www.hpmag.co.uk OCTOBER 2024 HYDRAULICS & PNEUMATICS VOL. 29 No. 7 OCTOBER 2024 p36 p32 Balancing power and precision in hydraulic robotics The cost of air leakage: A hidden drain on manufacturers’ resources New coating system enhances corrosion resistance effectively p20 Sealing solutions engineered for enhanced cylinder efficiency
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Industrial strategy set to drive re-shoring surge EDITOR’S COMMENT www.hpmag.co.uk HYDRAULICS & PNEUMATICS October 2024 3 While re-shoring alone won’t solve all the challenges facing the sector, it’s a solid foundation. ‘ ’ The latest Make UK and RSM UK survey offers a positive outlook for British manufacturing, with 70% of manufacturers expecting that a long-term industrial strategy will accelerate re-shoring - bringing production back to the UK. This is a significant shift, signalling that many companies are ready to invest more in UK facilities, automation, and research and development (R&D). The optimism is clear, and there’s reason to believe this could mark the start of a much-needed boost for the sector. The fact that half of businesses surveyed are prepared to increase investment in existing UK operations is a strong sign of confidence. After years of economic uncertainty, this commitment to expand local operations and modernise through automation is a step in the right direction. It suggests that UK manufacturers are ready to position themselves as key players in a more resilient and selfsufficient economy. The survey also highlights that UK-owned companies are already leading in investment intensity, outpacing foreign-owned firms in both plant and machinery and R&D. This shows that domestic businesses have the drive and capability to scale up. With the right industrial strategy in place, there is a real opportunity to capitalise on this momentum, fostering homegrown innovation and enhancing the UK’s competitive edge globally. Make UK is calling for the formation of sector-specific groups to focus on future technologies and national security. These groups, if given the necessary resources and support, could help the UK become more self-sufficient and resilient in critical areas like advanced manufacturing. With global competitors such as the US, Europe, and China moving quickly on green technologies, it is vital that the UK keeps pace to remain competitive and ensure its industries are futureproofed. There are still challenges, of course. High interest rates and the cost of raising finance remain barriers for some businesses, but the overall sentiment is clear: manufacturers are ready to invest, grow, and innovate. A strong, consistent industrial strategy could unlock this potential, driving growth in UK manufacturing, creating jobs, and boosting productivity. While re-shoring alone won’t solve all the challenges facing the sector, it’s a solid foundation. With the right policies and investment, British industry has a real chance to thrive in the years ahead. Aaron Blutstein Editor
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www.hpmag.co.uk HYDRAULICS & PNEUMATICS October 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. 22 30 6 NEWS 16 HYDRAULICS H&P reviews sealing profile and material considerations that address four of the most prominent hydraulic cylinder efficiency challenges - fluid leaks, contamination, friction, and hydraulic fluid quality. By exploring these factors, we aim to identify effective strategies for enhancing hydraulic cylinder performance and reliability in various applications. 26 PNEUMATICS 28 KNOWLEDGE BASE The British Pump Manufacturers Association (BPMA) has made a call to action for businesses within the UK’s industrial sector, urging them to prioritise energy audits as a vital strategy for improving operational efficiency. 30 APPLICATIONS A student project carried out by a TROX engineering apprentice has opened the door to valuable energy, embedded carbon, and cost savings for the Thetford-based factory. TROX’s modest investment of £600 in the student project is thought to have the potential to save the company up to £10,000 per year, by providing greater visibility of energy use for a compressed air system. H&P reports. 32 INTEGRATED SYSTEMS Hydraulics play a critical role in robotics and automation, offering unmatched power and durability. However, the challenge lies in achieving the precision required for modern applications. Advances in control systems, hybrid technologies, and AI are helping to enhance hydraulic systems, balancing strength with accuracy for diverse industrial tasks. H&P reports. 34 BFPA Hydraulics & Pneumatics’ issue-by-issue briefing on current activities and views involving the British Fluid Power Association. 36 COMPRESSED AIR, VACUUM AND GENERATORS 38 BCAS Our regular news and events update on the British Compressed Air Society. 40 SPECIAL REPORTS 46 NEW FACES 47 PRODUCTS & SERVICES DIRECTORY 40 Subscribe for your FREE copy now
NEWS 6 HYDRAULICS & PNEUMATICS October 2024 www.hpmag.co.uk Airmech celebrates 45 years in compressed air industry This October has seen Airmech celebrating 45 years of operation in the compressed air industry. Founded by Roy Emmett on 7th October 1979, the family-owned company has grown from its early beginnings into a well-established business, with several generations of the Emmett family playing key roles in its development. Throughout its history, Airmech has navigated the challenges of an evolving market while maintaining a strong commitment to quality and customer service. Charlotte Brown, Managing ERIKS, a leading specialised industrial service provider, has released a new guide designed to help manufacturers streamline their MRO operations. The guide, called 5 ways to enhance your Maintenance, Repair and Operations (MRO) supply chain, offers practical strategies to improve procurement, storeroom