Drives&Controls AUTOMATION FOR MANUFACTURING INSIDE MEDIUM VOLT TAGE. JANUARY 2026 www.drivesncontrols.com DRIVES: Unlocking the untapped potential of inverters GEARS AND GEARBOXES: Are magnetic gears an attractive option? PACKAGING AND PRINTING: Personalised packaging is driving a trend to unified controls
Website Scan the QR codes to find out more or search “ACS8080” Product info Video ENGINEERED TO OUTRUN REASONS TO CHOOSE ACS8080 High quality, fewer components The ACS8080’s high quality components and low parts count reduce potential points of failure, and minimise maintenance needs. Maximum compatibility Adapts to almost all applications and industries with a modular design and diverse configuration options. Rigorous accelerated lifetime test The ACS8080 drive has been tested rigorously at our dedicated testing facility in Estonia, simulating 20 years of operations in representative conditions. Flexibility to handle diverse applications One drive that fits almost any application, with output voltage from 3.3 kV to 6.9 kV, and output frequency up to 250 Hz for lowand high-speed applications. Sensing solutions Enhanced sensing capabilities and next-generation control hardware gather real-time information about the condition of critical drive components, allowing the collection of up to 10 times more diagnostic data compared to previous generations.
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 2026 NEXT ISSUE The February issue of Drives & Controls will look at what’s happening in the world of robotics and automated manufacturing, report on some of the highlights of the recent SPS show in Germany, and cover developments involving sensors and encoders. UPDATE 14 Comment 15 ABB Back to Basics 45 Gambica Column 46 New Products 48 Design Data and Multimedia 49 Products & Services IN DEPTH Follow us on X @DrivesnControls Drives Magazine Web site www.drivesncontrols.com Follow us on LinkedIn @ Drives & Controls Join us on Facebook Drives & Controls Drives& Controls REGULARS DfAmedia group 40 36 28 26 5 48 DRIVES & CONTROLS JANUARY 2026 Vol 42 No 1 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. 16 Technology Cutting-edge innovations in motion, power transmission, controls and related technologies. 26 EU Legislation A new piece of European legislation, known as the Data Act, has potential implications for UK machine-builders that want to export equipment to the EU. A compliance specialist examines these issues, and offers advice on what machine-builders need to do to ensure that they comply with the Act. 28 Drives How variable-speed drives are being used in two separate drinks container recycling applications, in Germany and the Netherlands. Plus a look at how low-harmonic drives are helping to ensure the efficiency of a large-scale heat pump installation, and advice on unlocking the untapped potential of inverters. 36 Gears and Gearboxes How magnetically geared motors can improve the efficiency, reliability and cost-effectiveness of applications in many industrial sectors. Plus how Gatwick airport has upgraded its gearboxes to use a biomass lubricant, and how a UK company that makes welds inspection systems is using spiral-bevel gears to grind the welds. 40 Packaging and Printing Changing consumer expectations are transforming packaging production from mass-produced uniformity, to personalisation and customisation, forcing suppliers to innovate. Plus how an Austrian label printing specialist has installed an inline inspection system that detects errors at an early stage, and how one of the Baltic’s largest furniture-makers has restructured its packaging operations. 44 Southern Manufacturing The Southern Manufacturing & Electronics exhibition is returning to its Farnborough venue next month. We look at what visitors can expect to find when they attend the exhibition. 44 45 Average net circulation January to December 2024 Subscribe for your FREE copy now 20,514 16 46
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NEWS n 5 SCHNEIDER ELECTRIC HAS RELEASED a report suggesting that closed industrial systems are eroding the competitiveness of mid-sized industrial companies, costing them an average of 7.5% of their annual revenues, through downtime, inefficiencies, compliance retrofits, and delayed production. The research, conducted for Schneider by Omdia, argues that these issues are often masked by the perceived reliability of legacy automation systems. For large enterprises, the losses can average $45.18m, while smaller manufacturers proportionally face even impacts, losing up to 25% of their annual revenues. For a mid-market company, with revenues of around $150m, the annual costs can amount to $11.28m, according to Schneider. The report – entitled Open vs Closed: The $11.28M Question for Industrial Leaders – argues that traditional, hardware-defined automation systems, built for static environments, are struggling to cope with today’s dynamic industrial demands. Their rigidity turns routine updates into costly technical projects, while proprietary architectures limit data access, reducing visibility and responsiveness. Some manufacturers are relying on more than ten different hardware platforms, each with its own unique maintenance needs. This fragmentation makes them dependent on a variety of equipment vendors, with 30% of their plant issues requiring specialised support. This strains workforce efficiency at a time when companies are facing skills shortages. Siloed systems also hinder predictive maintenance and fast resolution of issues, leading to costly downtime and lost productivity, says Schneider. These inefficiencies scale across operations, limiting agility. The research – based on interviews with executives in a variety of industries, and a survey of a further 320 www.drivesncontrols.com January 2026 people making plant-level decisions – highlights an urgent need for transformation. It suggests that open, softwaredefined automation offers a