VOL 24 NO 3 • THIRD QUARTER 2022
www.motioncontrol.co.za Third Quarter 2022 1 SAFPA news News & events New technology Product news OUR COVER 9 THIRD QUARTER 2022 03 04 10 31 REGULARS FEATURES 13 SEW-EURODRIVE, Beckhoff Automation 15 DNH Tradeserve, Stromag 17 Hydrasales, Omron Electronics, Hagglunds Drives South Africa, Hytec Fluid Technology, Axiom Hydraulics 20 Festo South Africa, Artic Driers International, CompAir, Hytec Fluid Technology 26 MC in Automotive MC in Leisure Hydraulics Drives Pneumatics ATI Systems imports, assembles and distributes precision measuring systems, specialised electrical enclosure systems and motor control and power distribution assemblies. It is also a complete drives company. Visit pages 9 and 11 to find out more about this speed and position feedback specialist’s sensors and encoders and its wide range of high quality Eldon enclosures. VOL 24 NO 3 • THIRD QUARTER 2022 BMG, Horne Technologies
2 Third Quarter 2022 www.motioncontrol.co.za welcomeTHIRD QUARTER 2022 EDITOR Kim Roberts MSc Chem [email protected] ADVERTISING Sales manager Jane van der Spuy [email protected] Tel: +27 83 234 5412 Heidi Hargreaves [email protected] Tel: +27 83 504 0436 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. I couldn’t resist watching TheWorld Industrial Reporter’s video on Ten Scientists Killed By Their Own Experiments. Some of themwould have deserved the Darwin Award for taking themselves out of the gene pool, but a couple attracted my attention because of their association with a key issue of today – alternative energy. For example, Max Vallier devoted himself to creating rocket powered trains and sleds but in 1930, desperate for a liquid-fuelled rocket, he died in his lab after a motor running on liquid oxygen exploded. Meanwhile Harry Daghlian in 1945 was working on the first atomic bomb and dropped a tungsten carbide brick onto a radioactive core. His hands began to glow and he died soon after from radiation poisoning; and Carl Scheele, who discovered oxygen, chlorine and manganese, regularly tasted toxic substances, eventually dying of mercury poisoning in 1786. Probably the best known is Marie Curie, who in 1934 died of leukaemia after exposure to radioactive materials over three decades. She would hold radiumwith her bare hands. We might laugh today, but they were all passionate about their science and made genuine contributions. Carbonless fuels Oxygen-fuelled rockets notwithstanding, there is a huge amount of research going on in the field of alternative fuels and sustainability, and dynamic new startups are springing up all over the place. The environment was highlighted as one of the key issues at Hanover Messe 2022. For example in one new development a company called Amogy has demonstrated a new ammonia-powered tractor. A 100 kW ammonia-to-power systemwas successfully integrated into a standard John Deere tractor, which can operate on liquid ammonia for several hours. Amogy sees ammonia as a viable, high density, zero-emission fuel for heavy-duty vehicles. Kinetic energy space launch Another report from theWorld Industrial Reporter describes Fifteen Emerging Technologies That Will Change The World. One of these is a kinetic energy space launch system that reduces dependency on chemically fuelled rockets. Developed by California startup SpinLaunch, and funded by Google and Airbus, the technology involves a small rocket that encloses a satellite, attached to a motor in a vacuumsealed centrifuge. This spins the rocket and hurls it into the upper atmosphere, escaping the pull of gravity before an onboard motor fires up to propel it to orbital velocity. The technology is expected to reduce the price of a space launch by a factor of 20 to under $500 000. Drowning fire with sound Deadly wildfires are another threat to the environment, and their occurrence is growing exponentially. The Killer science and alternative energy report describes another invention, the acoustic extinguisher, which uses low-frequency ultrasound to push oxygen away from the source of a flame and spread it over a larger surface area. This breaks the combustion triangle of heat, fuel and oxygen − the three elements needed for a fire to burn − and eliminates the need for large quantities of water and polluting chemicals. Hydrogen is the key Green hydrogen is also being promoted as the key to decarbonising energy. I have discovered that hydrogen comes in different colours, not all of it is green. Industrial processes like fertiliser production use grey hydrogen. This is produced from natural gas, which releases carbon dioxide. Green hydrogen is produced by the electrolysis of water, splitting the molecule to release hydrogen. This can be stored in tanks and transported through pipelines. When the energy is released again during combustion only water vapor is produced as exhaust gas. One caveat is that hydrogen is explosive, but the same principles that apply to the handling of natural gas can be used for hydrogen. Large companies from the oil industry and the traditional energy sector have set their sights on hydrogen. It is only a matter of time before green hydrogen can be produced on a large scale at a competitive price. Well-known truck manufacturers are developing hydrogen engines for their large vehicles, and the same is happening in shipbuilding and the aircraft industry. Germany’s first hydrogen-powered locomotives will be put into service this year. Green hydrogen is set to play a fundamental role in energy generation and the decarbonisation of industry. How to store it The next big question is how to store all this green energy, and batteries are the limiting factor. Here too there is a huge amount of innovation going on – inventions ranging from graphene-aluminium ion batteries to sand batteries to gravity batteries to lithium-metal batteries to microsupercapacitors. Some of the claims may be a bit far-fetched, but there is no shortage of ideas and projects working to improve energy storage. In the next issues of Motion Control we’ll have some more stories on these.
