I O P F INN ONO V A T NEE I O N ERS FOR COM WORLD’S MPRESSED AIR S FIRST ALUM UIDS AND FL MINIUM MODU DISTRIBUTION ULAR SYSTEM ouch get in t N M www.hpmag.co.uk September 2024 HYDRAULICS & PNEUMATICS VOL. 29 No. 6 SEPTEMBER 2024 p30 p18 Is a bigger bed size always better in Additive Manufacturing? How automation is transforming fluid power Beyond the cab: Making the case for remote controls p14
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The smart technology shift EDITOR’S COMMENT www.hpmag.co.uk HYDRAULICS & PNEUMATICS September 2024 3 The need for a skilled workforce capable of managing these advanced systems is more pressing than ever. ‘ ’ Since the beginning of 2024, the rising importance of smart technology in hydraulics and pneumatics has become increasingly evident, particularly with the advent of the new Labour Government. This shift underscores how digital advancements are enhancing system performance while aligning with the administration’s strategic priorities. The integration of advanced automation, Internet of Things (IoT) devices, and real-time data analytics is revolutionising hydraulic and pneumatic systems. As the new government emphasises innovation, sustainability, and productivity, these technologies are proving crucial. They offer greater precision, enable proactive maintenance, and minimise unexpected downtime—key factors in meeting the UK’s ambitious industrial goals and regulatory standards. Predictive maintenance, driven by data analytics and machine learning, aligns with the government’s focus on operational excellence and resource efficiency. This approach allows industries to anticipate issues before they escalate, thereby extending equipment lifespan and optimising performance, in line with Labour’s agenda for industrial efficiency and sustainability. The Government’s tentative support for digital transformation and smart manufacturing is reflected in its policies aimed at fostering innovation and maintaining the UK’s global competitiveness. The adoption of these technologies is vital for meeting regulatory requirements, boosting productivity, and driving sustainable growth— central to the administration’s industrial strategy. However, this technological shift brings significant challenges. The need for a skilled workforce capable of managing these advanced systems is more pressing than ever. Ensuring that engineers and technicians are properly trained is crucial for maximising the benefits of these innovations. Moreover, as the UK adopts more digital solutions, safeguarding against cyber threats and securing sensitive data becomes increasingly important. Robust security measures are essential for maintaining system integrity and operational reliability. In summary, 2024 has underscored the transformative impact of smart technologies on the hydraulics and pneumatics industry, particularly in the context of the new government’s focus on innovation and efficiency. While the full effects of these developments remain to be seen, it is crucial for the government to address the associated challenges and invest in manufacturing to align with its industrial objectives and ensure overall success. Aaron Blutstein Editor
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www.hpmag.co.uk HYDRAULICS & PNEUMATICS September 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 Manager Hope Jepson e| hope.jepson@dfamedia.co.uk Operations Manager: Emma Godden-Wood e| emma.godden-wood@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. 18 32 6 NEWS 14 INTEGRATED SYSTEMS Autonomy and teleoperation are big news, and with good reason. These advances in machine technology are helping overcome common industry challenges, such as job site safety and productivity. But there’s another method for delivering these same benefits, and one with much lower hurdles to entry: radio remote controls. 18 APPLICATIONS Stephen Crownshaw explores how bed size impacts productivity in Additive Manufacturing. 20 HYDRAULICS H&P looks at how the latest swaging and crimping technologies are meeting the demands for enhanced performance, flexibility, and durability. We also highlight the crucial role of temperature control in hydraulic systems, where compact, powerful equipment demands more from heat exchangers. Additionally, MP Filtri’s new Patch Imaging Kit is set to advance fluid analysis in hydraulic systems, significantly enhancing capabilities for contamination monitoring. 26 PNEUMATICS 30 KNOWLEDGE BASE As the demand for precision, efficiency, and safety grows, fluid power systems are increasingly integrated with automation technologies. H&P reports. 32 COMPRESSED AIR, VACUUM AND GENERATORS 34 SPECIAL REPORTS 36 BFPA Hydraulics & Pneumatics’ issue-by-issue briefing on current activities and views involving the British Fluid Power Association. 38 BCAS Our regular news and events update on the British Compressed Air Society. 39 NEW FACES 47 PRODUCTS & SERVICES DIRECTORY 31 Subscribe for your FREE copy now
NEWS 6 HYDRAULICS & PNEUMATICS September 2024 www.hpmag.co.uk Manufacturers report decline in road infrastructure while digital investment boosts growth Research from Make UK has found that more than half of Britain’s manufacturers believe the national road infrastructure has deteriorated over the past decade. This decline has led to higher logistics costs and challenges in labour mobility and access to skills. The study, titled “Infrastructure: Enabling Growth by Connecting People and Places,” highlights that 54% of manufacturers perceive a worsening in road conditions, with 75% acknowledging the critical role of road networks in their supply chains. Additionally, over half of the respondents disagreed with the decision to cancel the northern leg of HS2. Conversely, the research indicates a positive trend in digital infrastructure. Approximately 64% of companies reported improvements in digital connectivity over the last ten years, largely due to significant