A true gauge of our success 30 years young MANUFACTURERS VOL 24 NO 4 • FOURTH QUARTER 2022
www.motioncontrol.co.za Fourth Quarter 2022 1 SAFPA news News & events New technology OUR COVER 6 FOURTH QUARTER 2022 03 04 08 REGULARS FEATURES 10 SEW-EURODRIVE, Zest WEG Group Africa, Bison Gear & Engineering, Siemens South Africa 13 Axiom Hydraulics, Hydrasales, Epiroc South Africa, Hydraulic Tools 18 Beckhoff Automation, Parker Hannifin SA, Omron Electronics Siemens South Africa, Horne Technologies, Moog 20 27 Bosch Rexroth South Africa, Yaskawa Southern Africa, igus South Africa BMG, Hyprostatik Schönfeld 24 30 Drives Hydraulics Automotive Aerospace Pneumatics Robotics Bearings, seals, belts & chains SA Gauge is a proudly South African company that has stood the test of time as a supplier of high-quality pressure and temperature gauges. Celebrating its 30th birthday this year, the company marked the occasion with a comeback at Electra Mining Africa. SA Gauge is about more than just pushing product, as it strives to not only satisfy its customers, but also educate them to make the best possible use of their pressure and temperature gauges. Read the cover story on page 6 to find out how SA Gauge has survived the tough times, and grown and thrived over the last 30 years. A true gauge of our success 30 years young MANUFACTURERS VOL 24 NO 4 • FOURTH QUARTER 2022 EMVAfrica, Artic Driers International, Festo South Africa
2 Fourth Quarter 2022 www.motioncontrol.co.za welcomeFOURTH 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 recently took a drive down to Durban and stopped, as everyone does, at the Harrismith Engen. My attention was attracted by a charging station for electric vehicles (EVs) and it made me start wondering how things are going in South Africa EV-wise, so I thought I would investigate. I still remember my first assignment when I started at Technews some years ago when I had to cover a Siemens launch where they had on show their gorgeous electric Porsche. Editors were offered the chance of driving it round the Kyalami racetrack, but to my huge disappointment the battery went flat just when it was my turn. I also remember the promise of the Joule around that time, which was going to be a locally manufactured EV. Sadly it didn’t make it because of a lack of financial support. Internationally, EVs are well on their way. The International Energy Agency’s Global EV Outlook estimates that there were 10 million electric cars on the world’s roads in 2020; and all the big car brands have entered the South African market with EVs (although no Teslas yet). They have an eye-watering price tag but they are moving. Volvo opened its online order books for the XC40 Recharge in January, and the 25 allocated vehicles for South Africa were sold out in 24 hours. According to NAAMSA there were 6367 electric vehicles on South African roads at the end of 2020; and for the first half of 2022, a total of 2139 new electric vehicles have been sold compared to 896 during the whole of 2021. At the moment, loadshedding and the price tag are stopping us from thinking about buying an EV. Charging and ‘range anxiety’ are also an issue. However recent EVs have a range of 400 km which is fine for everyday use. You charge at home, usually overnight, just as you would charge your cellphone. So Eskom outages can be accommodated. And if you are on a long journey a GridCars map will show you the charging stations every couple of hundred kilometres all along our major highways. There are some advantages. EVs have one rotating part, a single-speed gearbox and no clutch, and they operate in silence with one-pedal driving. There is no torque convertor, no gearchanges, just linear power and acceleration. Regenerative braking recharges the batteries rather than dissipating the energy in brake heat. Maximum torque is at zero revs, so instant power is available from standstill and all through the speed range. The smooth driving experience cannot be matched by an internal combustion engine (ICE) car, however sophisticated and complex. The cost Going electric of charging is substantially less than filling up with petrol or diesel. Electric motors also run for more than a million kilometres with almost no maintenance due to their simplicity. In comparison ICE cars have highly complex mechanics with thousands of rotating and reciprocating parts that result in pollutants, noise, heat, vibration and high maintenance costs. The cost of an EV is already comparable with a similar ICE over five years due to lower running costs and minimal maintenance. By 2025, EVs will be on purchase price parity with ICEs internationally as economies of scale kick in and they become cheaper. Improvements in battery life will also extend the distance that EVs can travel on a single charge. According to the 2022 Greencape Electric Vehicles Market Intelligence Report highlighting investment opportunities in the local EV market, public transport is the best business case for manufacturing. Cape Town municipality has already experimented with e-buses, and the University of Stellenbosch has a research project, GoMetro to bring in electric minibus taxis. There is also an opportunity for EVs in underground and opencast mining. And MercedesBenz Vans is on track to introduce the first electric van. South Africa has a world-class auto manufacturing industry, and nearly 80% of the cars manufactured here are exported to Europe. However the UK will be banning ICE cars from 2030, and the EU from 2035. So politics notwithstanding, there is an urgency to convert to EVs, which is echoed by the Minister of Trade, Industry and Competition, Ebrahim Patel, who says that it is ‘absolutely critical’ that South Africa makes the shift towards EVs if the country is to have a large and growing auto sector. Would I get one? Hell yes if I had the budget, how cool would that be. It would be perfect for everyday driving. For now I think EVs will be left to the early adopters, but new technology comes slowly and then quickly. My guess is that eventually we will all be driving EVs.
