www.hpmag.co.uk January/February 2024 p28 p16 Selecting precision motors for smart defence applications The synergy of hydraulics and integrated systems in the food industry Health, safety and heat transfer systems p36 Navigating the future: The evolution of mobile equipment
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Manufacturers enter 2024 with renewed optimism EDITOR’S COMMENT www.hpmag.co.uk HYDRAULICS & PNEUMATICS January/February 2024 3 Amid the huge challenges posed by the pandemic and the shockwaves in energy prices, the survey reveals a resilient industry, poised for growth and innovation. ‘ ’ As we step into 2024, the manufacturing landscape in Britain appears to be more positive with a renewed sense of optimism, according to a major survey conducted by Make UK and PwC. The findings underscore a significant shift in perception, with British manufacturers increasingly viewing the UK as a more competitive destination compared to last year, outpacing their European counterparts. Amid the huge challenges posed by the pandemic and the shockwaves in energy prices, the survey reveals a resilient industry, poised for growth and innovation. The majority of senior manufacturing executives express confidence in the prospects for the sector in 2024, with opportunities now outweighing perceived risks. This newfound optimism is substantiated by strategic investments in new products, explorations into untapped markets, and an accelerated embrace of digital technologies to enhance operational efficiency. Nevertheless, the buoyant outlook is tempered by a cautious acknowledgment of external factors. Chief among these concerns is the challenge to their competitiveness emanating from the economic powerhouses of the United States, India, and China. The survey highlights a wariness among industry leaders regarding the global and domestic economic landscape, compounded by challenges like escalating energy and employment costs and a struggle for access to skilled domestic workforce. Stephen Phipson, Chief Executive of Make UK, emphasised the resilience displayed by manufacturers in the face of recent challenges, calling for a sustained and long-term industrial strategy to fortify the positive path. The acceleration in digital technology adoption, coupled with strengths in innovation and market expansion, positions manufacturing as a vital player in the broader efforts to stimulate growth. While Cara Haffey, Leader of Manufacturing at PwC, highlighted a cautious optimism prevailing in the industry. The survey indicates a proactive stance among manufacturers, with over half planning to explore opportunities in new products and a substantial portion looking to expand into uncharted territories. However, she acknowledges the persistent headwinds of economic challenges, geopolitical uncertainties, and rising costs, urging a pragmatic approach to navigate the path forward. As the UK manufacturing sector cautiously welcomes 2024 with both resilience and optimism, the journey ahead demands a careful balance between seizing opportunities and navigating the complex challenges inherent in the evolving global economic landscape. The survey underscores the need for sustained support, strategic planning, and a resilient mindset to ensure the continued growth and competitiveness of the manufacturing industry in the UK. Aaron Blutstein Editor
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www.hpmag.co.uk HYDRAULICS & PNEUMATICS January/February 2024 5 CONTENTS EDITORIAL Editor: Aaron Blutstein t| 01732 370340 e| editorial@dfamedia.co.uk Content Sub Editor: Leslah Garland t| 01732 370340 e| leslah.garland@dfamedia.co.uk SALES Sales Manager, UK & Overseas: Andrew Jell t| 01732 370347 e| andrew.jell@dfamedia.co.uk Italian Sales Office: Oliver & Diego Casiraghi t| 031 261407 f| 031 261380 e| info@casiraghi.info Turkey: Intersmart Media meltem@intersmartmedia.co.uk Managing Director: Ryan Fuller t| 01732 370344 e| ryan.fuller@dfamedia.co.uk Production Manager & Designer: Chris Davis t| 01732 370340 e| chris.davis@dfamedia.co.uk Reader/Circulation Enquiries: Perception t| +44 (0) 1825 701520. e| dfamedia@dmags.co.uk Marketing Executive Hope Jepson e| hope.jepson@dfamedia.co.uk Operations Manager: Emma Floyd e| emma.floyd@dfamedia.co.uk Financial: Finance Department e| accounts@dfamedia.co.uk Chief Executive Officer: Ian Atkinson e| ian.atkinson@dfamedia.co.uk Published by: DFA Media Group 192 The High Street, Tonbridge, Kent TN9 1BE t| 01732 370340 e| info@dfamedia.co.uk w| www.hpmag.co.uk In co-operation with Printer: Warners, UK © Copyright 2024, DFA Manufacturing Media Ltd ISSN 1366-1981 H&P is a controlled circulation magazine, published 8 times a year. Please contact DFA Media with any subscription enquiries. Paid subscriptions are also available on an annual basis at £110.00 (UK), £145.00 (Europe) or £180.00 (Rest of the World) P+P included. 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. 14 16 6 NEWS 14 KNOWLEDGE BASE The integration of mobile equipment with digital technologies represents a crucial aspect of modernising hydraulics and pneumatics in the industrial sector. This convergence, often referred to as Industry 4.0 or the Industrial Internet of Things (IIoT), offers a range of benefits that can significantly enhance the efficiency, productivity, and overall performance of mobile hydraulic and pneumatic systems. H&P reports. 16 APPLICATIONS Developing the latest smart munitions, today’s military contractors rely on specialist manufacturers to provide critical control and actuation. Whether utilising a bespoke or customisable off-the-shelf (COTS) approach, this makes motion solution design a critical requirement for smart munitions. H&P reports. 20 HYDRAULICS 26 PNEUMATICS 28 INTEGRATED SYSTEMS Consumer demands and technological advancements in the food industry are continually reshaping the playing field and the imperatives of efficiency, precision, and safety have become non-negotiable. H&P discusses further. 32 COMPRESSED AIR, VACUUM AND GENERATORS 33 BCAS Our regular news and events update on the British Compressed Air Society. 36 SPECIAL REPORTS Health & Safety 40 BFPA Hydraulics & Pneumatics’ issue-by-issue briefing on current activities and views involving the British Fluid Power Association. 44 NEW FACES 46 PRODUCTS & SERVICES DIRECTORY 36