investment in 5G and other digital technologies. This enhanced digital infrastructure has allowed 44% of manufacturers to invest in new technologies, leading to increased profitability and job creation. Moreover, 71% of companies believe that better quality infrastructure contributes to higher productivity. The study also uncovered regional variations in perceptions of infrastructure quality. Manufacturers in the North West were particularly critical, with 68% observing a decline in road infrastructure, compared to 43% in the North East. This discrepancy may be attributed to differing levels of investment in public transport and road infrastructure across the regions. The report suggests that successive governments have prioritised cost over potential benefits when evaluating infrastructure projects. However, the success of digital infrastructure investment demonstrates the positive impact that strategic investment can have on growth. The research draws parallels to historical projects, such as the Channel Tunnel, which, despite initial criticism, now contributes significantly to the UK economy. Stephen Phipson, CEO of Make UK, urged the new Government to adopt a bold approach to infrastructure investment, particularly in repairing roads and supporting local authorities. He emphasised the need for enhanced local decision-making and investment in bus networks to improve connectivity and support the manufacturing sector. Phipson also called for long-term rail projects to strengthen east-west connections and ensure equitable opportunities across the UK. igus launches ‘enjoyneering’ experience The unveiling of igus UK’s ‘enjoyneering’ experience marked the beginning of a new initiative aimed at providing a hands-on, interactive environment for customers to explore the company’s motion plastics technology. H&P’s Aaron Blutstein reports. Designed to demonstrate how igus solutions can help businesses save both time and money, this event is just the starting point in what is set to be an ongoing campaign. With a focus on sustainability and efficiency, igus is reinforcing its commitment to providing cutting-edge solutions to industries across the UK. A personalised approach: Customer success stories Managing Director of igus UK, Matthew Aldridge, launched the event with an indepth presentation on the significance of the new ‘enjoyneering’ experience. He highlighted its importance as a physical space where businesses can come to see how igus motion plastics products are used in real-world applications. Aldridge’s address set the tone for the day, focusing on the company’s dedication to innovative, sustainable technology that delivers measurable value to its clients. A key feature of the event was the inclusion of two igus customers, Automation & Robotics and CNC Guru, who shared their personal experiences with igus products. Both businesses spoke of how igus’ motion plastics have been integral in their respective operations, underscoring the practical benefits of these materials in modern machinery. Their accounts offered invaluable insight into how igus’ products not only improve efficiency but also can contribute to cost savings. The heart of the event was the unveiling of the ‘enjoyneering’ experience itself – a newly transformed showroom designed to engage attendees with igus’ latest innovations. This interactive space
discover more ASME B31.1-B31.3 UNI EN ISO 9001 2014/68/UE EN 13501-1:2007 Aluminium modular piping systems for the distribution of fluid energy. Systems for compressed air, vacuum, nitrogen, gas and technical fluids. Customised ergonomic solutions. Design, energy saving and pay-back services. HOLLOW BAR SYSTEM ALUMINIUM PIPING SYSTEM DROP COLUMN SYSTEM AIR & ELECTRIC TRACK SUPPLY MODULAR TROLLEY SYSTEM - PRESSURISED WORK BENCH FOR ASSEMBLY - PRESSURISED SWINGING ARM BRACKET - PRESSURISED ALUMINIUM MANIFOLD SYSTEM MULTIFLUID PIPING SYSTEM 25 BAR hbs dcs ats aps ams wba mts mps sab In 1988 Teseo Srl invented a market by developing and bringing to market worldwide innovative modular aluminium piping systems for compressed air and technical fluids distribution. Revolutionary systems, carefully designed and manufactured in Italy, designed to be quick to install, durable and efficient over time: all this with a view to economic, energy and environmental sustainability. Since then, Teseo has never stopped inventing and designing products and services tailored to each customer’s needs, also enhancing its range of solutions for the distribution of compressed air and technical fluids, in order to be a solid and reliable partner from the compressor room to the machine or workbench. With the experience and expertise that only the Company that invented the product can provide. ERGONOMIC CUSTOMISED SOLUTIONS MADE IN ITALY TESEO SRL Via degli Oleandri, 1 25015 Desenzano d/G (BS) T. 030 9150411 teseo@teseoair.com 100% RECYCLABLE ALUMINIUM LIGHTWEIGHT AND ROBUST QUICK AND EASY TO INSTALL PLUG & PLAY EASY TO ASSEMBLE AND DISASSEMBLE ZERO WASTE 100% LEAK-FREE ENERGY SAVING CONSULTING DESIGN REDUCED COSTS DURABLE AND RESISTANT HIGH TECH DESIGN