www.motioncontrol.co.za Fourth Quarter 2022 3 www.vdw.co.za | +27 11 061 5000 | [email protected] SAFPA NEWS SAFPA at Electra Mining At the recent Electra Mining 2022 Exhibition, SAFPA was on display. Seen here is Manny Vieira manning the SAFPA stand. SAFPA Golf Day This year’s SAFPA Golf Day was held on 29 July at the Benoni Country Club. It was a highly successful occasion and everyone enjoyed getting out for a game and networking afterwards, after missing out for the last two years. Team Aeroport team was the winner, followed by Bosch Rexroth and then Aeroport again. Winners of the nearest the pin challenges were Phil Venter and Kevin Sammons (twice).
4 Fourth Quarter 2022 www.motioncontrol.co.za NEWS & EVENTS BMG’s online shopping portal, which was launched in South Africa two years ago, is constantly upgraded to meet dynamic market requirements. “The BMG E-Commerce platform – which was developed to enhance the convenience for customers to procure engineering consumables – is gaining popularity at a time that our country faces rising fuel costs and consumers are reluctant to use their motor vehicles,”explains DarrynWright, group marketing executive, Engineering Solutions Group (ESG), part of Invicta Holdings. “Feedback from our customers indicates that in spite of Covid-19 restrictions being lifted, the ease of buying industrial products from the comfort of their homes and offices, without having to drive or wait in a queue, is an important advantage. Although our online delivery service saves fuel, money and time, digital shopping does not detract from the technical support and personal service offered by the BMG team.” The online portal, which is benchmarked on international best practice, is efficient, userfriendly and customer-centric. BMG Online is an easy-to-navigate platform, that enables 24-hour browsing and ordering. Over 75 000 BMG products are available on this platform, including bearings, seals, fasteners and power transmission Online shopping for engineering consumables Siemens is cooperating with Nissan to build production lines for the new all-electric crossover Nissan Ariya at the company’s plant in Tochigi, Japan. Nissan had already been using the Siemens Digital Industries software portfolio to optimise design and production. End-to-end digital threads enable Nissan to connect a wide variety of sources of information across product lifecycle management platforms. “Climate change and stringent environmental regulations are powerful drivers for the development of electrified powertrains,” says Cedrik Neike, Siemens Digital Industries CEO. The system architecture of Nissan’s newly developed electric powertrain aims to standardise the processing and assembly of the powertrain. Profinet creates end-toend communication from the field to the management level, and the engineering framework TIA Portal has also fully integrated all automation devices. This enables complete access to the entire digitalised automation process, from digital planning to integrated engineering and transparent operation. More intelligent automobiles require more high-performing electronic control units (ECUs) in the vehicle – as is the case in the new Nissan Siemens and Nissan cooperate on electrified powertrains Schneider Electric has launched the RM AirSeT, its newest gas-insulated (GIS) switchgear with pure air technology and digital connectivity. This equips grid operators with an innovative solution to decarbonise and modernise the grid, while enabling electricity distribution utilities to improve operational performance and reliability. It is completely sealed from the external environment, which provides extra protection against the harsh environmental conditions found in grids. Available in 12 and 24 kV options, the GIS switchgear uses pure air as the main insulating mediumwhich, among many advantages, mitigates the need for complex and costly gas recycling, which in turn minimises the TCO of equipment. The RM AirSeT provides an unprecedented opportunity to decarbonise. For decades, SF6 gas has been used for electrical insulation and arc quenching in high- and medium-voltage equipment. Replacing it with pure air and vacuum interruption solutions, like RM AirSeT, is a gamechanger for electric distribution grids – decarbonising and preparing grid operators for grids of the future. The average lifespan of switchgear is between 30 and 40 years, utilities therefore have a once-in-a-generation opportunity to take action to avoid the risk of additional greenhouse gas emissions. SF6 is a potent greenhouse gas, and is 23 500 times more potent than CO2. By eliminating its use in switchgear, the environmental footprint of electrical networks is reduced. It offers a single solution for 24/7 app-based condition monitoring and controls to check the quality of power connections and identify and isolate faults in seconds, with self-healing capabilities for reduced downtime. For more information contact Schneider Electric SA, +27 11 254 6400, www.se.com/za The next step in grid decarbonisation Ariya. The Siemens diagnostic commissioning system Sidis Pro, which has already been deployed in many automobile companies around the world, is implemented at Nissan’s new production line for data writing into ECU, and verifying automotive electric components. Sidis Pro is the advanced vehicle diagnosis and inspection data management system that provides optimal support for inspection processes, to enable quality of car production. It provides maximum flexibility in automotive production as it is easily modifiable according to the production plan, and the changes can be adapted quickly. For more information contact Siemens South Africa, [email protected], www.siemens.co.za components. Hand and power tools, abrasives, brushware, spanners, wrenches, and sockets are also available. Added to this are agriculturalspecific components, including PTO shafts. BMG constantly adds more products to this electronic platform, to meet market demand. BMG Online offers many benefits, including easy product browsing, selection and ordering; click and collect from the nearest branch; swift delivery for existing customers; and a fair returns policy. For more information contact DarrynWright, Engineering Solutions Group, +27 11 620 1516, [email protected], www.bmgworld.net Brighton Mwarehwa, offer and marketing director, Schneider Electric.
