ENERGY EFFICIENCY: You don’t need a new factory to boost your efficiency FOOD AND BEVERAGE: Food and beverage drives failures start at specification MAINTENANCE, SERVICE AND REPAIRS: What has changed for the ‘responsible person’? Drives&Controls AUTOMATION FOR MANUFACTURING INSIDE SEPTEMBER 2026 www.drivesncontrols.com
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 October issue of Drives & Controls will contain a special section devoted to developments in machine-building, as well as roundups of recent applications in precision engineering and motion control, and news from the water industry. UPDATE 14 Comment 15 ABB Back to Basics 54 New Products 56 Multimedia and Design Data 57 Products & Services IN DEPTH Follow us on X @DrivesnControls Drives Magazine Web site www.drivesncontrols.com Follow us on LinkedIn @ Drives & Controls Join us on Facebook Drives & Controls Drives& Controls REGULARS DfAmedia group 46 44 36 28 5 55 DRIVES & CONTROLS SEPTEMBER 2026 Vol 42 No 8 Editor Tony Sacks t: 01732 465367 e: tony@drives.co.uk Production Manager Sarah Blake t: 01233 770781 e: sarah.blake@dfamedia.co.uk Marketing Manager Hope Jepson t: 01732 370340 e: hope.jepson@dfamedia.co.uk Financial Finance Department t: 01732 370340 e: accounts@dfamedia.co.uk ADVERTISING Sales Director and DFA Direct Damien Oxlee t: 01732 370342 m: 07951 103754 e: damien.oxlee@dfamedia.co.uk Sales Manager Sara Gordon t: 01732 370341 m: 07505867211 e: sara.gordon@dfamedia.co.uk Italy Oliver & Diego Casiraghi e: info@casiraghi.info t: +39 031 261407 f: +39 031 261380 Managing Director Ryan Fuller t: 01732 370344 e: ryan.fuller@dfamedia.co.uk Reader/Circulation Enquiries Perception-MPS Ltd t: 01825 701520 e: cs@perception-sas.com HEAD OFFICE DFA Media Group 192 High Street, Tonbridge, Kent TN9 1BE t: 01732 370340 f: 01732 360034 e: info@dfamedia.co.uk www.drivesncontrols.com 5 News A round-up of the latest business and industry developments from around the world. 16 Technology Cutting-edge innovations in motion, power transmission, controls and related technologies. 24 Machine Vision AI is becoming one of the most important factors shaping the future of machine vision. It is expanding the number and variety of applications, and will be a primary driver of future growth. An expert observer considers how AI is transforming the market, and impacting various industries. 27 Energy Efficiency You don’t have to build a new factory to improve sustainability in your manufacturing operations. You can start by understanding where energy is consumed on existing lines. Plus how a ceramics producer has cut the time that it spends monitoring and controlling energy from hours to minutes. 34 Food and Beverage How a German brewery has slashed its can-printing downtime by 99% by installing a vision inspection system. And how a Spanish automation specialist has developed a system for applying labels automatically to Serrano hams – an arduous task, performed by humans until now. 40 Maintenance and Repairs Recent updates to the standard governing the repair, overhaul, and reclamation of equipment used in hazardous areas have seen notable updates to the “responsible person” role – placing much more responsibility on the function. An insider explains. 46 Artificial Intelligence AI software is already influencing how industrial assets are maintained, processes are optimised, and workforce planning is transformed. An expert outlines how AI is shifting from a future ambition, to a scalable technology that is reshaping industrial operations today. 48 Humanoid Robots What happens when a component in a humanoid robot fails when it is operating in a real-world environment? The CTO of Teradyne Robotics argues that the real test for humanoids isn't just how well they work, but how safely they respond when something goes wrong. 50 Interoperability Opting for interoperable components when modernising automation systems allows users to upgrade their systems gradually, lowering capital and operating costs, reducing risks and disruption, and prioritising investments to obtain the best operational benefits and returns. 52 Engineering Design Show preview The Engineering Design Show (EDS), now in its 14th year, has unveiled a new brand built around three key disciplines: mechanical design, electronic design, and embedded design. The organisers describe the rebrand as a “realignment”. 53 Gearboxes A German manufacturer of fitness and rehabilitation equipment has turned to industrial gearboxes, motors and controls to help provide the smooth, quiet operation needed for a range of strength training machines. 48 50 Average net circulation January to December 2025 Subscribe for your FREE copy now 27,126 20 53
Energy and Automation LOVATO Electric is always looking for ways to work smarter that benefit its customers and suppliers. This shortform catalogue makes browsing for products easier and more efficient. Detailed product descriptions, images, diagrams and specifications ensure informed decisions can be made before ordering. We like to save you time, reduce hassle, and enjoy a seamless browsing experience of our vast product range. Available as a digital download, or if you would prefer, you can email us at sales@lovato.co.uk for your own printed copy. 01384 899700 | lovato.co.uk | sales@lovato.co.uk YEARS NAVIGATING YOUR WAY THROUGH OUR PRODUCTS JUST GOT EASIER WITH THE LOVATO SHORTFORM CATALOGUE BY YOUR SIDE, YOU HAVE ALL THE INFORMATION YOU NEED. SCAN ME YOUR CATALOGUE IS A CLICK-AWAY 5 34 64 PRODUCT GROUPS PRODUCT RANGES PAGES OF PRODUCT DATA