8 HYDRAULICS & PNEUMATICS September 2024 www.hpmag.co.uk NEWS A virtual reality tour of ERIKS’ £22 million FCE (Fulfilment Centre of Expertise) is now available to view on its website. The virtual tour, provides an immersive look at the FCE, emphasising the advantages of central stock management in contrast to local stock management, providing insight into optimising logistics and improving efficiency. This state-of-the-art facility revolutionises the supply chain landscape by offering customers unparalleled flexibility, reliability, and efficiency through centralised stocking. In recent years, manufacturers across the UK and Ireland have faced unprecedented supply chain challenges forcing many businesses to reassess their supply chain strategies, with a noticeable shift from ‘Just In Time’ to ‘Just In Case’ approaches. However, ERIKS’ new virtual tour of the FCE demonstrates centralised stocking offers a more effective solution, eliminating inefficiencies and limitations of traditional local stock models. A key advantage of the FCE is its precise delivery options with the choice of next-day delivery, including pre-9 AM, pre-10 AM, and pre-12 PM slots. By utilising a courier service, ERIKS guarantee that customers receive their order when they need it. This level of service is not achievable with traditional service centre van deliveries, which are limited by the number of vehicles available and geographical area. was conceived as a hub of activity, featuring products tailored to a wide range of industries. From automotive to aerospace, the vast array of motion plastics solutions on display is designed to provide visitors with the chance to witness first-hand the versatility and applications of these materials. One of the standout features of the ‘enjoyneering’ experience is igus’ new initiative: GO ZERO LUBRICATION. This is part of the company’s broader commitment to sustainability, a principle that was woven throughout the day’s events. GO ZERO LUBRICATION aims to reduce the environmental impact of traditional lubrication methods by promoting maintenance-free, lubricationfree components made from highperformance plastics. The initiative supports igus’ long-term goals of achieving zero waste, reducing carbon emissions, and promoting recyclable materials wherever possible. Following the product showcase, I was invited on a guided tour of igus’ factory facilities, offering a behind-the-scenes look at its semi-automated readycable production line. This glimpse into the manufacturing process highlighted how igus is adapting to increasing demand. “This year, we have invested hundreds of thousands of pounds in our Northampton factory to help us meet the growing demand for igus products from UK industries,” said Aldridge during the tour. The factory’s state-of-the-art processes allow for the assembly and shipment of sub-assemblies within a 24-hour timeframe, reinforcing the company’s reputation for efficiency and responsiveness to market needs. A key element of the tour was the visit to the customer test area – a dedicated space where attendees could observe advanced robotic solutions in action. igus’ RBTX specialists were on hand to offer detailed explanations of the company’s wide range of automation options, demonstrating how igus products are being used to drive innovation in manufacturing. This area not only showcased the flexibility and precision of igus’ robotics solutions but also provided a platform for exploring the possibilities of further automation in industrial settings. The interactive cobot desk was another highlight, showcasing the cutting-edge technology behind igus’ automation systems. The centrepiece of this display was the ReBeL cobot, the world’s first collaborative robot made entirely from high-performance plastic. Lightweight and highly efficient, the ReBeL represents a significant breakthrough in the field of service robotics. Its unique construction opens the door to new applications, particularly in industries where traditional robotics solutions may be too heavy or cost-prohibitive. After a break for a festival-themed lunch – complete with freshly made wood-fired pizzas and ice cream – I also had the opportunity to test another of igus’ products, the RCYL bike, on guided bike rides around the Brackmills area, giving us the chance to experience the RCYL bike first-hand. This unique bicycle, constructed primarily from recycled ocean plastic waste, showcases igus’ commitment to sustainability and its vision for the future of manufacturing. Each year, millions of bicycles are discarded after rusting beyond repair, contributing to an alarming amount of waste in landfills. The RCYL bike aims to tackle this issue by offering a maintenance-free rust-proof alternative to traditional metal-framed bicycles. Thanks to its lubrication-free components, the RCYL bike not only reduces the need for regular upkeep but also highlights the versatility of high-performance plastics. The bike’s eye-catching design, available in a range of vibrant colours, further underscores the creative possibilities of sustainable materials. The igus ‘enjoyneering’ event successfully combined education, innovation, and sustainability, offering attendees a comprehensive look at the company’s forward-thinking approach. Whether through the factory tour, the customer presentations, or the interactive product displays, the event made clear that igus is committed to leading the way in motion plastics technology. With initiatives like GO ZERO LUBRICATION and the RCYL bike, igus is not only shaping the future of manufacturing but also making a strong case for sustainability at the core of industrial innovation. As the ‘enjoyneering’ experience continues, it promises to serve as a vital resource for businesses looking to optimise their operations while embracing environmentally friendly practices. With its blend of technological expertise and ecological responsibility, igus is paving the way for a smarter, more sustainable future. ERIKS launches virtual tour of £22m fulfilment centre
