Jan

2013
The Engineers guide to new products & design ideas

21: Energy strategies 26: Motor protection

Planning for energy efficiency? Beware
'short-termism' says Mike Malina

Protect your assets with more functions,

fewer wires says Stuart Greenwood
??? p? ?? p? ?? p?

dpaonthenet.net

Finishing
touches

Contents
Materials & Fasteners
Special Report

Cover Story:
Carbon fibre textures are bringing
exciting new finishes to the automotive sector. On page 5 we discover
how ARRK's 'lacquered carbon
weave' is setting the Noble M600
supercar apart from the competition

Editor:
Les Hunt
les.hunt@imlgroup.co.uk
Group Advertisement Manager:
Nicole Piesse Turner
nicole.piesse_turner@imlgroup.co.uk

05:
06:
08:
10:
12:
16:
19:

Alternative automotive finishes

Carbon fibre surface texture adds lustre to Noble's M600 supercar

Computer aided engineering

Modelling the performance of a complex, hydraulically operated offshore crane design

Computer aided manufacture

Roughing strategy cuts cycle times without compromising product quality or tool life

A razor-sharp service
A novel unisex travel razor gets the full prototype treatment

Getting stuck into the Airbus A350 project

Resin helps tooling specialist speed mould creation for composite airframe parts

Inserts for clean assembly

Tangless inserts don't leave debris behind to end up in critical parts of equipment.
Thermoplastics make Knoll's 'Generation' work chair responsive to the user

Motors & Drives

Special Report

20:

Summing up an energy strategy

24:
26:

'Oversize' isn't everything

Head Office:
IML Group, Blair House,
184/186 High Street,
Tonbridge, Kent TN9 1BQ

29:

Power conditioning pays

Tel: 01732 359990

Fax: 01732 770049
E-mail: dpa@imlgroup.co.uk

32:

Saving energy with PM motors

Classified Executive:
Nicola Crawley
nicola.crawley@imlgroup.co.uk
Publisher:
Andrew Quenault
andrew.quenault@imlgroup.co.uk

Copyright in the contents of Design Products &

Applications, itswebsites and newsletters is the
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sponsors of this magazine are not responsible
for theresults of any actions or omissions taken
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ofany claim based on or in relation to material
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13

Are you sitting comfortably?

Mike Malina advises taking the long term view when investing
in energy efficiency technologies
Stuart Harvey warns that the days of motor oversizing are well and truly numbered

Motor protection devices

Stuart Greenwood explains how to protect your assets with
more functions and fewer wires
Rob Morris describes a two-year study of power quality systems
to identify their real ROI performance.
PM synchronous versus standard asynchronous: what is the real gain?

35: ...and whats more! Les Hunts news & reviews

38: Data Focus Quick guide to new products
40: Buyers Guide Products & Services classified guide

16

Energy strategy: the long view

Mike Malina's presentation on the financial implications of an energy efficiency strategy, given last year at the MDS 2012 conference, provided food for thought on a raft of issues. What is
the best carbon-cutting policy - install renewable generating
capacity or simply use less energy by being more efficient?
How do you convince those holding the purse strings that
ROI is just one part of the equation, and that in the long term,
sustainability will bring its rewards? In this issue we run an
edited version of Mike's paper, which, while concentrating on
one particular area - sustainable buildings - is just as relevant
to those seeking light on this subject in a wider industrial
context.
Les Hunt, Editor

29
January 2013 3

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Feature: Carbon Fibre Composites

'Lacquered carbon weave'

- a finish to be proud of
iche automotive manufacturer, Noble gets its prototypes and low volume
composite production parts from materials specialist, ARRK. During the course
of development, the Nuneaton based supplier suggested an alternative to conventional
body paintwork for its customer's high-performance M600 supercar - a special finish
that took full advantage of the carbon fibre fabric surface texture.

Precision engineering, immaculate

handling, real performance, lightning
response - yes, that's everything the
Noble M600 supercar can offer, but
ARRK also likes to think that this description genuinely reflects the services
it offers its clients! As one of Noble's
key suppliers, ARRK provides a number of product development services,
including prototypes and composites,
as well as carrying out low volume
manufacturing of production components.
The ARRK team, based in Nuneaton,
have worked closely with their opposite
numbers at Noble, not just to understand their immediate production
needs, but to offer its expertise in the
latest processes and specialist materials that combine to make the Noble
M600 such a head-turner. ARRK claims
that its knowledge of materials, coupled with an ability to provide low volume production components to a tight
schedule, makes it a perfect partner for
clients, like Noble, operating in niche,
specialised markets.

The main centre section, rear body,

front nose and inner and outer door
panels are fabricated from carbon fibre
composites, which reduce the vehicle's
weight, and so improve its responsiveness and exceptional performance.
The original model was fully painted;
however, with an eye to market trends
and through a process of innovation
and development, the team tried its
hand at producing vehicles with a
coloured carbon weave roof, which is
then lacquered and polished, giving it
a particularly exclusive and individual
appearance.
Such was the impact of the lacquered
carbon weave effect, that some of
Noble's clients are now choosing to
have the complete vehicle manufactured in this way.
Thanks to some pretty deft craftsmanship that ensures a precision join and
balance of the weave, the Nuneaton
team have managed to make the vehicle look as if it has been produced from
a single roll of fabric.

The main centre section, rear body, front nose and inner and
outer door panels are fabricated from carbon fibre composites

From the moment the carbon fibre material is cut, through to lay up, the parts
are continually checked and validated
to maintain the highest quality of finish.
Once produced, the parts are trimmed,
drilled and inspected once more to ensure that they meet the specifications.
The components are then assembled
to ensure material alignment before
sign off, and from here the sections
are delivered directly to Noble for
assembly.
www.arrkeurope.com

The Noble M600 supercar

dpaonthenet.net 5

Feature: Computer Aided Engineering

Simulation lifts
design exercise
to a higher level
A Norwegian university
research project is
using computer
models to predict the
performance of complex
offshore materials handling
equipment. In the short term,
the work is helping designers
pick the best components for
the job; ultimately, the aim is to
automate more of the design process.

With offshore oil and gas drilling operations costing millions of dollars a
day, crews are under pressure to get
their jobs done as quickly as possible.
One of those jobs involves assembling the thousands of metres of flexible pipe that make up a drill string,
and doing so safely and consistently on a remote platform where space is at a
premium and weather
conditions are frequently
challenging.

Typically, the materials handling

equipment for this is hydraulically
operated and, to some degree, automated. The
control system design is
challenging; when a
crane is in motion its dynamic behaviour is dependent upon many
variables - the electrical and hydraulic
characteristics of control valves and
hydraulic actuators, the inertia of the
crane's structure and its load, and the
complex interactions between all
these components.
Moreover, the chosen hydraulic components must deliver the required
level of responsiveness, or 'bandwidth', while meeting requirements for
budget, size, weight, long term relia-

6 dpaonthenet.net

bility and ease of maintenance.

A research project at Norway's
Agder University, currently
being carried out in conjunction
with offshore equipment manufacturer Aker Solutions,
is hoping to simplify this
formidable design challenge by allowing engineers to build
and run detailed simulations of equipment before they assemble a single
part. Morten Kollerup Bak, a PhD research fellow in charge of the project,
takes up the story:

Feature: Computer Aided Engineering

"Our aim is to use model-based design to predict the behaviour of the finished products and
to support key design decisions. For that to
work, everything depends on your being
able to model the entire structure and
control system in sufficient detail to
get a realistic idea of its performance." For this work, Bak is
using the MapleSim simulation application from
Maplesoft, which is
supported in the UK
by Adept Scientific.
"I divide the whole
system into three
different models," he
says. "The mechanical structure, the hydraulic
actuation
system and the electrical control system. I'm using MapleSim to
model the first two parts and in some cases all
three.
"Our aim with this work is build the models of
hydraulics as much as possible from standard
catalogue data. But we quickly found that
component manufacturers don't always provide all the data you need, particularly when
you are looking at the precise behaviour of
their components in dynamic conditions."
To obtain the missing data, Bak has built custom models of key components, like control
valves, and validated their accuracy by conducting tests on single components operating
in isolation. Once he has confidence in the
performance of the custom elements, he integrates them into the MapleSim system models
and uses that to evaluate the likely performance of the crane.
"With my industrial partner, we have already
built a model of one of their existing cranes
and demonstrated that it predicts the behaviour of the real crane accurately. Now we have
begun to use the model in our design work by
looking at the likely impact of substitutions or
design changes to individual components."

The ability to model such changes before

doing them is obviously extremely useful for
the Aker Solutions designers, but the next
stage of the project has the potential to fundamentally change their roles.
"Ultimately, we want to use our models for design automation. In this approach we feed the
system with the performance requirements of
the finished product and with a library of options for hydraulic and mechanical components, then allow it to search for the optimum
solution."
Optimising the simulated model requires an
efficient search algorithm and for this Bak is
using the so called 'Complex' method. "In the
algorithm, we populate the simulation with a
number of randomly generated designs and it
evaluates the performance of each," he explains. "It then picks the poorest performing
design and 'mirrors' it across the centroid of
the remaining designs to produce a solution
that should work more effectively." This
process is then repeated, with the worst performing design substituted each time, until the
solutions converge on the optimum result.
Initially, Bak is using stability and accuracy as
performance criteria, and, consequently, the
optimum solution is the design yielding the
lowest level of oscillations in the hydraulic
system and with the best ability to follow
the position reference fed to the
control system. Later, Bak plans
to add other criteria such as
price, robustness and long term
reliability.
www.adeptscience.co.uk

dpaonthenet.net 7

Feature: Computer Aided Manufacturing

Pushing the
boundaries
of traditional
milling
Chris Bentley is managing director of Mach One Engineering, a company
that specialises in the manufacture of precision engineered components and
assemblies. A core customer base is the satellite communications business
for whom it manufactures aluminium 4G broadcast amplifier casings. In the five
years that he has been using Edgecam CNC software, he has discovered that the
Waveform Roughing Strategy has, in his words, pushed the boundaries of traditional milling, cutting cycle times without compromising product quality or tool life.
"It's exciting when new technology
comes along that changes things so
much for the better," says Mr Bentley.
"We find it a very powerful tool because
it enables us to do much deeper depth
cuts than before. And because we can
also increase feed and speed rates it
reduces our cycle times considerably."
Edgecam's waveform roughing strategy is designed to maximise material

removal rates while prolonging both

tool and machine tool life. It produces
rough milling toolpaths that deliver
shorter cycle times, greater tool life,
better surface finish and are kinder to
machine tools.
Waveform creates its toolpaths so that,
when viewed from above, the distance
between the roughing passes - also
known as stepover - varies, but this
variation allows the actual width of cut
to stay the same and at the optimum
level, meaning the spikes are removed.
Chip load stays constant, and the
depth of cut employs the cutter's entire
flute length.
It is proving to be invaluable in Mach
One's machining operations for their
biggest customer base, the satellite
communications industry. Chris Bentley highlights how it reduced the cycle
time from two hours five minutes, to
one hour 36 minutes, for an aluminium
4G broadcast amplifier casing.

Chris Bentley: in some cases we've increased the

depth cut five times from the depth we used to have

8 dpaonthenet.net

"We went from a 4mm depth cut to

15mm using a 25mm indexable insert
cutter, and we reduced the stepover
from 50 per cent down to 20 per cent.