scalable, future-ready alternative that can modernise legacy systems, accelerate ROIs, and strengthen industrial competitiveness and resilience. By decoupling software from hardware, manufacturers gain the flexibility to integrate multi-vendor systems, adapt rapidly to market shifts, produce small batches efficiently, and close skills gaps. Real-time data becomes actionable, driving smarter decisions, boosting productivity, and cutting costs. Schneider says that some of its customers are already realising these benefits. Many start with pilot projects or asset-level trials, and then expand to full-plant or multi-site deployments, unlocking data ownership, improving quality control and cost transparency, while protecting their existing investments. “This research echoes what our customers tell us every day: industrial systems must adapt as fast as their markets,” says Schneider’s executive vice-president for industrial automation, Gwenaëlle Avice Huet. “It’s particularly encouraging that smaller enterprises, the backbone of our economy, stand to gain the most in annual savings that can be reinvested in innovation and growth. Open, software-defined automation is a proven solution that empowers industrial players of all sizes build resilience, drive innovation, and thrive amid rapidly shifting consumer demands, regulatory pressure and market volatility.” The Schneider/Omdia report breaks down the annual $11.28m bill for a mid-sized company into four key areas: n $6.1m in operational agility and resilience losses Inflexible hardware systems hinder responsiveness to market shifts, because 77.4% need physical modifications to implement functionality updates, while multiple vendor platforms create integration complexity. Modifications can cost $25,000–50,000 per hour, rising to $250,000 per hour for companies worth more than $1bn. n $2.28m in optimisation and efficiency costs Companies are running 2-10 different industrial systems on average; 29% having more than 10 hardware platforms, each with unique management requirements. This results in maintenance burdens, downtime and talent gaps. n $1.2m in preventable quality failures and costly data maintenance Proprietary systems create data silos and limit integration. Only 28% of companies can access real-time insights, and half report that 20–39% of their critical data isn’t available in real time. n $1.7m in sustainability and compliance costs Regulatory changes demand hardware retrofits, driving up compliance costs. “In response to mounting pressures, industrial leaders are deploying tactical solutions to sustain their core priorities of growth, competitiveness, and trust,” says Omdia’s principal analyst, Anna Ahrens. “In a world where product lifecycles shrink, supply chains fracture, and talent gaps widen, agility and flexibility aren’t optional. They are survival. Every quarter a business delays addressing the cost of closed automation ecosystems is another $1m+ in lost value: money that could be reinvested in growth and innovation.” The report can be downloaded from https://drivesncontrols.news/8a2b0pp0 “This research echoes what our customers tell us every day: industrial systems must adapt as fast as their markets” Closed automation systems ‘are costing companies up to 25%of their revenues’ Huet: open, software-based automation is a proven solution
n NEWS January 2026 www.drivesncontrols.com 6 AN INDEPENDENT BODY HAS been created to give more than 325,000 UK SMEs operating in the engineering and manufacturing sectors, a voice in the corridors of power. The Policy Centre for Supply Chain and SMEs has been set up by Enginuity – the former Sector Skills Council – to bring together industry leaders, sector bodies, policymakers, and government, and to ensure that the realities facing British SMEs are not just heard, but drive meaningful change, at the highest level. The Centre’s mission is to unify and amplify SMEs’ voices, bringing together industry, trade bodies, policy organisations and government to collaborate on the skills and policy priorities needed to support a thriving and resilient supply chain. “SMEs are the lifeblood of the UK economy, yet often fail to be heard by those making policy in key areas at the heart of government,” says Enginuity CEO, Ann Watson. And those honing policy need to listen. “Effective government policy depends on meaningful engagement with the people and organisations whose insights and experience are essential to its success,” she adds. “SMEs are huge in number, but that can mean that they can be difficult to identify and engage and their individual voices lacks unification, amplification and clarity. “This is where Enginuity’s Policy Centre can really come in to its own, creating the epicentre between SMEs, Government and others, ensuring that positive and productive engagement and dialogue takes place.” The Centre will also provide guidance to help businesses navigate policy changes. “By gathering robust data, conducting research, and fostering honest dialogue, the Policy Centre will provide evidence-based recommendations to shape policies that strengthen SMEs and reinforce the UK supply chain,” says Watson. “We are here to do what’s right for SMEs and the supply chain-giving them a platform and the influence they deserve.” https://enginuity.org New body will champion UK manufacturing and engineering SMEs p Nidec has inaugurated six high-tech production plants on a 50-acre (20.2ha) site in Karnataka, India, known as the Orchard Hub Campus. The $55m development is Nidec’s largest and most advanced manufacturing facility in the country, and will make “nextgeneration” products including: highefficiency motors and drives; battery energy storage systems; motors, controls and chargers for EVs; and generators. p The industrial automation and process control supplier, Eltek Systems, has renamed itself as Actemium and relocated to a larger site in Peterborough. The move follows Eltek’s acquisition in 2020 by