www.hpmag.co.uk NOVEMBER/DECEMBER 2024 p30 p28 Pneumatic islands: The backbone of smart factories The growing need for cybersecurity vigilance in electro-hydraulic systems Five factors to consider when choosing safety footwear p20 Is the industrial metaverse worth writing home about?
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Shaping the future of fluid power EDITOR’S COMMENT www.hpmag.co.uk HYDRAULICS & PNEUMATICS November/December 2024 3 Looking ahead, the convergence of sustainability, digitalisation, and innovation is set to transform what fluid power systems can achieve. ‘ ’ As we approach the end of 2024, the hydraulics and pneumatics sector in the UK is in the midst of significant change. Advances in materials, digital technologies, and energy efficiency are opening up new possibilities for fluid power systems. This is not just an evolution but a period of reinvention. The demand for sustainable solutions has driven the development of greener hydraulic fluids and energy-efficient systems. Manufacturers are introducing biodegradable, high-performance fluids that align with Net Zero 2050 goals and ISO 14001 standards while maintaining reliability. At the same time, innovations like variable-speed drive pumps and electro-hydraulic actuators are reducing energy consumption, showing that fluid power can combine performance with sustainability. Digitalisation is another major shift. Smart hydraulic systems, featuring IoT sensors and advanced analytics, are making predictive maintenance and real-time performance monitoring a reality. These technologies are improving operational efficiency and helping to minimise downtime, bringing tangible benefits to a range of industries. However, the sector faces some significant challenges. The skills gap in fluid power engineering remains a concern. With many experienced professionals nearing retirement, there is an urgent need to train and attract new talent equipped to work with both digital tools and traditional hydraulic and pneumatic systems. Programmes like T-levels and initiatives from organisations such as the Institution of Mechanical Engineers (IMechE) will be critical for bridging this gap and ensuring the long-term health of the industry. In addition, global uncertainties and post-Brexit trade adjustments continue to impact component availability and costs. UK companies must focus on resilience through strategies such as diversifying suppliers, adopting modular system designs, and increasing local manufacturing capabilities. For small and medium-sized enterprises (SMEs) in particular, these approaches can provide vital stability. Collaboration across the hydraulics and pneumatics community is crucial. By sharing expertise, fostering partnerships, and working together, the sector can tackle challenges and accelerate innovation. The strength of collective effort cannot be underestimated as it allows the industry to address even the most complex issues effectively. Looking ahead, the convergence of sustainability, digitalisation, and innovation is set to transform what fluid power systems can achieve. By focusing on collaboration and innovation, we can ensure the sector continues to meet the demands of today while preparing for the challenges and opportunities of tomorrow. Aaron Blutstein Editor
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www.hpmag.co.uk HYDRAULICS & PNEUMATICS November/December 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 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. 28 34 6 NEWS 16 KNOWLEDGE BASE Tom Cash explains the computational, connectivity, interoperability and regulatory challenges of the metaverse while feeling very enthusiastic about the whole thing. 20 APPLICATIONS Choosing the right safety footwear is critical to ensuring the safety, comfort, and productivity of workers in industrial environments. Clair Weston highlights five key factors to consider when selecting footwear for applications where comfort and protection are paramount. 22 HYDRAULICS 28 PNEUMATICS The rise of pneumatic islands within smart factories is a critical yet often underappreciated development, playing a significant role in helping manufacturers navigate the complexities of digitalisation. These modular valve systems have evolved from simple mechanical tools into integrated solutions that support a more efficient and responsive manufacturing process. H&P reports. 30 INTEGRATED SYSTEMS 34 COMPRESSED AIR, VACUUM, & GENERATORS As industries face growing demands for efficiency and sustainability, the need for customised compressed air solutions is more important than ever. Tailored systems help optimise energy use, improve reliability, and meet specific operational needs. H&P reports. 37 BCAS Our regular news and events update on the British Compressed Air Society. 40 SPECIAL REPORTS LAMMA/ Southern Manufacturing 41 BFPA Hydraulics & Pneumatics’ issue-by-issue briefing on current activities and views involving the British Fluid Power Association. 46 NEW FACES 47 PRODUCTS & SERVICES DIRECTORY 40 Subscribe for your FREE copy now
