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www.motioncontrol.co.za Third Quarter 2023 1 SAFPA news News & events New technology OUR COVER 9 THIRD QUARTER 2023 04 05 10 REGULARS FEATURES 11 13 24 28 31 Drives Hydraulics Sustainability Pneumatics Food & beverage The global drive towards net zero and sustainable energy sources is accelerating the shift from fossil fuel to electric-driven machines, and reducing emissions is a challenge for many businesses worldwide. If you need to explore new options, Parker can support with varied technologies including hydrogen, electrification and natural gas. Read our cover story on page 9 to find out how Parker supplied components such as motors and inverters for Soilmec’s electrified microdrilling machine. VOL 25 NO 3 • THIRD QUARTER 2023 WE ARE IN OUR ELEMENT discover more Motion Tronic, Horne Technologies Hägglunds Drives South Africa, Stucchi South Africa, Axiom Hydraulics, ISO-Reliability Partners, Parker Hannifin SA, Hydrasales Beckhoff Automation, Festo, Neu Matics SA, Integrated Air Solutions Gravitricity, SKF South Africa, Masen Omron Electronics SA
2 Third Quarter 2023 www.motioncontrol.co.za welcomeTHIRD 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. Sustainabilty is a huge issue, and our sister magazine, SA Instrumentation & Control has published an industry guide on Sustainability in Manufacturing, which is available at www.instrumentation.co.za. While researching this extremely important topic I came across some truly outstanding projects that show the capacity of humans to collaborate. One is the world’s largest and most powerful magnet, the Central Solenoid magnet, in the ITER fusion reactor in France, and we have a story on that with some mindblowing statistics. Here comes quantum computing Another example of scientists pushing the envelope is quantum computing. This is part of quantum mechanics, which explores how the physical world works at the molecular level. Basically it’s a new future generation of super-fast computers that process information as qubits, or quantum bits, rather than the regular bits of classical computing that exist in either the zero or one state. The qubits of quantum computing are tiny subatomic particles that can exist in many different states. This means they can exist as one and zero simultaneously or in any state between one and zero, like a coin spinning in midair. This leap from dual to multivariate processing boosts computing power exponentially and will allow quantum computers to perform calculations far faster than classical computers. According to some estimates, quantum computers will operate 158 million times faster than the fastest supercomputers available today. Complex problems that currently take today’s most powerful supercomputer several years could potentially be solved in seconds. Even though large scale quantum computers are not yet commercially available, quantum computing is already with us in a limited form. The next five to ten years could see it leap into the mainstream in the same way that classical computers did in the 70s and 80s. The world’s biggest tech companies are racing to harness quantum. IBM has over 60 functioning quantum computers, and collaborators that include industry giants from Exxon-Mobil to Sony. Its new 433-qubit Osprey chip is the world’s most powerful quantum processor, the speed of which, if represented in traditional bits, would far exceed the total number of atoms in the known universe. IBM has recognised the importance of sharing in order to build an industry around quantum, and is making some of its technology available for free. It has more than 20 quantum computers available on its open source quantum toolkit Qiskit, which has been downloaded more than 450 000 times. Quantum is still in its infancy, and there are many challenges that need to be overcome before it becomes a mainstream technology. These include improving the stability of the hardware, and developing better Pushing the envelope algorithms and errorcorrection techniques. Nevertheless it’s here and it’s full of exciting possibilities. Recent breakthroughs and new government investment are taking us to a quantum revolution. Quantum computers could open new frontiers in mathematics and science, helping to solve challenges like climate change and understanding how changing climate patterns affect food security. It could be used to solve optimisation problems that are insoluble with classical computers, such as those encountered in logistics and supply chain management. Quantum machine learning could also make major improvements in data analysis and pattern recognition. This has implications for developing new materials, and tracing and routing financial transactions across global financial networks. All the big banks have their own quantum teams exploring what can be done in the next five to ten years. The potential industrial uses are boundless, for example for creating new car models from scratch, which now takes at least four years. Boeing has been working with IBM’s quantum team since 2020 on designing new materials for its next generation of aircraft. Other problems where quantum computers can potentially be put to use include monitoring and predicting traffic flow across complex urban environments; and by simulating complex chemical reactions that are impossible to model with classical computers, it could accelerate the discovery of new drugs. As with any new disruptive technology there are risks, and a major one is security. Today cybersecurity is based on RSA, an asymmetric cryptography algorithm used to transfer data safely. While a regular computer needs billions of years to crack RSA algorithms, a fast quantum computer would take hours. Today’s encryption algorithms would become obsolete, jeopardising communications, financial transactions, and even military defenses. The race is now on to devise post-quantum security. Researchers are working on developing new quantum-safe encryption methods that would be resistant to such attacks. Overall, the future of quantum computing is bright, with the potential to revolutionise fields ranging from medicine to finance to cybersecurity. Even though it may not be widely accessible and practical for real-world applications for several years.
