From filters and electronic systems to the most powerful electric motors. Parker helps its customers to improve operational efficiency for every off-road machine, enabling engineering breakthroughs that lead to a better tomorrow. VOL 24 NO 2 • SECOND QUARTER 2022 From filters and electronic systems to the most powerful electric motors. Parker helps its customers to improve operational efficiency for every off-road machine, enabling engineering breakthroughs that lead to a better tomorrow. parker.com/za From filters and electronic systems to the most powerful electric motors. Parker helps its customers to improve operational efficiency for every off-road machine, enabling engineering breakthroughs that lead to a better tomorrow. parker.com/za
www.motioncontrol.co.za Second Quarter 2022 1 SAFPA news News & events New technology Product news OUR COVER 7 SECOND QUARTER 2022 03 04 06 32 REGULARS FEATURES 08 Portescap, Festo, SEW-EURODRIVE, BMG, NSK South Africa, Bearings International, Parker Hannifin SA 15 Gates, Hydrasales, Parker Hannifin SA, Axiom Hydraulics 19 Bosch Rexroth South Africa Beckhoff Automation, Siemens South Africa 24 28 SICK Automation Southern Africa, Instrotech, Turck Banner Yaskawa Southern Africa, Omron Electronics 26 30 Drives Hydraulics Marine Food & beverage Pneumatics Sensors & encoders Robotics In today’s mining industry there are many challenges that have never been seen before. Mines must be agile and have the vision to maintain sustainability, safety and reliability at profitable levels. Harnessing the complex data from a connected mine’s equipment is key to maximising uptime. Parker Hannifin’s Mobile IoT makes it easy to identify usage trends and field-based problems with unparalleled design and operational insight. Read our cover story on page 7 to find out how the Parker Tracking System offers a better asset management approach by speeding up the product ordering and replacement process in response to market concerns over product availability. From filters and electronic systems to the most powerful electric motors. Parker helps its customers to improve operational efficiency for every off-road machine, enabling engineering breakthroughs that lead to a better tomorrow. parker.com/za VOL 24 NO 2 • SECOND QUARTER 2022 From filters and electronic systems to the most powerful electric motors. Parker helps its customers to improve operational efficiency for every off-road machine, enabling engineering breakthroughs that lead to a better tomorrow. parker.com/za From filters and electronic systems to the most powerful electric motors. Parker helps its customers to improve operational efficiency for every off-road machine, enabling engineering breakthroughs that lead to a better tomorrow. parker.com/za SMC Corporation South Africa, Artic Driers International, Emerson Automation
2 Second Quarter 2022 www.motioncontrol.co.za welcomeSECOND QUARTER 2022 EDITOR Kim Roberts MSc Chem [email protected] ADVERTISING Sales manager Jane van der Spuy [email protected] Tel: +27 83 234 5412 DESIGN AND LAYOUT Technews production department SUBSCRIPTION SERVICES For address changes, subscriptions, renewal status or missing issues, call +27 11 543 5800 [email protected] or write to: Technews Publishing (Pty) Ltd, Box 385, Pinegowrie 2123 SUBSCRIBE ONLINE www.technews.co.za PUBLISHERS Technews Publishing (Pty) Ltd, Box 385, Pinegowrie 2123 LETTERS TO THE EDITOR Letters to the editor should be addressed to Kim Roberts at [email protected]. Sending material to this publication will be considered automatic permission to use in full or in part in our Letters column. Be sure to include your name, e-mail address, city and zip code. We reserve the right to edit all letters. All rights reserved. No part of this publication may be reproduced, adapted, stored in a retrieval system or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of Technews Publishing (Pty) Ltd, Reg No. 2005/034598/07 Disclaimer While every effort has been made to ensure the accuracy of the information contained herein, the publisher and its agents cannot be held responsible for any errors contained, or any loss incurred as a result. Articles published do not necessarily reflect the views of the publishers. The editor reserves the right to alter or cut copy. Articles submitted are deemed to have been cleared for publication. Advertisements, inserts and company contact details are printed as provided by the advertiser. Technews Publishing (Pty) Ltd cannot be held responsible for the accuracy or veracity of supplied material. Making sense of the metaverse It wasn’t so long ago that nobody had heard of IIoT. Then the hype began and now it’s an integral part of the manufacturing environment. Recently I’ve been hearing more and more about the metaverse and how it is poised to become the successor to the web. I am wondering whether this is a flash in the pan, or the beginning of a dystopian future like in the sci-fi novel Snow Crash, or the opening of a whole new world of opportunity. I decided to investigate further. The concept of the metaverse is that you can strap on a VR headset and enter a virtual world in parallel to your normal world. You would be able to create a digital representation of yourself called an avatar – I am thinking like an extension of your Facebook profile − which can interact with other people’s avatars. People can shop, play, learn, go on a date, travel, go to a concert, do business (no more Zoom meetings in your pyjamas), exercise and just about anything you can think of. It merges the physical and virtual worlds. Basically it’s the internet in 3D and the predictions are that it will change how we learn, earn our living and connect to each another, just like the 2D internet did in 1995. It will give you the feeling of being present without actually being there. We will not just be on the internet but inside it. Nowadays we access the internet through our phones, tablets and laptops. We browse the web but we are not immersed in it. The metaverse will combine mobile devices, VR headsets and next generation 5G networks to create a “continuous immersive experience”. According to Bloomberg Intelligence, its value is expected to reach $800 billion by the middle 2020s, climbing to $2,5 trillion by 2030. There’s also an industrial metaverse developing quietly behind the scenes and it has the potential to be the next big revolution in manufacturing. IIoT gathers data and stores it in the cloud. If this is combined with the 3D world of gaming technology and VR