NEWS 6 HYDRAULICS & PNEUMATICS November/December 2024 www.hpmag.co.uk The recent UK budget has left manufacturing leaders weighing a complex mix of immediate financial challenges against longer-term strategic gains. In an economic environment that demands both fiscal responsibility and growth, the Chancellor’s new budget includes measures to increase costs for businesses, particularly through changes to Employer National Insurance contributions, while introducing commitments that could support the industry’s long-term development. Stephen Phipson, Chief Executive of Make UK, acknowledged the budget’s difficult balancing act, pointing out that while there is a clear focus on improving the economic landscape, the increase in Employer National Insurance contributions—alongside threshold changes and other cumulative employment costs—presents immediate challenges, especially for small and medium-sized enterprises. These cost pressures, he noted, come at a time when employment-related expenses, such as the National Living Wage and the UK Budget 2024: Manufacturing leaders respond to National Insurance hikes and Industrial Strategy commitment apprenticeship levy, are already climbing. Verity Davidge, Make UK’s Director of Policy, expanded on these concerns, suggesting that these increases could make employers hesitant to recruit, limit wage growth, and potentially lead to job losses. She warned that the “cumulative increase will send employers’ costs soaring,” a development that may deter some businesses from investing further in their workforce. Despite these financial pressures, industry leaders have welcomed some of the government’s broader initiatives, particularly the long-term commitment to a UK Industrial Strategy. Phipson remarked that this focus on industrial growth marks a shift for the UK, which has traditionally lacked a dedicated, sustained approach to manufacturing policy. The promise of a consistent industrial strategy, he suggested, could transform advanced manufacturing into a key driver of regional and national growth, offering the potential for increased investment and high-quality employment opportunities across the sector. Phipson urged the government to expedite the establishment of the necessary sector groups under the Industry Strategy Council, believing these will be essential to developing actionable plans. Another area of support lies in the newly introduced Corporate Tax Roadmap, which aims to bring predictability to tax policy for UK manufacturers. This commitment to a consistent tax approach is expected to offer businesses greater confidence in making long-term investment decisions. Fhaheen Khan, Senior Economist at Make UK, expressed that this stability could encourage manufacturers to invest in productivity-boosting initiatives, particularly within high-growth sectors such as automotive, aerospace, and life sciences. He emphasised that maintaining a careful balance between tax burdens and incentives for investment and innovation will be essential in promoting sustainable growth. Further optimism was sparked by the government’s decision to continue funding the Made Smarter programme, which has become a significant resource for small and medium-sized manufacturers in adopting digital technologies. Make UK’s Digitalisation Lead, Nina Gryf, described the programme as “the only initiative proven to be effective in helping smaller manufacturing businesses boost productivity.” She pointed out that, in a landscape where access to digitalisation support can be fragmented, Made Smarter offers critical guidance and resources that many SMEs rely on to make their first steps into automation and advanced technology. The budget leaves UK manufacturers with a blend of rising operational costs alongside measures that could bolster the sector in the coming years. While leaders are apprehensive about the impact of increased employer contributions and other expenses, they remain cautiously optimistic that the government’s longterm industrial strategy, tax stability, and continued digital support will provide a strong foundation for growth, innovation, and productivity across UK manufacturing.
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8 HYDRAULICS & PNEUMATICS November/December 2024 www.hpmag.co.uk NEWS Derbyshire-based AB Components Ltd has been appointed as the UK distributor for Hengst Filtration GmbH’s range of hydraulic filters. Hengst Filtration acquired the hydraulic filter division from Bosch Rexroth in 2021. This new role strengthens the existing relationship between AB Components Ltd and Hengst Filtration, enabling UK customers to source Hengst’s specialist hydraulic filters directly from stock held at AB Components’ Ilkeston facility. Customers will also benefit from technical advice and support from AB Components’ customer service team, as well as faster delivery times and reduced downtime. The ability to purchase filters in GBP through a UK-based account, with no minimum order requirement, provides added convenience, particularly in the post-Brexit trading environment. Established in 2007 by James Edgar, AB Components Ltd supplies more than 11,000 filtration products and began offering Hengst’s hydraulic filter range—previously branded under Eppensteiner and Rexroth—to complement its existing portfolio. This appointment reflects both companies’ plans to expand in the UK market. James Edgar, Managing Director of AB Components Ltd, expressed enthusiasm for the partnership. “Becoming a UK distributor for the Hengst Hydraulic brand is incredibly exciting for me and the team at AB Components Ltd. The strong reputation and quality of our industrial filtration range have always been important to us and our customers,” he said. “This strengthened association with Hengst Hydraulic Filtration, particularly through our relationship with Ian Micklewright, Market Manager for Hengst Hydraulic, enables us to maintain high service levels, improve delivery times, and keep costs stable. We see this as just the beginning of our collaboration as we aim to grow our position as leading filtration specialists in the UK market.” Ian Micklewright, Market Manager for Hengst Filtration, highlighted the