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50 CONTENTS n Drives & Controls is a controlled circulation publication. If you live in the UK and want to subscribe phone 0333 577 0801 or fax 0845 604 2327. Alternatively for both UK and overseas subscriptions please subscribe online at www.drivesncontrols.com. If you have any enquiries regarding your subscription, please use these numbers . The content of this magazine, website and newsletters do not necessarily express the views of the Editor or publishers. The publishers accept no legal responsibility for loss arising from information in this publication. All rights reserved. No part of this publication may be produced or stored in a retrieval system without the written consent of the publishers. Paid subscriptions UK: £110 per annum Europe: £145 per annum Rest of World: £180 per annum Printing: Warners Midlands PLC., PE10 9PH ISSN 0950 5490 Copyright: DFA Media Group 2026 NEXT ISSUE The May issue of Drives & Controls will contain our annual supplement on electric motors, plus a look at developments in linear motion technologies, and applications in the scientific, pharmaceuticals and medical engineering markets. We will also be previewing Smart Manufacturing Week 2026. UPDATE 12 Comment 13 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 34 26 24 22 5 46 DRIVES & CONTROLS APRIL 2026 Vol 42 No 4 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. 22 UK Manufacturing The UK manufacturing sector is undergoing a digital revolution, progressing from experimentation to using digital technologies across their operations. Following visits to some of the UK’s leading manufacturers, a digital transformation expert identifies what he sees as the key innovations that are shaping the next chapter in smart manufacturing. 24 Motion Control Compact motion control systems are essential for applications ranging from surgical robots to drones. While their design is based on the laws of motion, perfecting their operation is an iterative process. A motion control engineer discusses the process of designing such systems. 26 Machine-Building Reports from the world of machine-building, including how digital twins were used to develop a Swiss tram-washing machine, and how a German manufacturer has reduced the need for reworking with a new machine that screws profiles together using multiple heads. Plus how to prepare for changes to CE marking in the EU’s upcoming Machinery Regulation. 34 Machine Vision How machine vision technologies are being used in a variety of applications including cheese-making, fan manufacturing, and high-speed, roll-to-roll thinfilm production. Plus how Japanese researchers are using high-speed cameras to monitor robot vibrations without needing to use sensors. 40 Conveyors and Materials-Handling How an Italian producer of components for electric vehicles has turned to a linear transport technology to help it solve problems previously encountered when assembling battery cells. Plus three strategies to help users of conveyor systems in heavy industries to cut the cost of owning these systems. 44 Mach 2026 Preview Next month’s Mach 2026 manufacturing show will showcase a wide range of technologies, live and in action, as well as offering expert insights and the opportunity to catch up on the latest developments through a series of Knowledge Hubs located around the show. 42 44 Average net circulation January to December 2024 Subscribe for your FREE copy now 20,514 14 45
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NEWS n 5 THE BMW GROUP IS launching a pilot project to use humanoid robots at its Leipzig plant in Germany, with the aim of integrating humanoids into series production of its cars, and exploring their use in the production of batteries and components. BMW is working with the Swiss humanoid developer, Hexagon Robotics, which launched its first humanoid robot, called Aeon, in June 2025. Unusually, the robot has wheels instead of feet, allowing it to move rapidly in any direction. A variety of hand and gripper elements, or scanning tools, can be attached flexibly to the robot’s arms. Following an initial theoretical evaluation and successful laboratory tests on the Aeon robot, BMW started to test the humanoid at the Leipzig plant in December 2025. It is now planning further tests, before the full-scale pilot trial begins in the summer. “Our focus is on step‑by‑step integration into our production system to explore a wide range of applications,” explains Michael Ströbel, BMW’s head of process management and digitalisation. “The emphasis is on researching multifunctional use of the robot in various production areas such as battery manufacturing for energy modules, and component production for exterior parts.” The European pilot follows BMW’s first deployment of humanoid robots, at its Spartanburg plant in the US last year. This trial was based on Figure AI’s Figure 02 robot which was use to move and position sheet metal parts for welding – a task that is demanding in terms of speed and accuracy, as well as being physically exhausting. The trial showed that the humanoid added measurable value under real-world conditions. In ten months, the robot moved more than 90,000 components and completed around 1.2 million steps, working ten-hour shifts, five days a week. In total, it operated for around 1,250 hours and supported the production of more than 30,000 of BMW’s X3 model. www.drivesncontrols.com April 2026 BMW and Figure AI are now evaluating potential applications for Figure’s latest (03) robot. The US trial confirmed that humanoid robots can safely perform precise, repetitive work steps – such as positioning components with millimetre precision. It also provided important insights for the further deployment of physical AI in BMW’s operations. One key finding was that the transition from the laboratory to an actual production environment was faster than expected. Motion sequences trained in the laboratory could be transferred rapidly into stable shift operations. To ensure smooth coexistence with existing systems, the robot was integrated into BMW’s Smart Robotics ecosystem