NEWS 10 HYDRAULICS & PNEUMATICS September 2024 www.hpmag.co.uk of a million products, ERIKS is setting a new standard for responsiveness and reliability in the industry. The keynote speakers for Advanced Engineering 2024 have been confirmed, with six prominent industry figures set to deliver talks at the two-day event. Held at the NEC in Birmingham on 30-31 October 2024, the event will host over 150 speakers discussing critical issues across various forums. Among the keynote speakers is Brian Holliday, Head of Siemens Digital Industries for the UK and Ireland. Holliday, a recognised authority in industrial technology and digital manufacturing, oversees areas such as automation, industry software, and systems integration. He is also a regular commentator on productivity and industrial strategy. Matthew Atkinson, Lead Research Engineer at Jaguar Land Rover, will also be speaking. Specialising in automotive engineering, Atkinson has worked extensively on replacing traditional metallic structures with injection-moulded composites. His expertise spans the development of interior components, such as seating systems, and he holds several patents, including one for the Range Rover’s Executive Seating. Shaun Harris CBE, Director of Support and Chief Engineer at the Royal Air Force, brings decades of experience to the event. With a 37-year career in the RAF, his background includes leadership roles in engineering, logistics, and information warfare, having served in regions such as Afghanistan, Iraq, the UK, and the USA. Other confirmed speakers include Solange Baena, UK Lead for the Aviation Environmental Roadmap at Airbus, Leonie Moffat, Laser Radar Sales Account Manager at Nikon, and Stefan Lawrenson, Senior Polymer Chemist at Scott Bader. Lawrenson’s research focuses on sustainable polymer technologies and the development of eco-friendly materials. The organisers of Advanced Engineering, Easyfairs UK & Global, have emphasised the importance of this year’s speakers in addressing key industry topics, including Industry 4.0, supply chain management, and sustainability. The full programme of speakers will be announced in the lead-up to the event, which is expected to attract professionals from sectors such as aerospace, automotive, defence, and marine. Attendees can anticipate a broad range of discussions, from digitally-enabled supply chains to advanced propulsion technologies, reflecting the event’s role in fostering innovation and knowledge exchange within the engineering community. “The belief that local stock availability is essential is largely a myth,” said Sally Hill, of ERIKS UK & Ireland. “Local stocks often represent 12% of the inventory we hold at our FCE, which can be clearly seen via the virtual tour. When local stock runs out, companies are left scrambling to find what they need. This disrupts operations, compromises traceability and quality control. In contrast, our centralised model ensures quick access to over 250,000 products, all managed with the highest standards of quality.” The centralised stocking model at the FCE allows ERIKS’ staff to focus on supporting customers with less time spent managing stock and complex logistics. With more time to solve problems, offer expert advice, and delivering product and supply chain training, customers get the parts they need along with the insights to keep their operations running smoothly. The virtual tour of the FCE demonstrates the scale and efficiency of centralized stocking with the flexibility of modern logistics. With the ability to dispatch 50,000 items an hour and provide next-day delivery on a quarter Keynote speakers announced for Advanced Engineering 2024
ORGANIZED BY IN COLLABORATION WITH INTERNATIONAL AGRICULTURAL AND GARDENING MACHINERY EXHIBITION BOLOGNA (I), FROM 6 TO 10 NOVEMBER 2024
12 HYDRAULICS & PNEUMATICS September 2024 www.hpmag.co.uk NEWS Lydia Amarquaye, Education & Skills Policy Lead at the Institution of Mechanical Engineers recently congratulated all students receiving their A Level, T Level, and BTEC results last month. She noted that it was particularly heartening to see STEM subjects prominently featured among the top ten A Level choices this year. This trend underscored a growing recognition of the critical role that Science, Technology, Engineering, and Mathematics play in shaping the future. The knowledge and skills gained from these disciplines are essential for driving innovation and addressing the complex challenges of tomorrow. The notable increase in participation in maths, further maths, and physics was especially encouraging, with a 10.2% rise in maths and a 19.9% rise in physics compared to the previous year. These subjects are recognised as pivotal for those pursuing engineering courses at university. The year 2024 also marked the debut of the ‘Engineering and Manufacturing’ T Levels. Some of these students received apprenticeship offers following their placements, while others applied for new apprenticeships or advanced to higher education programmes. Amarquaye emphasised the ongoing need to support T Level graduates as they transition into technical roles or further studies, highlighting the importance of enhancing understanding of the T Level qualification and the depth of learning it encompasses. Additionally, students who completed engineering-related BTEC qualifications are now poised to apply for apprenticeships. Despite uncertainties surrounding future funding for BTECs, their indispensable role in providing a solid technical foundation for further development in apprenticeships and other qualifications was duly acknowledged. Amarquaye concluded by noting that the diverse range of educational options reflects the extensive skills gaps within the engineering sector. She reiterated the need for continued efforts to increase both the number and diversity of young people engaging in STEM subjects to effectively meet the demands of the industry. 