importance of the partnership. “This appointment is an excellent step forward in serving the UK market for hydraulic filters. We are pleased to name AB Components Ltd as a UK distributor, recognising their reputation for high-quality customer service and expertise. Strengthening our relationship with James and his team addresses growing demand in the UK for our specialist filters. We are confident that customers will receive outstanding technical advice and support.” Long-term customer Geoff Chapman of G.A.C. Filtration welcomed the development. “We have worked with James and the team at AB Components Ltd for nearly a decade and have always valued their customer service, technical advice, and reliability. This partnership with Hengst Hydraulic means we can now source filters directly from ABC’s Ilkeston site, with benefits including no minimum orders, quicker turnaround times, and the same excellent service and value.” AB Components named UK distributor for Hengst Hydraulic Filters Maritime sector’s cyber risk appetite exceeds their key industries, new report finds A new report published by DNV reveals that the majority (61%) of maritime professionals believe the industry should accept increased cyber risk from digitalisation if it enables innovation and new technologies. The sector’s appetite to take on emerging risks arising from digital transformation is notably higher than other critical infrastructure industries including energy, manufacturing and healthcare. The maritime industry’s growing appetite for cyber risk comes at a time when it must also contend with an increasing number of vulnerabilities. According to the report, 71% of the nearly 500 maritime professionals surveyed believe their organisation’s industrial assets are more vulnerable to cyber-attacks than ever before. Similarly, 71% also say that the leaders of their organisations consider cyber security to be the greatest risk facing their business. “In the maritime industry, we must align our ambitions for digital transformation and decarbonisation with a firm commitment to safeguarding our people, vessels, and the systems we rely on,” says Knut Ørbeck-Nilssen, CEO Maritime at DNV. “Cyber-attacks pose an ever-growing threat to the safety of the maritime industry. We can innovate and lead in ensuring the resilience of our businesses and societies, but this can only be achieved if we truly manage cyber risk.” As the sector moves towards greater digitisation to improve safety, efficiency, and sustainability, maritime stakeholders—
NEWS 10 HYDRAULICS & PNEUMATICS November/December 2024 www.hpmag.co.uk including ship owners, ports, and the entire maritime value chain—are becoming increasingly dependent on connected digital technologies. Key areas where maritime professionals see the greatest opportunities include advanced data analytics, the Internet of Things (IoT), artificial intelligence (AI) and machine learning, high-bandwidth satellite communications, and autonomous operations. However, while the interconnectivity these technologies provide brings new opportunities, it also heightens the sector’s vulnerability to cyber threats. Despite this, maritime professionals are generally confident in the industry’s ability to manage these risks. More than 80% (83%) of those surveyed say their organisation has a strong cyber security posture, and 71% believe their organisation would swiftly return to normal operations following a cyber-attack. A major contributing factor to this confidence is that nearly three-quarters (73%) of maritime professionals report their organisation is increasing cybersecurity spending compared to the previous year. Most also believe that their organisation is wellprepared for potential outcomes such as asset downtime, operational disruption, theft of sensitive data, physical injury or loss of life, and the grounding of a vessel. Despite the increased awareness of cyber risks and growing investment in cybersecurity, there are signs of a false sense of security within the sector. Only 53% of those surveyed are confident their organisation can fully monitor supply chain vulnerabilities, a significant concern given the rise in cyber-attacks targeting supply chains. Additionally, 68% believe their organisation’s IT security is stronger than its operational technology (OT) security—OT systems being those connected to physical assets like sensors, programmable logic controllers (PLCs), and those supporting automation, safety, and navigation. Furthermore, 76% say the cyber security training provided by their organisation is insufficient to defend against sophisticated threats. “Organisations may feel they are prepared due to increased resources being deployed to manage cyber risk, but the reality is more complex,” explains Svante Einarsson, Head of Maritime Cybersecurity at DNV Cyber. “Companies must protect both IT and OT systems and be ready to respond quickly should an attack occur.” Maritime professionals’ concerns are heightened by geopolitical tensions and a rise in criminal activity. A particularly concerning trend is the growing risk of ransomware attacks from criminal gangs, with 79% of maritime professionals expressing concern about this threat, up from 56% in 2023. A significant 95% of maritime professionals advocate for greater collaboration on cybersecurity across critical infrastructure industries. “The maritime industry, along with other critical infrastructure sectors, must make substantial progress in openly sharing cyber security experiences—the good, the bad, and the ugly—in order to collectively create best practice guidelines for security,” says Einarsson.