NEWS 6 HYDRAULICS & PNEUMATICS January/February 2024 www.hpmag.co.uk Manufacturers enter 2024 with increased optimism Britain’s manufacturers are viewing the UK as a more competitive place to locate their activities compared to twelve months ago, with an increasing number believing they are moving ahead of their European rivals. However, they remain wary of the huge threat to their competitiveness posed by the economic behemoths of the US, India and China. The findings come from a major survey of over two hundred senior manufacturing executives published by Make UK and PwC. The survey shows that after a very difficult few years through the pandemic and, the shock to energy prices, there are optimistic signs with companies more bullish about the prospects for manufacturing in 2024. As a result, the majority of companies are seeing opportunities outweighing the risks to their business. Manufacturers are backing this belief with investment in new products, expansion into new markets and accelerating use of new digital technologies to improve their business. However, the survey also shows that manufacturers are wary of the prospects for both the UK and global economies, while significant challenges remain in the faces of increased energy and employment costs, as well as access to domestic skills. Stephen Phipson, Chief Executive of Make UK, said: “The last few years have been a rollercoaster of emotions for manufacturers, yet they have more than demonstrated their resilience time after time. We are now seeing some hope that conditions may be improving, amid a more supportive and stable policy environment, but this must be cemented within a long term industrial strategy. While undoubted challenges remain, the accelerating use of digital technologies, our strength in innovation and expansion into new markets sets the scene for manufacturing to be at the heart of efforts to boost growth.” Cara Haffey, Leader of Manufacturing at PwC added: “After what has been a rocky few years for manufacturers, it seems there is a cautious optimism in the air. In fact, our research showed that in the year ahead, more than half of them are planning to seize opportunities in new products, with more than a quarter (27.3%) hoping to explore uncharted territory, and expand into new markets. For many, despite January’s todo list likely looming large, as the headwinds of sustained economic challenges, geopolitical instability, and steep employment and energy costs continue, the horizon seems brighter.” According to the survey more than half of companies (52.7%) see the UK as a more competitive place to manufacture. This compares to just under a third (31%) in the same survey a year ago following the political chaos of 2022. Less than a fifth (16.6%) believe the UK is not a competitive place in which to manufacture. Furthermore, almost a third of companies believe the UK is increasing its competitiveness against Germany and France (30.7% and 30.2% respectively) while more than a quarter believe the UK is moving ahead of Spain and Italy (29.3% and 28.3%). These figures are greater than those who see the UK’s competitiveness decreasing against EU rivals. However, by contrast, the share of companies who believe the UK is losing competitiveness against the US, India and China dwarfs those who believe the UK is gaining. The survey also shows manufacturers are bullish about their prospects for the coming year with more than four fifths (44.4%) believing that conditions in the sector will improve, while a fifth (20.5%) see conditions deteriorating. In addition, almost two thirds (62%) of companies see opportunities outweighing the risks this year while just 14% disagree. However, by contrast, more than four in ten companies (41.5%) see the UK economy deteriorating in 2024 compared to just over a third (36.6%) who see it improving. A similar proportion (37.6%) see the global economy getting worse this year compared to just under a third (31.2%) who see it improving. In the year ahead, more than half of manufacturers (52.7%) see opportunities in new products while more than a quarter (27.3%) are expanding into new markets and a similar proportion (26.3%) are net zero opportunities. Furthermore, digital technologies have the potential to boost productivity with almost three quarters of companies (71.2%) believing digitising operations will boost operational efficiency. In addition, more than half of companies (52.2%) see generative AI increasing the productivity of their workforce. However, more than half of companies still see risks from increased energy costs (53.2%) closely followed by the impact of political instability (43.9%). More than two thirds (36.1%) are still seeing supply chain disruption while a similar number (35.1%) see lack of access to domestic skills as a risk.
