The Beckhoff AX8000 multi-axis servo system VOL 26 NO 1 • FIRST QUARTER 2024
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www.motioncontrol.co.za First Quarter 2024 1 SAFPA news News & events New technology OUR COVER 9 FIRST QUARTER 2024 04 05 10 REGULARS FEATURES 11 Beckhoff Automation, ACTOM, Motion Tronic, Aerotech, Customised Motion Control, Bosch Rexroth Africa, SEW-EURODRIVE, Schneider Electric South Africa 18 BMG, Stucchi South Africa 20 Neu Matics SA, Emerson Automation Solutions, ifm - South Africa, Valve & Automation, Parker Hannifin SA, Integrated Air Solutions Busch Vacuum Solutions 22 30 igus South Africa, WEG Africa, Southern African Institute for Steel Construction ISO-Reliability Partners, Lubrication Engineers, Wearcheck 26 31 Drives Couplings & connectors Pneumatics Condition monitoring Hydraulics Mining & metals Lubrication For 50 years, Bausch+Ströbel in Germany has been developing packaging and production systems for the pharmaceutical industry. Today, substrates are made of plastic with the thinnest possible walls, but these are more prone to stretching than their paper counterparts. This makes high-speed processing much more difficult. However, printing can be decoupled from the labelling process via a separate servo drive, which allows fast and accurate positioning of the printing, even with plastic substrates. Read our cover story on page 9 to find out how the company’s new label dispenser was able to achieve a lower overall cost by merging all servo axes into a central TwinCAT motion controller from Beckhoff Automation. The Beckhoff AX8000 multi-axis servo system VOL 26 NO 1 • FIRST QUARTER 2024 Axiom Hydraulics, ISO-Reliability Partners
2 First Quarter 2024 www.motioncontrol.co.za welcomeFIRST QUARTER 2024 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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It‘s early in the year, and it‘s fun to see what the predictions are for 2024 in the industrial world. One thing for sure is that generative AI will be big. Among all the hype, an over-the-top app that attracted my attention was NewsGPT. It appears that NewsGPT is a reporter-less and biasfree news channel which is an alternative to normal news. It uses advanced proprietary AI algorithms and deep learning to automate the news production process. This includes selection of stories, research, putting together content, and delivery through AI avatars, which are basically virtual news presenters. NewsGPT says it is committed to eliminating fake news and biased reporting by avoiding human biases and preconceptions. It can also offer personalised news. If you let it know your personal preferences and interests it can adapt the news content so you get news articles that are relevant and meaningful to you. Tomorrow’s news today Shortly after launching NewsGPT, the team came up with an even wilder offering, the world’s first news forecast. This uses predictive science in the same way as today’s weather forecasting. The first forecast reported the results of Sunday football games in the USA still to be played. It seemed to me that there was a bit of a shortage of information on how these matched the actual results. But as NewsGPT CEO, Alan Levy said: “The results are less important than the methodology, our present focus isn’t accuracy. It’s about merging deep learning and the world of news forecasting.”The team, which includes MIT mathematicians and Cambridge machine learning experts, aims to forecast sports results, market trends, Oscar winners and election results, among many others. Levy says that just as weather forecasts evolved from hocus pocus to vital decision-making tools, NewsGPT envisions a similar path for its news forecasts. A horrible idea Not everyone is impressed. Futurism magazine calls it “an absolutely horrible idea”. Transparency is an issue. NewsGPT is not very forthcoming about the language models it uses. Language-generating AIs also have a tendency to hallucinate − to just make it up. They don’t know what words mean, they just predict what might come next in a sentence. Another issue is plagiarism. Journalists are starting to find that stories they have written are being extracted and remixed with other sources in NewsGPT. AI programs assemble articles by processing vast amounts The unhuman truth of publicly available information. Even the best automated stories are basically news clips, with no new findings or original reporting. They can’t go out and report or ask questions, so their stories will never break new ground or come up with a scoop. NewsGPT articles also don’t link back to references giving facts and figures, which have to come from somewhere. What’s it like? I decided to check out the NewsGPT website to see what this is all about. What I saw were some talking heads, the avatars, which were a little bit creepy; and a lot of the images looked like they came out of a comic book. I tried some of the articles. In one, the photo of President Biden had only three fingers, and in another King Charles looked like James Bond. The writing could have been human-produced, but it was bland and rigid, just like the AI-generated articles that we see online nowadays − not very exciting. It was kind of robotic. It’s not supposed to be biased, but a report on a drone attack in Ukraine brought in some phrases like ‘tragically’ and ‘heartbreaking discovery’ which looked contrived to me. Normal news doesn’t have that kind of emotion. I tried searching on South Africa but there wasn’t much. However, I thought a report on the green ammonia revolution was quite interesting; it pulled together most of the available information in a logical way. I think NewsGPT could be useful if something big happens. It could gather all the news reports into one place so you don’t have to read bits and pieces. To my disappointment, the forecasting section was blank, I was really hoping for something interesting there. NewsGPT is still a beta version, so it’s probably too early to draw any real conclusions. Humans bring invaluable insights, critical thinking, and investigative skills that AI can’t replicate. Human reporters can contextualise events, interview people with empathy, and detect subtleties that machines might not see. Meanwhile, AI is challenging this model and redefining the future of journalism. I’m sure that it will adapt and evolve, and find new opportunities. It seems to me that AI will complement human journalism, not replace it.