www.motioncontrol.co.za Third Quarter 2022 3 www.vdw.co.za +27 11 061 5000 | [email protected] From the President’s desk SAFPA NEWS SAFPA President, Michael Abbot. With the second half of the year well on its way, it appears to be business as usual. The year started off on a relatively sad note after council learnt of the passing of both Garnet Cross and Chris Arbous. A special thanks to those who wrote the eulogies for the respective gentlemen. The long-awaited Electra Mining Exhibition to be held from 5 to 9 September this year is fast approaching. I am pleased to announce after some negotiating that SAFPA will once again have a stand at the show. Counsil would like to invite each and every SAFPA member to visit the stand and hopefully bring some new faces with you. Training as always is high on the counsil priority. A Hose Safety Course was held in June with excellent feedback from all who attended the course. Further marketing material will be created to highlight the crucial nature of this course to attract more delegates. SAFPA recently held its annual golf day at the Benoni Country Club. A total of nine four-balls were booked for the day which was a little disappointing as we have seen larger fields in the past. It was a successful day as all who participated had a great time with a fantastic food selection at the end of the evening. Thanks to all who participated and assisted in the event. A survey will be sent out by the managing agent to ascertain why we had fewer participants than normal. Could it be that the event was hosted on the last day of the month? The cycle race from 2021 is still being rescheduled. Right now council is in talks with Serengeti and Modderfontien to host the event after the initial track at ERPM has been abandoned. Regards, Michael Abbot At SAFPA’s recent virtual technical meeting, Walter Heijboer from Hydac gave an in-depth presentation covering the use of filtration technologies to mitigate the ageing of oil and to protect equipment. Among the areas that he elaborated on were factors influencing the fluid condition, optimising filtration technologies, reducing energy costs, removing water from oil, air separation using filtration, properties of today’s hydraulic oils, and the removal of aged oil. Walter’s talk was very informative, and if anyone missed it and would like to find out more the link is at https://vimeo.com/726621100 SAFPA technical meeting Walter Heijboer.
4 Third Quarter 2022 www.motioncontrol.co.za NEWS & EVENTS Bosch Rexroth South Africa is committed to social investment and the advancement of all its employees, breaking down barriers to create a diverse and dynamic workplace. This upcoming Women’s Day presents a great opportunity to introduce three formidable women from its team. Louise Kleingeld, branch manager, Hytec Rustenburg Kleingeld’s career trajectory from receptionist to branch manager is defined by her tenacity. “I got very frustrated because I could not attend to the customers’ technical requirements and found the mining environment so interesting that I just had to knowmore,” she says. “Becoming branch manager and empowering 32 employees is a career highlight. While hydraulics and mining were traditionally viewed as male occupations, times have changed. I know that women look at hydraulics differently. Men and women are now seen as equals and are given the same opportunities to pursue a career in this field. Women bring something special to hydraulics. “We always want to make things look better and work more efficiently. We give attention to the finer details”. Establishing herself as an authority in the hydraulics profession did not come easily. Kleingeld describes how customers initially did not trust her. “I kept working as hard as I could until I gained their trust and respect. With the help of training courses, I learned to be assertive and to listen. This helped me gain the confidence I needed. If you have confidence in your product and in your solutions, nothing can stand in your way,” she says. “Always follow your passion, no matter what. Make a difference.” She points to Natascha Viljoen, CEO Bosch Rexroth SA celebrates women in hydraulics of Anglo Platinum, as her inspiration. “She is fierce, does not stand down for anyone, and had the passion to pursue her career.” Leyla Retief, project engineer, Hytec South Africa Retief was always drawn to mathematics and science. Mechanical engineering was the obvious field of study. “My role as a project engineer was the starting point of my hydraulics career,” she says. She is inspired by women with strong leadership skills who have managed to climb the ranks to achieve their goals, even when there was a lack of support systems for female leadership. “I think for a long time women felt intimidated by the prospect of stepping into male dominant environments. To overcome this barrier, women need to have confidence in their abilities, and a strong will to succeed in the field,” she comments. “The biggest challenge faced by women is the stigma that they need to prove themselves in these environments. I believe the best way that to overcome this is by focusing on teamwork and open communication”. While Retief is still relatively new to the field of hydraulics, she constantly seeks to learn about new applications and designs, developing her knowledge. “Anyone can make a great hydraulic specialist by paying special attention to detail and focusing on the bigger picture. If we continue to give women chances, they will excel in any field that they are passionate about,” she concludes. Michelle Bruwer, branch manager, Hytec Mogalakwena “Where I am today is my greatest professional achievement in my hydraulics career. The only way to do great work is to love what you do,” says Bruwer. She notes that misconceptions about the hydraulics industry may have played a role in making it a male-dominated sector. In addition, hydraulics careers were not deemed socially acceptable for women. “I think that this has changed over the past few years. Women are being empowered by other women, and changing mindsets about what women are capable of doing,” she says. By working hard to prove themselves, women can overcome the challenges faced when they are undermined. Bruwer believes that women make a unique contribution to hydraulics. “I think women tend to be more detail-oriented and we adapt better to change. We possess the skills to unite people, and draw together fresh opinions and creative proposals. These optimise the decision-making process. Women can introduce new methods or new approaches that have not yet been explored.” Noting that change is driven by technology, innovations, better processes, social demands and even new opportunities, Bruwer takes inspiration from Hannover Messe, and its 2022 slogan: “let’s create the industry of tomorrow”. Kleingeld, Retief and Bruwer demonstrate a commitment to professional excellence, the pursuit of partnerships and a drive to make the Bosch Rexroth South Africa Group of Companies Africa’s leading fluid power and automation company. For more information contact Gillian Allin, Bosch Rexroth South Africa, +27 11 979 4630, [email protected], www.boschrexroth.africa Leyla Retief. Louise Kleingeld. Michelle Bruwer.