discipline, data management, and operational efficiency in the face of evolving industrial challenges. In light of recent disruptions, such as Brexit, COVID-19, and global geopolitical tensions, the guide addresses the critical need for resilient and responsive MRO practices. By adopting the five strategies businesses can better navigate these complexities, ensuring they remain competitive and operationally efficient. Commenting on the launch, Nathan Cutler, Chief Business Development Officer, ERIKS Industrial Services said, “In today’s rapidly changing industrial environment, efficient MRO management is more important than ever. Our new guide provides simple, actionable insights that can significantly enhance the resilience and effectiveness of MRO operations, helping businesses to optimise their processes and reduce downtime.” The new guide addresses five critical areas. It begins by emphasising the importance of prioritising critical components, ensuring that businesses can maintain operational continuity even in the most resource-constrained environments. Another key focus of the guide is data management. ERIKS highlights the need for streamlined and accurate data to Director of Airmech, commented on the company’s success: “Our progress over the years has been the result of collective effort and long-standing relationships with customers and suppliers, who have been vital to our growth.” As Airmech reflects on its past, it is also looking ahead to the future. The company has made recent investments in advanced technology and sustainability initiatives as part of its strategy to meet the changing demands of the industry. Additionally, it is focusing on staff development, with an emphasis on training the next generation of engineers to ensure the continuity of its services. With plans to expand its reach across the UK, Airmech is poised for future growth. “We’re proud of our history, but we’re also excited about the opportunities that lie ahead,” Brown added. The anniversary marks a significant milestone for the company, highlighting both its enduring legacy and its forwardlooking approach as it continues to evolve within the compressed air industry. support decision-making processes within MRO operations. Proper data management not only reduces the risk of stockouts but also enhances overall operational efficiency by providing a clear view of inventory levels and needs. Managing obsolescence is also covered, with proactive strategies to identify and mitigate the risks associated with outdated or soon-to-be-unavailable components. The guide suggests leveraging predictive analytics and regular reviews to ensure that businesses are not caught off guard by unexpected shortages. ERIKS also explores innovative procurement models that address the inefficiencies often found in traditional MRO purchasing processes. By adopting more agile procurement strategies, businesses can reduce unnecessary spending and better manage their inventory levels. Finally, the guide underscores the importance of building strong relationships with MRO supply chain experts, emphasising the value of suppliers who can act as strategic partners to businesses and contribute to their continuous improvement efforts. By drawing on extensive technical knowledge and industry expertise, such suppliers can support manufacturers in refining their maintenance operations, improving efficiency, and addressing the evolving challenges of modern industrial environments. Five strategies guide to enhancing MRO efficiency
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. +39 030 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 October 2024 www.hpmag.co.uk NEWS Sir Chris Bryant MP, Minister of State at the Department for Science, Innovation and Technology and the Department for Culture, Media and Sport, recently visited the new Digital Catapult 5G Immersive Lab in Newcastle, exploring the facility that will enable companies in the North East to scale faster. The state-of-the-art innovation lab, based in Newcastle’s Eldon Square, will help SMEs to de-risk the adoption of 5G and immersive technologies, accelerating the practical application of deep tech across key industries. The facility will encourage SMEs to work alongside large businesses, developing proofs of concept that can solve complex business challenges. Digital Catapult is encouraging businesses in the North East from traditional industries including retail, agriculture and manufacturing, to engage with the lab, providing them with pioneering new technologies, enhanced 5G capabilities from Vodafone 5GSA, and access to expertise from Digital Catapult’s team. During the visit, the Minister explored the work of leading regional companies that are developing transformative solutions across consumer and training experiences. A futuristic augmented reality (AR) showcase, presented by local tech company Aircards, allowed the Minister to interact with the latest in ‘smart mirror’ technologies. The Minister also experienced a virtual hazardperception training exercise created by fellow North East innovator Luminous XR, which has presented to several participants on Digital Catapult’s programmes. With a view to boosting digital skills, productivity and innovation across the North East region, Sir Chris Bryant’s visit follows the Labour Party Conference, where the Minister made clear the ambition to improve connectivity across the country. New global partnerships strengthen hydraulic sector presence Digital Catapult’s 5G Immersive Lab opened by UK Tech Minister Hyserve Hydraulics, a North East-based firm established in 2020, has recently secured partnerships with two leading global manufacturers in the hydraulic sector. Founded by Jerome Dardillac, the company has experienced steady growth over the past four years, expanding from a one-man operation into a team of more than 30 employees