you can superimpose it on the physical factory world rather than just enhancing it like with AR and VR. Everything we now have in IIoT could be in a VR world. The race is on to become the first company to create a metaverse, with Facebook (now Meta) and Microsoft at the front. Other top manufacturers are getting in on the bandwagon. Boeing plans to build its next plane in the metaverse before doing it for real. Using digital twins, it will sort out design problems before production. Boeing says that when the quality “In two to three years, most business meetings will be held in the metaverse with digital avatars: Bill Gates” of the input materials is better, when building the airplane goes more smoothly, when you minimise the reworking, then the financial performance will follow. BMW has created a digital twin of its Regensburg production plant and ran a full production cycle in a virtual factory, testing changes without stopping production. It says the method is revolutionising its planning processes and is empowering way more people to design, invent and produce. AB InBev has created a full digital model of its breweries and supply chain. Hyundai is building a new road map and platform for a meta-factory that can be tested in the metaverse. Meanwhile Meta is building a haptic glove to enable you to ‘touch’ objects. It will give the wearer sensations like pressure, texture and vibration to give the impression of feeling a virtual object with your hands. It uses hundreds of tiny actuators to trick the wearer into thinking they’re touching something. To get thousands of these forces in different locations at different distances you need pneumatics, hydraulics or high density electroactive actuators. The Meta team is now looking into using electrical fields, pneumatic actuators and wireless connectivity to make you think your hand is feeling something. All the benefits of IIoT that we hear about will be enhanced many times over. It looks like we are in for a ‘factory of the future’ on another level. I love new technology and this is all very exciting. But at the end of the day I think I would far rather look out of my door at a sunset over a real mountain than take a virtual trip to the Himalayas.
www.motioncontrol.co.za Second Quarter 2022 3 From the President’s desk SAFPA NEWS SAFPA President, Michael Abbot. With the middle of the year fast approaching it’s pretty much business as usual as Covid is taking a back seat for now, although increasing infection rates are of concern. SAFPA’s online technical talks are kicking off again after the Easter break, The first one on filtration will be presented by Walter Heijboer from Hydac on 19 May at 10 and the second will be a discussion on seals in June (date and time to be advised). Education is high on the SAFPA council’s priority list and we have engaged with the Academic Institute of Excellence (AIE), a training body in Midrand. AIE is an accredited training provider looking at assisting SAFPA to create a recognised training course for learners wanting to enter the Fluid Power industry. Step one: An open day will be held at AIE. Originally planned for 12 May, it has now been postponed as a result of Covid. This open day is intended to introduce SAFPA to the learners and show the learners the size and diversity of the Fluid Power industry. It is believed that the Fluid Power industry is relatively unknown to most school-leaving students, and awareness of our industry is sorely needed. This open day will be extended to all SAFPA members, giving them the opportunity to exhibit on a small stand and essentially have a ‘show and tell’ for any interested students. Step two: AIE will create a specific course from existing course material. This course could then be marketed as ‘Hydraulic Technician’. Step three: AIE will get the course accredited with the likes of SAQA and ECSA. In order for this course to work successfully, it will require the full support of the SAFPA members, as onsite training will be required for these learners to become qualified. Social events Due to the adverse weather conditions that have plagued us thus far this year, the cycle race date has not been confirmed. Now that winter is approaching, the weather will be more favourable, with the early afternoons too cold, and a new date will be sent out shortly. Council members are also working on dates for a golf day and a soccer day. Again, these dates will be released as soon as more information is available. Regards, Michael Abbot. SAFPA will exhibit at career open day SAFPA will be organising an exhibition at a career open day organised by the Academic Institute of Excellence (AIE) in Midrand. Originally planned for the 12 of May, it has now been postponed due to Covid. Realising that training institutions and students are generally not aware of how large the fluid power industry is, and the wide range of industries that its spans, SAFPA’s goal is to make current and potential students aware not only of the industry, but also of individual companies that are looking for learners with both academic and practical backgrounds. According to Gerhard Scholtz, head of the School of Engineering at AIE, the purpose of the open day is to show students what industry can offer and bridge the gap between the academic world on one side and industry on the other. AIE’s aim is to get as many industry partners as possible to talk to the students and tell them about opportunities, such as apprenticeships, that are available. For more information contact Cynthia Badenhorst, VdW, +27 11 061 5000, [email protected], www.vdw.co.za