2024 A Level, T Level, and BTEC results reflect growing interest in STEM subjects The Institution of Engineering and Technology (IET) has issued a response to the UK Government’s proposal to restrict overseas hiring for technology and engineering positions. Stephanie Baxter, Head of Policy at the IET, expressed support for the Government’s commitment to addressing the UK’s skills shortages by focusing on training and developing domestic engineers and technicians. However, she cautioned that this effort should not undermine the sector’s ability to attract highly skilled international talent. Baxter highlighted the importance of the Migration Advisory Committee’s forthcoming review, which aims to assess the challenges employers face in recruiting and retaining engineers and technicians. She stressed the need for the sector to have a voice in this review to ensure that its concerns are considered before any decisions are made. The IET has observed significant recruitment challenges within the sector, with employers struggling to fill graduate roles. The recent increase in the salary threshold for a general skilled worker visa from £26,200 to £38,700 has made it difficult for many employers to recruit international graduates, as the new threshold exceeds the average salary for domestic employees. This change has led some employers to cease hiring international graduates, exacerbating the skills shortage in the UK. Baxter also pointed to the introduction of Skills England as a potential means to address these issues. The IET noted that the skills shortage in engineering costs the UK economy £1.5 billion annually and that despite ongoing reports of these challenges over the past 15 years, there has been little progress in resolving them. She emphasised the need for a balanced approach that includes building a robust domestic pipeline of engineers and technologists, starting from schools and extending through continuous upskilling and reskilling, while also maintaining the ability to attract global talent. Baxter concluded that limiting opportunities for international recruitment could hinder efforts to effectively address the skills shortage in key industries. Concerns over UK Government’s proposal to limit overseas hiring for engineering and tech jobs
www.hpmag.co.uk HYDRAULICS & PNEUMATICS September 2024 13 Global engineering technologies company Renishaw has provided Domin, a leading manufacturer of high-performance hydraulic valves, with its RenAM 500Q Ultra metal additive manufacturing (AM) system. The system will support Domin’s increased production of servo proportional hydraulic valves at its new Technology Centre near Bristol, UK. The RenAM 500Q Ultra is the latest model in Renishaw’s RenAM 500 series of laser powder bed fusion (LPBF) systems. It incorporates Renishaw’s patented TEMPUS™ technology, which reduces build times by up to 50% while maintaining high part quality. The TEMPUS technology allows lasers to operate while the powder recoater is in motion, significantly increasing productivity. Additionally, the system features advanced process monitoring software to ensure consistent quality. Domin had previously purchased a RenAM 500Q system in 2023 but required additional capacity due to growing demand. The new RenAM 500Q Ultra, Renishaw’s highest productivity model, will help meet this increased demand. Marcus Pont, Chief Executive and co-founder of Domin, commented: “The installation of the Renishaw 500Q Ultra marks another milestone in Domin’s growth. This technology will enhance our manufacturing capabilities, allowing us to deliver even greater value to our customers. Our continued partnership with Renishaw reflects our commitment to innovation and operational excellence.” Domin’s hydraulic valves, used in industries such as automotive, aerospace, and manufacturing, benefit from the use of metal AM to create complex internal geometries not achievable through traditional methods. This results in stronger, lighter components with reduced material waste. Domin’s approach combines AM with advanced technologies like high-speed motor control, modern electronics, big data, and connected systems, aiming to help the hydraulics industry reduce CO2e emissions by one gigatonne by 2030. The new system will help Domin maintain short production times while delivering highquality products to its growing customer base. Josh Whitmore, Senior Technical Sales Engineer at Renishaw, said: “We’re pleased to have installed the RenAM 500Q Ultra to enable Domin to boost their production. Our systems are designed and manufactured in the UK, and this sale to a UK-based AM producer is a strong result for the country’s manufacturing Advanced manufacturing system enhances production for UK hydraulic valve manufacturer
INTEGRATED SYSTEMS 14 HYDRAULICS & PNEUMATICS September 2024 www.hpmag.co.uk While adoption of wireless remote controls is widespread in some applications, there are pockets of the offhighway industry that have not yet taken the leap. Original equipment manufacturers considering the addition of remote controls may question the benefits and worry about machine redesign implications. This article offers a guide to remote control integration, addressing common concerns as well as the basics of remote control selection. Optimising operations, comfort, and safety From cranes and concrete pump trucks to machinery used in firefighting, mining, and demolition, remote controls are common in applications where visibility or safety are challenges for operators working in the cabin. Remote controls are also increasingly common in industries such as construction, agriculture, and forestry, where moving the operator away from the machine can increase productivity. In each of these applications, remote controls are optimizing operations, increasing operator comfort, and improving safety. These are the primary reasons OEMs should consider remote controls for nontraditional applications. Remote controls enable operational optimization as they allow users to exit the cabin and operate the machine from a location that provides a better view of the task or the machine’s surroundings. The elimination of blind spots leads to greater site safety and may also allow one person to perform a task that previously required two or more people. A better view can also prevent an operator from holding their head in an uncomfortable position, reducing the risk of muscular strains. Performing work from a more natural position increases operator comfort. In addition, providing operators with the option to work while standing — especially those who typically sit for the duration of their shift — can improve health and wellbeing. Another