across two divisions. This growth has earned Hyserve increasing recognition within the industry. Recently, the company was named the first official UK partner of Linde Hydraulics, marking a significant step in its development. As a Distributor and Service Partner, Hyserve will now handle pumps and motors for industries including industrial, oil and gas, marine, subsea, and recycling. Linde Hydraulics' Sales Manager, John Curno, praised Hyserve’s “impressive engineering pedigree” as a key factor in the partnership. This latest collaboration comes shortly after Hyserve strengthened its relationship with another global manufacturer, Hengst. Earlier this year, Hengst awarded the company the title of official Competence Partner in recognition of its expertise in hydraulic filtration and oil care. Managing Director Jerome Dardillac described these partnerships as a “significant milestone” in the company’s brief history, crediting the dedication and expertise of the Hyserve team for the firm’s growing reputation. Hyserve’s partnerships with Linde Hydraulics and Hengst underscore the company’s ambitions to continue expanding its presence in the hydraulic sector, with a focus on delivering quality solutions across a range of industries. Jerome Dardillac
NEWS 10 HYDRAULICS & PNEUMATICS October 2024 www.hpmag.co.uk SPS 2024 set to showcase innovations in industrial automation The 33rd edition of SPS – Smart Production Solutions, is set to take place in Nuremberg from 12 to 14 November 2024. This flagship event, which has grown in stature over the past three decades, brings together key players from across the globe, offering a platform for showcasing the latest advancements in industrial automation. With its longestablished reputation, SPS continues to foster technological innovation and international collaboration, cementing its place as a crucial gathering for industry professionals. In 2023, the event attracted more than 500 visitors from the UK, a notable figure considering the overall international attendance of around 50,000. This year, a similar UK presence is expected, as businesses and professionals from across the sector look to explore the newest trends in automation. Around 1,200 companies will exhibit at the event, representing a broad range of automation technologies and services. Spanning 16 exhibition halls and covering 125,000 square metres, the event promises to be a showcase of cutting-edge technology and forward-thinking ideas that are shaping the future of smart production. Several prominent UK-based companies will be present at the event, including ALLTORQ Ltd, Eaton Electrical Systems Ltd, Fortress Interlocks Ltd, and Trio Motion Technology Ltd. Alongside these established firms, SPS also provides a platform for start-ups and first-time exhibitors, offering them an opportunity to present their innovations to a global audience. The event’s focus on both established and emerging companies ensures a diverse range of automation solutions will be on display, catering to a variety of industries and applications. A key feature of SPS is its dedication to exploring the latest technological trends in automation. Across four forums, located in Halls 1, 3, 6, and 8, visitors can expect to attend expert presentations, panel discussions, and live demonstrations on a variety of topics. The "Technology Stage" in Hall 3, presented by the German Machinery and Equipment Manufacturers Association (VDMA) and the German Electro and Digital Industry Association (ZVEI), will offer insights into the current state of the industry. These sessions will be available both in person and online via the event’s digital platform, "SPS on air," ensuring that participants from around the world can access the content. Presentations will be conducted in both German and English, supporting the international appeal of the event. The main themes for SPS 2024 will include digital transformation in manufacturing, industrial communication systems, safety and security in automation, data-driven control concepts, innovations in sensor technology, advances in drives and automation, sustainability in industrial processes, and the growing role of artificial intelligence (AI) in automation. These topics reflect the increasing importance of data, AI, and sustainable practices within the automation landscape. By focusing on these areas, SPS aims to provide insight into the future direction of the industry, while also fostering discussions that could drive future innovations. In addition to individual exhibitors, SPS 2024 will feature several joint stands that have become popular attractions in recent years. The "Automation meets IT" stand in Hall 6, featuring around 20 exhibitors, will focus on the integration of IT solutions within manufacturing processes. Here, visitors can explore topics such as IT management, cloud and edge-based solutions, and IoT-driven innovations, as well as security measures for smart production environments. This stand offers a valuable opportunity for attendees to engage with industry experts and receive tailored advice on comprehensive IT solutions for manufacturing needs. Another highlight will be the "young INNOVATORS" stand in Hall 8, funded by the German Federal Ministry for Economic Affairs and Climate Action. This space will showcase the work of emerging German companies, with a particular emphasis on fostering young talent in the automation sector. In the same hall, the "Start-up Area" will feature companies from around the world, providing a platform for novel solutions from the next generation of industry leaders. These areas are expected to draw significant interest from attendees seeking the latest innovations in smart production. Attendees can expect to discover the latest trends, explore cutting-edge technologies, and engage with leaders from across the global automation industry.