4 First Quarter 2024 www.motioncontrol.co.za From the President’s desk www.safpa.org.za | +27 11 061 5000 | [email protected] SAFPA NEWS Uven Moodley. I hope the New Year, although over a month old by now, brings huge success to our members. Reflecting back on 2023, it was a busy year for the committee. Membership numbers were maintained, and we hosted successful sporting days, including golf and football events. We also hosted technical meetings that were well attended. It’s been a busy start to 2024, with the first technical meeting hosted on 1 February at the Birchwood Hotel. The topic, ‘Introduction to Fluid Power, was well received by the participants, and they were very complimentary about the subject material and presenting The 2023 SAFPA six-a-side soccer tournament was held on 25 November last year at the Boksburg Stadium. Hosted by local soccer club FC Porto, the happy family day was a huge success, and the turnout was amazing. SAFPA soccer day At a recent technical evening, SAFPA committee member, Russell Gill from Engineering & Hydraulic Services gave an interesting introduction to the field of fluid power. It was aimed at non-technical employees who work or wish to work in the fluid power industry. SAFPA technical evening skills of SAFPA council member, Russel Gill. The talk was attending by non-technical people employed in the fluid power industry, and its success warrants the need for another session in the third quarter of this year. Our first council meeting for 2024 was held on 2 February, where we took the opportunity to plan for the year ahead. We discussed some interesting topics for future technical meetings, and also looked at putting together a cycling event, along with the traditional golf and soccer days. Kind regards Uven Moodley Winning team, Hytec Engineering. The final was played between SMC and Hytec Engineering. Congratulations to both teams for reaching the final, and well done to Hytec Engineering for winning the cup.
www.motioncontrol.co.za First Quarter 2024 5 NEWS & EVENTS Young scientist invited to Nobel science seminar in Sweden Crawford student, Brandon de Greef embarked on an extraordinary journey last December with a lifetime opportunity to participate in the Stockholm International Youth Science Seminar during Nobel Week. De Greef was honoured with the prestigious University of Pretoria/ Professor Derek Gray Memorial Award at the Eskom Expo International Science Fair, following a successful showcase of his ground-breaking research project, ‘Powdered Insulators for High-Voltage Applications’. The project earned him the Derek Gray Gold Medal and a three-year bursary at the University of Pretoria. “My research involved finding if a powder-only insulator would be a possible substitute for high-voltage electrical insulators. This powder would be far easier to remove, repair and maintain than conventional oils and gases – which are toxic to humans and the environment, and are also very expensive. Systems are also hard to repair because they are messy and need to be completely replaced. The powdered insulator would be far cheaper and better for the environment,” said De Greef. He took part in the Eskom Expo International Science Fair last October with another research project, ‘Solar Optimisation for Personal PV Systems’, for which he was awarded a gold medal. The science seminar in Stockholm is an extraordinary blend of science and culture. The event features individuals selected from international science fairs and premier universities recognised for their remarkable research undertakings. Its unique programme unites young minds from diverse global Brandon de Greef. backgrounds, fostering a shared passion for science. The goal is to inspire youth to pursue scientific endeavours, while championing international understanding and friendship. For more information contact JeVanne Gibbs, Eskom Expo for Young Scientists, +27 76 674 1455, [email protected], www.exposcience.co.za
6 First Quarter 2024 www.motioncontrol.co.za NEWS & EVENTS ABB and Gravitricity to collaborate on energy storage systems ABB has signed an agreement with UK-based gravity energy storage firm Gravitricity to explore how hoist expertise and technologies can accelerate the development and implementation of gravity energy storage systems in former mines. Gravitricity has developed GraviStore, an innovative gravity energy storage system that raises and lowers Authorities, with collaborative support from SKF, recently conducted a large and highly effective raid on a very well-known bearing seller of SKF bearings in Cape Town. The bearing seller, who has been on SKF’s radar for quite some time, has been selling counterfeit SKF bearings to numerous customers in the region. “We gathered intelligence from our Cape Town Authorised Distributor and also from our customer, who unknowingly purchased counterfeit products,” explains contracts manager, Lynette Nieuwenhuizen. “Thanks to a great team effort, determination and smart investigating, we managed to seize over 15 bags filled with various types and sizes of counterfeit SKF products during the raid.” Nieuwenhuizen confirms that SKF is collaborating with police and legal authorities in further pursuit of the case. “Our Authorised Distributors and customers are our eyes and ears in the market, and subsequently play a pivotal role in providing intelligence. Their valuable input will assist us in carrying out more raids in the future,” says Nieuwenhuizen. “We solicit everyone’s support in spreading awareness around the negative effects and SKF’s successful raid action in Cape Town outcomes linked to counterfeits for SKF in terms of loss of business.” Nieuwenhuizen also points out that the use of counterfeits can be catastrophic for customers. Inferior bearings are known for failing prematurely, causing machine and equipment breakdowns that subsequently lead to downtime. This unlocks a domino costloss effect; alongside production losses, end users also face maintenance and replacement part costs. Additionally, counterfeit products are detrimental to both SKF and its customers’ efforts towards sustainability. SKF is extremely pleased with the raid’s successful outcome and pledges continued support