via standardised interfaces. BMW believes that a prerequisite for using AI effectively in production is to adopt a unified IT and data model across the entire production system. It has therefore transformed isolated data silos into a unified production data platform, with all of the data being consistent, standardised and available at all times. This allows digital AI agents to take on increasingly challenging tasks autonomously and in complex environments, while continuously learning and becoming available for new applications. BMW says that the introduction of intelligent and autonomous decision‑making agents marks “a paradigm shift” in production. “Our aim is to be a technology leader and to integrate new technologies into production at an early stage,” says Michael Nikolaides, BMW’s senior vicepresident for production network and supply chain management. “Pilot projects help us to test and further develop the use of physical AI – that is, AI‑enabled robots capable of learning – under real-world industrial conditions. “The successful first deployment of humanoid robots at our BMW Group plant in Spartanburg in the USA proves that a humanoid robot can function not only under controlled laboratory conditions but also in an existing automotive manufacturing environment,” he adds. BMW sees humanoid robots as potentially adding value to its automation systems. They are particularly promising for monotonous, ergonomically demanding or safety‑critical tasks. The aim is to relieve employees and improve working conditions. BMW will use humanoids for first time in Europe at a German plant BMW sees humanoid robots as adding value to its automation systems, especially in monotonous, demanding or safety‑critical tasks CYBERSECURITY IS NOW A bigger concern for automotive manufacturers than cutting costs, introducing flexible manufacturing, or adopting AI, according to a new survey conducted by ABB Robotics. The poll of 473 automotive industry decision-makers around the world reveals “a fundamental shift” in how manufacturers view digital risk, operational continuity and the future of vehicle production, according to the company. The Automotive Manufacturing Outlook Survey shows a high level of consensus, with 95% of respondents regarding cybersecurity as “significant”, and 53% identifying it as being “extremely significant”. Respondents in all regions, and across OEMs, and Tier 1 and 2 suppliers, all ranked cybersecurity as the industry’s top priority for the coming five years. ABB says that the results reflect the rapid expansion of connected technologies on the factory floor. Advanced robotics, vision systems, analytics, digital twins and AI are delivering major gains in productivity, quality and flexibility. But they also require secure, controlled connections to deliver their full value. “Cybersecurity is no longer something manufacturers are thinking about for the future – it is something they must address at the heart of production today,” says Joerg Reger, managing director of ABB Robotics’ automotive business. “As factories become more connected, software-driven and data-intensive, cybersecurity has become a core manufacturing discipline.” This survey’s findings differ from those conducted in previous years, when cybersecurity was just one of a broader set of concerns. Today, says ABB, manufacturers increasingly recognise that cyber-incidents do not simply affect IT systems – they can halt production, disrupt supply chains and affect finished products, even in environments where equipment is not directly connected to the Internet. With more than 90% of respondents expecting to increase their use of AI and big-data management, and a similar number planning greater adoption of digital twins and simulation, secure connectivity is no longer optional, according to ABB. www.abb.com/global/en/areas/robotics/industries/automotive/ manufacturing-outlook-survey Cybersecurity is now a bigger worry for car-makers than costs
April 2026 www.drivesncontrols.com 6 RS GROUP IS BUYING BPX GROUP, the Leicesterheadquartered distributor of industrial automation and control products, for £27m, plus a possible £3m linked to its 2026 performance. BPX, which has more than 6,000 customers and operates through 20 branches and two distribution centres (in Leicester and Huddersfield), will expand RS’s technical capabilities in automation and control – a segment that already accounts for more than 40% of its revenues. BPX, founded more than 50 years ago, employs around 230 people and has seven trading brands. It holds more than £10m of stock, spanning more than 100,000 products. It holds more than 60 distributorships, with Schneider Electric being its largest partner. BPX will operate as a standalone brand within RS. “We are delighted to welcome BPX Group into the RS family,” says Raj Patel, RS managing director for UK & Ireland. “This acquisition will strengthen our product technical capabilities in the automation and control category and help to accelerate our growth plans within the UK and Ireland markets. “Through the technical expertise and specialist knowledge of BPX, combined with the scale, knowledge and reach of RS Group, we will find new opportunities to win in the markets in which we operate, and continue to grow our businesses together,” he adds. “The BPX heritage is what makes it such a special business, so we want to celebrate that alongside our own RS story – and look ahead to a brighter future together.” BPX Group director, Guy Collins, says: “This is an exciting step for BPX Group which will take the business to the next level. BPX is a complementary business to RS in the UK and Ireland. Both are high-service level distributors of automation and control products with an overlap of product range and a customercentric focus, but each serving the market in different ways. p The Japanese motors giant Nidec is facing a possible loss of 250 billion yen (£1.175bn) after a third-party report found widespread accounting fraud in the group, which it blamed on intense pressure from the company’s founder, Shigenobu Nagamori, who formed it in 1973 and built it up to sales of