4 Third Quarter 2023 www.motioncontrol.co.za From the President’s desk www.safpa.org.za | +27 11 061 5000 | [email protected] SAFPA NEWS Motion Control’s editor had a chat with new SAFPA president, Uven Moodley to find out more about his background, and what his plans are for SAFPA. Uven started out in the hydraulics industry in 1992 straight out of school, in an admin position at Hyflo. Here he was given the opportunity to study and earned a Diploma in Mechanical Engineering. He fulfilled many roles during his time at Hyflo, and managed various projects. He then moved to Danfoss for two years, learning more about the mobile hydraulics business. In 2006 he was headhunted by local OEM, Smit Capital Equipment, which specialises in designing drilling rigs, where he eventually rose to the level of director and equity partner. In 2018 he went full circle in the hydraulics business by moving to HYDAC. He has recently established a new company, HK Mining Solutions, in partnership with HYDAC, and will be targeting the mining industry. Uven is married with a daughter who is studying at Stellenbosch. In his spare time he enjoys going to the gym, reading crime series and business books, and watching sport. He says when he became president, the first thing he did was to go to SAFPA’s Member Value Proposition Survey to see what the SAFPA members want. The two most important things were technical training sessions and social events. So these are in the pipeline. Uven and the committee members are encouraging technical talks by key suppliers into the hydraulic and pneumatic industries. Another area of focus will be new legislation affecting the fluid power industry. On the social side, soccer events are popular, with the next one being in November. He believes these events contribute to team spirit and networking, and bring out people’s competitive spirit. Cycling and golf events are also on the cards. He would also like to boost SAFPA’s presence on social media and get members to join SAFPA on their existing platforms. This is a good way to attract younger members. He says that SAFPA’s LinkedIn site, especially, has some good reads. “My goal is to keep our existing membership, and grow it by targeting hydraulics and pneumatics companies that are not already members,” he concludes. Uven Moodley. Meet your SAFPA Council members Welcome to Uven Moodley, who is the new SAFPA president. We wish you a happy and fruitful time in this prestigious position. The members of Moodley’s new committee are: Wessie Van Der Westhuizen (vice president), Pirtek Africa; Michael Abbot, CT Hydraulics; Gerhard Hauptfleisch, Honingcraft; Russell Gill, Engineering & Hydraulic Services; Thabiso Lebitsa, Parker Hannifin Africa; Tiaan du Preez, Alfagomma; Hannes Otto, Festo; Manny Vieira, SMC Corporation, and Dustin Pereira. Manny Vieira, SMC Corporation. Hannes Otto, Festo. Wessie van der Westhuizen, Pirtek Africa. Russell Gill, Engineering & Hydraulic Services. Gerhard Hauptfleisch, Honingcraft. Tiaan Du Preez, Alfagomma. Thabiso Lebitsa, Parker Hannifin Africa. Dustin Pereira. Michael Abbot, CT Hydraulics.
www.motioncontrol.co.za Third Quarter 2023 5 NEWS & EVENTS As its expansion into Africa gathers pace, SEW-EURODRIVE South Africa is getting closer to customers and building stronger direct partnerships – to push modernisation and efficiency. “It just makes sense for our customers to have direct access to the OEM,” says Jonathan McKey, national sales and marketing manager at SEW-EURODRIVE. “This is particularly relevant in Africa, where distances to sites can be lengthy, and the infrastructure is often limited.” He points out that SEW-EURODRIVE in South Africa is already serving large multinational corporations around Africa who have global agreements with SEW-EURODRIVE at head office level. These customers are active in industries such as food and beverage, automotive, mining and specialised machinery. “Big international customers want to know that all their subsidiaries around the world can receive the same high quality of service for their SEW-EURODRIVE equipment,” he says. “The same applies for any size of customer; Africa is now demanding higher levels of technical support, especially in those countries experiencing economic growth and technological advancement.” He notes that governments are also encouraging the global private sector to have a local presence in African countries, and SEW-EURODRIVE is responding to that call. This fits well with the SEW-EURODRIVE culture of being close to customers wherever they are, so that the service response can be quicker and more effective. “We are very serious about implementing this culture, and we are well positioned to drive our expansion initiative into Africa,” he says. SEW-EURODRIVE has already placed staff in Partnership focus marks SEW-Eurodrive progress in Africa Kenya and Zambia, and is planning to establish a presence in three more African countries during 2023. Placing its own people on the ground around Africa will enhance to value to customers, says McKey, especially with SEW-EURODRIVE’s continuous development and ‘zero complacency’ approach to innovation. “Our research and development cover a wide range of fields that can benefit customers – from gearing topography to specialised gearbox oils,” he says. “With more sophisticated tools to analyse our own products, we have been able to offer customers even higher reliability and improvements in aspects such as torque demand.” This progress has been enhanced by a strong digital offering, which Africa is already well placed to leverage. SEW-EURODRIVE has some of the most advanced technology for monitoring the condition of drives, paving the way for customers to apply more proactive maintenance. Raymond Obermeyer, managing director of