Vinci Energies, which already owned a UK subsidiary called Actemium. Eltek initially continued to operate under its own name. Now, five years later, it has adopted the Actemium brand, joining the other Actemium UK businesses which have a combined total of 635 staff working at 20 locations, providing electrical, automation and mechanical systems and services. p The Industrial Network Technology (INT) division of the Swedish industrial communications specialist, HMS Networks, is buying part of Molex’s Industrial Solutions business, including a product portfolio consisting of network interface cards and software stacks, as well as the French company, Woodhead Software & Electronics. The purchase price is $7m and will be paid in cash on closing, which is expected to happen this month. HMS says that its main reason for the acquisition is to obtain strategic IP and know-how from Molex’s engineering teams. p The Worthing-based servo specialist HT Servo has been acquired by the Swedish industrial group Teqnion. The terms of the deal have not been revealed. HT Servo was established in its current form in 2001. David Baillie joined as managing director in 2004. He has since expanded the company, and will continue to lead HT Servo. For the past three years, HT Servo has had average revenues of around £4.5m. Teqnion has almost 40 subsidiaries. It says it focuses on profitability and long-term sustainable relationships. pThe Japanese pumps, blowers and compressors manufacturer Ebara is buying Mitsubishi Electric’s three-phase motors business for an undisclosed sum. Mitsubishi plans to focus on its factory automation activities and technologies such as PLCs, servodrives and CNC systems. The assets being transferred include Mitsubishi’s three-phase and IPM motor businesses and production facilities, as well as industrial motor, pump, and diecasting businesses run by Mitsubishi’s Thai subsidiary. As well as the production plants in Japan and Thailand, Ebara is acquring Mitsubishi’s development facilities. NEWS BRIEFS Mitsubishi Electric Automation Systems has strengthened its sevenmember UK management team, led by divisional director, Mike Cairns (pictured), as it transforms from a products-based to a solutions-based business. Tom Cork has joined as indirect sales manager, after spending almost 20 years in industrial roles, including more than a decade at ABB. Dan Bull has joined from Rockwell as UK sales manager, while Stephen Chilton, previously with Omron, is the new product and marketing manager. David Bean has been promoted to the newlycreated role of business development group manager. Schneider Electric has appointed Alice Williams as VP for digital energy in the UK and Ireland. Her role will be to drive growth in the business through end-user energy savings using Schneider’s automation and energy management systems. She succeeds Kasim Mohammed who is now VP for services UK&I. Williams, who began her career in the British Army, has been with Schneider for more than six years, most recently as VP for services in the US, leading a team of 600 there for three years. The Hima Group has appointed Carl Ramsden to the newly created position of CEO of Sella Controls. Hima acquired Sella in 2023 following a long-standing partnership. Sella now acts as the group’s regional centre for the UK and Ireland, and as its global centre of excellence for railway activities, with more than 130 people working at its Stockport and Ashby sites. Ramsden has more than 20 years of leadership and financial expertise from the industrial and technology sectors, including senior positions at BASF and Yokogawa. He will assume overall responsibility for Sella, and will lead it alongside Chris Parr (CTO) and Eddy Turnock (CSO). Watson: SMEs are the lifeblood of the UK economy, yet often fail to be heard
n NEWS THE UK GOVERNMENT IS contributing half of the cost of a £20m UK-German project to develop an ultra-compact, high-power electric drive system for high-performance EVs. The Ignited project, led by Mercedes-AMG High Performance Powertrains – which produces engines for Formula 1 cars – is expected to create more than 150 high-value jobs in Northamptonshire and Oxfordshire, while securing a further 34 existing roles. UK partners in the project include the Oxfordshire-based electric motor developer Yasa, which is owned by Mercedes-Benz, and the Stoke-on-Trent precision gear specialist, DePe Gear. Production of the new drive system is expected to start within three years. The Government is backing the initiative with £10m through the UK’s Advanced Propulsion Centre, which provides funding to develop cutting-edge zero-emission vehicle technologies. The project is intended to strengthen the UK’s EV supply chains and reinforce Britain’s position as a global hub for automotive innovation, delivering on a central aim of the Government’s modern Industrial Strategy. According to Yasa’s founder and chief technology officer, Tim Woolmer, the project “represents an important milestone for the future of high-performance electric drive technology. Government support through the Advanced Propulsion Centre has been essential in enabling this next phase of R&D to remain in the UK, safeguarding specialist engineering roles and helping us accelerate breakthrough innovation alongside our partners at Mercedes-AMG. “As we continue to scale our industry-leading axial-flux motor technology,” he adds, “projects like Ignited strengthen the UK’s position as a global centre of excellence for advanced electric powertrain development.” The Government says the project demonstrates its commitment to the automotive sector. The Chancellor of the Exchequer recently announced an additional £1.5bn for the Drive35 programme, bringing the total capital and R&D funding for this programme to £4bn for the period to 2035 – the largest-ever UK Government investment in automotive history. Drive 35, part of the modern Industrial Strategy, aims to electrify