around 2.6 trillion yen (£12.23bn) and more than 100,000 employees. Although the report found no evidence that Nagamori ordered the fraud, it concluded that he was aware of, and had condoned, some of the practices. Nidec’s chairman and three other executives have resigned, while president and CEO, Mitsuya Kishida will take no salary until late 2026. Nagamori has resigned his position as honorary chairman. p ABB has appointed Halesowen-based Hayley Dexis as the first UK national distributor for its high-efficiency, lowvoltage electric motors. To support the partnership, Hayley Dexis has established a stock of ABB IE3 motors at its Dudley, West Midlands, facility. It is guaranteeing replacement stock within 5-7 working days. In the longer term, the agreement will give access to other ABB motors including its IE6 SynRM machines. For the first time, the agreement includes direct support from ABB for onsite commissioning and installation services for motors and drives. p The UK events organiser, Nineteen Group, is launching a US version of its Smart Manufacturing Week conference and exhibition in Detroit from 19–22 April, 2027. The launch marks the next step in its plans to build a platform for the advanced manufacturing, reliability and asset management markets. Smart Manufacturing Week US will consist of two shows – Smart Factory Expo and Maintec (covering maintenance, reliability and asset management) – as well as the Manufacturing Digitalisation Summit and The Reliability Conference, which Nineteen acquired when it bought Reliabilityweb. p Ipswich-based Boardley & Roberts has bought the East Midlands electric motors business, W H Shoebridge & Sons for an undisclosed sum. Shoebridge has been run by one family since it was founded in 1919. Operating in Northampton, Wisbech and Peterborough, it sells and repairs electric motors, geared systems and spares. Managing director Robert Shoebridge, the third generation to run the businesses, is retiring. He wanted to sell the firm to a buyer with a similar ethos. NEWS BRIEFS BPX’s headquarters are located in Leicester n NEWS RS buys Leicester-based automation and control distributor BPX, for £27m THE NORTHERN IRELAND industrial drives and motors supplier, Technidrive, has launched a scrappage scheme to help businesses to cut their energy consumption and operating costs. The scheme will allow them to trade in their existing motors or drives for IE3, IE4, IE5 or IE6 efficiency motors from WEG, and receive a scrappage value that can reduce the cost of the upgrade. The scheme includes a simple assessment and approval process, compliant recycling, and the disposal of the old equipment. Technidrive says that by cutting upfront costs, the scrappage allowance can shorten payback periods significantly for businesses upgrading their legacy equipment. The company will provide upgrade recommendations based on the application. Upgrades to the new high-efficiency motors, supplied and commissioned by Technidrive, will qualify for trade-in credit, cutting the cost of moving to the newer technology. Where speed control is possible, adding a VSD could deliver further savings by matching the motor output to demand. WEG has a payback tool that compares efficiency classes, forecasts energy savings and calculates returns on investment. It can include VSDs for centrifugal applications. “What many businesses don’t realise is how much value may be tied up in the equipment they already own,” says Technidrive’s technical director, David Strain. “By combining trade-in credit with a properly engineered upgrade and commissioning service, we’re helping our customers to modernise with confidence and to build a greener, more cost-effective operation.” www.technidrive.co.uk/solutions/ energy-efficiency Electric motor scrappage scheme will cut costs and emissions
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n NEWS THREE UK-BASED COMPANIES – Siemens, the robotics technology provider, Expert Technologies Group (ETG), and the robotics integrator, RMGroup – have joined forces to produce the UK’s first customisable AMRs (autonomous mobile robots). They say that the collaboration represents a strategically important milestone for UK industrial automation, creating the first comprehensive end-to-end manufacturing capability for AMRs that will enable users to boost productivity and efficiency at their sites. The robots have been designed to help factories and warehouses to move materials around more easily, without needing fixed tracks or heavy infrastructure. The AMRs can be adapted to suit different tasks, industries and environments, giving users a flexible, scalable way to boost productivity. “This partnership demonstrates how UK-led innovation can deliver the advanced manufacturing technology our industry desperately needs,” says Brian Holliday, Siemens’ managing director for the UK & Ireland. “By supporting UK manufacturers with locally developed, fully customisable solutions, we're showing that collaboration is essential to driving the digitalisation of British industry. “Together with RM Group and Expert Technology Group, we’re building the foundation for intelligent, autonomous operations that will help businesses be more productive through better, more reliable factory logistics, and help keep UK manufacturing competitive on the global stage." The AMR is based on ETG’s FlexDrive platform and uses Siemens Simove control systems and laser-based navigation software to deliver both track-based and free navigation capabilities. The vehicles have wireless safety on-board with real-time location-based safety zones. Their navigation options include path planning, obstacle avoidance and real-time dynamic positioning. The scalable, flexible AMRs can be modified to adapt to the needs of a facility. They can be used for autonomous logistics and warehouse management, as well as real-time data collection for digital twin simulations. Paul Fletcher, senior manager at Coventrybased ETG, says the new AMR “ represents a fundamental shift in how UK manufacturers can approach autonomous mobile robotics. Rather than forcing businesses to adapt to