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NEWS 12 HYDRAULICS & PNEUMATICS November/December 2024 www.hpmag.co.uk On 23rd October 2024, the National Fluid Power Centre (NFPC) in Worksop, Nottinghamshire, hosted its 12th annual Industry Open Day, marking its most successful event to date. Over 300 attendees, including students and representatives from national and international companies, gathered to explore advancements in hydraulics, electro-hydraulics, pneumatics, control, and automation technologies. This year’s turnout was the largest in the event’s history, reflecting the NFPC’s growing reputation as a hub for professional development and industry innovation. Among those in attendance were some of the centre’s approved partners and industry leaders, underscoring the importance of collaboration in fostering technological progress and career opportunities. A day of learning and networking The event provided students from colleges and universities with a unique platform to engage with experts and explore potential career pathways. Attendees had the opportunity to participate in a series of technical lectures presented by the NFPC’s approved partners. These sessions offered valuable insights into cutting-edge technologies and best practices in the field. Highlights of the lectures included: Webtec Products: Optimising and Maintaining Hydraulic Efficiency on Mobile Machinery Wandfluh: Amplifiers and Controllers for Proportional Valves Turck Banner: IIOT Data Collection These sessions not only educated but also inspired attendees, equipping them with knowledge to apply to their studies and future careers. The open day also featured an exhibition with 55 companies showcasing their products and services, providing a dynamic environment for networking and knowledge sharing. Attendees praised the event for its engaging format and the wealth of opportunities it presented. John Savage, Managing Director of the NFPC, expressed his gratitude for the event’s success: “What a fantastic event our Industry Open Day was this year, with 55 companies exhibiting representing hydraulics, pneumatics, control, and automation. On behalf of the NFPC, we’d like to take this opportunity to thank everyone who exhibited and attended for their continued support whilst ensuring the NFPC remains the UK’s flagship centre for the learning and development of the UK workforce. We look forward to the next event in 2025.” Looking ahead With over 20 companies already registered for next year’s event, anticipation is building for the 2025 Industry Open Day. The NFPC is committed to expanding its network and continuing to provide a platform for innovation and professional development in the fluid power and automation industries. For now, the NFPC celebrates the achievements of this year’s open day and the meaningful connections forged. As the flagship centre for workforce training in the UK, the NFPC remains dedicated to its mission of shaping the future of the industry, one event at a time. Record-breaking attendance at the NFPC’s 12th annual industry open day
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NEWS 14 HYDRAULICS & PNEUMATICS November/December 2024 www.hpmag.co.uk Pennine Pneumatic Services Limited (PPS), a compressed air distributor in Yorkshire, UK, has become part of Atlas Copco Group, after being acquired by Atlas Copco UK Holdings Ltd. PPS is based in Brighouse in Yorkshire, England, and was founded in 1991, but also has branches in Sheffield, Hull, Leigh and Alfreton. The company has 84 employees across the five locations. PPS offers energy-saving advice and solutions to manufacturers and other industries with applications that rely on compressed air and related systems and services. This includes compressors, gas generators, chillers, pneumatics, pipework, ducting, and assembly tools. Customers are found in all types of manufacturing industries, such as automotive and rail, chemical, construction and engineering, as well as food & beverages. “Pennine Pneumatic Services showcases strong sales and service presence in the North of England which will open additional opportunities for us going forward”, said Ariel Rubinstein, General Manager, Atlas Copco Compressors UK & Ireland. “I would like to welcome our new colleagues from PPS to Atlas Copco Group.” Matt O’Connor, Managing Director, Pennine Pneumatic Services Ltd, added: “Pennine Pneumatics Services Ltd (PPS) has been built on the strength and resilience of its people. Since PPS was founded 33 years ago, the team has continued to develop, diversify and embrace change. This growth mindset has been even more evident over the past 10 years where we’ve gone through a period of acquisitions and dramatic growth. Becoming part of Atlas Copco Compressors UK, with its focus on the wellbeing of the team, innovation and the environment, makes this next chapter the most exciting yet, for both our customers and the PPS team.” PPS has become part of the service division within Atlas Copco’s Compressor Technique business area. Pennine Pneumatic Services becomes part of Atlas Copco Group
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KNOWLEDGE BASE In July 2023, Siemens invested €500M in a new technology campus in Erlangen, Germany to help develop its vision of the industrial metaverse. The company intends to create a blueprint for the future — a real-time, photorealistic virtual representation of the world, where AI helps to create the next generation of high-tech, flexible and sustainable manufacturing technologies. But is that really all that new? Haven’t we been talking about, and even using, digital twins, extended and augmented reality, blockchain and virtual commissioning for more than a decade? Maybe so, but what sets Siemens’ initiative apart are the ambitious goals it aims to achieve within the industrial digital realm. The company wants to leverage AI to pioneer high-tech, flexible and sustainable manufacturing technologies, which go beyond mere duplication of physical systems in the virtual world. Instead, it involves creating a dynamic, intelligent ecosystem that can revolutionise