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8 HYDRAULICS & PNEUMATICS January/February 2024 www.hpmag.co.uk NEWS Hydroscand strengthens market presence with dual acquisitions Hydroscand Ltd, a leading provider of hydraulic solutions, has recently confirmed the successful acquisition of Leicester Hose & Hydraulics Limited, a company established in 2004 and located in the heart of Leicester. The transaction, finalised on December 31, 2023, is Hydroscand’s first investment for 2024 and is part of the firm’s strategic efforts to support the transition of businesses in the hydraulics industry. Leicester Hose & Hydraulics, with over 25 years of experience, has built a strong reputation for excellent service and offers a diverse range of products to customers in the local and surrounding areas. This acquisition adds another trade counter for Hydroscand in the Midlands, strategically fitting between existing locations in Nottingham and Birmingham. Gary Brooks, founder of Leicester Hose & Hydraulics, will collaborate with Rebecca Galley, Hydroscand’s Managing Director in the UK, to ensure the successful integration of the company into the Hydroscand Group. Rebecca Galley commented: “We are really pleased to welcome Leicester Hose & Hydraulics to the Hydroscand Group – our shared expertise and commitment to our customers makes this an obvious and complementary partnership.” In addition to the Leicester Hose & Hydraulics acquisition, the company also announced the successful acquisition of Yorkshire Hose & Fittings Limited, a well-established company with roots dating back to 1992. The acquisition was also finalised on December 31, 2023, and marks Hydroscand’s second strategic investment in 2024, underscoring the company’s commitment to expanding its presence in the UK market. Originally founded in Doncaster, Yorkshire Hose & Fittings has built a reputation over the years for its customer service. While initially catering to the local mining industry, the company has successfully diversified its s ervices to meet the needs of various industries in the region. The decision for acquisition was driven by the succession planning of Yorkshire Hose & Fittings’ owners. The move is seen as a mutually beneficial and complementary addition to Hydroscand’s UK business. As a long-standing customer of Hydroscand, Yorkshire Hose & Fittings brings added value through its trade counter, further enhancing Hydroscand’s presence in the region. The acquisition also provides a strategic base for Hydroscand’s HoseExpress mobile hose replacement business to extend its operations into the South Yorkshire area. Following the completion of the acquisition, Yorkshire Hose & Fittings founder Paul Jeffs will be stepping down from his position immediately. Scott Kennedy, a vital part of the company since 1995, will continue with the business, playing a crucial role in supporting its development and integration over the coming months. Rebecca Galley, a representative of Hydroscand, expressed enthusiasm about the acquisition, stating: “We are very happy that Yorkshire Hose & Fittings will become part of Hydroscand Group. As a long-standing customer, we already have an excellent working relationship with Scott, and I am very much looking forward to building the business together in Doncaster and the surrounding area.” In response, Paul Jeffs shared his sentiments on the transition, saying: “Having dealt with Hydroscand for many years, I am happy in the knowledge that YHF will go from strength to strength under their control. I wish them all the very best.” Both acquisitions exemplify Hydroscand’s expertise in supporting seamless business transitions and reflect the company’s commitment to seeking further opportunities for growth in the hose and fittings sector, as well as mobile hose repair businesses. HOS organises accredited mental health first aid training Sunderland based fluid power experts Hydraulic & Offshore Supplies (HOS) is taking the topic of mental health seriously by organising accredited training for its employees. The company, which is part of the R&G Fluid Power Group, has been based next to Sunderland’s riverside for over 35 years and has diversified and grown during recent years. Supplying sectors including engineering, offshore, renewables, ship repair, automotive and oil & gas, it is passionate about providing the very best training, support and encouraging personal development to its staff. Hose technican Laura Fenwick was keen to learn more about how to support mental health in the workplace so was eager to take part in the Mental Health First Aid at Work training. The course, which is accredited by Mental Health First Aid England, covered how to recognise warning signs of mental ill health, develop the skills and confidence to approach and support someone while also keeping yourself safe.
NEWS 10 HYDRAULICS & PNEUMATICS January/February 2024 www.hpmag.co.uk With mental health in the workplace such an important subject, HOS was keen to ensure it had a trained first aider within the business, gaining an understanding of how to support positive wellbeing and tackle the stigma which can sometimes be associated with mental health. On successfully completing the twoday course, Laura commented: “When I had the opportunity to take part in the training, I was really keen to learn more so I jumped at the chance to attend. “The course covered such a variety of subjects and I know will be useful for not only within the workplace but also within day-to-day life too. Mental health is such an important subject and it’s great that we can talk about it openly without feeling judged, many people don’t like to discuss these issues openly so it was great for me to learn how to spot signs that somebody may be struggling and how to deal with this.” During 2023, over half of European firms have taken significant steps towards digitalisation, focusing on enhancing their digital presence, according to the latest report “Digitalisation in Europe 20222023” by the European Investment Bank. In a significant response to the COVID-19 pandemic, 53% of companies in Europe have expanded their online services, closing the technological gap with the United States. In addition, 69% of EU firms implemented advanced digital technologies in 2022, in contrast to 71% in the US. However, the report also highlights a disparity in digital adoption across the EU, with only 30% of microenterprises prioritising digitalisation compared to 62% of larger