www.hpmag.co.uk HYDRAULICS & PNEUMATICS October 2024 11 New BARA Chair announced BARA (the British Automation and Robotics Association) has named FANUC UK’s Head of Sales, Oliver Selby, as its new Chair. Taking over from current Chair George Thompson, Selby will be supported in his new role by Vice-Chair Rosie Davies from Reeco Automation. Part of Automate UK, BARA’s remit is to promote and support the development and adoption of industrial robots and automation in the UK, providing a voice to government, industry and academia. With more than 20 years’ experience, Selby is a longstanding and vocal supporter of the UK automation sector, and of manufacturing more widely. In his role as Chair, he plans to drive the association’s activities forward, supporting BARA’s aim to increase automation uptake while placing members’ needs firmly front and centre. Peter Williamson, CEO of Automate UK, commented: “Oliver is an influential voice within the industry, his passion for all things manufacturing, automation adoption and future skills, will be a key factor in developing BARA alongside the existing committee, and with the full support of Automate UK.” One of Selby’s key pledges is to ensure the association delivers real value to its members: “I am excited to bring my knowledge, influence and passion for automation to a wider audience, and will be fully focused on delivering value to all facets of the BARA membership and other stakeholders – from OEM robot manufacturers and system integrators to companies in the supply chain, academic institutions and High Value Manufacturing Catapults. “It has been widely reported that, despite our status as a leading manufacturing nation, the UK is still lagging behind the rest of the world when it comes to automation adoption. Communicating the myriad benefits that automation can bring, including through events such as Automation UK (7-8 May 2025, CBS Arena, Coventry) is key to increasing uptake. It is essential that we highlight how automation can alleviate manufacturers’ key challenges by helping to mitigate labour shortages, increase productivity, boost sustainability credentials, and cut operational costs.” Selby added: “However, it is also important to understand the challenges that manufacturers – particular SMEs – are facing. At BARA, we will strive to offer the right tools to manufacturers of all sizes, to ensure they can make the right automation choice for their business, with the right partners, and with the right technology, to futureproof their manufacturing operations as riskfree as possible.
NEWS 12 HYDRAULICS & PNEUMATICS October 2024 www.hpmag.co.uk RS, a digitally enabled global distributor of product and service solutions for industrial customers, has released the ‘Performance in Focus’ 2024 Maintenance Engineering Report in conjunction with the Institution of Mechanical Engineers (IMechE). This is based on findings from a survey that aimed to uncover the challenges facing the profession and its priorities. The survey drew responses from almost 400 maintenance professionals based in the UK and Ireland. The respondents were from sectors including manufacturing, working in job roles like maintenance engineer and engineering manager. Most respondents came from hands-on or operational roles, working in sectors including facilities and intralogistics, manufacturing, energy, and oil and gas. The resulting report covers key areas including challenges, strategies and priorities, maintenance maturity and data, and tackling unscheduled downtime. While attracting talent was a top three issue for maintenance engineers in the 2023 report, staffing fears have risen to the top of the agenda for 2024, with half of respondents now citing this as a prominent concern. More than a third (37%) point to this as their top challenge, RS releases ‘Performance in Focus’ 2024 maintenance engineering report rising to 42% for larger organisations. Lydia Amarquaye, education and skills policy lead at the IMechE, isn’t surprised that skills have risen up the agenda and cites a need to work together to get more people into engineering. She said: “We need to raise the profile of engineering in schools and help to raise the profile of maintenance, in particular, as a valued part of the mix. Industry needs to take responsibility for developing talent, including developing apprenticeships and helping graduates who join with a broad skill set to gain specific skills for their particular industry.” With a growing requirement for data analysis in the quest for more effective maintenance strategies, lack of data interpretation capabilities presents a challenge. The skill set of the current engineering pool appears not to be catching up with evolving technology. The report highlighted an increased reliance on Excel spreadsheets and paper records, with 37% and 59% respectively saying they are still used in-house. But while paper and manual records are on the rise, the report showed that 62% of organisations use computerised maintenance management systems (CMMS) – up from 49% the year before – and the use of Excel spreadsheets is most common among firms with low levels of maturity. Only one in five (22%) use enterprise asset management systems, down from 39% in 2023’s report. The nightmare scenario of unscheduled downtime is still all too common, with the average organisation spending 15 hours a week battling it, down from 20 hours last year. This is down by a quarter on last year’s figures, which is mildly encouraging. However, it still accounts for 24 hours a week for more than one in five (21%) of organisations. The average hourly cost of downtime was higher this year at £5471.95 (£5121.81 last year). The biggest single cause of unscheduled downtime was cited as ageing assets, by 29% of respondents, followed by mechanical failure, cited by 21% of respondents. Managing ageing assets is an ongoing challenge for maintenance professionals, according to Richard Jeffers, solutions and technical director at RS: “Businesses don't want to replace assets simply because they’ve reached a certain age and, as maintenance professionals, they should be focused on how they can maximise the life of an asset, which can increase cash flow for the business.” The survey findings highlighted that organisations are taking steps to reduce unscheduled downtime, the most common strategies being upgrading equipment and improving training (both 49%), plans to introduce a preventative maintenance strategy (40%) and a change in approach towards maintenance (30%). Raj Patel, RS UK & Ireland managing director, said: “Modern maintenance professionals face a tricky balancing act between the day-to-day realities of ensuring facilities are safe and operational, and longer-term projects designed to prevent future breakdowns or inefficiencies. “It was encouraging to see organisations are deploying a variety of strategies to help reduce unscheduled downtime in the report. But there’s a wide spectrum of results here in terms of maintenance maturity and there’s still clearly a way to go. Maintenance professionals should seek to leverage suppliers for both reliability and quality of parts supply, and solutions providers to outsource elements of maintenance, particularly if the required specialist skills aren’t available in-house.”