rigid, offthe-shelf solutions, we're creating hyperflexible platforms that adapt to their needs. This partnership gives us the scalability and technical foundation to support everything from small-scale deployments to enterprise fleets of one hundred plus robots.” “We've seen too many AGV and AMR implementations fail due to inadequate support or integration issues with overseas engineering teams,” adds RMGroup’s operations and commercial director, James Nicholls. “This collaboration tackles that problem head-on by creating a truly UK-made, UK-supported end-toend solution that our customers can rely on.” April 2026 www.drivesncontrols.com 8 UK trio joins forces to create Britain’s first customisable AMRs The couplings, brakes and hydraulic components supplier, KTR UK, has appointed David Smith (left) as its new managing director, succeeding Geoff Ancliff, who has retired after was 27 years with the company. Smith brings more than 16 years of experience with KTR. For the past 13 years, he served as sales manager and off-highway specialist for the construction sector. Gary Doyle is the new UK managing director of the power supply specialist, Puls. Doyle has nearly 20 years of experience with industrial companies including Lapp, PP Electrical Systems and Harting, where he worked for more than 11 years, most recently as UK and Ireland sales and distribution manager for more than a year. The systems integrator, ITI Group, has appointed Nick Leeder as a strategic advisor. Leeder, who has previously worked for Dyson, Philips, SKF and PTC, is an authority on manufacturing transformation and an advisor on advanced manufacturing to the World Economic Forum. His appointment follows ITI’s acquisition of the AssetMinder condition-monitoring technology. The companies behind the new AMRs say the development represents “a strategically important milestone for UK industrial automation” EVENTS 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 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 CWIEME Berlin / EEMODS 26 19-21 May, 2026 Berlin, Germany The world’s largest coil-winding and electrical manufacturing exhibition will host the biennial EEMODS (energy efficiency in motor-driven systems) conference for the first time in 2026. The conference is expected to attract experts and policymakers from around the world to discuss efficiency and regulatory issues regarding motors, pumps and compressors. 2026 also marks CWIEME Berlin’s 30th anniversary. https://berlin.cwiemeevents.com/home 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 Hillhead 2026 23-25 June, 2026 Hillhead Quarry, Buxton, Derbyshire The UK’s largest quarrying, construction and recycling equipment exhibition takes place every two years in a working Derbyshire quarry. It includes live demonstrations of quarrying equipment. Across its three days, the show is expected to attract around 600 exhibitors and nearly 20,000 visitors. Hillhead 2026 is on course to be the largest event in the show’s 44-year history. www.hillhead.com
n NEWS April 2026 www.drivesncontrols.com 10 ROCKWELL AUTOMATION HAS opened a customer experience centre in Bologna, Italy, to help machinebuilders and end-users from across the EMEA (Europe, Middle East and Africa) region to address the challenges facing them. The centre, the third of its type in the world (the others are in Milwaukee and Singapore), will support customers in sectors such as packaging, material handling, converting and heavy industries. The centre will offer hands-on experience of control, motion and mechatronics products, as well as advanced technologies such as AI, independent cart Italian technology centre will help OEMs to tackle challenges TERADYNE ROBOTICS, THE OWNER OF the Danish cobot specialist Universal Robots and the AMR manufacturer MiR, is accusing the German subsidiary of the Chinese robot-maker, Elite Robots, of infringing Universal Robots’ software copyright. Teradyne says it has “irrefutable evidence” of copyright infringement by Elite, and will be looking to the German justice system to protect its IP (intellectual property) rights. Teradyne Robotics previously sent a cease-and-desist letter to Elite Robots’ German affiliate, and has now referred the matter to the German courts. Teradyne stresses that wider interests are at stake and that, without strong enforcement of IP rights, Europe risks losing its ability to scale automation, maintain competitiveness, and safeguard high-standard manufacturing. As well as taking the legal action against Elite, Teradyne Robotics has also alerted safety authorities in Europe about safety concerns relating to Elite Robots’ robots. Teradyne says it has pioneered standards for robot safety and specialises in advanced robots which, subject to safety assessments, can work safely alongside people. In recent years, it adds, it has seen growing competition from robot companies which sometimes lack the same rigorous approach to safety. Teradyne Robotics Group president Jean-Pierre Hathout describes the legal action as a “decisive step” that “underscores our commitment to protecting IP and ensuring automation customers have access to safe and high-quality solutions. “Both automation and innovation are critical to Europe’s future,” he adds. “We will not allow the products of companies that unlawfully copy protected technologies to compromise customer experience, the intellectual property of our technology sector or Europe’s industrial future.” If Europe allows IP infringements to go unchecked, Teradyne argues, it effectively subsidises non-European competitors, while undermining its own innovators. It is calling on policymakers and industry leaders to ensure that Europe remains a secure environment for innovation. “Teradyne Robotics is choosing to take a stand against any competitors willing to copy proprietary hardware or software design to undercut on price,” Hathout says, “and we invite other leaders to join us in defending the integrity of our industry and strength of our economy.” systems and dynamic digital twins. It will also provide digital strategy planning and training services, as well as collaborative