Drives&Controls AUTOMATION FOR MANUFACTURING INSIDE OCTOBER 2025 www.drivesncontrols.com MACHINE BUILDING: How to optimise the speeds of round and profile rails PRECISION ENGINEERING: Three ways to improve linear drive performance WATER: $9.7bn project will transform Egyptian desert to farmland
50 CONTENTS n Drives & Controls is a controlled circulation publication. If you live in the UK and want to subscribe phone 0333 577 0801 or fax 0845 604 2327. Alternatively for both UK and overseas subscriptions please subscribe online at www.drivesncontrols.com. If you have any enquiries regarding your subscription, please use these numbers . The content of this magazine, website and newsletters do not necessarily express the views of the Editor or publishers. The publishers accept no legal responsibility for loss arising from information in this publication. All rights reserved. No part of this publication may be produced or stored in a retrieval system without the written consent of the publishers. Paid subscriptions UK: £110 per annum Europe: £145 per annum Rest of World: £180 per annum Printing: Warners Midlands PLC., PE10 9PH ISSN 0950 5490 Copyright: DFA Media Group 2025 NEXT ISSUE The November/December issue of Drives & Controls will contain our annual feature on machinery safety, as well as a look at what’s been happening in the world of controlgear and enclosures, and a report on recent developments in controllers, HMIs and software. UPDATE 14 Comment 15 ABB Back to Basics 44 Gambica column 46 New Products 48 Design Data and Multimedia 49 Products & Services IN DEPTH Follow us on X @DrivesnControls Drives Magazine Web site www.drivesncontrols.com Follow us on LinkedIn @ Drives & Controls Join us on Facebook Drives & Controls Drives& Controls REGULARS DfAmedia group 36 30 28 26 8 47 DRIVES & CONTROLS OCTOBER 2025 Vol 41 No 9 Editor Tony Sacks t: 01732 465367 e: tony@drives.co.uk Production Manager Sarah Blake t: 01233 770781 e: sarah.blake@dfamedia.co.uk Marketing Manager Hope Jepson t: 01732 370340 e: hope.jepson@dfamedia.co.uk Financial Finance Department t: 01732 370340 e: accounts@dfamedia.co.uk ADVERTISING Sales Director and DFA Direct Damien Oxlee t: 01732 370342 m: 07951 103754 e: damien.oxlee@dfamedia.co.uk Sales Manager Sara Gordon t: 01732 370341 m: 07505867211 e: sara.gordon@dfamedia.co.uk Italy Oliver & Diego Casiraghi e: info@casiraghi.info t: +39 031 261407 f: +39 031 261380 Managing Director Ryan Fuller t: 01732 370344 e: ryan.fuller@dfamedia.co.uk Reader/Circulation Enquiries Perception-MPS Ltd t: 01825 701520 e: cs@perception-sas.com HEAD OFFICE DFA Media Group 192 High Street, Tonbridge, Kent TN9 1BE t: 01732 370340 f: 01732 360034 e: info@dfamedia.co.uk www.drivesncontrols.com 5 News A round-up of the latest business and industry developments from around the world. 16 Technology Cutting-edge innovations in motion, power transmission, controls and related technologies. 26 Augmented reality Is AR more than a fun gimmick in industrial applications? An expert explores some of the immediate gains from adopting AR, as well as looking at some of the less obvious ways in which it can pay off, with real-life examples drawn from industrial users already transforming their operations with AR. 28 SPS Preview The SPS automation mega-show returns to its venue in Nuremberg, Germany, next month. It is expected to attract more than 1,100 exhibitors across its 15 halls. There will also be four presentation stages and several shared stands focusing on specific topics, such as Automation Meets IT. 30 Machine Building How software-defined motion systems can help manufacturers to accommodate changes in consumer demand, and improve batch-level control. Plus, advice on how to optimise the operating speeds of round and profile rails, and a look at a report that documents the skills crisis affecting machine-builders on both sides of the Atlantic. 36 Precision Engineering Simple mistakes when specifying electric linear drives can lead to serious problems. An expert outlines three of them, taken from a free guide that lists ten such errors. Plus, how Bode Plots can be used to fine-tune complex servo systems, as well as enhancing diagnostics. 40 Water Egypt plans to convert a large part of the Nile delta into lush farmland, cutting its food imports and driving economic growth. The scheme includes a 114km-long artificial river and the world’s largest water treatment plant, where VSDs and soft-starters are playing a key role. 42 Automation The future of industrial automation is not just smart, but is also agile and safe. The director of industrial automation at one of the world’s largest industrial component distributors, examines some of the latest trends driving the sector. 40 Average net circulation January to December 2024 42 44 Subscribe for your FREE copy now 20,514 16
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NEWS n 5 ABB shrinks IE5 synchronous reluctance motors down to 750W ABB HAS EXPANDED ITS portfolio of IE5-efficiency synchronous reluctance (SynRM) motors by adding three smaller frame sizes (90, 100 and 112), spanning ratings from 0.75–450kW. The motors can cut energy losses by up to 40% compared to IE3 motors, resulting in payback periods as short as five months, the company says. ABB claims that it now offers the broadest range of magnet- and rare-earth-free motors on the market. It is now producing SynRM machines in frame sizes from 90–132. The company reckons that over a 20-year period, a 90kW SynRM motor could save €79,800 ($94,000) in energy costs and cut CO2 emissions by 95,760kg. With industrial sites typically operating dozens or even hundreds of smaller motors, as well as larger ones, these savings and environmental benefits can multiply substantially, it adds. The new motors, with their extended power options and operating speeds of up