Made in South Africa – Always in stock VOL 25 NO 4 • FOURTH QUARTER 2023
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www.motioncontrol.co.za Fourth Quarter 2023 1 SAFPA news News & events New technology OUR COVER 9 FOURTH QUARTER 2023 03 04 10 REGULARS FEATURES 12 Motion Tronic, Schneider Electric South Africa, Beckhoff Automation, SMC Corporation South Africa, ABI Research, SEW-EURODRIVE 18 Axiom Hydraulics, Stucchi South Africa, Hydrasales 22 Zest WEG, BMG, Epiroc South Africa BMG, NSK South Africa, SKF South Africa, Wearcheck 24 29 Omron Electronics Valve & Automation 28 32 Drives Hydraulics Mining Bearings, seals, belts & chains Pneumatics Robotics Aerospace Water hammer is a high-pressure surge created by the kinetic energy of moving fluid when it is rapidly forced to stop or change direction. Rapid stopping or starting, or changing of direction of an incompressible fluid like water or oil in a system is common in valves and pumps. Pressure spikes can reach up to eight times the system pressure. Even though they may last only milliseconds, the potential damage can be lasting. Read our cover story on page 9 to find out from SA Gauge how to protect against water hammer. Made in South Africa – Always in stock VOL 25 NO 4 • FOURTH QUARTER 2023 Neu Matics SA, SKF, Valve & Automation
2 Fourth Quarter 2023 www.motioncontrol.co.za welcomeFOURTH 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. 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Nowadays I’m trying to get my mind around AI, and figure out all the things I can do with it; but there’s another buzzword around, this one is ‘hyperautomation’. Today, it’s not smart manufacturing, but ‘hyperintelligent automation’. Please forgive me for thinking that’s what IIoT did. Anyway, I thought I would try and make sense of all these terms, and find out how they differ from automation, and if hyperautomation is part of AI and ML or the other way around, and where IIoT comes in, or gigafactories, or lights-out factories. Or is this yet another amazing new technological development? So here goes. It’s clear that automation is the carrying out of a repetitive task without human intervention. It typically occurs on a smaller scale than hyperautomation, and involves separate jobs. An example would be robotic process automation (RPA) − a robot that can perform low-level repetitive functions based on rule-based processes, for example a welding robot. Hyperautomation, on the other hand, is a combination of advanced automation technologies like generative AI, ML, natural language processing, digital twinning, data analytics, predictive maintenance algorithms and more, that automate processes without human intervention. From what I can see, hyperautomation is the concept of leveraging all these new technologies and automating everything in an organisation that can be automated – basically if it moves, you automate it. One description of hyperautomation I saw is that it’s RPA on steroids. Another is that it’s the automation of automation. The end goal is to automate as much of a task as possible, while allowing human workers to focus on other jobs that require creativity, judgement, and emotional intelligence. IIoT at scale I found it more difficult to decide if IIoT is part of hyperautomation, or the other way around. One school of thought is that hyperintelligent automation is a driver of IIoT; but eventually I decided that IIoT is the enabler, arising out of the convergence of OT and IT. I remember when not very long ago we used to publish articles on how the machines are talking to each other. Hyperautomation needs manufacturers to think on a greater scale, and this is what’s driving the adoption of the IIoT technologies we already have. Complex automation is only possible in digitally interconnected systems. Gartner has listed hyperautomation as one of the top ten strategic technology trends of 2023, and believes it is shifting from a nice-to-have to a matter of survival for many organisations because it has the ability to eliminate outdated work processes, which are a top workforce issue. Whatever you call it, many manufacturers are already dabbling in hyperautomation in preparation The automation of automation for a scaled-up IIoT because simple, task-based automation doesn’t deliver the cross-functional results that they are looking for. Many of the examples I found are clients of Motion Control or have featured in our stories − companies like Siemens, ABB, Rockwell Automation, Fanuc, Schneider Electric, Festo and Honeywell. As an example, Schneider Electric automates the process of creating, labelling, documenting and organising switchboards. Human interaction is eliminated from the process, apart from data input and the physical installation of the finished product. In South Africa, we have some world-class industries such as the automotive, and food and beverage, and they are on the way to hyperautomation. The benefits are pretty much the same as we heard when IIoT first came in: optimised processes, increased efficiency, and improved overall performance. So are the caveats. The explanations that jobs won’t be lost, they’ll just be different and more satisfying, are no different. Avoid the traps One of my favourite Bill Gates quotes is: “The first rule for a technology used in a business is that automation applied to an efficient operation will magnify the efficiency. The second is that automation applied to an inefficient operation will magnify the inefficiency.” There is a fine line between elegant networking and a tangle of hyper-automated systems − excessive automation. Elon Musk discovered this in 2018 when the production line for the Tesla Model 3 came to a complete halt for four days. Musk said the plant became a manufacturing nightmare, with its complex network of conveyor belts struggling to manage production, and instead resulting in bottlenecks. Businesses can take digitalisation, connectivity, and artificial intelligence to an extreme without understanding fully what they hope to achieve. Anyway, I have come to the conclusion that the road from manual to automation to hyper-automation is a continuum, and each manufacturer has its place on the scale, whether it’s a small factory creating lots of jobs or a Tesla gigafactory.