SEW-EURODRIVE South Africa, highlights that Africa is generally well advanced in digital communication. “Access to the cellular network makes everything possible, from selecting and buying gearboxes to monitoring and analysing their performance remotely,” says Obermeyer. Indeed, the range of SEW-EURODRIVE equipment has been designed to use multiple communication methods, and to communicate to every device from scada systems to computers and mobile phones. Systems like DriveRadar can therefore be installed on a product and monitored from anywhere in the world where there is a data signal. Given this depth of technology and innovation, McKey emphasises that direct contact with customers is preferable to working through a ‘middle man’. Through its extensive and ongoing training efforts, the company upskills its own employees and customer staff, to fully understand both the operation and the potential of its technology. “We have invested in our in-house Drive Academy for precisely this purpose. It can provide skills development in-person, at our Johannesburg facility or remotely,” he says. “This creates a symbiotic relationship with customers, where we support each other in the trend towards modernisation.” This applies to both the company’s modular ranges and its purpose-built products – such as the air-cooled condenser (ACC) solutions. Greater in-house expertise also ensures that constant advancements are brought to customers’ attention. A recent example of this was the evolution of the robust X series industrial gear units to the state-of-the-art Generation X.e units, delivering new possibilities in performance, safety and efficiency. Obermeyer points out that the most advanced SEW-EURODRIVE products are already found all over Africa, showing how the continent has embraced technology. The company’s expectation is that this equipment is supplied and maintained to the same highest standards anywhere in the world. The growing footprint of SEW-EURODRIVE branches across Africa will ensure that this is achieved, he says. For more information contact SEW-EURODRIVE, +27 11 248 7000, [email protected], www.sew-eurodrive.co.za
6 Third Quarter 2023 www.motioncontrol.co.za NEWS & EVENTS Robotics is an ever-growing industry, and South African manufacturers are increasingly adopting automation into their production processes to remain competitive. Yaskawa’s long-standing training academy offers its customers, and individuals looking to enter the industry, the opportunity to learn and upskill in various in-demand positions, including programming, operations, maintenance, safety and robot troubleshooting. “At the Yaskawa Southern Africa Training Academy we offer a variety of courses and training programmes designed to meet the needs of different skill levels, from beginner to advanced,” says training officer, Leon Coetzer. “Our staff comprises experienced engineers who are experts in their fields.” Since the academy’s inception in 2002, over 2200 students have been trained. Both individuals wanting to enter the industry, and existing customers of Yaskawa Robots, can expect a hands-on approach to training. In-person classes ensure trainees gain the necessary knowledge and skills to operate Yaskawa’s robotics training programmes and maintain Yaskawa robots effectively. With South Africa’s skills shortage, this creates more opportunities to strengthen the country’s workforce and reduce unemployment. Yaskawa’s approach to training goes beyond initial skill acquisition, recognising the importance of ongoing professional development of its employees. “We provide continuous mentoring and coaching to our employees to help them set and achieve their career goals,” says Coetzer. Yaskawa’s training programmes play a crucial role in the growth and development of the robotics industry in South Africa by providing accessible opportunities for both beginners and advanced students. The academy is poised to leave a lasting footprint on the robotics industry and empower the future of automation. For more information contact Leon Coetzer, Yaskawa Southern Africa, +27 11 608 3182, [email protected], www.yaskawa.za.com Beckhoff Vision now includes a complete hardware portfolio in addition to the TwinCAT Vision software solution that was introduced in 2017. From the very beginning, its development was oriented around an optimal design and concepts for industrial use. The expert jury for the renowned Red Dot Award recently confirmed that these goals have been successfully achieved as they honoured Beckhoff with an award in the automation category. This prize is only awarded to products that have an excellent design. This was further confirmed with the iF Design Award Gold, the highest distinction in this competition. The Beckhoff portfolio of vision hardware includes area scan cameras, C-mount lenses, multi-colour LED illumination, and complete vision units that meet industrial requirements perfectly, both as individual components and as an entire machine vision system. The Adrian und Greiser design agency has developed a consistent design concept for Beckhoff that gives this product range a look and feel that marries sophisticated optics and electronics with industrial robustness. Relevant design aspects include the IP65/IP67 anodised aluminum and tempered anti-reflective glass housing, smooth glass surfaces that provide high resistance to cleaning agents and other chemicals, various options for flexible mounting and application, and optional shatter protection. For example, the lenses have a sleek and streamlined look, and are very easy to mount, with reliable, lockable adjustment options. For more information contact Beckhoff Automation, +27 11 795 2898, [email protected], www.beckhoff.com Red Dot Award for Beckhoff Image copyright: Beckhoff.