NEWS n 5 Motor and drive developers secure £47m of government funding UK ELECTRIC MOTOR AND DRIVETRAIN developers, including Yasa and Turntide, are among those that will benefit from 33 projects chosen to receive more than £47m in funding as part of the UK Government’s £4bn Drive35 automotive programme. The initiative is designed to support the development and commercialisation of next-generation automotive technologies, while strengthening UK manufacturing, innovation and supply chains. It supports businesses through targeted funding from early-stage innovation, through to commercialisation and manufacturing. The Drive35programme – delivered by the Department for Business, Innovation, Science and Trade (BIST) in partnership with the Advanced Propulsion Centre UK (APC) and Innovate UK – forms a key part of the Government’s Advanced Manufacturing Sector Plan and Industrial Strategy, supporting the transition to zero-emission vehicle technologies. It is said to represent the biggest government investment in the UK car industry since the Second World War, with a planned total investment of £4bn in the period to 2035, aimed at speeding up the electrification of the automotive sector. The goal is to create tens of thousands of high-quality jobs and to contribute around £66bn to the UK economy by 2040. The programme aims to help businesses to bring innovative technologies to market, creating skilled jobs, attracting private investment, strengthening domestic supply chains and reinforcing the UK’s position as a global leader in automotive innovation. When combined with private sector investment, the new grant funding represents a total investment of more than £90m, supporting electrification and battery technologies, advanced manufacturing, digitalisation, the circular economy and zero-emission mobility. The successful projects have been broken down into five categories supporting different stages of the innovation process. Mobilise This covers early-stage start-ups, university spin-outs and SMEs. In total, 16 businesses have been awarded more than £2.7m, including: n Cooled Motors, which is developing a magnet-free motor topology that matches the performance of rare-earth magnet motors, while reducing costs. It uses standard manufacturing processes and inverters, simplifying the transition from magnet to magnetless motors for OEMs. n Electric Aviation Group, which is developing a compact electric drive system that combines several key parts into a single assembly that could make vehicles lighter, more efficient, and easier to build. n Aeramine, which is developing a way to turn used copper into high-quality material that can be used again in EV parts. Collaborate Two collaborative R&D projects have been awarded more than £8m, including one, called Autoloom, that brings together: n Q5D Technologies, Artifex Interior Systems, JLR and the University of Warwick to industrialise Q5D’s digital manufacturing technology for wiring harnesses, replacing labour-intensive manual assembly with an automated, CADdriven process. Demonstrate Ten projects have been awarded £9m for real-world demonstrations of innovative technologies, including: n Yasa (owned by Mercedes), whose Project Resilience seeks to demonstrate an axial-flux motor free of heavy rare-earth materials, intended to improve sustainability and increase resilience to supply chain problems. n Nexperia UK, which will demonstrate a next-generation silicon power Mosfet architecture designed to improve efficiency in EV electrical systems. Scale-up This is awarding £26.9m to five businesses to help them bridge the gap between innovation and manufacturing at scale. They include: n Empel Systems, which is aiming to create scalable UK manufacturing capabilities for advanced power electronics assemblies. n Turntide Technologies, whose Supreme project (which has won £17m of funding) aims to scale up production of watercooled axial-flux motors, achieving expected cost reductions of 59%. According to Ian Constance, chief executive of the Advanced Propulsion Centre UK, the 33 projects selected for support “demonstrate the depth of innovation and engineering excellence that exists across the UK automotive sector. Through Drive35, we are supporting businesses to move promising technologies to commercial deployment and manufacturing at scale. “This investment is about far more than individual projects,” he adds. “It is about strengthening the UK’s capability to design, develop and build the technologies that will define the vehicles of the future. By bringing together industry, government and academia, Drive35 is helping create the conditions for long-term growth, increasing investor confidence and reinforcing the UK’s position as one of the world’s leading destinations for automotive innovation.” www.drivesncontrols.com September 2026 The motor developer Yasa will use its Drive35 funding to design and develop a new generation of rare-earthfree axial-flux motors
n NEWS September 2026 www.drivesncontrols.com 6 Siemens merges four automation businesses p The Government has announced that agri-tech businesses can now apply for part of a £20m funding pot to develop robots and other technologies for planting, tending and harvesting crops. The successful bidders will collaborate with researchers and farmers to develop the next generation of farm automation and robotic technologies. p Neura Robotics is buying Bosch Rexroth’s Active Shuttle AGV (automated guided vehicle) business for an undisclosed sum. The acquisition will expand Neura Mobile Robots’ autonomous intralogistics portfolio and help Neura to build an open AI ecosystem. Neura plans to enhance the Active Shuttle technology with AI capabilities and interfaces. Neura has also acquired Adlatus Robotics, which makes autonomous cleaning robots. p The UK’s automation trade body, Automate UK, is working with the Health and Safety Executive (HSE), the Regulatory Innovation Office (RIO) and the Manufacturing Technology Centre (MTC) to draw up the first official guidance on how to use collaborative robots (cobots) safely alongside humans. Their aim is to support the safe and responsible adoption of robots in the workplace, providing businesses with clarity on regulatory requirements and helping to increase their uptake. p The Liverpool robotics integrator, CNC Robotics, has closed after failing to attract investment to secure its long-term viability. The company, founded by Jason Barker in 2010, was a pioneer in the use of industrial robots as an alternative to traditional machine tools. The company announced its closure “with deep sadness” adding that “for 16 years, CNC Robotics has been our passion, our livelihood and, for many of us, a significant part of our lives”. In its 16 years, the company completed more than 150 projects in 12 countries. p TE Connectivity is buying the industrial power management and filtering specialist Astrodyne TDI for around $1.4bn. The acquisition, which