manufacturing hotspots nationwide, strengthening supply chains and securing jobs. The funding is supporting the electrification of vehicle plants alongside investment in batteries, electric motors, hydrogen fuel cells, and power electronics. Yasa, which recently produced its 50,000th axial-flux motor, has also been demonstrating a prototype in-wheel drive based on a 12.7kg motor that can deliver 750kW of peak power and a continuous output of 350–400kW. Yasa has also developed a matching 15kg inverter that can deliver 1.5MW of power – equivalent to a power density of 100kW/kg. Yasa says that the current state-of-the-art for such inverters is 50–70kW/kg. The company adds that due to the in-wheel drive’s “incredible” regenerative performance, it could dramatically downsize, or even eliminate the need for, conventional braking systems on the rear axle. Eliminating components such as disc brakes and drive shafts could save up to 200kg and, by optimising the vehicle’s structure for inwheel motors, the potential weight savings could amount to around 500kg. January 2026 www.drivesncontrols.com 8 Woolmer: strengthening the UK as a global centre of excellence for powertrain developments. Image: Yasa £20m UK-German project aims to develop high-performance electric vehicle drive systems EVENTS Southern Manufacturing & Electronics 26 3–5 February, 2026 Farnborough, UK The regional event is expected to attract more than 500 exhibitors from a variety of sectors including mechanical engineering, electronics, electrical engineering and production hardware. More than 10,000 people are likely to visit the Farnborough site where they can hear talks from over 50 experts, as well as attending the exhibition. www.southern-manufacturingelectronics.com/en National Manufacturing Summit 26 February, 2026 MTC, Coventry The event brings together leading UK manufacturing and engineering experts to discuss, debate and set the agenda for the key subject areas that will drive the country’s manufacturing competitiveness forwards. https://nmsummit.co.uk MACH 2026 20–24 April, 2026 NEC, Birmingham The manufacturing technologies event, organised by the Manufacturing Technologies Association (MTA), has sold more than 90% of its available floorspace. More than 30,000 members of the UK manufacturing community are expected to attend. Spread across five halls will be a series of interactive Knowledge Hubs providing visitors with impartial advice. One Hub will be dedicated to Automation and Robotics; another will focus on Data and AI. https://www.machexhibition.com Hannover Messe 2026 20-24 April, 2026 Hannover, Germany The industrial mega-show returns to its North German venue and is expected to attract around 4,000 exhibitors (including more than 300 start-ups) from the engineering and digital industries, as well as the energy sector. AI will be a common thread. There will be three main exhibition areas: Automation & Digitalisation; Energy & Industrial Infrastructure; and Research & Technology Transfer. The partner country for 2026 is Brazil. www.hannovermesse.de/en Smart Manufacturing Week 2026 3–4 June, 2026 NEC, Birmingham Smart Manufacturing Week (SMW), described as the UK’s biggest festival of advanced manufacturing and engineering, will have a fresh look and new features for 2026. It includes Drives & Controls, Smart Factory Expo, Maintec, Design & Engineering Expo, the Manufacturing Digitalisation Summit and The Manufacturer Top 100 Awards. New attractions for 2026 include fighting robots, extra showfloor theatres, and Future Stage – a window into the future of industry. www.smartmanufacturingweek.com
— ADVERTORIAL MEDIUM VOLTAGE. MAXIMUM RELIABILITY. Website Scan the QR codes to find out more or search “ACS8080” Product info Video ENGINEERED TO OUTRUN Unlike in other MV drives, the ACS8080’s topology allows the transformer to be separated from the drive. This means that the transformer can for instance be kept outside the e-room, reducing the amount of heat generated, which in turn can reduce the load on air conditioning systems. External transformer configuration and flexible cooling options reduce energy consumption, leading to a lower total cost of ownership. Enhanced performance and energy saving The ACS8080 is equipped with ABB’s latest and most advanced motor control technology – Model Predictive Pulse Pattern Control (MP3C), ensuring efficient, precise and reliable process control in all industrial applications. This also allows the system to achieve maximum power output while minimising losses, with a converter efficiency of up to 98 percent when operated with an external transformer. ABB’s ACS8080 next-generation medium voltage drives take reliable performance to another level. Designed for almost all industrial applications, it seamlessly integrates to meet your specific needs with unmatched compatibility and flexibility – all in a single drive platform. Maximum reliability for your peace of mind The reliability of ACS8080 provides peace of mind that processes and equipment will operate continuously and without interruption. This is achieved with a highly robust design, using high-quality components. A low parts count reduces potential points of failure, lowering the risk of downtime. Maintenance is also straightforward, with easy front access to the drive’s components for simplified service and parts replacement. In-built condition monitoring provides early malfunction prediction, with fast and effective diagnostics and troubleshooting to ensure that maintenance is carried out when and where it’s needed, while intervention time is kept to a minimum. Unmatched flexibility A modular design ensures the ACS8080 is equipped for the demands of a wide variety of applications and industries. Highly customisable, the system offers various supply-side configurations, and motor-side compatibility for both single- or multi-motor configurations for induction motors, synchronous motors, and permanent magnet motors.