to 3,600 rpm, are suitable www.drivesncontrols.com October 2025 for pump, fan and compressor applications. They will cost around 10% more than similarly rated induction motors, but when the cost of a variable-speed drive (which is essential for SynRM motors) is included, the differential will be smaller. “Smaller motors are often deployed in high volumes and in continuous-duty or space-constrained environments where thermal performance, precise control, and high efficiency under partial load are critical”, says Stefan Floeck, president of ABB’s IEC LV motors business. “With our expanded SynRM range, we’re ensuring that every motor, no matter the size, plays its part in helping boost productivity for our customers while cutting emissions.” Since ABB launched its first SynRM drive in 2011, it has broadened the range to include variants such as liquid-cooled versions, and motors for explosive atmospheres. In 2024, it introduced “IE6” SynRM motors in ratings above 90kW that deliver up to 20% lower losses than IE5 machines, even though there is no official definition of IE6 yet. ABB says it may extend the IE6 ratings to the smaller SynRM motors if there is a demand. As well as cutting energy use by up to 40%, SynRM motors operate with winding temperatures that are up to 30% lower than induction machines, and bearing temperatures that are up to 15% lower, helping to improve their reliability and reducing the need for servicing and maintenance. Bearings are the biggest cause of failures in induction motors, often as a result of overheating. Daniel Eberli, ABB’s business line manager for process performance motors, points out that the high efficiencies and outputs of synchronous reluctance motors mean that OEM machine-builders can produce more powerful machines that are the same size – or smaller machines that are just as powerful as versions with less efficient drives. One recent project that has made extensive use of SynRM motors is at a site in Bulgaria operated by Europe’s largest copper producer, Aurubis. It has replaced 460 outdated motors with a combination of 265 IE5 SynRM machines for variable-torque loads, and 181 IE4 induction motors for constanttorque loads. The upgrade is delivering annual energy savings of 28%, resulting in a return on investment of just 3.5 years, as well as delivering a 12,000tonne reduction in CO2 emissions. Another application is at an aquatic centre in Hobart, Tasmania, which was threatened with closure because of its high energy bills. The centre has been able to stay open by installing 19 SynRM motors and drives, cutting the centre’s energy consumption by 18%, saving 259MWh of electricity a year, and slashing its energy bills by $36,000 AUD (£17,740). www.abb.com ABB’s smallest synchronous reluctance motors are now rated at just 750W SCHNEIDER ELECTRIC HAS OPENED its £42m state-of-the-art smart plant in Scarborough, North Yorkshire, which will manufacture electrical equipment needed for the move to cleaner energy. The 16,500m2 plant, which was announced last year, is due to be fully commissioned by the end of this year, and is expected to create more than 200 jobs. The factory will act as a blueprint for sustainable design for Schneider’s manufacturing operations worldwide. Netzero in Scope 1 and 2 emissions, the plant uses modern technologies to cut energy waste. Almost a third of its power will come from its own solar energy system. By manufacturing locally for UK customers, Schneider Electric says it is building resilience into the nation’s critical electrical infrastructure, reducing its exposure to global supply chain shocks, and slashing costs and carbon emissions through shorter, optimised transport and logistics routes. UK production will mean faster, more flexible delivery of bespoke engineering systems, tailored to the needs of UK projects. Customers will be able to visit the site, work with product designers and engineers, and ensure that products meet their needs before manufacturing begins. The site will produce equipment to meet British standards, making it ready for export to Commonwealth markets. “UK manufacturing is the backbone of the nation’s infrastructure drive,” says Kelly Becker, president of Schneider Electric in the UK & Ireland, Belgium & Netherlands. “With electricity demand set to hit new heights, our Scarborough site – rooted in Yorkshire expertise – gives us the scale and agility to respond quickly to market changes and support the UK’s energy transition and beyond. By expanding our local footprint, we’re working even closer with customers to deliver a decarbonised, resilient energy system for the future.” Schneider’s £42m smart factory in Scarborough nears completion
n NEWS October 2025 www.drivesncontrols.com 6 THE UK HAS climbed one place to eleventh position in the global league of manufacturing nations, according to the latest figures from the manufacturers’ association, Make UK. Last year, the UK dropped out of the top ten, plummeting from eighth position to twelfth. The figures are contained in a new edition of Make UK’s Manufacturing – The Facts publication, which reveals that that in 2023 (the latest year for which global comparisons are available), the UK’s manufacturing output was worth $279bn, putting it just behind Brazil ($290bn), which has moved back in to the top ten for the first time since 2012. China is by far the largest manufacturing nation, with an output worth $4.8 trillion, followed by the US on $2.8tn and Japan on $840bn. Germany (on $838bn) remains Europe’s biggest manufacturer by a considerable margin, and is still the world’s fourth-largest manufacturer, followed by South Korea and India – which have swapped fifth and sixth positions – and Mexico, with Italy in eighth position ($353bn) and France in ninth ($296bn). Manufacturing currently accounts for 42% of the UK’s