brings annual sales worth more than $250m, is expected to close this year. p Rockwell Automation has announced a service that will deliver continuous, realtime monitoring of operational technology (OT) environments to help protect them against cyber-threats. The Security Monitoring and Response service will integrate with existing architectures to help industrial organisations to stay ahead of cyber-threats and to build resilient operations. p Electro-Wind has delivered 54 bespoke IP65-rated 28V DC trailer transformers, designed and manufactured at its plant in Stoke-on-Trent. Each transformer has a heavy-duty steel enclosure, finished with a durable outdoor-grade paint, and all were delivered within eight weeks NEWS BRIEFS THE US AIR QUALITY specialist Madison Air Solutions is buying ebm-papst, the German manufacturer of high-performance airflow technologies and a pioneer in EC (electronically commutated) fans and motors, for $5.4bn. The acquisition will nearly double Madison Air's addressable market, while vertically integrating differentiated air flow technologies, and growing its commercial and services opportunities. The three families that currently own ebmpapst see Madison as the ideal partner for its continued growth. “With Madison,” they say, “ebm‑papst gains a new, long-term-oriented owner with strong innovative capabilities and operational scaling expertise to accelerate growth. In turn, the partnership gives Madison access to differentiated air flow technology and highly attractive markets, particularly in Europe, enabling the company to further scale its business outside North America.” ebm-papst’s headquarters, r&d and manufacturing operations will stay in Mulfingen, Germany. Madison Air says it intends to strengthen ebm‑papst and its more than 13,000 employees – including around 5,800 in Germany – and“stands ready to make additional investments”. ebm-papst, founded in 1963, has more than 250 million fans installed worldwide. It is expected to generate revenues of around $2.8bn and an adjusted EBITDA of some $343m in 2026. Last year, ebm-papst sold its Industrial Drive Technology (IDT) division to Siemens. Madison Air supplies air quality systems for commercial and residential use. Its brands include Addison, AprilAire, Big Ass Fans, Broan-NuTone, Nortek Air Solutions and Reznor. It employs more than 9,000 people and achieved sales worth $3.5bn in 2025. Madison generates most of its business in the US, and will gain access to European markets via the ebm‑papst acquisition. Madison Air buys German fan-maker ebm-papst for $5.4bn SIEMENS IS COMBINING its four automation businesses – Factory Automation, Motion Control, Process Automation and Customer Services – into a single Automation organisation from 1 October. Rainer Brehm, currently COO and CTO of Siemens Digital Industries automation business, has been appointed president of the new Automation operation, and will report to Siemens board member and CEO of its Digital Industries division, Cedrik Neike. The changes are designed to advance Siemens’ One Tech Company strategy, and to strengthen its automation business to help customers build more flexible, productive and resilient production systems. “The future of industry lies at the intersection of automation, software and AI, enabling faster innovation, greater scalability and more tailored customer solutions,” says Neike. “That is exactly why we are creating the Automation unit. “I am pleased that Rainer Brehm will lead this new organisation,” he adds. “He understands the technologies, markets and customer needs and has been deeply committed to automation throughout his career. Together with our strong team, he will further develop and strengthen this business.” Commenting on his future responsibilities, Brehm says: “Artificial intelligence is transforming industry. This makes a strong automation partner more important than ever. I look forward to working with our teams around the world to further strengthen Siemens’ leadership in automation. Together, we aim to shape the next phase of industry and advance AI-enabled autonomous production, helping our customers become more flexible, productive and competitive.” In his current role, Brehm has been driving the strategic development of Siemens’ automation portfolio, including technologies such as software-defined automation and industrial AI. He previously served as CEO of Siemens’ Factory Automation business. Brehm: shaping the next phase of industry
NCC 8-pole bayonet locking > 5000 mating cycles Panel mount parts unplugged IP67 Solder and dip solder contacts www.binder-connector.co.uk
n NEWS September 2026 www.drivesncontrols.com 8 SHIPMENTS OF COLLABORATIVE robots (cobots) will almost double between 2025 and 2030, expanding at an average annual rate of 17.3%, according to a new report from Interact Analysis. The growth is being driven by a combination of factors including equipment upgrades in electronics manufacturing, cyclical recoveries in the semiconductor industry, the increasing use of automation in logistics and warehousing, improved safety, easier operation, and falling cobot prices. In 2025, global shipments of cobots rose by 14.5% to hit around 57,000, while revenues climbed by 10.5%, from around $1.1bn to more than $1.2bn. Between 2025-30, Interact predicts that global cobot revenues will grow by an annual average of 13.6%, to reach more than $2.3bn in 2030, when it expects 128,918 cobots to be shipped. It attributes the gap between shipment and revenue growth rates to falling average prices for cobots. However, the rate of decline is predicted slow due to the stabilisation of the price war in China, and escalating manufacturing costs in Europe and the US. China continues to dominate the global cobot market, with its growth outpacing other major regions. Interact reports that China’s share of global cobot revenues rose from 28.9% in 2018 to 54.7% in 2025, and predicts that it could reach 61.4% by 2030. By contrast, it expects EMEA’s market share to drop from 18.1% to 13.5% by 2030, and to be overtaken by the Americas. Interact suggests that industry is shifting towards medium- and high-payload cobots. Traditionally, cobots have focused on payloads below 10kg, but the market is