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NEWS 14 HYDRAULICS & PNEUMATICS October 2024 www.hpmag.co.uk MTC has teamed up with Lumentum, a leading laser manufacturer, aiming to accelerate the use of lasers in UK manufacturing. Lumentum brings a rich history of producing high-performance commercial lasers, including high-power ultra-short pulse lasers. MTC has been engaged in laser-based manufacturing for over twelve years, covering a wide range of laser technologies from continuous wave to ultra-short pulse lasers, for various InProcess, a spinout from the University of Strathclyde, has developed the world’s first real-time inspection system for welding. The innovation, which uses ultrasonic waves to detect defects as they occur, has the potential to save manufacturers millions of pounds by reducing rework and delays in production. The breakthrough system was recognised at this year’s Converge Awards, where InProcess secured the top prize for its innovative technology. The Converge Awards, an annual event that highlights leading academic innovations from Scotland, awarded InProcess the prestigious Converge Challenge award, which recognises business ideas with strong intellectual property (IP) potential and scalability. The company received a £50,000 cash prize and £20,500 in business support. InProcess was co-founded by University of Strathclyde researcher, Momchil Vasilev, who highlighted the importance of welding in various industries, including the manufacturing of net-zero infrastructure like wind turbines: “Welding is an integral part of modern society and enables a number of crucial sectors. Currently, weld defects are usually found at the end of production, with up to 20% of assets requiring repairs.” He added: “Our ultrasonic sensor is the first to detect these defects in real time, during the manufacturing process, which could save fabricators millions. We aim to revitalise the UK’s manufacturing sector by bringing high-value component production back to the country and creating high-quality jobs in Scotland.” InProcess was not the only University of Strathclyde spinout to be recognised at the awards. PCAD, another Strathclydebased project, earned the runner-up prize in the Converge Challenge category. Led by Iain McDougall and Anthony McGarry, PCAD is transforming prosthetic care by digitising the process of limb fitting. Its solution reduces the time required for fitting prosthetics from hours to seconds, improving both efficiency and patient comfort. In the Create Change category, which recognises social and impact-driven Lumentum partners with MTC to drive laser technology advancements in UK University of Strathclyde spinout InProcess develops real-time welding inspection industrial applications including welding, cutting, and surface engineering, and has made a noticeable impact on the UK manufacturing. Historically, the focus within the UK, including much of MTC’s work, has been based on low-power ultra-short pulse lasers has been based on low-power lasers, which has limited productivity. The new partnership will enable MTC to expand its portfolio to include high-power ultra-short pulse laser processing. To kick-start the collaboration, a 200W picosecond laser, equipped with the ability to operate across three different wavelengths (IR, Green, and UV), has been installed at MTC. Moreover, this laser system offers flexibility in beam delivery, with options for both Galvoscanner and Polygon scanner. This new setup, for the first time in the UK, will enable low to mid-TRL research using polygon scanner-based ultra-short pulse laser processing. This partnership not only pioneers new research in the UK but also has the potential to significantly impact the future of the UK manufacturing sector. The collaboration between Lumentum and MTC opens exciting possibilities for addressing some of the unique challenges faced by the UK manufacturing sector. Lumentum’s ultrafast lasers can help overcome hurdles in processing hard, brittle, or composite materials, crucial in industries like aerospace and defence. By leveraging Lumentum’s technical expertise and innovative product capabilities, MTC aims to push the boundaries of materials processing further. As we look to the future of UK manufacturing, the partnership between Lumentum and MTC represents a significant step forward in driving industry innovation and competitiveness globally.
