14 April 2020

Industrial
Technology EXTRA!
FOR DESIGN ENGINEERS, MACHINE BUILDERS AND SYSTEMS INTEGRATORS

ENERGY CHAINS ARE

KEY IN BOTTLING SECTOR

FASTENER IS
JUST THE TICKET
www.industrialtechnology.co.uk
CONTENTS...

Process control
4 PLCs bring tons of improvement at Crisp
Connectivity
8 Seamless connectivity from the workpiece to the cloud
Fasteners
12 Fastener is just the ticket for the Rocky Mountain way
Food and drink industry
14 How energy chains are being used in the bottling industry
Electric motors
16 Eliminate design compromise in industrial power tools

Industrial EXTRA! is published by

Industrial Technology Ltd
Registered Office:
Industrial Technology Ltd

Technology www.industrialtechnology.co.uk
Tel: +44 (0)161 374 5615
Victoria House, 2 Mornington Road
Sale, Cheshire M33 2DA
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PROCESS CONTROL...

PLCs bring tons of

improvement at Crisp
When the UK’s leading independent malting company decided it was being held back
by a legacy control system, it turned to Mitsubishi Electric for a solution. The
upgrade, implemented in only four days, slashed downtime and empowered operators
to fully govern the manufacturing processes, leading to improved product quality

S
ince 1870, Crisp has been processing a
broad variety of barley, cereals and other
grains, supplying quality malts to leading
food and beverage producers all over the
world. Presently the company owns five production
sites across the UK and has additional malting
capacity in Germany and Poland.
To ensure optimal productivity and product
quality, the Norfolk based plant employs automatic
control systems that monitor all the processes
involved in the conversion of grain into malt. Malting David Spiers, Group Engineering Manager at Crisp
is a very delicate process, as the quality of the raw explained: “The existing PLCs were becoming
materials can vary and the grain kernels must be kept unreliable which left us exposed to the risk of long-
alive in order to germinate. This means that small lasting unplanned downtime events. For example if
improvements in process control can reap big rewards we had a power outage it would take the engineers 3-
in terms of quality. 4 hours to return the system to full operation, which
Keeping the malting process balanced requires a with our production process and fixed delivery
highly responsive control system and timely upgrades schedules to meet really wasn’t acceptable.”
to the plant are regarded as essential by the company. In addition, it was difficult for Crisp to find spare
Increasing the speed at which process anomalies are parts when necessary. This issue was becoming
detected and responded to has a significant impact on increasingly impactful as the PLC components were
the overall process. With batch sizes measured in reaching the end of their service life and needed to be
tons, this was the main reason why Crisp decided to replaced. Also, engineers at the malting production
replace six legacy GEM80 PLCs with new high- site struggled to interrogate the old control system in
performance Mitsubishi Electric Q Series systems. order to troubleshoot, repair or modify the existing

6 April 2020 • INDUSTRIAL TECHNOLOGY EXTRA! • p4

functions. Neither could the maltsters operating the
plant adjust the processes involved to the extent they
wanted.
To address these issues, Crisp contacted Suffolk
Automation, local specialist in process control
systems. To source the new PLCs, Suffolk
Automation’s software engineers turned to their
preferred process automation vendor, Mitsubishi
Electric.
Mark Chisnall, Managing Director at Suffolk
Automation, commented: “We’re familiar with
Mitsubishi Electric’s full range of automation
components and we like working with the company’s
PLCs in particular. Technically they are well supported
and for the customer the cost versus performance is
very good, they are reliable, high-quality products.”
David Spiers agrees: “It wasn’t just the integrator’s
recommendation that convinced us, we considered
April 2020 • INDUSTRIAL TECHNOLOGY EXTRA! • p5
various suppliers and were sold on Mitsubishi
Electric’s offering thanks to a reputation for speed,
reliability and flexibility.”
High-speed PLCs
Paul Judge, Key Account Manager at Mitsubishi
Electric adds. “Due to the limited room available in
the existing panels, conducting a phased system
migration was not a feasible option.” Therefore,
Mitsubishi Electric, Suffolk Automation and Crisp had
to complete the entire re-fit operation in one go. In
order to minimise plant downtime the three partners
worked together and used a scheduled service
window to replace the control system in a record time
of four days.
The six Q-series PLCs were installed in specific
locations around the factory, where the existing
devices had been located. Technically this
 understanding of real-time variations in the process.
The operations team can now monitor and access
parameters such as temperature and throughput live,
anomalies are quickly detected and acted upon
thanks to visible alarms. The wider management
team benefits in-turn from better plant performance
and more accurate reporting.
Looking forward, the maltsters now have a control
system that is user-friendly and easy to adjust. They
are free to modify and fine-tune the functionalities and
process parameters that govern different aspects of
the malt as required. In this way, the malthouse has
access to state-of-the-art tools that can be used to
improve and refine the quality of its products.
David Spiers concludes: “The key to successful
system migration lies in the expertise and support
provided by Mitsubishi Electric and Suffolk
Automation, it’s safe to say we are extremely pleased
with the results of this collaboration. As there are
other areas in our plants that could also benefit from
more up-to-date process automation, we will continue
encompassed two plants at Ryburgh malthouse. All with the upgrade of our control systems and work
the PLCs were then connected via CC-Link IE, open towards achieving a smarter factory.”
Ethernet network with 1 Gigabit bandwidth, using gb3a.mitsubishielectric.com
fibreoptic cables. In this way, Crisp could benefit from
real-time communications between the different
manufacturing areas and upwards to enterprise level
software systems.
The seed of automation germinates offering
greater product consistency
Replacing the old control system addressed the
reliability issues of the plant and the ongoing support
issues related to the GEM80 PLCs. David Spiers
observed: “If we experience a power cut now it takes
minutes to restart the system, not hours. The new
PLCs save the live process data into permanent
memory, so the system does not lose operating data
or any updated parameter settings during a power
loss.”
The new automation solution also provided Crisp
with the level of detail needed to have a greater

