: Levitating, contactless, intelligent! VOL 25 NO 1 • FIRST QUARTER 2023
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www.motioncontrol.co.za First Quarter 2023 1 SAFPA news News & events New technology Product news OUR COVER 9 FIRST QUARTER 2023 03 07 10 32 REGULARS FEATURES 11 SEW-EURODRIVE, Zest WEG Group Africa 14 BMG, Instrotech, Bosch Rexroth South Africa, Axiom Hydraulics, Alba Hydraulics 18 BMG Yaskawa Southern Africa, University of Bristol, Omron Electronics, Bosch Rexroth South Africa 22 28 Beckhoff Automation, Pepperl+Fuchs, Fuchs Lubricants South Africa, NSK South Africa 23 Drives Hydraulics Condition monitoring Robotics Pneumatics Sustainable energy & energy efficiency Planar movers that travel like flying carpets are creating new possibilities in machine design. XPlanar, a new breed of transport system, brings unprecedented flexibility to product transport, and could revolutionise manufacturing plant and machine design. Read our cover story on page 9 to find out more about the potential benefits that XPlanar offers users and machine builders looking to simplify machinery and boost performance. : Levitating, contactless, intelligent! VOL 25 NO 1 • FIRST QUARTER 2023 SMC Corporation South Africa, Deprag Schultz
2 First Quarter 2023 www.motioncontrol.co.za welcomeFIRST QUARTER 2023 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. Artificial intelligence has been around a while, and AI is part of our vocabulary. I seem to remember that in my last editor’s letter I said that new technology comes slowly and then fast. Now I’m wondering what happened − the world has ChatGBT. It was released on 30 November last year, and in less than a week over a million people had tried it. In comparison it took 41 months for Netflix to get its first million users. ChatGPT is an advanced chatbot created by the software company OpenAI. GPT stands for Generative Pre-trained Transformer. It is based on neural networks that have learned to perform a task by drawing on huge amounts of existing text generated by humans, and uses machine learning to create realistic, relevant, and intelligent sounding text in response to questions. Apparently it can compose emails, create poems and essays, put together recipes, write funny dialogue, generate images, answer follow-up questions, admit its mistakes, and challenge incorrect premises. It is capable of explaining complex issues and can be used to categorise text, such as spam or not spam, or positive and negative sentiment. It also has the ability to write and debug code like a developer. It has the potential to boost productivity in the same way that steam engines, electricity, and computing have done in the past. Phew! Here are some things it can be used for. It is potentially useful for a wide range of tasks, from creating software, to generating business ideas, to writing a wedding toast. Customer service is a huge area of opportunity. Businesses can automate tasks typically done by humans and greatly improve response time. They can monitor customer sentiment, summarise long texts, assist with customer service enquiries, provide product recommendations, and help with R&D. One application is as a replacement for search engines like Google, and the big players are rising to the challenge. OpenAI investors include Microsoft and LinkedIn. A potential application in motion control is to use natural language to monitor and control automated machines and systems, and to adjust parameters like speed, direction and position. It could also help with predictive maintenance; and it could generate interactive training and educational material for engineers on hydraulic and pneumatic systems. I thought I would give it a try. I entered ‘trends in hydraulics and pneumatics’ and this is what I got. “Some recent trends in the field of hydraulics and pneumatics include the increased use of smart technologies, such as sensors and control systems, to improve the efficiency and performance of hydraulic A new disruption and pneumatic systems. Another trend is the use of high performance materials, such as lightweight metals and composites, to reduce the weight and size of hydraulic and pneumatic components. Additionally, there is a growing interest in using renewable energy sources, such as solar and wind power, to drive hydraulic and pneumatic systems in order to reduce their environmental impact.” So there you have it, quite a lot. Hopefully, we are covering these things. I also thought I would see how it handles an editor’s letter. The result is too long for this column, but it didn’t do a bad job, although it was a bit bland and generic. But it left me wondering what it would produce next time. As an editor you can’t write the same thing every time. Some caution is needed. One area where it is causing huge disruption is in the academic world, where it can generate believable abstracts of scholarly articles or write a student’s term paper while scoring 100% on a plagiarism detector. There is also fear that it will replace jobs and make many tasks currently handled by humans obsolete. It can generate convincing prose, but that doesn’t mean what it says is factual or logical. The system is only as good as the data that it’s trained with. The answers can sound so authoritative that users may believe it is accurate. It may be putting out text that reads nicely and sounds smart, but is incomplete, biased or wrong. OpenAI has tried to limit its ability to accept inappropriate requests and generate hate speech and misinformation, but another risk is the potential for it to engage in malicious activities. The other day I saw a report on how ChatGPT gave extensive advice on how to join a cartel and smuggle cocaine into Europe. I’m not sure whether all this is exciting or frightening, I think both. The question is not whether this new version of AI will be able to take on more cognitive tasks but rather how we will adapt.