manufacturing processes. Whether this investment will come to pass remains uncertain, as is the case with many plans. However, one thing for sure is that the companies actively engaged in developing metaverse hardware, software and infrastructure are well aware of the difficulties when transforming traditional industries. The concept The metaverse concept has been used in recent years primarily to describe the development of a 3D internet, referring to virtual environments used mostly — so far — for entertainment. It now aims to create precise simulations of industrial equipment, where it’s used as an umbrella term for various existing technologies that can be combined to digitally replicate real world objects and processes. For example, accurate simulations of factory equipment would allow manufacturing and other industrial firms to optimise operations without disruption, while improving collaboration amongst workers and frontline employee training. As with the consumer vision of a 3D internet, the industrial metaverse concept is a work in progress with extraordinary potential. Interoperability According to a new report released by the Manufacturing Leadership Council, the NAM’s digital transformation division, 16 HYDRAULICS & PNEUMATICS November/December 2024 www.hpmag.co.uk Tom Cash, director of industrial parts supplier Foxmere, explains the computational, connectivity, interoperability and regulatory challenges of the metaverse while feeling very enthusiastic about the whole thing. Is the industrial metaverse worth writing home about?
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KNOWLEDGE BASE 18 HYDRAULICS & PNEUMATICS November/December 2024 www.hpmag.co.uk and Deloitte, 92 per cent of manufacturing executives say they are experimenting with or implementing at least one metaverserelated use case. However, there are concerns about integrating existing technologies and systems when developing the industrial metaverse. Here, data preparation and transformation within complex workflows often present as major hurdles. This comes as no surprise. Companies are already grappling with integrating systems across multiple plants, let alone the advent of industrial metaverse initiatives, which is heightening the demand and complexity of integrating both similar and disparate technologies. Simply put, for the metaverse to become the next iteration of the internet, it must be interoperable. That is to say, the virtual worlds that constitute the metaverse must be able to freely exchange data, enabling seamless connections between people, processes, data and systems. Picture a high-tech factory using digital twins for not only replicating equipment but for predictive maintenance purposes too. AI could analyse data from the sensors on physical machinery and virtual counterparts, and when AI detects a potential issue, it would automatically schedule maintenance. Sounds pretty cool, doesn’t it? Regulatory changes Without getting too excited too soon, ensuring interoperability in the metaverse does have its challenges. It requires widespread agreement on standards, unlike the collaborative origins of the internet with foundational standards like HTML and TCP/IP. Metaverse building blocks operate differently, using various rendering engines and file formats that make post-facto standardisation complex. Therefore, the rapidly evolving metaverse space requires regulatory standards to ensure safety, fairness and interoperability. In Europe, the Digital Services Act (DSA) and Digital Markets Act (DMA) have recently been implemented to promote fair competition and prevent anticompetitive practices among digital platforms. This can indirectly benefit the industrial metaverse by encouraging interoperability and data sharing between different platforms and services. As the industrial metaverse requires, this would make it easier for systems and processes to connect and exchange data seamlessly. Open source Regulatory standards are typically established through government agencies, industry associations and international bodies. However, market competition can put pressure on getting standards to pass. When doing so, it is essential to encourage collaboration among the various stakeholders in the metaverse community. This collaboration would ideally lead to the development of standards that benefit the entire community rather than favouring specific players. A way that supports industry collaboration is open source. This is a software model where the source code of a program is made available to the public, which would allow companies to contribute towards developing interoperable options, ensuring the metaverse’s infrastructure is accessible and adaptable. For instance, developers could build upon existing functionality, introduce new features and integrate emerging technologies. These could, for example, include AI, blockchain and spatial computing. With that in mind, the possibilities are truly endless. But the metaverse is not a reality yet, and we’ve been talking about these technologies since the term metaverse was coined in 1992, by author Neal Stephenson. While we can get excited by the whole thing, especially in the industrial realm, manufacturers must look after and upgrade their current processes in the meantime. To start this process, establishing a trusted industrial equipment supplier is a crucial first step. Be it for the monitoring of current equipment or wanting to build accurate digital twins, receiving parts like Programmable Logic Controllers (PLCs) can help manufacturers save on costs, increase efficiency and reduce downtime. By sourcing parts manufacturers can lay the foundations for the metaverse future. And by doing so, they will initiate the process of gathering and effectively managing data from their equipment, serving as a means to bridging the physical and digital realms of the industrial landscape. For further information please visit: https://foxmere.com/en