8 Third Quarter 2023 www.motioncontrol.co.za Valve & Automation’s control valve, more than four metres tall, produced for Siemens Energy in Duisburg, has broken ARCA’s internal design height record. In September 2021, Valve & Automation ran a special type of acceptance test at one of its factories in Tönisvorst, Germany. With the production of this ‘control giant’ with a design height of 4,20 metres, the company confirmed that it is a leader in control valve design and manufacture, and is a first contact partner in compressor construction. This record was achieved by the pairing of a 60 cm valve with a special bonnet, which in addition to its conventional components, also included a bellows seal, which was specially designed to prevent any emission of the medium through the stuffing box. The enormous design height made it necessary to switch to alternative assembly steps in order to The control giant from Duisburg manufacture the valve according to customer requirements. Together with this colossus, this project from Siemens Energy included a 50 cm valve and a 157 cm perforated disc. Siemens Energy required these valves for a plant owned by Formosa Petrochemical Group, which will be built in the eastern Chinese coastal city of Ningbo. The control valve was part of a delivery of a gear type turbo compressor train, which is to be used in a purified terephthalic acid plant (PTA) to manufacture plastic products. The compressor train consisted of a gear type compressor of the STC-GV (200-4) type and a cold gas expander STC-GT (160-2),driven by an electromotor. For more information contact Desmond Delport, Valve & Automation, +27 11 397 2833, [email protected], www.valve.co.za FUCHS Lubricants has clinched an accolade from the Green Building Council South Africa (GBCSA) Leadership Awards for 2021-2022 for its Net Zero submission. In addition, the new FUCHS Isando head office has been certified as being net zero carbon, valid from July 2022 until June 2025, according to sustainability director, Esther Seabi. Not only has the head office been designed to be as energy efficient as possible, it generates renewable energy in excess of its requirements. This translates into net zero carbon emissions from energy usage on a yearly basis. The process started at building design phase, where the focus was on alignment with natural climatic elements to minimise the need for the artificial illumination, heating and cooling required for a comfortable indoor environment, for example, the use of shading and glazing. FUCHS head office certified as net zero carbon The next phase was the use of energy-efficient equipment and systems such as automated LED lighting and energy-efficient appliances and HVAC systems. Lastly, the solar PV system generates renewable energy equal to or exceeding the energy requirements of the building. The current certification is based on design and is valid for three years. To maintain the rating following this, FUCHS has to submit data on actual usage to demonstrate whether or not it is net zero. “We have online metering for the various energy consumers. This also helps us with management, as for instance we can see if aircons are left on when the building is unoccupied. We have also had instances where we were alerted when the PV system tripped,” explains Seabi. Other sustainability features include a rainwater harvesting system, supported by double piping in the plumbing system to separate potable and grey water. “This enables us to use the rainwater harvested in the bathrooms. It also assists in the event of any water outages because the toilets can still flush. We focused on energy efficiency as well as conserving water, with all our fittings being water efficient,” Seabi explains. FUCHS has staked out its ambition to be the most sustainable lubricants company and has also set a net zero targe for the whole company. “To have one net zero building is already a good start. It is great to see such a level of commitment to social responsibility,” she concludes. For more information contact Kayla Van Vught, Fuchs Lubricants South Africa, +27 11 565 9738, [email protected], www.fuchs.com/za NEWS & EVENTS
www.motioncontrol.co.za Third Quarter 2023 9 The global drive towards net zero and sustainable energy sources is accelerating the shift from fossil fuel to electric-driven machines. Some European companies are already setting conditions for electric-driven equipment on their tender requirements. Large machines are more complex to convert because of the high power demand. Nevertheless, as electric technology develops, the ground engineering sector is making progress in transitioning the industry to electric power. Soilmec is a leading ground engineering company with a history of over 50 years in designing, manufacturing and distributing equipment. In line with global trends toward sustainability, Soilmec has embarked on creating a zero local emission line of machines, choosing the microdrilling machine SM-13e as the first in this range. This machine is typically used in soil consolidation work, anchorage, and tunnel construction. Parker Hannifin supplied several components for the SM-13e, including the GVM210 series motors and GVI-G650 inverters. This project aimed to meet the functional requirements for speed and power, while significantly reducing operating costs and improving performance relative to the diesel-powered machine. The challenges of electric ground engineering machines Ground engineering machines work in extreme conditions. Construction sites are exposed to the elements and dusty conditions associated with earthmoving. Additionally, drilling through rocky ground results in strong vibrations. Sensitive electronic components must be designed for these conditions. In the case of the Soilmec SM-13e ETECH machine, the functional requirements created some specific challenges. The SM-13e required four electric motors, each Sustainable machines for groundworks with an inverter. Two of these motors were mounted on top of the mast in the rotary head. The elevation was particularly challenging because cooling systems had to supply the motor at heights up to 10 metres, without interfering with the machine’s operation. Two motors in the rotary head drove the rotational movement, and the other drove the push-pull movement of the drilling head. The control of the rotary’s motors had to be highly synchronised, making the inverter and motor design and control critical for machine operation. The rotational speed could vary from a high of 130 rpm to a low of 1 rpm. The push-pull motor also had a wide speed range from to 0,08 to 50 m/min. The electric technology behind the SM-13e Parker supplied several components for Soilmec’s electrified microdrilling machine, including