4 First Quarter 2023 www.motioncontrol.co.za From the President’s desk SAFPA President, Michael Abbot. www.safpa.org.za +27 11 061 5000 [email protected] SAFPA NEWS 2023…. A little late to wish all compliments of the season with the first letter being released in February. I would however like to wish all a successful year and hope everybody returned to work after a safe and relaxing festive break. Unfortunately for SAFPA, things have started off being very busy within our industry, thus not allowing time for most of the council members to focus on SAFPA duties. This has also led to the council meeting of February 2023 having to be cancelled. However, council members have been looking at alternate avenues for training programmes that could assist members in basic training of staff members, assisting businesses to grow their staff. Further details to follow once a trail period has been completed. On a brighter side, SAFPA has managed to arrange its first technical meeting for the year. The meeting will be hosted by Hydranet & Trelleborg Sealing Solutions. This meeting will be as a virtual/on-line meeting as the presenter is based in Europe. The meeting will be held on the 2nd March. It’ll be a technical talk/discussions on the latest sealing solutions from the world’s leading seal designers and manufacturers. SAFPA looks forward to a positive attendance from its corporate members and associated staff. The Hose Accreditation Course is still not being supported by industry as Council had intended. A course is being planned for the 18 & 19 April, with a few spots being booked. We ask that all members buy into this programme as it creates awareness within the work place with the intent of safety and knowledge being passed to the learners who are given this opportunity to learn. An event schedule for 2023 was proposed by the Secretariat. This schedule was approved by the council members. I ask all SAFPA members to take note of the events planned, with some additional technical meetings being squeezed in during the year.
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6 First Quarter 2023 www.motioncontrol.co.za SAFPA NEWS SAFPA recently hosted its first Soccer Day in three years, and it was a great success. The teams enjoyed themselves and a full day of clean fun was had. Ryco took home the 1st place prize, followed by runners-up CT Hydraulics. SAFPA would like to thank everyone who registered, and looks forward to seeing everyone at the next one. SAFPA soccer day The fluid power industry is changing due to global megatrends such as urbanisation, the need for infrastructure replacement, and climate change initiatives driven by regulations. To meet this challenge the International Fluid Power Exposition (IFPE), being held in Las Vegas from 14 to 18 March, is showcasing the latest leading edge innovations and expertise in the fluid power, power transmission and motion control industries. IFPE’s publication How Digitalization & Electrification improve Efficiency in Fluid Power has insights from companies such as International Fluid Power Exposition Bosch-Rexroth, Parker and ifm. The book reviews changes to the fluid power industry as a result of electrified technology, and gives input from leading industry experts on the challenges, and the industry’s future direction. The experts quoted are from the over 375 companies exhibiting this transformative technology at the exposition. Here are some of the issues highlighted. Predictive maintenance The ability to predict problems accurately is critical for efficiency. Bosch-Rexroth is featuring digital and electric products that help deliver this. The technology includes electric motors, power distribution units, onboard chargers and a new series of electronic controllers. Supply chain The past two years have demonstrated the importance of supply chain efficiency and how disruptive life becomes when it’s not efficient. Add to that the pain of inflation, and these factors begin to impact the speed of electrification. One solution is to accelerate product development using 3D printing. Safety No one wins if equipment does not address safety. One way digitalisation delivers safety is by enabling the regulations. It has a direct correlation to improved safety, which enhances efficiency. Parker has sensors, connected hydraulic valves, and other components with less wiring and cables that could fail. The company also offers intelligent machine controllers that leverage AI to make logical decisions automatically before sending the data to the cloud. A more data-driven approach to fluid power How do we turn machine data into machine wisdom? IIoT is about connecting functions together to improve the whole. Leveraging technology to automatically connect one engineer with another can leverage the expertise of both disciplines to achieve the maximum possible efficiency beyond the individual component level. Designing modular components that engineers can arrange and integrate into customised systems is the enabler for elevating fluid power efficiency beyond anything possible today. One thing the experts agree on is that the most crucial consideration when developing new technology for electrification is this: companies that build technology that maximises overall system efficiency will win, and society will be the beneficiary. To view the e-book visit www.motioncontrol.co.za/*ifpe
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 Siemens Digital Industries Software has launched Hour of Engineering, an engaging online learning programme to empower educators to introduce students to engineering and technology with right-sized, kid-friendly learning content in as little as one hour. Through this new programme, Siemens intends to inspire, engage and educate students about the role and fundamentals of engineering before they begin high school, helping to create a robust pipeline of future engineers. Without that spark of interest, by the time students reach high school many will have already decided against engineering, based on common misconceptions about the field. “A career in engineering can take many different paths, all of which can be rewarding and help make the world a better place. It is vital that pre-high school students are exposed to engineering careers and concepts earlier. Our aim is to empower educators to do exactly that, with resources that can be deployed without additional training and which don’t place additional burdens on tight budgets,” said senior director of Siemens Digital Industries Software, Brian Grogan. Hour of Engineering is a direct response to the shortage of engineers. It aims to get Siemens Hour of Engineering sparks interest in STEM students excited about engineering careers early and build confidence and problem-solving skills that they can apply in all fields of study, including engineering disciplines. Hour of Engineering learning content is aligned to science, technology, engineering and mathematics standards. Each learning activity is easy to implement and includes a teacher guide that provides suggested sequences for learning with options for one to 20 hours. For more information contact Siemens South Africa, [email protected], www.siemens.co.za