moving to larger payloads – including machines with capacities above 20kg – blurring the lines between industrial and collaborative robots. Cobot sales could double by 2030 A GROUP OF US GOVERNMENT agencies have issued a warning of an active cyberthreat to Siemens S7 series PLCs in which the attackers are using AI-generated scripts, disguised as legitimate monitoring tools, to find Internet-exposed PLCs that are poorly protected or running outdated software. They say that this use of AI represents “an evolution in threat actor capabilities, dramatically reducing the technical expertise and time required to develop working ICS exploitation scripts and malicious tools”. In addition, AI allows the attackers to leverage additional attack vectors rapidly, and to adapt to defensive measures. The threat actors can easily collect public information about vulnerabilities and weaknesses, find exposed and exploitable PLCs, and use AI-generated scripts to act on this information. The agencies warn that exploitation of poorly protected PLCs could lead to disruption of critical industrial processes, safety incidents, downtime or equipment damage, compromise of sensitive data, compliance violations, and cascading impacts across interconnected systems,. “If PLCs are exposed to the Internet, they are at high risk for exploitation,” they say. “This is not a theoretical risk – it is an active threat.” The agencies – which include the NSA (National Security Agency), Cisa (Cybersecurity and Infrastructure Security Agency), FBI (Federal Bureau of Investigation), DoE (Department of Energy) and the EPA (Environmental Protection Agency) – recently issued another warning about cyberattacks by “Iran-affiliated cyberactors” on PLCs used in critical infrastructure applications. This warning was followed by reports of cyberattacks on water utilities in at least seven US states. The latest warning does not identify the potential attackers, but says that the Siemens PLC risks are “one subset of a wider threat landscape”. The agencies are urging all owners and operators of OT (operational technology) systems that use Siemens S7 series and other PLC devices to check that their systems: n are properly protected with all applicable security patches and updates, n are isolated from the Internet wherever possible, and n have strong access controls, and employ security tooling to monitor ICS environments for anomalous or malicious activity. They say that these mitigations are particularly important for owners and operators who work with third-party service providers or systems integrators who may have remote access to their PLCs, because the owners may not realise that their systems are exposed and at risk. For more details see our Web site at www.drivesncontrols.com Cyberattackers are using AI to find vulnerable Siemens S7 PLCs, US warns Siemens S7-1500 PLCs are one of the models identified by the US agencies as being possible targets for cyberattacks
Small Dimensions, High Performance Small Modules SMS Quickly chosen, quickly delivered. Contact us at: sales@boschrexroth.co.uk
n NEWS September 2026 www.drivesncontrols.com 10 THE UK MANUFACTURING SECTOR has become the nation’s top target for ransomware attacks, according to a new report from the cybersecurity expert, SonicWall. It reveals that while extortion attempts against other sectors have dropped significantly, cyberattackers are targeting industrial facilities and critical OT (operational technology) environments aggressively with concentrated ransomware strikes. According to SonicWall’s Threat Research team, 364 specialised sensors located in UK manufacturing environments recorded 15.8 million Intrusion Prevention System (IPS) events and 12.2 million malware threats between January and May 2026. It says that the combination of legacy OT systems and modern Web portals leave industrial operations exposed to cyberattacks. Intrusion attempts against UK factories so far this year are running about 28% higher than for the whole of 2025, on an annualised basis, indicating a rising tide of automated network probes aimed at British production lines. According to Sonicwall, the manufacturing sector recorded 1.84 million ransomware events in just five months, confirming it as the single most ransomware-impacted sector in the UK. It blames almost all of these attacks on the Filecoder ransomware family. Almost half (45%) of the monitored manufacturing sensors recorded attacks exploiting React Server Components (RCE) which target newly digitised operational dashboards. SonicWall analysts suggest that the concentration on manufacturing targets highlights active, dedicated campaigns aimed at bringing specific high-value manufacturing plants to a halt – rather than the broad, speculative scattergun activity seen elsewhere. Unlike other UK sectors that are heavily targeted via smart physical surveillance, IoT volume in manufacturing remains low (with around 230,000 hits), indicating that hackers prefer application and legacy infrastructure flaw-vectors. “Our data this year shows a clear pattern – silent reconnaissance against financial services, relentless stress-testing of healthcare, and direct, heavy-handed extortion against UK manufacturing,” says SonicWall’s executive vicepresident for the Emea region, Spencer Starkey. “With 1.8 million ransomware hits – heavily concentrated on individual facilities – attackers clearly see factory floors as prime extortion targets, where downtime means lost revenue and supply chain chaos. “UK manufacturers are navigating a toxic mix of old and new digital risks,” he adds. “Legacy Java sits unpatched in Scada and MES systems because plant managers can't afford production downtime. Meanwhile, new digital frameworks are being scanned by attackers at speed. Manufacturers have got to secure legacy OT, without slowing modern operations." UK factories are a top target for ransomware Schneider Electric has appointed Alex Richards as vice-president of its industrial and process automation business in the UK & Ireland. Richards joined Schneider in 2008, most recently serving as vice-president of segments and strategic accounts in Europe. Before that he was vice-president for mining, minerals and metals in the EMEA region. Siemens