to ensure that only genuine SKF products are used. “As the custodians of our quality brand, we will continue our efforts to protect our valued customers and Authorised Distributors from counterfeits.” Nieuwenhuizen emphasises that SKF Authorised Distributors offer customers the best sales channel for sourcing genuine products, and the responsibility therefore rests on their shoulders to ensure that their supply chain is always free of counterfeits. Doing its part, SKF also takes proactive initiatives to ensure its network of Authorised Distributors always remain clean from counterfeit. For more information contact Samantha Joubert, SKF South Africa, +27 11 821 3500, [email protected], www.skf.com heavy weights in underground shafts – to offer some of the best characteristics of lithium-ion batteries and pumped hydro storage. Future GraviStores will store more than 20 MWh, providing long-duration storage and rapid power delivery to network-constrained users and operators, distribution networks and major power users. Unlike batteries, the Gravitricity system can operate for decades without any reduction in performance. Gravitricity has already proven the system with a scale demonstrator and is exploring the potential to deploy its groundbreaking technology in decommissioned mines worldwide. As a market leader for mine hoists with a large installed base of more than 1000 hoist solutions worldwide, ABB will collaborate by providing research and development, product development and engineering teams specialising in the design, engineering and operations of mine hoists and mechanical, electrical and control technologies for hoisting. Gravitricity will bring specialist expertise in grid compliance and control systems. The decommissioning of mine shafts is a costly process for mining companies. When disused mine shafts are repurposed for energy storage, they can fill a productive function for up to 50 years beyond their original lifetime and mitigate decommissioning costs, while creating new job opportunities and contributing to the green energy transition. For more information contact ABB South Africa, +27 10 202 5105, [email protected], www.abb.com/za C M Y CM MY CY CMY K
NEWS & EVENTS In a strategic move to fortify its presence in South Africa, I-MAK, a premium brand under the umbrella of Bearings International (BI), recently embarked on a very successful countrywide roadshow. I-MAK specialises in gearboxes, geared motors and power transmission solutions, a focus it has maintained for over 50 years. The company’s gearboxes power and propel hundreds of thousands of machines worldwide across diverse applications. BI general manager, Robert Sillis emphasised the importance of this initiative. “The Country Road Show was not merely a product showcase, but also played a crucial role in unveiling I-MAK’s cutting-edge products across BI’s extensive local branch network,” he said. The roadshow included product training sessions and the distribution of sales tools to managers and sellers. It focused on industrial sectors grappling with downtime challenges, specifically targeting the mining, food and beverage, utilities, agriculture and automotive sectors. It also presented I-MAK’s complete standard geared unit range to Bearings International representatives and senior managers in the geared units division. This comprised inline, bevel and shaft mount helical I-MAK shifts gear with successful roadshow units. The event included presentations on the features and benefits of the brand and products, and how they fit into the overall strategy of Bearings International. The roadshow proved to be an invaluable experience for all stakeholders, as sellers underwent rigorous training conducted by internal product experts. Armed with this knowledge, they can now present the product to customers and decision makers, identifying winning factors and delivering tailored solutions to maximise uptime. For more information contact Kobus Groenewald, Bearings International, +27 11 899 0000, [email protected], www.bearings.co.za JHB: 011 801 8200 CT: 021 930 9666 DBN: 031 701 2701 PE: 041 364 0415 www.phoenixcontact.co.za For more informa�on: Industrial Ethernet switches Our Industrial Ethernet Switch por�olio comprises Managed and Unmanaged Switches with Gigabit, PoE, IEC 61850 cer�fica�on, and for DIN rail moun�ng. This gives you the flexibility to build powerful and secure networks, even in harsh environments: copper and FO ports, as well as redundancy func�ons, enable the flexible networking of your systems and the easy segmenta�on of your industrial network. Industrial Unmanaged and Managed Switches from Phoenix Contact Switches, Motion Control, 1.2 A4, Q1.pdf 1 2024/02/14 10:46:51
8 First Quarter 2024 www.motioncontrol.co.za NEWS & EVENTS At the recent Investing in African Mining Indaba 2024, Bosch Rexroth Africa, a leader in hydraulics, pneumatics and automation, bolstered its presence and showcased its innovative solutions for the mining industry. The Group aligned with the event’s theme, ‘Embracing the power of positive disruption in African mining’. The focus of the stand was on the provision of the most technologically advanced solutions and services to the mining industry. This highlighted that Bosch Rexroth Africa is disrupting conventional ways of operation. This is through award-winning Bosch Rexroth solutions, Artificial Intelligence of Things (AloT) mining solutions offered by fellow company Smart Mine, and a range of Hägglunds drive systems that are designed to optimise operational efficiency. Bosch Rexroth recently presented its comprehensive three-year strategy #ThinkGroup, which highlights the Bosch Rexroth Africa showcases mining solutions at Mining Indaba Throughout 2023, SKF Authorised Distributor, Bearings 2000 has supported SKF’s Remanufacturing Services with a strong focus on remanufacturing spherical roller bearings used in food and beverage applications, and also larger sized spherical roller bearings and SKF and Bearings 2000 contribute to the circular economy importance of collaboration and the interdependence of three pillars: people and culture, digital transformation and sustainability. “#ThinkGroup enables us to harness the power of