www.motioncontrol.co.za Fourth Quarter 2022 5 NEWS & EVENTS As an electro-mechanical solutions provider to many industries throughout Africa, including the mining sector, Vert Energy showcased products and services at this year’s Electra Mining Exhibition from its three specialist divisions – Electric Power Generation, Electric Motors and Drives, and Energy on Call. “Vert Energy has a close a partnership with Nidec Control Techniques, and we launched the new Commander S200 drive at the show. This is the first drive that has been designed with NFC Technology and an app interface as a standard feature, enabling the user to program the drive from a mobile phone,” explains sales and marketing director, Ryan Robertson. “With a feature set that has been optimised for simple applications, this advanced system provides a cost-efficient solution for installations that require plug and play convenience, particularly in remote locations across the continent. The Marshall app provides a new way to interface with the drive, covering commissioning, monitoring, diagnostics and support. The stand also showcased some of Vert’s key branded products, including the Yanmar Electro-mechanical solutions 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 engines, which range from 9 to 60 kVA, and AGG engines from 50 to 250 kVA. Also on display were power management solutions from DEIF. “Product efficiency, competitive market positioning, pristine quality standards and guarantees of extended service life are Vert Energy’s critical selection criteria,” concludes Robertson. For more information contact Ryan Robertson, Vert Energy, 086 111 VERT (8378), [email protected], www.vertgroup.co.za
Chris and Judith du Plessis founded SA Gauge with a fairly modest vision, but one that was vivid and focused enough to lay the groundwork for a proudly South African company that has stood the test of time. Celebrating its 30th birthday this year, the company’s welcome return to the first postCOVID-19 Electra Mining Africa was somewhat bittersweet, as it marked its first showing at the event without its spearhead in attendance. Chris du Plessis passed away on 12 January 2021 at the age of 61, but his legacy is an SA Gauge that is barely recognisable from the original, back when he and his wife used to stay up at night making gauge scale plates by hand. Armed only with the idea of manufacturing pressure gauges and thermometers locally, a can-do attitude and six staff members, the Du Plessis couple steadily grew the business to encompass two self-owned branches and two SANAS-approved laboratories, one for pressure and the other for temperature. Through thick and thin As with any business, SA Gauge has had its ups and downs over the years, and relocations to accommodate its growing market share and number of personnel. Since its inception in 1992 as one of only two local manufacturers of branded pressure gauges and thermometers, many milestones have followed. The company’s first branch was in Germiston, where Chris and his family lived at the time, and when they moved to Durban in December 1995, a second branch was opened there which SA Gauge: A shining example of South African resilience became its new head office. Initially located at 9 Beechfield Crescent in rented 250 m2 premises, the headquarters moved directly across the road for a spell before SA Gauge bought its own property in 2007. There have been no more moves since, and SA Gauge is based at 8 Beechfield Crescent in Springfield Park, Durban to this day. In 2011 the Johannesburg branch also moved from Germiston to a larger, self-owned factory in Croydon, Kempton Park on the East Rand of Johannesburg. In 2008 the company opened its first SANAS-accredited lab, in Durban, specifically for the pressure gauge side of its business. As the SA Gauge team puts it, “the places we move into always seem so big when we move in but within a few years we manage to outgrow them.” A second lab, this one for its temperature gauge business, was opened in Croydon in February 2019 before moving to Durban in March 2020. As was the case for almost everyone, COVID-19 was a trying time for the staff as fears of job losses escalated. Fortunately, Chris and Judith always believed in being prepared for a rainy day and were able to pay all their employees in full for the entirety of the lockdown, and no jobs were lost. Very unfortunately, the company suffered the double-whammy of losing two teammembers in January 2021: Chris and Dinesh Betchan, technical salesperson and SANAS laboratory manager. Emerging stronger than ever Now, backed by a complement of more than 50 staff members and having managed to meet sales targets since lockdown, and in some cases far exceeding them, SA Gauge is back in growth mode. It recently completed the construction of an additional 100 m2 factory floorspace to allow for a new press and lathes, into which it will be moving two sections of its manufacturing operations. A new SANAS lab is also being built and is expected to be up and running in January 2023. At 145 m2, it will be a fair bit bigger than the current lab to accommodate more equipment and improve turnaround times. A major headache the company is dealing with right now is the unstable electricity supply, which necessitated an investment in generators to keep its systems up and running. In future, it plans to investigate the addition of solar power systems to keep critical systems online all the time. The future, though, looks bright for SA Gauge as it continues to draw from the principles instilled by Chris du Plessis. “Chris was very big on being prepared and trying to make sure that whatever was thrown at us, we could find a way around it or over it. Loyal staff members also makes things much easier. Everyone pulls their weight and helps out when needed, without management having to ask. If SA Gauge fails, we all fail. We have managed to create a range of products that is of a superior quality and marketed at competitive pricing,” reads a joint message from the team. Technical advice for industry SA Gauge is about more than just pushing product, as it strives to not only satisfy its customers, but also educate them to make the best possible use 6 Fourth Quarter 2022 www.motioncontrol.co.za