8 First Quarter 2023 www.motioncontrol.co.za NEWS & EVENTS Bosch Rexroth South Africa has announced that Mike Harrison, current Bosch Rexroth regional director East Africa and general manager of Hytec SA, has been appointed to the role of chief operating officer at Bosch Rexroth South Africa, reporting to Chris Riley, group CEO. In his new role, Harrison retains responsibility for Bosch Rexroth Africa Development, Mozambique and Namibia, while assuming responsibility for group strategy. He has been at the helm of Hytec for more than a decade, with the more recent extension of his role and responsibility to East Africa. Through his leadership, the company has experienced significant geographic expansion, both locally and at a regional level. He also played an instrumental role in the successful merger between Bosch Rexroth and the previously known Hytec Group. Harrison will be succeeded by Freddie Kühn as the new general manager of Hytec SA. Kühn is the current sales director at Hytec SA, having assumed responsibility for sales in the organisation three years ago as part of the group’s succession plan. He has contributed to the success of Hytec SA for more than 25 years and will now take responsibility for the rest of the functions within Hytec SA. Kühn has worked closely with Harrison and has made significant contributions to Hytec SA. For more information contact Gillian Allin, Bosch Rexroth South Africa, +27 11 979 4630, [email protected], www.boschrexroth.africa New leadership appointments at Bosch Rexroth South Africa Korea Hydrogen Green Energy Network (KOHYGEN) has chosen Emerson’s advanced automation solutions to help ensure the safety and reliability of its pioneering hydrogen infrastructure initiative, which recently marked the completion of the world’s largest hydrogen refuelling station for commercial vehicles. The project is an important step toward the two organisations’ goals of reducing emissions, driving investment in hydrogen, and accelerating the transition to a net-zero global economy. “We are committed to building smart, safe hydrogen refuelling infrastructure by leveraging IT-based integrated operations, using large capacity, high-efficiency charging systems and, most importantly, strengthening design safety standards,” said KyungSil Lee, KOHYGEN’s chief executive officer. The JeonjuPyeonghwa hydrogen refuelling station is the first gas hydrogen refuelling station of the 35 high-capacity gas or liquid hydrogen refuelling stations KOHYGEN plans to construct across Korea by 2025. The first station has a charging capacity of 300 kilograms per hour, which can fuel up to 15 buses and trucks per hour, or over 100 per day – 12 times more than an average-capacity hydrogen station. To further lay the foundation for a stable hydrogen supply chain, Emerson and KOHYGEN World’s largest hydrogen refuelling station are collaborating on technical standards for future high-capacity commercial refuelling stations and similar projects. KOHYGEN plans to expand its hydrogen supply platform to service hydrogen-powered aircraft, ships and other diverse forms of transportation. “In line with Emerson’s ‘Greening By’ sustainability strategy, we have worked on a range of hydrogen projects globally, applying our expertise and innovative technologies to scale hydrogen consumption and make renewable energy a reality,” said Mike Train, Emerson’s chief sustainability officer. “Partnering with KOHYGEN is another critical step forward in diversifying our global energy mix.” In addition to deep domain experience across the hydrogen value chain, Emerson is providing core technologies, including temperature transmitters, flowmeters, pressure transmitters, PLCs and valves, to deliver the high level of performance necessary for developing a commercially-viable hydrogen charging model that can expand Korea’s domestic hydrogen market and serve as a template in other countries. For more information contact Emerson Automation Solutions, [email protected], www.emerson.com Schneider Electric has been recognised in the Bloomberg Gender-Equality Index (GEI) for the sixth consecutive year. This recognition highlights Schneider’s ongoing efforts to increase gender equity across the company and build an inclusive and caring work environment. The 2023 Bloomberg GEI lists 484 companies across 54 industries in 45 countries, and measures their performance according to five key pillars: leadership and talent pipeline, equal pay and gender pay parity, inclusive culture, anti-sexual harassment policies, and external brand. Schneider Electric achieved an overall score of 81%, up from 77% the previous year and well above the index average of 73%. The company has maintained its consistently strong performance for equal pay and gender pay parity (88%). Its above average score for leadership and talent pipeline (55%) reflects progress toward its goal of improving gender representation through Schneider Electric achieves in Bloomberg Gender-Equality Index Mike Harrison, incoming chief operating officer, Bosch Rexroth South Africa. Freddie Kühn, incoming general manager, Hytec SA. increased hiring, promotion and retention of women. As of December 2022, women represent 41% of Schneider’s executive committee and the company is committed to achieving 50:40:30 gender balance (ie., women representing 50% of all new hires, 40% of all frontline managers, and 30% of senior leadership) by 2025. Schneider Electric has also been named as one of Fortune’s 2023 World’s Most Admired Companies for the sixth consecutive year, ranking third in the electronics industry. This is a testament to the company’s ongoing commitment to fostering an inclusive and equitable workplace while reducing its environmental impact and providing sustainable solutions for its customers. For more information contact Schneider Electric South Africa, +27 11 254 6400, [email protected], www.se.com/za/en/