exports, 48% of its business R&D, and 17% of its business investment. The statistics also reveal that the average salary in the UK manufacturing sector rose by 7% in 2024 to £41,220 – compared to an average of £38,224 across the economy as a whole, and £37,559 in the services sector. The US remains the UK’s largest export market, and was worth £59.3bn in 2024. Germany is the second-biggest destination (£32.1.bn), with The Netherlands in third place (£27.9bn) – although Make UK warns that this figure could be inflated artificially by goods being routed through Rotterdam for onward travel to other destinations. Ireland is the UK’s fourth-largest export market (£23.9bn). Seven of the UK’s top ten export markets are in the EU, with a combined value of around £143bn. This is more than twice the value of exports to the US, and around nine times higher than exports to China (£16.7bn). According to Make UK, this highlights the need for the Government to smooth out trade barriers with the UK’s dominant export market. “These figures reflect not just the importance of manufacturing to the economy but factors and trends which are redrawing the contours of the global economy at an accelerating rate,” says Make UK’s chief economist, Dr Seamus Nevin. “These trends reinforce why it was vital to introduce a long-term industrial strategy to take competitive advantage of our undoubted strengths. This will ensure the UK retains its place at the top table of advanced manufacturing nations where it has many world-class sectors.” UK climbs to 11th place in global manufacturing p Mitsubishi Electric is buying Nozomi Networks, the US developer of security systems for OT (operational technology) applications, for $883m, with the aim of becoming the world’s top supplier of OT security systems. Mitsubishi plans to create new global services that accelerate its Serendie digital platform. Nozomi, founded in 2016, had revenues of $75m in 2024, and a CAGR of 33% from 2022 to 2024. It employs around 315 people and has gross margins of more than 70%. It has more than 1,000 customers in 75 countries. p The German cognitive robotics specialist, Neura Robotics, has acquired the AGV manufacturer, ek robotics, from administration. The terms of the deal have not been disclosed. Neura plans integrate ek's capabilities to create what founder and CEO, David Reger, describes as “the dawn of a new dimension in mobile robotics”. Ek, founded more than 60 years ago, has more than 300 employees at five sites, including Buckingham in the UK. Its revenues in 2024 were around €60m. p The private equity firm Foresight Group is investing £7m in Spartan Motor Holdings, the parent company of TEC Electric Motors, which claims to be the biggest independent distributor of electric motors in the UK. The investment will be used to enhance TEC’s services and broaden its product range. Duncan Cooper, who was managing director of the pump-maker Grundfos for more than 30 years, joins TEC as chair. TEC was founded in 2006 by Scott and Tina Edwards, with Gareth Richardson. It distributes LV electric motors, gearboxes and inverters from a 90,000ft2 facility in Worcestershire, with a satellite site located in Sheffield. p Anybotics, the Swiss developer of fourlegged inspection robots, has raised €127m which it will use to support its global expansion and to bring “the world’s first Excertified legged robot” to market. The Anymal X robot, designed to perform inspections in hazardous and explosive environments, is due to go on sale in 2026. Anybotics earlier raised €46m in 2023 and €57m in 2024. p Guidance Automation, the Leicesterbased supplier of autonomous transport systems for factories and warehouses, has launched a scheme that allows manufacturers to deploy autonomous vehicles without capital investments. It says that its “Autonomous Go” automation-by-the-hour model will make automation more accessible. Businesses will pay only for the hours that their systems operate, thus aligning their costs with their outputs. Guidance says that this “flexible, norisk” approach turns automation into an operating expense, delivering cost savings and productivity gains. www.guidanceautomation.com NEWS BRIEFS The UK’s top ten markets for exports of manufactured goods Omron Industrial Automation has appointed Marc Ioannidis as general manager of its UK & Ireland operation, succeeding Sam Tilley, who is now general manager for the Nordic countries. In his new role, Ioannidis – previously general sales manager for the UK & Ireland – will lead Omron’s operations in the region, driving growth, and strengthening the company’s position in key markets. He will report to Vince King, sales director of Omron’s North and Emerging Region. Ioannidis has more than 25 years’experience in the automation sector. He joined Omron in 2008 and has held a series of sales and channel management roles. The West Midlands manufacturing outsourcing specialist PP Control & Automation has named Pinaki Banerjee as its new CEO, with Tony Hague stepping down to take on a commercial and customer-focused role. Pinaki previously led a 900-strong team as CEO of the Central Eastern Europe region of Rubix, and earlier worked for the Hoffman Group and Pilkington. The appointment comes at a crucial time in PP’s growth, with a possible expansion of its manufacturing operations into Europe and North America through acquisitions. It hopes to double its revenues by 2027 to more than £70m through a combination of organic and inorganic growth. CKF Systems has appointed Declan Walker as its head of automation. He has more than a decade of experience in control systems, robotic automation, AMRs and vision technologies. Walker will lead CKF’s controls and applications team, integrating leading-edge technologies into systems, and will focus on developing new strategic opportunities for CKF.