enterprises, KEPsoft Collaborative from the University of Glasgow secured the runner-up position. Co-founded by Glasgow academics David Manlove and William Pettersson, along with strategic consultant and renal transplantee Vijay Luthrn, KEPsoft is working to improve the efficiency of kidney transplant donorrecipient matching through a software platform. Other special awards included the Ventures Lab Award, presented by the Challenges Group, which went to Professor Sebastien Chastin from Glasgow Caledonian University for his work with MosaIQ. MosaIQ is a consultancy and training agency that facilitates collective intelligence-driven solutions. Commenting on this year’s winners, Adam Kosterka, Executive Director of Converge, emphasised the global potential of Scotland’s university-based innovations. “InProcess, PCAD, and KEPsoft Collaborative exemplify how academic brilliance can lead to revolutionary technologies that could transform industries ranging from manufacturing to healthcare. At Converge, we support university founders by equipping them with the business acumen and networks they need to succeed,” Kosterka said. Scotland’s Deputy First Minister, Kate Forbes, praised the role of universitydriven innovation in driving economic growth. “Translating world-class research into innovative technologies and businesses is central to Scotland’s National Innovation Strategy. Converge provides a crucial platform for innovators to showcase their ideas and connect with investors, mentors, and industry leaders,” Forbes stated, congratulating the award winners for addressing global challenges. Since its inception in 2011, Converge has trained over 670 aspiring founders and supported the creation of more than 420 companies, with a three-year survival rate of over 80%. Funded by the Scottish Funding Council and a network of corporate partners, the programme works with 18 of Scotland’s universities to support the development of new businesses through training, networking, and financial support. www.hpmag.co.uk HYDRAULICS & PNEUMATICS October 2024 15 Dependable Under Pressure www.dualpumps.co.uk Tel: 01664 567226 • Email: info@dualpumps.co.uk UK Official Distributor Since 1983 • Pumps & Pumping Equipment • Cleaning Equipment • Hose & Hose Reels • Fluid Handling Components • Fittings, Connectors & Filters • Spraying & Watering • Engines, Motors & Generators Follow / Like / Subscribe Your trusted partner since 1975 ITALY 100% MADE IN Dual Pumps 178x124 Oct.indd 1 15/10/2024 12:10:25
HYDRAULICS Harnessing the power created by a fluid power system into usable linear motion is the fundamental function of every hydraulic cylinder. Hydraulic cylinders are used in a wide range of industrial applications across various markets. Some common industries include agriculture, construction and off highway, material handling, mining, and oil and gas. Included in many of these systems is a large network of seals and sealing systems. Although seals typically make up less than five percent of the cost to manufacture the cylinder, they are critical to maintain the cylinder’s movement. However, several challenges can hinder their efficiency. Fluid leaks Leaks in seals or hoses can lead to loss of hydraulic fluid, reducing pressure and efficiency. But it is important to note that dynamic seals in hydraulic cylinders require small amounts of fluid at the seal lip to provide necessary and important boundary layer lubrication. Boundary layer lubrication is often visibly identifiable as a thin layer of hydraulic media that passes under the sealing lip to reduce both friction and heat, allowing the seal to operate longer. This minimal boundary layer lubrication leakage is necessary for the optimum performance of hydraulic seals; however, the amount of leakage varies by application and the requirements of the end-user. High-performance hydraulic sealing material options help mitigate leakage issues. Several materials are designed to enhance the performance of sealing solutions and help prevent leaks in a hydraulic system. Polyurethane seals, known for excellent wear resistance and flexibility and Nitrile (NBR) rubber are two examples. Composite seals that combine various materials to leverage the strengths of each also offer enhanced durability and leak prevention. Contamination Contaminated hydraulic fluid can cause wear and tear on components, leading to malfunctions and reduced performance. Rod wipers are commonly exposed to dirty environments, especially mobile equipment, and prevent contaminants such as dirt and moisture from entering the hydraulic system as the piston rod retracts. Contamination can cause significant damage to the rod, cylinder wall, seals, and other components in the hydraulic system, and is a major cause of premature seal and component failure. Hallite’s 846 double-lipped, snap-in rod wiper is moulded in Hythane 181 high-performance polyurethane. The 842 is a single-lipped, snap-in rod wiper developed specifically for use in environments with heavy contamination, such as agriculture, off-highway equipment, forestry, the aggregate industry, and longwall mining. Both the 846 and 842 wipers feature Umbrella Wiper Technology— including a H&P reviews sealing profile and material considerations that address four of the most prominent hydraulic cylinder efficiency challenges—fluid leaks, contamination, friction, and hydraulic fluid quality. By exploring these factors, we aim to identify effective strategies for enhancing hydraulic cylinder performance and reliability in various applications. 16 HYDRAULICS & PNEUMATICS October 2024 www.hpmag.co.uk Sealing solutions engineered for enhanced cylinder efficiency