n NEWS January 2026 www.drivesncontrols.com 10 FOUR INDUSTRIAL COMMUNICATIONS organisations have joined forces to release a document containing key extensions for standardising Single Pair Ethernet (SPE) and enhancing the EthernetAPL physical layer. The technologies are already being implemented in plants worldwide. The new SPE specification supports higher powered devices and includes Power-over-Data-Line (PoDL) capabilities, as well as details of power classes and definitions of connectors. It is expected to lead to the wider use of SPE in discrete, non-hazardous factory environments, such as automotive and packaging plants. For Ethernet-APL, Power Class B, which supports devices up to 1.16W, has been incorporated into the second edition of IEC TS 63444. The Ethernet-APL standard also extends interoperability to non-hazardous SPE applications. The new standards have been produced by the Independent Protocol Physical Layer (10Base-T1L) working group, which includes representatives from the FieldComm Group, ODVA, the OPC Foundation and PI Unified SPE and Ethernet-APL standard will lead to ‘smarter automation’ THE UK INDUSTRIAL AI start-up Matta has raised $14m of funding to help it transform how products are designed and manufactured. The money will be used to accelerate development of the company’s AI that helps factories see, understand, and improve themselves in real time. London-based Matta was founded in 2022 as a spin-out from Cambridge University. It has already deployed its technology in factories in the UK and Europe making a variety of products (see Drives & Controls, November/December 2025). Matta’s AI spots defects, traces root causes, and helps teams fix problems before they become costly. The technology can work across all types of manufacturing from electronics and automotive to defence and clothes, and on manual inspection stations, conveyor lines, or robot arms. The funding round was led by Lakestar, alongside investors Giant Venture, RedSeed VC, InMotion Ventures, 1st Kind (Peugeot family), Unruly Capital, and Boost VC, with grant support from Innovate UK and the Royal Academy of Engineering. Matta will use the funding to accelerate customer adoption and AI development, expand deployment, and support its expansion across Europe and the US. Matta’s AI learns the physical rules of a production line and applies them to the line. Its initial applications are using machine vision to automate quality control and anomaly detection, perform measurements, diagnose root causes, and recommend corrective actions in real time. Matta says it has a waiting list of more than 300 potential customers, and is installing a new system every two weeks. (Profibus & Profinet International). “This milestone establishes the foundation for vendor-independent communication based on SPE and Ethernet-APL, paving the way for the decisive and necessary digitalisation of industrial sectors,” says PI board member, Harald Müller, who led the working group. “Building on this, we have already implemented Profinetover-APL in productive plants and will continue to drive adoption with these new enhancements.” The developments are intended to strengthen the foundation for reliable, vendor-independent communications and data from the field level upwards, leading to smarter automation. Another milestone has been the preparation of certification systems. A test system has been developed to ensure quality and physical layer interoperability. Parallel activities are underway to offer technical guidelines and seminars, and to develop SPE demonstrators. Further enhancements are planned, such as adding a 100Mbit/s bandwidth for two-wire Ethernet applications (100Base-T1L), and incorporating the documents into IEC standards. “The alignment of Ethernet-APL and SPE provides a solid foundation for unified, vendor-independent Ethernet communication in industrial automation,” explains Stefan Hoppe, president and executive director of the OPC Foundation. “Together with OPC UA, these technologies enable consistent and interoperable information exchange across all system levels.” ODVA president and executive director, Dr Al Beydoun, adds that his organisation is “pleased to support the continued development of EthernetAPL and SPE to drive the immense benefits of Ethernet digital communication down to the field level. The Ethernet-APL and SPE physical layers will allow for simplified wiring, reduced cost, and longer cable runs for EtherNet/IP network users in factory and process automation worldwide.” The SPE and Ethernet-APL developments were announced at the SPS show in Germany, where there were several multi-vendor demonstrations of SPE products, amid predictions that the technology is on the verge of a breakthrough following the recent decision by two rival SPE consortia to settle their differences. A number of SPE products were launched at SPS, including one by TE Connectivity which premiered a hybrid SPE connector in an M12 format that supports the integration of powerdemanding field devices into networks and can transmit large amounts of data in real time to control systems or the cloud. The connector, which complies with IEC 63171-7, has a 2 x 8A capability, thus supporting components needing up to 1kW. It can also carry data at up to 1Gbit/s – ten times faster than earlier devices complying with IEC 61076-2-113. Weidmüller also demonstrated several SPE developments, including a miniaturised, field-assembly SPE connection system, as well as IP20- and IP67-protected SPE PCB components with optional LED indicators. Weidmüller was one of many suppliers demonstrating SPE products at the recent SPS show in Germany UK industrial AI start-up raises $14m to help it build ‘sentient factories’
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n NEWS January 2026 www.drivesncontrols.com 12 A PROJECT TO PRODUCE a new set of axles for a 129year-old steam locomotive has been chosen as the project of the year in the 2025 AEMT Awards, announced recently. The accolade went to Liverpoolbased Rewinds & J Windsor & Sons, which designed and manufactured replacement axles for the Locomotive No. 5 steam engine, which hauls passengers up the Snowdon Mountain Railway in North Wales. Routine inspections had discovered surface flaws in the locomotive’s axles and further testing revealed internal issues that made repairs impossible. Forging new axles in the traditional way was ruled out because of the long lead times and high costs. So RJW manufactured entirely new axles from solid steel billets. Analysis determined the chemical composition of the original steel and the team used 3D laser scanning to produce accurate models and engineering drawings from the original components. Each of the two new axles began life as a solid, 1.7mlong four-tonne billet of steel, 580mm in diameter. Around 75% of the mass was machined away during the manufacturing process. The project involved mechanical engineering apprentices, who gained hands-on experience in applied manufacturing, problem-solving, and heritage engineering. The new axles were delivered on time and on budget, helping to ensure that the railway’s summer timetable could continue without disruption. Other winners of 2025 AEMT Awards included: Product of the year: Hidrostal, for its high-efficiency, low-maintenance SuperBetsy IPS autonomous mobile