www.motioncontrol.co.za First Quarter 2023 9 Planar movers that travel like flying carpets are creating new possibilities in machine design. XPlanar, a new breed of transport system based on floating planar movers able to travel freely over a floor of planar tiles, brings unprecedented flexibility to product transport, and could revolutionise manufacturing plant and machine design. Beckhoff’s senior product manager of Drive Technology, Uwe Prüßmeier discusses the potential benefits that XPlanar offers users and machine builders looking to simplify machinery and boost performance. The planar movers used to transport products can be positioned with absolute flexibility, anywhere within a two-dimensional space. How does this new freedom benefit product transport? Prüßmeier: This ability to travel independently in two dimensions not only allows movers within a system to overtake one another on the same plane, called floor in XPlanar, but also to form product buffers and bypass these buffers. As a result, products no longer need to proceed from one processing station to the next in the exact same sequence. Instead, because the movers can be positioned literally anywhere, they can be sent to processing stations in any order; this means that each individual product need only travel to those stations required to process it. Clearly, this opens up huge potential when it comes to designing faster and more efficient process flows, and optimising machine and plant layouts, with a view to bringing down space requirements and costs. Can you give specific examples of ways in which processes can be streamlined? Prüßmeier: One example is that movers can easily be extracted from the production process – for example to allow maintenance or to discard flawed parts. Also, being able to set up special holding zones for in-process parts can lead to significantly better process efficiency. The ability to let faster movers overtake slower movers is useful too, as this allows sub-processes to execute swiftly, in parallel. Connecting up different sections within a plant is also easy. Another way to enhance process efficiency is to split up a machine’s product stream. Much like road traffic spread across multiple lanes at highway toll booths, separate product streams can be sent through different sets of stations to optimise processing, and then re-merged and synchronised later. Image copyright: Beckhoff Automation. A new breed of transport system Interview with Beckhoff’s senior product manager of Drive Technology, Uwe Prüßmeier on the potential benefits of the company’s XPlanar transport system. The movers can travel with six degrees of freedom. What particular benefits does this afford? Prüßmeier: The planar movers not only carry payload products to their intended processing stations, they can also move the products inside the stations, rotate them through all three axes, and even ascend, descend and tilt a few millimetres to allow a product to be processed or inspected easily from any side. A slight tilt can also help prevent spills when accelerating quickly with a container full of liquid. The planar floor over which the movers hover can be configured individually to suit specific machine designs. What role does this play in machine optimisation? Prüßmeier: Here too, we put flexibility front and centre. The tiles can be laid out in any shape – and even wall or ceiling mounted – so the XPlanar system can be configured to suit a given application’s requirements perfectly. For instance, you can leave gaps within the tiled floor to accommodate processing stations or lay tracks around plant components. This means users can set up a transport system in a cost-optimised fashion, and at the same time reduce machine size to a minimum. In addition, it’s easy to modify the planar motor system subsequently, just by adding more tiles when necessary – for instance to accommodate new processing stations or gain extra space to optimise motion through curves. Can XPlanar be used universally in machine and plant engineering? Prüßmeier: Yes. There are almost no limits on using it in production plants and machines, provided a product’s weight and volume are within the planar movers’ payload carrying capacity. The system is particularly interesting for those sectors with special requirements in terms of hygiene and cleanability, zero emissions or low noise, because mover transport is contact-free, and therefore silent and completely wear-free. The food and pharmaceutical industries are a case in point, and processes like semiconductor production that require a vacuum can benefit particularly from an abrasion- and contamination-free product transportation system. For more information contact Dane Potter, Beckhoff Automation, +27 79 493 2288, [email protected], www.beckhoff.com/en-za/, https://youtu.be/On_QL8znZHg
10 First Quarter 2023 www.motioncontrol.co.za NEW TECHNOLOGY Automated cultivation of biomass Algae are small climate savers. Even in their natural state they are extremely efficient photosynthesisers and absorb ten times more carbon dioxide than land plants. In bioreactors equipped with appropriate sensors, control technology and automation, the efficiency of algae can be increased to a hundred times that of land plants. This shows that they have a significant potential for a climate-neutral circular economy. The PhotoBionicCell research project, part of the Festo Bionic Learning Network, is demonstrating a potential approach for industrial biologisation in the future. “Our aim is to make a significant contribution to the quality of life of today’s and future generations through the large-scale cultivation of biomass using our automatic technology,” says Dr. Elias Knubben, Festo vice president of Corporate Research and Innovation. Algae are automatically cultivated and their growth controlled in the bioreactor. The algae liquid is pumped upwards into the surface collectors where it is distributed in an even flow and then flows back to the cultivator. During this circulation, the algae cells, through photosynthesis in their chloroplasts, convert sunlight, carbon dioxide