4 Fourth Quarter 2023 www.motioncontrol.co.za From the President’s desk SAFPA NEWS Uven Moodley. It’s hard to believe we are in the fourth quarter of 2024. Time indeed flies. It’s been a busy time at SAFPA. Ruveer Persad at Zest WEG electric motors was kind enough to host a technical talk on Minimum Energy Performance Standards (MEPS) in South Africa. It centred around South Africa – specifically the DTI and the phase out of IE1 and low-efficiency motors. The adoption of new MEPS for electric motors in South Africa will provide significant energy savings, and in so doing alleviate pressure on the country’s electricity supply crisis, while improving operational competitiveness. Some electric motor OEM companies believe that during the course of next year the IE1 will no longer be accepted at South African customs, as these motors will not align with the country’s push towards energy efficiency. Zest described the MEPS platform, saying that consumers should rather be selling savings related to lower energy consumption from the higher efficiency motors, as opposed to the cost saved on capital equipment. SAFPA is also keeping an eye on SANS 347 – 2019 and its impact on our industry, and will report back on the impact it will have on various stakeholders, including importers, retailers, users, and repair companies. On a fun note, SAFPA hosted a successful golf day at the Benoni Country Club. The event was well attended and a great day out for all. Congratulations to the winners, Honingcraft. There is loads of excitement building up for our upcoming Soccer Day, to be hosted at the Boksburg Stadium on 25 November. It’s a six-a-side format and is generally the best supported social event on our calender. Thanks to all the member’s companies for their continued support and wishing them all the best. Kind regards Uven Moodley SAFPA technical talk At SAFPA’s recent hybrid virtual and physical meeting, Ruveer Persad and Fanie Steyn from Zest WEG Group gave an interesting presentation on minimum energy performance standards (MEPS) in South Africa. They covered the adoption of MEPS standards for electric motors, highlighting that 65% of the electricity consumed in industry is by electric motors, and if we can save even 0,5% in efficiency, this would have a substantial impact. They also explained the various motor efficiency classes and methods of measuring efficiency and global requirements, highlighting the need to create awareness of these standards in the country. They added that big users of motors have moved to IE3, and by the end of 2024 this could well be standard in South Africa. SAFPA recently held a highly successful Golf Day at the Benoni Country club, and the winners were Honingcraft. In addition to a very nice trophy, the team members each won a R600 Pro Shop voucher, with bottles of red wine going to the runners up. SAFPA Golf Day Ruveer Persad. Fanie Steyn. The winning Honingcraft team, from left: Ig van Rooyen, Gert Myburgh, EW Ellis. Also part of the team was Renier de Beer.
www.motioncontrol.co.za Fourth Quarter 2023 5 NEWS & EVENTS Bosch Rexroth appoints new Nigerian distributor Bosch Rexroth Africa Development (BRAD) has appointed AETOS Technical Services (AETOS) as an official distributor in Nigeria. This allows AETOS to sell and support all the products and technologies in the Bosch Rexroth South Africa Celebrating two decades of innovation in industrial automation Motion Tronic, leading specialists in industrial automation, recently celebrated 20 years in business. “During the widespread unrest in KwaZulu-Natal in 2021, our premises in Waterfall fell victim to the flames, leaving behind only ashes and ruins. The impact on us was severe, and the business suffered a complete loss, including our testing equipment. We refused to succumb to adversity, and embarked on a journey of rebirth and renewal,” says Bradley Douglas, Director of Motion Tronic. In October 2021, Motion Tronic relocated to new 800 m2 premises in New Germany. The team began the process of reconstructing the offices and workshop, and within just one month the Motion Tronic headquarters were up and running. “Rebuilding our testing equipment and workshops was a crucial step in our revival and we spared no effort in replacing all the stock that had been lost, ensuring we were well equipped to serve our customers. We also invested in state-of-the-art motor testing technology, enabling us to offer our clients even more precise and efficient solutions,” explains Douglas. A key milestone in Motion Tronic’s resurgence was the construction of a new load testing station. “This allows us to test drives rigorously under various conditions, ensuring our reliability and performance. We also built new testing amenities, specifically designed for servo motor and drive Rental service growing at Integrated Air Solutions The compressor Rental Division of Integrated Air Solutions, which was established only a year ago, is seeing exceptional growth, with many sizeable long-term contracts that call for large-capacity machines having been secured. “While there are (BRSA) portfolio. AETOS is a leading provider of industrial components and solutions to industries that include oil and gas, marine, power generation, mining and cement. AETOS will focus predominantly on the oil and gas sector, which is growing rapidly in West Africa. “The Bosch Rexroth South Africa product line fits perfectly with our current offering of industrial component supplies,” says BRAD business development manager, Louis Potter. “AETOS has supplied major oil and gas companies with various mechanical components, and our offering is complementary to that of AETOS.” AETOS will also support other industries such as processing and packaging, electricity supply, cement and sugar. It now has access to all products and services Bosch Rexroth South Africa has to offer. These consist of hydraulics, pneumatics, electric drives and controls, linear motion and assembly technologies, tightening systems, and service solutions. To further solidify its footprint, AETOS has invested in a hose and fitting workshop to service the local market with hose and fitting assemblies. BRAD runs ongoing training sessions for AETOS staff on