pumping system, designed for demanding applications from flood response, to sewage and construction site management. Service centre of the year: IPS Newcastle for its fullservice motor, generator, and pump repair centre with in-house coil manufacture and rewind expertise. Supplier of the year: TEC Electric Motors, which has become the UK’s largest supplier of low-voltage electric New axles for Snowdon Railway win AEMT project of the year motors, offering three-phase motors up to 630kW, including IE3 and IE4 efficiency models, supported by a 24/7, 365-day call-out service. Contribution to skills and training: Sulzer, which aligns its internal growth with industry standards and third-party certification. Through cross-functional collaboration and digital innovation, Sulzer is said to be shaping a futureready workforce and establishing a scalable model of excellence in technical skills. Rising star: Dominic Harvey of Sulzer Services (UK), who manages high-value projects and drives innovation across the business. The award cited his passion for engineering, commitment to professional development, and leadership in outreach initiatives. Diversity in engineering: Innomotics, which says that diversity, equity and inclusion have been part of its DNA from day one. Its policies, ambassador network and global initiatives bring inclusion to life through training, fair recruitment, and programmes such as the Academy of Mining Digitalisation for Women. Sustainable organisation of the year: WEG UK, which drives sustainability through innovation, circular operations, and community engagement. With 73% of its revenues coming from sustainable products and a 28% reduction in emissions since 2021, WEG is said to exemplify environmental leadership. The call for nominations for the 2026 AEMT awards will open in the spring of 2026. A project to replace a Welsh steam engine’s axles has won an AEMT award ROCKWELL AUTOMATION IS BUILDING a new manufacturing plant in the US which could become its largest manufacturing site globally, with a “significant” footprint and the flexibility to scale operations. The new greenfield site, in Southeastern Wisconsin, is the latest step in the company’s plan to invest $2bn in plants, digital infrastructure and talent, in an effort to grow its market share, build resilience, and expand margins over the coming five years. This new facility will include more than 1 million square feet (92,900m2) of manufacturing and warehouse space, and will be equipped with advanced automation, robotics, and digital systems that will showcase Rockwell’s manufacturing capabilities. “It will integrate the latest in Rockwell’s production technologies, including AI and analytics tools, to increase efficiency and precision, while providing team members with access to advanced tools and training,” explains Rockwell’s chief supply chain officer, Bob Buttermore. “Designing a new facility presents the opportunity to create the future of industrial operations, with highly orchestrated production,” adds Rockwell’s chairman and CEO, Blake Moret. “We are expanding our US manufacturing footprint with advanced production capability that supports growth and performance with the latest Rockwell technologies and solutions.” Rockwell says that the planned site reinforces its long-term commitment to American manufacturing and to its skilled workforce. The Southeastern Wisconsin location will be near the company’s global headquarters in Milwaukee. The company has not revealed what it will be manufacturing in the new plant. Construction and site planning are already underway. New Rockwell factory could be its largest in the world
NEWS n SPRINT ELECTRIC, THE UK MANUFACTURER of AC and DC drives, has signed a strategic agreement with the motor specialist, Innomotics, at the SPS automation show in Germany. The partnership brings together Innomotics’high-efficiency low-voltage motors with Sprint’s new Generis regenerative AC drive technology, which made its commercial debut at the show. The agreement gives Sprint preferred access and support for Innomotics’ range of low-voltage AC motors. “The motors are proven technology – highly efficient with terrific performance – which is exactly what we want need to in order to deliver the full potential of Generis advanced control,” says Alan Baird, Sprint’s head of global AC sales. “The range of low-voltage motors from Innomotics is unparalleled,” he adds. “The reliability and robustness of the products will give our AC drives added versatility. The emphasis on sustainability at Innomotics is a perfect match for Generis, which provides fully regenerative AC power with ultra-low harmonics.” Innomotics, formerly Siemens’ motors and large drives business, can trace its history back 150 years. “This is a fantastic partnership, and I am pleased to be part of the launch of Generis,” says Ethan Warburton, Innomotics’business development manager for low-voltage motors. “Our products are geared towards technological innovation. With highly efficient drive systems, together we can replace conventional systems that are less sustainable.” Sprint signs deal with Innomotics linking LV motors to new regen drives 13 www.drivesncontrols.com January 2026 Innomotics’ product promotion manager Ryan Stewart, at the SPS exhibition with Alan Baird, Sprint Electric’s head of global AC sales SIEMENS HAS ANNOUNCED AN enhanced services for repairing and refurbishing its automation products designed to help endusers to move towards a circular economy by restoring nonfunctioning devices, optimising resources and reducing scrap. The new Circular Repair Services offering allows users to operate their Siemens devices cost-effectively and reliably, increasing availability while making lifecycle costs more predictable. There will be two levels of service: n Circular Repair Advanced This will restore products to full performance, with preventive measures being applied in a reliable and cost-effective way. It covers products such as Simatic HMI panels and IPCs, as well as industrial drives including some products in the Sinumerik, Sinamics S and Simodrive families. Siemens’ service experts will identify the cause of non-functioning or worn-out devices and replace them to restore full performance. Minor cosmetic blemishes on the housings that do not affect functionality will be left. Software and firmware updates will be applied if required to meet safety and industry standards, without modifying the equipment’s original purpose and functions. Each function will be tested “meticulously”. n Circular Repair Premium This remanufacturing service, which comes with a 24-month warranty, will be Siemens’most comprehensive repair sevice. It will cover automation products including selected Sinumerik, Sinamics S, and Simodrive products. Experts will disassemble the devices and inspect them, with the help of AI, to identify the cause of a malfunction. Non-functioning components and damaged housings will be replaced. In addition, parts that are still working, but likely to break down soon, will be replaced with original, factory-tested components. If the original housing shows signs of wear, it will be replaced. The device will then be updated to the latest software and firmware, and hardware components renewed, if needed, to achieve full technical equivalence with the original