has appointed Steve Goldspink as its head of electrification and automation in the UK & Ireland. Goldspink, who has been with Siemens for more than 25 years, was previously head of business development for smart infrastructure. In his new role, he will lead a business focusing on technologies that connect, protect and optimise the grid – combining electrification, automation and industrial AI. Oliver Selby (top) has moved from his role as head of sales at Fanuc UK to the newly created position of strategic key account manager for aerospace and defence, reflecting the growing long-term importance of these sectors to Fanuc. Dan Fisher (below) has succeeded Selby as head of sales. Selby will be responsible for developing partnerships with aerospace and defence organisations, and identifying new opportunities for automation. Fisher previously worked in Fanuc’s business development division. EVENTS PPMA Show 2026 22-24 September, 2016 NEC, Birmingham The UK’s largest processing and packaging machinery, robotics and industrial vision event is expected to attract more than 350 exhibitors and 1,500 brands. The show will be the first that Automate UK has organised since it launched its Apprenticeship Cluster programme designed to address skills shortages in the manufacturing and engineering sectors. The show will offer advice and support to organisations on how to bridge the skills gap. www.ppmashow.co.uk AEMT Conference 24 September, 2026 Manchester, UK The Association of Electrical & Mechanical Trades says that this year’s event will have the broadest programme yet of practical engineering insight, technical expertise, and networking opportunities. It is aimed not only at the AEMT’s electrical and mechanical repairs members, but also at asset owners, manufacturers, and engineers responsible for specifying, maintaining, and improving the performance of rotating equipment. The programme combines technical presentations with discussions on reliability, technology, business leadership and skills. www.theaemt.com/ems-event-calendar/ aemt-conference Engineering Design Show 7–8 October, 2026 Coventry Building Society Arena The organisers say that EDS has entered a new era, with a sharper identity built around the show’s three core disciplines: embedded design, electronic design and mechanical design. They add that EDS is built around the needs of UK design engineers, connecting exhibitors with an engaged audience looking for innovations. More than 200 exhibitors and 4,500 visitors are expected, and there will be more than 50 conferences and workshops. www.engineeringdesignshow.co.uk Digital Manufacturing 2Day 13 October, 2026 MTC, Coventry This event brings together manufacturers, technology providers, experts and innovators to explore how data, automation and AI are transforming operations across the sector. Built around real-world implementations rather than theory, the event focuses on the practical challenges facing manufacturers today, from connecting systems and unlocking the value of data, to scaling automation and delivering measurable business results. https://eur.cvent.me/Pqmavv MachineBuilding.Live 14 October, 2026 National Agricultural Exhibition Centre, Stoneleigh Park The event returns to this venue for a second year. It is aimed at machine-builders, systems integrators and manufacturing professionals needing industrial automation systems. It is billed as “a unique opportunity to meet faceto-face with the largest array of machine building, systems integration and industrial automation technical experts ever assembled in one place at one time in the UK”. https://machinebuilding.live
Meet the W22 Prime, the evolution of WEG induction motors, available as IE4 and IE5 efficiency across the widest range of frame sizes on the market, with uncompromised simplicity. Designed to meet new and future legislation, it integrates seamlessly into existing systems, providing immediate energy savings, reduced emissions and streamlined path to next-level performance. Suitable for all starting devices including Direct-on-line, Star-delta, Soft Starter and VSD, the W22 Prime delivers greater versatility. With a 3 year warranty as standard, the new motor offers efficiency, sustainability and reliability. scan the QR code for more info www.weg.net
n NEWS September 2026 www.drivesncontrols.com 12 TURNTIDE TECHNOLOGIES, a UK-based developer of electric motor, power electronics and energy storage technologies, has secured a £17m grant from the UK Government to accelerate volume production of its watercooled axial-flux motors through increased automation and innovation, helping it to meet a growing global demand for more efficient, high-performance powertrains. Cost reductions of up to 59% are expected, helping to support large-scale adoption. In its match-funded Project Supreme (ScaleUp of PRoduction of Electric Machines), Turntide will automate critical, labour-intensive production processes such as winding, creating tooling components, and validating its products ready for volume manufacture. In the early stages of the 18-month project, the company says it will also register and deliver “breakthrough” intellectual property. Turntide says that faster and more efficient manufacturing at scale will allow it to better serve OEMs (original equipment manufacturers) across a wider range of applications and volumes globally. As part of the project, Turntide will expand the use of its Gateshead production and R&D campus, while re-establishing a dedicated component and validation facility in Cramlington, Northumberland. The project will secure jobs in North East England, while further enhancing workforce skills and development. “Project Supreme is an important step in scaling next-generation electric motor technology production in the UK for the global market,” says Turntide Technologies CEO, Steve Hornyak. “By enabling highvolume axial-flux motor production through automation and overall cost reduction, we’re driving wider adoption of more efficient, lighter electric powertrains across automotive and industrial applications.” Compared to conventional radial-flux designs, axial-flux motors need less space, weigh less, and deliver more power in a smaller package. But manufacturing challenges