and water into oxygen and chemical energy carriers, or organic recyclable materials. That is how biomass is cultivated in a closed cycle, which is highly efficient and conserves resources. Efficient photosynthesis in the high-tech bioreactor The combination of tried and tested open-loop and closed-loop control systems with state-of-the-art automation components creates the ideal conditions for the microorganisms. An integrated gassing concept ensures that the carbon dioxide from the air is evenly distributed into the circulating biofluid. A major challenge for bioreactors is how to determine the volume of biomass precisely. Festo’s developers are using a quantum technology sensor supplied by the startup company Q.ANT to do this. It returns accurate information on the growth of the organisms in real time. Using microfluidics, the algae are automatically and continuously pumped past the sensor. The quantum sensor is able to optically detect individual cells so that the amount of biomass can be determined exactly. In addition, it examines the cells for their vitality. Only then is it possible to react to process events in advance and to regulate them. Biological recyclable materials for climate-neutral end products Depending on the nutrients fed to the algae biomass, the products that are formed as part of the metabolic processes are fatty acids, colour pigments and surfactants. They can be used as the starting materials for the production of medicines, foodstuffs, plastics, cosmetics or fuels. Unlike petroleum-based products, biologically-based end products can usually be biodegraded and, in keeping with an overall circular economy, recycled in a climate-neutral process. Festo’s researchers have also focused on the cultivation of the blue-green algae in their work for the PhotoBionicCell. They are producing colour pigments, omega-3 fatty acids and polyhydroxybutyrate (PHB). By adding other substances, the resulting PHB can be processed into a filament for 3D printing. Complex forms of sustainable plastic components or packaging can be manufactured in a short time with this modern production technology. For example, specific fastening clips made of bioplastic are installed in the PhotoBionicCell. Artificial Intelligence and digital twins Festo’s developers are also using AI to evaluate the data. This allows the bioreactor to be optimised for the propagation of the algae cultures or to maintain specified growth parameters with minimal energy input. It can also be used to forecast the service life of valves and other components. The use of digital twins created with the help of AI is also possible. They could be used in future to simulate complete lifecycles of bioreactors and to show virtual images. The expected cell growth of different microorganisms could also be estimated with great accuracy before the physical setup up of a real system. Synthetic biology for maximum efficiency However, it is not just the individual building blocks of photosynthesis that can be optimised. The scientists are working on the digital optimisation of complete metabolic paths. This approach is referred to as synthetic biology. A metabolic path optimised on the computer is packed in synthetically manufactured cells, referred to as droplets. They have a diameter of around 90 microns and contain all the required enzymes and biocatalysts. This enables them, like their biological models, to absorb carbon dioxide using light energy. For more information contact Festo South Africa, 08600 FESTO (33786), [email protected], www.festo.co.za
www.motioncontrol.co.za First Quarter 2023 11 Many critical industrial and other applications can benefit from medium voltage (MV) electric motors, due to their reliability and low total cost of ownership. According to Zest WEG sales specialist, Floris Erasmus, the benefits of MV electric motors include being purposedesigned and well protected. This makes them very reliable, and thus well suited for critical applications where the risk of failure-related disruption must be mitigated. “Any motor application – from pumps and fans to crushers and conveyors – can present a critical risk if a significant portion of the whole operation relies upon it,” he says. “In these cases, it is often worth considering the MV motor option in new projects or in circumstances where motors are being replaced.” He adds that while the category of low voltage (LV) electric motors tends to end at about 1000 V, MV motors range from 1000 V up to as high as 33 kV. In the South African market, the upper end of the MV range is usually 11 kV. MV motors are generally not off-the-shelf, and are rather specially designed for their application. The construction is also different to an LV motor. The wire used in the windings, for instance, is more like a rectangular bar. Normally covered with mica tape, they make up form-wound coils. The coils are individually wrapped with thicker insulation to accommodate the higher voltage. There is only one turn in a slot, so there is no potential difference between turns; this MV motors deliver reliability and better total cost means that there is less chance of an inter-turn failure or short circuit between coils. An important difference in the winding of an MV motor is that it is conducted using vacuum pressure impregnation (VPI) and the use of an epoxy resin. Applying this resin in a vacuum allows all air and moisture to be removed. The absence of air allows the resin to flow more effectively into the spaces between the steel core and the copper winding. The incidence of air pockets in the slot of the stator is where many winding failures in motors begin. If resin is not effectively distributed, this can undermine the mechanical strength of the winding. The epoxy resin used in MV motors is very strong compared to varnish. In addition, the removal of moisture during the VPI process reduces the possibility of short circuits caused by water particles trapped inside the motor windings. “Another benefit of MV motors is their low starting and operating current,” he continues. “The kilowatt rating of a motor – the power it consumes – is a function of the voltage; by raising the voltage, the amperage drawn in reduced. The starting current of a motor tends to be about six times higher than the operating current. By reducing the operating current, an MV motor helps to reduce the strain that high starting currents can place