motors and inverters. The design of the SM-13e utilised the following technologies: GVM210300 motor, GVI-G650 inverter, QDC-050-B hydraulic cooler, and P2075L hydraulic variable piston pump. The SM-13e solution was designed with maximum flexibility in mind. There were three operating modes: Normal, Eco and Boost. The Normal mode delivered standard operational performance, and the Eco mode allowed for conserving energy when power demands were lower, lengthening battery life. The Boost mode enabled short periods of maximum performance. A collaborative approach In developing the Soilmec SM-13e machine, Parker and Soilmec engineers worked together in a collaborative approach. They went through several iterations of refining the requirements, selecting components, and designing a system that worked as an integrated whole. As a result, the first Soilmec SM-13e machine is already delivering excellent results in the field. The benefits of electric ground engineering machines Electric machines, like the SM-13e, deliver significant benefits to ground engineering companies. Firstly, they enable users to reduce their carbon footprint substantially. The SM-13e is much more efficient than the diesel equivalent. As the energy source is electrical, the CO2 and other greenhouse gas (GHG) emissions are vastly reduced. At the same time, electric machines are much quieter than internal combustion engines. In contrast to endothermic machines, electric motors are off when the utilities are active but the machine is not drilling. This drastically reduces both the noise to which the operator is subjected, and the energy consumption of the machine. Secondly, improved efficiency also reduces running costs. Diesel engines tend to run on a time-based service interval. This interval is calculated based on the running time of the machine, including idle time. On the other hand, motors on electric machines can be individually monitored for running time. Thus, maintenance intervals can be significantly extended, resulting in operating costs as much as 56% lower. Additionally, the machine is more available due to reduced downtime, and jobs can progress quicker. Maintenance costs are also reduced because there are fewer maintenance tasks required on an electric motor than on a diesel engine. Lastly, electric machines offer higher performance than their diesel equivalents. This benefit is due to the constant torque availability from electric motors, regardless of speed. For more information contact Parker Hannifin SA, +27 11 961 0700, [email protected], www.parker.com/za Image copyright: Soilmec
10 Third Quarter 2023 www.motioncontrol.co.za The world’s largest and most powerful magnet is the Central Solenoid magnet in the ITER fusion reactor in France. Built by General Atomics, it is the result of over five years of research and development, and the statistics are mind-blowing. This giant pulsed superconducting electromagnet is 18 metres tall, 4,2 metres wide, and weighs around 90 700 tons. Its strength is 13 teslas at its core, which is about 280 000 times the strength of the earth’s magnetic field. It will play a critical role in the new ITER fusion reactor, which is a collaborative project among 35 nations. The project aims to achieve sustained nuclear fusion to replicate the process of energy production in the centre of the sun. If successful, the fusion reactor will be a major breakthrough in providing large-scale clean electricity and combating global climate change. General Atomics says that Central Solenoid is strong enough to lift the 101 600 ton USS Gerald R Ford, the world’s biggest aircraft carrier, two metres into the air. It is so strong, a structure has been built to house it which needs to be able to withstand forces twice that of a space shuttle taking off. The promise of fusion In nuclear fusion a small amount of vapourised deuterium and tritium is released into a large, doughnut-shaped vacuum chamber known as a tokamak. The tokamak superheats these isotopes, stripping away the electrons and converting the gas into plasma. This superhot plasma reaches 150 million °C, or ten times hotter than the core of the sun. At this temperature, the atoms undergo fusion, giving off large amounts of energy, which can be The world’s largest magnet used to create electricity by heating water, and creating steam to turn turbines. One of the biggest hurdles to sustained fusion is containing and manipulating the searing plasma inside the reactors. This is where the Central Solenoid comes into play. The powerful magnetic field it creates will pin the plasma in place inside the tokamak, and maintain the reaction. How its made The Central Solenoid is made up of six individual modules stacked inside the centre of the ITER reactor. Each individual module is essentially a big coil containing around 5,6 kilometres of steel-jacketed niobium-tin superconducting cable. The module is then heat treated in a large furnace for several weeks to further increase its conductivity, after which the cables are insulated and the coil is wrapped into its final shape. After insulation, the module is enclosed in a mould, and 3800 litres of epoxy resin are injected under vacuum to saturate the insulation materials and prevent bubbles or voids. When hardened at 650°C, the epoxy fuses the entire module into a single structural unit. The finished module is subjected to a series of demanding tests, placing it in the extreme conditions it will experience during operation, including near complete vacuum, and a cryogenic temperature of -270°C required for the magnet to become superconducting. The mission The Central Solenoid will play a critical role in ITER’s mission to prove that energy from hydrogen fusion can be created and controlled on an industrial scale, and to establish fusion energy as a practical, safe and inexhaustible source of clean, abundant and carbon-free electricity. The materials to power hydrogen fusion for millions of years are readily abundant, and the only by-product is helium. Like a gas, coal, or nuclear fission plant, a fusion plant will provide highly concentrated, baseload energy around the clock. Yet fusion produces no greenhouse gas emissions or long-lived radioactive waste. The risk of accidents with a fusion plant is very limited – if containment is lost, the fusion reaction simply stops. Conclusion Although ITER will not generate electricity, it will be a critical testbed for the technologies necessary for the commercial production of fusion-based electricity. The lessons learned at ITER will be used to design the first generation of commercial fusion power plants. Central Solenoid is currently around 75% complete. The construction remains on track to finish by 2025, but full-scale fusion reactions won’t take place until 2035 at the earliest. “This project ranks among the largest, most complex and demanding magnet programmes ever undertaken,” says John Smith, General Atomics’ director of engineering and projects. “The ITER project is the most complex scientific collaboration in history,” says Dr. Bernard Bigot, director-general of ITER. “Without this global participation, ITER would not have been possible; but as a combined effort, each team leverages its investment by what it learns from the others.” For more information visit www.iter.org