firms, underlining the need for inclusive digital strategies to encompass businesses of all sizes. The European Union’s commitment to digital transformation is evident in its allocation of over €165 billion towards the Digital Decade objectives. This investment, particularly through the Recovery and Resilience Facility (RRF), is a testament to the EU’s dedication to supporting digitalisation in both the public sector and businesses. Different levels of digital transformation and funding allocation are observed across EU member states, which have received a significant share of the Digital Decade budget. In 2023, UK businesses were heavily investing in digital transformation, demonstrating resilience and adaptability in the face of economic challenges. According to a report by Boston Consulting Group, as referenced in Consultancy.uk, a significant number of executives from large companies are planning to increase their spending on digital initiatives. This surge in investment is driven by the need to adapt business models and capitalise on new Fast track of digital transformation revenue growth opportunities, even as a global recession looms. Key technologies such as artificial intelligence, blockchain, and the Internet of Things (IoT) are garnering substantial interest, with executives convinced of their crucial role in business success. However, the path to digital transformation is fraught with challenges for UK companies – a study highlighted in Grand View Research reveals that many large UK businesses are struggling with a shortage of technical skills and the challenge of integrating new technologies with legacy IT systems. This situation is a significant barrier, potentially delaying the transformation process. Additionally, the healthcare sector in the UK is expected to witness substantial growth in digital transformation. This growth is primarily driven by the need for enhanced quality of care and the ability to respond effectively to changing health scenarios, as indicated by the increased adoption of technologies like Electronic Health Records (EHR) during the COVID-19 pandemic. In this digital evolution, digital identity solutions, encompassing identity document verification, electronic IDs, identity proofing or authentication based on biometrics, access to identity data sources, and electronic signatures, among others, play a crucial role when it comes to digitisation. Digital identity technologies not only streamline business processes but also strengthen security, leading to significant time and cost savings. A very simple and clear example of how digital identity solutions are key for companies of any size and sector to digitise their processes is electronic signatures. Signicat, a pan-European leader in Digital Identity, recently released a study commissioned from Forrester Consulting on the Total Economic Impact (TEI) of Signicat and, found that companies saved on costs and processes through the use of the digitalisation of signatures as well as avoiding more than 1.1 million printed pages, after the first year of implementation of their solutions. On the other hand, the study found that digital identity solutions could improve the operational efficiencies of a company from an automated identity verification process resulting in 40,000 hours per year saved in identity verification. These findings not only underscore a growing opportunity for businesses in the digital identity sector but also for the private and public sectors: as European companies continue to embrace digital transformation, the demand for robust digital identity solutions is expected to rise, offering a promising market for innovation and growth. While businesses and governments in Europe are on the right track toward their digitisation, there is still a lot of work to be done, especially with the arrival of the eagerly awaited EU Wallets. A key element in Europe that will once again test the ability of both public administrations and private companies to offer 100% digital access to their services, this time through a single point of access: their national digital identifications.
www.hpmag.co.uk HYDRAULICS & PNEUMATICS January/February 2024 11 Smart Manufacturing & Engineering Week 2024 (https://www.mandeweek.co.uk/) will address the key issues that concern manufacturing and engineering businesses currently, irrespective of the market sector they serve. The main topics that all elements of the wide-ranging events touch upon are innovation, the supply chain, sustainability, digital transformation and people and skills. Demonstrating the importance of the event to their members The British Fluid Power Association (BFPA) has become a Strategic Partner for Smart Manufacturing & Engineering Week 2024 where, naturally, their focus is on the Fluid Power & Systems and Air-Tech events. Chris Butcher, Managing Director, across many market sectors. We think there’s a great synergy between the different areas of the event to provide our members, and the visitors that come to see them, with a showcase that covers all aspects of their technical challenges, and the new innovations that are driving system efficiency, automation, sustainability and power density.” The BFPA will have a stand at Fluid Power & Systems and representatives will be available to meet with both members and prospective members to discuss their education and training courses as well as giving presentations at the main theatres on key topics. Educational content & summits One of the standout attractions for readers of Hydraulics and Pneumatics will be the Manufacturing Automation & Robotics Summit which will see operations, automation and control and manufacturing professionals coming together to discuss the latest automation and robotics opportunities and find actionable solutions to industry challenges. When talking about the summit Grace Gilling, Manufacturing Portfolio Director of Smart Manufacturing & Engineering Week 2024 said: “Manufacturers in the UK are experiencing a monumental shift in the way they operate. Automation and robotics are not just buzzwords; it’s a fundamental revolution that is reshaping how goods are produced, processed, and delivered to the market. While the promises of increased efficiency, reduced costs, and improved quality are enticing, the road to embracing these technologies is not without its hurdles. Fluid Power & Systems and Air-Tech return for 2024 showcase Fluid Power & Systems and Air-Tech, alongside Drives & Controls, will be taking place at the NEC on June 5th and 6th as part of Smart Manufacturing & Engineering Week 2024. Readers of Hydraulics & Pneumatics will find much of interest among the new technology and educational content both in the events mentioned above and in the adjoined Smart Factory Expo, Maintec and Design Engineering Expo events. H&P takes a closer look at what visitors can expect. said of the partnership, “The event is fantastic, for our members to have such a shop window to present their products, technologies and innovation is fantastic news for UK manufacturing. “The fluid power industry has gone through a significant technology transition with the integration of electronics, robotics, mechatronics, and the high level of automation and control