We'd expect even better results from

using solid carbide, because it would
give us more flute length. But we can
push the indexable insert cutter particularly hard, and we ended up moving
from 2.4m/min to 4.5m/min - just under
double the feed rate."
Other satellite communications equipment that the ISO 9001-accredited
company now manufactures with
Waveform includes a component
which houses electronics for a HD television broadcasting unit. "Traditionally
we roughed the open pockets with a
16mm cutter making 6mm depth cuts
at a feed rate of 1,800mm a minute,"
says Mr Bentley. "With waveform we
were able to take a 29mm depth cut
with a stepover of 20 per cent."
Although they did not increase the
feed rate too much for that particular
job - taking it to 2.5m/min, the feed
rate for another component has more
than doubled. An aluminium casing for
a person-to-person communication
unit is produced with a feed rate of
5.4m/min, up from 2m/min. Prior to
Waveform, the 8mm ripper created a
depth cut of 4mm. That has now been
increased to 12mm using the same

Feature: Computer Aided Manufacturing

tool, with a 20 percent stepover.
With many of Edgecam's waveform
roughing parameters being outside
the traditional machining comfort
zone, Mach One's machinists were
unsure originally that the process
would work without damaging the
tools.
"In some cases we've increased the
depth cut five times from the depth we
used to have," says Chris Bentley.
"And even though we were reducing
from a 50 per cent stepover to 20 per
cent, the confidence just isn't there at

first to start pushing the feed rate

higher as well. But I've put some radical programs in place, and they've all
worked.
"Your instincts as a skilled miller tell
you combining these depths of cut
with the amount of stepover and increased feed and speed rates is going
to go badly wrong. But it doesn't.
Waveform is real, it does work, and is
actually pushing the boundaries of traditional milling.
"The quicker cycle times are increasing our capacity. Quality and service is
always
our
number one
priority, and
Edgecam's
Waveform
Roughing
Strategy will
definitely
make a major
contribution
towards that."

the Waveform Roughing Strategy in Edgecam CNC

the Waveform Roughing Strategy in Edgecam CNC

part of their manufacturing process,

driving three XYZ mills,
a
Cincinnati
Arrow
and
Dugard
Eagle. The 3,500 square foot
factory, which machines a variety
of materials as well as providing
anodising services, also benefits
from an unexpected side-effect of
Waveform roughing: it's noticeably
quieter. The machines don't 'squeal',
making it a more comfortable working
environment for the machine operators.

Having used
Edgecam for
five
years
now,
Chris
Bentley says it
is an integral

www.machoneengineering.net
www.edgecam.com

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Feature: Rapid Prototyping

Star delivers
a close shave for
unisex travel razor

tar Prototype has helped turn an innovative idea for a unisex travel razor into a
commercial product for the discerning traveller by delivering the key elements
of Cormia Design's new Pocket Razor.

Designed by Mario Cormier, the owner

of Canada-based Cormia Design, the
Pocket Razor is TSA approved meaning
it is ideal for men and women on the go,
and can also be used on an everyday
basis. It is manufactured in high quality
aluminium, comes with a cover and keychain and accepts all popular twin blade
cartridges.
Cormier said: "Since I started shaving
back in 1980 I've experimented with virtually every kind of razor imaginable, but
never found the perfect travel one. So
with the intention of developing a solution that ticked the boxes the others
failed to satisfy I set about creating the
Pocket Razor."

Shaving on the
move: Cormia
Design's new
Pocket Razor

work and communication was excellent.

I'm certainly looking forward to working
with them again."
Star's brief was to develop the tooling
and parts for the Pocket Razor. A job
that included producing a cover made of
Aluminium 6063, which was created
using extrusion processing. The team
also developed 15 samples of the different cover finishes available so that
Cormia was able to select the right option for them. The chosen satin finish
was then cleaned and coated in order to
protect its surface and prevent oxidisation. Star also made the razor by die
casting with ADC12.

"Of course the job of taking these designs and developing a working product
out of them is a huge challenge, and I
couldn't have picked a better partner
than Star Prototype.

Prior to delivery, all 500 parts developed

by Star were put through a rigorous inspection process to ensure everything was the correct shape, the right
material and that it passed the Faro
test.

"They were a great company to do business with. Their service was always fast
and efficient and the quality of both their

Gordon Styles, managing director

of Star Prototype, said: "While we
pride ourselves on the speed of our

10 dpaonthenet.net

service, we will never allow the quality of

our work to suffer as a result of trying to
complete a project in the quickest possible time.
"Everything we do undergoes a full inspection prior to delivery. We check
everything from size, shape and finish to
the exact content of the metallic material
used and only when everything has
passed every test do we allow the product to leave our factory."
To find out more about Cormia Design
and
the
Pocket
Razor
visit
www.cormia.ca
www.starprototype.com

an excellence in engineering
comprehensive range of components
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Comparing the characteristics of the Elika pump range to other volumetric pumps, it can
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ELI2 is the first series in the ELIKA family and includes pumps with displacement from 7 to 35 cm /rev. Maximum
operating pressures up to 300 bar.
The helical gear ensures the continuity of motion despite the low number of teeth. The low number of teeth and shape of the
profile significantly reduces pressure-oscillations and vibrations during operation transmitted to the other components,
reducing the noise of the hydraulic system. Axial forces induced by the helical teeth are optimally balanced in all operating
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Feature: Carbon Reinforced Polymer Composites

Tooling specialist
gets stuck into
Airbus project
rench tooling specialist, Loiretech is using Araldite 8615 resin in the manufacture
of prototype lower front panels for Airbus' new A350 passenger airline,
which is expected to go into service with launch customer,
Qatar Airways in approximately two years time.

Originally founded in
1988 under the name
Loire
Modelage,
Loiretech designs and manufactures tooling for large, complex
thermoplastic and composite parts,
serving customers primarily in the
aerospace, automotive, defence and
rail industries. One of the company's
specialities is resin infusion.
On the Airbus project, Loiretech was
subcontracted by airframe manufacturer and Airbus partner, Aerolia, to
design and produce moulds for the
European aerospace giant, working to
a demanding schedule.
The new Airbus 350 is the latest
in a family of long range, wide-bodied
jet airliners developed by the European aircraft manufacturer. Capable
of carrying between 250 and 350 pas-

Step 1: master model milling operations

12 dpaonthenet.net

Airbus A350 XWB

passenger aircraft

sengers,
depending on the specification, it is the first aircraft of its kind

which has wings and fuselage made

primarily of carbon reinforced polymer.

Step 2: the resin infusion process set-up

Feature: Carbon Reinforced Polymer Composites

Loiretech chose Araldite 8615 for this
particular application primarily for its
very low viscosity, which delivers optimum impregnation of the carbon fibres during the infusion process. It
also offers a long pot life that facilitates the very large tooling capability
required in aircraft manufacturing;
parts typically up to 20m in length are
not uncommon. The Araldite system
was supplied by DiL France, a Huntsman Advanced Materials' area distributor.
Working with products
and technical support
supplied by Huntsman Ad-

Step 3: the mould structure assembly

vanced Materials, the team from

Loiretech completed the project in
just 16 weeks. Loiretech president,
Marc Moret, takes up the story:
"With a customer such as Airbus
and an application of this kind,
there can be no compromise in the
quality
of
the
manufacturing
process. The mould was created
using resin infusion on a CNC
milled master model. Araldite
8615's high Tg is an important
parameter for such moulds. With its
ability to withstand 300 curing cycles at temperatures up to 180C, it
fulfils critical performance criteria
and we have al-

ready used this type of system to

make large composite moulds for the
aerospace industry in serial production."
In August 2012 Airbus successfully
powered up the flight deck of the
A350 for the first time. The A350
XWB (extra wide body) will feature
large carbon reinforced polymer
panels for the fuselage skin and
composite fuselage frames for the
aircraft structure.
www.huntsman.com/advanced_materials

Step 4: the final mould

Advertorial: Werma
Monitor efficiency in the workshop

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ditional accessories can be se-

ever as each WIN slave acts as a

lected

repeater one to another the net-

extensive range available.

work distance capability is in fact

Both starter kits allow a network

considerably greater.

containing up to 50 machines to be

at

any

time

from

the

built up and monitored. Further inConvenient starter kits available

formation on WERMAs Lean Pro-

Two different starter kits are offered

duction solutions can be found on

which allow the user to set up and

www.werma.co.uk.

start monitoring and counting without

complicated

installation

WERMA (UK) Ltd.

process. With the all round starter

Linnell Way

kit WIN complete with WIN slave

Telford Way Industrial Estate

performance for KombiSIGN 71 the

Kettering

user can set up monitoring three

Northamptonshire

machines and comes with three

NN16 8PS

signal tower kits as well. A second

Tel: +44 (0) 1536 486930

starter kit, WIN system with WIN

Fax: +44 (0) 1536 514810

slave performance is designed for

www.werma.co.uk

an existing WERMA KS70/71 instal-

uksales@werma.co.uk

Feature: Threaded Inserts

Tangless inserts
save time in critical
assembly
tainless steel fasteners are used
in many applications where zero
foreign object debris (FOD) is
essential. Such applications include
the food industry, clean rooms,
electronics, aerospace, satellites,
safety critical applications, space
and other vacuum environments.
The tangless insert was developed
to eliminate the potential problem
of tangs being broken off after
installation and being left behind,
or ending up in critical parts of
equipment.

Tangless Kato CoilThread inserts

from Advanex have all the characteristics of tanged threaded inserts,
without the need for tang break-off
and retrieval; moreover, they are
easily adjusted or removed after
installation. This ensures significant
time savings on each installation,
especially in applications that
usually require the counting of
each removed tang.
Additional time savings are made
because of the bi-directional design
of tangless threaded inserts which
avoids having to ensure that each
part is correctly orientated, and the
availability of special tools to speed
installation. These benefits are obviously multiplied for high volume
users.
There is, however, a problem with
stainless steel inserts when they
are used with mating stainless
steel fasteners: they can be susceptible to galling, a cold welding process
which can occur when pressure
builds between the contacting
thread surfaces of male and

16 dpaonthenet.net

Advanex tangless Kato CoilThread inserts are available in a variety of materials.

The standard insert range is made from 304 stainless steel (Material Spec:
AS7245), meeting most application requirements. Inset: tangless Inconel X750 inserts (Material Spec: AS7246) are also available for high temperature applications

female fasteners during assembly.

At the least this may cause some
damage to thread forms or, in severe
cases, prevent disassembly of the
threaded joint. To lessen the effect
of galling, some users apply lubrication before joint assembly. However,
this can lead to unreliable torque/
tension results in the joint and
also have FOD issues that may
not be acceptable for a critical
application.
For applications where galling or
magnetic permeability is an issue,
tangless inserts made from an antigalling wear resistant austenitic stainless steel, comparable with materials
like Nitronic 60 (UNS S21800) are
available. The gall resistant stainless
steel material has strength properties
similar to the standard stainless steel
material, providing galling prevention
without the need for lubrication or
plating.

Combining the benefits of a tangless

insert with a special anti-galling material, customers with critical applications finally have a truly FOD free
solution. This material is also nonmagnetic and can be used in manufacturing facilities that have a vacuum
process environment or equipment.
For high temperature (550C) applications, tangless Inconel X750 inserts
(AS7246) are now available. Inconel
X750 is a non-magnetic, high corrosion resistant nickel based super-alloy
with excellent heat resistance and
strength characteristics. And for salt
water and electrical applications, as
long as you don't need the strength of
stainless steel or Inconel, tangless
phosphor bronze inserts (PB102) are
also available.
These Advanex Kato Precision products and associated tooling are available in the UK from ASM Fasteners
www.asmfasteners.com

www.goss-springs.com

Standards are important. So is quality.

We specialise in manufacturing small, high precision components and assemblies.
Our components range from simple helical springs to complex multi-stage pressings with precious metal contacts.
We also offer a design and technical service.
Aerospace
Automotive
Defence
Electrical
Electronics
Medical
Security
Sport & Leisure
Hobbies & Toys
Marine
ISO/TS16949 automotive accreditation
AS9100 Aerospace accreditation
Victoria Works, 30 Victoria Rd, London E17 4JU
Tel: 0208 527 5599 Fax: 0208 527 1142
Email: enquiries@goss-springs.com
www.goss-springs.com

In-House Check Valve

vs.