www.electramining.co.za Keraysha Pillay, Senior Marketing Manager Tel: +27 (0) 10 003 3057 | Cell: +27 (0) 79 816 9122 Email: [email protected] Contact our team Organised by: YEAR S Register Online For Free Entry Electra Mining Africa Elenex Africa POWERex Transport Expo Automation Expo Why visit? knowledge from technical experts Acquire products & brands Compare from daily free seminars Learn live demos of machinery & equipment Experience with suppliers & service providers Network cutting-edge products and technologies Source with 650+ knowledgeable exhibitors Connect Connecting people since 1972 in the areas of mining, electrical, automation, manufacturing, power and transport. 5 - 9 September ExpoCentre, Nasrec, JHB, SouthAfrica 9AM - 5PM DAILY
6 Third Quarter 2022 www.motioncontrol.co.za NEWS & EVENTS When a kind stranger took a photograph of Momelezi Sifumba standing at a busy roadside with a cardboard sign stating: ‘Help Me to Find a Job’ and posted it on LinkedIn, little did the unemployed graduate know it would catch the attention of Graham Abrahams, senior vice president at ABB, who would change the course of the young man’s life. Having graduated with a BTech in Electrical Engineering in 2018, Sifumba was unable to find employment, even after knocking on the doors of many companies. “Despite the constant rejection, I still had a hunger for success, knowing all I needed was an opportunity to prove myself,”he says. It was this determination and self-belief that resulted in his decision to stand by the roadside with a placard. Abrahams comments: “Business has a responsibility to help develop our youth. Sifumba overcame many challenges ABB’s lifeline to unemployed graduate The islands of Ærø and Als in Southern Denmark are connected by Ellen, the longest ranging fully electric ferry in the world. Ellen set a new world record on 9 June 2022. On her return from a conference where participants explored how international ambition on energy efficiency can be translated into faster and stronger real world progress, Ellen sailed 92 kilometres on a single battery charge. Senior lecturer at the Denmark Naval Academy, Henrik Mikkelsen, who helped specify the technical solutions for the ferry during its design phase, was on board for the trip. “The 92 kilometre trip on a single battery charge is the longest distance for an electric ferry to carry both passengers Danfoss to apply for GuinnessWorld Record Bearings International (BI) is entering the fastgrowing realm of e-commerce by expanding its current website to provide more detailed BI launches new e-commerce platform to get his education, and ABB will ensure he has the opportunity to complete his practical experience and qualify fully as an engineer.” He is employed as a graduate apprentice in the Electrification business area. With a bright future suddenly in front of him, he says there is nothing to stop him from aspiring to a team leader or management role. One day he will be able to mentor other unemployed youth. ABB’s communications and marketing manager, Busisiwe Molefe says that this inspiring story speaks to the spirit of Nelson Mandela Day, where we are called upon to reflect on how best to effect the change we want to see around us. Since 2020, 60 graduates have been permanently employed at ABB, and 80% of the candidates from the company’s training programmes have found gainful employment. For more information contact ABB South Africa, +27 10 202 5523, [email protected], www.abb.com/za information. “The aim is to create a 24/7 access experience for our existing customers, as well as reach out to new customers, including those in remote areas,” says BI MD, Bart Schoevaerts. The e-commerce platformwas launched in May during the 2022 Nampo agricultural exhibition. Customer benefits of using the new e-commerce platform include 24/7 access to pricing, product range and stock availability. Existing customers will have the ability to trade on agreed pricing. Besides purchasing, the website will be a ‘go to’ platform for technical information, product selector tools, installation guides, maintenance advice, and a wide variety of applications to help the customer make a well-informed product selection. “It is critical that customers understand that since Covid-19 the world has changed, and new ways of interacting are critical,” says Schoevaerts. “We can see a clear trend in how efficient young engineers have become in terms of self-education and research. In many cases, the need for specific technical advice and the classic sales approach are no longer required. We now see those engineers become more independent. Availability and speed of delivery at competitive pricing are important. In the new business world, our private and work lives are more and more interwoven. We believe that companies need to find ways to interact 24/7. Our e-commerce platform is a good way to not only have information about product and price on hand, but also extras like installation, training and maintenance tips and tricks,”he concludes. For more information contact Bearings International, +27 11 899 0000, [email protected], www.bearings.co.za and vehicles anywhere on the globe. We are talking about a clear record.” Ellen does not emit carbon and operates at 24% lower cost than a new diesel ferry. She started sailing in 2019. Danfoss supplied electric Editron drivetrains and propulsion motors for the ferry. Vice president of Danfoss Editron, Kimmo Rauma said: “Ellen is an excellent example of the future for electric transport. It is cleaner, greener and more efficient than any fossil fuel competitor. Electrifying maritime transport is a clear-cut way to reduce greenhouse gas emissions; and Danfoss has the solutions to build new electric ferries and to retrofit existing ones to electrify themwith the potential to reduce carbon emissions worldwide.” Danfoss Editron plans to submit the world record to Guinness World of Records. For more information contact Amanda Chick, Danfoss South Africa, +35 79514 5470, [email protected], www.danfoss.com Bart Schoevaerts, MD, Bearings International.
