www.hpmag.co.uk June 2023 p32 p14 The must have Industry 4.0 technologies Ex-proof hydraulics for offshore mooring systems Prevent equipment failure with proactive maintenance p44 Keeping food and beverage production moving
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The need for a long-term industrial vision EDITOR’S COMMENT www.hpmag.co.uk HYDRAULICS & PNEUMATICS June 2023 3 The need for a clear strategic approach has also laid bare how it is even more crucial for a diverse and inclusive workforce to build an economy that works for everyone. ‘ ’ Britain’s manufacturers are seeing a continued rebound in activity in the second quarter of the year, easing fears of a significant recession according to a survey published by Make UK and accountancy and business advisory firm BDO. However, although, the findings in the Make UK/BDO Q2 Manufacturing Outlook survey show a continued positive picture with the improvement being driven by strong demand in the Other Transport and Electronic sectors in particular, Make UK’s Stephen Phipson has said that many businesses are warning that a habitual short-term focus on quick fixes and political publicity stunts from successive governments is impeding economic development. He highlights that a new report launched in May by Make UK, shows Inconsistency in public policy breeds uncertainty in private industry. This in turn prevents businesses from planning effectively so instead of incentivising investment, it incentivises intransigence. The lack of a coherent long-term industrial strategy has been emphasised as being a major stumbling block. I agree with Phipson that although a long-term strategy is not without its challenges and means making difficult decisions about where to allocate resources, what to prioritise and what to sacrifice, the alternative, as we are now seeing, is stagnant productivity, increasing inequality, and low or zero economic growth. A modern industrial strategy according to Phipson, will require a significant, game-changing shift in the way policymakers approach business and economic policy. The need for a clear strategic approach has also laid bare how it is even more crucial for a diverse and inclusive workforce to build an economy that works for everyone. This was highlighted at a recent event in the lead-up to International Women in Engineering Day (INWED) 2023 (23rd June). Dr Hayaatun Sillem, CEO of the Royal Academy of Engineering, led the panel of female leaders to explore the challenges around female representation in industry to discuss how to broaden the appeal of engineering careers to women. Despite progress in promoting gender equality across various industries, the field of engineering still faces a considerable gender imbalance where women remain vastly underrepresented, accounting for only a small fraction of the workforce. This was highlighted at the INWED event and suggested that to address this issue concerted efforts are needed at various levels. The panel discussed that it begins with encouraging young girls to consider STEM subjects early in their education. By fostering a supportive environment and debunking gender stereotypes associated with engineering, young girls can be inspired to pursue careers in this field. Interestingly, Susan Scurlock, Founder of Primary Engineer, also highlighted that the majority of shortlisted finalists from its annual Leader Award competition where children are asked to identify a problem and draw a solution to it, were girls. Therefore, it was highlighted that it is not only the government that has a responsibility, but also educational institutions, including universities and colleges have a significant role to play in creating an inclusive environment for female engineering students. Scholarships, mentorship programmes, and networking opportunities tailored to women can help break down barriers and provide the necessary support and guidance to aspiring female engineers. Increasing the number of women in engineering is also not just about achieving gender parity which was also highlighted; it is about harnessing the benefits of diversity. When women are included in engineering teams, a wider range of perspectives, ideas, and problemsolving approaches emerge. This diversity fosters innovation and leads to more effective and sustainable solutions. By promoting inclusivity, breaking down barriers, and providing the necessary support, the industry can create a more diverse and equitable engineering workforce. And if this formed part of a long-term industrial strategy, perhaps we would see a very different vision for our economy now and into the future. Aaron Blutstein Editor
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www.hpmag.co.uk HYDRAULICS & PNEUMATICS June 2023 5 CONTENTS EDITORIAL Editor: Aaron Blutstein t| 01732 370340 e| editorial@dfamedia.co.uk Content Sub Editor: Leslah Garland t| 01732 370340 e| leslah.garland@dfamedia.co.uk SALES Sales Manager, UK & Overseas: Andrew Jell t| 01732 370347 e| andrew.jell@dfamedia.co.uk Italian Sales Office: Oliver & Diego Casiraghi t| 031 261407 f| 031 261380 e| info@casiraghi.info Turkey: Intersmart Media meltem@intersmartmedia.co.uk Managing Director: Ryan Fuller t| 01732 370344 e| ryan.fuller@dfamedia.co.uk Production Manager & Designer: Chris Davis t| 01732 370340 e| chris.davis@dfamedia.co.uk Reader/Circulation Enquiries: Perception t| +44 (0) 1825 701520. e| dfamedia@dmags.co.uk Marketing Executive Hope Jepson e| hope.jepson@dfamedia.co.uk Operations Manager: Emma Floyd e| emma.floyd@dfamedia.co.uk Financial: Finance Department e| accounts@dfamedia.co.uk Chief Executive Officer: Ian Atkinson e| ian.atkinson@dfamedia.co.uk Published by: DFA Media Group 192 The High Street, Tonbridge, Kent TN9 1BE t| 01732 370340 e| info@dfamedia.co.uk w| www.hpmag.co.uk In co-operation with Printer: Warners, UK © Copyright 2023, DFA Manufacturing Media Ltd ISSN 1366-1981 H&P is a controlled circulation magazine, published 8 times a year. Please contact DFA Media with any subscription enquiries. Paid subscriptions are also available on an annual basis at £110.00 (UK), £145.00 (Europe) or £180.00 (Rest of the World) P+P included. 