eight specialist companies within our group. By working together, we provide the most diverse range of turnkey solutions for the mining industry. This is supported by our extensive multibrand offerings and a healthy supply chain that gets solutions to clients in the shortest time frame possible. Through teamwork, we can reach our full potential,” said Bosch Rexroth Africa CEO, Chris Riley. “With a multi-brand approach, a drive for innovation, and collaboration, we can meet our clients’ demands. This is our competitive edge.” Riley also highlighted the significance of presenting innovative solutions at Mining Indaba. “Participating in this event helped expand our footprint across the industry and continent. The opportunity to engage with industry leaders about our most innovative products and services was invaluable,” he added. Riley’s sentiments mirrored one of the major goals of the Indaba − to have more conversation-based interactions. For the past three decades, Investing in African Mining Indaba has been vital for the largest players in Africa’s mining industry. It is the hub of networking and innovation for the continent’s largest sector. In the time that the conference has become an integral part of mining in Africa, Bosch Rexroth Africa has made its own significant strides. These include growing its product range and expanding its presence to over 11 African countries. For more information contact Gillian Allin, Bosch Rexroth South Africa, +27 11 979 4630, [email protected], www.boschrexroth.africa deep groove ball bearings for the pulp and paper industry. This resulted in the reuse of 5354 kg of high-quality bearing steel, contributing to a total energy saving of 42 080 kWh. The outcome of this translates to avoiding 19 120 kg of CO2 emissions. Bearing remanufacture plays a key role in the global drive to decarbonise and promote environmental sustainability. The process of remanufacturing a bearing, compared to manufacturing a new bearing, eliminates the use of raw materials, and reduces energy consumption and CO2 emissions. SKF’s Remanufacturing Centre aligns with the global organisation’s commitment to the circular economy through the development of cutting-edge product, advanced technology, and professional service solutions. “Remanufacturing Services is a three-way win, adding value for customers, for the environment and for SKF,” says circular economy centre manager, Lourens Pretorius. “Our remanufacturing lead time is five to ten working days. Compare this to the delivery period of an overseas order. The waiting period for large size bearings can be up to several months. We will continue to bolster our collaborative efforts with Bearings 2000 to achieve our environmental and circular economy goals to the ultimate benefit of our customers and our fragile planet.” For more information contact Samantha Joubert, SKF South Africa, +27 11 821 3500, [email protected], www.skf.com
COVER STORY For 50 years, Bausch+Ströbel in Germany has been developing packaging and production systems for the pharmaceutical industries. The company’s goal is to offer the best technical and economical solutions for the challenges of modern industry. Its new ESA1025 labelling machine shows how this is achieved with PC-based control from Beckhoff as the central motion controller. High-quality liquid and powdered pharmaceuticals are filled into syringes, vials, cartridges and ampoules. The process starts with cleaning and sterilising the objects and extends to labelling and syringe assembly. Modular label dispenser with servo drive technology Self-adhesive labels on a roll are used for labelling vials and similar pharmaceutical containers. To ensure these can be applied quickly, accurately and reliably, the ESA1025 labelling machine is equipped with a new modular label dispenser. The benefits include precise and gentle labelling, fast, tool-free changeover to other object and label sizes, and increased print quality through servo drive technology from Beckhoff. The system is also extremely compact, as the entire electrical system and control components have been integrated into the machine to save space. The high requirements for control can be seen in the complexity of the process flow. Object transport in the system: The vials are brought in via an infeed screw, which is engaged and disengaged on the main star while the system is running. The main star can have different star pitches (ratios) depending on the object size, which is relevant when coupling with the inlet screw and the electronic cam switch. The outfeed wheels are mechanically coupled to the main star and have no drive of their own. Accumulation: This is operated at a constant speed derived from the label dispenser. Good synchronisation is required to avoid wrinkling. Labelling: The label dispenser is operated in a cycle, and the gearless label web feed is restarted at full speed every 75 ms. The label web feed is stopped by a sensor, which detects the gap between the individual labels. A special logic ensures that correct positioning takes place even in the absence of labels (missing triggers). The servo drive of the label tape feed generates different, highly accurate trigger signals that are required to control the vision and printing systems. Gerald Kreft, a programmer in the software development department at Bausch+Ströbel, explains further special features that are important for PC-based motion control on a labelling machine transporting pharmaceutical containers. The labelling machine can process fragile objects with very thin walls, such as vials. It is also essential to ensure that the labelled object shows no signs of cosmetic damage. This is why the through transport has to be as stress-free as possible. Today substrates are made of plastic with the thinnest possible walls; but these are more prone to stretching than their paper counterparts. This makes high-speed processing much more difficult. With the new label dispenser, however, the printing can be decoupled from the labelling process via a separate servo drive, which allows fast and accurate positioning of the printing, even with plastic substrates. Benefits of central control architecture In the previous model of the