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n NEWS ABB IS SELLING ITS robotics division to the giant Japanese investor SoftBank Group (SBG) for $5.375bn. In doing so, it has decided not to pursue its earlier plan to spin off the business as a separately listed company. The transaction is subject to regulatory approvals and customary closing conditions, and is expected to close in mid-to-late 2026. The ABB Robotics division has a workforce of around 7,000 and revenues in 2024 of $2.3bn – about 7% of ABB’s total revenues. Last year, it had an operational EBITA margin of 12.1%. The business is a leader in its sector, but the ABB board felt that there were limited business and technology synergies with the rest of its operations, which have different demand and market characteristics. Softbank has earmarked AI robotics as one of four “essential” sectors in which to invest and expand. The other three are AI chips, AI data centres and energy. It is also investing in companies at the forefront of generative AI. SBG expects the ABB acquisition to strengthen its AI robotics business “significantly”. It says the business is a globally recognised brand, known for its reliability and high performance, supported by extensive sales channels and customer relationships. SBG believes it is “well-positioned to reignite the robotics business’s growth”, particularly through investment in cutting-edge technologies such as AI. The robotics platform will complement SBG’s existing robotics-related investments – which include SoftBank Robotics Group, Berkshire Grey, AutoStore Holdings, Agile Robots and Skild AI – and will help to accelerate innovation in AI robotics and drive progress towards “artificial super intelligence” (ASI). “SoftBank’s next frontier is physical AI,” explains SBG’s chairman and CEO, Masayoshi Son. “Together with ABB Robotics, we will unite world-class technology and talent under our shared vision to fuse ASI and robotics – driving a groundbreaking evolution that will propel humanity forward.” “SoftBank will be an excellent new home for the business and its employees,”says ABB’s CEO, Morten Wierod. “ABB and SoftBank share the same perspective that the world is entering a new era of AI-based robotics and believe that the division and SoftBank’s robotics offering can best shape this era together. ABB Robotics will benefit from the combination of its leading technology and deep industry expertise, with SoftBank’s state-of-the-art capabilities in AI, robotics and next-generation computing. This will allow the business to strengthen and expand its position as a technology leader in its field.” ABB’s chairman, Peter Voser, reports that Softbank’s offer for the robotics division was “carefully evaluated by the board and executive committee and compared with our original intention for a spin-off. It reflects the long-term strengths of the division, and the divestment will create immediate value to ABB shareholders. Our ambitions for ABB are unchanged and we will continue to focus on our long-term strategy, building on our leading positions in electrification and automation.” Following the deal, ABB will change its reporting structure and will operate in three business areas. From this quarter, the robotics division will become a “discontinued operation”. At the same time, ABB’s machine automation division, which together with ABB Robotics currently forms the Robotics & Discrete Automation business, will become a part of the process automation business. Sami Atiya, president of ABB’s Robotics & Discrete Automation business and member of its executive committee, will leave ABB by the end of 2026. He will step down from the executive committee at the end of 2025 and will continue to support the robotics business and the carve-out process in 2026 as a strategic advisor. September 2025 www.drivesncontrols.com 8 ABB has one of the broadest ranges of industrial robots in the sector ABB sells its robotics division to Japan’s SoftBank for $5.375bn EVENTS Digital Manufacturing 2Day 22 October, 2025 MTC, Coventry A one-day event at the Manufacturing Technology Centre dedicated to the technologies, strategies, and people driving the digital transformation of manufacturing. The theme is: Navigating and Mastering Digital Transformation. In addition to presentations by expert speakers and panel sessions, the event will include an exhibition. https://mtcevents.co.uk/upcomingevents/digital-manufacturing-2day Advanced Engineering 2025 29-30 October, 2025 NEC, Birmingham The organisers says that Advanced Engineering is the only UK event connecting all industrial ecosystems, driving high-value manufacturing and supply chain solutions. There will be more than 400 exhibitors, and five forums hosting talks by more than 150 speakers. Additions this year include an SME village, an electronics zone and an expanded composites pavilion. www.advancedengineeringuk.com SPS 2025 25-27 November, 2025 Nuremberg, Germany The SPS (Smart Production Solutions) automation show returns to its traditional late November slot following several years of taking place earlier in the month. Last year, the event attracted 51,291 visitors and 1,114 exhibitors. The organisers are expecting an increase in UK visitors this year, pointing out that many of the exhibitors are multinationals already active in the UK. https://sps.mesago.com/nuernberg/en.html Southern Manufacturing & Electronics 26 3–5 February, 2026 Farnborough, UK The regional event is expected to attract more than 500 exhibitors from a variety of sectors including mechanical engineering, electronics, electrical engineering and production hardware. More than 10,000 visitors are likely to visit the Farnborough site where they can hear talks from over 50 experts, as well as attending the exhibition. www.southern-manufacturingelectronics.com/en Hannover Messe 2026 20-24 April, 2026 Hannover, Germany The industrial mega-show returns to its North German venue and is expected to attract around 4,000 exhibitors (including more than 300 start-ups) from the engineering and digital industries, as well as the energy sector. AI will be a common thread, playing a key role on many stands. There will be three main exhibition areas: Automation & Digitalisation; Energy & Industrial Infrastructure; and Research & Technology Transfer. The partner country for 2026 is Brazil. www.hannovermesse.de/en