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APPLICATIONS 1. Ensure a proper fit for all workers Industrial footwear fits differently compared to everyday shoes. This is due to the materials used for durability and protection, and the inclusion of safety features like toecaps. Sizing can also vary between brands. A proper fit for all employees, regardless of gender, is essential. Traditionally, safety footwear has been designed with a unisex approach, often neglecting the specific anatomical differences between men’s and women’s feet. Women typically have narrower heels and wider forefeet than men and using unisex footwear can lead to an improper fit, reduced comfort, and a higher risk of injuries. Footwear designed explicitly for women provides a better fit and more comfort, reducing the risk of foot-related issues such as bunions, corns and blisters. It also enhances safety by ensuring the footwear stays securely in place, minimising the risk of slips, trips, and falls. Employers should offer a range of sizes and styles tailored to both women and men to ensure every worker has the appropriate protection and support. If an employee has wide feet, don’t think sizing up will help. Safety footwear can be customised using insoles certified for that brand and model. These insoles allow the wearer to alter the dimensions inside the shoe for a customised fit. With the footwear and the insole working in tandem to support the foot and evenly distribute body weight. 2. Prioritise comfort Comfort is crucial, especially for workers who spend long hours on their feet in demanding environments like construction sites or manufacturing floors. Footwear that provides proper support is essential to reduce fatigue and prevent discomfort. Comfortable safety footwear can help prevent common foot problems such as plantar fasciitis, sore feet, and blisters. Features like shock-absorbing soles, cushioned insoles, and ergonomic designs can minimise the impact on joints and muscles, improving comfort throughout the workday. Some safety boots1 are designed with ergonomic soles made from materials like polyurethane to provide excellent cushioning and slip resistance. Certain technologies in footwear can enhance comfort by redistributing the energy from each step across the sole, a process that reduces fatigue and supports the musculoskeletal system. When workers are comfortable, they are less likely to suffer from fatigue and related injuries, leading to improved productivity and job satisfaction. 3. Match footwear to workplace hazards Safety footwear must protect against specific workplace risks. Key features to consider include: Slip resistance: For environments with a risk of slipping, especially on wet or uneven surfaces, footwear with a sharp self-cleaning tread pattern, and a pronounced heel is crucial. This design improves grip and stability, reducing slips and falls. Water resistance: Preventing water from penetrating the footwear is essential to avoid discomfort and foot health issues. Footwear with an S3, S6, or S7 rating under the EN ISO 20345 standard ensures water resistance, helping to keep feet dry and comfortable in wet environments. Some advanced waterresistant technologies2 are designed to provide durability that exceeds standard expectations, offering longer-lasting protection in challenging conditions. Impact and penetration protection: A sturdy toe cap (steel or composite) and a penetration-resistant midsole protect against falling objects and sharp hazards. In high-risk environments, additional metatarsal protection can enhance safety for the top of the foot, like the Heckel MACCROSSROAD 3.0 S3 HIGH META safety boot, which features D3O technology for flexible yet robust protection. 4. Invest in quality for workforce wellbeing High-quality safety footwear is not just about meeting standards; it’s about safeguarding your workforce’s health and wellbeing. Quality footwear offers several benefits: Reduced injury rates: Properly fitting, comfortable footwear minimises foot20 HYDRAULICS & PNEUMATICS November/December 2024 www.hpmag.co.uk Five factors to consider when choosing safety footwear Choosing the right safety footwear is critical to ensuring the safety, comfort, and productivity of workers in industrial environments. Clair Weston* highlights five key factors to consider when selecting footwear for applications where comfort and protection
www.hpmag.co.uk HYDRAULICS & PNEUMATICS November/December 2024 21 related injuries, slips, trips, and falls, creating a safer work environment. Enhanced comfort and productivity: Comfort that supports feet correctly reduces fatigue and discomfort, boosting productivity and job satisfaction. Improved employee morale: Providing footwear that meets workers’ needs and prioritises comfort shows that employers care about their employees’ wellbeing, improving morale and reducing turnover. 5. Consider sustainability and style Modern safety footwear is evolving to meet the growing demand for sustainability and style. Workers increasingly expect footwear that is not only safe and comfortable but also environmentally friendly and aesthetically pleasing. Using sustainable materials, such as recycled PET bottles, help to create products that offer protection, comfort, and sustainability. There is also an increasing number of safety footwear styles suitable for vegans and vegetarians. These are made from synthetic materials and are also suitable for people allergic to chrome. Stylish safety footwear with contemporary designs and lightweight materials encourages workers to wear their safety shoes more consistently, ensuring continuous protection without sacrificing personal style. *Clair Weston is head of marketing at uvex 1 The uvex 3 safety boot has an ergonomic two-layer sole made from polyurethane, and according to the manufacturer provides cushioning and slip resistance. The uvex i-PUREnrj technology enhances comfort by returning the landing energy over the entire sole unit back to the wearer. Often referred to as ‘rebound’ footwear, the absorption and redistribution of energy helps reduce fatigue supporting the musculoskeletal system. 2 uvex’s waterstop technology provides water resistance that the company says lasts four times longer than the standard, ideal for wet environments.