innovation, helping users to accelerate their digital transformation. “Manufacturers across EMEA are facing a perfect storm of technology, workforce and supply chain challenges,” says Paolo Butti, Rockwell’s regional president for global industry accounts. “The Bologna customer experience centre is our answer to these challenges – a place where OEMs can access the latest innovations, validate solutions in real-world scenarios, and empower their teams for the future. This centre will help our customers turn disruption into competitive advantages.” The opening of the Bologna centre comes at a critical time for machinebuilders. According to a recent Rockwell survey of 500 OEMs in 17 countries, manufacturers are facing unprecedented challenges: n Technology adoption gaps 29% of OEMs globally cite a lack of appropriate technology as being a barrier to achieving their strategic goals. n Workforce instability High employee turnover and skills shortages are among the top five challenges for OEMs, with many in the EMEA region reporting workforce issues. n Downtime costs Globally, unplanned downtime costs an average of $92,000 per hour, with the best OEMs recovering 40% faster from incidents by using advanced automation and digital technologies. Rockwell has published the results of the survey in its OEM Advantage Playbook. The new centre will help to address these issues, and includes three areas for customer engagement: n A leadership area This highlights remote access capabilities and live connections to manufacturing plants, supporting executive-level collaboration and strategic planning. n A technology and proof-ofconcept area This provides hands-on demos and machine testing, allowing OEMs and end-users to validate solutions before full-scale deployment. They can explore digital twins, virtual AMRs (autonomous mobile robots) and advanced mechatronics, accelerating innovation and reducing risk. n A competency area This will deliver technical training, product updates and workforce development programmes, helping customers to upskill their teams and to close the talent gap. Rockwell says that the centre offers an immersive, collaborative environment where manufacturers can overcome technology challenges and build workforce resilience. Rockwell says its experience centre will help machinebuilders and OEMs to overcome technology, workforce and supply chain challenges. Teradyne accuses Chinese robot-maker of infringing UR copyright
n NEWS NEWS n www.drivesncontrols.com April 2026 11 THE JAPANESE CLUTCH and automotive transmission manufacturer Exedy is buying Protean Electric, the UK-based developer of in-wheel motors (IWMs) for electric vehicles, for around €30m. Exedy says the acquisition will help it to transform its portfolio to provide new opportunities in the automotive sector as it undergoes “a major transformation”. Exedy expects Protean’s in-wheel motor technology to improve vehicle control and increase freedom in vehicle designs. It also believes that Protean’s technology – which combines mechanical, electrical and control engineering – has the potential to contribute to changes in drivetrain architectures. It predicts that the integrated technology could advance control integration, which is often cited as a challenge in the shift toward software-defined vehicles. Another potential attraction of Protean’s technology is that it could allow two-wheel-drive platforms to be converted to four-wheel operation quickly and at relatively low cost. Exedy says that Protean could also help to address an “internal challenge” that it is facing – its limited number of engineers with expertise in both mechanical and electrical technologies. “Our acquisition of Protean allows Exedy to address the ongoing shift towards electrification in the automotive industry – a key pillar of our business,” explains Exedy CEO, Tetsuya Yoshinaga. “Protean is a market-leader that develops, manufactures, and sells in-wheel motors – drive motors integrated into the wheels – which already has a track record of commercial deployment. Through the acquisition, Exedy intends to combine the technological strengths of both companies to continue providing competitive products and services.” Protean says that under its new ownership, it will be able to meet the market demand for its in-wheel motors at an industrial scale and at a competitive cost. As the automotive industry moves towards electrification and software-defined platforms, the backing of a Tier 1 supplier will allow Protean to develop its products further and to expand into new markets. “This transaction represents a major step in the adoption of ProteanDrive as a mainstream drivetrain solution for the automotive industry,” says Protean Electric’s CEO, Andrew Whitehead. “Our acquisition by Exedy allows our OEM customers to confidently enable their future products with in-wheel motors. The potential for ProteanDrive to allow OEMs to deliver better electric vehicles has been clear to many for years – this transaction provides us with the industrial scale to offer a sustainable, cost-competitive product that turns the potential into reality.” Exedy is buying Protean from Bedeo, a UK company specialising in electric transport technologies, which acquired Protean from National Electric Vehicle Sweden (NEVS), a subsidiary of China’s Evergrande New Energy Vehicle Group, in 2021. Protean, founded in 2008, has had a chequered history, with several changes of ownership. The company has more than 330 patents across 75 patent families, and operations in the UK, China and Turkey. According to Exedy, Protean made an operating loss of £4.6m in 2025. Last year, Protean claimed that the latest generation of its ProteanDrive wheel motor technology would cost the same as conventional twin-axle drive systems, offering the potential to lower electric vehicle costs and to deliver other advantages. It also claimed that it was the first IWM supplier able to deliver production-ready, high-performance IWMs for passenger car applications. Protean also announced that Renault is planning to use two of the integrated wheel-motors in its Renault 5 Turbo 5E electric