considerable benefit of remote controls is their ability to increase operator safety. In many industries, machines operate in challenging areas: steep slopes or unstable ground; within or close to buildings lacking structural integrity; and in environments that are flammable, explosive, or have poor air quality. Remote controls allow operators to work in these areas, but from a safer position, mitigating or eliminating safety hazards. While remote controls are suitable for many applications, they may not be right for every situation. Device range varies, but typically reaches up to 500 meters (1,640 feet). For applications requiring remote operation over longer distances, teleoperations may be a better, safer choice. Autonomous operation may also Autonomy and teleoperation are big news, and with good reason. These advances in machine technology are helping overcome common industry challenges, such as job site safety and productivity. But there’s another method for delivering these same benefits, and one with much lower hurdles to entry: radio remote controls. Still at the cutting edge, these devices are becoming more technologically and ergonomically advanced. Idoia Maiz, portfolio manager, Connect and Control Solutions, Danfoss Power Solutions, explains further. Beyond the cab: Making the case for remote controls be an option. Environments requiring radio silence or areas with high interference will need a tethered backup. Overcoming remote control resistance OEMs considering the addition of remote controls often have questions or concerns. Cost is sometimes a factor, particularly for base-level machines or those destined for the rental industry. A cost-benefit analysis or voice-of-customer study can help determine if the added value remote controls provide justifies the higher machine price. Another concern may be whether the devices will work in every country the machine is exported to, but many remote controls today operate on a universal 2.4 gigahertz radio frequency. Among the more frequent concerns, however, are safety and security, operator acceptance, and machine redesign.
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INTEGRATED SYSTEMS and functions. This will minimize machine redesign needs. Selecting the right solution Remote controls are a combination of transmitter and receiver, with receivers typically being straightforward to specify. The primary choices are its connection to the machine – discrete outputs vs. CAN – and its voltage output control. Compact machines need compact receivers, and if the device will be inside a metallic enclosure, it may require an external antenna. Transmitters can be a bit more involved to specify, but understanding a few key points will help determine the correct type for the application. For offhighway machinery, there are three common types of transmitters: handheld, pistol grip, and console box (also known as belly pack). A handheld transmitter is a small device held in the palm of a hand. These devices are narrower in width but thicker in depth than a mobile phone. Handheld transmitters are on the basic end of the spectrum with limited mechanism types, which makes them ideal for machines with fewer and simpler functions. They have between two and 14 buttons, which From a safety perspective, machines need to be protected from unintended movement and access. Movement is covered by emergency stop functionality, which is standard on all remote-control transmitters. Look for performance level E certification, the highest possible safety rating for this function. The ability to integrate deadman switches, free-fall detection, tilt detection, twohanded/interlocking operation, and range limiters provide additional measures of protection. As for access, look for remote control suppliers with proven secure solutions and the inclusion of cybersecurity in product development and testing processes. Operator familiarity and acceptance can be a challenge, as operators used to controls within the machine’s cabin may be reluctant to learn and use a remote control. To increase operator comfort and acceptance, it’s important to configure the transmitter in a way that mimics the controls look and layout within the cabin. This includes mechanism type and placement plus overall look and feel, such as icons and display design. Remote control configuration and programmable display capabilities are key to enabling this replication. A key question in considering the addition of remote control capabilities is whether and to what extent the machine needs other design modifications. Fortunately, many machines today are ready for remote control integration as the basic requirements are minimal. The remote control receiver requires either digital control such as CAN bus, or it can be wired directly to the machine’s proportional valves and sensors. The receiver is capable of handling machine logic and direct control of valves. The solution depends on the machine, so look for a supplier with a flexible portfolio that can adapt to different types of machines 16 HYDRAULICS & PNEUMATICS September 2024 www.hpmag.co.uk