12 HYDRAULICS & PNEUMATICS January/February 2024 www.hpmag.co.uk NEWS This summit is dedicated to exploring the rapidly evolving landscape of automation and robotics in the manufacturing industry, and more importantly, addressing the challenges that manufacturers face in this transformative era.” Topics to be covered at the summit include Integration Complexity, Developing a Skilled Workforce, Cost and ROI Concerns and Regulatory and Safety Compliance. Notable tech companies Smart Manufacturing & Engineering Week attracted some of the biggest, most innovative industrial and tech businesses in the world to its 2023 event (Google and IBM as well as Siemens, ABB and Amazon RME) and the 2024 event will be no different. Among the biggest names in the fluid power industry Festo UK will be exhibiting and in a recent interview head of operations, Swapnil Khedekar spoke about their focuses for the year, “Simplification is a key business driver for 2024. Adding the power of electronics and software to traditional mechanics offers increased flexibility and performance, but it can also bring complexity. We need to reduce complexity for the industrial user – as smart phones have done for consumers. Simplifying the connectivity of so-called smart devices reduces the barriers for inexperienced users and accelerates the deployment of new technologies. Making things simpler is not easy but it has to be our future.” Co-located events Although the main attraction for Hydraulics & Pneumatics readers will be the fluid focused areas of the event, there is a whole host of other activities and attractions taking place during Smart Manufacturing & Engineering Week at the NEC on 5th and 6th of June. For instance, Smart Factory Expo is where manufacturers explore digital transformation solutions to gain a competitive advantage. It’s a carefully- curated shop window for manufacturers at all stages of their digital journey and there is great synergy with those exhibiting here and the fluid power sector. Also taking place is Maintec the UK’s longest standing event dedicated to the maintenance, reliability and asset management industry. The Design & Engineering Expo focuses on innovation so that design and engineering professionals from all tiers of the supply chain who want to reduce costs, streamline and optimise future design and engineering strategy can find what they need. Of key importance and the traditional stablemate of both Fluid Power & Systems and Air-Tech is Drives & Controls. Being presented as part of Smart Manufacturing & Engineering Week for the first time this event obviously holds great interest for Hydraulics & Pneumatics Readers as it brings together key suppliers of state-of-the-art equipment covering critical areas such as energy efficiency, machine safety, drives, motors, motion control, robotics and automation plus much more. On the fringe Aside from the exhibitions themselves there is a multitude of events taking place on the ‘fringe’ of the exhibitions that range from the serious to the fun and frivolous! The Manufacturing Digitalisation Summit, for example, is an innovative and interactive conference featuring both plenary session presentations and lively round table discussions with industry leaders. The Oscars of the manufacturing sector The Manufacturer Top 100 will be held on the evening of 5th June, and it publicly recognises the heroes of UK manufacturing, those who stand out for their contribution to changing the face of the industry. Plus, The Manufacturer Directors’ Forum will take place; a 10+ year-old professional network of senior manufacturers drawn from across the industrial spectrum who attend targeted events and roundtable discussions. On the fun side The Guitar Legends competition, where any visitor can show off their guitar skills and win a 3D printed guitar, will take place once again as well as the Day 1 after show party with The Shadow Monkeys providing live music. Allocating time away from the workplace to visit events at the NEC is a challenge and this is appreciated by Nineteen Group, the organisers of Smart Manufacturing & Engineering Week which is why they are doing everything they can to ensure there is a huge amount to see and do to maximise the Return On Investment for a visitor. As well as the events mentioned in this article taking place at the NEC at the same time are other relevant events including the UK Garage & Bodyshop event run by Messe Frankfurt; Med-Tech Innovation Expo and TCT 3Sixty from Rapid News Group and Subcon from the Mark Allen Group. A single visitor registration to Smart Manufacturing & Engineering Week provides access to all the events. To register or for further information please visit: https://www.mandeweek.co.uk/ IndustrySuperstore.co.uk/pages/box “You don’t know what I got”