ESA1025, the servomotors for the label dispenser and for the through transport were each controlled via separate servo drives. “Separate controls meant having to establish, manage and maintain several communication paths,” says Kreft. “By merging all servo axes into a central TwinCAT controller, and achieving a higher degree of standardisation, we are able to achieve a lower overall cost. In addition, PC-based control from Beckhoff makes optimum use of the limited installation space due to the integrated control cabinet.” The super-fast label dispenser is capable of handling up to 48 000 units per hour. The actual maximum output that can be achieved depends on the material being processed, such as the vial size and label length; however, the new dispenser makes it possible to cut reduce dependence on the label material. The consolidation of all servo drives in a central motion controller achieves this. Another advantage is the modular design. This means that the labelling system can easily be used on other types of machines. The core of the centralised motion control system is the Beckhoff CX2062 Embedded PC with eight-core processor and TwinCAT software, and also the AX8000 multi-axis servo system. The latter features a modular design consisting of an AX8620 power supply module and three AX8206 dual-axis modules, which control the OCT servomotors in the AM8000 series. The range of PC-based control systems used is rounded out by various EtherCAT terminals and the operating unit, consisting of a CP3918 multi-touch control panel and the C6930 control cabinet industrial PC connected via the CP-Link 4 single-cable solution. For more information contact Beckhoff Automation, +27 11 795 2898, [email protected], www.beckhoff.com Picture copyright: Bausch+Ströbel. Picture copyright: Bausch+Ströbel.
10 First Quarter 2024 www.motioncontrol.co.za Several leading academic institutes in Germany are collaborating on the future of hybrid electric flying. The partners are researching an entirely new propulsion system for medium-range aircraft with up to 35 passengers. They include the Fraunhofer Institutes and the Brandenburg Technical University, under the leadership of Rolls-Royce Germany. The Clean Sky programmes of the European Union serve as important guidelines for the aviation industry to achieve a significant reduction in nitrogen oxide and noise emissions caused by aviation. A promising technology for this purpose is hybrid electric flying. This is how the partners envision a future hybrid-electric aircraft: a gas turbine generates electrical energy, which charges intermediate battery storage; the aircraft draws its electrical energy from this storage for propulsion. This technology banks on larger, slower rotating rotors that produce less noise on the ground, creating a significantly smaller noise footprint than conventional propulsion aircraft. The modular structure of the proposed concept also allows for the future use of alternative fuels or entirely new power sources. By mid-2026, the partners aim to develop manufacturing technologies for hybrid electric propulsion components, qualify existing technologies, and produce prototype components. The focus is on accelerating the development and delivery of prototypes in a sector characterised by high competition. An example is the project’s goal to shorten the lead times significantly from the finished design of a functional prototype to handing it over to the client, reducing them from several months to a few weeks. Other projects involve creating highly flexible production concepts essential for efficient mass production. Thrust for hybrid electric flying Each of the participating Fraunhofer Institutes contributes its specific expertise to provide solutions for the aircraft manufacturer’s later serial development. The planned production technologies, such as additive manufacturing, have not been applied in aircraft construction before. Qualifying them for this industry, with its particularly stringent requirements for quality, reliability and durability, is a challenge that they are now addressing. The high interdisciplinarity of the research projects requires utilising the competencies of multiple institutes, and discussing technical issues synergistically. One key component involving multiple institutes in its development is the combustion chamber of the gas turbine. In hybrid-electric flying, a gas turbine generates electrical energy, which charges an intermediate battery storage system. The aircraft draws its electrical power from this storage for propulsion. The Fraunhofer Institute for Machine Tools and Forming Technology has built a reputation for developing cutting-edge manufacturing processes and production systems. It takes on the coordination role among the research partners. Relying on its expertise in forming technology and high-performance machining, it is involved in production processes for the combustion chamber housing via bulk-forming and flexible component machining. Another focus is the arrangement or geometry of the coils in electric drives that enables more efficient operation and higher torque. Fraunhofer specifically supports continuous digital representation in all sections of the development cycle through to serial production. The Fraunhofer Institute for Material and Beam Technology focuses on laser-based additive manufacturing. In direct energy deposition, metal is melted and subsequently welded where needed. This technology allows components of up to ten metres in length to be printed in any shape or size. The Fraunhofer Institute for Manufacturing Technology and Advanced Materials further develops a specifically innovative metallic 3D printing process established by the Israeli company, Tritone Technologies. MoldJet combines two manufacturing processes that work alternately for layer-wise component manufacturing. In the first layer, the form is produced as a negative to the component geometry from a wax-like polymer using inkjet print heads. This printed layer of form material is then filled with metal powder paste through a slot nozzle and a squeegee. Due to the layer-wise construction, it is possible to manufacture complex components with undercuts or internal channels, without support structures. No gas turbine is complete without cast components such as turbine blades or housings. ACCESS is responsible for the development of these cast components. ACCESS refines the latest additive processes to accelerate the complex precision casting route. The goal is to develop tool-free precision casting parts in a shorter time, at lower costs, but with greater design freedom. Rolls-Royce develops and delivers complex energy and propulsion solutions for safetycritical applications in the air, on water and on land. Rolls-Royce Germany is very active in the aviation industry. It is the only German aircraft engine manufacturer authorised for the development, production and maintenance of modern civil and military turbine engines. For more information contact Andreas Hemmerle, Fraunhofer Institute for Machine Tools and Forming Technology, +49 371 5397 1372, www.iwu.fraunhofer.de/en