April 2020 • INDUSTRIAL TECHNOLOGY EXTRA! • p6

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CONNECTIVITY...

Seamless connectivity from

the workpiece to the cloud
Warren Harvard, Product Manager at Festo, looks at how
improving connectivity supports machine builders

T
he 4th Industrial Revolution is redefining
manufacturing business models, value
chains and even the classic automation
control pyramid. One area that is
developing rapidly and offering users improved
automation efficiency, is connectivity – networking
and communication within a system.
The Industry 4.0 roadmap defines standards to
make it far easier to connect networked, flexible
production, creating modular structures and
hierarchies by utilising intelligent products with
embedded smart functions. As a result, the classic
machine architecture with its central control system is
increasingly moving towards more versatile,
distributed automation subsystems. These are
decentralised and closely communicating with each
other. This approach brings greater flexibility in
production processes enabling more variation in
machine architecture concepts, ideal to meet the Servo drives with controller CMMT-AS and
increased requirements of global production. motor EMMT-AS integrated directly in
The increasingly networked components require a Ethernet-based control solutions
high level of compatibility and integration across all
system participants. Unobstructed data exchange Connectivity explained
facilitates smoother processes, but it depends on all Essentially, connectivity is the ability to connect and
components being aligned to the application, whilst at link up individual participants i.e. eliminating the
the same time perfectly matching one another. interfaces between devices. Connectivity describes
Effective networking and communications between the ability of the component or a subsystem to be
components and the production systems ultimately integrated within peer, or higher-level architecture
depends on their connectivity. structures, as well as their optimal coordination