product- and process-specific topics. The training is conducted virtually by various specialists within the Bosch Rexroth South Africa group. AETOS will also leverage its technical expertise and solutions when promoting and selling BRSA’s products and services. For more information contact Gillian Allin, Bosch Rexroth South Africa, +27 11 979 4630, [email protected], www.boschrexroth.africa a number of contributing factors, including the supply of top quality, reliable rental machines, our success is first and foremost thanks to our dedicated rental team,” says managing director, Wayne Jacobs. “It’s a new division and a new team, but their years of experience in the sales, rental and air compression space, combined with their commitment and passion, is making a difference.” “We have expanded our original fleet of four secondhand machines to 50 units, 46 of which are brand new,” says rental sales manager, Rudi Denton. “Our work only really begins once we have delivered the rental machine, because we have to ensure that we support the customer throughout the rental agreement. The Rental repairs.” In 2022, Motion Tronic became the African partner agency for Inovance, a global leader in programmable logic controllers (PLCs) and variable frequency drives (VFDs). For more information contact Motion Tronic, +27 31 701 1620, [email protected], www.motiontronic.co.za From left: Rudi Denton, rental sales manager; Zenda Kleu-Pedersen, rental administrator; Rene Smith, rental sales representative Division is on call 24/7, with a response time of approximately 60 minutes in Gauteng and KwaZulu-Natal, and 24 hours in neighbouring countries. If on-site repairs are not possible, customers are provided with a replacement unit. “Our success has not made us complacent, but rather even hungrier for more business. The team will continue pulling out all the stops to uncover the countless opportunities that are out there so that we can continue to grow and corner the rental business,” says Jaobs. For more information contact Cristina Straussner, Integrated Air Solutions, +27 11 894 2906, [email protected], www.air-solutions.co.za
6 Fourth Quarter 2023 www.motioncontrol.co.za NEWS & EVENTS Modern technologies require modern skills to drive employability. We have witnessed the industry evolve from the first industrial revolution to what is currently known as the Fourth Industrial Revolution (4IR). This current revolution, also known as Industry 4.0, is defined by a combination of advances in digitalisation, integration, big data, virtual reality (VR), artificial intelligence (AI), robotics, the internet of things (IoT), 3D printing, and a wide range of other technologies. The job market’s needs and requirements are quickly changing because of this revolution. As a result, it has become even more crucial for educational institutions to implement a curriculum that prepares students to graduate confidently into a 4IR labour market. merSETA, which is part of the 21 Industry Sector Education and Training Authorities for skills development, partnered with Festo, a leading supplier of industrial automation solutions and a global leader in technical education, to establish a 4IR skills centre at Maluti TVET College. The college is a key educational institution in the rural parts of the Free State in Phuthaditjhaba. It has established itself as the institution of choice in technical and vocational education and training, with the vision to offer training for Industry 4.0 through a curriculum that incorporates the rapid advancements in current technology and the necessary future skills that can place the country on a global pedestal. Maluti TVET College is now in a position to provide its students with the skills required to increase their employability and productivity in the workplace. Hands-on skills in industrial robotics, digitalisation, control in pneumatics, smart production lines, 3D printing, VR and augmented reality, networking and IT security, and mobile robotics are some of the key topics the centre can now provide. merSETA and Festo to establish 4IR centre The 4IR lab was launched on 8 December 2022 in the Free State. The opening was officiated by the acting principal of Maluti TVET College, Motlalepula Tsotetsi; the acting CEO of the merSETA, Ncedisa Mpande; and Festo’s head of Didactic in southern and eastern Africa, Horst Weinert. “This skills centre will offer students a fresh and unique opportunity to address youth unemployment by specifically adjusting TVET education models to upskill the next generation and catalyse innovation for digital transformation,” said Mpande, positioning the role of the merSETA during her speech at the launch of the skills centre. The state-of-the-art 4IR skills centre is equipped with industrial technology that will uniquely address Industry 4.0 topics across different streams. The cutting-edge equipment includes: • Bionics, robotics and coding. • Embedded microcontrollers. • Fluid power technology, sensor technology. • Digitalised pump system 4.0. • Digitalisation, PLC programming, cybersecurity. • Mobile robotics and smart factory integration. Werner Joubert has been appointed general manager of Hytec Fluid Technology, while remaining general manager of Hydraulic and Automation Warehouse. Voith Turbo, South Africa has appointed Themba Baloyi as managing director. Appointments Bosch Rexroth Africa has appointed Sebastian Hardt as chief financial officer. Hytec South Africa has appointed Kane Herbert as regional sales manager for KwaZulu-Natal. • Connected learning and virtual reality. • 3D printing additive manufacturing. • Intelligent components and Industry 4.0 systems. • Smart sensors and actuators. • Mechatronic modular production systems. During his speech, Weinert mentioned that as an employer his interest lies in the students’ technical ability, and these skills can be achieved through an industry-driven curriculum. He added that the Industry 4.0 technology, paired with this curriculum, would transform Maluti TVET College to become a highly attractive place for future engineers to study. This will be beneficial to the greater community, and moving South Africa to a knowledge economy. Festo is honoured to have been a part of building a legacy that will reform the education of the people of Phuthaditjhaba, the district, the province and the country. For more information contact Festo South Africa, 08600 FESTO (33786), [email protected], www.festo.co.za