12 First Quarter 2024 www.motioncontrol.co.za DRIVES The EP3751-0260 EtherCAT Box module by Beckhoff connects an acceleration sensor with an inertial measurement unit (IMU) − a gyroscope. This unit measuring just 30 x 86 x 22 mm provides accurate detection of acceleration and rotational motion in addition to shock, vibration and tilt measurement, both as preprocessed values and as raw sensor data. An ultra low noise three-axis accelerometer with 20-bit resolution and an adaptable measuring range of ±2, ±4 and ±8 g is integrated. The sampling frequency is 4 kHz. The built-in sensor is suitable for applications where low frequencies need to be monitored with as little noise as possible, for example in monitoring building work, bridge monitoring, robotics or condition monitoring. In addition, the I/O box module features a low noise, temperature stable three-axis MEMS gyroscope sensor (6DoF IMU) to record rotational motion across the three axes. With these two sensors, a wide variety of motion applications can be measured using just one I/O box module, and even complex rotational motion can be recorded precisely. The high-performance EtherCAT connection also ensures virtually delay-free transmission to the evaluating measuring system. The sensor data is parameterisable and can be transmitted as raw values (unprocessed/unfiltered) or as preprocessed measurement data. The latter can then be filtered, processed and evaluated using TwinCAT Analytics, for example. Precise detection of complex rotational movements In August 2022, Marthinusen & Coutts (M&C) Zambia was requested by a smelter based in the Copperbelt to provide an in-country repair solution for its two critical 4,5 MW compressor motors. The company was given only three weeks in which to overhaul and commission the motors. The scope of work was to dismantle, clean and assess all parts, dynamically balance the rotors at operating Rapid overhaul of compressor motors For more information contact Beckhoff Automation, +27 11 795 2898, [email protected], www.beckhoff.com Image copyright: Beckhoff. speed using M&C Zambia’s own 12 ton balancing machine, supply new bearing assembly parts, assemble the motors, and no-load test and laser align the motors on site. “Upon dismantling both motors we identified that the stator coils indicated partial discharge and the stator wedges had deteriorated significantly over time. We therefore requested M&C’s workshop in Cleveland, Johannesburg to carry out partial discharge treatment of the stator coils and to manufacture the stator wedges that needed to be replaced,”said Eugene Lottering, M&C Zambia’s General Manager. “Our team is well experienced in how to approach and action various stages throughout the overhaul of these motors. We successfully completed various medium voltage overhauls up to 4650 kW. The motors were no-load tested at 11 kV with exceptionally good results and the customer then gave us the go-ahead to commission the motors,” Lottering explained. “Installing them onsite turned out to be a complicated procedure, especially the alignment of the motors to the compressors.” The motors were finally tested on load, recording satisfactory vibration levels of below 1.34 mm per second. They were successfully installed and commissioned three days before the scheduled deadline for completion. For more information contact Mamiki Matlawa, ACTOM, +27 10 136 0216, [email protected], www.actom.co.za
www.motioncontrol.co.za First Quarter 2024 13 DRIVES Customer profile Headquartered in Prospecton near Durban, Toyota South Africa Motors (TSAM) is a manufacturer of Toyota vehicles. Since its establishment in South Africa in 1961, global motoring giant Toyota has become part of the country’s culture, and is one of its best-selling automotive brands. A wholly-owned subsidiary of the Japanese Toyota Motor Corporation, TSAM has a strong focus on quality control, deliverables, safety, and ease of use. Motion Tronic, founded in 2003 in Durban, is an official distributor of Inovance products in South Africa, providing a wide portfolio of motion control solutions. The company also offers local specialist support from engineers who have completed dedicated training on Inovance products, including installation, commissioning, and technical and mechanical support. The challenge The TSAM exhaust plant was looking for a way to ensure that all exhausts were manufactured with the correct catalytic converter for the applicable model before assembly. Assembly staff needed a quality control solution that would ensure the correct part matching of the units being assembled, and significantly reduce the risk of errors relating to incorrect part matching. Case study on automotive quality control Motion Tronic selects high-performance PLCs and HMIs from Inovance Technology to engineer a smart catalytic converter quality control solution for the exhaust facility at Toyota South Africa Motors. The solution TSAM approached Inovance’s South African distributor, Motion Tronic for help in designing and building a solution to check the quality of its catalytic converters before assembly. Motion Tronic worked with the team at TSAM’s exhaust plant to create a quality control system for catalytic converters that checked part numbering inside the unit, checked the weld seam, and