Lee Chek
(Pre-assembled, autoinsertable, 100% tested)

(Find the parts, coin the seat, assemble

the parts, stake in place, test)

Why fuss with the in-house approach when Lee Chek Valves install in less time, work more
reliably, last longer, and cost less?
For a free Lee Chek valve, email your application to
Lee Chek features include:
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Quick, Automated Installation

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Innovation in Miniature

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PRODUCT CATALOGUE

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Tel: 01753 886664 www.industrial-microhydraulics.co.uk e-mail: sales@leeproducts.co.uk

Feature: Performance Thermoplastics

Are you sitting

comfortably?
noll's 'Generation' work chair embraces the idea of elastic design - where a product
rearranges itself in response to its user. Key to the chair's flexing and supportive
features is the use of high performance thermoplastics supplied by DuPont.

"By getting DuPont involved early

in the design process, we were able
to evaluate a huge variety of material
ideas to achieve our comfort and
performance targets," says Knoll's
Nicole Mirchandani "The use of renewably sourced materials also enables
us to deliver a pace setting design
that reinforces our commitment to
sustainability."
According to Rick Tobar, Development
Programs Manager at DuPont: "As well
as introducing lots of different samples,
we demonstrated how the different materials could be used and how the designers could extract the maximum
value out of them in terms of balancing
functional attributes against design
needs... such as increased support
while maintaining the necessary flex."
Designed by Formway Design of New
Zealand, Generation uses high performance DuPont materials in a way
that is quite new to the furniture industry. The 'Flex Back Net' and 'Dynamic Suspension' control work
together to give the chair its
flexibility and structure - allowing it to move to suit the
extended range of motion
required in a contemporary
working environment - and
yet still retain the memory of its original
position.

The Flex Back Net, which deploys renewably sourced Hytrel, supports
many different postures and facilitates
a wide range of multi-dimensional
movement - not just from front to back,
but also from side to side. Users can
also push against the Flex Top of the
backrest and it will bend over to support their arm as they turn in the chair.

Generation was the first product in the

furniture industry to be rated Sustainable Platinum by the SMaRT Sustainable Product Standard, which
measures a product's environmental,
economic and social benefits over its
life cycle and throughout its global supply chain, from raw materials extraction
through reclamation or re-use.

The chair's innovative Dynamic Suspension control, which uses Hytrel thermoplastic polyester elastomer and Crastin
PBT polyester, is a simple, non-mechanical control concept that provides
a smooth, weight-compensated ride.
Without the complexity of metal links or
springs, it uses one-third the number of
parts of a traditional ergonomic chair
mechanism - helping to ensure
that it is also 20 percent lighter
than most other high performance chairs.

www.dupont.com.

Using the inherent properties

of DuPont high performance
thermoplastics and particularly
its Hytrel RS TPC-ET for the
Flex Back Net, Knoll's 'Generation' work chair literally flexes
as you change position

dpaonthenet.net 19

Feature: Energy Efficiency

The financial
implications of an
energy strategy
hort termism damages sustainability, says Mike Malina, founder and director of
Energy Solutions Associates, and award winning building engineering services
consultant. Here, we present an edited version of a presentation he made at the
Motor Driven Systems conference last year, in which he makes the case for taking
the long term view when investing in energy efficiency technologies.

The current financial system is geared

to short-termism. To demonstrate
this, we only need to look at the
volatility of the stock markets. It
seems to be human nature to measure only up to the horizon. In business, we seem to concentrate on
looking at annual budgets rather than
over the long term. There needs to be
a total culture change, as sustainability is for the long term. But the whole
economic system, from stocks and

shares to commodities, continues to

be driven by speculation and sentiment.
What will hopefully focus minds, however, is the significant pressure on energy and commodities prices, as the
incentives will be greater than ever to
make sure that savings are made. But
to achieve this, investment will have
to be made; as the old saying goes,
you have to speculate to accumulate.

Efficient technologies
To meet environmental and business
objectives for the future, energy efficient technologies will be a mainstay
for economic survival for all businesses. This will be coupled with wider
efficiency programmes. The key will be
the communication of our solutions
and technology developments to a
much wider audience than we have
considered before.
Developing a way to integrate wider
sustainable engineering and finance
will be the big challenge. How can we
define sustainable building services
and buildings in such a way that enables investors; developers; and finance professionals, including valuers
and occupiers, to measure and attribute a financial value to sustainability?
The answer must be to change the way
we conventionally measure finance.
How we construct longer term measures will be the big question. A good
example of how measurement is being
changed would be the introduction of
carbon accounting and the CRC energy efficiency scheme (formally known
as the Carbon Reduction Commitment).

Figure 1: a traditional financing model

20 dpaonthenet.net

This involves measuring the price of

carbon, which is obviously adding a
completely different dimension to the
conventional way of measuring finance
in relation to energy consumed. So as
well as paying for the energy, business
is also paying a carbon tax on the use

Feature: Energy Efficiency

ect, which means many projects will
need the total cost as up front capital.
This can be illustrated as a graph (Figure 1) showing traditional ROI.
An alternative model (Figure 2) develops a system of financing a project that
delivers a much shorter payback - ROI
funded in stages by a finance provider.
This commercial model is potentially
similar to how the Green Deal may be
financed over the term of many projects, small and larger scale.

Figure 2: an alternative financing model

of energy. In the future this may be extended in some form to cover the domestic energy market, but has so far
been held off due to the likely unpopular reaction to this at a time of significant energy price rises and recessional
times.
When the CRC was first introduced,
the idea was geared to a performance
table where the top performers would
get a rebate and gain financially in
order to incentivise the process. However, many companies were shocked
when the scheme changed in 2010,
when the coalition government decided to keep all the payments, so that
the CRC in effect became a carbon tax.
Industry and building owners were up
in arms. It seems they didn't realise
that the situation created an even bigger incentive to save, offset and reduce
their energy consumption. The effect of
the CRC seems to have been very
much about concentrating people's
minds on the price of carbon per ton.
In this process, they seem to have forgotten about the initial cost of energy.
By reducing their payment of the carbon tax, they would at the same time
be reducing their energy bills by saving
their energy resources, so creating
a double benefit on energy use.
People become obsessed with
the politics and the tax, but they
need to see the CRC as an example of integrating a financial mechanism to incentivise sustainability.

companies seem not to want to borrow

money to fund what others would consider a good return on investment
(ROI). Especially if the debt charges
would cover the on-going cost of the
loan repayments, gained from the energy savings. This is very much a convention in finance where the funds may
be available but the company doesn't
want to accept any risks.
There are a number of established
ways companies appraise investment
potential, but the majority will be concerned at how long it will take to break
even. With current investment rates
and financial uncertainties it surprises
me that so many good energy efficiency projects are held back, because
even with return on investments within
five years (which can cover a whole
range of energy saving technologies)
these projects do not get approval for
funding.
All sorts of accounting techniques are
used to measure traditional
financial
models. All rely on
a capital sum to
finance
the
proj-

To achieve an integration of finance

and sustainability, and break down the
barriers that currently exist, I believe
that there has to be a significant and
serious discussion between finance institutes and their equivalents in the engineering and sustainability fields to
create a mutual understanding of the
issues on both sides. Experience
shows that, currently, finance people
don't really have a grasp of sustainability issues and vice versa. Once we
achieve this, integration can easily become the norm.
The cheapest kWh is the one you
never use!
The reduction in energy use should be
the priority issue, although many people and companies are looking at the
installation of low carbon and renewable technologies as well. The big
dilemma people are facing is when exactly to make the decision to install renewables, as there is so much
conflicting information regarding their
performance and the financial returns
on different technologies. What is clear
is that energy prices will inevitably continue to rise over the longer term.
An analogy might be deciding when to
buy a new computer or
upgrade an existing one. Ideally, it is best
to buy a machine that is

Page 22

Funding for sustainable building

projects
Finding the finance in difficult economic times can be a challenge, not to
mention attitudes to payback. Many

dpaonthenet.net 21

Feature: Energy Efficiency

reducing the energy demand.
We have to look at energy and all the
other resource issues and impacts,
from cradle to grave, for all activities
we employ inside and outside our
buildings and all the associated activities. Most importantly, there needs
to be a simple process for the end
user and/or consumer to evaluate
and understand the true impact, both
financially and from a sustainability
point of view.

Figure 3: the energy hierarchy - what delivers a low carbon energy efficient building?

upgradable - the same goes for renewable and low carbon technologies.
However, this could be very difficult
with photovoltaics for instance. The
panels are manufactured, sealed
and installed for a 25 year life, so it
would be very hard to make them
upgradable. During the 25 years of a
photovoltaic panel's life, technology
will undoubtedly develop and future
panels will become more efficient. At
present, the conversion rate from sunlight to electricity is just 12-18%,
but there is the possibility that this will
have increased to about 25% in a few
years. This will improve still further as
time goes on.
Faced with this fact, the incentive for
early adopters was the feed-in tariff
(FiT), which was really the only incentive to invest in current technology.
Without this, it would be totally uneconomic to buy now. Those that took up
the FiT in 2010-12 were guaranteed 43
pence per unit generated. At the time,
the early adopters had to use the level
of technology that was available. If they
waited however, in the same way that
one might wait to upgrade a computer,
then they received a diminishing FiT, so
it was clearly designed as a reward for
early adopters, which of course would
stimulate and create a market. On the
other hand, as the technology develops and becomes more efficient, the
photovoltaic panels will generate more
electricity as the conversion ratio from
sunlight to electricity will have improved.

22 dpaonthenet.net

The choice: renewables or efficiency

This argument, for both efficiency
from technological development and
costs, has also been made to me on
the issue of fitting technology such as
variable speed drives or EC fans. I
counter this with the fact that the efficiencies and paybacks for motor driven
systems far exceed any renewable
technologies and don't require any
subsidies or special financial treatment,
such as FiTs or renewable heat incentive payments.
People tend to like new technologies
and want to be part of their development in society. Nevertheless, this can
distract our attention from the fact that
the cheapest kilowatt of power is not
solar: it's the kilowatt we never use in
the first place. I would maintain that the
key is still to focus on the energy hierarchy (Figure 3) since the financial and
environmental impact is far better
served by reducing energy in the first
place. Perhaps another way of looking
at this is to combine the hierarchy with
finance.
Whilst reducing energy usage is key,
that is not to suggest that I'm not
keen to see further investment in
renewable energy. Once we've
achieved the first steps on the energy
hierarchy we must ultimately invest in
renewables, perhaps by ring-fencing
the savings from energy use reduction.
That way, we could fund our
photovoltaic panels from the energy
hierarchy savings made earlier by

I propose we adopt the tried and

tested 'A to G' rating method, which
gives everyone a good understanding
of what is efficient and what isn't.
Complex arrangements for making
sure that a universal and robust system is put in place can take place behind the scenes; for the decision
maker, the simpler the system, the better. A-G can be used universally to label
all products on a common measurable
scale of energy with the cost and lifecycle data.
Ultimately, any energy efficiency measure to improve building performance,
which can be financed from the savings on energy bills, should be considered.
The key to a universal and a much
wider adoption of a motor driven system technology efficiency programme
will be the education, training and
awareness of not only the end users,
but even more crucially of the industry
itself.
Mike Malina is author of Delivering
Sustainable Buildings: An Industry Insider's View published by Wiley-Blackwell this month. For details copy this
URL into your browser: goo.gl/vbZX6.
DPA readers can obtain a 20 percent
discount on the price of this title by
using the discount code VBB09 at the
Wiley.com checkout
www.energyassociates.co.uk

Mike Malina

Precision engineering

Light as
a Feather
Inspired design using todays
materials means that you can
generate 4.4Nm from 62g

Call or visit our web-site

to nd out about this
revolutionary concept
produced with engineers
in mind.