www.motioncontrol.co.za Fourth Quarter 2023 7 NEWS & EVENTS A recent report by market research firm, Interact Analysis forecasts that the motion controls market will return to steady growth following a period of high demand for consumer products in 2021/2022, which boosted investment in automation. In total, the firm anticipates the global motion controls market will be worth $18,9 billion in 2023, a rise from $17,7 billion last year. In 2022, the report says China led the APAC region, which accounted for 37% of global motion controls revenues, followed by Europe, the Middle East and Africa (EMEA) at 33%, and Japan and the Americas (16% and 14% respectively). This year, the report projects that while the Asia-Pacific region (APAC) will remain the largest market, the Americas will show the highest growth rate at 7,4% in 2023. Even so, the firm expects global growth of the sector to fall in 2024 but bounce back in the mid- to long-term. Interact Analysis’ research found that while some vendors were optimistic about the pace of growth, anticipating rates as high as 20%, others were more cautious, anticipating a flat year compared to 2022. Motion controls market worth $18,9 billion in 2023 Eskom Expo honours young scientists Globally, the Americas is expected to suffer least from the impending market slowdown, with some of the largest industries for motion controls, such as semiconductors and electronics machinery, performing well due to the uplift from the US CHIPS and Science Act. The analyst firm foresees a decline in demand for industrial automation in 2024, due in part to interest rates and high inflation. Even so, the firm forecasts that global motion controls market will grow with a CAGR of 4,6% between 2022 and 2027, increasing from $17,7 to $22,2 billion. “Siemens continues to dominate the motion controls market with its market share increasing by almost 1% in 2022,” said Alexander Jones, research analyst at Interact Analysis. “Interestingly, Inovance’s market share increased by 0,6% in the same year, making it now the fifth-largest global motion control vendor in the world. In 2018, the company did not even feature in the top 10.” For more information visit www.interactanalysis.com At this year’s Eskom Expo International Science Fair (ISF), young scientists reaped the benefits of their hard work and ingenuity, receiving full and partial bursaries, cash prizes, laptops, and opportunities for work-based exposure during their school holidays. The fair brought together the brightest young scientists from across South Africa and various other countries. Title sponsor, Eskom awarded 23 full bursaries valued up to R450 000 each, and four special awards to the best female, best development, best energy and best innovation projects in the energy category. Eskom Development Foundation acting CEO, Mologadi Motshele congratulated the remarkable young scientists, who have not only displayed exceptional talent, but also a steadfast commitment to scientific inquiry and innovation. “Your achievements are a testament to your hard work, dedication and boundless curiosity. We are also excited to see a growing number of young women scientists emerging as true change agents in the fields of science, technology, engineering, mathematics, and innovation,” he said. Eskom Expo executive director, Parthy Chetty added: “I wish to thank the many partners and sponsors who share our vision of promoting STEM education by rewarding deserving young scientists for their hard work and dedication.” Through their generous sponsorships, Siemens, Innomotics and Siemens Energy supported previously disadvantaged schools with their prizes. FFS, Babcock International, Ekurhuleni Drums, Trisim Logistics, Berea Plumbers and the National Institute for Theoretical and Computational Sciences (NIThECS) supported learners with laptop computer sponsorships. The University of Witwatersrand, the University of Pretoria, and the Durban University of Technology provided academic support in the form of bursaries and mentorships. Engineering giant, Siemens Energy awarded two full bursaries worth close to R1 million for winners to study towards a Bachelor of Science in Engineering at any South African university of their choice. These included tuition fees, textbooks, accommodation, meal allowances and a laptop. The prestigious University of Pretoria/Dr Derek Gray Memorial Award consisted of the Derek Gray Gold Medal, attendance at the Stockholm International Youth Science Seminar during Nobel Week, and a three-year study bursary in science or engineering at the University of Pretoria. For more information contact JeVanne Gibbs, +27 76 674 1455, [email protected], www.exposcience.co.za
8 Fourth Quarter 2023 www.motioncontrol.co.za NEWS & EVENTS This book covers information compiled from academic references, plant and field manuals, and fieldwork experience. It is not a textbook, nor can it be measured against any academic level or curriculum; but it contains useful practical information that can be used in the instrumentation and process control area, regardless of academic level. The book covers instrumentation, electrical and electronics principles. The wide range of principles covered includes level, pressure, flow, temperature, valves, Field reference handbook for instrumentation and process control SEW-EURODRIVE launches online purchasing switches, PLC, telemetry, fault-finding methods, programmable instruments, isolation procedures, speed, dust monitoring, consistency, analytical methods, weight and mass, indicators and displays, moisture and humidity, relays, PIDs, VSDs, terminology, converting tables, and more. It is divided into chapters that illustrate principles, topics and tasks, with examples of how each principle can be applied. Each chapter includes basic principles, typical drawings, diagrams or pictures of the principle, calibration procedures, and typical problems and solutions. It also gives tips and advice on fault finding in electronic