www.motioncontrol.co.za Third Quarter 2023 11 igus® (Pty) Ltd. Tel. +27 11312 1848 [email protected] Change your bearing now... Moving energy made easy... motion plastics® SA-1296-BRG+ECS 85x120_CC (GS).indd 1 20.03.23 15:59 Industrial automation group Inovance Technology, and its partner Motion Tronic, are bringing market-leading improved performance with ultra-fast current loop technology to South Africa with the launch of the SV660N servo solution for industrial automation applications. A single-axis EtherCAT servo drive, the SV660N is designed for high dynamic performance in a compact footprint, and achieves radically improved system performance with a shorter settling time and higher throughput. Position control loops are coordinated with the synchronisation signal to further improve the accuracy of multi-axes control. Companies in South Africa are now able to contact Motion Tronic to purchase the SV660N, which uses a processor for high-speed EtherCAT communications, achieving a cycle time of 125 μs for all seven EtherCAT CiA402 profile operation modes available. Complete with user-friendly installation through easy setup and tuning, the servo drive delivers ultra-fast 4,5 kHz current loop, with speed loop bandwidth of up to 3 kHz, allowing the motor to follow the motion profile with minimal error. South African OEMs can also be reassured by the SV660N, which features functional safety via SIL3 Safe Torque Off, short output winding for safe braking, and compliance with CE and UL standards. It has been designed to operate in harsh environments. Available with single-phase 220 V, three-phase 220 V and three-phase 380 V supply voltage, multi-turn absolute information can be also saved at power down, avoiding the need to perform machine homing at every startup of the servo drive, and it even has comprehensive data storage in case of failure. David Bedford Guaus, Inovance’s global strategic marketing manager for AC drives says, “We are pleased to launch our robust and reliable SV660N in South Africa. With an average 30% smaller footprint than the previous generation, the next generation servo drive provides increased power density all within a compact footprint. Working closely with our partner Motion Tronic, we are showcasing the huge potential and high dynamic performance the SV660N offers through our ultra-fast current loop technology.” Bradley Douglas, Director at Motion Tronic, adds, “The 0,1 to 7,5 kW SV660N is a great addition to our portfolio of Inovance products. We are looking forward to promoting it widely to our customers across South Africa, demonstrating how this market-leading, EtherCAT-enabled servo drive can meet their needs and improve their productivity. Inovance has the wide range of industrial automation products and components Inovance EtherCAT servo drive for compact dynamic performance DRIVES that OEMs demand, and its commitment to extensive research and development shines through in the quality of the advanced solutions it launches.” Both Inovance Technology and Motion Tronic were founded in 2003. A leading South African distributor of industrial automation technology, Motion Tronic is based in Durban, and provides a range of industrial automation technology services to OEMs, including installation, commissioning, technical and mechanical support. For more information contact Bradley Douglas, Motion Tronic, +27 83 641 1487, [email protected], www.motiontronic.co.za
12 Third Quarter 2023 www.motioncontrol.co.za DRIVES What would a mechanical watch look like if it was reimagined and redeveloped from the bottom up? Master watchmaker Benoît Mintiens asked himself this question. He came up with a unique mechanism in the world of mechanical timepieces, a wristwatch that ‘sleeps’ when you take it off and wakes up when you put it back on, setting the correct time automatically. This fascinating animation is powered by the smallest series motor from Faulhaber. Innovative functionality and revolutionary product design The basis of his success is a series of unique features that can be found only in watches from Ressence. It is not the hands that move on the dial but instead the dial itself. To be precise, there are multiple dials – a different one for each hand. The smaller hands are integrated in the large hand, circling one another like a planetary gearhead, and are constantly seen in new constellations. In spite of the unusual picture that forms as a result, one intuitively recognises the big and small ‘hands’ as the markers for minutes and hours. Also missing is the crown, the small dial on the side which, on other mechanical watches, is pulled out and used to set the time. Its function is performed by a hinged lever on the bottom of the watch. The initial winding is also performed with the mechanical movement for the setting of the time. From then on, an automatic movement ensures spring tension and accuracy. Time signal plus motor drive With the help of an accelerometer, the Type 2 also recognises whether it is currently being Time follows function worn or if it has been set down. In the latter case, the spring energy is conserved and the movement paused − the dials stop moving. In addition to the mechanical movement, this model also has onboard electronics called the e-Crown. When first set, it saves the time and continues to measure the time during the rest phases. The sensor registers when the watch is again put on, and the electronics release the spring. The movement is started by double-tapping the bezel, and the correct time is then automatically set – even if the watch has not been worn for months. “With the e-Crown, we expand the concept of the mechanical watch with a new dimension,” says Mintiens. “The correct time is always available, and a person can also select a second time zone that the watch then likewise automatically sets. For the selection of the zone, the electronics communicate via Bluetooth with an app developed specifically for this purpose. Nevertheless, the watch remains an independent unit thanks to its automatic movement; the electronics do not interfere with its actual function. The electronics are used only for the adjustment steps that are otherwise