4 Second Quarter 2022 www.motioncontrol.co.za NEWS & EVENTS Panasonic Industry has announced the Gold sponsorship of ETH Zurich’s RoboticWeeding System (Rowesys) project and will assist the student teamwith engineering know-how, as well as components and products from its portfolio. With a vision of combining robotics and agriculture to develop an autonomous smart farming solution, it took the students of the Rowesys team only ten months to build the prototype. The goal is to use the robot as a mechanical weed control device and drastically reduce the use of herbicides, resulting in a more sustainable farming method. “Innovative solutions for a sustainable future are engrained into the Panasonics philosophy of contributing to society. The idea and commitment of the students convinced us to support these young talents,” says Daniel Prohart, global brand manager, Panasonic. Cameras underneath the battery-powered and GPS-guided vehicle scan the field and the crops, allowing it to navigate through the rows and identify weeds. Thanks to small ploughs mounted on the back of the robot, the roots of the weeds are pulled from the soil and thereafter dry out. As a result, the farmer can reduce the use of herbicides, which is beneficial for the crop and the soil. Innovation for sustainable agriculture The new head office and warehouse for Fuchs Lubricants South Africa is on track to be completed this month. The company is investing over R250 million in the expansion at its existing location in Isando, Johannesburg in the wake of rapid growth in sub-Saharan Africa. The Phase 1 New head office and warehouse for Fuchs Lubricants Bosch Rexroth Africa Development has appointed a Tanzanian company as its in-country distributor. Transec is a general mining equipment supplier with an established countrywide presence. In line with the distributor agreement, Transec will have access to the full range of components and services offered by the Bosch Rexroth South Africa Group of companies, for the benefit of the mining, cement and sugar industries. “Transec will be a good ambassador for our product range and our brand in the Tanzanian market,”explains Louis Potter, business development manager for Bosch Rexroth Africa Development. The company is a specialist in the provision of mining supplies and services. This includes maintenance labour, fire suppression installation, conveyor belt sales and maintenance, process pump and valves supply, as well as the Bosch Rexroth Africa Development appoints Tanzanian distributor “New ideas, innovative solutions and a goal to increase sustainability – these three pillars are the core values of Panasonic Industry and the Rowesys team. We are very happy to engage in this partnership and are looking forward to working with the students of ETH Zurich,” concludes Panasonic Industry division head, Alexander Schultz-Storz. For more information contact Moritz Cehak, Panasonic Industry, +49 89 45354 1228, [email protected], www.industry.panasonic.eu supply of large mobile machine components, undercarriages, pumps, hose and fittings, final drives, gearboxes and machine tracks. “Transec has good relationships with the major mining companies in Tanzania, and holds established maintenance contracts with some of the largest gold mines, with permanent presence on site. In addition, Transec has positioned itself to be the preferred supplier of mobile equipment spare parts to some of the larger mines in the Lake Zone region,” adds Potter. Transec employs well-qualified personnel who have completed extensive product training. They will be empowered with further training and skills development to enable them to provide exceptional aftersales service and assist in technical installation and commissioning services. For more information contact Gillian Allin, Bosch Rexroth South Africa, +27 11 979 4630, [email protected], www.boschrexroth.africa expansion, which consists of the office complex and new warehouse, commenced in June 2020. While Phase 2 is still in concept development, it is planned to comprise a new lubricants plant to bolster the company’s strong growth and expansion plans for the continent. The warehouse itself will incorporate the latest technology, including all product being wrapped, with 100% selectivity and batch control introduced. The latest materials handling equipment will also be implemented, such as narrow-aisle lift trucks stacking to 17 m high. The warehouse system itself will be based on a fully integrated barcoding system using SAP. In addition, the fire protection system is being designed to the latest international best practice. Looking to the future MD, Paul Deppe is confident that the new head office with its visibility will be testament to Fuchs’ strong growth prospects on the continent. “We have a lot of confidence and are growing market share. This makes our expansion such an important step forward, and will consolidate our South African operation as the regional hub for subSaharan Africa,”he concludes. For more information contact Kayla Van Vught, Fuchs Lubricants South Africa, +27 11 565 9738, [email protected], www.fuchs.com/za
www.motioncontrol.co.za Second Quarter 2022 5 NEWS & EVENTS Cummins has a world-class customer service and support network to better serve its global customer base, including 21 Master Rebuild Centres (MRCs). In support of the Africa and Middle East region, the Johannesburg MRC is a trusted partner for the mining industry and can rebuild any high-horsepower engine for applications from marine to mining, power generation and construction. The MRCs provide the latest cutting-edge technology to meet industry needs, including dynamometer testing to full power for some of Cummins’ largest engines, and rebuilds ranging from 19 to 95 litres. Apart from the wide engine size range, the main advantage for customers is zero-hour rebuilds and a strip-and-quote service. Cummins rebuild centres Bosch Rexroth South Africa has participated in local government’s 2021 Youth Employment Service (YES) Programme, which took place from 1 March 2021 to 28 February 2022. This experiential learning programme is a joint venture between government and the private sector, with the aim of creating one million work opportunities for unemployed youth. Through this programme, Bosch Rexroth SA empowered 17 learners between the ages of 18 to 25 with workplace experience and workplace readiness skills by putting them to work in various departments across the group over YES to youth employment Bosch Rexroth South Africa has appointed Jacobus Claassens as country manager, Bosch Rexroth Ghana. Appointments Tectra Automation has appointed Paul Springorum as general manager. Tectra Automation has appointed Cobus Snyman as operations manager. Bosch Rexroth South Africa has appointed Petrus Viljoen as manager of Bosch Rexroth Africa Development. Hytec Engineering has appointed Jannie Swanepoel as sales manager. Added value features of a Cummins rebuild include: • ISO 9001 quality certification, with a common global process to resolve quality issues. • ISO 14001 and OHSAS 18001 safety and environmental certification. • Maximising customer uptime with a swing engine programme. • Rebuild warranty coverage. • Lean manufacturing process. • Use of genuine new and recon parts. • All engines are 100% dynamometer tested, including mini-patch lube oil sampling test, and in accordance with high-horsepower engine testing standards. • Assembled to