Feature: Motor Driven System Design

Engineers:
you no longer need
to oversize motors
or generations engineers happily oversized electric motors to allow for worse
case working conditions, plus an extra margin of comfort. But what made good
sense then is something of an anathema to today's energy conscious engineers,
claims Stuart Harvey

Electrical engineers have had a common thread running through their

work for the last five or ten years, reducing energy consumption to cut
carbon emissions. This has the very
useful additional benefit of cutting
electricity bills. Not surprisingly, new
regulations and guidelines have
emerged to encourage this drive, the
latest of which is the EU's Minimum
Energy
Performance
Standard
(MEPS). This is being phased in, with
the first part already a legal requirement and the last part due to be enacted in 2017.
Under MEPS the current Eff1 and Eff2
efficiency classification will be discontinued. Indeed Eff2 rated motors will
become illegal. Also a new testing
procedure that gives highly accurate
efficiency figures will be introduced. It
is expected that the increased purchase price of the new high efficiency
motors will be recouped many times
over by the energy savings.
However, in the past designers routinely oversized motors by 10-20 percent. And these motors may have
been driving equipment via equally
oversized and therefore inefficient
gearboxes, lead screws, belt or chain
drives, clutches or couplings. Added
to this is the fact that motors have a
fairly narrow optimal efficiency band
of typically 80-85 per cent full load,
and many will not be running within
the range.

24 dpaonthenet.net

The water industry has long understood the

energy saving benefits of drives and soft starts

Feature: Motor Driven System Design

The new MEPS addresses this by
measuring the efficiency level of
the whole drive system rather
than just the motor on its own.
This means every installation
has to be assessed individually,
whereas in the past motors
could be bought with an
efficiency rating.
All systems go
Fan systems are already subject
to MEPS, and pumps will be from
2013. These are by far the two
biggest user groups for motors,
so OEMs need to make sure they
are up to speed and comply with
requirements. Over the subsequent four years all motor drive
systems will be drawn into the
system, but it is likely that end
users will start specifying compliance to their OEMs rather sooner.
Thus engineers of a certain age
who were brought up over-specifying motors, need to move to a
new paradigm. This may simply
be a matter of changing habits
and assumptions, but it may also
mean getting company policies
and design procedures changed.
Established OEMs may need to
inform their regular customers of
the changes.
End users are not obliged to
change existing equipment, but it
may be worth modernising
equipment in line with MEPS in
order to improve their own energy efficiency and enhance their
green credentials.
Significantly if a motor is used in
conjunction with a soft start or
variable speed (VS) drive, the
electronic component is also
considered to be part of the system for which overall efficiency is
calculated. This means mainsborne harmonics and power factor correction will have to be
brought into the efficiency calculations, as will filters and other
associated line equipment.
It is also notable that a drive may
make a significant contribution to
overall efficiency by allowing a
smaller motor to be specified.
The motor would be sized for
'normal' duty, but the drive can
push through a bit more power
when required for short-lived unusual circumstances. The net result could be a significant energy
saving, with a payback period of
just a few months, leading to a

positive contribution to the overall bottom line within the first financial year.
It should also be understood that
a variable speed drive can be a
good investment for a fixed
speed application. If the load is
to run at a different speed than
the output speed of the motor,
the speed shift can be achieved
with a gearbox, belt/chain drive,
mechanical variator or an electronic VS drive. Each of these will
cost something, and the advantage of a drive is that it can easily
be reset if requirements change.
However it must be made clear
that a drive will not improve the
efficiency of the motor it is feeding. Thus if a low efficiency motor
is specified, it cannot be made
more efficient by the addition of
a drive.
The advantage of lower efficiency
motors is that they are cheaper to
buy, so may be suitable for duty
cycles that have low overall running times. As a rule of thumb
there are 9,000 hours in a year
and if a motor is expected to run
for less than 2,000 hours a year,
the total running cost of a high
efficiency motor won't be significantly below those of a lower
category motor.
Before MEPS is fully implemented the EU intends to introduce a similar scheme for VS
drives. Hopefully the two
schemes will be so similar that
they will mesh together seamlessly rather than burdening engineers with even more paperwork!
Stuart Harvey is managing director of Softstart UK
www.softstartuk.com

Harvey: It is no longer acceptable to waste energy by oversizing motors. A variable speed

drive on a right-sized motor is a
far greener solution

dpaonthenet.net 25

Feature: Motor Protection

Protect your assets

with more functions,
fewer wires
or the majority of processes, motors have a significant
influence on production efficiency, so motor protection
is of central importance. Stuart Greenwood reviews the
latest developments and describes how motor-protective
circuit-breaker technologies are increasingly being merged
with electronics and lean automation technologies

The key tasks of motor-protective circuit-breakers include the switching,

protecting and disconnection of current
circuits primarily for motor loads. At the
same time they protect motors from
being destroyed by overloads and
guarantee safe disconnection in the
event of a short-circuit. They are also
suitable for the operational switching of
motor loads with a low switching frequency, and safe disconnection from
the supply for maintenance or modification work.
While development in the past primarily
focused on the mechanical side of
things, today's development increasingly comes from the field of
electronics and

26 dpaonthenet.net

automation with regard to

communication and fieldbus
technology.
Motor-protective circuit-breakers
with
electronic wide-range
overload protection
offer several key benefits compared to devices with
thermal releases. These include large
setting ranges, low heat dissipation,
tripping classes above Class 10, precise and exceptionally long-time stable
tripping characteristics, as well
as the possibility
Eaton's PKE motor-protective circuitbreaker in combination with the SmartWireDT bus-based lean panel wiring system

Feature: Motor Protection

to read parameter data.
Illustrative of these advances is Eaton's PKE
motor-protective circuit-breaker with electronic
wide-range overload protection. This device
measures the current rise via an integrated current transformer in the trip block, and evaluates
it using a special electronic circuit which, in the
event of an overload, sends a pulse via an actuator system to the switch mechanism. PKE circuit-breakers operate with a larger current
transfer ratio and the device has a wide current
setting range in the ratio 1:4 (conventional
bimetal motor-protective circuit-breakers have a
ratio of 1:1.6).
Wide current setting ranges also reduces the
number of product variants needed - reductions
of up to 75 percent are possible, compared with
bimetal trip type devices. This has a positive impact on both inventory costs and maintenance
logistics.
Energy consumption is also important when
considering the life cycle costs of an industrial
installation. PKE motor-protective circuit-breakers with electronic wide range overload protection feature low heat dissipation (up to 85
percent less than a bimetal alternative), limiting
temperature rise in the switching cabinet and
often eliminating the need for forced cabinet
ventilation.
Smarter wiring
As well as the purely basic functions of on/off
switching under normal operating conditions,
and the basic protective functions available from
a circuit-breaker, users also want additional information

from these devices in order to maximise operational and maintenance efficiency.

While it was previously only possible to evaluate
switch states or differentiate overload or shortcircuit trip indications, motor-protective circuitbreakers with electronic overload protection
offer rather more, including diagnostics, status
or overload messages, and even the actual current flow.
The necessary data transmission platform is
provided by the SmartWire-DT wiring and communication system, which offers an alternative
to point-to-point control wiring, and avoids the
laborious process of setting up device addresses via DIP switches. In place of multi-wire
control lines there's a single bus cable.
Data from networked motor starters are transferred directly to the controller and made available over the entire system. Indeed, adopting
the lean panel wiring capability of SmartWire-DT
greatly improves the transparency of the automation system. Since fieldbus and network
based field wiring already supports information
exchange, the addition of lean panel wiring systems means, in essence, that any information
about any aspect of the automation system's
operation and status can be made available
wherever it is needed.
Stuart Greenwood is with Eaton's Electrical
Sector
www.moeller.co.uk

The author, Stuart Greenwood

dpaonthenet.net 27

Drives Datafocus:

To advertise here please call

Nicola Crawley on 01732 359990 or
email nicola.crawley@imlgroup.co.uk

SIEMENS TECHNOLOGY IN WORLDS FIRST COMMUNITY TIDAL DEVELOPMENT

Siemens is supplying specialised gear and control technology to growing UK tidal power
generation company Nova Innovation, for the worlds first community tidal power project.
Siemens Industrys Mechanical Drives has supplied a planetary unit plus IE2 electric motor,
along with inverter drive and control system through Siemens specialist technology partner
HMK.
The Siemens technology features in the worlds first community-owned tidal power project,
based in the Bluemull Sound in Shetland, between the islands of Yell and Unst, the two most
northerly inhabited islands in the UK. It is a 30kW unit with horizontal axis and three-bladed
rotor, and is being deployed in early 2013 to provide power to a local ice-house and industrial
estate. The local community will reap the benefits of the project, safeguarding jobs and
providing valuable income.
For more information contact Siemens
Web: www.siemens.co.uk/drives

COST-EFFICIENT AND COMPACT,

THE PIEZOMOVE LINEAR
ACTUATOR P-604 FOR OPEN-LOOP
OPERATION FROM PI

The immensely cost-efficient and

compact P-604 lever actuator
supplements the PIs PiezoMove series
portfolio.
The linear actuator achieves a travel range
of 300 m and is exclusively designed for
open-loop operation.
The P-604 features properties that make
it ideal for OEM applications in optics,
medicine, biotechnology and
microfluidics: It is designed particularly
for cost-effective production of large
quantities with installation space kept to
a minimum (19.5mm x 13mm x 4.1mm).

PLANETROLL THE UNIQUE VARIABLE SPEED ATEX DRIVE

PICMA multilayer piezo actuators are
the driving force of the P-604-type lever
actuators.
They have an all-ceramic encapsulation
that makes them extremely robust and
durable.
Information on the P-604 and
PIs other products available online at:

www.pi.ws
or call 01234 756369.

ABB INTRODUCES NEW 8 MW HIGH

VOLTAGE FLAMEPROOF MOTOR
planetroll is a leader in the field of drive technology with an extensive technical know-how
in developing and manufacturing of variable speed gearboxes. planetroll variable speed
gearboxes are wet running transmissions. There is no friction inside the gear resulting in a
long service life and high levels of reliability.