on the electrical system in a mine, plant or factory.” The MV option also has a distinct advantage when it comes to the use of variable speed drives (VSDs). The transformers that are part of the MV motor installation ensure that no extra filters or add-ons are required to achieve near perfect sine waves. He notes that MV VSDs are also better at disrupting harmonics in the electrical system. Protection systems on MV motors are an important aspect of ensuring their longevity. Erasmus explains that they are normally electrically protected with a smart relay, which is password protected. This makes it difficult to bypass the overload systems that protect the motor, and prevents the motor from being started under fault conditions. While this protection might slightly increase installation costs, it helps reduce total cost of ownership. “In terms of our own MV offering, WEG has recently launched its W51 range, which includes MV motors,” he says. “This new range offers improved efficiencies and higher output to weight ratios, and the motors are suitable for VSD.” Availability is from a 315 to 450 frame, which, with four-pole motors, translates to a range of 132 to 1400 kW. The standard range reaches 6,6 kV but motors up to 11 kV can also be requested. The range includes motors for hazardous areas, where there may be gases which are susceptible to ignition. For more information contact Zest WEG Group Africa, +27 11 723 6000, [email protected], www.zestweg.com
12 First Quarter 2023 www.motioncontrol.co.za To best meet urgent local needs and harsh conditions with massively improved lead times, SEW-EURODRIVE is on a mission to localise its modular drive concept for a variety of industrial drive applications. Jonathan McKey highlights a few of the advantages this presents for the power generation sector. The company’s expanded local capability from its new Aeroton facility will include the assembly of its latest X.e Series industrial gear units (IGs); its modular air-cooled condenser units (MACCs); standard, VSD- and servo-driven gearmotors; along with customer specific drive-train packages. For the power industry these include conveyor, cooling tower and ash drives; girth-gear solutions; fans; pump drives; and many other purpose-built modular solutions. X.e Series gear units Modular X.e Series units, the latest evolution in the IG range, are now even more robust, reliable, efficient and easy to maintain than their predecessors. Significantly increasing the number of possible torque/speed combinations and fine-size graduations enables solutions to be custom-built to suit client specification precisely. Additional modular features and options include motor adapters; integral and load sharing backstops; sealing; and shaft Modular drives for power generation systems. All these add to the ease of use and reliability of X.e Series drive solutions. The X.e series offers an optimised choice of gear unit sizes, reduced gear unit weight and sufficient centre distances. In addition, when the drive needs to be operated at low speed during maintenance, for example, the drive package can be equipped with a directly mounted slow-speed auxiliary drive to advance the system while the main drive is switched off. The new X.e range is also ideal for girth gear applications, where the new generation units have become the global standard for use with the company’s segmented mill drive solution. MACC Series drives MACC drives are purpose designed for driving the modern fan-based air-cooled condenser (ACC) systems used in steam-driven power generation plants. ACCs need to generate huge air flows to cool and condense exhaust steam from turbines. “Our modular air-cooled condenser (MACC) drives have specific optimisations to make them tailor-made to best suit these applications,” McKey explains. “These include a stiffer case with built-in cooling veins for improved cooling; the internal extended bearing distance (EBD) system, which better enables the gearbox bearings to accommodate the very high axial and radial forces transferred through the fan; and the drive shaft. “These are compelling reasons for power stations to replace faulty ACCs with our MACCs. To make this easier for plant operators, we build customised adapter plates to enable our design to be easily retrofitted as a direct replacement for any older-generation boxes currently in use. We also customise the output shaft length to perfectly match the ACC infrastructure onsite and to establish the ideal fan position for maximum efficiency,” he continues. The typical lead time for imported large industrial gearboxes by most gearbox OEMs can range from 18 to 24 weeks or more. Once the company’s assembly plant is complete and operational, it will be able to assemble most common modular designs locally at capacities of approximately three to five per week. Electric motors, gearmotors and VSDs Supporting drive trains for the power generation and other industrial sectors are the SEW electric motors, which are available in the power range from 0,09 to 375 kW, and in efficiency classes IE1, IE3 and IE4. “Our IE3 DRN motors have now replaced our IE2 range, and we can also supply premium efficiency DRU motors which meet IE4 efficiency requirements if requested,” notes McKey. “All of these motors are directly compatible with SEW’s modular approach to drive packages, either in combination with an industrial gear unit – as directly coupled to a helical or bevel-helical gear unit or as part of a complete drive package on a base-plate – or fully incorporated into a gearmotor unit.” SEW-EURODRIVE’s inverters, controllers and other electronic systems, including AGVs, will also be locally assembled in a clean and staticfree area of the new Johannesburg factory. These are perfectly tailored to control the speed, torque and application-specific functions of drive systems to get the most out of the company’s modular drive trains and gearmotors in terms of energy efficiency and functionality. “Local assembly of these modular systems demonstrates our commitment to being part of solving South Africa’s long lead supply problems, while also attracting business from across the world from those experiencing long delays in meeting urgent needs,” McKey concludes. For more information contact Jana Klut, SEW-EURODRIVE, +27 11 248 7000, [email protected], www.sew-eurodrive.co.za DRIVES