instrumentation equipment. Recommendations on how to use equipment correctly in a particular application are also included. The aim is to simplify the daily life of a technical person in the field of industrial instrumentation. The book is ideal for: • Instrumentation apprentices. • Learnerships (instrumentation, electrical and mechanical). • Technicians or engineers newly qualified in the abovementioned fields. • Millwrights and process controllers (cross-trades). • Companies in mining, manufacturing, power, and municipal technical departments. • Lecturers at universities and colleges. • Individuals who need to understand how a certain instrument or electronic item works. • Rusty personnel who need a refresher. Let each of your artisans or technician have a copy in his or her tool bag or shelf. Even long-qualified artisans or technicians can use this book as a reference as it contains helpful practical advice that cannot be found in the usual academic texts. This book is for all. For more information contact Manqoba Siya Gumede, GUMCO Holdings, +27 83 672 6511, [email protected] In an important digital initiative to make product selection and procurement easier for customers, SEW-EURODRIVE South Africa has launched an online purchasing feature on its website. According to training manager, Zander Claassens, the portal allows customers to not only order products or parts, but also to find support in the form of documentation and CAD data. To maintain the personal touch, there is even a dedicated person to assist customers with their online requests from 7 a.m. to 9 p.m. every day. “The online purchasing portal offers users useful tools and functions, valuable information and practical assistance,” says Claassens. “It is clear that many customers are embracing online procurement platforms, especially since the COVID-19 lockdowns, and we are excited to enhance our sales and support channels further.” He explains that the wide and dynamic range of configurations in SEW-EURODRIVE’s offering needed the functions of the shopping cart to be specially developed to make it as user friendly as possible for customers. There are four different functions that customers can choose from when adding a product to the shopping cart. The first is the product configurator, which guides customers in configuring their required equipment using dropdown options from the company’s vast range of products. The next channel is the spare parts or replacement product selection function, where one of two routes can be chosen. In the first, the customer can make use of the SEW-EURODRIVE serial number found on the product nameplate. Entering that serial number is a quick and simple way of requesting a replacement and ensuring that the exact configuration is replicated. Another route enables customers to find an SEW-EURODRIVE replacement product for a third-party drive which is not an SEW-EURODRIVE item. The online tool will not understand the non-SEW-EURODRIVE serial number, but if the specific criteria are supplied, the system will identify what the customer needs so that the product can be delivered. Registered customers who have already been trading with SEW-EURODRIVE can also use a third option, a customer transaction overview, to help select what they are looking for. When they log onto the online purchasing portal, they will be able to view their history of quotations and orders. This makes it simple to re-order a component that has been purchased before, as they can select the item from a previous transaction or quotation. Lastly, customers can use the drive selection assistant – a smart online tool that guides the user through three simple steps to find the right drive. Claassens emphasises that customers wishing to transact on the portal can find support from a real person behind the portal who can provide hands-on advice and assistance. Customers can also rest easy in the knowledge that the security of the portal is world class. “Our cybersecurity is handled by a dedicated IT team in our group headquarters in Germany,” he explains. “Our customer and transaction data are double-encrypted when working online, while the online support is run on hyper-text transfer protocol secure (HTTPS) and is backed up on a geographical redundancy cloud-based system.” For more information contact SEW-EURODRIVE, +27 11 248 7000, [email protected], www.sew-eurodrive.co.za
www.motioncontrol.co.za Fourth Quarter 2023 9 Water hammer is a high-pressure surge or wave created by the kinetic energy of moving fluid when it is rapidly forced to stop or change direction, altering the liquid’s velocity. Rapid stopping or starting or changing of direction of an incompressible fluid like water or oil in a system is caused by a variety of valves or pumps. It is a myth that a pressure spike cannot exceed the normal pressure in the system. The fact is that pressure spikes can reach up to eight times the system pressure. Even though they may last only milliseconds, the potential damage can be lasting. Pressure gauges and transmitters fitted to measure normal line pressure at the receiving end of these pressure spikes are often irreparably damaged if not suitably protected. One of the main concerns of hydraulic and other system designers is how to eliminate or minimise water hammer. Methods and formulas for calculating water hammer pressures are freely available online. How water hammer affects pressure gauges and transmitters Pressure gauges and transmitters are designed to measure pressures up to the full-scale value of the instrument. For short periods, these instruments may accept an overpressure of a percentage of the rated full-scale pressure without permanent damage. The measuring sensors of pressure gauges (bourdon tube) and transmitters (diaphragm) are normally manufactured from a flexible elastomeric type of material to ensure accuracy and repeatability. Good quality pressure gauge bourdon tubes are designed, manufactured and tested to withstand up to 1,3 times the rated pressure in normal pressure gauges for short periods. In the case of some diaphragm-operated pressure gauges that do not use bourdon tubes (but with a limited range of 2500 kPa maximum) these can handle up to five