checked the part number stamped on the outside of the catalytic converter. Global industrial automation company, Inovance was selected by Motion Tronic to provide a solution. Technical support engineers from Inovance worked alongside Motion Tronic’s project engineer to develop the correct solution to TSAM’s quality control challenge. The solution comprised two IFM infrared cameras that identified the numbering inside the catalytic converter, and also the stamped numbering on the outside of the catalytic converter. These were linked to a high-performance Inovance H3U PLC, which provided communication over Ethernet, and acted as a central processing unit. Data was processed by the PLC and compared with recipes programmed into an IIoT-ready Inovance IT7000 HMI to determine whether the catalytic converters were within the acceptable range. This delivered a clear pass/fail result that could be easily read by Toyota’s assembly staff. The benefits Inovance was chosen by Motion Tronic because it offered a cost-effective, high-quality solution. Motion Tronic and Toyota found Inovance very easy to work with, and the Inovance range of industrial automation products provided the required communication interfaces and displays needed to acquire, process and deliver test results directly to Toyota assembly staff. The quality control solution engineered by Inovance, Motion Tronic and TSAM provided a cost-effective and high-performance solution to the problem. The new quality control system ensured that all exhausts assembled at the plant were manufactured with the correct catalytic converter for the applicable model. Key benefits The solution brought a number of benefits: • Cost-effective quality control. • High performance. • Ease of use. • Fast communication. • Clear display of data. • Reliability. • Increased productivity. • IIoT capabilities. “We really enjoyed working with Toyota, and we hope to do so again in future. The project was very successful and this was in no small part due to the high-quality, costeffective performance of the Inovance PLC and HMI used to solve the quality control problem at the exhaust plant,” said Motion Tronic director, Bradley Douglas. “Inovance provides built-in communication, even on mid-level PLC units. We are very pleased to see how well our H3U Series PLC and smart HMI suited this project. Our wide range of industrial automation products provides the flexibility and capabilities to deliver the best possible solution for projects across all industry sectors,” added David Bedford Guaus, strategic marketing manager at Inovance. For more information contact Motion Tronic, +27 83 641 1487, [email protected], www.motiontronic.co.za
14 First Quarter 2024 www.motioncontrol.co.za Aerotech has been supplying standard product solutions such as motors, drives, controls and positioning tables since 1970. Customised motion subsystems include positioning systems on granite structures with undercarriage and vibration isolation, and also external measurement systems. The integrated systems are turnkey machines that have been developed together with the customer for the implementation of an automated process. These include not only precision components manufactured in-house for motion control, but also complete automation integration for parts handling, process instruments, safety elements and customised software. Developing holistic processes “Over the past few years, we have worked closely with customers from a wide range of industries, and have progressed further into the field of process automation,” says Simon Smith, European director at Aerotech. “When it comes to drive components and control elements in particular, the motion control experts now have a high level of vertical integration. Thanks to the accumulated application knowledge from the individual industrial sectors, the right components for the right use in the application can be recommended after a short time. The ideal solution is then developed together with the customer. As a manufacturer of automation systems, we support manufacturing companies holistically from the initial idea through to implementation. We therefore always ensure that our customers can automate their processes optimally with the precision motion systems we manufacture.” Working together to find the best solution Aerotech offers its customers the complete spectrum of integration options, from low- to high-integration motion components. This Precise knowledge for precise applications sets the motion control specialist apart from standard suppliers or traditional integrators. “Some customers want to build the machine themselves, while others are not entirely comfortable with this option,” says Smith. “We are flexible in our approach and work closely with our customers to find the best solution for their requirements. For example, if we develop a turnkey system for one of our customers, we see this as a partnership. The customer knows the application and understands the process for manufacturing the part. We are experts in correctly categorising the customer’s process, in order to build a machine that carries out this process with the highest accuracy and the highest possible throughput.” Laser precise control of processes The basis for this is Aerotech’s philosophy of vertical integration, which has matured over many years and makes it possible to be flexible, and at the same time guarantee quality and performance at all levels of the machine. Aerotech manufactures its own drives, motors, controls and positioning mechanics, so the experts know exactly how they work together and within a machine, and how they interact with each other and within a system. This enables the team to adapt and optimise a machine so that it produces the best possible output during operation. For example, for a laser process in which the laser beam needs to be deflected as quickly and precisely as possible, the experts at Aerotech work out which axes are suitable for this, in combination with which galvo scanner. “We can then prepare this accordingly so that the customer ultimately only has to couple in their laser and control it,” explains Smith. “They may also use our control platform to control their lasers and