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8 Third Quarter 2022 www.motioncontrol.co.za NEWS & EVENTS Several teams of third-year engineering students took to the track for the ultimate robot showdown as the highly anticipated annual TUKS Robot Race Day took place at the campus recently. Now in its ninth year, the event – which is coordinated by the University of Pretoria’s Faculty of Engineering, Built Environment and Information Technology – has grown in leaps and bounds, with more students getting involved and showcasing their innovation, programming and engineering skills. This year more than 50 teams registered to compete for the title. Professor Tania Hanekom, function head for undergraduate studies at the University of Pretoria, said that providing world-class education to its students is what the institution strives for across all departments, and the Robot Race Day is just one of the ways education is enhanced. “Our annual Robot Race Day provides a platform to stimulate TUKS campus taken over by robots! curiosity and creativity, which is crucial for the innovation and entrepreneurship that a career in engineering demands. The project guides aspiring engineers through a carefully planned process to develop a fundamental set of engineering skills, which include hardware and software design, systems integration, the ability to work and function in a team, time management, perseverance and the good old indispensable ‘engineering gut feeling’ which comes only with experience in the execution of engineering projects,” she said. The TUKS Robot Race Day offers students the opportunity to put theory into practice. Students are required to build autonomous robotic vehicles with a sensor system able to detect specific colours on the multi-coloured track, and is developed as part of their analog electronics module. The Race Day also gives them a platform to work as a team and to demonstrate innovation and technical skills in developing these robots. One of the many teams with their robot ready to take on the track. Professor Hanekom added that the educational objectives of the Robot Race Day were strongly supported by the university’s partnerships with industry, which provide the necessary resources to maintain this flagship event. “On behalf of the students and the engineering faculty, I would like to thank RS Components South Africa for assisting us with the various components, batteries and support over the years. We look forward to future engagements with RS,” she added. The 2022 Robot Race Day winners – Natalie Hanekom, Brendon De Beer and Karl Etsebeth – were elated after their robot beat the others to claim the win. Wesley Hood, education specialist for RS Components SA, said that nurturing the next generation of engineers was at the top of RS’s agenda. “RS Components’ continued involvement in this project is in line with the company’s policy of supporting both professional and future engineers by giving them access to the components, tools and resources that they require to excel in their endeavours. “This is echoed in our DesignSpark platform, which is a free online community for engineers, inventors and tech enthusiasts from around the world, offering free CAD software and other technical resources to help bring ideas to life. With more than 1,2 million members, this community can be of assistance to students and engineers working on real-world applications. I encourage anyone interested in engineering and inventing to register and be a part of this global community,” he said. View a brief video of the day here: https://youtu.be/Be4dIHJZwpw Wesley Hood with this year’s winners, Karl Etsebeth, Natalie Hanekom and Brendon De Beer. Wesley Hood from RS Components SA and Professor Tania Hanekom fromTUKS.
NEWS & EVENTS www.bmgworld.net BEARINGS • SEALS • POWER TRANSMISSION • DRIVES • MOTORS • MATERIALS HANDLING • FASTENERS & TOOLS HYDRAULICS • PNEUMATICS • FILTRATION • LUBRICATION • VALVES • TECHNICAL RESOURCES • FIELD SERVICES BMG-WEB-2022-Shop-Online SHOP BMG ONLINE FOR: • Electronic Motion Control • Maintenance Chemicals • Tools and Equipment • Power Transmission • Electric Motors • Adhesives • Fasteners • Bearings • Sealants • Gaskets • Seals Eldon Hoffman enclosures are distributed in southern Africa by ATI Systems. The product range consists of a complete range of highquality enclosures in mild steel and stainless High quality enclosures steel, with all the important certifications for territories worldwide. The stainless steel range consists of a full lineup of wall-mounted and floor-standing enclosures. A wide range of enclosures for any application is stocked in both 304 and 316 grades. The range is further complemented with a variety of panel air conditioners and filter fans. ATI Systems carries a complete range of panels in its warehouse in Wadeville, Germiston, from where all areas of southern Africa are serviced. An additional warehouse with a good range of functional stock is situated at Stikland, Belville in the Western Cape. The Eldon range of panels carries all the important certifications from certification authorities worldwide. Eldon is a favourite with machine builders, who see the product as an excellent complement to their own build, and the brand is accepted globally. Eldon Hoffman is part of the nVent Group, a diversified company in the electrical industry. For more information contact ATI Systems, +27 11 383 8300, [email protected], www.atisystems.co.za