times more, without permanent damage to the instrument. How to protect against water hammer Most pressure transmitters can withstand 1,5 to two times the rated full-scale value for short periods, without permanent damage. Pressure spikes exceeding these limits can cause the elastomeric sensors to deform permanently, making them unable to return to zero. Accuracy and repeatability may be affected, and in extreme cases rupturing of the sensor may occur. Gauges are sometimes returned to the manufacturer for investigation, completely over-pressured, and often with a ruptured bourdon tube. When SA Gauge informs the customer of the gauge’s condition, they often get responses such as: “But how can it be possible? This is a 1000 kPa gauge and the pump can generate a maximum of 600 kPa.”Water hammer is the most likely cause of damage in such a scenario. Protecting against water hammer The progression of the water hammer shockwave needs to be detained and slowed before reaching the instrument sensor. SA Gauge manufactures several such devices in order to achieve this. The most common and economical is a simple threaded snubbing screw that screws into the process connection of the gauge, restricting the pressure port to minimise flow into the gauge. In severe cases, a length of small-bore capillary tube is attached to the snubber to increase the effectiveness. Other devices like external adjustable flow restrictors, piston type snubbers, and needle valves are also available to choke the offending pressure surge to an acceptable level. It is important to note that these devices will not protect the instruments against sustained overpressure, which will still damage the instruments. An overpressure protector will be required in these cases. For more information contact SA Gauge, +27 31 579 2216, [email protected], www.sagauge.com
10 Fourth Quarter 2023 www.motioncontrol.co.za There is a misconception that there is not much innovation in the pneumatics field, but a closer look reveals otherwise. As a technology, pneumatics has long been crucial to the accomplishment of mechanical work. Additionally, it is often a key component of automation systems, and numerous industries make substantial use of pneumatic systems. The majority require a steady flow of compressed air through a network of pipes and valves in order to transmit and regulate energy. Revolution alters the landscape Some shark species must swim continuously to keep water flowing over their gills in order to survive. Similarly, if a technology stops developing and going forward it is in danger of extinction. Thankfully, new sensing and data communications solutions are making pneumatics smarter and easier to integrate into IIoT, which is good news for those in charge of designing and maintaining the pneumatic systems found throughout industrial environments. With new technology, this sector has recently demonstrated tremendous development potential. Miniaturisation A general trend is toward miniaturisation. Smaller is preferable because it is lighter and typically requires fewer input costs such as raw materials, handling, labour, and conversion energy. The amount of practicable miniaturisation possible varies depending on the application. There is a Latest trends in pneumatics systems limit to how far manufacturers can go along the miniaturisation road in fluid power motor applications before cooling and flow rate difficulties come into play. Nanotechnology systems, which are one billionth of a metre in size, are being used in other applications, such as liquid and gas monitoring. Emission standards have been introduced worldwide with the goal of significantly reducing emissions of carbon dioxide and nitrogen oxides. This has been the main driver of miniaturisation for off-highway vehicles. In the US the near-zero emissions Tier 4 Final was launched in 2014. In the EU, a similar policy went into effect in 2015. The necessity to increase fuel efficiency is a direct result of these rules, and therefore hydraulic reservoir sizes and circuit capacities have decreased, resulting in smaller and lighter vehicles. In response, manufacturers have strengthened component integration, created smaller devices that can handle larger flow rates, and raised system pressure. Pneumatics 4.0 Due to its inherent safety in hazardous applications, its simplicity, and its dependability, pneumatics is an established technology and will continue to be preferred for a wide variety of applications. Despite all of its advantages, there is always potential for development in terms of energy efficiency, particularly when compared to rival hydraulic or electrical technologies. In addition to global government crackdowns on industrial energy usage, decreasing energy expenses, which make up a sizable amount of operating costs in pneumatic systems, is an important end user issue. The main parts of a pneumatic system include valves, actuators, air filter regulators, lubricator units and fittings, in addition to the compressor. Although all of these components can be viewed as commodity goods, IIoT largely affects the valves and actuators, since these items have a tendency to effect consumer purchasing habits for other components. These products are the key growth engines for this market. Utilising cutting-edge technologies has advantages in two key areas: productivity and maintenance. Reduced air usage in the pneumatic system will be a major priority for OEMs and end users alike in their drive to minimise energy consumption; and pneumatic valves regulate the air flow in the system. A crucial end user requirement is to increase the amount of control in pneumatic actuators. The end user can get operational and performance data such as speed, force, air consumption, and cycle time by adding sensors to the system. This data can be utilised to discover inefficiencies, which can then be fixed to increase productivity. In addition, using data analysis to find performance profiles suggestive of declining performance might assist the end user in anticipating component failure. By doing this, a valve or actuator can be changed at the following predetermined interval, reducing machine downtime and increasing operational effectiveness.