of their pressure and temperature gauges. In that spirit, the company offers the following tips for end users to bear in mind. Accuracy class This helps to determine whether or not the unit under test (ie, the customer’s gauge) is within its specification. Master gauges boast a high accuracy: often around 0,5% or 0,3% of full-scale for analog models, while digital gauges can range all the way from 1% to 0,01%. In order to know if your item is within specification, simply take the full range and multiply it by the accuracy percentage of their item. Pressure media For lower-pressure gauges, air is most commonly used, but other gases like nitrogen can also be used. With higher pressure ranges, liquid media such as water or oil are more common. Oxygen gauges need to be degreased to ensure that there are no common contaminants, such as water or oil, that can get into the gauges and cause an explosion. Generating pressure Oftentimes the company sees pressure gauges coming in that have been over-pressured due to an unseen spike in the customer’s system, usually upon startup. This spike can occur very quickly, but it is often too quick and too high a pressure for the mechanical gauge to endure. When this happens, a snubber can be fitted to the gauge to prevent it from happening again. Hysteresis Hysteresis occurs when there is a difference in the pressure point reading when the pressure is increased and then decreased again. To find out the hysteresis of the gauge, it should be calibrated first with increasing pressure only, and then again with decreasing pressure. Both readings should be recorded. ‘Tapping’ the gauge Due to analog pressure gauges being mechanical in nature, ‘tapping’ is often needed. This occurs when the desired calibration point has been achieved and the calibrator gently taps the side of the gauge to correct any mechanical ‘lag’ or stickiness. This ensures a truer reading of the value. Adjustment/correction Mechanical gauges often drift over time. When this happens, the internal components can be adjusted to bring the item back into its specified accuracy class. Adjustments can also be made on gauges that have been bumped or dropped, where the gears may have shifted as a result. Calibration certificates Calibration certificates are critical pieces of documentation, since they show the unit’s history in addition to pertinent information such as the calibration lab’s company details, the unit’s accuracy and the error calculation. Order the right gauge for your application There are several things customers of SA Gauge either get wrong, or fail to consider, when ordering a gauge. To ensure that what you buy is exactly what you expect, take note of these key points: • Provide the correct information about the gauge you require – dial size, fitting size, bottom or rear entry, etc. • Specify the correct unit of measurement, such as kPa or MPa versus bar in the case of a pressure gauge. • Understand the application the gauge will be used in. Failure to do so can lead to ordering standard pressure gauges instead of diaphragm seal gauges, or glycerine-filled gauges for oxygen applications. • Do not assume that all new gauges come with calibration certificates; SA Gauge clearly specifies that this is an optional extra. • Do not order the incorrect calibration certificate under the assumption that the SA Gauge calibration will be sufficient for ISO auditing purposes. • When ordering thermometers, specify the correct probe length – for the most part, specifications from SA Gauge include the thread length. • For tonnage gauges or kN gauges, choose the correct ram sizes of the press and hand pumps. This is crucial, as it could lead to people being injured if incorrect pressure ratings are used to manufacture the gauge. For more information contact SA Gauge, +27 31 579 2216, [email protected], www.sagauge.com COVER STORY
8 Fourth Quarter 2022 www.motioncontrol.co.za An untethered robot, invented at the Oregon State University College of Engineering, and produced by OSU spinout company Agility Robotics, has established a Guinness world record for the fastest 100 metres by a bipedal robot. Named Cassie by its inventors, the robot set a time of 24,73 seconds, starting and finishing the sprint from a standing position without falling. Unlike a human sprinter, Cassie has bird type legs like an ostrich, with knees that bend backwards. The robot does not have a vision system and operates without cameras or external sensors, essentially as if blind. To learn how to sprint, the OSU researchers say the robot’s programming was conducted in a week-long simulation. The simulation compressed a year’s worth of training experiences by computing numerous calculations simultaneously. The 100 metre dash is Cassie’s second record setting performance. In 2021, the robot completed a 5 km run in just over 53 minutes on a single battery charge, making it the first untethered bipedal robot to use machine learning to control a running gait on outdoor terrain, the researchers say. Cassie was developed under the direction of OSU robotics professor, Jonathan Hurst, with a 16 month, $1 million grant from the Defense Advanced Research Projects Agency (DARPA). Introduced in 2017, the robot became Agility Robotics’ first commercial robot, and has been used by top universities and robotics labs in the U.S. as a platform for exploring machine learning. Since Cassie’s introduction in 2017, in collaboration with artificial intelligence professor Alan Fern, OSU students funded by the National Science Foundation and the DARPA Machine Common Sense programme have been exploring machine learning options in Oregon State’s Dynamic Robotics and AI Lab. “We have been building the understanding to achieve this world record over the past several years, running a 5 km stretch