have historically made axial-flux motors more difficult and expensive to produce at scale, limiting their broader adoption. The project is intended to tackle some of these challenges. Funding for the Turntide project is coming from the UK government’s £4bn Drive35 (Driving Research & Investment in Vehicle Electrification) programme, launched in July 2025 as part of its advanced manufacturing sector plan (see page 5). Turntide, originally based in California, expanded to the UK in 2021 when it acquired three motors and energy businesses based in the North East of England: Cramlington-based Avid Technology, which designed and manufactured powertrain components and systems for heavy-duty and high-performance electric and hybrid vehicles; Sunderland-based Hyperdrive Innovation, a manufacturer of energy storage systems for off-highway and material-handling vehicles, as well as stationary and portable energy storage systems; and the former engineering technical centre of BorgWarner, located in Gateshead. These businesses formed the basis for basis for a new UK division focusing on intelligent motor systems for commercial transport. ROCKWELL AUTOMATION HAS ANNOUNCED a remote support service designed to help manufacturers to cut downtime, resolve problems faster, and simplify software and firmware updates. The TechConnectIQ service makes it easier for maintenance, engineering and operations teams to get help when issues arise. It provides faster access to Rockwell's experts and digital resources, helping teams to stay productive and respond more effectively to challenges. Technical support engineers, available 365 days a year, will assist with installation, configuration, troubleshooting and issue resolution across industrial automation systems. The service will reduce the need for on-site field visits and help teams to work more efficiently through improved access to knowledge and updates. “Manufacturers are being asked to do more with fewer resources and support needs to keep pace,”explains Matt Fordenwalt, senior vice-president for lifecycle services at Rockwell Automation. “TechConnectIQ brings together our expertise and AI capabilities to help customers stay productive when on-site resources are limited.” Benefits of the new service are said to include: n Real-time access to specialists through Web-based tools with scheduled callbacks and live support n Improved data visibility via the myRockwellAutomation TechConnect hub, including installed base and support history n Simplified support structure with consolidated hardware and software coverage and three support tiers: basic, standard and professional n AI-support tools including federated search, augmented reality guidance and instructional videos to assist with maintenance and remote support tasks The new service is available now for single-site contract customers in North America, and Rockwell plans to extend it to other regions during 2027. Rockwell launches digitally-enabled support service to help resolve customer issues faster UK developer wins £17m government grant to boost axial-flux motor plans Turntide will use the UK government grant to accelerate production of its axial-flux motors
THE GEOPOLITICAL THREATS TO INDUSTRIAL AUTOMATION Industrial automation seems to have become a politically hot topic in recent months. First of all, we had a group of US government agencies – including the FBI and the National Security Agency – accusing “Iran-affiliated cyber-actors” of targeting OT (operational technology) devices, including Rockwell Automation PLCs (specifically the Allen-Bradley MicroLogix 1100 and 1400 series), resulting in a potential loss of control and monitoring functions. After accessing Internet-connected devices remotely, they warned, attackers could change IP address and passwords, potentially leading to effects such as loss of pressure and flooding. At least one organisation reported that its PLC files had been modified, after noticing ladder logic discrepancies across several sites. Shortly after this warning, reports emerged that water utilities in at least seven US states – with more than 30 in Minnesota alone – had suffered a series of cyberattacks on their PLC-based control and monitoring systems, resulting in customers being told to boil water, and the need to operate the plants by hand. A few weeks later, the US agencies issues another warning – this time about cyberattackers using AI-generated scripts, disguised as monitoring tools, to find Internet-exposed Siemens S7 PLCs that are poorly protected or running outdated software (see page 8). Although the agencies didn’t identify the source of the attacks this time, they said that the use of AI represents “an evolution in threat actor capabilities, dramatically reducing the technical expertise and time required to develop working ICS exploitation scripts and malicious tools”. They added that exploitation of poorly protected PLCs could lead to disruption of critical industrial processes, safety incidents, downtime or damaged equipment, compromised data, compliance violations, and cascading impacts across interconnected systems. “This is not a theoretical risk – it is an active threat,” the agencies cautioned. Meanwhile, an inter-agency body convened by the White House identified another threat, this time in the form of foreign-made goods including inverters (but excluding variable-speed drives) and advanced robotics devices – such as AMRs (autonomous mobile robots), humanoids and quadrupeds – saying that such items posed “unacceptable risks to the national security of the US, or the safety and security of US persons”. The Federal Communications Commission then banned their sale in the US. This time, the main target was thought to be China – the world’s biggest producer of humanoid robots as well as inverter systems. And the main aim of the ban seems to be to protect US manufacturers operating in these sectors (even though Chinese manufacturers of humanoid robots have yet to enter the US market). Although these warnings have so far focussed on the US, the implications could be global – especially the risk of cyberattacks on the control systems that we now rely on to run our critical infrastructure. With Russia making vociferous threats against the UK, we need to ensure that such systems are protected as effectively as possible. Tony Sacks, Editor n COMMENT