MAYR TRANSMISSIONS LTD

INTRODUCES NEW SOFTWARE FOR
2D AND 3D CAD MODELS

The outstanding characteristics of the planetroll variable speed gearbox is the result of an
extraordinary system of torque transmission. The basis for this is the interaction of a perfect
geometrical body incorporating 4 rings, the ball and a traction fluid with an appropriate
coefficient of friction - This is elasto-hydrodynamic power transmission
Contact: Labtex Ltd
01484 600200

ROCKWELL AUTOMATION BUNDLES KEYS TO MACHINE CONTROL DESIGN IN

ONE-STOP SOLUTION

The new motor offers considerable

benefits for the chemical, oil and gas
industries, including low vibration levels
increasing reliability, and reduced
maintenance requirements for lower
cost of ownership.
Designed for fixed speed applications
from 375 to 3,000 rpm, it is especially
suitable for driving pumps and
compressors.
ABB has launched a new high voltage
flameproof induction motor certified to
IEC frame size 900 and rated to 8 MW.
Ms Karita Forss of ABBs high voltage
induction motor product management
said, Higher output motors are needed
to drive bigger machines, and our new
flameproof motor will be ideal for these
applications.
For more information contact
ABB Limited
Email: energy@gb.abb.com
Web: www.abb.co.uk/energy

28 dpaonthenet.net

Rockwell Automation introduces

the Connected Components
Accelerator Toolkit (CCAT), a
bundled, one-stop solution that
simplifies and expedites complete,
cost-effective, small-machine
control design and
implementation. The CCAT
combines a simple, yet powerful
controller with a full suite of
compatible components and
class-leading application
development tools that enable
OEMs to focus engineering and
development resources on
creating compelling and
differentiating machine features.
The CCAT speeds the basic,
common design functions that
every machine design requires. By
providing this functionality, the
CCAT allows the OEMs to invest
their design work in developing
better, more competitive
machines.
For more information contact Rockwell Automation Ltd
Tel: 0870 242 5004
Email: ukmarketing@ra.rockwell.com

Mayr Transmissions Ltd has installed new

software allowing them to produce 2D
and 3D CAD models of all of Mayrs
standard products in just a few seconds.
Rather than a catalogue drawing or a
generic model, Mayr can now supply
detailed drawings and models reflecting
their customers requirements.
Details including bore sizes, coupling
sleeve lengths, hub designs or brake
torques are programmed into the package
and an e-mail containing a set of approval
drawings is immediately generated.
This saves Mayrs OEM customers hours
recreating designs that already exist,
allowing them to simply drop Mayrs
models straight into their own design.
For more information contact
Mayr Transmissions Ltd
Tel: 01535 663900
Email: sales@mayr.co.uk
Web: www.mayr.co.uk

Feature: Power Quality

Power conditioning
delivers proven ROI
roblems
associated with
power quality can
take a huge toll on
companies, with
interruptions to the
power supply such
as impulses, noise,
sags, surges,
brownouts and
outages causing
sensitive electronic
and computing
equipment to fail.
Rob Morris describes
his company's twoyear study of power
quality systems
installation to identify
their real return on
investment (ROI)
performance.

The benefit of installing power

conditioning equipment to manage
and eliminate power quality issues
such as those described above
has long been clear. However, it has
not always been easy to quantify
whether improving the power quality
supply has a significant effect on the
bottom line.
With the state of the economy continuing to make headline news and the
future uncertain, businesses are looking to make their assets work harder
for longer. They also have to justify
every penny of spending.
With that in mind, my company recently undertook a two-year study,
which looked to better understand
how improving power quality affected
the bottom line. Put simply is there a
return on investment when installing
power conditioning equipment?

Variable power quality

While there are only around nine
hours of power outages on average
each year in developed countries, the
quality of the power produced by the
grid does not meet desired standards
for around 79 hours per year. Generally speaking, the power that comes
from the grid still meets the standards
that were set out in the early days of
electricity. This was more or less acceptable up until a few years ago
when hi-tech equipment with sensi-

tive components was introduced. This

equipment requires good quality
power if it is to perform correctly.
These irregularities can cause systems to fail, crash or lock up suddenly
and without warning, leading to cumulative damage to integrated circuits and electrical systems. Failures
lead to down-time, lost production,
lost customers - possibly even lost
lives where medical devices are concerned - and it can take days for systems to recover.

Page 30

dpaonthenet.net 29

Feature: Power Quality

In manufacturing, if computers and
other sensitive electronic equipment
that control processing lines are
knocked out, production can be
halted entirely. In retail, problems can
include failure of point-of-sale systems and other back-office systems
essential for successful day-to-day
business. Equipment failures such as
these inevitably lead to call-outs and
service visits, which can come at significant cost. We call this on-going
cost the 'service burden rate' and it
can often be very high for bespoke or
critical systems.
To find out whether the financial benefits of cutting the service burden
would outweigh the capital expenditure of a power management system,
we set out to measure our customers'
service burden rate before and after
installing our equipment and compare
it with the cost of power management. This enabled us to identify the
true ROI of power conditioning equipment.
Our extensive research found that the
typical service burden rate for a piece
of commercial electronic equipment is
in the region of 4 - 8 per cent of its
original price. Taking into account the
high capital cost of specialist equipment, and this service burden rate becomes a significant factor. When we
compared the results gathered from
more than a thousand pieces of installed power conditioning equipment,
customers
reported
a
significant fall in service costs of between 43 and 88 per cent. Taking into
account the cost of buying the power
protection equipment, we found the
ROI in these applications varied from
154 per cent to a staggering 1,148 per
cent.

ing the 'hidden' problems caused by

power fluctuations frees up time and
resources to focus on the business in
hand.
ROI in practice
In theory, therefore, the research
showed that businesses that install
power-conditioning equipment can
expect a minimum ROI of around 154
per cent - but what is the reality? One
example is James Hall & Co, a major
Spar Group wholesaler that installed
power quality equipment to protect its
electronic point-of-sale equipment
and back office systems in shops and
petrol forecourts.
At outlets where the power conditioning equipment was tested, staff
reported an 80 percent fall in hard
disk failures and data corruption,
a figure which prompted the
company to invest in power conditioning equipment across all 500 of its
retail stores.
James Hall & Co currently rents retail

systems to its outlets for five years

but is confident that an investment of
around 130,000 in power conditioning equipment would make it possible
to extend the trouble-free life of front
and back office systems by 20 per
cent and deliver additional rental income of more than 2m.
With pressure on budgets, the power
quality market is having to evolve and
demonstrate the financial benefit of
installing power quality management
equipment and associated UPS.
Our recent study proves that there is
a strong financial case for investing in
this type of equipment as it can
demonstrate savings from the measurable areas of service and warranty
costs with proven ROI as well as the
softer benefits of improved customer
satisfaction and retention.
Rob Morris manages the UK based
operations of the US power conditioning specialist, Powervar
www.powervar.com

For high value electronic equipment,

a service burden at four per cent, the
lower end of the spectrum, represents
a large ongoing cost to a business,
meaning that a reduction in costs of
43 to 88 per cent can represent a saving of hundreds of thousands or even
millions of pounds.
The research found that the benefits
were not just financial. There is a
softer side to consider, such as improved customer satisfaction, greater
customer loyalty, less downtime and
fewer call-outs to manufacturers. For
example we found that calls to help
desks decreased by an average of 60
per cent, which can represent a significant saving to an OEM in client
servicing. The service burden rate
also includes software training, hardware and staffing issues; so, address-

30 dpaonthenet.net

Morris: research found that the benefits were not just financial

make it how
you want it*
prole assembly solution
fast. versatile. simple.
*we mean MiniTec solutions as well as sandwiches

free

design
samples advice

& design
tools

machine guards
workstations
conveyors
customised
enclosures

www.minitec.co.uk
visit us and see the versatility of MiniTec

T: 01256 365 605

E: info@minitec.co.uk
www.minitec.co.uk

Feature: Permanent Magnet Motors

Saving energy w

synchronous m
direct product comparison test was recently
conducted to see how a Bauer Gear Motor
IE4 rated, super premium efficiency permanent
magnetic (PM) synchronous motor performed
against a standard asynchronous motor. The test
was carried out on a Huber disc thickener, at a
waste water treatment plant in Germany, in partnership with inverter drive specialist Danfoss.

In order to ascertain that any differences in efficiency could be attributed to the motors, each
drive used the same Bauer gearbox with a reduction ratio of 381:5 and an efficiency of 94 percent

Bauer believes the market is gradually

coming round to the fact that energy
efficiency has to be one of the key determining factors when specifying a
motor. Energy prices are only going to
go one way, so it is important that a
motor's lifelong running costs are considered, rather than simply the cost of
procurement. The company developed
this new range of super premium efficiency permanent magnetic synchronous motors (PMSM) in anticipation of
the new IE4 classification and customers' needs for higher efficiency
drives.
The PMSM series features an efficient
design of rotor with embedded rare
earth magnets that replaces the squir-

32 dpaonthenet.net

rel-cage construction of conventional

LV induction motors. The design offers
a number of key benefits; it eliminates
heat losses from the rotor, while total
losses are reduced by approximately
25 percent to give an overall improvement in total efficiency of 10 percent or
more. This translates into a lower total
cost of ownership, a reduction in CO2
emissions, and ongoing savings that
buffer against future increases in energy costs.
PM motors have been much in the
trade news of late, but there is still reluctance in the market to buy them, as
the purchase cost is higher than that of
standard motors. In some light duty applications, where the motor is rarely on,

it is still more economical to specify a

standard motor, but if the duty cycle
is high then a PM motor can quickly
deliver a satisfactory return on investment and then go on to achieve operational savings for a long time to
come.
The test
The disc thickener
mentioned in the introduction to this
article is in continuous operation for
seven hours per
day, seven days a
week, so it provided
an excellent opportu-

Feature: Permanent Magnet Motors

with PM

motors
nity to test the PMSM against a
standard asynchronous motor
(ASM). Prior to the test the existing ASM was controlled by a
standard inverter, so prior to the
PMSM being installed, a Danfoss
inverter drive was retrofitted to
the original system to achieve a
fair comparison.
The frequency inverter was programmed to monitor the loads on
each motor to ensure that they
ran at optimum efficiency. In
order to ascertain that any differences in efficiency could be attributed to the motors, each drive
used the same Bauer gearbox
with a reduction ratio of 381:5
and an efficiency of 94 percent.
It was found that with the frequency inverter installed the ASM
created 2.62Nm torque at
1,350rpm, achieved 61.5 percent
efficiency
and
consumed
0.26kWh. Following its installation, the Bauer PMSM created
3.5Nm at 1,500rpm, delivering
87.7 percent efficiency and consuming just 0.16kWh.

Thus the energy savings from installing the PMSM yielded a 40

percent saving in energy use over
the ASM, both motors being controlled by the same inverter.
Over a four year period it was estimated that, with an inverter
used in both cases, an ASM
would
consume
2,657kWh
whereas Bauer's PMSM would
consume 1,635kWh - a total saving of 1,022kWh.
Bauer head of R&D, Jens Gabel
says the aim of this development
effort was to give customers very
real savings in terms of their energy costs. "We are very happy
with the results of the test as they
show that super premium efficiency motors do deliver a real
life measurable benefit and in
many higher demand applications should certainly be considered both by design engineers
and maintenance engineers
alike."
www.bauergears.com

dpaonthenet.net 33

Driven By Quality

Tel: +44 (0) 1707 28 31 00

Stock Products

Spur | Helical | Bevels | Splines | Spiradrive

Racks & Toothed Pulleys | Gearboxes | Couplings
Worms & Wheels | Timing Belts

Standard parts or modied

to your requirements
Approved Distributor for:
SDP/SI | HYDRO.MEC | POGGI | GATES | CGI | FRANCIA
Contact us now with your enquiry or for your free catalogue
www.davall.co.uk

KELLER

pressure sensors

PRECISION PRESSURE TRANSMITTER SERIES 33X

- Ranges: 00.2 to 01000 bar, adjustable
- Output: 420 mA, 010 V, RS485 Digital
- Mathematical, on-board error correction
7RWDO(UURU%DQG)6&
2SWLRQDOHQKDQFHGSUHFLVLRQWR)6
- Flexible and modular mechanical construction

OEM PRESSURE TRANSMITTERS

SERIES 4 LC9 LC
with embedded electronics

KELLER (UK) Ltd.

Dorset Green Technology Park
Winfrith Newburgh, Dorchester, DT2 8ZB
UK and Ireland: T. 0845 643 2855
UK and Ireland: F. 0845 643 2866
E-Mail: sales@keller-pressure.co.uk
Web: www.keller-pressure.co.uk
www.keller-druck.com

- Ranges 01 bar, thru to 01000 bar

- Signal 0.5 V4.5 V, Supply 5 Vdc
- Electronics hermetically sealed inside
/RZFRVWVHQVRUHOHFWURQLFVVROXWLRQ
7RWDO(UURU%DQGEHWWHUWKDQ&
&KRLFHRIPDWHULDOV

...and whats more

Southern
Manufacturing &
Electronics 2013
f variety is the spice of life, get ready for a vindaloo you won't forget at
Southern Manufacturing & Electronics, returning to FIVE, Farnborough
on February 13 and 14 2013.