and also going up and down stairs,” says graduate student Devin Crowley, who led the Guinness effort. “Machine learning approaches have long been used for pattern recognition, such as image recognition, but generating control behaviours for robots is new and different.” Fern says that the Dynamic Robotics and AI Lab melds physics with AI approaches more commonly used with data and simulation to generate novel results in robot control. Students and researchers come from a range of backgrounds including mechanical engineering, robotics and computer science. “Cassie has been a platform for pioneering research in robot learning for locomotion,” Crowley adds. “Completing a 5 km run Bipedal robot breaks Guinness record was about reliability and endurance, which left open the question of how fast Cassie can run. That led the research team to shift its focus to speed.” Cassie was trained for the equivalent of a full year in a simulation environment, compressed to a week through a computing technique known as parallelisation – multiple processes and calculations happening at the same time − allowing Cassie to go through a range of training experiences simultaneously. “Cassie can perform a spectrum of different gaits but, as we specialised for speed, we began to wonder which gaits are most efficient at each speed,” Crowley explains. “This led to Cassie’s first optimised running gait and resulted in behaviour that was strikingly similar to human biomechanics.” The remaining challenge, a “deceptively difficult” one, is to get Cassie to start reliably from a free-standing position, run, and then return to the free-standing position without falling. “Starting and stopping in a standing position are more difficult than the running part, similar to how taking off and landing are harder than actually flying a plane,” Fern continues. “This 100 metre result was achieved by a deep collaboration between mechanical hardware design and advanced artificial intelligence for the control of that hardware.” Hurst, also chief technology officer at Agility Robotics, calls the Guinness-recognised accomplishment “a big watershed moment”. “This may be the first bipedal robot to learn to run, but it won’t be the last,” he says. “I believe control approaches like this are going to be a huge part of the future of robotics. The exciting part of this race is the potential. Using learned policies for robot control is a very new field, and this 100 metre dash is showing better performance than other control methods. I think progress is going to accelerate from here.” For more information contact Steve Lundeberg, Oregon State University, [email protected], www.oregonstate.edu “Unlike a human sprinter, Cassie has bird type legs like an ostrich, with knees that bend backwards. The robot does not have a vision system and operates without cameras or external sensors, essentially as if blind.” NEW TECHNOLOGY
Improving Operational Efficiency The Challenge 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
10 Fourth Quarter 2022 www.motioncontrol.co.za One of the star attractions at SEW-EURODRIVE’s stand at the Electra Mining Africa 2022 exhibition was the company’s new generation MOVI-C all-in-one modular drive solution, which had its African launch at the show. In essence, MOVI-C is a suite of products that automates drive applications, whether they are simple or very complex. It is ideal for optimising or expanding existing automation systems or for rapidly implementing new automation projects where flexibility, rapid deployment and costeffectiveness are key. A true 4IR solution that offers huge productivity benefits to users, MOVI-C can be used in a wide range of applications where processes and operations need to be automated – for example, production lines or packaging operations. “It can be applied to any situation where the speed, acceleration and torque and position of drives needs to be regulated and controlled,” says Dylan Enslin, SEW-EURODRIVE’s MAXOLUTION engineer. He adds that MOVI-C can be used to implement standards-based single-axis or multi-axis applications or customised and/ or particularly complex motion control applications or automation solutions. “Generation C is a big step up from its predecessor Generation B, with better control, higher efficiency, added flexibility and a muchimproved interface,”he says. “It represents the future of automation and we see it having a big future in South Africa, and further afield on the African continent.” High tech drive solution MOVI-C has four main components – the requisite engineering software (MOVISUITE); advanced control technology (MOVI-C Controller); cutting-edge inverter technology for motor control (MOVIDRIVE); and decentralised drive technology (MOVIGEAR and MOVIMOT). Together these components represent a single end-to-end modular automation system, all available from SEW-EURODRIVE, with no need for any add-ins from third parties. All the components can be fully integrated into any automation design, fieldbus technology or network standard. There is complete freedom of configuration when it comes to the communication technology, as MOVI-C is compatible with protocols from Profibus and Industrial Ethernet through to Modbus, Profinet and EtherCat. Another benefit is the EtherCat CiA402 protocol. SEW-EURODRIVE has used MOVI-C to automate operations at its brand-new Aeroton facility in Johannesburg, which now acts as the hub for its African operations. The complex includes a factory, which significantly expands SEW-EURODRIVE’s manufacturing capability and which will ultimately assemble most products in its range. The main production conveyor at the new facility is based on MOVI-C. The installation includes the MOVIGEAR mechatronic drive system. The MOVIGEAR units – which combine an energy-efficient IE5 motor, gear unit and corresponding drive electronics in a single housing – control and drive a conveyor line used in the assembly of gearboxes. The modular nature of the installation means it can be easily extended in the future