April 2020 • INDUSTRIAL TECHNOLOGY EXTRA! • p8

 Classic automation
pyramid with its different
hierarchy levels
within the system. Simply translated to industrial
applications, this means individual components work
together better.
For seamless connectivity, the mechanical,
electrical and the intelligent interfaces all need to be
considered, across all components. Connectivity in
automation technology must be carefully considered
from the workpiece to the cloud.
The objective of seamless connectivity is to make
the interfaces as simple and easy to handle as
possible, so that using the devices is more reliable
and faster. Design and commissioning becomes easier
and faster allowing machine builders and end users to
concentrate more effectively on their tasks.
The automation control hierarchy typically used in
machines and production systems is based on the
classic automation pyramid (shown opposite)
April 2020 • INDUSTRIAL TECHNOLOGY EXTRA! • p9
whereby individual products and automation
components are assigned to individual levels
(actuator, field and control).
On every level, the machine builder must consider
the multiple interfaces. For example, the design of the
mechanical system for the automation of motion must
match the configuration of the servo drive system.
This in turn needs to be integrated optimally into the
control environment. Software tools for design,
configuration and commissioning play a key role here.
No single communication standard can be applied
across all levels. In most cases stand-alone solutions
handle subtasks, but these do not always allow a
seamless approach. This causes many challenges for
integrators: for example, where linear mechanical
systems and servo drive technology need to be
combined quickly and easily from different
manufacturers. At the same time, it creates
opportunities to increase efficiency and offers huge
potential for improving the machine development
process.
Meeting machine builders’ needs
An almost overwhelming number of products,
components and solutions are available from
thousands of manufacturers for mechanical axis and
control systems, all with their own interfaces,
hardware solutions, programming languages,
software systems and communication protocols. This
means that machine builders spend a lot of time
researching, combining and integrating them into
their machines. A typical question is “how can I easily
combine a mechanical axis, a servo motor and a
servo drive so that they perfectly complement each
other without over specifying or spending?”
Series and bespoke machine builders have quite
different requirements when it comes to automation
platforms and connectivity. Series machine builders
seek to standardise their drive solutions, whilst
bespoke machine builders require highly flexible
solutions to enable them to respond to the highly
individual needs of their customers. They need to
reconfigure each machine and commission it
individually time and again. They want to do this as
simply and quickly as possible, without investing time
to familiarise themselves with the idiosyncrasies of
each component.
For both types of machine builder, there are
convenient and simple solutions that meet their
respective requirements. For example, when Festo
developed their new automation platform, priority
was placed on seamless connectivity from the outset.
The mechanical system, the drive system with motor
and controllers, as well as the software modules were
designed as one system. Compatibility with the many
controller manufacturers was also key.
For example, the latest generation of Festo servo
drives (CMMT) and motors, together with the intuitive
April 2020 • INDUSTRIAL TECHNOLOGY EXTRA! • p10
commissioning software, Festo Automation Suite,
makes integration easier and speeds up
commissioning significantly. These components can
be integrated virtually seamlessly into all commonly
available Ethernet-based external controllers with the
intention that users will not even notice the hardware
manufacturers are different. Festo Automation Suite
combines parameterisation, programming and
maintenance in one program.
Conclusion
Seamless Connectivity from the workpiece to the
cloud offers a solution to many of the challenges faced
by today’s machine builders. Reducing the complexity
of the automation task enables faster, more reliable
build times, reduced work-in-progress and lower
costs. Festo has invested intensively in this approach
and developed software tools that all but eliminate
the ‘friction at the interfaces’ i.e. making it easier
mechanically, electrically and in programming
software to connect automation devices such as
electric servo drives into the complete machine
environment.
From the initial conceptualisation, through the
design phases to build, programming and
commissioning, product data can be digitally
collected, collated, processed and then re-used in the
next phase without unnecessary double working or
errors. This is a major benefit for machine builders
and as it utilises many of the principles of Industry
4.0 becomes the Digital Twin ready to be
incorporated in the future into the complete digital
system.
www.festo.co.uk
 
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FASTENERS...

Fastener is just the ticket for

the Rocky Mountain way
The Rocky Mountaineer is said to be a super way to see the Canadian Rockies and
has proved a great success. Use of SNAP-LOC fasteners from Bollhoff allows seat
bases to be changed quickly and without special knowledge or tools

T
he Canadian Rockies are recognised
worldwide as one of the greatest of natural
spectacles and many will claim that the best
way to see the stunning scenery at its finest
is from a carriage on the Rocky Mountaineer.
Owned and operated by Canada’s Armstrong
Group, the Rocky Mountaineer is a purpose-built
tourist train that was designed from the outset to be
what has since become: one of the country’s greatest
and most popular attractions for both domestic and
overseas visitors alike.
Operating over four routes across the Canadian
Rockies and with each train capable of carrying up to
900 passengers at a time, the Rocky Mountaineer
offers customers a high level of luxury. For the train
operators, as with airlines, safety and serviceability