www.hpmag.co.uk HYDRAULICS & PNEUMATICS October 2024 17 protective debris guard flap on the wiping lip that covers the gland housing and prevents the water and slurry trap that often occurs with conventional wipers. Friction Friction losses occur in fluid power components on industrial equipment due to the dynamic nature of their operation. For example, as hydraulic cylinders extend and retract on a bulldozer, friction can lead to greater energy requirements for operation potentially causing overheating. Reducing friction in the components that interact with the machinery contributes to reducing energy consumption and improves the overall sustainability of the equipment. This has led companies to explore new types of lubrication, materials, and product geometries that offer less frictional drag. Hallite for example highlights that it is focused on reducing friction in hydraulic cylinder sealing systems by test methods to assess friction durability and understand the impact on longer term sealing properties. This has been the catalyst for the development of new seal profiles and materials, such as the 683 low friction rod seal, an asymmetric single-lipped rod seal designed with precision-trimmed sealing lips to provide a dry sealing solution in light and medium-duty applications. Its design provides low friction to help lower fuel consumption, reduce emissions and optimise performance. Minimising friction through proper design, material selection, and maintenance can deliver optimal performance and longevity of hydraulic sealing components. Hydraulic fluid quality Using substandard fluid can affect lubrication and cooling, leading to premature wear and inefficiencies. Hydraulic fluid types are broadly defined by ISO6743-4 into three categories: biodegradable, mineral oil, and fire resistant. Therefore, it is important to properly pair sealing materials with hydraulic fluids. The right fluid and material combinations can ensure the longevity of hydraulic sealing systems to prevent downtime and minimize leaks caused by potential incompatibilities. Using improper viscosity fluids can starve the seal of essential lubrication, resulting in excessive wear. On the other hand, the right viscosity ensures optimal lubrication, reducing friction between seals and their mating surfaces, which minimise wear and tear. This balance prevents overheating, allowing seals to maintain their shape and integrity over time, which also reduces the likelihood of leaks. Finally, fluids with the correct viscosity facilitate efficient fluid flow, enhancing the overall responsiveness of the hydraulic system. By maintaining consistent pressure and reducing cavitation risks, proper viscosity fluids help protect seals from damage, ensuring reliable operation and extending the lifespan of hydraulic components. When it comes to hydraulic sealing solutions that promote cylinder efficiency, there are several options depending on the application and operating environment. Solutions that address the most common challenges must consider design and material parameters that contribute to the greatest potential for successful performance. For further information please visit: www.hallite.com
HYDRAULICS Large machine tools and universal milling-boring machines use electrohydraulic systems to counterbalance the weight of the saddle and spindle during vertical movements. This counterbalance ensures smooth and precise motion control for the electromechanical driving unit. Two hydraulic approaches are typically used for this purpose: the active circuit with a power unit, and the closed circuit with accumulators. In an active circuit, three-way highperformance pressure-reducing valves equipped with onboard digital electronics manage closed-loop pressure control in counterbalance cylinders. A pressure transducer built into the valve's pressure ports enhances accuracy. This system requires a power unit with a variable displacement piston pump to generate line pressure. The Atos Smart Tuning feature optimises the valve's dynamic performance, ensuring stable pressure regulation, even during variations in headstock load, with response times as fast as 15 milliseconds. The closed-circuit system, often used in high-speed counterbalance operations, leverages accumulators to store and release large volumes of fluid with minimal pressure variation. This lowpower system includes a PED-certified safety control block with integrated functions such as a shut-off valve, pressure gauge, leak-free pressure relief valve, and manual override. Stick-slip in hydraulic cylinders In machine tool counterweight systems, stick-slip refers to irregular movement caused by adhesion between cylinder seals and sliding surfaces. This effect occurs during the transition from static to dynamic friction, resulting in vibration when the cylinder rod first moves. Stick-slip is often linked to the microstructure of cylinder housing surfaces and intermolecular forces between the sliding components. Over time, it also contributes to accelerated seal wear. G9 piston seals The G9 sealing system, was developed by Atos R&D by conducting software simulations, test bench trials, and collaboration with specialised suppliers and European OEMs. These efforts identified a polymer compound that significantly reduces the difference between static and dynamic friction coefficients, addressing the root cause of stick-slip. Eliminating stick-slip not only improves operational smoothness but also extends the lifespan of the hydraulic cylinders. Field tests show that the reduced friction provided by this solution leads to better dynamic performance and improves the efficiency of the milling head’s vertical motor by lowering power consumption. The G9 system incorporates a singleacting seal with a specially designed lip that ensures zero leakage across its full operating range. This is particularly beneficial in closed-circuit