HYDRAULICS Thermal fluid systems typically run well for many years with limited intervention. However, all thermal fluids degrade over time, and so a reactive maintenance strategy means that any degradation or build up of contaminants may go unnoticed until it significantly impacts operations, leading to reduced efficiency and/or a drop in quality. When problems arise or production levels drop, engineers may have to resort to a quick fix to minimise downtime, such as turning up the heat of the system — increasing resource and energy consumption. This, combined with the risk of downtime, means many facilities are moving away from reactive and towards a more proactive approach. Reactive to proactive Implementing a proactive thermal fluid maintenance strategy, tailored to the system’s specific needs enables engineers to better understand and maintain their system. Proactive maintenance can help improve uptime, conserve resources and extend the lifetime of fluid and equipment. By conducting an assessment of existing practices and considering common failures or pain points, manufacturers can identify potential areas for improvement. The maintenance plan should include regular inspections of core components, preventative maintenance tasks, increasing staff knowledge and predictive analytics. By identifying potential issues during these inspections, engineers can intervene promptly. Proactive maintenance enhances operational efficiency by preventing equipment failures and minimising unplanned downtime, allowing for smoother production processes and increased productivity. Beyond operational efficiency, proactive maintenance promotes sustainable practices by reducing waste, emissions and energy consumption. Adhering to proactive fluid maintenance procedures can optimise performance, extend equipment lifespan 22 HYDRAULICS & PNEUMATICS November/December 2024 www.hpmag.co.uk Thermal fluid systems are often perceived as low maintenance because of their stability and reliability, operating effectively a closed-loop system with minimal intervention. However, with rising operational costs, changing environmental regulations and increased competition, uptime and process efficiency are more critical factors than ever. That’s why manufacturers should take proactive steps to maintain their heat transfer fluids and HTF system, says Dave Dyer, technical sales engineer at thermal fluid experts Global Heat Transfer. How proactive heat transfer fluid maintenance impacts performance
and reduce the regularity of thermal fluid changes, helping to reduce waste and conserve energy. Furthermore, by extending equipment lifespan and optimising fluid performance, proactive maintenance helps manufacturers reduce long-term maintenance costs and improve overall profitability. Fluid maintenance Regular fluid monitoring is a key part of proactive maintenance because once the thermal fluid enters the system, it is no longer visible. Sampling fluid when the system is closed, hot and circulating will help provide an accurate representation of what’s happening inside the system. Analysis of the fluid sample enables engineers to determine if there are any immediate signs of degradation. Engineers can also track sample data over time to better identify trends in performance and contamination levels to better monitor fluid condition. By monitoring trends, engineers can plan in maintenance, devising a plan for how to intervene, with options such as fluid dilution or filtration available to address changes in fluid condition as needed. Installing a filtration system that can remove solid carbon deposits or other contaminants can help improve the condition of the existing fluid and reduce wear on system components caused by contaminants. Remote condition monitoring tools can further support thermal fluid management. By continuously tracking fluid condition, engineers can access real-time data from any location. Maintenance engineers can receive alerts as soon as fluid condition changes, so that they can address it quickly before a problem occurs. Knowledgeable staff Having a well-trained team of engineers proficient in operating and maintaining equipment is integral to improving maintenance procedures. Increasing team understanding about the heat transfer system and thermal fluid equips engineers with the knowledge and skills necessary to anticipate and address potential issues before they escalate. Training on key activities, such as thermal fluid sampling, maintenance, safe handling and storage of fluids and system checks ensures that employees are aware of what’s required for compliance and proactive maintenance. Training on safety, PPE and where to access equipment like fire extinguishers and spill kits in case of a leak is also important. Comprehensive training on proactive maintenance not only prevents costly downtime and extends equipment lifespan, it can also help conserve resources, reduce energy consumption and maintain uptime. Safeguarding your system When signs of thermal fluid degradation appear, engineers can install complementary components to address any issues. Insulation, for example, can minimise heat loss, decrease energy consumption and improve facility temperature control, extending fluid and system lifespan. Another possible situation is a build-up of light ends, short chain hydrocarbons that can form as a degradation product of thermal oil, which