Drives&Controls & BACK TO BASICS n SPONSORED BY Is your AHU due for a health check? Many air-handling units (AHUs) in hospitals were adapted during the Covid-19 pandemic to increase ventilation rates and to maximise air changes. In some cases those temporary adjustments are still in place, leading to chronic inefficiency and unnecessary strain on equipment, as Richard Lane from Bristolbased APDS – an ABB Value Provider – explains. Working with healthcare estates teams across the UK, APDS regularly carries out surveys of hospital AHUs. Those surveys frequently reveal motors running beyond their intended operating point (max 50Hz speed ref), drives with incorrect commissioning parameters, and mechanical components preventing systems from achieving peak performance. For instance, during Covid-19, hospitals reduced airborne transmission risks by increasing ventilation rates. Often the quickest way to do this was simply to increase fan speeds. While this met the immediate operational need, many of these changes remained in place long after they were needed, leaving AHUs operating outside of their original design parameters, and putting motors into field weakening. How do we fix this? The first step is not necessarily about replacing equipment, but about assessing and understanding whether the system is operating as intended. A mechanical and electrical survey can identify issues that have developed gradually over time, but remain hidden during routine maintenance. Many AHU systems have evolved over decades, with different teams making different adjustments to keep systems running. Again, these adjustments are often made in good faith. But without a holistic view of the whole installation, inefficiencies can accumulate. A motor might be updated, yet the drive settings are kept the same. Or changes in the facility’s power factor or harmonic content are not reflected in the complete power drive system. In my experience, around 30-40% of installations will have incorrectly configured equipment – I routinely see obsolete equipment from more than 30 years ago. Motors, drives, and mechanical components should all be correctly matched to achieve expected performance. Power quality is also an important factor. Hospitals are continuously adding more and more harmonic-generating equipment, yet the electrical infrastructure often remains unchanged – and may, by now, be operating close to its limits or in bypass. Reviewing harmonic levels and ensuring mitigation strategies, such as ULH (ultra-low harmonic) drives, can improve resilience and availability, without having to upgrade cables and distribution devices. Optimising AHUs is about understanding the complete system rather than replacing individual components. As an ABB Value Provider, we‘re able to take a step back and consider systems from both an electrical and mechanical perspective, ensuring your whole AHU system gets a clean bill of health when it comes to offering peak efficiency, reliability and performance. Lamonde Automation Limited Quality Products: Expert Advice +44 (0)20 3026 2670 sales@lamonde.com | www.lamonde.com Lamonde Automation Limited Quality Products: Expert Advice Easy installation and terminals that make wiring-up simple AS EASY AS COMMANDER S CLICK, WIRE, GO
n TECHNOLOGY September 2026 www.drivesncontrols.com 16 SICK HAS ADDED AI deep-learning algorithms to its Nova 3D machine vision platform to allow quick customisation, and open up new capabilities, including height analysis. Sick says that the AIpowered 3D image processing goes far beyond the human eye to ensure faulty products are removed from production and packaging processes at an early stage. The AI capability allows configurable 3D machine vision, and improves quality control using intelligent inspection. An example-based approach, combined with on-device training, simplifies the development of vision applications and offers a cost-effective way of incorporating deep learning into quality control, without needing any extra equipment. A 3D height analysis capability unlocks advanced quality-control applications that Sick says were previously difficult or impossible to achieve with traditional rules-based inspection. Key applications include: n inspecting deformed packages in sectors such as food & beverage and consumer goods; n detecting empty boxes or missing objects in totes or matrix packaging, in fulfilment and logistics operations; n verifying assembly and inspecting surfaces in electronics and battery production; n inspecting and classifying in automotive applications; and n checking completeness in manufacturing operations. For example, AI-powered inspection of deformed packages can validate the appearance, integrity and function of packaging after filling, measuring deviations in the shape and surfaces of packages. It can detect defects at high speeds, even if there is no colour contrast. Teach-by-example using sample images simplifies set-ups. The AI is trained using an organisation’s own data. Users collect data, train models and execute inspection tasks directly on the device, with quick set-up of inspection tasks, allowing rapid batch changes. Every pixel carries a height value, enabling 3D data and defects to be reconstructed by a trained neural network in the Nova AI software. It allows colour- and contrast-independent inspection and improves quality control, with defects being displayed on an anomaly heatmap. The toolset also includes traditional rules-based machine vision software tools. “Our latest innovation combines Sick quality, expertise and consistency with deep learning to meet demand in two of the highest growth product categories in machine vision: AI software and 3D imaging,” says Sick product manager, Diego Quintana Tukasaki. “Introducing neural network AI capabilities into our high-performance Nova platform expands 3D inspection beyond its traditional limits. “Seeing far beyond the human eye, it provides greater control over data and analytics to deliver highly accurate, configurable, easy-to-train, customised intelligent inspection solutions,” he adds. “Inspected items fulfil required quality and