www.motioncontrol.co.za Fourth Quarter 2023 11 NEW TECHNOLOGY Smart pneumatics Old pneumatic processes are being changed into smart pneumatic systems with sensory information flowing in both directions, and with data being sent to local networks and relayed to higher level controllers. Particularly in situations where dependable high quality, speed and reproducibility are crucial, continuous position sensors are an excellent solution for process management and optimisation. They can be modified with customised additions, including resistance to vibration, shock, chemical exposure and water intrusion, making them perfect for long-term deployment in difficult settings. Since pneumatics can tolerate a wide range of temperature, pressure and environmental extremes, it is already the system of choice for many of these applications. Today’s production methods and material qualities have advanced to such a degree that high-volume manufacturing is spreading throughout the sector. This lowers the price of essential parts like pneumatic valves and cylinders, while also enhancing overall quality and reliability. Pneumatics is the only technology that can function in such a wide range of circumstances, making it the natural choice for repeated, high-volume ‘fit and forget’ applications. The efficacy of the equipment as a whole, which is increased by our deeper comprehension of machine systems and processes, is one of the fundamental ideas guiding the direction of pneumatics in the future. Pneumatics still has a future, even though the emphasis is largely on electronic and digital control of automated systems. This is because many material components of the pneumatic system may modify their designs and processes to operate in line with IIoT. Electropneumatic pressure regulation With the incorporation of electropneumatic control capabilities in the valve manifold, advancements in valve performance and versatility have taken a significant stride ahead. A straightforward directional control valve is a basic valve. The valve spool is changed by an electrical signal, and the air is forced out of a port pressure by electropneumatics. Based on the input signals, regulating valves can deliver a range of pressures up and down a linear scale. Previously, the analogue signal scale was used to modify pressure in the initial analogue versions. According to the signal, it gave the cylinder a linear output pressure. The capabilities of digital valves and fieldbus communication have since raised the level of sophistication of the system’s electropneumatic pressure control. The usefulness and adaptability of pneumatics are enhanced for a variety of automated systems by this high level of control. It enables more exact control of movement during the production process. Diffusion welding operations can be optimised by electropneumatic pressure regulators and an innovative valve manifold with an integrated communications bus. The pressure is dynamically controlled and may be exactly customised for the application. The grippers are controlled by intelligence embedded into the manifold, which simultaneously monitors and records all valve operations for better quality control and process tracking. Lower downtime, lower costs Five years ago, a long time in terms of technology, it was predicted that predictive maintenance could save expenses by as much as 30%, while reducing equipment downtime by up to 70%. This is now becoming a reality with Industry 4.0. For instance, valve terminals that have embedded intelligence are already in use to track numerous operating parameters continuously, and produce data for diagnostics. These variables include things like the quantity of switching operations and run-time hours, and the state of the power supply. With IO-Link features built-in, pressure, position and flow sensors can give sophisticated data diagnostics and hot-swap capability, enabling manufacturers to anticipate specific component failures and replacement schedules. Pneumatic systems have historically been criticised for being uneconomical due to the high cost of compressed air and the whole lifecycle of pneumatic equipment. To boost the effectiveness of the usage of compressed air, pneumatics producers have responded by creating best engineering practices and more efficient product designs. The development of smart sensing technologies will have an impact on pneumatics in the future. All sorts of fluid power equipment, from connectors, tubing and hoses to pneumatic cylinders, actuators and filters, are increasingly include cost-effective sensing and information processing devices. Vishwakarma Institute of Technology, https://tinyurl.com/y6nzu6f4, www.vit.edu/
12 Fourth Quarter 2023 www.motioncontrol.co.za DRIVES Inovance brings advanced motion control to South Africa Inovance and its South African distributor, Motion Tronic are launching the Easy Series PLC in this country, bringing its flexible, high-performance motion control solution to customers across South Africa in a wide range of industry sectors. With the ability to deliver the simplest to the most complex motion control, the advanced EtherCAT-enabled Easy Series can be programmed to meet any requirement. Motion Tronic director, Bradley Douglas said: “Motion Tronic is pleased to be able to offer its customers the opportunity to cut costs and improve their overall competitiveness with the Easy Series range, which has multiple communication protocols. I am excited about the potential of the Easy Series PLC to transform motion control for businesses in South Africa. The compact footprint of the product, and its suitability for a wide range of applications, makes it an excellent addition to Motion Tronic’s portfolio of Inovance products. “Inovance and Motion Tronic chose to bring the Easy Series PLC to South Africa because it is a high-end product and gives OEMs the ability to solve a wide range of problems. The company’s commitment to research and development is clear in the quality of its products, and the Easy Series PLC