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n NEWS October 2025 www.drivesncontrols.com 10 THE NUMBER OF INDUSTRIAL robots installed in the UK last year plunged by 35%, from 3,800 in 2023 to 2,500. The figures come from the International Federation of Robotics, which points out that the 2023 figure was a one-off peak (51% higher than in 2022), driven by the “super-deduction” tax credit scheme, which ended after the first quarter of 2023. The UK now ranks rank 19th globally in terms of robot installations. Many industrial countries recorded declines in the number of robots they bought last year. Across Europe there was an average 5% drop, with six of the EU’s top ten vehicle-producing countries recording double-digit declines. The largest, Germany, experienced a 25% fall in automotive robot sales, while the Czech Republic, the third-largest car-maker, recorded a 28% fall. France, in fourth, had a 41% decrease, while in Slovakia (fifth) orders plunged by 75%. Italy (sixth) fell by 11%, while Romania (seventh) halved its orders. The IFR stats (published in its World Robotics Report 2025) show that 542,000 industrial robots were installed worldwide in 2024 – more than double the number ten years ago. Annual installations exceeded 500,000 for the fourth year running, buoyed up largely by sales in China. According to IFR president, Takayuki Ito, the number of robots installed globally in 2024 was the second-highest ever and was only 2% lower than the all-time-high two years ago. “The transition of many industries into the digital and automated age has been marked by a huge surge in demand,” he reports “The total number of industrial robots in operational use worldwide was 4,664,000 units in 2024 – an increase of 9% compared to the previous year.” China was by far the world’s largest market in 2024, accounting for 54% of global deployments. It installed around 295,000 industrial robots last year – the highest annual total on record. For the first time, Chinese robot-makers sold more machines in their home market than foreign suppliers, taking a 57% share – up from about 28% a decade ago. China’s operational robot stock now exceeds two million – the world’s largest fleet. Across Europe, industrial robot installations fell by 8% to 85,000 in 2024 – but this was still the second-highest number in history. Demand benefited from the trend to nearshoring. Germany remains Europe’s largest robot market, and the world’s fifth-largest. But installations fell by 5% to 26,982 in 2024. This represents 32% of the European market. The number of installations in Italy, Europe’s second-largest robot user, fell by 16% to 8,783. Spain is now in third place (5,100), with a strong demand from the automotive industry. France (4,900) slipped to fourth place, with the number of robots it purchased dropping by 24%. Cobots (collaborative robots) are slowly making inroads into the industrial robot market, with 64,542 being sold last year – representing 11.9% of all industrial robot sales. In 2017, just 11,107 cobots were sold, representing just 2.8% of the robot market. Despite the substantial publicity that humanoid robots have received in recent years, the IFR reports that there have been few commercial deployments yet, and that true multipurpose humanoids are still “far off”. The IFR reports that there is no indication that the long-term growth in the robotics industry will come to an end any time soon. While regional trends vary substantially, the aggregate global trajectory remains positive. Globally, robot installations are expected to grow by 6% to 575,000 in 2025. By 2028, the 700,000-mark will be passed. New robot installations in the UK plummeted by 35% in 2024 SIEMENS HAS LAID THE cornerstone for a €500m Technology Campus in Erlangen, Germany, which, among other things, aims to develop a new generation of converters and controls that will steer the movements of systems and machines even faster, more precisely and more efficiently. The campus is part of a €2bn global investment strategy that the company unveiled in 2023, half of which is being spent in Germany. The Technology Campus will make Erlangen “the worldleader in technology activities for the industrial metaverse” – the virtual environment in which technologies such as AI and digital twins are used to simulate, test and optimise processes, products and systems digitally before they are implemented in the real world. In the first phase of the campus, a 7,000m2 centre for logistics, services and flexible automation, employing up to 300 people, will be built by 2027. In a second phase, a development and innovation hub for power electronics, combined with space for manufacturing, will be added. This is due to be completed by 2030. Siemens’ existing facilities in Erlangen develop and manufacture components for industrial automation and digitalisation technologies. Around 3,000 people work in production, research, development and administration in the area. €500m technology campus will work on a new generation of controls Chinese dominance of the global market for industrial robots is clear from this graph which shows 2024 sales in the ten biggest markets (in 1,000s of machines shipped) and their growth since 2023. Source: World Robotics 2025
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n NEWS October 2025 www.drivesncontrols.com 12 THE UK GOVERNMENT SAYS that since it launched its Modern Industrial strategy in June, it has secured more than £250bn of investment in the eight sectors where it believes the UK is already strong, but could grow faster. These include advanced manufacturing and digital technologies. The first Quarterly Update on the strategy reports that it is already delivering tangible results – unlocking private investment, creating high-quality jobs, and positioning the UK as a global leader in future-facing sectors. “Our Industrial Strategy has hit the ground running – securing over £250bn in investment and supporting 45,000 jobs in just a few months,”says business and trade secretary, Peter Kyle. “This shows our strategy is not just working – it’s transforming communities and industries across the country as we deliver on our Plan for Change. “From pioneering clean energy to scaling up advanced manufacturing and digital innovation, we’re backing the sectors that will define the future,” he adds. “This strategy is about delivery, not just ambition – and it’s already laying the foundations for a stronger, more resilient economy that works for everyone.” A new Made Smarter delivery model is being co-developed with Mayoral Strategic Authorities to boost productivity and innovation. It is due to be rolled out in 2026. Meanwhile, the Made in the UK, Sold to the World’ roadshow is connecting small businesses with global trade opportunities and showcasing British enterprises globally. In the advanced manufacturing sector, the new Drive35 programme is injecting £2.5bn to support investment and R&D in the automotive sector. More than 50 cutting-edge automotive projects have secured £70m in innovation funding, while the Government’s £650m electric vehicle grant scheme is accelerating consumer adoption. A £150m redevelopment project at the Port of Tyne with a new deepwater quayside will create potential for 12,000 jobs in advanced manufacturing and clean energy industries. The creation of a new AI Growth Zone in the North East is expected to generate more than 5,000 jobs and attract more than £30bn of private investment. The government says that the achievements so far “are just the beginning of a long-term plan to build a more productive, innovative, and resilient economy. The Industrial Strategy is not just a vision – it is a delivery programme, already shaping the UK’s economic future.” Industrial Strategy ‘secures £250bn of investment and supports 45,000 jobs’ Kyle: Industrial Strategy has hit the ground running