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KNOWLEDGE BASE – MOBILE EQUIPMENT The future of mobile equipment in the industrial sector is undeniably smart and autonomous. Advancements in artificial intelligence (AI) and machine learning are paving the way for machinery that can operate with minimal human intervention. From self-driving construction vehicles to automated material handling in warehouses, the integration of smart systems will redefine the efficiency and safety benchmarks in the industry. Predictive intelligence and maintenance Predictive intelligence will emerge as the cornerstone of maintenance strategies. Enhanced algorithms, fuelled by vast datasets and real-time monitoring, will predict component failures before they occur. This shift towards predictive maintenance not only minimises downtime but also ensures optimal equipment performance, reducing overall 14 HYDRAULICS & PNEUMATICS January/February 2024 www.hpmag.co.uk operational costs and extending the lifespan of critical components. Sustainable hydraulics and pneumatics Eco-Friendly fluids and energy efficiency: Sustainability will be a driving force in the evolution of hydraulics and pneumatics which is set to witness a transition towards eco-friendly hydraulic fluids, mitigating environmental impact. Additionally, a heightened focus on energy efficiency will lead to the widespread adoption of advanced technologies such as variable displacement pumps, regenerative systems, and intelligent power management, making hydraulic and pneumatic systems not just powerful but environmentally responsible. Electrification and hybridisation: The future will witness an increased emphasis on electrification and hybridisation in mobile equipment. As the world shifts Navigating the future: The evolution of mobile equipment The integration of mobile equipment with digital technologies represents a crucial aspect of modernising hydraulics and pneumatics in the industrial sector. This convergence, often referred to as Industry 4.0 or the Industrial Internet of Things (IIoT), offers a range of benefits that can significantly enhance the efficiency, productivity, and overall performance of mobile hydraulic and pneumatic systems. H&P reports. towards cleaner energy sources, the integration of electric and hybrid systems in hydraulic and pneumatic applications will become more prevalent. This shift not only aligns with global sustainability goals but also addresses concerns related to fuel consumption and emissions. Digital integration for Industry 4.0 Connectivity and real-time decisionmaking: The future of mobile equipment in the industrial sector lies in the seamless integration with Industry 4.0 principles. Connectivity will be the linchpin, with mobile equipment becoming part of a larger network of interconnected devices. Real-time data streams will empower operators with the information needed for instantaneous decision-making, optimising processes and ensuring a responsive and adaptive industrial ecosystem. Advanced human-machine interfaces: User
interfaces will undergo a transformation, with augmented reality (AR) and virtual reality (VR) technologies becoming integral to operator interfaces. These advanced human-machine interfaces will not only enhance the operator’s situational awareness but also provide immersive training experiences, making the operation of complex mobile equipment more intuitive and efficient. Collaborative innovation and standardisation Industry collaboration and standards: The future is collaborative, with industry players coming together to set standards for interoperability and compatibility. Common communication protocols and shared technological frameworks will likely foster innovation and create a cohesive ecosystem where different components and systems can seamlessly work together. This collaborative spirit will accelerate the pace of technological advancements in the industrial sector. Conclusion As we step into the future, the integration of mobile equipment with hydraulics and pneumatics in the industrial sector is poised to redefine how we operate and build. Smart, sustainable, and interconnected systems will not only drive efficiency but also contribute to a greener and more resilient industrial landscape. The journey ahead holds the promise of pioneering innovations, where the realms of mechanics and technology seamlessly come together to shape an industrial future that is both efficient and sustainable.
APPLICATIONS Precise control for missiles and guided bombs, as well as for the seekers that maintain their path, is imperative. In these most critical situations, it is also essential that the motion control solution is reliable, as well as safely integrate with the avionics and electronics within the wider aircraft or launch system. Actuation control in use Vital to the position of control surfaces on a missile, a control actuation system makes high speed adjustments to the fins or canards based on the inputs from the missile guidance system. Similarly, the extension of a wing deployment system on a guided bomb is vital to achieve the desired range and targeting. The priority in motion design for both of these systems is precise control to actuate the flight surfaces with speed and smoothness which is key to determining whether a missile or guided bomb will strike its intended target. This control must be achieved within an extreme temperature profile, ranging from a low of -55°C to an excess of 100°C, and the motion solution must also withstand high levels of shock and vibration during operation. This reliability must be maintained through a long storage period that could extend to more than 20 years. Working in a compact space and weight envelope, low mass and a small footprint of the motor are also compulsory. The electro-optical or infrared systems in missile and guided bomb seeker heads (also used in vehicles and land-based guided munitions), demand similar characteristics. To achieve target accuracy, the azimuth, elevation, and zoom axis motors must precisely coordinate, and it is imperative that the system performs in the most demanding environmental situations. Here too, footprint, mass, and electromagnetic compatibility (EMC) compliance are imperative. Even if the overall duration of use is short, the limited onboard power budget requires a high-efficiency motor to minimise power draw from the vehicle power system. Designing the motion solution Typical motor choices for smart defence applications 16 HYDRAULICS & PNEUMATICS January/February 2024 www.hpmag.co.uk Selecting precision motors for smart defence applications Developing the latest smart munitions, today’s military contractors rely on specialist manufacturers to provide critical control and actuation. The motion solution is central to ensuring targeting accuracy, and while each specific smart defence application has its own unique challenges that demand an exacting approach, the design will essential attributes common across applications. Whether utilising a bespoke or customisable off-the-shelf (COTS) approach, this makes motion solution design a critical requirement for smart munitions. H&P reports. Precision motor choice is crucial for critical control and actuation in smart defence applications