systems with accumulators, where continuous leakage would otherwise necessitate frequent oil refilling. The G9 seal also prevents the milling head from descending when electrical power is lost, a problem seen in conventional systems due to leakage. The design of the G9 seal, without an energised O-ring, provides additional stability by preventing the seal from tilting in its groove. The lip design improves low-pressure sealing and contributes to the hydraulic system's overall dynamic stability. Atos hydraulic cylinders with the G9 sealing system, have been widely adopted in the milling machine industry due to their operational consistency and durability, which have been demonstrated through extensive research and field testing. For further information please visit: https://www.atos.com/en-it The performance of machine tools can be compromised by the stick-slip effect, a common issue in hydraulic systems. The G9 sealing system, addresses this problem effectively, eliminating stick-slip in both active hydraulic circuits and closed circuits with accumulators. 18 HYDRAULICS & PNEUMATICS October 2024 www.hpmag.co.uk Preventing stick-slip in hydraulic cylinders: The role of advanced sealing systems Hydraulic cylinder for counterbalance machine tool
STAINLESS STEEL HYDRAULIC HOSE AND PIPE FITTING SPECIALISTS We are the leading manufacturer and stockist of stainless steel hose fittings, tube fittings and adaptors. Call one of our friendly and knowledgeable specialists today to see how we can help. 30 TRADINGFOR OVER YEARS CALL 01274 852 066 sales@customfittings.com www.customfittings.com PROUDLYMADEINTHEUK leading manufacturer and of stainless steel hose fittings, Discover excellence in sealing solutions with Hallite Whatever your application, Hallite has the right sealing solution to meet your needs. ` Premium materials: Our seals are engineered to the highest standards, utilising high-performance materials to withstand a wide range of pressure and temperature challenges. ` Innovative designs: We leverage cutting-edge technology to provide solutions that meet the evolving needs of our customers. ` Global reach: With a presence in over 50 countries, Hallite is your trusted partner worldwide. ` Expert support: Our team of experienced engineers is always ready to assist you with tailored solutions and technical support. Visit our website at hallite.com to learn more and find the perfect sealing solution for your needs.
20 HYDRAULICS & PNEUMATICS October 2024 www.hpmag.co.uk HYDRAULICS New coating system enhances corrosion resistance effectively Corrosion is a significant contributor to increased operational costs across various industries. In response to this challenge, Rastelli's engineering team has developed the Zi-Ni Total Screen System (RRTS), a new coating technology designed to improve resistance to red corrosion. Rastelli Raccordi has a long-standing focus on environmental sustainability, reflected in its approach to product development and manufacturing. This includes mechanical processing, packaging, and surface treatments, the latter of which is particularly critical. The company’s efforts in this area have led to its certification under UNI EN ISO 14001:2015. Hexavalent chromium and cobalt-free technology Working in conjunction with its R&D department and galvanising facilities, Rastelli’s engineering team developed the Zi-Ni Total Screen System. This technology has been applied across the full range of Rastelli Raccordi products, including 24-degree DIN 2353 tube fittings, 37-degree SAE-J-514 adapters, hose fittings, and BSP, BSPT, and NPT adapters. Corrosion protection The Zi-Ni Total Screen System is based on a new electrolytic process that is free from hexavalent chromium and cobalt, ensuring compliance with EU2000/53/EC and RoHS 2007 European regulations. The system is produced in zinc treatment plants located at the company's facilities in Villanterio (PV), which are designed to minimise environmental impact while maintaining anti-corrosion properties. Corrosion can lead to substantial maintenance and replacement costs, including potential production delays and equipment downtime. It spreads quickly and requires careful monitoring, particularly in environments exposed to chemicals, salt, fertilisers, and high humidity at elevated temperatures. Consistent and stable results The Zi-Ni Total Screen System demonstrates consistent performance, with a uniform nickel distribution rate of 12-15% across a wide range of current densities. This contributes to stability in corrosion resistance over time. Red corrosion resistance The system ensures thorough galvanic deposition, even in challenging areas such as the interior of bolted joints, resulting in increased coating thickness in regions with low current density. Salt spray testing Rastelli Raccordi subjects its products to salt spray tests to verify the effectiveness of the galvanising process. These tests use saline solutions and controlled temperatures to simulate exposure to corrosive agents that cause red rust. The results provide insight into how the protective coating performs over time when exposed to harsh conditions. The tests, which include passivation and sealing stages, have demonstrated that the system provides greater resistance to red rust compared to other available solutions, with technical performance exceeding standard industry requirements. For further information please visit: https://rastelliraccordi.com Passivation and sealing provide technical performance and red corrosion resistance well above the usual standards. The galvanisation treatment process (RRTS) has improved the uniformity of the deposit, which in turn has significantly improved corrosion resistance and appearance.
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