r drives, ntegrated ervomotor Geared DC motors s technologies Slip ring assemblies and rotary joints Planetary and spur gear units ste inte Ste rives o Motors & D epper motor elligent & in pper and se drives Serv Stepper Motors & Drives P A s Rob abs Precision resolvers, AC and DC servomotors bust incremental and olute encoders High performance, O earboxes evices eedback D Systems V Harsh industrial, vacuum UHV, cryogenic & space Vacuum and F G Our comprehensive product range S ll b h d d harsh industrial Small brushed and brushless motors, frameless torque motors Int se mo ww tegrated AC rvo and stepper otors ww.mclennan.co.uk C Small & precision stepper, brushed and brushless motors epper , y g p rated st r motors +44 (0) 1252 531444 sales@mclennan.co.uk g Challenge us to provide you ARE WE LEARNING TO LOVE ROBOTS? The cobot giant, Universal Robots, has surveyed 2,174 automation “professionals” across eight European countries, including 372 in the UK, on their attitudes to robots and automation. The results make interesting reading. Just over half of those surveyed (51%), think that robots will create more jobs than they displace by 2030. Only 22% disagree with this prediction. According to UR, this marks a distinct change with earlier surveys which reported widespread fears that robots would replace workers. Almost all (84%) of those surveyed report positive employee attitudes towards robots, with resistance reported by just 3%. UR says that this marks a turning point in how automation is perceived. It is now welcomed, rather than feared. In the UK, there is slightly more scepticism, with just 44% of those surveyed expecting robots to create more jobs than they eliminate. UR suggests that this reflects a heightened awareness of skills gaps and concerns about workforce readiness for advanced automation. Across the surveyed countries, productivity is cited as the main reason for investing in automation, with 68% of respondents ranking it among their top three drivers. Cost reduction was second most common driver (cited by 57%), followed by quality improvement (54%). In the UK, productivity is rated even higher, at 73%, with 65% citing cost reduction as being a critical motivator. Half (51%) of UK respondents expect robotics and automation to be the most transformative technology by 2030, mirroring the European figure of 48%. AI and machine learning are cited by 37% of UK contributors (and 38% in Europe). Turning specifically to cobots – UR’s main interest – 93% of those already using automation in Europe expect that at least of 10% of their staff will be working alongside cobots within a decade. And 47% anticipate that more than 25% of their employees will be doing so. 91% think that cobots can cut labour shortages by at least 10%, with 44% citing reductions of 25% or more. Of those who have already used cobots, 89% report they are achieving measurable productivity improvements, with 52% seeing increases of 10–25%, and 30% achieving a 26-50% boost. Six per cent report gains of at least 50%. In the UK, more than a quarter (27%) of those surveyed report that they are already using cobots, with a further 16% saying they are familiar with cobots but not using them yet (compared to 21% across Europe). UR says that this suggests that as UK companies become aware of cobots’ capabilities, they are more inclined to move swiftly towards adoption. More than a third of UK respondents (37%) cite initial investment costs as the main barrier to them adopting cobots more widely (compared to 29% across Europe). In the Continent, integration with existing systems is more important, cited as a challenge by 33%, compared to around a quarter in the UK. So it seems that robots – and cobots, in particular – are winning increasing numbers of converts, both on the shopfloor and at higher levels. Tony Sacks, Editor n COMMENT
Drives&Controls & BACK TO BASICS n SPONSORED BY Cyber Resilience Act: what it means for you The EU’s Cyber Resilience Act comes into full force in December 2027, and applies to any product with digital elements – including drives. Liam Blackshaw, ABB’s UK product manager for LV drives, explains what you need to know. The Cyber Resilience Act is a new regulation which establishes mandatory cybersecurity requirements for hardware and software products with digital elements that are placed on the EU market. All UK businesses selling products to the EU must comply. The regulation entered into force in 2024, with requirements for compliant products becoming mandatory from 11th December 2027. Products with digital elements can include devices such as smart speakers, routers and switches, as well as software and mobile apps, all the way up to industrial control systems. It also includes variable-speed drives. The main obligation is on manufacturers to ensure that their products meet the requirements of the Act, but there are also some elements that end-users should be aware of. Modern drives are designed to be integrated into industrial networks, and are capable of manipulating code on a PLC, sending data into local networks, or even communicating with the cloud for real-time condition-based monitoring. As such, they need to be considered as part of any cybersecurity assessment. The regulation applies to new products entering the market and to existing ones that remain on the market after its enforcement date. While the main burden is therefore on vendors, from a product perspective, improving your company‘s cybersecurity is always a good idea. End-users should be asking their drive vendor what their cybersecurity strategy is, what firmware updates are or will be available, and whether there is any specific guidance for securing their systems. Many smaller companies typically won’t have a cybersecurity specialist in-house, so it’s down to vendors to make sure that their drive products are secure. Moreover, reputable vendors