www.hpmag.co.uk HYDRAULICS & PNEUMATICS January/February 2024 17 include brushed DC coreless designs, as well as brushless cylindrical and flat motors. The brushed DC coreless motor includes a coil arrangement rotor, free of iron laminations, and a stator with fixed magnets. Meanwhile, brushless DC (BLDC) cylindrical motors utilise a stationary coil with a rotating permanent magnet and coil windings as part of the stator, and these designs remove the need for brush commutation. In addition to the cylindrical designs, a BLDC slotted flat motor includes coils in lamination slots, but unlike their cylindrical counterparts, they incorporate an outer rotor in a flat architecture. Selecting the right motion solution As each design offers varying advantages, the motor selection depends on the prioritisation of parameters, particularly within the required size and weight envelope. Of these parameters, torque density is a typical priority. High-energy magnets that generate high flux density coupled with a coreless coil configuration is an optimal design, and both BLDC slotless and slotted motor technologies can provide high continuous torque without magnetic saturation. In comparison to cylindrical motors, BLDC flat designs typically offer the highest torque density to form factor. Maximum motor speed is also a common requirement, and electrically commutated BLDC motors can achieve higher speeds, with cylindrical designs achieving over 40,000 rpm. At these high speeds, motors require specially designed bearing systems, and the package is balanced to minimise vibration. For dynamic speed operation, the BLDC slotted motor is the preferred choice for low rotor inertia due to the relatively small rotor diameter. Friction counteracts heat and energy efficiency, so LEFT: Portescap motion solutions have numerous applications in smart munition development
APPLICATIONS 18 HYDRAULICS & PNEUMATICS January/February 2024 www.hpmag.co.uk combating this factor is also an important design consideration. Low-friction materials can minimise the effect, even in brushed motors, while BLDC designs remove the issue of friction in commutation. For the same reason, BLDC motors also have a longer operational life than their brushed counterparts. Creating a similar impact on heat and energy efficiency, iron core DC motors generate eddy current losses at higher speeds, meaning that coreless designs are favoured for higher-speed applications. However, magnetic design and material selection can minimise loses even for iron core motors. Meanwhile, cogging torque, which can create uneven motion, is the result of the rotor’s preferred magnet position in relation to the stator lamination teeth. Coreless technology eliminates iron laminations, removing the problem. While slotted designs are inherently susceptible to cogging torque, this can be minimised with an adjusted alignment of the core laminations, or by optimising the combination of poles and slots or teeth. Deployed in any environmental arena, the flexibility to handle harsh conditions is also a key consideration. The BLDC slotted motor is best suited to handle high shock and vibration, as well as high humidity and saline conditions, due to its robust stator and rotor designs. However, BLDC slotless and DC coreless motors can also be used in, and prepared for, applications that must withstand the requirements of MIL-STD-810. Motion solution customisation While meeting the STD-MIL810 environmental specification is essential, to achieve the application’s performance requirements, specific design is required. Additionally, meeting the needs of operational deployment, long term storage requirements, such as preventing corrosion and retaining lubrication, might also be necessary. While a fully bespoke design might be required, a customisable off-the-shelf (COTS) design approach could be used to meet operational needs, while speeding up time to market and reducing development costs. Whichever strategy is used to achieve the motion solution’s exacting specification, design experience and expertise for smart defence applications is crucial. For further information please visit: www.portescap.com Portescap’s Athlonix and Ultra EC motors Occo Coolers Telford Limited Available from Stock OFFLINE COOLERS RETURN LINE COOLERS WATER COOLERS RADIATORS ACCESSORIES Motors, Pumps.Thermostats, Axial fans, DC Fans and more Contact details Tel: 01952 616381 Email: Sales@occocoolers.co.uk Website: www.occocoolers.co.uk
• Pig’s Tail® Protective Wrapping is designed to protect hydraulic and pneumatic hoses against impact and abrasion. Also suitable for protection of cables including fibreoptics either singular or bundled. • It is a heavy duty form of spiral protection suited to heavy industrial applications. • Made from High Density Polyethylene (HDPE). • Can be used for single hoses or multiple hose bundles. • Operating temperatures -50°C up to +120°C. • Suitable for use with all hydraulic fluids including glycol and phosphate ester based products. • Rounded edges for enhanced performance and safe handling. 0114 349 0766 info@plascompo.com www.plascompo.com PIG’S TAIL Wrapping ALSO PIG’S TAIL RAIL • Flame Retardant – UL94 class V-0 • Complies with EN45545 HL2 • Suitable for use in underground rail Plascompo_H&P_July 2020 Half Pig's Tail.qxp_Layout 1 13/07/2020 17:30 Page 1 STAINLESS STEEL HYDRAULIC HOSE AND PIPE FITTING SPECIALISTS We are the leading manufacturer and stockist of stainless steel hose fittings, tube fittings and adaptors. Call one of our friendly and knowledgeable specialists today to see how we can help. 30 TRADING FOR OVER YEARS CALL 01274 852 066 sales@customfittings.com www.customfittings.com PROUDLY MADE IN THE UK