purpose and functions of the equipment. After reassembly, products will undergo extensive testing. By combining original parts with expert knowledge, the equipment will be restored to as-new performance and appearance. “With Circular Repair Services, companies can choose the extent to which they want to restore the performance and appearance of their Siemens devices to high-quality,” says Marc Konrad, Siemens’ head of global customer services for motion control. “This comprehensive offering helps our customers extend the useful life of products, use resources more effectively, achieve reliable efficiency and is therefore the direct answer to the market requests we have received.” The new services are being rolled out initially in selected countries and for specific products. Siemens plans to expand both the product range and the geographic coverage. https://drivesncontrols.news/dpxq2q5b Siemens’ two-tier repair services will help users to move to a circular economy Siemens’ new repair services will extend the lifetime of its automation products, and help users to move towards a circular economy
GOOD NEWS AND BAD We start the new year with things looking marginally rosier for the UK manufacturing sector than you might expect. For example, 2025 ended with the news that the sector grew for the first time in more than a year, according to the S&P Global UK Manufacturing PMI (Purchasing Managers’ Index), which hit a 14month high of 50.2 in November – the first time it has been in expansion territory (above 50) since September 2024. Domestic demand strengthened, while the downturn in new export work eased to a 12-month low. Breaking down the data by company size suggests that while large firms have increased their production volumes, SMEs experienced renewed downturns, and foreign demand dropped for the 46th month in a row. However, the outlook for the manufacturing sector showed some positivity. Business optimism rose to a nine-month high, with 56% of manufacturers reporting that they expect their output to be higher a year from now. Only 11% are anticipating a contraction. On the other hand, manufacturing job losses continued to mount for the 13th month in a row. Then, in mid-December, Make UK and BDO released their Q4 Manufacturing Outlook, based on a survey of 263 companies. This revealed that both UK and export orders had expanded during the quarter, and that investment intentions remained positive (at +19%). But the good news ends there. The report also showed that recruitment had weakened significantly, and that confidence had dropped for a second quarter in a row. And, after expanding by about 0.5% in 2025, Make UK now expects the UK manufacturing sector to contract by a similar amount this year. James Brougham, Make UK’s senior economist, cautions that “the prospects for any form of significant growth remain remote”. “It’s now essential that Government brings forward the proposed energy support scheme and, at the same time, extends it right across the sector so the broadest possible range of companies are covered,” he adds. “With firms set to take a hit on increased employment costs, employers also want to see reassurances from Government that the upcoming Employment Rights Bill will not add further financial burdens on businesses.” Richard Austin, BDO’s head of manufacturing, describes 2025 as “a volatile one for UK manufacturers. While the last six months have shown tentative signs of growth in output and orders, the sector is lacking the confidence and assurance they need to put their hands in their pockets and invest.” Although the November Budget gave manufacturers some relief in terms of investment, green transition and positive skills measures, “it fell short in addressing some of the biggest concerns the sector is facing,” Austin warns. “Businesses need decisive action if growth is to be realised.” So, despite some glimmers of hope, is seems that 2026 will be another tough year for UK manufacturers. It sometimes seems difficult to discern any light at the end of the tunnel. Tony Sacks, Editor n COMMENT pot en ti a l o f y o Are you inve our workforce? esting in the mproves Comp Creates an Adaptable a ncreases Productivi mproves Safe W Industry recognised co I I a I any Reputation nd Flexible Workforce y and Performance orking Practices ourses from the BFPA W t a p Please call 01608 6479 00 or bfpa.co.u RITISH FLUID POW B email enquiries@bfpa.co.uk k/training WER ASSOCIATION / Drives&Controls Follow us on LinkedIn @Drives & Controls Join us on Facebook Drives & Controls Follow us on X @DrivesnControls For the latest news visit www.drivesncontrols.com Drives& Controls
Drives&Controls & BACK TO BASICS n SPONSORED BY Mitigating long cable distances Cable runs in motor-drive applications should ideally be kept as short as possible, but in some situations long cable distances are unavoidable. Liam Blackshaw, ABB’s UK product manager for LV drives, discusses some of the mitigations that can be used to ensure that both drive and motor function optimally. In general, the less cabling you have between a motor and its drive, the better. But in hazardous environments, or in mining, pumping or offshore applications where the drive has to be situated away from the motor, long cable runs are sometimes unavoidable. The longer the cable, the higher its capacitance and impedance. There is also the impedance of the motor’s windings to consider – smaller motors tend to have higher impedances than larger ones. A very long cable paired with a small motor will lead to an impedance mismatch, which creates reflected waves in the cable. This can then lead to a voltage overshoot at the windings, and a brief voltage spike. This can be further compounded by the rise time of the IGBTs in the drive – a faster rise time will lead to a bigger overshoot. If the voltage overshoot exceeds the insulation rating of the windings then, over time, the insulation will start to break down, eventually resulting in motor failure. When it comes to cabling, how long is too long? That depends on the rating and frame size of the motor and drive, the length and type of the cabling, the application and the environment. For lower power applications the maximum can be a few metres. For larger applications, it can be hundreds of metres. The motor and/or drive manufacturer will specify the maximum cable length so, if in any doubt, contact them to make sure. Bear in mind also that multiple motors being operated from a single drive count towards the same cable length allowance, so two 50m cables in a multi-motor arrangement are equivalent to one 100m cable for a single motor. There are several ways to mitigate long cabling. The most common is to add an output filtering device between the drive and motor. This can be an output reactor, a dV/dt filter, or a sinewave filter. These all work slightly differently, but in general they work to filter out any high-frequency voltage spikes, reduce reflected waves, and eliminate voltage peaks. This may however have knock-on effects for motor operation – a lower voltage to the motor means higher current, and a hotter motor, so this also needs to be taken into account to ensure maximum system efficiency. If in any doubt, contact your motor and/or drive manufacturer, and they will be able to advise the most appropriate solution for your assets.
