmental Product Declaration (EPD) status for a GMD (gearless mill drive) ring motor, which is used to drive large grinding mills in the mining industry. An EPD is a standardised document that provides detailed information about the environmental impact of a product throughout its lifecycle. A GMD transmits torque between the motor and mill via the magnetic field in the air gap between the motor’s stator and rotor. p A Japanese company, Telexistence, has launched a “groundbreaking” service that will generate large-scale, cost-effective robotic motion datasets tailored to customer needs. At its core is a “motion data factory” – a new infrastructure for the robotics industry, functioning like a critical utility that delivers motion data for advancing robot intelligence, thus accelerating the growth of robotics companies and research institutions. https://youtu.be/5Q8rIQ6HA4M TECHNOLOGY BRIEFS Edge gateway ‘revolutionises’ data processing, saving time and money THE CHINESE ROBOT DEVELOPER Unitree has announced a four-legged robot that can carry loads of up to 25kg, and move at speeds of up to 5m/s – three times faster than Boston Dynamics’rival Spot quadruped robot, which can handle loads up to 14kg. A video of the A2 Stellar Explorer robot shows it performing acrobatics, running up and down steps and steep hills, climbing 1m-high blocks, navigating through complex terrains, carrying a 30kg weight for 12.55km, and supporting a person jumping up and down on its back. The robot’s 12 joints are powered by permanent magnet synchronous motors with high-speed inner rotors, that can each deliver 180Nm of torque. It weighs around 37kg – about 6kg of that being a hotswappable 453Wh battery. Carrying a 25kg load, the aluminiumand-plastic robot can walk for more than three hours, covering around 12.5km. Unloaded, it can walk for more than five hours, covering around 20km. It can handle slopes of up to 45 degrees, and steps up to 30cm high. When stationary, the robot can support up to 100kg. The IP56-protected A2 carries one or two Lidar sensors (front and rear) and an HD camera. Unitree claims that it has no blind spots. The robot’s joints incorporate dual encoders and crossed roller bearings A wheeled version will be available. www.unitree.com Acrobatic four-legged robot can run at speeds of up to 5m/s and carry 25kg Rockwell’s OptixEdge gateway allows users to take control of their data “like never before”
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n TECHNOLOGY September 2025 www.drivesncontrols.com 18 PROTEAN ELECTRIC, THE UK-BASED developer of in-wheel motors (IWMs) for electric vehicles, says it is the first motor producer to develop and supply IWMs for a mainstream passenger car. It is providing a pair of rear-wheel motors, each rated at more than 200kW, for the Renault 5 Turbo 3E, which is designed to accelerate from 0–62 mph in less than 3.5 seconds, and hit a top speed of 167 mph (269km/h). The £135,000 electric sportscar was shown to the public for the first time at the recent Goodwood Festival of Speed. The in-wheel motors – an updated version of Protean’s Pd18 design – will deliver an instant combined torque of 4.8kNm. By placing the motors inside the car’s 20-inch wheels, all of the power will be delivered without drivetrain losses, resulting in good responsiveness and high efficiency. The design reduces the number of parts needed and the weight of the vehicle (to 1,450kg) enhancing its agility, performance and delivering a driving range of 248 miles (400km) from its 70kWh battery. The distribution of the torque to each wheel can be controlled to enhance the car’s grip and agility. Renault is planning to build just 1,980 of the 5 Turbo 3Es. Protean says that the “landmark” project positions it at the forefront of EV propulsion innovation. Not only does it mark a key step in the commercialisation of IWMs, but it also reinforces their viability as a scalable propulsion technology for mainstream automotive applications. “We are thrilled to see Protean’s in-wheel motor technology being integrated into such an iconic vehicle as the Renault 5 Turbo 3E,” says the company’s CEO, Andrew Whitehead. “This collaboration represents a significant milestone in the future of vehicle electrification as it shows clearly in-wheel motors have no limits. We look forward to continuing our work with Renault and other OEMs as they seek to use in-wheel motors to deliver better electric vehicles for their customers.” Farnham-based Protean has was founded in 2009 after the UK pancake motor pioneer, PML Flightlink, entered administration. In 2019, it was acquired by National Electric Vehicle Sweden (NEVS), a subsidiary of the Chinese Evergrande Health group, which had been created from the assets of Saab Automobile following its bankruptcy in 2012. Evergrande subsequently got into financial difficulties, leading to Protean being acquired in 2021 by the Bedeo Group, a UK company specialising in transport electrification technologies. Bedeo (formerly BD Auto), founded in 2009 by Osman Boyner, has its headquarters in the UK, with manufacturing operations in Turkey and China. Protean Electric holds more than 330 patents across 75 patent families. www.proteanelectric.com UK-developed in-wheel motors will propel Renault 5 Turbo 3E to 62mph in 3.5s The Renault 5 Turbo 3E electric sportscar will be powered by a pair of motors in its rear wheels A Chinese high-performance car-maker claims to have set a new world speed record for electric vehicles by hitting a speed of 472.41km/h on a test track in Germany. Yangwang – a high-end sub-brand of the Chinese EV giant BYD – says that its U9 Track Edition supercar broke the record propelled by four 555kW, 30,000 rpm motors, with a combined rating of more than 3,000hp. The vehicle has a power-to-weight ratio of 1,217hp per tonne. The record was set last month at the Papenburg test track by German driver Marc Basseng, who set the previous EV speed record in 2024. “Last year, I thought I'd peaked,” he says. “I never expected to break my own record so soon – but here we are, at the same track, with new technologies that have made it possible.” Each of the EV’s four motors has an independent torquevectoring system that monitors road feedback continuously, adjusting torque more than 100 times a second. Even at high speeds, the system is said to maintains absolute control over body posture, ensuring no wheel slip or loss of traction. The car also incorporates the world’s first mass-produced 1.2kV ultra-high-voltage platform, paired with a thermal-management system optimised for extreme conditions. During aggressive acceleration and cornering, or on uneven surfaces, an intelligent body control system performs rapid, independent vertical adjustments to the suspension at each corner of the vehicle. This not only suppresses pitch and roll – enhancing driver comfort – but also optimises the contact area between the tyres and the road, to maximise grip. The Yangwang U9 Track Edition is based on the same e4 Platform and DiSus-X architecture as the U9 model which is currently on sale in China. Four 550kW motors help to accelerate electric sportscar to new world speed record Yangwang’s U9 Track Edition supercar has set a new world speed record for EVs on a track in Germany
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