performed with the crown.” The e-Crown consists of 87 components; its flexible PCB with four layers is just a quarter of a millimetre thick. All parts are of the smallest dimensions and optimised for minimum energy consumption. As a result, the watch gets by on just 1,8 joules of energy per day. The electronics check the position of the dials at least once per day and make a correction if necessary. When putting the watch on again, or when switching between the time zones, an automatic adjustment process is triggered. Micro-powerhouse During this process, the large and small dials are turned to the appropriate positions. The power for the mechanical work of the e-Crown comes from the smallest series motor from Faulhaber, the 0308…B brushless DC-servomotor, in combination with the 03A micro planetary gearhead. With a diameter of just three millimetres, the drive unit fits into the extremely small installation space present in the watch. The available electric power is also quite limited there. It flows from six micro lithium-ion batteries, which are charged by very small solar cells. They supply just 1,2 V. “This is actually not enough to overcome the intrinsic inertia and friction of the system,” explains sales engineer Hein Vos from Faulhaber Benelux. “We therefore made a number of changes to the gearhead. These include a modified shaft, an adapted gear ratio, and a special lubricant.” There may have been other products small enough for his watch, but for Mintiens the choice was clear. “One expects that a mechanical watch will function flawlessly for decades. The technology from Faulhaber guarantees the high quality and reliability of the drive that I need,” he concludes. For more information contact Horne Technologies, +27 76 563 2084, [email protected], www.hornet.cc
WE MOVE. YOU WIN. Now. Next. Beyond. Moving specialist hydraulic components from the world’s leading manufacturers to your shop floor. We bring premium hydraulic hose and fittings, mobile components and accessories to your operation, so you enjoy maximum hydraulic performance, every day. That’s why HAW is now a Bosch Rexroth Company. Call us: +27 (0) 11 281 3800 or Visit our website at: www.boschrexroth.africa A Bosch Rexroth Company The Hägglunds Quantum hydraulic motor range exceeds previous performance limits in torque, speed and efficiency. Hägglunds Quantum is the new name for the Hägglunds CB range, and these direct drives can be used in heavy-duty and mobile applications. “The Quantum motor has evolved so significantly that it can no longer be considered the same motor as the CB range. Tweaks in design and materials have increased its efficiency and tripled its life expectancy, resulting in a bold new step in the market,” says Hägglunds Drives South Africa managing director, Leif Duwel. The Hägglunds Quantum range comprises two parts: Hägglunds Quantum, the motor, and Hägglunds Quantum Power, which features additional ports and an innovative internal design that enables higher speeds with full torque capacity and high efficiency. The Hägglunds Quantum range offers a top speed of over 150 rpm, yet it provides a sustainable maximum torque of more than 350 kNm. At corner power, where the two extremes meet, users can achieve a powerful Bending the law of size, power and speed 3 MW without sacrificing compactness or efficiency. Quantum Power can deliver high power with greater economy and sustainability than any previous solution. “The Hägglunds Quantum range rewrites the rules of power density, especially when it comes to efficiency at higher speeds,” says Wolfram Ulrich, vice president of sales. “Hägglunds Quantum Power is lighter in weight than the previous CBp motor. This saves resources and reduces emissions during production and transport. For mobile applications, this means reduced weight and fuel consumption.” For more information contact Kay Govinder, Hägglunds Drives South Africa, +27 11 454 4933, [email protected], www.boschrexroth.africa HYDRAULICS
14 Third Quarter 2023 www.motioncontrol.co.za HYDRAULICS Quick couplings offer a quick, practical, and safe solution for the connection and disconnection of multiple parts of hydraulic circuits; coupling is carried out without the need for tools and stays sound, preventing leakage while the fluid is under residual pressure. They are used in a variety of sectors that require frequent procedures to be carried out on circuits, for example attachment replacements. These include earthmoving, oil and gas, heavy goods vehicles, and agriculture. There are situations, however, where it is not possible to carry out coupling of male and female connections because one of the two ends oppose resistance. What could cause this? In a closed circuit subject to a change in heat, there is an increase in the internal pressure of the fluid, even if the machinery or the attachment is not in active use. When an attempt is made to connect male and female connections, this will be made impossible by the resistance opposing the pressure formed inside the circuit. It is not unusual for this phenomenon to occur during a working day. In machinery or attachments exposed to solar heat hour after hour, an increase in pressure may be created that is sufficient to prevent the quick coupling from being connected. As a result, operators will need to undertake time-consuming procedures to eliminate the pressure in the circuit, but more often than not, these methods, besides losing precious time, are not particularly safe for the operator. In the case of earthmoving equipment, moments of machine downtime can become a very frequent occurrence. Such a situation undermines one How to solve the pressure connection problem of the great advantages of quick couplings, i.e., the ease and speed of connection and disconnection of the line which allows instantaneous changeover of tools. Quick couplings manufacturer, Stucchi has long been an industry frontrunner when it comes to the development of innovative coupling solutions, with the Italian company’s connection under pressure (Easy CUP) technology paving the way for the safe, secure and efficient management of connections under pressure. Stucchi’s commitment to technological innovation is evident in the integration of its Easy CUP system into a wide range of products, assisting with productive operations across a range of industries and applications. Threaded, flat face quick couplings provide a simple but extremely effective solution to the problem of residual pressure. An internal valve makes quick male/female connection possible without the need for tools, even in these conditions of resistance. Stucchi’s Easy CUP technology is integrated with the following product lines: • Flat face couplings: the APM male flat face quick coupling