sportscar, designed to accelerate from 0–100km/h in less than 3.5 seconds, and hit a top speed of 269km/h (167 mph). Deliveries of these sportscars are due to start in 2027 using Protean’s Pm18 2500 drive system, which delivers more than 2.5kNm of torque and 220kW of power per wheel motor. Exedy’s global sales in 2024 amounted to 309.6bn Japanese yen ($2bn). It has operations in 25 countries and employs around 14,200 people. Japanese clutch-maker buys UK in-wheel motor pioneer for €30m A Protean Electric in-wheel motor being tested Building work starts on UK motor manufacturer’s new plant in Somerset THE UK ELECTRIC MOTOR manufacturer Electrified Motors has started to build a new state-of-the-art manufacturing facility in Bridgwater, Somerset. The company designs and manufactures highperformance PMAC (permanent magnet AC) motors for off-highway vehicles and other applications, including industrial. The development of the new 25,000ft2 (2,323m2) site represents a milestone in the company’s growth strategy and will upgrade its production capacity significantly to meet a growing market demand. The facility, due to open in third quarter of 2026, will initially employ around 40 people. This number is expected to double to 80 over the coming four years. “It’s fantastic to see construction progressing so well on our new Bridgwater facility,” says managing director, Jim Winchester. “The investment is aimed at supporting growing demand for electrification across off-highway, industrial and specialist vehicle applications. “Our new site will allow us to scale our manufacturing output through advanced automated production lines, while continuing to deliver the performance and quality our customers expect.” Electrified’s IPM (interior permanent magnet) motors span ratings from 3–12kW (7–44kW peak), with peak torque ratings of 30–140Nm. They operate from 24–96V supplies and have a top speed of 7,000 rpm. Electrified has also developed stator assembly and overmoulding technologies.
THE TECH BROS ARE COMING FOR MANUFACTURING Amazon’s founder, Jeff Bezos, is reportedly looking to raise $100bn for a new fund that would acquire manufacturing businesses and use AI to enhance their use of automation. According to a report in the Wall Street Journal, he has met with asset and sovereign fund managers in the Middle East and Singapore to raise the funds for what is described as “a manufacturing transformation vehicle”. He has also asked the investment bank JP Morgan to get involved. Bezos wants to target the electronics, defence and aerospace sectors, in particular. The proposed fund is linked to Project Prometheus, an AI start-up that Bezos co-founded last year with Vik Bajaj, previously with Google X. Prometheus, headquartered in California, and with offices in London and Zurich, employs more than 120 people, some of whom have been poached from Meta, OpenAI and DeepMind. It has been valued at around $30bn. Prometheus launched with $6.2bn in funding and is apparently looking to raise a further $6bn. The company is creating AI models designed to improve manufacturing and engineering in aerospace, automotive and other sectors. The AI models understand and simulate real-world engineering environments, rather than relying on digital data. Bezos plans to use the new fund to buy up manufacturers and implement Prometheus’ models in their operations. Bezos’ fund will be one of the biggest ever targeting the manufacturing sector. It is similar in scale to Saudi Arabia’s Alat company, launched in 2024 with the aim of making Saudi a global leader in advanced manufacturing and electronics. The Alat project is intended to create $100bn of investments and 39,000 jobs by 2030 – although these plans may be affected by recent events in the region. Alat has already formed a strategic collaboration with the Chinese computer-maker Lenovo, which is building a 200,000m2 advanced manufacturing facility in Riyadh. And the Finnish liftmaker, TK Elevator (currently the subject of takeover rumours involving Kone) is setting up a €160m venture with Alat to make lifts and escalators in Saudi. There are other, smaller initiatives looking to transform manufacturing. For example, Uber founder Travis Kalanick recently announced a company called Atoms that is developing (non-humanoid) mobile robots for the food , transportation and mining sectors. And the venture capital firms Thrive Capital and General Catalyst have also launched vehicles to acquire legacy industrial firms and boost their margins using software. Thrive has a $10bn fund focusing on AI-enabled industrial technologies and robotics, while General Catalyst has invested $120m in an initiative called Re:Build Manufacturing, aimed at creating a new type of industrial firm focusing on local manufacturing. Meanwhile, Elon Musk is repurposing Tesla as “a physical AI company” and investing more than $20bn in his Optimus humanoid robot and AI ventures, including retooling a Tesla car plant in California to make robots. Between them, these initiatives have the potential to reshape manufacturing. But predictions by tech entrepreneurs aren’t always achieved in reality. Tony Sacks, Editor n COMMENT Kno e ow mor Uptime d LeineLin Ear Do deliver reliability in hars nde’s 800 Series encode . more rn less. h e • Increa • Plan m • Predic give you c Wireless ase returns maintenance es ct failur e complete insight—befor diagnostics and conditio o eland Sales UK & Ir +44 1444 247711 sales@ //w @heidenhain.co.uk https:/ www.leinelinde.com