rank highest on a list of design priorities that will
ultimately lead to a popular and profitable business.
So, when the carriage design teams set to work on
the Rocky Mountaineer, they needed to consider
seating systems that were of the highest quality, but
which also allowed for worn or damaged seats to be
replaced quickly, quietly and cleanly, either
’underway’ while the train was en-route or on
turnarounds between journeys. The manufacturers
were also keen that replacement parts, such as seat
bases, could be fitted without the need for either
special tools or specialist knowledge.
Wear, tear and breakage
With so many passengers expected, planning in
advance for the necessary rectification caused by
inevitable wear, tear and breakage was essential. At
the same time, the operators also identified the need
for the Rocky Mountaineer to take with it a separate
carriage containing all the spares likely to be called for
in the field. Canada is a vast expanse and, should
urgent repairs be required, the only way to guarantee
access to either a workshop or spare parts is to take
everything with them on the train in their own
carriage.
Mindful of a growing list of specifications and
requirements for seating, the Rocky Mountaineer
team engaged with a company called Probatec, based
in Germany, which has specialist skills and a long
track record of innovation in the field of automotive,
April 2020 • INDUSTRIAL TECHNOLOGY EXTRA! • p13
mass transit and military seating applications. Many
of the western world’s special-purpose and military
vehicles have seating systems designed by Probatec,
which is also a market leader in table design and
production for such applications, too.
Focusing on the needs described by the train
operators, Probatec investigated a variety of options
and then turned to Bollhoff’s well-proven SNAP-LOC
fastener as its preferred (and, in this case, only)
method of attaching the seat bases to subframes in all
of the carriages of the Rocky Mountaineer.
Ball and receptor socket
This fastener, already used extensively in a wide
variety of applications (including wing mirror mounts
on some models of BMW motorcycles and tail light
cluster mounts on top-of-the-range motorhomes from
Burstner), is based on Bollhoff’s ball and receptor
socket design. SNAP-LOC® offers significant strength,
is light, clean and, when installed, is completely
invisible to users. Yet, when required, a seat base can
be changed by just about any staff member in
seconds, with a secure and guaranteed perfect fit
every time. A damaged unit is simply pulled off and
the replacement base positioned accordingly, before
being ‘clicked’ into place. An added advantage is that
SNAP-LOC® also acts as an isolator between the
carriage chassis and the seat base, thus further
reducing any vibration that may be experienced by
passengers.
Commenting on this latest success for SNAP-LOC,
Bollhoff UK Industry Manager Clive Brown observes:
“This is just one of many important applications for
SNAP-LOC that have emerged in the transportation
market recently. As users demand lighter, quieter
vehicles of all sorts, they are also keen to source
simple, durable fasteners that anyone can use in the
field without specialist knowledge, because it is
another way of reducing the overall cost to the
customer over a lifetime of use.”
www.bollhoff.com
FOOD AND DRINK INDUSTRY...

How energy chains are being

used in the bottling industry
In its latest ‘Video of the week’, Igus explains how its energy chains and other
plastic products are being used within the food and drinks sector

A
lthough high-performance plastics used
to be overlooked as suitable materials for
machine components, they are now a
standard feature in food processing
equipment. But their potential has by no means
been exhausted. Igus supplies energy chains based
on hygienic design guidelines and wear resistant
plain bearing components for a wide range of
solutions.
The open design of the TH3 plastic energy chain drinks industry, is FDA/EU-compliant and is highly
makes it very easy to clean, while rounded corners resistant to aggressive cleaning agents and chemicals.
and simple, threadless connections prevent dead As well as energy chains, Igus offers the blue
spaces where debris and germs can build-up. In bearing materials iglidur A160 and iglidur A181,
additional, the structure of the e-chain avoids which comply with EU regulation 10/2011 and FDA
surfaces rubbing against each other; this prevents requirements. iglidur A160 is resistant to chemicals,
abrasion and material shedding. The blue material, making it impervious to aggressive cleaning agents.
which is typical of plastic elements in the food and iglidur A181 on stainless-steel shafts, on the other

April 2020 • INDUSTRIAL TECHNOLOGY EXTRA! • p14

hand, has a low coefficient of friction and is therefore
more suited in applications involving pivoting and
rotating movements. In addition to plain bearings,
Igus also supplies both materials as a tribo-tape for
lining sliding surfaces, and as plate or bar stock for
further machining.
As the safety standards for the protection of
consumers are extremely high, the demand for
detectable materials in food processing machinery is
high. A special high-performance plastic material
which can be easily traced with standard metal x-ray
machines, is to be found in selected products of the
igubal series, as well as in swivel joints and clevis
joints, flange bearings, spherical bearings and pillow
block bearings.
Igus also supplies a wide range of stainless-steel
components specially for the food & drinks industry.
April 2020 • INDUSTRIAL TECHNOLOGY EXTRA! • p15
For conveyor systems, the drylin ZLW toothed belt
axis kit is available in various widths and lengths
ready-to-install. Except for the toothed belt and the
liner, the axis has a very open design and is
completely made of stainless steel. An extremely long
service life is possible if used in combination with
liners made of iglidur E7. FDA-compliant guide rollers
are also available, each consists of two xiros ball
bearings and one tube.
To enable Igus to guarantee service life and make
it calculable for all products, the firm carries out
extensive testing. The results of which are fed into a
database, to drive the online product finders and
service life calculators. Engineers are therefore always
able to find the most suitable solution that improves
the technical performance of their equipment.
www.igus.co.uk
ELECTRIC MOTORS...