sorting demands, helping to improve yield, reduce waste and increase customer satisfaction, while problems with batches or production lines are swiftly identified with the anomaly heatmap.” www.sick.com/gb/en TELEDYNE DALSA HAS ANNOUNCED a “groundbreaking” shortwave infrared (SWIR) hyperspectral camera that, it says, redefines the cost-to-performance ratio for this type of inspection. The Kaleido camera has been designed to overcome the integration and performance barriers of industrial sorting, improving material discrimination and increasing throughput “significantly”. The camera delivers a spatial resolution of up to 1,280 pixel and line rates exceeding 2.3kHz, allowing more items to be inspected in less time, without sacrificing spectral precision. The camera, which incorporates a sensor, spectrograph and interface, is aimed at critical applications in recycling, food safety, pharmaceuticals and waste management. Built‑in spectral band selection and spectrograph‑based aberration correction simplify its use, ensuring consistent calibration across the operating temperature range. These innovations are claimed to accelerate time-to-market for machine-builders. Teledyne has integrated proven functions from its linescan products, such as metadata tagging and multiple regions of interest, ensuring that only the most relevant data is delivered to the processing engine. The camera has a 10 GigE interface that complies with the GigE Vision and GenICam standards. Its sensor maintains strong signal integrity even in low‑light conditions, allowing energyefficient SWIR LED lighting to be used. The camera “combines deep sensor physics, advanced optical design, and world-class system engineering to reduce the complexity and cost of hyperspectral deployment,”says Sadiq Panjwani, senior executive vice-president and general manager of Teledyne Dalsa’s machine vision cameras group. “Kaleido is a scalable solution that improves global outcomes by ensuring food safety, driving cleaner manufacturing, and enabling more responsible resource management. This is the future of industrial intelligence.” www.teledynevisionsolutions.com High‑speed hyperspectral inspection camera overcomes sorting barriers AI-powered 3D machine vision system combines deep learning with height analysis Sick says that its AI-powered 3D machine vision system goes far beyond the capabilities of the human eye
IMO has announced that its Jaguar NXG Variable Speed Drive range has received approval from Elta UK for use with selected Smokevent Axial Fan applications, extending the range of tested drive options available for smoke control, ventilation and life-safety systems. The approval provides system designers, panel builders, contractors and specifiers with additional confidence when selecting a variable speed drive for compatible Elta UK fan installations. In smoke control applications, verified product compatibility is critical because system performance depends on the coordinated operation of every component under demanding emergency conditions. Elta UK holds UKCA Certificate of Constancy of Performance No. 0086 CPR 750823 in respect of BS EN 12101-3:2015, the standard covering powered smoke and heat control ventilators. The certificate applies to Elta UK powered smoke and heat control ventilator products, including Smokevent Axial Fans, with fire-resistance classifications available across F200, F300 and F400 configurations, depending on the specific fan model and application requirements. The Jaguar NXG is IMO’s latestgeneration variable speed drive. It has been developed to support compact installation, flexible motor control and straightforward commissioning across modern fan, HVAC and automation systems. Its inclusion within Elta UK’s approved drive options gives project teams a current, space-efficient solution for applications where compatibility, reliability and compliance-led design are essential. Variable speed drives are a vital contribution to ventilation and smoke control system design. By regulating motor speed and output, a drive can help engineers manage airflow, optimise normal operating efficiency and simplify control strategies. However, life-safety applications require more than standard motor-control functionality. The selected fan and drive combination must be suitable for the intended duty and supported by the relevant testing, approval and system documentation. The Jaguar NXG approval builds on a long established relationship between IMO and Elta UK. Previous approvals have covered IMO’s SD1, HD2 and HD2IP Variable Speed Drive ranges. Adding Jaguar NXG broadens the choice available to customers and enables designers to select an inverter drive that best matches the installation environment, control requirements and panel configuration. For building-services engineers and contractors, the approval will also support a more streamlined specification and procurement process. Using a tested and approved combination reduces uncertainty during design reviews, panel manufacture, commissioning and project handover, while helping to maintain a clear compliance trail. For project teams, the expanded approval portfolio offers greater flexibility when standardising control equipment across multiple ventilation duties. The Jaguar NXG sits alongside IMO’s established drive ranges, allowing engineers to balance enclosure, footprint and control needs without moving outside of an approved product family. This continuity can simplify training, spare-parts planning and longterm maintenance across buildingservices installations, upgrades and refurbishment programmes. The IMO Jaguar NXG range is supported by technical expertise and industryleading warranties, providing an additional level of assurance for customers working across smoke control, HVAC, ventilation and wider fan-control projects. ADVERTORIAL IMO Precision Controls | +44 (0)1707 414 444 | sales@imopc.com | www.imopc.com IMO Jaguar NXG Variable Speed Drives Approved by Elta UK Further information about the IMO Jaguar NXG Variable Speed Drive range and its use with selected Elta UK Smokevent Axial Fans is available at imopc.com or by scanning the QR code. Customers can contact the sales team by emailing sales@imopc.com.
RkJQdWJsaXNoZXIy MjQ0NzM=