As preparations for the 2013 show

move into high gear, it is becoming
clear that it is heading towards yet another record-breaking year. Confirmed
exhibitor bookings are already well
over the final total for 2012 and as a
result, the total floor area of the show
has been increased by over 35 percent, bringing it to a decidedly roomy
5,350 square meters - larger than five
of the halls at the NEC. The exhibitor
list continues to grow in both length
and stature as befits an event which
has long-outgrown its provincial roots
to become a show of national importance.
Visitors to FIVE, Farnborough on February 13 and 14 2013 will meet with
the largest and most diverse gathering of manufacturers and equipment

Certification specialist TUV Rheinland exhibits for the first time in 2013

suppliers, covering everything from

major international machinery makers

names that are now regularly exhibit-

time exhibitors REO(UK), Manutech

to purveyors of packing materials.

ing at Farnborough; names such as

Europe, Merit Plastic Mouldings and

The show's increasing gravity within

Mazak, Haas Automation, Fanuc,

membrane

industry is pulling in not just the big-

Renishaw, Faro, Amada Machine

Mekall join an impressive list of well-

ger names, but companies from fur-

Tools, igus (UK),EAO, Finder and Agie

established names, such as RS Com-

ther afield. In 2013, visitors will be

Charmilles are just a sample. Joining

ponents,

Anixter

Component

able to meet companies from the

this year, for the first time, are Amphe-

Solutions,

Ambersil,

Electrolube,

USA, Germany, Netherlands, Italy and

nol, the Paragon Electronics Group,

Brady, Bulgin and Goepel Electronics.

Latvia, alongside firms from every

Fronius, Farsound Engineering, TTI

Together, these companies bring liter-

corner of the UK, from Scotland to

Inc and Salvagnini, amongst many

ally thousands of parts, components,

Somerset.

others.

consumables, sub-assemblies, pro-

One of the strongest indications of

An enlarged Electronics Pavilion will

this growth can be seen in the impres-

host a variety of component suppliers

sive roll-call of big international

and sub-assembly specialists. First-

keyboard

specialists,

duction aids and design tools to a single, easily accessible venue.

The show's location close to the con-

Page 36

dpaonthenet.net 35

...and whats more

centration of technology, aerospace

nance firms specialising in manufac-

Knox with an update if his extremely

and automotive engineering busi-

turing industry.

popular Designing for Commercial

nesses around the south and the

Success and New Product Develop-

M3/M4 corridors makes it an impor-

But hardware and services are only

tant annual showcase for designers

part of the story. Southern Manufac-

and design-led businesses. BitBox

turing is also a good place to see ad-

Meanwhile, Sergey Putintsev from

Limited exhibits for the first time; Hot-

vanced

action.

TUV Rheinland will give a presentation

house Design, the multi-award win-

Additive manufacturing specialists 3T

on selling to emerging markets - in

ning design firm responsible for the

RPD and Laser Lines both return for

particular, the BRIC countries and the

Yoomi self-heating baby bottle, and

2013 alongside companies such as G

Middle East. Bob Willis presents two

ByteSnap Design both return for

English Electronics, able to provide

sessions on how to stop counterfeit

2013, together with a number of firms

rapid prototyping services.

components and a look at package-

manufacturing

in

that specialise in taking design ideas

ment.

on-package assembly techniques.

from the drawing board to the pro-

Composites, engineering plastics and

duction line. Briton EMS, with its

components from firms like K D Fed-

For a full list of sessions - and to pre-

clever electronic linesman's flag and

derson, Broanmain, igus (UK), FB

register for the show - visit www.in-

Heber Electronics with its long track-

Avak, Andel Plastics, Rose Plastics,

dustrysouth.co.uk.

record of success with global names

Cotswold Plastic Parts are also well

like Dyson and Electrolux, are just two

represented. Advanced production

FIVE, Farnborough is easily accessi-

of them.

methods are also much in evidence,

ble by road and public transport. On

with companies like Tesa, Henkel Loc-

site car parking is also free, and a free

The show organiser claims that, what-

tite and Lohmann Adhesives tapes

shuttle bus service operates daily be-

ever your requirement, there will be

among others providing alternative

tween the show and both North Camp

subcontractors waiting to speak to

assembly ideas.

and Farnborough Main railway sta-

you at Southern Manufacturing &

Electronics 2013.

tions. Visitors can keep up with all the

No preview could be complete with-

latest news on the show blog site,

out mention of the ever-popular free

http://blog.industrysouth.co.uk or by

There are also hundreds of companies

technical seminar programme, featur-

joining the Southern Manufacturing &

able to help with essential services,

ing 24 sessions over both days of the

Electronics group on LinkedIn.

from outsourcing to compliance, fi-

show in two lecture theatres. High-

nance and training. Certification spe-

lights of the 2013 programme include

cialist TUV Rheinland exhibits for the

the return of Bang Creations' Stefan

first time in 2013, alongside EMC

Specialists such as Hursley EMC and
Kemtron, training services such as
STEM and Electronics Yorkshire, and
even accountancy and business fi-

36 dpaonthenet.net

Trumpf will be showing its solid state

laser range, including the TruDisk
systems for high performance
welding and soldering, and thin
sheet metal cutting

To advertise here please call

Nicola Crawley on 01732 359990 or
email nicola.crawley@imlgroup.co.uk

Datafocus:
LOW COST HIGH SPEED IMAGE
RECORDING
STEMMER
IMAGING has
announced
Gecko, a
low cost
application
that captures
and
compresses
video streamed directly from GigE
cameras onto a standard PC in real time.
The latest version of Gecko supports fast
uncompressed ring buffers for capturing
short high speed events plus an incredibly
fast JPG RAM compressor capable of
recording to memory at high rates for long
durations. Events may be triggered by
mouse, keyboard or camera digital I/O
with pre and post event recording buffer.
Gecko is designed for applications
requiring a digital video recorder for
process monitoring and event capture and
records video to standard formats.
For further information contact
STEMMER IMAGING Ltd
T: +44 1252 780000
E: info@stemmer-imaging.co.uk
W: www.stemmer-imaging.co.uk

NEW ROTOR INSERTION

FLOWMETER CAN BE INSTALLED
HOT INTO LIVE PIPEWORK TO
CUT INSTALLATION AND
OPERATIONAL COSTS
Spirax Sarco has
launched its RIM10
rotor insertion
flowmeter for steam,
gas and liquids
featuring rapid
installation in live
pipework. The RIM10 can be fitted directly
into operational pipework using standard
hot-tapping techniques, eliminating
production disruption for installation and
saving substantial costs by keeping
productivity high. The hot tap
configuration allows sites to install the
flowmeter when needed instead of having
to wait for planned plant shutdowns, and
enables the easy withdrawal of the meter
should the rotor need changing for
maintenance or re-ranging. Its suitability
for a wide range of liquids, gases and
steam also saves costs.
For more information contact
Spirax Sarco
Email: ukenquiries@spiraxsarco.com
Web: www.spiraxsarco.com/uk

CUT TIME CUT WASTE CUT COSTS

The new Kistler Stasa QC software for

injection moulding requires fewer physical
trials to increase process stability and part
quality whilst optimizing cycle and set-up
times. With the help of a statistical Design
of Experiments (DoE), it determines the
effect of relevant machine parameters on
part quality and optimizes the operating
point. A stabilized process, high part
quality and short cycle times translate into
higher output rates and significant
savings. The primary advantage is that
running the initial tests on a PC allow a
wide variety of parameters to be changed
interactively by clicking and dragging with
the mouse.
For more information contact
Kistler Instruments Limited
Tel: 01256 741550
Email: sales.uk@kistler.com
Web: www.kistler.co.uk

38 dpaonthenet.net

FREELINE STANDS FOR DEAD ZONE-FREE CONNECTIONS MADE OF HIGHQUALITY STAINLESS STEEL

Eisele uses stainless steel grades 1.4307 or higher for the FREELine series. As a threaded
fitting with a hose they offer a maintenance-friendly, flexible alternative to classic pipework
and are just as easy to clean. The dead zone-free construction means that no residue
remains in the fittings. Outer diameters up to 22 mm allow even liquid foods to flow through
the lines at the required pressure. While product purity is decisive for paints and lacquers,
hygienic aspects are another important factor for foods and pharmaceuticals. In all cases,
easy and extremely thorough cleaning of the media circuit is necessary, to enable fast
changing of media. Residue must be absolutely eliminated. The design of these fittings
without an additional seal ring is another advantage, especially when used with aggressive
cleaning agents.

EFD AUTOMATED FLUID

DISPENSING SYSTEMS OFFER
RELIABLE OPERATION WITH
EXCELLENT REPEATABILITY

Precise and consistent application of

adhesives, sealants and lubricants
Three- and four-dimensional motion
control for dispensing of dots, stripes,
arcs, compound arcs and patterns on
different planes
Quick set up and easy programming
thanks to specialized PC dispensing
software and CAD download capabilities
Flexibility of working either as a standalone system or a key part of an
automated solution

For more information contact Eisele

Web: www.eisele.eu

EFD International, Dunstable, Beds. UK

Phone (0)1582 666334
uk@nordsonefd.com
www.nordsonefd.com

PCB PIEZOTRONICS ANNOUNCES LOW COST ICP DYNAMIC FORCE SENSORS

AVAILABLE FROM STOCK

LEISTER LHS INTEGRATED

INDUSTRIAL AIR HEATERS

PCB Piezotronics, a world leader in vibration, acoustic, pressure,

force and torque sensors, offers a wide range of ICP quartz
piezoelectric force sensors. These durable measurement devices
possess exceptional characteristics for the measurement of
dynamic force events and typical of the range is the 208 series
offering low cost solutions available for UK delivery in under a week. The 208 series dynamic
force sensors feature a female thread in top and bottom and are capable of measuring in
tension and compression modes making them ideal for an extensive range of applications,
including tensile testing, fatigue testing, drop and impact testing.
For more information contact PCB Piezotronics Ltd
Tel: +44 (0) 1462 429710 Email: ukinfo@pcb.com Web: www.pcbsensors.co.uk

INNOVATIVE FASTENING SOLUTIONS AND LOWER ASSEMBLY COSTS

The complete range of engineered fastening solutions available from
Spirol Industries is featured in a new eight page overview brochure.
The publication provides specifiers with information on the features and
benefits of all Spirol products including Coiled & Slotted Spring Pins,
Spacers, Rolled Tubular Products, Solid Pins & Drive Studs, Inserts for
Plastics, Ground Hollow Dowels, Dowel bushings & Spring Dowels, shims
and Compression Limiters. The brochure also provides information on the
Application Engineering Services and examples of potential applications
of Spirol products within markets as diverse as aerospace, agriculture,
automotive, cosmetics, electronics, defence, power tools, medical and
many others.
For more information contact Spirol Industries Ltd
Tel: +44 (0) 1536 444800 Email: uksales@spirol.com

NEW PRODUCT LITERATURE: FREE BULLETIN FROM PENNENGINEERING

PROFILES COMPLETE LINE OF MICROPEM FASTENERS
A new comprehensive product bulletin available free from
PennEngineering profiles the complete line of
microPEM fasteners ideally suited for attachment
applications in compact electronic assemblies. These
extremely small fasteners can serve as practical, costeffective, and permanently secure solutions enabling
quicker assembly of devices ranging from hand-held
consumer electronics including tablets, phones, and
laptops to medical equipment, among others.
Bulletin MPF includes all specifications and installation
and performance data for the entire microPEM product
family. Solutions include self-clinching pins with threads
as small as M1 for positioning and alignment applications,
self-clinching and surface-mount standoffs and nuts in
lengths as short as .040 / 1mm for mounting and/or
spacing requirements, TackPin fasteners in a variety of
styles enabling sheet-to-sheet attachment, inserts
providing strong metal threads in plastic assemblies, and
screws available in sizes as small as M0.8 and as short as .040 / 1mm.
Bulletin MPF can be downloaded at http://www.pemnet.com/fastening_products/micro.html,
where free part drawings (PEM CAD Library) for these RoHS-compliant fasteners additionally
can be accessed.
All microPEM products are manufactured by PennEngineering, founded in 1942 and this
year celebrating 70 years of excellence in fastening technology.
For sales or marketing information, contact Liam Foy, Director of Marketing EMEA,
PennEngineering, Tel: +353 91 7471186 email: lfoy@pemnet.com