14 First Quarter 2023 www.motioncontrol.co.za HYDRAULICS Hydraulic systems − which operate under extremely high pressures with tight tolerances − are susceptible to wear from abrasive particles, and therefore require efficient filtration to offer adequate protection of equipment. Contaminants can enter the hydraulic system from several sources, for example the manufacturing process of system components or exposure to environmental dirt, dust and moisture during production. Problems also result from low quality or unclean hydraulic fluids used during the filling process, or from wear over time. Because filtration is the only effective defence against wear and tear when contaminants are present, it is critical that effective filter components are used to ensure dependable performance, high efficiency and extended service life of machinery and vehicles. “Without a structured control and contamination prevention programme, premature equipment failure is likely to occur, resulting in unnecessary downtime and costly replacement of parts,” explains BMG product specialist, Hanli Schutte. “BMG Fluid Technology’s filtration solutions comprise a wide range of fluid power components and systems, supported by the team’s broad technical capabilities, to ensure fluids − including oil, fuel and lubricant oil − operate within the required cleanliness standards.” BMG’s premium filtration partner, Filtration Group, manufactures advanced filters that ensure that the fluid in the circuit of the process meets the required cleanliness class. Design and materials used for the construction of filter housings and elements exceed industry standards and through the latest technologies, like PulseShield and e-protect, the dirt holding capacity of filter systems is increased to ensure full functionality, even in the most challenging environments and applications. Filtration Group’s product portfolio comprises desiccant breathers, which are designed to replace conventional dust caps or breathers of equipment like hydraulic units, where there are high humidity and temperature fluctuations. With this highly efficient filtration system, Why efficient filtration is critical in hydraulic systems contaminated air passes through layered filter media, which blocks particles from entering the breather. A bed of silica gel absorbs any moisture in the air to keep equipment dry. This technology prevents problems associated with condensation, ageing of hydraulic oils, degradation of additives, and corrosion. Within a hydraulic system there are typically four locations where filters are required: suction line, return line, pressure line, and reservoir breathers. Suction filters are designed to remove large particles that accumulate within the hydraulic fluid reservoir, while safety filters can be positioned inside the reservoir or outside the reservoir on the suction side of the pump. The objective of return line filters is to remove contaminants from the hydraulic fluid before it is returned to the reservoir. Pressure line filters – also known as point of use filters − remove fine particles before application and can withstand high operating pressures and temperatures. Breathers on reservoirs protect the hydraulic system from environmental contaminants like dust and moisture. An important feature of Filtration Group filter elements is that they are fully compatible with housings of other filter manufacturers and increase the efficiency of the installed filtration system. Through the acquisition of OMSA in 2013, BMG extended its services into the filtration sector. BMG’s OMSA ECO spin-on elements enable fast and convenient protection for the offloading and dispensing of bulk fuel. This range includes fuel and water separating filter elements for 6 micron and 3 micron particle removal. These filters are used extensively in BMG’s custom-designed offloading and dispensing filtration systems. In addition to the design and manufacture of new bulk fuel systems for oil and lubrication purification, BMG’s technically skilled team offers a refurbishment service for existing systems. Typical applications are in machine tools, mining, power generation, sugar, pulp and paper, cement, marine, and hydraulic industrial equipment. These systems are designed and manufactured to exact customer specifications and generally include all mechanical, electrical and pneumatics as required. Bulk fuel systems can be designed as permanent in-line or off-line systems, as well as portable systems that can be used in multiple applications. In order to provide customers with continuous contaminate-free fuels and lubrication solutions, BMG’s Field Services department offers services that include the inspection, service and maintenance of bulk fuel and hydraulic systems. Oil analysis is conducted by BMG’s qualified tribologist, to ensure the required cleanliness of oils and fuel. BMG’s fluid technology services include solutions for fuel and industrial filtration systems, hydraulics and pneumatics, lubrication, hydraulic hose and fittings, and instrumentation, pumps and industrial valves. Through its specialist skills and dependable stockholding of components, BMG is able to meet high demand from customers for dependable filtrations services throughout the African continent. For more information contact Hanli Schutte, BMG, +27 11 620 7449, [email protected], www.bmgworld.net
Tel: +27 11 334 3068/86 | Fax: +27 11 334 4543 | www.axiomsa.co.za
16 First Quarter 2023 www.motioncontrol.co.za HYDRAULICS Sailing has been a means of transport for millennia, and the spirit of sportsmanship is as old as humanity itself. At the Vendée Globe 20-21, a non-stop, round the world regatta which takes place every four years, a total of 167 solo sailors started on the Clipper route. Entrants navigated 44 000 km between November 2020 and March 2021. Regatta rules allowed participants to moor with an anchor, but not at a dock or next to another boat. Besides that, they received no other external assistance. The French-German skipper, Isabelle Joschke set sail in this challenging race in November 2020. Her boat was fitted with a tiltable keel so that when the keel was tipped to the windward side, the tilt of the boat was reduced. In case of possible capsize, the boat could be righted again by tipping the keel to its maximum extent. These keels are mandatory in sailing races. The French company Hydroem delivers assembly kits for boats which are fitted with this type of