should the need arise. “Installation of MOVI-C at the Aeroton facility has resulted in a 40% productivity gain compared to the less advanced, more manual systems used for assembly in the past,” says Jacques Kemp, SEW-EURODRIVE’s geared motor production manager. “This increase in productivity stems fromMOVI-C’s ability to eliminate ‘wasteful activities,’which were previously carried out manually but which are now being done by machines.” Kemp points out that automation should not be seen as a means of reducing employee headcount. “We have not replaced a single worker – quite the opposite, in fact. Instead, we’ve empowered our existing employees to be far more productive. This is what MOVI-C does.” The installation not only demonstrates SEW-EURODRIVE’s confidence in MOVI-C but it will also allow the company to show its customers the system in operation in a realworld application. As Enslin says: “It showcases our abilities very effectively. It will allow customers to see MOVI-C in action and judge for themselves the efficiencies that can be achieved when SEW-EURODRIVE’s advanced drive technology is installed in a production environment.” For more information contact Jana Klut, SEW-EURODRIVE, +27 11 248 7000, [email protected], www.sew-eurodrive.co.za
www.motioncontrol.co.za Fourth Quarter 2022 11 DRIVES Classified as hazardous areas, offshore oil rigs require that any equipment installed on them is designed and certified accordingly – including electric motors to drive critical gas compressors. Foster Yeboah, Zest WEG’s regional sales manager for the West African Region, says that WEG electric motors for these applications comply with IEC standards and associated hazardous area specifications, which certify equipment for use in ‘explosive atmospheres’. Considering the hazardous marine environment, all the WEG machines were supplied with tough epoxy paint and conformed to an IP65 rating. Six large WEG motors are being installed on an oil platform off the coast of Ghana, over a staggered schedule from late 2020 through 2022. Four of the new motors are large 9500 kW, WEG MGW800 machines, and two are 7000 kW MGW710 machines. With weights of up to 23 tons, these electric motors exceeded the 19 ton weight limit of the oil platform’s crane, which meant that the motors were shipped to site in component form for assembly on site. “Despite COVID-19 disruptions and challenging logistical conditions, Zest WEG is successfully supplying, testing and installing these motors for the customer,” says Yeboah. “These six WEG motors are upgrades of previously installedWEG motors, which have been operating successfully on this site for over a decade. Of course, the Factory Acceptance Test (FAT) is always vital, so this has to be conducted on all the motors after they are manufactured and tested. COVID-19 initially made it impossible for the client to be physically present at the factory in Brazil, so some tests were witnessed virtually.” He explains that to deal with the weight restriction of the crane on site, the electric motors then had to be dismantled in the factory before shipping. Rather than being shipped as a single unit – as is normally done – the motors were carefully packaged into component form. Particular care had to be taken with protecting the rotor during shipment. “The rotor is a critical item, and it is crucial that great care is taken when transporting this item,” he says. “The packages are then shipped and stored at the customer’s warehouse in Ghana, before being taken to the offshore oil rig.” Zest WEG technicians assemble the electric motors on the oil platform, including the various electrical and hydraulic connections and piping. Commissioning and testing are done before the system goes online. The first of the six installations had to be done when COVID-19 Large motors for oil rigs #MakeitOMRON industrial.omron.co.za Make it flexible. Make it sustainable. Make it OMRON. restrictions required quarantining periods – adding to the complexity of planning. The large WEG motors in this application are cooled using the IC81W air-water cooling principle. Air is circulated through the motor base where the rotor and stator generate the most heat. A heat exchanger then extracts the heat from the internal circuit air flowing through it. For more information contact Zest WEG Group Africa, +27 11 723 6000, [email protected], www.zestweg.com
12 Fourth Quarter 2022 www.motioncontrol.co.za DRIVES Bison Gear & Engineering, a leader in the power transmission industry, announced that its proven PowerSTAR high-efficiency right angle gearmotor is celebrating ten years of industry-leading product excellence. Featuring, advanced hypoid gearing technology for improved energy efficiency over traditional right angle worm gearmotors, PowerSTAR offers maximum power density in a compact profile that does not compromise performance. Its sleek design offers easy mounting in several orientations, ground gearing for low noise, and a variety of frame sizes to fit numerous design specifications. Ground gearing provides whisper-quiet operation and low backlash precision, while larger diameter pinions offer more surface area contact. With multiple tooth contact that handles larger loads at better efficiency, PowerSTAR offset gears transmit higher torque output in a smaller profile, along with high energy efficiency sustained throughout all standard gear ratios. Bison Gear and Engineering began in 1960 by designing problem-solving gearboxes and gear motors for its customers. Today, the company has grown into an industry leader for fractional and low integral horsepower electric motor, gearmotor and gear reducer products by implementing innovative lean manufacturing processes, world-class engineering, and customer support teams, driven by its Robusticity design High-efficiency right angle gearmotor Delba Electrical has been certified as an Approved Partner, which includes field and repair services for the Siemens Large Drives highvoltage motor portfolio in South Africa, East Africa, Nigeria