The established range of LEISTER air

heaters for production processes has
released a new series of process heat
units for connectivity directly into a PLC
control system enabling better control and
functionality for systems designers and
line production managers alike. Designed
for professional integration directly into
machine systems, the new LHS series
enables many applications including
sterilisation, drying, welding, cleaning,
shrinking, shaping, curing, deburring and
activation. Operating from temperatures
controlled to 650 degrees, the System
range can be controlled by a PLC or
standalone controller using a 4-20mA
signal or 0-10V allowing for easy
integration into a control system.
For more information contact
Welwyn Tool Group
Tel: 01707 331111
Email: info@welwyntoolgroup.co.uk

WEIDMLLERS DC-UPS
SAFEGUARDS AGAINST MAINS
POWER FAILURES FOR UP TO 30
MINUTES AT 40 A

Weidmller's uninterruptible power supply

(DC-UPS) ensures a highly available 24V
DC power supply for automation
applications. The maintenance free buffer
module is perfect for short interruptions in
the range of several 100 milliseconds;
depending on usage, customers can get a
life time of up to 10 years from the device.
The UPS controller, in connection with a
battery module, bridges longer mains
power failures safely and reliably. This
module provides power up to 40 A for 30
minutes or 1 A for 30 hours, depending on
the requirement.
There are four finely graded battery
modules between 3.4 and 17 Ah. The
DC-UPS controllers can be installed
adjacent to one other, so they take up only
66 mm of width in the cabinet.
For further information visit:
www.weidmuller.co.uk

To advertise here please call

Nicola Crawley on 01732 359990 or
email nicola.crawley@imlgroup.co.uk

Datafocus:
WEIDMULLER LAUNCHES NEW,
COMPACT OMNIMATE SIGNAL LMF
PCB TERMINALS WITH INNOVATIVE
PUSH IN CONNECTION SYSTEM.

MULTI-ANGLE LED LIGHT TUBES FROM OMC ARE BRIGHT,

ROBUST AND LONG LIFE

Weidmllers new,
compact OMNIMATE
Signal LMF PCB
terminals with the
innovative PUSH IN
connection system
meet the stringent
design requirements of
industrial devices needing a reliable power
supply connection system. These
requirements include a 250V voltage
supply, high electrical safety for the
insulation material and access to cable
wiring to suit the relevant application.
The PUSH IN connection system results in
valuable time savings and features an
integrated test point and variants with 90
and 180 conductor outputs, allowing for
designs with different wiring direction
configurations. The LMF PCB terminals
are available with 5.0mm and 5.08mm grid
dimensions and as 2 to 24 pole versions.
For further information, visit us at
http://tinyurl.com/d6gn75r or email us
at marketing@weidmuller.co.uk.

AFFORDABLE DEW-POINT
TRANSMITTER DESIGNED FOR OEM
DRYER MANUFACTURERS
The SF52
dew-point
transmitter
from Michell
Instruments
provides a
heavy-duty,
cost-effective
solution to monitor moisture content in
industrial dryers. The easy to install
instrument has an exceptionally low cost
of ownership with no maintenance
required during its lifetime use of typically
five to seven years. Its robustness gives a
fit and forget solution with benefits that
make this a smart and appealing choice
for use in industrial dryers. The SF52
offers an affordable solution for dew point
measurement for harsh environments. The
SF52 transmitter covers the key dew-point
measurement range of -40 to +60C for
most common industrial drying
applications.
For more information contact
Michell Instruments
Tel: +44(0)1353 658 000
Email: uk.info@michell.com

GILL SENSORS LAUNCH THEIR

SMALLEST, FASTEST, HIGHEST
RESOLUTION POSITION SENSOR
TO DATE

Gill Sensors, a UK company and specialist

manufacturer and supplier of position
sensors has announced the launch of the
new Blade20 non-contact position sensor.
This latest addition has been developed in
response to customer demand for a
smaller, faster and higher resolution
position sensor able to withstand to harsh
industrial environments in applications
such as process control machinery,
materials handling equipment and robotic
systems. The Blade20 features Gills
patented induction technology principle
and represents a significant breakthrough
in position sensing, with a single product
allowing the measurement of linear and
shallow-arc motion and long-stroke
measurement with a single micro sensor.
For more information contact
Gill Sensors Ltd
Tel: +44 (0) 1590 613400
Web: www.gilltechnology.com

OMC, the pioneer in optoelectronics, has announced a new version of their rugged, robust
and high-brightness multi-angle LED light tube range which can be used to replace
traditional light sources in hundreds of applications, saving power and lasting longer than
fluorescent products. These compact, low voltage linear LED lighting fixtures feature
advanced lens/reflector assemblies that provide extremely bright and uniform illumination
across a broad and well-defined target illumination area, with a power consumption of just
2.9W per foot of tube. With a slim profile and robust metal housing, the new light tubes are
easy to install and require no additional fixtures or fittings. The adjustable mounting brackets
allow the light to be directed as needed, and low voltage 24V DC operation ensures they are
safe and simple to power electrically.
For more information contact OMC
Web: www.omc-uk.com

HANDLES TYPE PF
Blte Plastics have added two new references PF150 and PF180 to its product
range Handles Type PF. Blte handles are easily and quickly assembled for a
perfect finish. These polyamide (Nylon) handles are resistant to corrosion, impact
and common chemicals; they have good dimensional stability and high thermal
resistance. our Handles are suitable for applications such as gates, guards,
cabinets and caravans, as well as industrial applications in general. Handles (flat profile) can be
attached with M6 (only for PF94) or M8 hex head screws. Available in two heights (36 and 45 mm)
and lengths from 110 to 201 mm. Standard colour is black but other colours are available, on request.
A catalogue detailing our full range of products is available free, on request, or visit our web site.

Blte Plastics UK (Ltd), 13 John Street, Stratford-upon-Avon, Warwickshire CV37 6UB

Tel.: +44 1789 263 753 Fax: +44 1789 264 015
E: bulte@bulte.com W: www.bulte.com

NEW SITE FOR SURFACE ENGINEERING SOLUTIONS

For more than 50 years, Henkel solutions have been essential to
maintenance personnel involved in rebuilding, repairing and protecting
industrial equipment. Carrying the Loctite Nordbak and Hysol brands,
these innovative products have helped to extend equipment life, improve
efficiency and minimise downtime in the harshest industrial environments.
Now this range has been given its own section on the Loctite website.
Visitors to www.loctite.co.uk/surface-engineering will see a complete overview of the
products that broadly cover cleaning, metal-filled compounds, protective coatings and
compounds. Collectively the products address problems caused by wear, abrasion, chemical
attack, erosion, corrosion, impingement and mechanical damage.
For more information contact Henkel Ltd
Web: www.loctite.co.uk/surface-engineering

ANDON LIGHT WIRELESS MONITORING

Quick and easy to install without hard-wiring
or complex programming, the WIN system
from WERMA provides a simple low cost
means of monitoring shop-floor efficiency.
Use as a means to monitor idle time and
running time of a machine, or as a call to
action system for workstations. The kit can
be fitted to existing WERMA signal towers (KS
71/70 series), or it can be installed as a stand
alone device without lights.
A transmitter unit fitted to the signal tower
sends any signal light status change
immediately to a wireless receiver plugged
into the USB port of your pc.
This data is presented as different visuals with
which allows you to monitor the operation and
performance of the machine or workstation
being guarded by the signal tower.
WERMA (UK) Ltd.
Linnell Way
Telford Way Industrial Estate
Kettering, Northamptonshire
NN16 8PS
Tel: +44 (0) 1536 486 930
Fax: +44 (0) 1536 486 810
www.werma.co.uk
uksales@werma.co.uk

AMPHENOL LAUNCHES NEW

HERMETIC CONNECTOR AT
SOUTHERN MANUFACTURING 2013
Amphenol is one
of the leading
manufacturers of
interconnection
products in the
world servicing
customers at a
national and an
international level
to provide
innovative solutions across many market
sectors. As a global leader in hermetic
glass-to-metal seal interconnect
technology, Amphenol has the expertise
to offer connectors to support many
demanding applications. On show will be
the latest hermetic technologies and
product ranges optimised for high
temperature sensors and pressure feedthroughs, and other high end applications.
Also exhibited will be the latest Heavy
mate F Series, a modular-based system
intermateable with other brands of
rectangular modular-format connectors.
For more information contact
AMPHENOL at STAND NO. 270
Web: www.industrial-amphenol.com

WEIDMLLERS OMNIMATE PGK 4

FEED-THROUGH TERMINAL FOR
TIGHT SPACES
Weidmller
has developed
the new
OMNIMATE
PGK 4 throughpanel terminal
with PUSH IN
connection
system, for times when space for
applications is limited, and flexible, spacesaving connection systems are needed,
enabling simple and secure installation in
housing walls. Incorporating Weidmller's
PUSH IN connection system means a
conductor connection is provided on the
inside and outside of the device which is
easy to operate, without tools. The
connection blocks enable a large number
of poles to be quickly and simply
assembled, without taking up valuable
space, whilst the terminal block
engagement mechanism is suited to
panel thicknesses of between 1.50mm
and 3.00mm.
For further information, visit
http://www.weidmuller.co.uk/ or
www.push-in.com or email
marketing@weidmuller.co.uk.

EMPARRO THE POWER SUPPLY

UNIT WITH MAXIMUM EFFICIENCY
Murrelektronik
presents Emparro,
a highly innovative
power supply unit
with maximum
efficiency and
minimum power
loss. The
combination of
the Power Boost
function with a
power limiter
output allows large loads to be started
easily. The wide input voltage range
makes Emparro a global player. Modern
machine builders and users are paying
attention to power consumption. Our
new power supply units put the focus on
efficiency because energy is a precious
commodity and unused machine energy
increases costs. Emparro has an
innovative circuit concept and an
efficiency rating up to 95% - so only
5% of the energy remains unused.
For more information contact
Murrelektronik Ltd
Email: info@murrelektronik.co.uk
Web: www.murrelektronik.co.uk

dpaonthenet.net 39

To advertise here please call

Nicola Crawley on 01732 359990 or
email nicola.crawley@imlgroup.co.uk

Buyers Guide:
Adhesives

Bearings

Brakes

Control Panels

A full range of Engineering Adhesives,

Sealants, Fillers, Lubricants and
Dispensing Equipment

Henkel Limited
Technologies House, Wood Lane End.
Hemel Hempstead
Hertfordshire HP2 4RQ

Precision Miniature Bearings

Precision Assemblies
Precision Ballscrews
Tel: 01908 227123 Fax: 01908 310427
www.myonic.com
E: info.uk@myonic.com

Technical Helpline: 01442 278100

Fax: 01442 278071
Email: technicalservice.loctite@uk.henkel.com

www.loctite.co.uk

Batteries

Coolings Systems

Aluminium Framework

To advertise here
contact
Nicola Crawley on
Tel: 01732 359990
or email
nicola.crawley@imlgroup.co.uk

Modular aluminium
profile system.
Ideal for Safety Guards,
Conveyors, Workstations
and special purpose
machinery.