Drives&Controls & BACK TO BASICS n SPONSORED BY The EU Machinery Regulation: what you need to know The new EU Machinery Regulation comes into force in January 2027 and has potentially far-reaching consequences for machine-builders, particularly when it comes to cybersecurity. ABB’s industrial automation product manager, Carl Eely, explains some of the key points. The EU’s Machinery Regulation (Regulation (EU) 2023-1230) comes into force on 14 January, 2027. It supersedes the Machinery Directive 2006/42/EC. At first glance, it may seem like a logical progression, with the usual expansion of scope and greater conformity requirements for health and safety. However, whereas previously the directive’s focus was on physical machine safety, the new regulation links safety inextricably with cybersecurity. Furthermore, this is not merely a box-ticking exercise – it fundamentally changes how machine design needs to be approached. PLCs and drives, as connected components at the heart of many modern machines, sit squarely within its scope. Machine-builders will have to carry out cybersecurity risk assessments, identifying where and how their systems might be exposed to the threat of cyberattacks. A risk assessment in itself is not hugely onerous, and it doesn’t necessarily have to be carried out by a third party (although this may be advisable if your organisation lacks in-house cybersecurity expertise). The risk assessment may reveal that the cybersecurity provisions for a machine are solid, and no specific actions are required. A machine that operates entirely offline, for example, might need little more than a certificate of its isolation. However, any machine with remote access, network connections or cloudbased functions, will need evidence that its digital defences are solid and fit-for-purpose. It should also provide any recommended mitigation measures for end-users. Even if the assessment requires no further action, this needs to be documented. However, this is where the regulation makes things slightly easier, with fully digital documentation now allowed. The intent of the regulation is to encourage deliberate and well-justified choices, rather than simply ticking a box. The wider shift here is to encourage consideration of cybersecurity at the earliest stages of machine development, as well as throughout its lifecycle. One of the most straightforward ways to meet the new requirements is to use components that already comply. Reputable vendors will be able to advise on relevant products and how to implement them. For more information, search for “ABB EU Machinery Regulation”. 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
n TECHNOLOGY April 2026 www.drivesncontrols.com 14 RESEARCHERS AT MIT (the Massachusetts Institute of Technology) in the US have developed a 3D-printing platform that can create a working linear motor in a matter of hours using just five materials. The technology could allow motor users to produce their own replacement motors on-site, avoiding the need to order new machines, and potentially ending costly delays. A motor failing in automated machinery can bring production to a halt. If the site engineers don’t have a replacement available, they may have to order one from a distributor and wait for it to be delivered, causing considerable disruption. Fabricating motors needs specialised equipment and complicated processes, restricting production to specialised manufacturing sites. The new MIT system offers a time- and moneysaving alternative. It processes multiple materials, including electrically conductive materials and magnetic materials, using four extrusion tools. The printer switches between the extruders, which fabricate the motor a layer at a time. The researchers only needed to perform one post-processing step to produce a working motor. They say that their motor performs as well as, or better than, similar motors that need more complex fabrication methods or additional post-processing steps. The researchers suggest that, in the long run, their 3D printing technique could be used to fabricate customisable components rapidly for robots, medical equipment and other applications, with much less wastage. “This is a great feat, but it is just the beginning,” says Luis Fernando Velásquez-García, a principal research scientist in MIT’s Microsystems Technology Laboratories (MTL), and senior author of a paper describing the 3D-printing platform. “We have an opportunity to fundamentally change the way things are made by making hardware on-site in one step, rather than relying on a global supply chain. With this demonstration, we’ve shown that this is feasible.” The researchers focused on 3D extrusion printing, which involves squirting materials through nozzles to fabricate objects one layer at a time. To produce the electric machine, they needed to be able to switch between multiple materials with different characteristics. For instance, the motor needed an electrically conductive material to carry electric current, as well as hard magnetic materials to generate magnetic fields for efficient energy conversion. Most multi-material 3D extrusion printing systems can only switch between two materials which both have to be in the same form – for example, filament or pellets – so the researchers retrofitted an existing printer with four extruders, each of which handles a different feedstock. They designed the extruders to balance the requirements and limitations of the material. For instance, the electrically conductive material had to be able to harden without needing large amounts of heat or UV light, because these could degrade the dielectric material. The best-performing electrically conductive materials come in the form of inks that are extruded using a pressurised system. This process has different requirements to standard extruders that use heated nozzles to squirt melted filament or pellets. “There were significant engineering challenges,” Velásquez-García reports. “We had to figure out how to marry together many different expressions of the same printing method – extrusion – seamlessly into one platform.” The researchers used strategically placed sensors and a novel control framework to allow each tool to be picked up and put down consistently by the platform’s robotic arms, and to ensure that each nozzle moves precisely and predictably. This guarantees that all of the material layers line up with each other correctly. Even a slight misalignment could affect the performance of the finished machine. After perfecting the printing platform, the researchers produced a linear motor similar to those used in pick-and-place robots and conveyors. They produced the motor in about three hours and only needed to magnetise the hard magnetic materials after printing