keel. The keel is activated with a hydraulic cylinder built into the floor of the boat and connected to the keel. The distributor is between the hydraulic group (electric motor, Sailing the seven seas Image copyright: Jean-Marie LIOT. hydraulic pump and oil tank) and the hydraulic cylinder. This contains electrical valves needed for controlling the hydraulic pressure. The Keller Sensor 21Y is also connected to the distributor, and measures the pressure of the keel cylinder. The skipper can influence the system and keel directly using a control box, using this to power the distributor or, to save energy, make the keel sink down using a release button. For more information contact Instrotech, +27 10 595 1831, [email protected], www.instrotech.co.za Product: https://bit.ly/3JDtK3b Bosch Rexroth Africa made its first appearance at this year’s Investing in African Mining Indaba in conjunction with Bosch Rexroth companies Hägglunds Drives and Smart Mine. The theme of the stand was ‘We’re closer than you think’ and it focused on the ways that Bosch Rexroth Africa can assist customers with taking African mining and automation to new heights. Smart Mine showed how mining operations can be optimised through its Bosch at African Mining Indaba range of state-of-the-art solutions – Smart Inspection, Start/Stop Retrofit, Smart Lockout, and Smart Conveyor. Smart Inspection offers optimal support during onsite and offsite inspection and maintenance processes through the use of digital devices. The Stop/Start Retrofit system can reduce CO2 levels by automatically shutting down vehicle engines during operational waiting periods. This reduces fuel consumption and emissions, while increasing the engine life of construction fleets. With global supply chains experiencing constraints, Smart Mine aims to boost the productivity of African mines with its Smart Lockout and Smart Conveyor solutions that reduce downtime through automation and digitalisation. They enhance safety, increase asset availability and productivity, and assist customers with reaching their ESG goals. On the hardware side, Hägglunds Drives South Africa showcased Fusion – its most compact hydraulic drive yet. The motor provides unbeatable torque across a range of low power applications, while increasing productivity for apron feeders, belt feeders and infeed conveyors. This modular solution is not only durable, reliable, space- and cost-saving, but also highly flexible, ensuring that it remains efficient for clients and meets their expectations. For more information contact Gillian Allin, Bosch Rexroth South Africa, +27 11 979 4630, [email protected], www.boschrexroth.africa
www.motioncontrol.co.za First Quarter 2023 17 HYDRAULICS Sun Hydraulics has released the company’s first solenoid-operated, three-way proportional flow control valve as part of the expanding line of FLeX Series valves. The patent-pending, compact FREP combines an electroproportional adjustable orifice and pressure compensator in one valve, and can provide a constant priority flow rate independent of load pressures. It is well suited to situations where you need to maintain constant actuator speed, regardless of the load on the actuator, and it provides excellent variable flow control when using a fixed-displacement pump. The FREP valve brings precise control to orbital motors on conveyors, spinners or fans for equipment like salt spreaders, agricultural spreaders and seeders. Equipment designers and operators can control material output directly, avoiding excess application of material, saving money, optimising yield, and protecting the environment. With these applications in mind, Sun offers a standard assembly for the FREP with the OMP motor interface so it can be mounted easily on an orbital motor, reducing hosing and providing a more compact solution. A cost-effective flow control valve The benefits of the FREP are clear: • Space-saving, pressure-compensated flow control in a single valve solution. • Very low leakage compared to competitive valves. • More compact than competing valves with comparable flow rates, using a large hit area on port 3 to deliver higher flows. The FREP’s patent-pending design uses a pull-type solenoid that allows the main throttle spool to be less sensitive to flow forces. This means you get greater efficiencies, with more flow control, using less power than similar valves from the competition. In demanding, cost-sensitive applications, the FREP is the smart solution. For more information contact Lance Tondolo, Axiom Hydraulics, +27 11 334 3068, [email protected], www.axiomsa.co.za Stucchi has opened its fifth commercial subsidiary, Stucchi South Africa. The new company was established in a joint venture with Stucchi’s historical distributor, Alba Hydraulics, to sell Stucchi products directly to the South African market and nearby countries. After many years of fruitful cooperation, Stucchi and Alba Hydraulics have decided to join their efforts by creating this new company, with the goal of providing the best possible products and service to the market. “This new company is the evolution of a longlasting relationship between manufacturer and distributor,” says Albert Epprecht, director of Alba Hydraulics. “The market will benefit from their increased synergy.” Stucchi CEO, Lorenzo Zaffaroni adds: “The hydraulics market in Africa still has great potential for growth, and our choice to invest with Alba makes us confident for the future success of Stucchi South Africa.” The long distribution experience of Alba Hydraulics, combined with the increased proximity to the Italian Stucchi headquarters, will translate to an advanced supplier of the high-quality Stucchi quick couplings. Claudia Epprecht and Sergio Assi will be the directors of Stucchi South Africa, in addition to Lorenzo Zaffaroni. “We are excited to start this adventure to serve and support our existing customers, and to explore new opportunities in all the different fields where hydraulic quick couplings are used,” says Epprecht. Stucchi South Africa has liftoff Stucchi is a major manufacturer of hydraulic quick couplings, with a wide range of applications. The company’s products are sold worldwide to premium OEMs through a solid distribution network. For more information contact Claudia Epprecht, Alba Hydraulics, +27 11 458 1202, [email protected], www.stucchigroup.com/en/
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