and Ghana. This also includes certification as a Service Delivery Partner for the repair of Siemens mobile mining rotating equipment. “Siemens Large Drives is proud to have Delba Electrical on board as a trusted partner. This qualification process requires stringent partner certification assessments conducted by Siemens at Delba Electricals’ world class facilities in South Africa,” explains Tim Walwyn, country CEO for Siemens Large Drives in South Africa. Delba Electrical will benefit from ongoing service module training and support through the worldwide Siemens network in order to perform the authorised services, including full access to original spare parts and technical support. Dave Balocco, managing director of Delba Electrical says: “This certification is proof that we are an entrusted partner with the highest quality of repair, field service and maintenance support for the wide range of products offered by Siemens Large Drives in the field of high-voltage motor technology. Siemens Large Drives is one of the world’s leading manufacturers of medium-voltage motors and converters. These products form the basis for drive systems optimised for a wide range of industries and applications. In the field of test benches, mining and cement, the portfolio is expanded to include complete solutions including electrification and automation. Digitalisation solutions and the extensive global services complete the range. For more information contact Siemens South Africa, [email protected], www.siemens.co.za Siemens Large Drives certifies Delba philosophy. This allows Bison to consistently expand its product line with newmotion control and power transmission solutions. For more information contact Bison Gear & Engineering, +1 800 282 4766, www.bisongear.com
www.motioncontrol.co.za Fourth Quarter 2022 13 Sun Hydraulics has applied more than 50 years of valve design experience to its rapidly expanding line of electro-hydraulic products. It have studied the future of fluid power, benchmarked the competition on performance and price and applied what it learned to develop some of the most reliable, hard-working solutions in the market today. Sun builds your solutions from the ground up, starting with a wide range of pressure control, flow control, directional and proportional valves with pilot-flow, full-flow and high-capacity versions available. It drives those electro-hydraulic valves with more than 100 different high-power, low-power and explosion-proof coils, providing precise control over millions of machine cycles. And then it puts you in charge, combining the XMD valve driver with its CANpoint Configuration Software to make implementation of your next solution simpler, more powerful and a lot smarter. Choose from open- and closed-loop configurations, with PID closed-loop pressure, position and speed control, variable-speed fan drive control and cylinder, pump and motor control. The valves It all starts with the valves. Sun offers more than 80 base model electro-hydraulic valves and hundreds of configuration options to give you the flexibility you need to configure the perfect solution for your application. Models include pressure and flow control; directional two-, three-, four- and six-way control; and a range of electro-proportional valves. Choose the DTAF 2-way directional blocking poppet valve – a small, powerful workhorse with extremely low leakage that delivers more than 10 million operational cycles and can be used to pilot larger Sun valves for higher flow rates in mobile applications. Or consider the Rugged, reliable electro-hydraulics From simple switching valves to sophisticated closed-loop control, Sun’s line of E-H products powers your most demanding applications. patent-pending RVC family of two-stage, fully adjustable, ventable and blockable reliefs that reduce circuit complexity by combining two functions in one valve and provide convenient field-adjustable relief settings. They offer precise, dependable pressure regulation with flow rates up to 100 l/min. Recently, Sun introduced the space-saving, pressure-compensated FREP flow control valve, combining an electro-proportional orifice and pressure compensator. This is ideal for situations where you need to maintain constant actuator speed regardless of the load on the actuator. This innovative design provides excellent variable flow control when using a fixed-displacement pump. The coils Every solenoid-operated valve needs a coil. Sun offers a full range of coil options to support your system requirements. Models are available in low- and high-power versions with options for 12-, 14-, 24- and 28- V DC and for 115- and 230 V AC. Connector options include DIN, Deutsch, AMP Junior, Metripack and twin leads. For hazardous locations, Sun offers explosionproof coils that are ATEX, IECEx and CSA certified, with 90° and 180° connector options and in Vdc and Vac versions. Sun has the coils to drive your application in any direction. The drivers Sun makes it easy to control it all with the XMD electro-hydraulic driver. The XMD gives you the power and flexibility you need for demanding applications. Available in single- and dualoutput versions, it is compact, incredibly rugged and can be configured quickly and easily using a smartphone and Sun’s XMD Mobile app or on a PC using Sun’s new CANpoint XMD Configuration Software. The XMD driver is CAN configurable and designed for extreme conditions – perfect for demanding mobile environments. It is powerful, affordable, dependable and flexible. In addition to the discrete XMD driver, Sun offers a line of configurable IR embedded amplifiers that includes proportional and switching coil/controller models in 12 and 24 Vdc versions with either current or voltage command. The software CANpoint Configuration Software is what brings it all together. It taps into the full capabilities of the XMD driver, providing quick, easy configuration over CAN bus using a computer. It allows XMD-02 users to implement open-loop, closed-loop (PID) and hydraulic fan drive control using pre-programmed modes for Sun’s dual-output driver. CANpoint is a free software configuration program for the XMD mobile drivers that simplifies advanced hydraulic control using a clear, simple software interface that allows for point-and-click output shaping with excellent resolution and predictable results. It requires no programming to take you from connecting to configuring to completing your application setup. The solutions Sun makes it easy to build your own electrohydraulic solutions using its QuickDesign browser-based schematic tool. You can take your idea from product specification to design using drag-and-drop, point-and-click tools. Once you are satisfied with your circuit, you can submit it and get a finished package design in as little as 10 minutes. For more information contact Lance Tondolo, AxiomHydraulics, +27 11 334 3068, [email protected], www.axiomsa.co.za