should be taking steps not just to ensure that their new products are compliant, but that older products are secure as well. If you’re running an older drive, then it may well require a firmware update. In ABB’s case, you can simply ring us up and we’ll sort it out for you. In many cases, updates can be downloaded from the cloud, but they can also be installed manually by accredited personnel. ABB also has cybersecurity guides available for specific drive models, providing you with everything you need to ensure compliance. If your drive is affected by this legislation, then there’s a strong chance that other equipment will be as well. It would be prudent to use this legislation as an opportunity to evaluate the security of your systems generally. As the high-profile ransomware attacks over the summer have demonstrated, the cost of not doing so can be potentially catastrophic. For more information, search online for “ABB drive cybersecurity”. cobots One marketpla ... all cobots 2.71 ace 5, B £25,812 ABB 2 0 y! BeL F £3 super co UR From su it t 4 l 2,253.20 ost-efficiency 4970 ReB £4 ® eB 32, s 2,253 R 3.20 igus eB y t per qualit to £4,970 £7,136 Dobot 36
n TECHNOLOGY October 2025 www.drivesncontrols.com 16 KOLLMORGEN HAS ANNOUNCED a range of servo products designed to simplify high-performance motion control and make it more affordable for almost any axis. The pre-configured Kollmorgen Essentials system allows easy sizing and selection, while a choice of onboard communication protocols simplify integration with common controllers. The system is said to offer “unmatched ease of installation and commissioning,” and to ensure reliable performance across applications from packaging and warehouse automation, to materialhandling and forming. This is achieved while reducing engineering times and system costs. Every Kollmorgen Essentials motion system consists of a matched combination of a servodrive, servomotor with absolute multi-turn feedback, and a combined power/data cable. The drives support multiple protocol options, allowing users to choose between EtherCat, EtherNet/IP or Profinet. Synchronisation capabilities give designers precise control of multi-axis systems via a choice of CIP Sync, Profinet IRT or EtherCat. This flexibility gives users access to highperformance motion in their existing environments, without high system costs. It also simplifies ordering and inventory management for machine-builders, allowing them to support different communications protocols for customers around the world. Functional safety is provided via integrated dual-channel STO, SIL2/Cat 3 PLd capabilities. The compact drives are easy to install and commission using the Express Setup function built into Kollmorgen’s WorkBench software. Drive setup, configuration and tuning are said to be simple, even for engineers with little motion experience. A graphical configuration tool supports them throughout the commissioning process. The full suite of WorkBench tools is included for more advanced motion programming and tuning tasks. The servodrives are available for 120–240V or 240–480V AC supplies and can deliver continuous power up to 4kW, at 3, 6 or 12A. The matching Essentials servomotors are rated at 120, 240, 400 or 480V AC and are designed for applications from 200W to 4kW. Each delivers a rated speed of 3,000 rpm, with peaks of up to 6,000 rpm. An 24V DC brake is available as an option. Standard mountings reduce the need for inventory and improve flexibility. With a simple kit, users can adapt the shaft configuration to any type of coupling. The servomotors incorporate Kollmorgen’s SFD-M multi-turn absolute encoders, which provide a 24-bit singleturn resolution and 16-bit multi-turn resolution. A power-harvesting technology eliminates the need for batteries. The encoder retains absolute positioning information even when the system is powered down. Kollmorgen says that users can expect positioning performance comparable to Hiperface or EnDat feedback systems. The high-performance encoders cost no more than an equivalent motor with resolver feedback. The single-cable technology that combines power and data allows rapid installation, with just one cable to route, and just one connection at the drive and motor ends. It also enhances reliability with a strong immunity to electromagnetic noise and fewer connection errors. The cables are available in lengths up to 25m. The system is optionally available with regen resistors, line filters and spare drive-side connectors. It supports DC bus-sharing, which balances energy between the connected drives, helping to save energy, and a more constant DC link voltage for better control performance. “Kollmorgen has always been the motion leader for torque density, responsiveness and control in compact systems that offer the flexibility and features to suit practically any application,” says Chris Cooper, the company’s global director of product management. “We’re pleased to now offer all these advantages in complete, optimised systems that allow design engineers to more easily and affordably integrate Kollmorgen high-performance motion across all axes of their machines, with easy connectivity to their existing PLC environments. “The new Kollmorgen Essentials motion system is truly a game-changer for our business and the essential industries we serve.” www.kollmorgen.com ABB CLAIMS TO HAVE BROKEN its own world record for the energy efficiency of large synchronous electric motors with a new machine for a steel plant in India. The motor has achieved an efficiency of 99.13% during testing – a significant improvement over the previous record of 99.05%, set in 2017. The efficiency for synchronous motors of this type is typically 98.2–98.5%. The motor will drive an air separation unit that will liquify atmospheric air at the unnamed Indian plant, allowing oxygen and nitrogen to be separated out to provide pure gases for steelmaking. It is estimated that the steel plant will save an estimated 61GWh of energy and $5.9m in electricity costs through improved energy efficiency over the motor’s 25-year lifespan.The installation is expected to pay for itself in just over three months. ABB has designed the motor in line with its Top Industrial Efficiency (Tie) initiative, which delivers motors and generators designed to exceed standard benchmarks. They help users to cut electricity use, operating costs and TCO (total cost of ownership), without compromising performance or adding complexity. Record efficiency motor will pay for itself in three months ‘Game-changing’ servo systems simplify motion control and cut costs Kollmorgen’s Essentials motion system promises high-performance affordable precision motion for all industrial axes.