Axair Fans UK Limited

Lowfield Drive - Centre 500
Wolstanton - Newcastle-u-Lyme
Staffordshire ST5 0UU - UK
T: 01782 349 430 F: 01782 349439

t: 01256 365605
e: info@minitec.co.uk
www.minitec.co.uk

Cable Accessories
& Plastic Fasteners

Automation & Control

www.axair-fans.co.uk
sales@axair-fans.co.uk

Displays

MOTION

control

Components, systems
and support.

COMPONENT SOLUTIONS

Batteries & Chargers

Motion products and systems for

scientific, industrial and defence
organisations.

Unit A Nimrod Way,

East Dorset Trade Park,
Wimborne, Dorset BH21 7HY
Tel: +44 (0) 1202 865222
Fax: +44 (0) 1202 865270
www.anixtercomponents.com
sales@anixtercomponents.com

Displays
Touchscreens
Industrial Pcs
Display systems

Engineering excellence - by design

Review Display Systems Ltd

LG Motion Limited
t: +44 (0)1256 365600

www.lg-motion.co.uk

Connectors

www.review-displays.co.uk
01959 563345

Ball Screws
Drives / Gearboxes

Power transmission by planetroll

To advertise here
contact
Nicola Crawley on
Tel: 01732 359990
or email
nicola.crawley@imlgroup.co.uk

40 dpaonthenet.net

Murrelektronik - one the of the world's leading

connector manufacturers.

M12 leads and self wire

M8 leads and self wire

Valve connectors

Distribution systems

in IP67,IP68 & IP69K

Murrelektronik Ltd
Albion St, Pendlebury Ind.Est.
Swinton, Manchester, M27 4FG
Tel: 0161 728 3133 www.murrelektronik.co.uk

well-established planetary
gearheads planetdrive PD
stainless-steel planetary
gearheads planetdrive VPD
low-backlash planetary gearheads
planetdrive PDH
geared motors and special gearboxes for
custom-designed solutions by planetroll
planetroll is one of the world's leading manufacturers
of variable-speed gearboxes for use in explosion-proof
areas according to ATEX 95.

sales@labtex.co.uk www.labtex.co.uk
Tel: 01484 600200

To advertise here please call

Nicola Crawley on 01732 359990 or
email nicola.crawley@imlgroup.co.uk

Buyers Guide:
Enclosures

Geared Motors

Lead Screws

Sensors

Systems
Unimeasure Pull Wires
www.unimeasure.com

Pull-Wire Displacement sensors Easy Installation

Compact-Low Cost from 99.00
Where small size is required Ranges to 2000(50m)
Repairs to any manufactures

SE Systems Ltd
Tel: 01702 530174 Fax: 01702 530200
sales@sesystems.co.uk www.sesystems.co.uk
Linear Motion

Environmental
Test Chambers

position and motion sensors

Geared Motors
12mm / 90mm dia

Assemtech Europe Ltd

Rice Bridge Industrial Estate
Thorpe Le Soken
Essex CO16 0HL
T: 01255 862236 F: 01255 862014
Sales@assemtech.co.uk
www.assemtech.co.uk

   #

 #  

Servo Motor
& Drive Repairs

Offer Truly Economical Solutions To drive

application problems with a comprehensive
range of motors, geared motors and
accessories. Hybrid solutions also available at
moderate cost.
Our products are widely used in industry,
education and R&d markets, with some of the
following as typical applications.

Fasteners & Fixings

Tappex Thread Inserts Ltd

54 years of UK
manufacturing excellence
in Threaded Inserts for
Plastics, Composites &
Light Metal alloys

Robotics, laboratory equipment, surveillance

cameras, slot machines, shop displays,vehicle
equipment, telecoms equipment,lighting and
ventilation control. Locking mechanisims,
machinery activators, shop displays etc etc.
MFA/Como Drills
Felderland Lane, Worth, Deal
Kent CT14 0BT
Tel: 01304 612132 Fax: 01304 614696
www.mfacomodrills.com



  !

   
  

###! "

Plastic Mouldings

Hot Air Sources

ab

Tappex provide an Applications technical service,

prototyping and bespoke installation tooling historically
across multiple industry sectors: OEM/Automotive/
Medical & Industrial Equipment manufactures
Tappex offer fastening solutions produce from Brass,
Steel & Stainless Steels with both Metric, Unified and
British Standard threads
Contact details:
Tappex Thread Inserts Ltd
Tel: +44 1789 206600
Email: sales@tappex.co.uk;
New Website: www.tappex.co.uk
Downloadable catalogues and applications advice on the website.

Service from
Bosch Rexroth
Bosch Rexroth, formerly known
as Indramat and Bosch offer:
Local repairs

Field service

Genuine
spare parts

Warranty up to
5 years

These services are available for

control systems, servo drives,
servo motors & PLCs
Contact Service on:

Design and Tooling

Latest Moulding Technology inc Gas Injection
Machining and Assembly

Tel: 01572 723476

www.rutlandplastics.co.uk

Email:
Freephone:
0800 169 6624 servicebrc@
boschrexroth.co.uk
Telephone:
+44 (0)1285 863049

www.boschrexroth.co.uk

dpaonthenet.net 41

To advertise here please call

Nicola Crawley on 01732 359990 or
email nicola.crawley@imlgroup.co.uk

Buyers Guide:
Springs

Surface Treatments

Test Chambers

Transformers

Blackfast Chemicals Ltd

Goss Spring components Ltd,

30 Victoria Works,
London
E17 4JU
Tel: +44 (0) 208 527 5599
Fax: +44 (0) 208 527 1142
Email: dgoss@goss-springs.com
www.goss-springs.com

462 Ewell Road

Surbiton
Surrey
KT6 7EL
Tel: 020 8339 7370
Fax: 020 8339 7371
Sales@blackfast.com
www.blackfast.com

New and refurbished

standard range chambers.
Specials manufactured to
customers requirements.
Chambers for hire.
Service and Calibration.

www.jts-test-chambers.co.uk

Temperature Measurement

James Technical Services Limited

Tel: 01874 711209 Fax: 01874 712010
Email: sales@jts-test-chambers.co.uk

www.goss-springs.com

P
.ONCONTACT4EMPERATURE-EASUREMENT

TO#

MANUFACTURERS OF SPRINGS
PRESSINGS WIRE FORMS
Unit 1, Latimer Road Industrial Estate
Latimer Road, Wokingham
Berkshire RG41 2YD
T: 0118 978 6573 F: 0118 989 4434
E: simpson.springs@btinternet.com
www.simpsonsprings.co.uk

0ROCESS-ONITORING#ONTROL
s&IXEDREMOTEINFRAREDSENSORS
s4HERMALIMAGINGLINESCANNERS

WWWRAYTEKCOM
WWWIRCONCOM

The Unique Independent

Supplier of Temperature &
Humidity Test Chambers,
Laboratory Ovens,
Drying/Curing Ovens &
Associated Equipment &
Services.
Tel: 01772 600771
E-mail: sales@teslatest.co.uk
Website: www.teslatest.co.uk

To advertise here
contact
Nicola Crawley on
Tel: 01732 359990
or email
nicola.crawley@imlgroup.co.uk

To advertise here please call

Nicola Crawley on 01732 359990 or
email nicola.crawley@imlgroup.co.uk

Sitefind:
AUTOMATION

DC MOTORS

HEAT SHRINK PRODUCTS

SENSORS

ABB
www.abb.co.uk

Trident Engineering Ltd

www.tridenteng.co.uk

CPL ness heatshrink

www.nessheatshrink.co.uk

BATTERIES

DRIVES

INSTRUMENTATION

Sensor Technology
www.sensors7.co.uk
Labfacility
www.labfacility.co.uk

Creasefield Ltd
www.creasefield.co.uk
DMS Technologies
www.dmstech.co.uk

ABB
www.abb.co.uk
Bosch Rexroth
www.boschrexroth.co.uk
Lenze Ltd
www.lenze.co.uk

Chell Instruments
www.chell.co.uk

BEARINGS
IEC Ltd
www.iecltd.co.uk

BLIND FASTENING TOOLS

Gesipa Blind Riveting Systems Ltd
www.gesipa.co.uk

Anixter Ltd
www.anixtercomponents.com

OKW Enclosures Ltd

www.okw.co.uk
Rittal Ltd
www.rittal.co.uk
Rolec Enclosures
www.rolec-enclosures.co.uk

Axair Fans UK Ltd

www.axair-fans.co.uk
FASTENERS

COUPLINGS
JBJ Techniques Ltd
www.jbj.co.uk

CUSTOM BATTERY PACKS

Cell Pack Solutions
www.cellpacksolutions.com
Creasefield Ltd
www.creasefield.co.uk

42 dpaonthenet.net

Oriental Motor
www.oriental-motor.co.uk

ENCLOSURES

FAN BLOWERS & AIR KNIVES

CABLE ACCESSORIES & PLASTIC FASTENERS

LINEAR MOTION

MOTORS & GENERATORS

ABB
www.abb.co.uk
MINIATURE MOTORS & GEARBOXES
Mfa/Como Drills
www.mfacomodrills.com

SENSORS & TRANSDUCERS

Keller UK Ltd
www.keller-pressure.co.uk
SPRINGS
Goss Springs
www.goss-springs.com
Simpson Springs & pressings Ltd
www.simpsonsprings.co.uk
Associated Spring
www.assocspring.co.uk
TEST CHAMBERS
TeslaTest Systems Ltd
www.teslatest.co.uk

PLASTICS & RUBBER MOULDINGS

THREAD FASTENERS

Applications Engineering Ltd

www.appeng.co.uk
Rutland Plastics Ltd
www.rutlandplastics.co.uk

Tappex Thread Inserts Ltd

www.tappex.co.uk
TORQUE LIMITERS

Alcoa Fastening Systems

www.afshuck.net
BigHead Bonding Fasteners Ltd
www.bighead.co.uk
TFC Plc
www.tfcplc.com

PROCESS LEVEL &

PRESSURE INSTRUMENTS

GRIPPING SYSTEMS & ROBOT ACCESSORIES

SEALS - PTFE

VACCUM PUMPS

Schunk Intec Ltd

www.gb.schunk.com

Moontown Ltd
www.moontown.co.uk

KNF Neuberger UK LTD

www.knf.co.uk

Howdon Power Transmission Ltd

www.howdon.com
TRANSMISSIONS

Vega Controls
www.vegauk.net

Mayr Transmissions
www.mayr.co.uk

A passion for

Quality

Visionary
ifm electronic now has an extensive range of sensors to
solve machine vision applications. The O3D is the first
industrial 3D sensor that can detect objects in three
dimensions at a glance; the O2D dualis object recognition
sensor is perfect for orientation-independent contour
verification and the O2V object identification sensor or
pixel counter allows checking of presence, size, position
or completeness of objects.
All units are simple to set up and combine sensor,
processing and lighting in one robust industrial housing.

ifm electronic close to you!

www.ifm.com / uk/vision

 THE PLUS FOR ADDED FLEXIBILITY

The next generation
The innovative multi-protocol fieldbus system from Murrelektronik,
which has radically simplified and modernized decentralized
installation has taken a step further with a plus.
The single bus node can support up to 20 I/O modules
in a 30m circumference and with a reduced number
of cables. The range of I/O modules continues to
grow and includes digital and analogue ports,
safe outputs, logic, counter, valve island,
temperature, I/O link etc. Both IP67 or IP20
are available.
Cube67+ : a truly flexible system.
t
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PQUJPOT

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EJTUBODF

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Cube67 the modular bus system

Murrelektronik Ltd
5 Albion St, Pendlebury Ind.Estate,
Swinton, Manchester, GB
M27 4FG

Phone 0161 728 3133

www.murrelektronik.co.uk
sales@murrelektronik.co.uk