14 Fourth Quarter 2022 www.motioncontrol.co.za HYDRAULICS How has the hydraulics market changed? Sourcing of products has become a very erratic and difficult business. Despite technology, buyers are faced with serious challenges to find filter and element replacements, as some older equipment is no longer available in the country. They often find it difficult to identify the product through the brand or product code. Most hydraulic systemmanuals recommend that field service personnel replace filter elements according to the operational system specifications with the OEM’s component part. This is identified on the filter element or clearly marked on the housing identification plate. The designated system must be maintained appropriately to obtain optimum operating performance. With ongoing supply chain constraints, production delays and the ever growing need to reduce operating costs, buyers are having to source cheaper replacement elements, and are increasingly sourcing aftermarket replacements due to long lead times from OEMs. Maintenance engineers first need to investigate the performance output and criteria of the original branded elements and consider the factors below relating to specifications and criteria. When considering the purchase of aftermarket filters and/or elements, equipment maintenance teams must ensure that the original specifications of the system are retained and achieve the specified cleanliness levels. Incorrect filter replacement will seriously affect plant and equipment. Factors to consider are the appropriate design characteristics of the original filter, type of filtering media (efficiency) and micron rating. Hydrasales specialises in hydraulic and lubrication filtration equipment. Filtering surfaces are separated into two distinct groups that are suitable for a wide range of applications, whether it be return line, suction, inline, low- or high-pressure filters. Surface filtration Surface filtration prevents any particles greater than the pore size entering the system by direct intervention. Here the filter media normally comprises metal mesh material, and is used in strainer applications and suction lines, or lube systems where higher contamination levels are acceptable. A buyer’s guide to hydraulic filter and lube filter replacements Depth filtration Depth filters are composed of overlapping fibre mats, which form flow paths in various shapes and dimensions. The particles are retained in the pores, which are smaller than the diameter of the particles. During filtering with inorganic fibres (commonly called microfibres), the filter layers are often placed on top of each other to increase the element’s efficiency in arresting and retaining contaminants. Within depth filtration, system maintenance personnel will commonly be offered two types of media with differing filter efficiencies. The first is commonly referred to as paper or nominal filter cartridge (a single layer of cellulose fibre reinforced with resins). The element may be of the correct micron rating but has lower filtering efficiency. The second, referred to as absolute filter elements, is more sophisticated and may comprise six differing layers of filtering material, including multilayer microfibre, metal mesh, and internal and external support, as well as a PET layer for protection during the installation process. Buyers are often lured into buying a cellulose paper filter to replace a microfibre element. This is due to the substantially lower price, with the filter having the same micron rating. Lowering the efficiency of a filter will allow for a higher threshold of contamination within the oil. Replacing a microfibre element with a cellulose fibre element can reduce the filtering efficiency by as much as 50%. This can result in frequent breakdowns and higher repair costs as a result of an increase in leaking seals, component failure, and downtime. Filter beta ratios and efficiencies Two identically sized filters with the same micron rating can have completely different makeups, and be suitable for very different applications or cleanliness requirements. Filtering elements need to adhere to and be tested in accordance with ISO 16889, Hydraulic Fluid Power – Multi-pass Method for Evaluating Filtration Performance of a Filter Element. The efficiency of microfibre and paper filtration is measured by the Multipass Test. The beta ratio is the ratio of the number of particles of a maximum given size upstream of the filter to the number of particles of the same size and larger that are found downstream. The higher the beta ratio, the higher the capture efficiency of the filter. Referring to types of filtering surfaces, a cellulose paper element has a beta 2 ratio with a 50% efficiency, whereas a microfibre element has a 99,9% efficiency, being a 1000 beta ratio. It is imperative to not only look at the micron rating, as it is not possible to evaluate a filter without considering the efficiency or beta ratio at that micron particle size. For more information contact Hydrasales, +27 11 392 3736, [email protected], www.hydrasale.co.za
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