10 Third Quarter 2022 www.motioncontrol.co.za The best of hydraulics meets the advantages of electric Hydraulic systems have long been necessary for off-highway mobile equipment because of their power density. However a variety of factors – including regulatory trends and advances in technology and economics – is making electrification the way of the future. Diverse industries are working to rethink their operations and equipment to adapt to one of the biggest game changers to impact consumer and commercial markets in decades. Electrification is not new. The difference is the convergence of three powerful forces: stricter governmental regulations; ESG initiatives by the top companies in the world; and TCO. As adoption rates for electric passenger cars accelerate, experts predict an increased migration of electric technologies into larger, heavier equipment, which has been limited due to insufficient and inefficient power sources. This article explores how hydraulic components, electrical machines and vehicle controls are coming together to optimise machine performance, and how they are positioned to meet future challenges. No complete replacement for hydraulics The amount of money invested in new research and electric technologies is unprecedented. Global automakers are planning to spend more than half a trillion dollars on electric vehicles and batteries through 2030, according to a Reuters analysis, weaning car buyers away from fossil fuels and meeting increasingly tough decarbonisation targets; but hydraulics for work functions is not going away any time soon. There will likely always be some applications that are best served by hydraulics. Hydraulics is unique in power transmission because it has power density. It is the most compact method of mechanical actuation when considering power-to-size ratio. Hydraulics is not replaceable, but adding electrics can improve performance and decrease noise levels. The most promising technologies combine the best of hydraulics with the advantages of electric. Manufacturers are leveraging opportunities to recover energy through the hydraulic system. The right technology can help store energy in an accumulator or in the battery system through the electric motor that drives the hydraulic pump, enabling the motor to effectively run as a generator when travelling downhill or during deceleration. This is already common in hybrid consumer vehicles, where electric motors recover energy as the car brakes. However, better hydraulic and electric component integration is necessary to achieve the greatest efficiencies. Hydraulic pumps and the electric motors that Continued on page 12
Head Office 011 383 8300 [email protected] www.atisystems.co.za 159 Galjoen Rd, Wadeville, Germiston Speed and Position Feedback Specialists Magnetostrictive Sensors We measure through walls Industrial Duty &Mill Duty Incremental Encoders Programmable Encoders & Linear Potentiometers Accurate Measurement for all Industries ATI Systems Committed to Quality Programmable Incremental Encoders, Absolute Encoders & Inclinometers ONLINE SHOP www.atisystems.co.za/shop
12 Third Quarter 2022 www.motioncontrol.co.za NEW TECHNOLOGY power them must work together in harmony; smarter hydraulic components that can sense load requirements and systems for energy recovery are needed to achieve efficiency gains. Additional effort is required to ensure all components and subsystems contribute to a holistically smarter, more efficient machine. The marriage of hydraulic and electric designs The intersection between the domains of hydraulics and electrification is where today’s innovations are taking place. The goal is to bring together the best of hydraulics, such as robustness, with the controllability and precision that comes from an electrical approach. Machine builders must balance the need to deliver enough torque to drive the machine against the need to make the most economical use of electric power. As with the drivetrain, engineering the drive elements for the maximum load needed is a critical calculation. A full size excavator must dig and move thousands of kilograms of soil or rocks all day long. It is typically hydraulically driven, drawing its pressure and flow from a pump powered by the mobile machine’s diesel engine. In an all-electric system a heavy-duty electric motor powers a ball screw or other linear component to do the work. However, the size of the actuator and the drain on the battery are substantial, even for a hybrid electric platform. A more effective solution combines electric power and hydraulic power. It takes power to move a load – whether it’s voltage and current with an electric motor, or flow and pressure with a hydraulic cylinder − to generate the torque needed to do the work. Rather than powering the hydraulics from the diesel motor, the motor runs a generator which then supplies power to an electric motor driving the open-loop hydraulic pump for the cylinders powering the excavator’s tools. This leverages the power density of hydraulics from the combustion engine platform to electric power. Challenges remain on the road to electrification Electric power transmission is clean, efficient and accurate at levels that hydraulics cannot match. However barriers still exist. While breakthrough technologies mean batteries charge faster, last longer and are lighter in weight, some will not be commercialised for years. The reality is that a large percentage of batteries on the market today are still heavy, expensive and unable to meet demand. But with work done by companies like Tesla, historic battery costs of $140/kWh will soon realistically be down to $50. Despite impressive developments, neither batteries nor fuel cell technologies are ready to meet the very high power requirements needed for the harsh conditions to which many heavy-duty vehicles are exposed. Another challenge is energy transmission. It takes 45 seconds to fuel up that 20 litre diesel tank. This compares with 33 minutes to ‘fuel up’ a similarly sized battery pack at 25 kW charging capacity. Significant research is also being undertaken to identify new materials and heatresistant power electronics to help minimise heat, which is key to improving the overall safety of the vehicle and maximising battery charging speed, longevity and overall lifetime. Thermal runaway is a real fear for batteries. The key driver is to minimise the energy storage size, which will reduce installed cost as operating hours increase between charging. Hybrid is today’s reality Hybrid electric systems are well positioned as an interim solution. Hybrid electric equipment combines the power density of a diesel engine with the emissions-cutting capabilities of a battery. A smaller diesel engine alongside a rechargeable battery and electric motor is ideal for both high-intensity jobs and locations requiring low emissions. The battery in a hybrid system can be relatively small and function as a buffer that allows the pump and engine to work at higher speeds where the efficiency is best. The engine is not loaded at idle, which reduces fuel consumption, emissions and noise. The pump size can be reduced by 40% because