to achieve a working machine. They estimate that the total material costs for the 3Dprinted motor were about 50 US cents. The motor was able to generate actuation forces several times higher than linear motion devices that rely on complex hydraulic amplifiers. “Even though we are excited by this engine and its performance, we are equally inspired because this is just an example of so many other things to come that could dramatically change how electronics are manufactured,” says Velásquez-García. In the future, the researchers want to integrate the magnetisation step into the multi-material extrusion process, fabricate 3D-printed rotary motors, and add more tools to their platform to enable monolithic fabrication of more complex devices. “We have an opportunity to fundamentally change the way things are made by making hardware onsite in one step, rather than relying on a global supply chain. We’ve shown this is feasible.” 3D printing breakthrough could let you print your own motors The tools used in MIT’s 3D motor printing platform. From left to right: an ink extruder; a pellet extruder; a filament extruder; and a heater. Image: Courtesy of the researchers
In today’s high performance manufacturing landscape, reliability has become the economic foundation of every production strategy. As facilities increase throughput, compress maintenance windows, and integrate more digital processes, the financial impact of unexpected downtime continues to grow. Leine Linde’s ADS Uptime directly targets this challenge. By embedding advanced condition monitoring inside encoder technology, it enables plants to predict faults, optimize maintenance planning, and achieve measurable gains in operational resilience—delivering a practical and scalable path toward Industry 4.0. At its core, ADS Uptime is a diagnostic platform built into Leine Linde’s encoder systems, providing continuous insight into the health of rotary equipment and its operating environment. Instead of treating encoders as passive electromechanical devices, ADS Uptime transforms them into intelligent monitoring nodes. Real time diagnostics on vibration, shaft speed, temperature, and humidity help maintenance teams detect early warning signs and convert encoder supervision from a reactive task into a predictive maintenance discipline. Wireless Diagnostics That Transform Maintenance Workflows A standout advantage of ADS Uptime is its wireless capability on the 800 series encoders. Using integrated Bluetooth, maintenance personnel can access real time condition data through a mobile app from anywhere on the plant floor. This turns traditional inspection routines into fast, data driven evaluations. Technicians can instantly review vibration trends, temperature behaviour, and environmental impacts, while adjusting alarm thresholds to match specific application demands. The mobile interface is more than a visual display. It functions as a strategic analytics tool, storing historical encoder data and presenting it through clear, actionable graphs. This enables users to identify gradual changes, correlate patterns, and intervene before anomalies escalate into failures. With improved awareness of mechanical stressors, plants can extend equipment lifetime, enhance safety margins, and significantly reduce unplanned shutdowns. Seamless System Integration With ADS Link For operations dependent on higher level industrial automation, ADS Uptime integrates smoothly through ADS Link—an OPC UA based gateway that feeds encoder diagnostics straight into existing monitoring, SCADA, or maintenance systems. This makes encoder health data available to operators, engineers, and maintenance planners across the organization. The effect is transformative: encoders become active contributors in a unified, plant wide predictive maintenance ecosystem. With richer datasets and automated condition reporting, organizations can shift away from time based maintenance toward proactive, data driven decision making. Preventing Failures Before They Disrupt Production In industries where every hour of downtime carries high financial impact, ADS Uptime delivers the early detection capabilities required to protect production. Its alarms—both predefined and user configured—offer immediate visibility into harmful working conditions. Variations in vibration, frequency, and run time metrics highlight developing mechanical issues long before they compromise equipment integrity. Preventing even a single unplanned stop can justify the entire investment in ADS-equipped encoders. Driving the Proactive Maintenance Mindset Traditional preventive maintenance relies on fixed intervals rather than real operational behaviour. ADS Uptime fundamentally changes this model. By continuously collecting diagnostic data and identifying emerging failure signatures, it supports more accurate decisions on service timing, component replacement, and performance optimization. Over time, these insights foster a culture built on predictive diagnostics rather than reactive repair. A Scalable Platform for the Smart Factory Era Designed for both new installations and retrofits, ADS Uptime aligns with modern industrial digitalization strategies. With Bluetooth access, OPC UA architecture, and app based workflows, it fits seamlessly into connected factory environments and remains adaptable as plants evolve. Conclusion: Turning Uptime Into Competitive Advantage Uptime is no longer simply operational—it is strategic. Leine Linde’s ADS Uptime combines intelligent sensing, advanced diagnostics, and streamlined connectivity to provide the visibility and foresight industrial teams need to act early, prevent failures, and maintain peak performance. For manufacturers pursuing greater reliability and smarter maintenance, ADS Uptime is more than a monitoring tool—it is a decisive step toward safer, more efficient, future-ready operations. n CORPORATE PROFILE Leine Linde are distributed in the UK & Ireland by HEIDENHAIN GB Ltd.: T: 01444 247711 E: sales@heidenhain.co.uk How Leine Linde’s ADS Uptime Is Redefining Industrial Reliability
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