can be on/off or proportional. Pistol grip remote controls are held, as the name suggests, in one hand like a pistol. There is a trigger used for proportional control of a valve or as a deadman switch in conjunction with thumbsticks on the main body. The face plate can include a variety of functions, such as buttons, switches, joysticks/thumbsticks, and graphical display screens. The sides of the device can also house functions, typically auxiliary. The pistol grip has more functionality than a handheld transmitter, but not as much as a belly pack. The most flexible transmitter is the console box, which the operator straps on around their neck, shoulders, and/or waist, depending on the harness, with the transmitter resting against the operator’s stomach. A console box can have multiple different functions through buttons, switches, and joysticks/thumbsticks. They can also incorporate high-resolution, sunlightviewable display screens. Console box transmitters are ideal for machines with more – and more complex – functions. The number of inputs/outputs needed can narrow transmitter selection to one type, but some applications can be covered by more than one option. In this case, operator familiarity or preference is typically the decision-making factor. For example, both a handheld and a console box transmitter are suitable for some applications, but if the cabin has levers rather than buttons, the belly pack is the better choice. Keep in mind, operator preferences can vary by country and device operation time. In choosing between models from different suppliers, look at size, weight, ergonomics, customization and branding capabilities, local supply and service, and ruggedness as the differentiators. Ruggedness refers to the device’s ingress protection ratings and ability to withstand drops and vibration. Many OEMs looking to optimize operations and improve operator comfort and safety have already implemented remote controls. Usage is widespread and operator acceptance is high. OEMs weighing whether it’s time to move controls beyond the cab would be wise to consider the low barriers to entry and abundant benefits of radio remote controls. For further information please visit: https://www.danfoss.com/en/ www.hpmag.co.uk HYDRAULICS & PNEUMATICS September 2024 17
APPLICATIONS The trend of increasing bed sizes in additive manufacturing (AM) is gaining momentum. Larger bed sizes are essential for producing large components, but some manufacturers are using these bigger systems for the volume production of smaller parts. However, smaller machines, optimised for productivity, could offer a better return on investment (ROI). The importance of reducing costs Reducing cost per part is crucial for the broader adoption of AM technology. Since a significant portion of part costs is generated during on-machine build time, original equipment manufacturers (OEMs) have prioritised machines that can reduce the time per part. One approach to achieve this is by making machines larger to accommodate higher volumes of parts. While the standard bed size for many AM machines is 250 x 250 mm, machines with build areas exceeding one metre are now available. Is a larger bed size necessary? The most obvious reason to opt for a larger bed size is if you are producing large parts that cannot fit within a standard 250 x 250 mm footprint. However, most components produced using metal AM tend to be smaller. Crownshaw notes that approximately 80 per cent of the parts customers inquire about are designed to fit within a standard bed size. These include small structural components for automotive frames or medical implants. For those seeking to produce small parts in volume, a larger platform is not always the most efficient option. While a bigger machine can produce more parts per build, it does not necessarily guarantee greater efficiency or productivity. To achieve optimal productivity, manufacturers must carefully assess their specific application and determine which machine is best suited to their needs. Key considerations around bed size When choosing a machine with a larger bed size, several considerations need to be taken into account. Firstly, is your manufacturing process equipped to handle a large number of parts being produced at once? For instance, downstream processes such as heat treatment, blasting, and post-processing could become bottlenecks if the system is producing too many parts at once. Another potential drawback of using a large machine for small part production is the increased risk of build failure. If a failure occurs during the production of many parts on a single large machine, the impact could be more significant than if the parts were spread across multiple smaller machines. ROI is another crucial factor. Large machines often come with a higher price tag, which can lead to longer payback times. In some cases, investing in two smaller machines may deliver better ROI, while also managing the risks associated with build failure and facilitating a smoother production process. Alternative approaches to productivity There are other ways to boost productivity in AM that do not involve increasing bed size. Technologies that increase laser-on time, improve machine turnaround, and streamline powder handling can all contribute to greater efficiency. For instance, integrating powder handling processes like sieving directly into the machine can reduce the time spent removing unmelted powder for recirculation. Additionally, some manufacturers are incorporating vacuum processes that allow the machine to start processing more quickly by removing oxygen faster, thereby reducing the need for consumables like argon gas. One of the most significant challenges in improving laser-on time in laser powder bed fusion machines has been recoating time. Traditionally, the laser stops firing during the recoating process, which can slow down the build. Recoating times of around nine to eleven seconds per layer can add up to tens of hours over the course of a build that involves thousands of layers. By making AM systems faster and more efficient, manufacturers can reduce the cost per part and increase production output — without necessarily requiring a larger machine. For businesses considering whether to invest in machines with larger bed sizes, it is essential to weigh up the specific demands of their application, the risks involved, and the overall impact on productivity and ROI. For further information please visit: https://www.renishaw.com 18 HYDRAULICS & PNEUMATICS September 2024 www.hpmag.co.uk Is a bigger bed size always better in Additive Manufacturing? Stephen Crownshaw, Head of AM Sales at global engineering technologies company, Renishaw, explores how bed size impacts productivity in Additive Manufacturing.