Cummins global manufacturing standards. • High-quality paint finish to meet customers’ colour and quality standards. For more information contact Sbu Gule, Cummins Africa Middle East, +27 11 451 3400, [email protected], www.cummins.com a 12 month period. Participants learned about the roles that the various departments fulfil, as well as the functions performed by employees. In March this year, the group proudly celebrated the graduation of 16 learners from the programme. Nine of these leaners have been offered employment at Bosch Rexroth South Africa − in positions ranging from contractual employment (apprenticeships and limited duration contracts) to permanent employment. “We believe this is a worthy initiative that offers learners valuable experience which they can add to their CV once they have graduated, making themmore sought after in a competitive job market. We are proud to have enriched these learners with various skills, especially workplace readiness, which will enable them to easily adjust to future workplace environments, empowered with effective communication skills,” says CEO, Chris Riley. The success of the 2021 programme has prompted the group to commit to the 2022 programme, but with a more ambitious goal of doubling its current enrollment to 34 learners. For more information contact Gillian Allin, Bosch Rexroth South Africa, +27 11 979 4630, [email protected], www.boschrexroth.africa
6 Second Quarter 2022 www.motioncontrol.co.za NEW TECHNOLOGY Hydraulic components are traditionally manufactured through machining or casting. Now hydraulic equipment manufacturers are producing manifolds, servo valves and hydraulic adapter blocks using 3D printing. This is bringing in a new generation of hydraulic systems going beyond the limits of today’s hydraulic components. 3D printing builds up layers of material to create a three-dimensional object. Direct metal laser sintering is typically used for hydraulics. A laser traces a micron-thin cross-section of a part, selectively melting and fusing a metal powder layer by layer. This allows control of the amount of material that goes into the part. Previously, hydraulics was outside the scope of 3D printing due to the limited materials available; but developments in powder bed processes have been a game-changer, enabling manufacturers to rethink the design of hydraulic components. New applications requiring higher load and pressure handling capabilities are now possible. Products can be printed in materials such as stainless steel, aluminum, titanium or platinum. Parts can now be made lighter and smaller. Current manufacturing is a subtractive process, where material is machined from a block of metal to get the required shape. Removing excess metal is expensive and often the excess is not removed, resulting in a part that weighs 3D printing for hydraulics more than necessary. 3D printing builds the part layer by layer so there is no extra material and the part is lighter. Printed parts weigh 50 to 75% less than conventional parts. 3D printing also makes components more compact by integrating many parts into one. This eliminates complex assemblies of components, and improves the structural integrity since there are fewer weak joining points that can cause leaks. They also fit better into small spaces. These advantages make 3D-printed hydraulic components sought after in applications that require high precision and light weight. It also offers new opportunities for hydraulic valves and makes more complex internal geometry possible that optimises for higher fluid flow and reduced pressure drop in a smaller space. Engineers can place internal flow channels exactly where needed in a variety of shapes and sizes, and configurations that are impossible using conventional manufacturing techniques can be achieved. This means flow channels can be curved, and spaced closer together than with conventional manifolds. Curved flow paths can improve flow efficiency by 30 to 70%. Redesigning the shape of the cross-section of the flow channel in valve spools also makes a difference, increasing flow capacity by up to 20% and reducing pressure drop. Traditional manifolds often require auxiliary holes drilled to connect internal passageways and these need to be plugged to prevent cross-channel flow and oil leakage. This creates potential leak paths that can cause system failure, while sharp corner connection points generate turbulent flow, resulting in energy inefficiencies. Unused horizontal channels can accumulate dirt, lowering the operational life of the hydraulic system. 3D printing removes the need to create cross-drilled passages. 3D printing lets Italian manufacturer, Aidro produce fast prototypes, spare parts and functional products that reduce size and weight by 75%. It is being used to make high-pressure manifolds, valve blocks, heat exchangers, hydraulic spools and many other components. GKN Additive has 3D printed a hydraulic adapter block linking valves, pumps and actuators. The weight of the hydraulic block was reduced from 30 to 5,5 kg, without sacrificing any of the functionality. Liebherr Aerospace redesigned a highpressure spoiler actuator valve block used in aircraft to make it lighter and more efficient by integrating ten functional elements, eliminating the complex system of pipework. The titanium valve block provides primary flight control functions on the Airbus A380 and was successfully put through a test flight. It has the same performance as the existing valve block but is 35% lighter and has fewer parts. The manufacturing process is less complex and extremely material-efficient compared to the traditional milling process. UK-based hydraulic systems manufacturer, Domin has redeveloped its high-performance direct drive servo valves using 3D printing. Domin says this gives it the ability to build complex parts, faster and free of tooling. For example, one of its drives is 25% of its original size and 25% more powerful. The part was produced for a third of the cost, and the manufacturing time reduced from 5,5 hours to one hour. There is huge untapped potential in both the application of 3D printing to hydraulic equipment and the opportunities for mass customisation. While it is not suited for every application, acceptance is growing. For now it ideal for low-volume applications such as parts for prototyping and small series in special machinery; but printing machines are getting bigger and faster, and it is set to become a viable alternative to traditional manufacturing. By Kim Roberts.