complete their laser system immediately.” Exactly what is needed In addition, customised specifications can be incorporated into the subsystem that go far beyond Aerotech’s component level. For example, if the customer uses a control cabinet, the Aerotech control electronics can be flexibly integrated into it. Other elements, such as those required to control the laser when measuring parts, can also be installed in the control cabinet. On the mechanical side, Aerotech also supplies partially integrated systems, which the customer only has to complete. If an adjustment system on granite is required for the machine, for example, the experts prepare this for the customer. The user can then integrate other additional applications such as laser beam guidance or sensor technology, as required. “These are tasks that we are faced with every day,” explains Smith. “The aim is to offer the customer a freely expandable solution that is ready for use as quickly as possible without much effort, and can also be adapted to future process requirements.” However, the first step towards actual integration at Aerotech always begins with a detailed application consultation. Customers also learn that Aerotech control technology can be used to move far more than the six axes of a hexapod positioning system. If, for example, the laser needs to be triggered depending on the position of the hexapod and pulse-fire at a certain point, this can be realised using the Automation1 control platform. In this way, the entire process can be operated from a central control unit. For more information contact Uwe Fischer, Aerotech, +44 1256 855 055, [email protected], www.aerotech.com
www.motioncontrol.co.za First Quarter 2024 15 DRIVES In the machine manufacturing industry, more drive systems are being converted from servo-hydraulic throttle to electrohydrostatic actuation systems (EAS). The four-quadrant capability of the electrohydrostatic pump unit and servo drive used in this technology, in combination with the new Moog energy management system (EMS), allows regenerative power flows generated during braking or pressure relief to be stored and reused. The Moog EMS, consisting of power supply and energy storage, also supports machine builders in the important goal of reducing the connected load in an EAS-based machine to a fraction of the peak power, compared to the hydraulic equivalent. This is done by using actively or passively operating capacitors and/or kinetic storage. Applications Ideal use cases for the Moog EMS are in oscillating applications such as elastic material testing or gas compressors and pressure intensifiers, where very high positive and negative power peaks occur, and low process energies are required. These peak-shaving approaches also make sense for forming presses, injection moulding machines and hexapods. In customer applications in testing and forming technology, the use of the Moog EMS has enabled the maximum power consumption from the power grid to be reduced by a factor of six in some cases. Energy management system for electrohydrostatic actuation systems As from 1 September 2023, Customised Motion Control (CMC) is the exclusive distributor and authorised repair centre for Moog for most of the Africa region. This came about when CMC bought Moog SA as a going concern in a management buyout initiated by Moog as part of a footprint rationalisation. For more information contact Willie Steyn, Customised Motion Control, +27 12 653 6768, [email protected], www.c-m-c.co.za Hägglunds Drives South Africa, a Bosch Rexroth Company, recently completed a retrofit project on the bucket wheel of a stacker reclaimer at Richards Bay Coal Terminal (RBCT). The project, acquired via a tender process, was realised late in 2022 and entailed replacing a gearbox drive solution with a direct drive solution from Hägglunds Drives SA. Installation of the drive unit commenced at the end of August 2023 with commissioning conducted in late September. In addition to supplying the equipment, Hägglunds Drives SA’s scope of work involved fitting the motor to the main shaft of the bucket wheel and positioning the drive unit on the slew, with all relevant piping installed. “While we were awarded the contract via tender, we have a long-standing relationship with RBCT, having provided solutions and services to them over the years,”says Ashley Mohun, sales engineer at Hägglunds Drives SA. Drive solution for stacker reclaimer RBCT was established in 1976 as a 12-million ton export terminal and, over the years, expanded to its current 91-million ton capacity export terminal providing coal to the global market. “Hägglunds Drives systems are incorporated in our tipplers and stacker reclaimers due to their high availability and high reliability,” says Kubendren Naidoo, general manager of Asset Management at RBCT. “The terminal prides itself on being a world-class, efficient, and technologically advanced terminal, and Hägglunds Drives solutions offer high efficiency, reliability and availability that ensure fast turnaround times of trains and vessels. “Hägglunds Drives’systems eliminate delays and unnecessary stops and ensure that we get the maximum useful life of our equipment,” adds Naidoo. “They also ensure maximum availability, especially on our stacker reclaimers where we use the Hägglunds Drives CBM motor. “The Hagglunds Drives team provides a professional and excellent service to RBCT,” he continues. “The technical teams from Hägglunds Drives and RBCT work together to ensure that the systems work efficiently, from concept and design phases through to implementation. The team from Hägglunds Drives provides an excellent aftersales service, with no challenges envisaged or experienced.” The direct drive solution installed on the stacker reclaimer is accompanied by a 12-month warranty on parts and workmanship, and a service agreement has been tailored to meet the requirements of RBCT. “RBCT can be assured of our commitment and ongoing support”, concludes Greg Daniels, service engineer at Hagglunds Drives SA. For more information contact Gillian Allin, Bosch Rexroth Africa, +27 11 979 4630, [email protected], www.boschrexroth.africa
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