Award Programme Partners The BPMA’s annual Pump Industry Awards programme has been recognising and rewarding the achievements of pump businesses, large and small for over two decades. Throughout that time it has become one of the leading events to serve the industrial and commercial arena. So, if you or your company have a pump related success to shout about, these awards provide the perfect platform. The gala presentation dinner caps off the awards programme in style, providing excellent networking opportunities, great food and superb entertainment. It’s your chance to celebrate with colleagues, interact with peers, entertain customers and be part of the pump industry’s biggest and best celebration. Manufacturing and distribution prowess, product development and application, environmental consideration, skills development and customer support will all be acknowledged through this wide reaching awards programme. So why not consider which of your engineering successes are deserving of industry wide recognition, and be sure to join us at our wonderful venue - the home of English football - on Thursday 13th March 2025. The 2025 entry forms open on the 1st July, so be sure to visit the Pump Industry Awards website to review the award categories and decide which ones you will be entering! PUMP INDUSTRY AWARDS 2025 Dale Croker, BPMA President, says of the Pump Industry Awards, “The pump industry continues to be a hotbed of competitiveness, where the constant search for greater operational performance and improved efficiencies amongst its broad customer base, demands all those operating within this important sector to be at the top of their game. This BPMA backed awards programme allows the pump industry to come together in celebration of that drive for engineering excellence.” NOMINATIONS OPEN 1ST JULY Rewarding pump industry excellence once more! Event Calendar Nominations Open: 1st July 2024 Nominations Close: 29th November 2024 Judging Session: Mid December 2024 Voting: 13th – 17th January 2025 Winners Announced: 13th March 2025 www.pumpindustryawards.com Organised by on behalf of Venue: Hilton at St George’s Park, Burton upon Trent Date: Thursday 13th March 2025
20 HYDRAULICS & PNEUMATICS September 2024 www.hpmag.co.uk New Patch Imaging Kit enhances contamination monitoring HYDRAULICS MP Filtri has expanded its range of contamination monitoring products with the introduction of a new Patch Imaging Kit, designed to enhance fluid analysis capabilities in hydraulic systems. This latest innovation complements MP Filtri’s existing portable and inline particle analysers, which offer real-time, highly accurate detection of contaminants in fluids. The Patch Imaging Kit brings an additional layer of insight by allowing operators to assess particles under a digital microscope, helping to pinpoint the root cause of system contamination. The kit facilitates fast and precise testing of fluid samples by capturing contaminants on a patch, which can then be examined in detail using the highperformance digital microscope included in the package. The microscope, with magnification capabilities of up to 400x, enables operators to measure, record, and evaluate individual particles. By analysing the composition of these particles, maintenance teams can identify the source of system wear and tear. For instance, the presence of rubber particles may indicate hose degradation, while metal fragments could reveal excessive wear on pumps or other critical components. Understanding the exact nature of these contaminants is crucial for maintaining system integrity. By highlighting specific causes of degradation, the Patch Imaging Kit enables teams to take proactive measures, such as replacing damaged parts before they lead to system failure. This preventative approach helps to protect complex hydraulic systems, extend their service life, and significantly reduce both maintenance costs and downtime. The Patch Imaging Kit boasts a range of advanced features that make it an essential tool for contamination control. Its sophisticated software allows for detailed measurement and analysis of particles, while the complete patch testing kit makes fluid sampling quick and easy. The kit’s Windows-based software is designed for seamless installation on PCs and laptops, and with user-friendly step-by-step instructional videos, operators can master the process without the need for formal training. Durability and portability are also key considerations. The kit is housed in a heavy-duty Peli case with a laser-cut foam surround, ensuring the equipment remains well-protected during transport or field use. This makes it ideal for operators who need to perform contamination assessments in various locations. Geoff Grant, Product Manager at MP Filtri UK Ltd, highlighted the value of the new kit, stating: “This new Patch Imaging Kit allows for precision assessment of individual contaminants. Alongside the latest generation of particle counters, it plays a key role in enhancing any company’s contamination control strategy.” MP Filtri’s Patch Imaging Kit is now available and is part of the company’s premium range of contamination control products, which also includes an extensive selection of hydraulic filters and accessories. To learn more please visit: http://www.mpfiltri.co.uk
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