www.motioncontrol.co.za Second Quarter 2022 7 Various technologies, ideas and approaches are being reviewed by mine operators. In today’s mining industry there are many challenges that have never been seen before, and it seems that suppliers, academics and big mining companies are increasingly working together to rethink innovative business models and technologies. Mining operations must identify creative ways to handle the increased demand for minerals and resources as global economies become even more reliant on mineral sales. As a result, mine operators must dig deeper into the earth to accommodate the growing demand. Not only must productivity and output be increased, but also environmental standards must be met. This requires smarter interaction between humans and machines, with increased connectivity. Today’s mines must be agile and have the vision to maintain sustainability, safety and reliability at profitable levels. “Harnessing the complex data from a connected mine’s equipment is key to maximising uptime. Parker’s Mobile IoT makes it easy to identify usage trends and field-based problems with unparalleled intellectual design and operational insight,” said Kyle Cambridge, sales leader – Motion Systems Group, Parker Hannifin South Africa. Increasing automation and electrification in mining is driven by green initiatives for reduced emissions as well as a desire for increased safety and productivity. Mining types tend to require different motivations. Underground mining, for example, has continued to electrify as a result of health regulations and cost savings in ventilation systems. In contrast, the surface mining sector is influenced more by corporate carbon neutral programmes. Whatever the motivation, many industry experts believe that automation and digital solutions will work Impact of innovative technologies on the mining industry alongside electrification to monitor energy usage and help miners reach their sustainability targets while also improving the quality of the working environment. Many mines have digitised their operations, effectively embracing digital transformation by adding equipment sensors and adopting unified networks to transmit data, but it seems the industry still has progress to make. According to BCG’s Digital Acceleration Index (DAI), the metals and mining industry is roughly 30-40% less digitally mature than comparable industries such as automotive or chemicals. Mining companies can increase productivity, adapt to a challenging labour market, manage assets more effectively and minimise their environmental footprint by accelerating digital transformation. Many mines are already engaged in the electrification journey. This is particularly the case for underground mines, where tethered or battery-powered load-haul-dump (LHD) vehicles are common. They significantly reduce ventilation costs while also reducing greenhouse gases. Other benefits include reduced maintenance costs, with battery vehicles having 25% or so fewer parts compared with diesel propulsion systems, and less noise, vibration and heat. In surface mining, the use of electricpowered mining trucks has historically focused on the use of trolley-assist trucks, which are diesel-electric drive haul trucks that receive the power to run the wheel motors from catenary/ overhead electric wire lines constructed on specified routes. Converting to electric drives on these vehicles is the most promising option. In a poll conducted by Mining-Technology.com, between March and May 2021, 30% of the 496 respondents felt that the use of batterypowered vehicles would have the greatest impact on reducing emissions frommining operations over the next five years. This compared with 16% expecting the greatest impact to come from hydrogen-powered vehicles and 21% from use of on-site renewable energy. Miners typically face risks ranging from flying debris, to a full mine collapse to vehicular incidents. Oversized equipment and lack of visibility could cause bodily harm to miners. Plus, there are ongoing air movement/ventilation issues. In underground mining, methane is one of the biggest safety concerns, as even a small spark could cause a catastrophic explosion. Advances in technology and the introduction of strict safety regulations by MSHA have resulted in a reduction of workplace incidents in recent years. Maintaining adequate inventory is critical for any product-intensive industry. In the context of mining, ease of ordering, and advance stock arrangements are crucial considering the high-risk environment. Yet, predicting the need for safety stock is the biggest challenge that mining operations face today. The onus then falls on the procurement teams to deep dive into identifying the future requirements of commonly used materials and also analysing the historical stock consumption trend to maintain adequate stock levels and manage advance orders accordingly. If supply chain predictions are not accurate, products need to be obtained locally in an efficient manner. Parker developed the Parker Tracking System (PTS) in response to market concerns over product availability. PTS offers a better asset management approach by speeding up the product ordering and replacement process. For more information contact Lisa de Beer, Parker Hannifin SA, +27 11 961 0700, [email protected], www.parker.com/za