HYDRAULICS The Sulzer AHLSTAR WPP endsuction single-stage pump has demonstrated its effectiveness as a suitable choice, meeting performance requirements with notable advantages. Its efficient operation not only consumes less energy but also significantly reduces maintenance frequency. According to Hannu Makkonen, Head Tendering Support at Sulzer, the selection of wear-resistant hydraulics, a low operating speed, and proper material of construction for the wetted components could contribute to a considerable extension of the average pump lifetime in this very demanding position. This allows the customer to run the process without frequent interruptions. Severe conditions for rotating equipment Phosphoric acid is produced with a hemihydrate process, which is considered to be very severe for the rotating equipment installed in the reactor. The relatively high concentration of phosphoric acid and the presence of impurities combined with the elevated reaction temperature create a very aggressive environment. The constraints for the slurry filter feed pump consist of multiple factors: 41% P2 O5 acid with corrosive contaminants (HF, H2 SiF6 , H2 SO4 , Cl-) 33% of solids (CaSO4 .0,5H2 O) Presence of gas Operating temperature 95-100°C High total head (>30 m) Low rated power A slurry filter feed pump is in a very critical role at a phosphoric acid plant. A failure would have a direct deteriorating impact on the production rate of the plant, which is why robust and reliable equipment with the longest possible lifetime was considered to be of prime importance. Sulzer selected an AHLSTAR WPP53-100 single-stage process pumps for the site. The WPP pumps are designed to be extremely wear-resistant and especially suitable for abrasive and erosive industrial applications. The series offers a comprehensive material selection, and the pumps can be tailored to suit the most demanding industrial applications with accessories such as shaft sealing solutions and heavy-duty bearing units. The earlier pumps were made of a material that is very commonly used in phosphoric acid applications, CD4MCuN. This duplex stainless steel can give acceptable results in some applications of a dihydrate process, but it is not one of our solutions in a hemihydrate process. In this case, our preference was a higher-grade alloy, 654 SMO. This material, classified as 6%Mo super austenitic stainless steel, has an excellent resistance to corrosion by hot acid with a high chlorides content. It is more and more commonly used in the phosphate industry because it combines a very good resistance to corrosion and better erosion resistance than some more common austenitic stainless steels. Increased durability The previous pump at the site was rotating at a speed of around 1800 rpm, which is too high for this application. A pump with a 20 HYDRAULICS & PNEUMATICS January/February 2024 www.hpmag.co.uk Durable, energy-efficient slurry pump for phosphoric acid plant operations By combining optimal hydraulics and wear-resistant materials of construction in a pump replacement, Sulzer has helped a leading phosphate fertiliser producer to increase productivity. H&P reports. Pump at the site AHLSTAR-WPP53-100 Phosphoric acid produced in hemihydrate process
www.hpmag.co.uk HYDRAULICS & PNEUMATICS January/February 2024 21 low speed of rotation and a full-diameter impeller was sought after. An AHLSTAR WPP53-100 with a significantly bigger impeller diameter than in the previous pump was selected. Although the head is fixed, a lower rotation speed contributes to reduced wear. Other features adding to the prolonged lifetime of the pump are the wear-resistant design of a semi-open impeller and a casing fitted with a front wear plate. Increased productivity Due to the modular construction of the new AHLSTAR WPP, only worn parts of the pump must be replaced. In the earlier pumps, the lifetime of the parts subject to the highest erosion and corrosion was very short, between 3 and 6 months. Along with the pump replacement, the average lifetime of the parts was increased to 12 to 24 months, reducing the maintenance frequency by up to 75% from what it used to be. Given the harsh operating conditions and the vast improvements compared to the former installation, the replacement is considered to be very successful. After a few years in operation, the pump has proven to be such a major upgrade that more pumps at the site are replaced with AHLSTAR pumps. For further information please. visit: https://www.sulzer.com Technical details The pump is installed in the attack reaction unit where it is connected to the digestor. It feeds the slurry filter with phosphoric acid slurry produced in the reactor. Application – HH slurry filter feed pump Liquid – Reaction slurry with HH solids Flow / head – < 170 m?/h/< 35 m Pump type – AHLSTAR WPP53-100 Material of construction – Cast wetted parts in 654 SMO® Nominal speed – < 850 (rpm) (VSD) Lubrication – Oil Installation – Horizontal (common baseplate) Motor – 75 kW – 440 V – 60 Hz Transmission – Flexible coupling Mechanical seals – Dual mechanical seal SE2 AHLSTAR-WPP pump construction with closed dynamic seal Numerous specialised agricultural machinery feature a multitude of ancillary functions and individual modules integral to various agricultural processes. Notably, not all of these functions necessitate direct supply from the central hydraulics. Using compact decentralised mini hydraulic power units for driving and controlling these specific functions not only reduces tubing but also streamlines installation in close proximity to the control function. Examples of decentralised controllable functions in the harvester are the control of the discharge pipe or the ejection flap in combine harvesters and forage harvesters or the conveyor belts in potato and beet harvesters. In the HAWE Hydraulik product range, there are mini hydraulic power units for this purpose, which take over the power generation and control directly at the consumer. Due to their low size, they can be installed close to the consumer. The hydraulic power pack works as a self-sufficient unit and only needs to be powered. The machine manufacturer saves long hydraulic hose lines, reduces losses and simplifies commissioning. Two product types from the HAWE Hydraulik modular product kit include the mini hydraulic power pack type A100 - available with either DC or AC motor. In the case of the HR type, the built-in possibility of reversing the direction of rotation of the engine also makes it easy to control a double-acting cylinder. An additional directional valve is then no longer required for this. Furthermore, the mini hydraulic power unit type HR ensures overload protection of the motor by an integrated temperature switch and can be connected to various actuators. The installation position remains flexible, allowing for an arbitrary placement, while control remains consistent, facilitated, for instance, through a joystick within the driver’s cab. Upon scrutinising the machine design from the perspective of decentralised power generation and minimal energy consumption, additional functionalities inherent to this decentralised drive become apparent, yielding further advantages. For more information, please visit: https://www.hawe.com/products/mini-hydraulics/ Optimising agricultural efficiency: Streamlining machinery with decentralised mini hydraulic power units
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