its speed is not tied to the engine’s idle condition. This produces several advantages in terms of cost, weight and installation. Hybrid drives still burn diesel fuel, but they can recover and reuse energy that would otherwise be wasted as heat. This can allow downsizing if the engine can be sized for average loads. If there is a clutch between the engine and drivetrain, the vehicle can be temporarily operated in a purely electric mode, depending on energy storage capacity. The hybrid system also allows OEMs to design certain auxiliary functions as ‘power on demand’, using electric motors that are not drawing from the engine all the time – for example an electric fan used in lieu of a beltdriven fan. Another version of hybridisation is the series hybrid, where the hydrostatic drivetrain is replaced with two electrics: one on the engine operating primarily as the generator, and the traction drive operating primarily as a motor. It also has energy storage so there is the possibility for recovering energy, operating in pure electric mode, productivity improvements, and peak shaving. Hybrid systems have effectively been used to power propel functions on large trucks and buses and offer significant benefits. In some applications, they have reduced fuel consumption by up to 50%. It is not just about batteries There are other sustainable options. There are currently four true zero-emission technologies to power vehicles, of which battery electric vehicles is one. The other zero-emission technologies are hydrogen fuel cells, hydrogen internal combustion engines, and biofuel internal combustion engines. The use of internal combustion engines with fuels such as biomethane and green hydrogen offer the greatest potential in the short term. Fuel cells work like batteries, but they do not run down or need recharging. They produce electricity and heat as long as fuel is supplied. Hydrogen fuel cells can refuel rapidly and carry heavy cargo due to the system’s efficiency in storing electrons. In addition, fuel cell electric vehicles have a much higher energy density by weight, allowing them to overcome the range and weight challenges of battery electric vehicles. Hydrogen tanks are also more compact and lighter than an array of fully charged batteries. The future is electric Driven by successes in the automotive industry, interest in electric machines is at an all-time high. The reduction of battery costs has been a huge enabler, making battery technologies more affordable and attractive. Digitalisation has made a huge impact on system operations, performance monitoring and predictive maintenance. Greater connectivity allows for in-depth analysis of how well the entire system is operating and can ward off problems. As part of the effort to fast-track electrification-enabling technologies, there is an unprecedented level of collaboration taking shape. OEMs, suppliers and industry leaders have come together to share their knowledge in the hopes of identifying smarter solutions. To read the full article visit http://www.instrumentation.co.za/17011r For more information contact Lisa de Beer, Parker Hannifin SA, +27 11 961 0700, [email protected], www.parker.com/za Continued from page 10
www.motioncontrol.co.za Third Quarter 2022 13 MC IN AUTOMOTIVE Most South African motor vehicle plants also export into international markets, which means they must all adopt world-class manufacturing processes using state-of-the-art equipment. SEW-EURODRIVE has a long history of innovating solutions for the global automotive industry. “A large portion of our product range was developed in cooperation with one of Germany’s prestigious automotive OEMs, and we are listed as one of their global best-practice suppliers,” notes MAXOLUTION engineer, Dylan Enslin. Vehicle assembly in the automotive industry depends on just-in-sequence (JIS) processes, which require highly flexible and efficient drive solutions. Parts required by each individual vehicle must be identified and then delivered to the exact position on the assembly line at the exact time of need. Any errors or delays can cause very costly downtime across the whole assembly line. “Our company has developed a fully integrated portfolio of modular drive solutions specifically tailored to these production needs, which can be used in any combination imaginable. Our MAXOLUTION packages for conveyor lines, for example, can be precisely tailored to individual plant layouts and applications, while seamlessly interconnecting a range of other complex assembly and tracking activities,” he says. Typically consisting of standard MOVIMOT gearmotors, each with a built-in inverter and all controlled by the MOVIFIT MC master controller, the MAXOLUTION systems can Advanced drive solution for the automotive industry Dylan Enslin of SEW-EURODRIVE South Africa talks about some of the global best-practice drive solutions available to the South African automotive industry. also be set up to run completely integrated overhead, guided-vehicle or traditional conveying lines with multiple interconnected systems. The modular and decentralised structure of these systems makes maintenance extremely user-friendly, delivering high availability while the cost-optimised materials handling concept significantly reduces installation complexity and costs. MOVI-C: an end-to-end solution The new MOVI-C range combines four modules to give automotive plants access to a complete modular automation system that can be fully integrated into the overall automation system of assembly operations. These are: • MOVISUITE engineering software for planning, startup and operation. • MOVI-C CONTROLLER. • MOVIDRIVE inverter technology. • MOVIGEAR or MOVIMOT drive technology along with a full range of gear units, linear actuators, etc. The MOVI-C module range also includes gear units for standard and servo applications that come in different sizes and with different outputs, speeds, torques, designs and varied finishes, all combined with asynchronous or synchronous servo motors. Linear motors, electric cylinders, brakes, built-in encoders and diagnostic units provide the finishing touches for this wide-ranging portfolio. “Typically, each interconnected subsystem will be driven by its own MOVIMOT mechatronic drive system, with all the necessary decentralised peripherals