8 Second Quarter 2022 www.motioncontrol.co.za Mini motor applications utilise DC motor technology because of compactness, low weight, and reliability. Stopping, slowing or holding the position and load of these motors is crucial for many applications, from controlling robotic joints through to automated window shades. This control is achieved by integrating an electromagnetic brake, accurately specified according to the application requirements and parameters of the DC mini motor. Louis Mongin, BLDC product strategic manager at Portescap, explains the technology behind electromagnetic brakes for DC mini motors. In miniature DC motor applications, electromagnetic brakes are used to hold, stop or slow down a load. Without a brake, a motor would continue to rotate without control, even after cutting its supply of voltage or current; or it would fail to hold position against a competing power. While alternative torque control devices could be used, electromagnetic brakes can combine precision with a compact, reliable, energy-efficient and cost-effective design. To hold a DC mini motor in position at a specific stopping point across a variety of industrial and medical applications, the general design includes a fixed field coil that acts as an electromagnet to generate torque to brake or hold the load. The coil’s electromagnetism controls an armature that either engages or disengages with a structure. The design of the brake mechanism features a hollow shaft mounted onto the shaft of the DC motor, which gives compact integration. Brakes are available in a power-on design, which means that the brake is only engaged when current flows in the field coil. This is acceptable when the brake doesn’t have to Electromagnetic brakes for DC motors hold a high load, or if holding torque isn’t required after power-off. Alternatively, with a power-off brake, the brake remains engaged at all times unless current is flowing in the electromagnet, which creates an inherently safer design for some applications. Spring-set brakes utilise power-off braking and are used to automatically stop and hold a load in the event of a power failure or emergency stop situation. In this design, braking force is applied through a compression spring, and the brake is usually released by manual control. The advantages include repeated braking cycles from full motor speed with no torque fade, and the designs can be customised in aspects such as voltage rating and dynamic friction material according to the spring force requirement. The disadvantage of a spring brake is that it can present backlash, affecting the precision it can offer for dynamic braking or position holding. Instead, for applications where dynamic stopping and holding a moving load is required, as well as for high cycle rate stopping, a permanent magnet power-off brake should be used. In this design, brakes are engaged magnetically and disengaged electrically, providing safe load holding in power shutoff. When voltage or current is applied to the brake, the coil becomes an electromagnet and produces magnetic lines of flux counteracting those of the permanent magnet. This action releases the armature, creating an air gap and allowing the load shaft to rotate. Increasing voltage or current also enables braking force to be controlled with precision, as opposed to the spring brake’s on/off functionality. As the permanent magnet brake design includes no moving parts, the brakes can operate at very high speeds. Unlike spring brakes, they don’t allow backlash, because the design includes a fixed connection between the armature, spring and hub. This allows them to be controlled with precision. As heat is generated during dynamic braking, this means that the brake must be correctly sized to deal with friction, load and torque requirements. Permanent magnet brakes require consistent and specific current, meaning that these brake designs should be carefully considered before using them in conditions that could cause current fluctuations, such as high or changing temperatures. Thanks to the precision control of a permanent magnet brake, they are well suited to use in robotic arm joints. Their zero-backlash capability means they can precisely hold torque and also provide dynamic stopping. An example of a DC mini motor application that requires safety in holding torque is the control of automated window shades. Providing automatic operation, the power-off brake also allows the motor to hold the shade position when power is removed. Portescap’s engineers regularly integrate DC mini motor braking solutions into bespoke OEM applications. The team ensures exacting sizing and specification, as well as recommending the most effective technology and features for specific requirements. Design is combined with rapid prototyping and testing to ensure safety and precision, before moving the development to volume production. For more information contact Nicole Monaco, Portescap, +1 404 877 2534, [email protected], www.portescap.com
www.motioncontrol.co.za Second Quarter 2022 9 Festo South Africa is taking its customers on a journey to higher productivity from Process, to Electric to Pneumatic Automation. Its recently launched campaign “heart of absolute Automation 2.0”, that focuses on its Process Automation solutions, pilots its journey. Through this campaign, Festo will meet the industry’s growing demand for increased productivity, reduced manual tasks and simplified production. The first leg of the campaign creates an analogy between the human heart and its Process Automation solutions. The heart is at the centre of the vascular system, which is a network of blood vessels that deliver nutrient-rich blood to the brain, lungs and every part of the human body. In industry, the heart can be equated to a pump in a company’s plant, as it ensures the adequate distribution of fluids, solids and powdery media in machines. Sturdy and reliable enablers of flow In every Process Automation application, pressure, temperature and flow are required to be precisely regulated, as with the human body’s vascular system. Festo offers actuators that are suitable for controlling the flow of media and regulating ball valves, air dampers as well as butterfly valves. These actuators are tailored specifically to meet the process Festo Process Automation solutions for all production levels industry’s requirements in terms of force, corrosion resistance and standardised interfaces. They conform to the standard ISO 5211, which defines the interface between the quarter-turn actuator, process valve and NAMUR VDI/VDE 3845. Their actuator’s sturdy, corrosion-resistant design is ideal for use in harsh and explosive ambient conditions. They are also suitable for water/ wastewater, beverage, pharmaceutical and general Process Automation applications. Valves that keep media moving The human body consists of valves that ensure that blood and oxygen are flowing in the right direction. Festo valves such as the Angle Seat Valve VZXA, and Pinch Valve VZQA, ensure the smooth flow