is no exception.” The recent impressive growth in output by South Africa’s manufacturing sector bodes well for production. Figures from StatsSA show that it expanded by 1,2% month-on-month in June 2023, and 5,5% year-on-year. South African manufacturers are seeing activity increase, and many are turning to industrial automation technologies to handle higher output, improve their overall efficiency, and reduce costs. Inovance’s Easy Series PLC is therefore expected to prove popular with Motion Tronic’s customers. The Easy Series PLC was launched in Europe in November 2022 at the well-known Smart Production Solutions (SPS) exhibition in Nuremburg, Germany. Explaining how the product can help companies in South Africa to meet their production goals, Inovance’s David Bedford Guaus, strategic marketing manager for AC Drives and Servos said: “I am proud to be able to offer the Easy Series PLC to South African customers through our strong and effective partnership with Motion Tronic. Inovance’s advanced Easy Series PLC provides the simplest to the most complex motion control solution through its complete range of products.” Emphasising how the Easy Series PLC offers flexibility from simple to complex motion control, Guaus pointed out that it features PLCopen compliant axis control and multiple communication protocols such as Modbus RTU, EtherCAT (on the Easy5xx models), optional CANopen (except on the Easy301 model), and Ethernet/IP and Modbus TCP (both available in the Easy320 and Easy523 models). This is provided alongside ST, LD and SFC language support to ensure compatibility with a wide range of existing systems and applications. “The Easy Series PLC is the next level in PLC motion control, with simulation mode for offline debugging, real-time fieldbus, axis group for linear and circular interpolation, and CAM table functionality. The PLC series also supports function block and function for encapsulation, code reusability and scalability. Industrial automation giant, Inovance and its South African distributor Motion Tronic, based in Durban, were both founded in 2003. Together they provide South African OEMs with a wide range of world-leading industrial automation technology and services, including installation, commissioning, mechanical and technical support. For more information contact Motion Tronic, +27 83 641 1487, [email protected], www.motiontronic.co.za Bradley Douglas, Director, Motion Tronic. David Bedford Guaus, Strategic Marketing.
14 Fourth Quarter 2023 www.motioncontrol.co.za DRIVES Motor management plays an all-important role controlling motor energy costs in various industries, segments and applications. Research and practical experience have consistently shown that effective motor management practices can result in significant energy savings, reduced operational costs, and improved overall system reliability. The above also makes a compelling case for organisations to use motor management to control motor energy costs, while maintaining operational resilience. From plant stoppages, damage to equipment, and risk to people or even the environment, motor failure can be quite expensive. Implementing a holistic motor management strategy requires careful planning and the right combination of technologies. In the past, companies have been reluctant to implement a complete motor management due to the perceived technical complexities. Fortunately, with the advent of IIoT, digitisation and advanced connectivity, a motor management strategy is far more attainable. Here are some important steps: Implement application-oriented tools: For machine builders who source many of the The time is now to implement a motor management strategy By Christo Kotze, product application leader, TeSys, Power Products Division at Schneider Electric. motorised solutions, efficiencies increase when core machine components are easy to select, install, wire, commission, and can be remotely maintained. Taking this one step further, automated configuration tools now allow OEMs, panel builders and even end users to generate quick and comprehensive solutions. These tools have been proved to reduce design and selection time by up to 40%. Optimise energy performance: Connected service-orientated devices have the intelligence to operate motors at the optimum efficiency points, which in turn reduces electrical consumption by at least 30%. Furthermore, intelligent motor starters such as Tesys Island and digital load management solutions make it much easier to optimise machine performance. Each load feeder can provide asset data to optimise the machine and the process, and to provide actual line current data. These devices offer machine builders the option to monitor installed devices remotely, to provide their clients with a cloud-based predictive maintenance service, and ultimately monetise the newly accessible load asset data. Improve software analytics: With intelligent motor management solutions in place, maintenance personnel can troubleshoot equipment remotely. Abnormal occurrence can be addressed before it becomes critical and results in production interruption. This intelligent pre-alarming is based on pre-set behavioural parameters. The data gathered is combined and analysed with dedicated software solutions such as Schneider Electric’s EcoStruxure Asset Advisor, which allows for the future asset performance prediction. By implementing a sound motor management strategy, organisations can accurately estimate how long a motor has been in use, when maintenance is needed, and how efficiently it is being utilised. Ultimately, there are motor management solutions that are tailored to specific segments and which prioritise uptime, safety and efficiency. At Schneider Electric we provide the tools and data needed to make informed decisions about motor management and energy consumption across various industries For more information contact Schneider Electric South Africa, +27 11 254 6400, [email protected], www.se.com/za/en
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