Precise object scan for reliable quality control Missing seals, incorrectly engaged connections, the wrong type of screw: none of this escapes the PMD Profiler. With a measuring accuracy of 500 μm, the photoelectronic line scanner reliably detects even the smallest deviations. As precisely as the PMD Profiler does its work, it is tolerant when it comes to its working environment: immunity to ambient light and independence from distance enable flexible positioning. Thanks to the intuitive button operation and colour display, the sensor is ready for use within minutes, even without software . ifm - close to you. Takes contours very precisely: the ifm Profiler. ifm.com/uk Go ifmonline years WARRANTY onifmproducts
n TECHNOLOGY October 2025 www.drivesncontrols.com 18 THE SWISS MEASUREMENT SPECIALIST Kistler has announced a system that provides wear-free, wireless transmission of signals to monitor processes and equipment in dynamic structures such as machine tools. The Telemetric Measurement System (TMS) system delivers data reliably without needing sliprings, batteries or cables. Kistler says it opens up entirely new possibilities for process monitoring in series production. Traditional hard-wired measurement systems reach their limits when machine parts are moving or difficult to access. It is not wear-andtear, but the risk of cable breakage that poses the biggest challenges – especially for components subject to dynamic loads. In addition, cables can disrupt operation and restrict the flexibility and movement of sensor systems. Coolants, chips and dust can cause connectors to malfunction. If batteries are used, they need regular maintenance and/or replacement. As a result, critical processes often go unmonitored, posing risks of wear, wastage and process instability. Kistler’s TMS transmits signals wirelessly, accurately and continuously. It was developed primarily for use with single-channel piezoelectric measurement devices in moving machines such as turret lathes, multi-spindle machines, robots and assembly lines. Compared to indirect methods, such as spindle current analysis, the TMS – in combination with the piezoelectric sensors – offers much higher sensitivities. Even tiny forces of a few newtons can be detected directly, “for the first time” according to Kistler. The system is claimed to deliver consistent measurement data in demanding locations such as machine rooms or industrial facilities, making it a cost-effective, reliable alternative where conventional technologies fail. “Existing wireless solutions are primarily designed for R&D environments,” explains Kevin Meier, Kistler’s product manager for cooperation solutions in advanced manufacturing. “They only have a limited measuring capability and rely on specially configured systems. They are often too large or specially designed, making permanent integration into 24/7 production equipment only possible to a limited extent.” Kistler’s Telemetric Measurement System consists of two modules that are matched mechanically and electrically. One is a miniature, single-channel charge amplifier that is mounted directly onto moving machine elements, such as tool turrets. It converts a sensor’s piezoelectric signal into a voltage and transmits it wirelessly to a base station mounted on the machine, which powers the amplifier inductively. The base unit receives measurement data via a near-field interface, providing a stable connection even when complex movements are involved. The gap between the modules is 1mm (±0.5). The signals are processed with a resolution from ±48 to ±140,000pC (picoCoulombs) at an analogue voltage output of ±10V. Alternatively, digital data can be output via Ethernet at a sampling rate of up to 25 kilosamples/s, via a Web UI. Ethernet interfaces allow integration into control systems or higher-level monitoring platforms. Tool wear (in metal-cutting, for example), material deviations, or irregularities in chip formation, can be detected in real time. Following an initial set-up and coupling via the near-field interface, the base station identifies the sensor automatically and reads all relevant parameters, including calibration data, measuring range and sensitivity, within milliseconds. The system is immediately ready for measurement – without manual intervention or waiting times. Installation is said to be fast, precise and reproducible, thanks to defined coupling points. The contactless, high-frequency signal transmission is bidirectional and resists interference, even under harsh conditions. The measurement system also resists chips, coolants, and vibrations because of its closed aluminium die-cast housing and ceramic-reinforced transmission surfaces. www.kistler.com/GB/en p Following the transfer of the FDT/DTM assets to FieldComm Group in 2024, the organisation has accelerated its efforts to unify device integration. It has announced a timeline for releasing an updated Field Device Integration (FDI) specification, marking a critical step towards unifying integration across the process, hybrid and factory automation sectors. With contributions from OPC Foundation, ODVA and PI, a committee is harmonising the FDI and FDT technologies, with the aim of delivering a unified, scalable integration standard that addresses the needs of modern manufacturing. The updated FDI Specification is due for release by the end of 2026, with the first FDI-enabled systems and devices expected to reach the market in 2029. p Siemens has formed a partnership with machine tools and laser manufacturer Trumpf aimed at elevating industrial production by harnessing advanced digital manufacturing technologies. The collaboration combines Siemens' Xcelerator portfolio with Trumpf's machine-building and software expertise. The partnership will address a key challenge in manufacturing: the gap between IT (information technology) and OT (operational technology) systems, that has historically hindered production efficiency and innovation. By combining the Xcelerator portfolio with Trumpf’s manufacturing know-how, the two aim to deliver technologies that bridge the gap. They are working on open, interoperable IT interfaces that advance AI readiness for motion control applications. p ABB has introduced software that allows real-time coordination of production planning and operations across entire paper mills, aimed at improving their quality, efficiency and profitability by enabling end-to-end traceability, dynamic optimisation and smarter decision-making. The ABB Ability Plant Optimizer for Pulp Mills will help pulp producers to bridge the gap between production planning and realtime operations. p The US robotic tooling and automation specialist, IPR Robotics, has launched a customisable dual seventh-axis system that extends robot reaches, enhancing flexibility and reducing complexity. The StackTrax system can extend a robot’s working envelope, while saving space and deployment time compared to overhead or gantry-style systems. It combines two linear axes in a compact system that gives robots the working envelope of a gantry without the overhead supports, long lead times, or costly custom engineering. It works with all major robots, and can handle a wide range of payloads. The system has been designed to meet the needs of CNC, material removal, and other machine-tending robotic applications www.iprrobotics.com TECHNOLOGY BRIEFS Wear-free wireless system ‘revolutionises’ monitoring of moving machinery Kistler’s Telemetric Measurement System installed on a machine tool. The system consists of a mobile charge amplifier (below left) and a stationary base station (below right).
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