of media in the plant, as in the human body. Furthermore, these valves determine the dynamic response and withstand high dynamic forces. The valves are sturdy, durable and reliable, just like healthy valves in anatomy. Festo has always been committed to a high standard of quality valves. The company supplies valves with up to 100 million switching cycles. These valves can be used in all industry segments, typically the food and packaging industry, automotive and electronics, amongst others. DRIVES Configurator tools to create your flow The Festo configurator tool for process valves makes selecting the right solution easy and less time-consuming. A task that used to take a few hours now takes minutes to complete. This configurator tool has made finding, selecting, sizing and ordering the perfect Ball Valve Unit KVZB or Butterfly Valve Unit KVZA simple, with just a few clicks. These valve units control the fluids across a wide range of temperatures and pressures. In the human body, they can be compared to arteries that ensure that healthy blood is distributed to the body tissues. The company aims to propel its Process Automation customers to thrive, even during unpredictable periods. It continually analyses the value creation chain and communicates with its customers to understand their needs. This is why its Process Automation campaign products cater for all the individual levels of the automation pyramid, from the operating level to the field level. Festo solutions ensure that customers never miss a beat through reduced downtime and increased efficiency. For more information contact Festo South Africa, 0860 033 786, [email protected], www.festo.co.za
10 Second Quarter 2022 www.motioncontrol.co.za “To cater for our growing customer base in markets across Africa, it has become necessary to increase local production capacities. Our new SEW-EURODRIVE building in Aeroton, Johannesburg, which will house our head office as well as assembly, warehousing and repair facilities, is now complete and we are currently in the final stages of laying out the assembly lines for geared motors and industrial gearboxes,” says national operations manager, Greg Perry. Geared motors, industrial gears (IGs), VSDs, AGVs and servo motors will all be assembled in the new factory, with space to also conduct repairs. The assembly lines for geared motors are designed for 7000 units per month, and the company is planning to build up to 100 IG units per month, doubling its current capacity. New spray booths and automated oil filling stations are being installed to cater for these volumes. All local assembly of gearboxes, VSDs and servo motors is conducted in accordance with the company’s global quality standards, and SEW South Africa is already certified by Germany’s quality department, as well as having ISO 9001 quality certification. The standardised assembly and logistics processes are now incorporated into its SAP system, which will give better traceability and visibility of all orders as they move through the assembly processes. “We are starting to design the assembly flows for our X.e range, and we will be adding additional industrial gearboxes ranges as time goes by. Initially, we will be assembling the Generation X.e Series in sizes from 120 to size 250, in nominal torque classes from 12,8 to 175 kNm,” Perry says. The latest generation industrial gear units in the X.e series have been designed with a Gear units assembled in Johannesburg The advantages of Generation X.e industrial gear units and the benefits of assembling these units locally. host of new improvements to be more robust, reliable, efficient and easier to maintain. This modular series is designed to be custom-built, based on the exact needs specified by clients, most notably by significantly increasing the number of possible torque/speed combinations and fine-size graduations. A large number of additional modular features and options, such as motor adapters, backstops and various sealing and shaft systems, also add to ease of use and reliability. Key applications across Africa include: • Conveyor drives, which are often required to operate in extremely dusty and very hot or cold conditions. Due to new thermally optimised housings, along with the contactfree Taconite sealing system design, these drives offer excellent reliability under these conditions. • Hoists, which often feature the rope drum and the motor on the same side of a parallel-shaft unit. The X.e hoist series offers an optimised choice of gear unit sizes, reduced gear unit weight and sufficient centre distances. • Bucket elevators, which are required to lift bulk materials. The drive needs to be operated at low speed during maintenance. X.e series bucket elevator drives are equipped with a directly mounted auxiliary drive to perform this function while the main motor is switched off. • Agitator and aerator drives. X.e agitator gear units in the 22 to 90 kNm size range have extended bearing distances to absorb high radial and axial forces. In addition, due to their thermally optimised housings, these units can be used without external cooling, even in high-performance agitation applications. Other key improvements include: • Contactless sealing systems, which reduce shaft and seal wear. • Thermally improved oil levels, which reduce oil use, extend oil change intervals and improve the thermal performance of the units. • Optimised bearing preload, which gives users a choice between greater operating reliability in critical drive conditions or a longer bearing service life in moderate conditions. • Improved bevel pinion housing, which increases the service life of the sealing systems and improves cold starting behaviour. • Optimised tooth flank topology, to enable the operating torques and external forces to be transferred more accurately and reliably. The DriveRadar suite of condition monitoring solutions for vibration, temperature and other key parameters can be seamlessly incorporated for early detection of damage to bearings or gears, providing instant notification to equipment operators about potential problems. “We expect our delivery times to be significantly reduced. We will also be in a better than ever position to deliver complete drive systems to industry, including system components such as couplings, brakes and sensors, all of which can be pre-mounted on a baseplate, along with VSDs, soft starters, sensors and all the connectivity needed to link to a customer’s control interface,” he concludes. For more information contact Jana Klut, SEW-EURODRIVE, +27 11 248 7000, [email protected], www.sew-eurodrive.co.za C M Y CM MY CY CMY K