series allows for manual coupling with residual pressure in the circuit due to a triple valve system, which discharges pressure and increases tightness. • Flat face screw couplings: the VEP-P, VEP-HD and VP-P series use special threaded bodies, allowing quick coupling, to withstand strong impulses and extreme conditions, neutralising premature wear and brinelling, and integrating a triple valve system, allowing for connections under pressure. • Multi-couplings: the DP and GR series, assembled with FAP couplings, combine a lever system, allowing for several lines to be quickly and easily connected and disconnected, with a triple valve for connections under pressure. • Casting blocks: the Saturn and Saturn HF, respectively connect three and five lines, having been created in close collaboration with earthmoving companies. This makes them a logical choice for machines with multifunction accessories, with a special manual valve allowing for the simultaneous discharge of the residual pressure of all the lines. Together, these design choices provide a product that impacts positively on operations in the many sectors that use hydraulic circuits – connections and disconnections that can be carried out safely and quickly, even under conditions of residual pressure, thereby offering improvements in productivity by speeding up operations that are carried out many times a day. Stucchi South Africa is a new company that has been established in a joint venture with Stucchi’s historical distributor, Alba Hydraulics, in order to sell Stucchi products directly to the southern African market, thereby offering the best possible service. For more information contact Conan Lane, Stucchi South Africa, +27 11 458 1202, [email protected], www.stucchigroup.com or visit www.youtube.com/c/Stucchiquickcouplings
Tel: +27 11 334 3068/86 | Fax: +27 11 334 4543 | www.axiomsa.co.za
16 Third Quarter 2023 www.motioncontrol.co.za Sun Hydraulics has launched the Sun Common (SC) cavity cartridge valves. Joining the broad range of existing Sun Hydraulics cartridge valves, these new cavity cartridges are optimised for lower pressure systems. These valves boast a common SAE style cavity, which is compliant with SAE cavity standard ISO 17209:2013. There are several great options that will allow you to engineer optimised, interchangeable solutions and enhance the functionality of your demanding applications. Common solutions for your unique applications Sun Common cavity cartridges are versatile and offer cross compatibility with many valves and manifolds within the industry, making them an excellent choice for an array of applications. As a bonus, they can be effortlessly implemented into Sun’s QuickDesign solutions. Built with the quality and reliability you are used to from Sun Hydraulics, these cavity valves will put the power to engineer optimised solutions for a broad range of hydraulic applications in the palm of your hands. Creatively designed for high reliability, the DNUC and DNTC are direct-acting, solenoidoperated, four-way, three-position spool valves that are spring centred to the neutral position. The DNUC is rated to 250 bar and features nominal flow ratings up to 28 l/min, as well as four spool configurations. This valve can be installed into an SC-10-04 cavity and utilised with the 779 Series coils. Best incorporated in applications such as outrigger controls, scissor lifts, municipal trucks and aerial work platforms, Cavity cartridges for lower pressure systems the DNUC offers highly compact cartridge solutions. In contrast, the DNTC is compatible with the 769 Series coils and designed to fit into an SC-08-04 cavity. Rated to 210 bar, the nominal flow rating of the DNTC is 11 l/min, making this valve ideal for smaller actuators or pilot circuits. Solenoid-operated and direct acting, the DNUT is a four-way, two-position balanced spool directional valve that requires no minimum hydraulic pressure for its optimal functionality. Rated to a maximum operating pressure of 210 bar, the DNUT features a 30 l/min capacity and caters for an SC-10-04 cavity. This valve is compatible with the 780 Series coils and can be utilised in applications such as tractors and bulldozers, as well as a wide variety of applications requiring pilot control. The DMUT and DMUQ are solenoid-operated, three-way, two-position balanced spool directional valves. No minimum hydraulic pressure is required for optimal functionality of these cartridges. Both valves can be installed into SC-10-03 cavities, and they are equally compatible with the 780 Series coils. The maximum operating pressure for the DMUT is 210 bar, and the capacity is 28 l/min. In juxtaposition, the DMUQ maximum operating pressure is rated to 110 bar, and its capacity is 28 l/min. Industrial pilot machinery, bulldozers and tractors are all best suited for the DMUT cartridge, while the DMUQ can functionally support the hydraulic control of pilot nozzle actuators for water spraying trucks or industrial pilot machinery. The DLUT is a solenoid-operated, direct-acting, two-way, two-position balanced spool directional valve that is offered in an SC-10-02 cavity and a normally closed configuration. This bi-directional valve has a preferred flow path of 2 to 1. No minimum hydraulic pressure is required for the operation of the valve. The DLUT is compatible with the 780 Series coils . The valve offers great functionality and can serve as an optimal solutionof r sweepers or other industrial hydraulic machines with maximum pressures less than 210 ba.r The Sun common cavity shuttle valve, CSTT, works with the connection of a single ball shuttle, which permits the higher of two work ports to the signal or common port. The single ball allows for the decay of the pressure signal when both load ports fall to a lower pressure. The signal is sensed at port 2, and all ports are rated to a maximum operating pressure of 210 bar. Installed in SC-08-03 cavities, this SC shuttle valve is best suited to the necessities of load sense systems and features hardened steel balls and seats for superb wear characteristics and contamination tolerance. The CXUT is a free-flow, nose-to-side check valve that functionally provides a 5 drops/min load holding leakage rating . These two-port check valves allow free flow from the inlet (port 1) to the outlet (port 2) and block flow in the opposite direction. With a maximum operating pressure of 210 bar, the CXUT also features a nominal flow rating of 60 l/min. This valve can be installed into an SC-10-02 cavity and features a low-profile design for compact cartridge solutions. For more information contact Lance Tondolo, Axiom Hydraulics, +27 11 334 3068, [email protected], www.axiomsa.co.za
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