lower the flash point of the fluid and can be detrimental to health and safety. A light ends removal kit (LERK) installed onto the system effectively captures and removes these volatile compounds, further extending the lifespan of the fluid. Even with diligent maintenance, after years of service a thermal fluid will eventually degrade to a point at which it must be replaced. At this point, a thermal fluid specialist can help dispose of the fluid as sustainably as possible by arranging repurposing or reprocessing of material for a different application or industry where possible. By implementing procedures that improve proactive maintenance and system efficiency, manufacturers not only minimise downtime, they can conserve resources, reduce costs and reduce emissions where possible, resulting in a more resilient manufacturing process. For further information please visit: http://www.globalhtf.com www.hpmag.co.uk HYDRAULICS & PNEUMATICS November/December 2024 23
HYDRAULICS Swaging is essential for ensuring the structural integrity and performance of landing gear assemblies, helping to reduce operational risks and minimise costly repairs. Landing gear accounts for approximately 20% of total aircraft maintenance and around 7% of the total weight of modern commercial aircraft. When an aircraft lands, the landing gear must support the entire weight of the aircraft, which ranges from around 64,500kg for an Airbus A320 to approximately 201,800kg for a Boeing 777. In addition to handling vertical loads, the landing gear must also manage horizontal forces generated by the aircraft’s forward motion. During landing, it must absorb significant impact energy, especially in hard or emergency landings. This requires the use of materials and designs capable of dissipating energy effectively while avoiding structural failure. Specialist suppliers Landing gear is typically manufactured by specialist suppliers, who provide components to major aircraft manufacturers. This is due to the highly specialised nature of landing gear and shock absorption technologies, which differ from other aspects of aviation. Beyond impact absorption, landing gear systems must also ensure stability and control on the ground, as aircraft often encounter varying conditions such as uneven or slippery surfaces and crosswinds. The design must allow the aircraft to maintain directional control during taxiing, take-off, and landing, even under adverse weather conditions. Modern landing gear systems incorporate features like shock absorbers, anti-skid braking systems, and steering mechanisms, all working together to prevent the aircraft from veering off the runway or skidding. These systems are crucial for ensuring passenger safety and minimising wear on tyres and other components. Furthermore, landing gear designs must consider weight and space constraints, as fuel efficiency plays a significant role in overall aircraft performance. To achieve this, landing gear must be lightweight yet strong, often using advanced materials such as titanium alloys or high-strength composites. Additionally, the landing gear must be retractable to reduce aerodynamic drag during flight, requiring complex mechanical systems to ensure reliable extension and retraction. Balancing strength, stability, and weight efficiency while integrating the landing gear into the aircraft’s overall design makes this one of the most challenging aspects of aircraft engineering. Precision bearings and tooling equipment Specialist bearings are vital to the advanced landing gear systems used in modern aircraft, particularly in components such as struts and actuators. Carter Manufacturing, an approved supplier to major landing gear manufacturers, provides aerospace bearings and tooling solutions designed to meet the sector’s high standards. The company holds accreditations including Aircraft landing gear systems are essential engineering components, designed to withstand the demanding forces encountered during take-off, landing, and ground operations. One critical aspect of maintaining these systems involves the use of precision swaging tools, which play a significant role in securing key components such as bearings and housings. H&P reports. 24 HYDRAULICS & PNEUMATICS November/December 2024 www.hpmag.co.uk The role of swaging tools in supporting aircraft landing gear systems ISO 9001, AS9120, and AS9100. In addition to bearings, Carter develops custom aerospace bearing tools, addressing challenges such as clearance restrictions, flight control maintenance, and production efficiency. The company says its tooling solutions are tailored to specific applications and draw on an wide catalogue of established designs. Carter highlights that its swaging tools are precision-engineered to fit specific landing gear bearings, significantly reducing operational risks and costs. These tools help prevent damage to expensive bearings and housings. For certain applications, where customers prefer not to use portable tools, Carter’s drill press-style swaging tools offer a superior alternative to traditional anvil staking tools. The swaging force required is much lower than staking, improving the overall quality of the swage. For more information please visit: Bearings: https://www.carterbearings.co.uk/ industries/aerospace Tools: https://www.carterbearings.co.uk/ aerospace-bearing-tools
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