Speed Starter, Motion Control, 1.2 A4, May issue.pdf 1 2022/05/11 14:46:52 BMG’s NORD predictive maintenance solutions offer fast, efficient and comprehensive evaluation of analogue and digital data, to enhance the operational efficiency and safety of machines. The intelligent PLC in NORD drive technology forms the basis for condition monitoring and predictive maintenance. The NORD status-oriented maintenance system replaces traditional time-based maintenance to enhance the performance of the gear unit, electric motor and frequency inverter, for increased efficiency of the entire plant, as well as reduced downtime. Digitalisation in drive technology boosts the added value customers derive from drive data, especially in demanding production environments, where industrial gear unit installations are used in critical applications. The drives are based on intelligent algorithms and software in an IIoT environment, where networked drive units collect condition data in the inverter’s integrated PLC and pre-process it, together with data from connected sensors and actuators. An important advantage of this system is that it allows dependable data analysis, rather than merely data reading. Results of pre-processing or complete data can be transmitted to an edge device, from which the data of all subsystems is managed and evaluated. This information is then available as preselected and edited smart data for further use and clear visualisation. A common application example is the sensorless determination of the optimum oil change time, based on the oil temperature − which is the key factor for oil ageing in gear units. This information is used Drive-based predictive maintenance solutions in conjunction with gear unit and operational parameters to calculate the appropriate oil change time precisely, without the need for a temperature sensor. For more information contact Deon Crous, BMG, +27 21 493 3250, [email protected], www.bmgworld.net DRIVES
12 Second Quarter 2022 www.motioncontrol.co.za Machining centres feature ball screws with nut cooling to increase surface quality of milled parts. NSK ball screws with nut cooling are setting new standards in the precision of machine tools with mechanical drive components. Confirmation comes not only from NSK’s own testing, but from machine tests conducted with Chiron Group, a well-known manufacturer of machining centres. NSK ball screws contribute to the outstanding surface quality of milled parts produced by Chiron Group’s new CNC machining centres. The machine tool industry uses ball screws to convert the rotary motion of an electric motor into linear motion. Very often, the positioning accuracy, as well as the travel speed and acceleration, have to endure extreme demands. As a result of axial forces, acceleration and speed, the ball screw generates frictional heat. This heat can cause the length of the screw to increase due to thermal expansion and hence lead to very slight but often critical positioning inaccuracies that may impair machining quality. To help avert this outcome, many machining centres are equipped with a length scale that measures the actual position of the tool, while for those that require higher positioning accuracy it is possible to use ball screws with Ball screws with nut cooling hollow shafts. In the latter, coolant passes through the shaft to remove heat from the system. This method is quite costly, however, because rotating screws require a rotary union in addition to the hollow bore. A new approach is to cool the nut, which means there is no need for an expensive hollow bore and rotary union as cooling takes place directly at the point where the heat is generated. Another key benefit is that the heat generated in the ball screw no longer dissipates directly in the machine. This thermal decoupling between the machine and ball screw is important because any heat can impair dimensional stability. The results now prove that by cooling the nut, it is possible to increase the surface quality of machined components. NSK engineers designed the nut body so that the changes to the ball screw caused by cooling have no negative influence on its performance profile, as confirmed by endurance tests at NSK’s Technology Centre. Many years of cooperation with Chiron Group have also confirmed these results in practice. The use of NSK ball screws with cooled nuts means that machining centres of the PR 16 and 22 Series operate with exceptionally high precision, which not only applies to ease of positioning, but also to machining accuracy and surface quality. In two specific Chiron series, the ball screws are also equipped with NSK’s highly effective X1 seal, which protects the nut from contamination and retains lubricant within the nut for an extended period. Looking ahead, NSK intends to pursue its collaboration with the Chiron Group and thus continue optimising precisely targeted cooling technology for ball screws. This teamwork will enable developers to deepen their knowledge of ball screws and how they influence machine performance. The Chiron Group, headquartered in Tuttlingen, is a global company specialising in CNC vertical milling and mill-turn machining centres, as well as turnkey manufacturing solutions. The group has a global presence, with production and development sites, sales and service subsidiaries and sales agencies worldwide. Around two thirds of machines and solutions that are sold are exported. Key customer sectors are the automotive, mechanical engineering, medicine and precision engineering, aerospace industries and tool production. For more information contact Geraldene Govender, NSK South Africa, +27 11 458 3600, [email protected], www.nsk.com
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