such as position and speed sensors. These will all be linked to a MOVI-C CONTROLLER via EtherCAT or SBusPLUS to achieve real-time synchronisation,” Enslin explains. MOVISUITE engineering software runs on a laptop and covers commissioning and all aspects of the motion control in operation as well as diagnostics. “All the components in a MOVI-C automation system, from inverters and controllers to motors, gear units and drive systems, can be configured, commissioned and monitored, end-to-end, using this software,” he adds. In South Africa the company has recently invested R200 million in a local assembly plant, which helps support localisation initiatives in the automotive industry. “Our new assembly plant in Aeroton, Johannesburg is enabling us to reduce lead times for all of our standard products, while also enabling us to rapidly engineer customised solutions for automotive clients,” he assures. “Our engineers are completely familiar with the MAXOLUTION and MOVI-C products for the automotive industry. They also understand the automotive industry’s needs for an increasing range of models, faster throughput, and a smarter and safer environment that is energy efficient and minimises production costs,” Enslin concludes. For more information contact Jana Klut, SEW-EURODRIVE, +27 11 248 7000, [email protected], www.sew-eurodrive.co.za
14 Third Quarter 2022 www.motioncontrol.co.za MC IN AUTOMOTIVE Assembly line for the automotive industry How do you design a new assembly line and go on to reduce the footprint of the concept by another quarter? And how can you later increase the productivity of this highly consolidated line even further? Canadian automation expert, Eclipse found the answer in Beckhoff’s linear XTS transport system. After the second modernisation, the assembly line could produce two different types of pumps on the same small footprint. Eclipse recently updated a successful system for a customer using the eXtended Transport System (XTS) to assemble automotive transmission pumps. While increasing functional capabilities, the custom solution needed to minimise the footprint. “When we proposed the system, they asked us to make it 25% smaller,” says JeffWerner, general manager for Eclipse. The XTS-based assembly line features four separate cells with more than 50 stations for pressing, soldering, screwdriving, flatness checks, dispensing, plasma treatment, leak testing and inspection. Many stations require precise synchronisation to robots. In the first three machine cells, operators place the pumps on pallets attached to XTS movers. The carefully calculated pitch of the pallets enables micronlevel positioning. When all assembly processes are complete, the operator moves the pump to the next cell. At the fourth cell a robot lifts the completed pump in front of two GigE cameras for a final vision inspection, then places it on a conveyor for outfeed. “XTS transitions products from station to station quickly and accurately, and if there’s an issue with a part we can bypass other stations and simply remove it,”Werner explains. “We grouped multiple processes into a single station, which helped us further decrease footprint. It was the most condensed automation system I’ve ever seen.” The first Eclipse assembly machine exceeded expectations and is still in use today. Then the automotive supplier requested a second machine with a new challenge. It would need to make a second pump on the same system. The pumps were different sizes and for different vehicle makes. Also some assembly steps happened in different orders for the two pumps. To maintain high throughput, the system could not afford the downtime to purge one pump type and then perform a lengthy changeover. Working with the Beckhoff team, Eclipse created a new concept relying on the fast cycle times of EtherCAT and the flexibility of XTS. “The system allows operators to quickly release and replace the pallet with a second type. This new pallet indexes forward and its position is measured to determine an offset. We apply those offsets to each pallet and make sure that components and parts line up exactly for the processes,”Werner explains. “Also, because each mover appears as an individual motion axis, they are not linked as in traditional designs. They can freely move workpieces around the track to specific process steps as needed, even if the order is different between the two pumps.” In addition to the XTS systems, the assembly line relied on other EtherCAT and PC-based automation technologies from Beckhoff. The cells featured an IPC to control their XTS track and peripheral devices. The IPCs communicated via EtherNet/IP to a secondary machine controller that controlled other portions of the line. Real-time EtherCAT synchronisation with robotics and servo components allowed the engineers to perform interpolated motion for different dispense processes such as applying adhesive in intricate patterns. To make this advanced functionality possible, TwinCAT 3 automation software was critical. The universal engineering and runtime platform from Beckhoff allowed Eclipse engineers to program G code that enabled the XTS and Beckhoff AM8000 servomotors to perform coordinated motion for high-precision dispensing. With this innovative design, the updated transmission pump assembly system met the specified cycle time of 20,2 s per part with the micron-level accuracy required. The system has produced 1000 parts per shift, running the two parts in separate batches. The easy release and attachment of pallets, along with the instant automatic indexing of XTS, almost eliminated changeover times, reducing them from more than an hour to just one minute. Both controls and mechanical engineering ensured easy release of the pallets without removing a single bolt. “Eclipse has innovation in its DNA,” says Werner. “For programming pallet control, pallet offset tables and similar requirements, Beckhoff offers many advantages compared to other options, and saves a significant amount of engineering time. With Beckhoff’s help we have tackled many other unprecedented high speed and micro-assembly applications, including Covid test kits.” For more information contact Dane Potter, Beckhoff Automation, +27 79 493 2288, [email protected], www.beckhoff.co.za