Eliminate design compromise

in industrial power tools
Choosing the right motor for an industrial power tool is no trivial task. Thomas Baile,
Business Development Manager at Portescap, examines the performance
requirements of power tool applications and looks at how the latest advances in
motor technology for these tasks are helping to address typical design compromises

S
o often in product design there are
conflicting operational requirements. The
industrial power tool is a typical example,
with an operating profile that is quite
different from other motor-driven applications.
Whether the specific tool is fastening, gripping or
cutting, there is a specific motion profile that is split
into two phases.
First there is the speed phase, where there is little
resistance – perhaps as bolts thread in or as the jaws
of a cutting or gripping tool approach the workpiece.
During this phase, a motor that operates at a faster
free-run speed reduces cycle time and boosts
productivity.
Then there is the torque phase, as the tool
performs the more forceful work of tightening, cutting
or gripping and the need for torque becomes
paramount. A motor that delivers high peak torque
can perform a wider range of tough jobs without
excessive heating.

Demanding application
These alternating speed and torque cycles must be
constantly repeated in demanding industrial
applications. The different speed, torque and duration
characteristics complicate the motor selection

April 2020 • INDUSTRIAL TECHNOLOGY EXTRA! • p16

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process, calling for a design that minimises losses to
achieve the best solution possible. This is even more
critical for battery operated tools, where only limited
power is available yet where the design engineer
wants to be able to achieve the maximum number of
operations from a single charge.
Conflicting requirements
Given these conflicting requirements, it might seem
that there is no ideal solution. The electrical
performance of a motor is defined by the magnetic
circuit, so every option requires a compromise. The
first component within the circuit, the magnet, has a
fixed value. However, the second component, the
Typical working cycles for industrial power tools repeated
continually
April 2020 • INDUSTRIAL TECHNOLOGY EXTRA! • p18
copper winding, can be easily modified: by changing
both the wire diameter and the number of turns, the
torque constant (Kt) and resistance (R) can be fine-
tuned.
In the speed phase of the industrial power tool’s
operation profile, the motor needs to run fast with
little resistance. Here, a lower Kt value gives
increased speed. During the torque phase, however,
the motor is expected to deliver peak torque at low
speeds. A higher Kt value gives a higher output torque
at a given current. Here we have conflict.
We might think to select a low Kt value to increase
speed, and compensate the low Kt with more current
to reach higher output torque. However, a higher
current would increase the copper losses, generating
heat and thus limiting the maximum torque available.
Excess heat impacts on the comfort of the user, while
the increased current impacts on battery life.
There are also iron losses to consider, which are
related to speed. Eddy current losses increase with
the square of speed, heating up the motors simply
when rotating – even in a no-load condition.
Optimised for power tools
There is no unique solution, and in the past design
engineers would have had to accept the performance
compromise in the different phases of operation and
in the broader utilisation requirements for the tool.
However, Portescap has
developed a new range of
brushless slotless motors
optimised for use in
power tools that go
a long way to
minimising the in the industrial power tool
traditional design compromise. mostly hand-held: leading to the battery
Brushless motors have inherent being drained more quickly and reducing user
advantages over brushed motors in power tool comfort and safety.
designs. Brushless motors are less susceptible to The latest development from Portescap represents
mechanical wear (no brush friction), can be operated a significant evolution of the brushless slotless motor,
at much higher speeds (shortening cycle time and specifically for industrial power tool applications. The
increasing productivity) and can sustain high peak new Ultra EC™ family of brushless slotless motors
current (no brushes) – for example during the employs a revolutionary and patented U coil
tightening phase of a fastening tool’s operation – technology. These miniature motors contain a winding
providing far greater life in the hand tool. that is parallel to the motor axis, unlike the skewed
In terms of power density, a brushless slotless arrangement of a conventional slotless motor,
motor is a better option than slotted, providing perpendicular magnetic forces are minimised,
superior ability to maintain speed under load. Further, reducing copper losses and enabling the motor to
while the slotted motor can develop more power.
handle higher temperatures Iron losses at high speed in slotless motors are
to allow for more torque already greatly reduced compared with slotted
generation, this is not of direct designs. With this new straight winding, Ultra EC
benefit to industrial power tool motors have a shorter rotor length which allows for a
applications. Heat is the enemy lower rotor inertia and further reduced iron losses.
This revolutionary new design optimises speed and
torque in a compact package for the most
challenging applications.
With these new products,
Portescap has gone a long way to
eliminating the compro-mises
design engineers have traditionally
faced in selecting motors for
industrial power tools. Fasteners,
grippers and cutting tools can all
benefit from this increased
performance, lower weight and
greater energy-efficiency.
www.portescap.com

April 2020 • INDUSTRIAL TECHNOLOGY EXTRA! • p19

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