n TECHNOLOGY January 2026 www.drivesncontrols.com 16 THE WELSH DRIVES-MAKER Invertek Drives unveiled the latest addition to its Optidrive family of variable-speed drives (VSDs) at the SPS exhibition in Germany. The Optidrive E4, due for release later this year, represents a significant step in Invertek’s general-purpose drive technology, offering enhanced diagnostics, improved connectivity, and advanced motor controls. The E4 has a built-in flight recorder, dual-channel SIL3 Safe Torque Off (STO), USB-C and Bluetooth connections, and industrial Ethernet communications for real-time integration with other systems. The E4 provides extra capabilities compared to the existing E3 model, which will continue to be offered for generalpurpose applications. “The Optidrive E4 was engineered to give OEMs and system integrators a smarter, more connected platform without adding complexity,” explains E4 product manager, Justin Walker. “From USB-C plugin setup, to embedded diagnostics and mobile app support, we’ve focused on accelerating commissioning and simplifying maintenance, while enhancing control performance across an even wider range of motor types.” The E4 supports both induction motors and hybrid permanent magnet motors. Invertek’s latest precision current control algorithms ensure optimum torque production, superior thermal management and reduced electromagnetic interference. There is a built-in C1 EMC filter. With industrial Ethernet interfaces including Profinet, EtherCat and Modbus TCP, the E4 enables real-time data exchange for precision control and diagnostics. It supports predictive maintenance strategies and integrates with Industry 4.0 and IIoT systems. “The E4’s embedded intelligence and network readiness are a direct response to customer demand for drives that communicate, analyse, and adapt,” says Invertek’s sales and marketing director, Rhydian Welson. “By combining fast setup, advanced safety functions and detailed diagnostic insight, the E4 helps users reduce downtime and increase overall equipment effectiveness.” Each Optidrive E4 carries a QR code that acts as a digital product passport. When scanned with a mobile device, the code opens a dedicated app, which provides instant access to detailed information about the drive, including its build data, specifications, and configuration history The code also provides access to configuration data, manuals, and troubleshooting tools, allowing engineers, OEMs and installers to view a complete digital record of the drive, simplifying commissioning, traceability, and lifecycle support. The built-in flight recorder logs operational parameters continuously, helping to analyse events rapidly, and cutting the time taken to resolve issues. The Optidrive E4 will be available from Q3 2026 in frame sizes 1 and 2, with IP20 enclosures. Larger sizes will follow. Invertek Drives CEO, Adrian Ellam, says that the Optidrive E4 “demonstrates how Invertek continues to combine ease-ofuse with cutting-edge innovation. It’s the most connected and diagnostic-capable drive we’ve ever produced, ready for today’s automation challenges and tomorrow’s efficiency standards.” Invertek, which is part of Sumitomo Heavy Industries (SHI), is manufacturing the new drive at its global headquarters in Welshpool, Wales. www.invertekdrives.com ROCKWELL AUTOMATION HAS announced a “breakthrough” that brings generative AI to the industrial edge, using Nvidia’s Nemotron Nano – a small language model (SLM) that has been optimised for Rockwell’s FactoryTalk Design Studio platform and other Rockwell products, marking “a major step in real-time industrial intelligence”. In collaboration with Nvidia, Rockwell is using the open-source Nemotron-Nano-9B-v2 model and NVvidia NeMo to deliver an edge-based generative AI capability aimed at industrial environments. Nemotron Nano provides the basis for an SLM that can run in edge environments with low space and power requirements. Rockwell is fine-tuning the model with data used by its FactoryTalk Design Studio Copilot. The new model – built for use across design, development, production and maintenance operations – runs on HMI panels, industrial appliances, desktop IDEs (integrated development environments) and server or private cloud environments. It supports both edge and air-gapped deployments, and is claimed to offer better reasoning, predictability and responsiveness than other SLMs. Early evaluations are said to have demonstrated the model achieving reasoning, parallel processing and key performance breakthroughs. The results highlight that it is a good fit for industrial edge applications where instant responsiveness, data security and offline operation are needed. “Industrial automation demands AI that works reliably at the edge and in secure environments,” says Rockwell’s FactoryTalk Design Studio business manager, Tony Carrara. “By fine-tuning the open Nvidia Nemotron model with FactoryTalk Design Studio data, we’re creating solutions that can be deployed anywhere to help our customers accelerate workflows without compromising predictability or control.” “Small language models like Nvidia Nemotron Nano bring realtime intelligence to where decisions are made – from factory floors to power grids,” adds Joey Conway, Nvidia’s senior director for enterprise generative AI software. “With Nvidia Nemotron Nano, enterprises using Rockwell FactoryTalk Design Studio can deploy AI in environments with limited space and power, extending AI from data centres into the heart of real-world operations.” www.rockwellautomation.co.uk Generative AI at the edge extends AI from data centres to the real world Invertek says its new Optidrive E4 is a response to a demand for drives that communicate, analyse and adapt Invertek’s new drive is its ‘most connected and diagnostic-capable’ ever
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