MC IN LEISURE Swiss bicycle manufacturer Thömus is launching the world’s first full suspension cross-country electric mountain bike weighing less than 15 kg. This record-breaking weight is made possible by the small and efficient maxon Bikedrive Air drive in the extremely lightweight Thömus ultra-high modulus carbon frame. With a slim, rigid frame, the Lightrider E Ultimate is a real racing bike that can be manoeuvred easily and agilely over any terrain. The barely noticeable additional weight of the maxon drive of only 3,5 kg, in combination with superior carbon technology fromThömus, delivers a ride that feels as natural on the trail as on the bike of overall World Cup winner, Mathias Flückiger. As soon as you begin to climb, the Lightrider E Ultimate feels as if a tailwind is gently pushing you uphill, making it perfect for training or riding in a group. The unique freewheel technology of the maxon system ensures natural transitions from supported to non-supported riding. The result is an e-bike with the perfect balance between weight and agility that feels just like a normal bike. maxon’s experience in the development of drive motors for Mars rovers is reflected in the The world’s lightest electric mountain bike WE MOVE YOU WIN Moving specialist hydraulic components from the world’s leading manufacturers to your shop floor. We bring premium hydraulic hose and fittings, mobile components and accessories to your operation, so you enjoy maximum hydraulic performance, every day. That’s why HAW is now a Bosch Rexroth Company. Call us: 27 (0) 11 281 3800 or Visit our website at: www.boschrexroth.africa A Bosch Rexroth Company system’s compact size, which allows the battery to be integrated invisibly into the frame. Only an inconspicuously integrated control element on the top tube hints at the extra power hidden in the bike. Equipped with a 250Wh battery and an optional range extender with an additional 250Wh capacity, technically challenging trails can be tackled with ease. For more information contact DNH Tradeserve, +27 11 468 2722, [email protected], www.dnhtrade.co.za
16 Third Quarter 2022 www.motioncontrol.co.za MC IN LEISURE A well produced theatre experience is capable of entrancing the audience to the point that the members are fully immersed. Ironically, this means that most theatregoers fail to appreciate the engineering required to move the lights, scenery and props that contribute to a memorable performance. One general contractor ensures that its stage equipment is positioned precisely where it is required, thanks to Stromag Series 51 limit switches. Behind the scenes Installed above the stage of many theatres is the upper machinery − mostly winches and hoists driven by motors. These winches and hoists raise and lower lights, scenery and props to support the performances of the actors on stage, providing extra atmosphere and immersion for the audience. However, with a multitude of heavy equipment operating above the performers, it is imperative that loads stop exactly where needed with total reliability. One stage equipment business applies the latest theatrical technologies to deliver large-scale installation projects, a particular area of expertise being upper machinery. The Limit switches for show-stopping performance contractor often relies on Series 51 geared cam limit switches from Stromag, a leading brand of Altra Industrial Motion, to ensure precise and reliable stopping for upper machinery. Reliable stopping Marco Niehnus, global product manager of Controls at Stromag, explains: “The upper machinery in theatres is similar to a crane application, with loads being moved up and down. Ensuring that these loads stop reliably is critical for the safety of performers on stage below. Our Series 51 geared cam limit switches set the upper and lower stopping points of these loads by accurately measuring the number of shaft turns, delivering highly reliable stopping performance.” This reliability is evidenced by the TUV DGUV V17 certification held by the Series 51. This is the German quality standard for upper machinery used in theatres and TV studios. While not a legal requirement globally, many customers follow this standard to ensure that upper machinery equipment offers the utmost reliability. As a result, the Series 51 is a popular selection for stage applications in Japan, Australia, Russia, Europe and the USA. The Series 51 is suitable for many upper stage machinery configurations. This includes fly bar drives, which feature a lifting device with steel wires wound around a single drum and attached to a bar or traverse; tubular shaft drives, where each wire is wound around its own drum and can move multiple bars; as well as point hoists, which feature a single wire for lifting. The limit switch can be installed to measure the turns of the motor or the winch drum, ensuring versatility. Precise performance “Precision and ease of adjustment are key advantages of the Series 51,” Niehnus adds. “The stopping points can be set with a simple worm gear, which when turned, moves the cam disc and actuates its switching position. A cam disc gear ratio of i=146 means that it takes 146 turns of the worm gear to fully rotate the cam disc. This ensures incredibly precise adjustment for the contractor’s requirements.” While this level of precision may seem excessive, this high gear ratio actually makes it easier for users to set an exact stopping point. Limit switches with lower gear ratios offer a reduced accuracy for setting stopping points due to the less available points per rotation, making it difficult to find the optimum position. Conversely, the more accurate Series 51 allows fine adjustments to be carried out easily – ideal for stopping scenery, props or lighting in exact positions. Proven on stage “Over the years we have worked with this stage equipment contractor, we have built a strong technical relationship. They provide us with detailed information regarding the applications and the number of turns to our local team, and we deliver Series 51 limit switches to the required gear ratio. This ensures we can offer a solution precisely to their requirements on a project-by-project basis,” Niehnus concludes. For more information contact Patricia Ullrich, Stromag, +49 230 310 2239, [email protected], www.stromag.com
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