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. 36 14 6 NEWS 14 KNOWLEDGE BASE Greg Moyle, Head of Energy & Discrete Industries, SAP UKI, discusses the Industry 4.0 technologies that manufacturers must embrace to remain resilient to global uncertainty. 18 APPLICATIONS 20 HYDRAULICS There are several individual prerequisites when it comes to selecting a braided hydraulic hose, including working pressure, fatigue life, bending radius, abrasion resistance, construction integrity, corrosion resistance, chemical/fluid compatibility, temperature resistance and flexibility. H&P takes a closer look. 28 PNEUMATICS Andy Macpherson, Industry Manager for Food & Beverage at Festo GB, offers advice to help system designers adhere to food safety guidelines while improving machine utilisation and performance. 32 INTEGRATED SYSTEMS 36 COMPRESSED AIR Choosing the most suitable systems and components for conveying can have a significant impact on operational performance – guaranteeing product quality, avoiding blockages and reducing costs. Atlas Copco spoke to H&P about selecting the right pneumatic conveying equipment which can be challenging, with many considerations coming into play. 38 BCAS Our regular news and events update on the British Compressed Air Society. 40 SPECIAL FOCUS Food & Beverage/ Maintenance 45 BFPA Hydraulics & Pneumatics’ issue-by-issue briefing on current activities and views involving the British Fluid Power Association. 46 NEW FACES A selection from our industry’s most recent high-profile appointments. 47 PRODUCTS & SERVICES DIRECTORY 40
NEWS 6 HYDRAULICS & PNEUMATICS June 2023 www.hpmag.co.uk Engineers Without Borders UK has launched the Global Responsibility Competency Compass, with support from the Royal Academy of Engineering. The tool was launched at Manufacturing & Engineering Week, which took place at Birmingham’s NEC. The self-led educational tool has been developed to help engineers respond effectively to the complexity and uncertainty of pressing global challenges such as climate change and will help individuals and their wider teams reflect on their strengths and weaknesses, highlighting gaps in the skills needed to act sustainably, ethically, and equitably. The launch event emphasised the need for practitioners working in engineering to be motivated and competent to participate in the urgent and rapid transition to a net zero economy. Data from the Institution of Engineering & Technology has highlighted that only 7% of companies surveyed had the necessary skills to deliver their sustainability strategy. Developed through extensive consultation and testing, the Compass comprises 12 essential competencies to deliver on the four principles of global responsibility – Responsible, Purposeful, Inclusive and Regenerative – articulating the vital skills, knowledge and mindsets required. The Engineering Council is endorsing the use of the Compass as a “progressive interpretation of the UK standard for professional qualifications for engineers and technicians”. “The Global Responsibility Competency Compass is an introductory and action-orientated tool aimed at anyone in the engineering sector who wants the skills to respond effectively to the complexity, uncertainty and challenges of our age,” says John Kraus, CEO of Engineers Without Borders UK, a charity organisation whose mission is to put global responsibility at the heart of engineering, ensuring a safe and just future for all. “It is a learning tool for individuals and teams, giving confidence that responsible engineering principles are being embedded at every level and that decisions made balance the needs of all people with the limits of our planet.” Individuals can use the Compass to support self-assessment. It provides a template to create a sustainability skills action plan, using a learning library of relevant professional development opportunities and resources. According to Engineers Without Borders UK, embedding the tool into day-to-day activities will strengthen the evidence individuals need to attain and retain professional qualifications. The tool also helps managers to identify and articulate the strengths and gaps in team capabilities regarding responsible engineering. It empowers teams to ensure projects deliver the greatest benefit to people and the planet and can support Engineers Without Borders UK launches tool to address sustainability skills gap in engineering engineering organisations to assess and bridge the sustainability skills gap across their entire workforce. Kraus added that the organisation developed the Global Responsibility Competency Compass as a practical resource: “We want it to help practitioners make better decisions, leading to improved outcomes for everyone and the planet we share.” With the development of the Global Responsibility Competency Compass, Engineers Without Borders UK has taken a significant step towards providing engineering professionals with the navigation tools that will allow them not only to understand what is important but to commit to making a difference to the way they support society now and for generations to come. John Kraus concluded: “Closing the global responsibility skills gap in our profession is a collective responsibility, and Engineers Without Borders UK, its partners and supporters are committed to upskilling at least 250,000 individuals by 2030. Become a responsible practitioner and start using the Compass today”. Engineers Without Borders UK is working to reach the tipping point to ensure a safe and just future for all. Part of a global movement of over 60 Engineers Without Borders organisations, we inspire, upskill and drive change in the engineering community and together take action to put global responsibility at the heart of engineering. Domin, a start-up based in Bristol, is partnering with Renishaw, the global engineering technologies company headquartered in the UK, to upgrade its additive manufacturing technology, by installing Renishaw’s RenAM 500Q system. The company says that this development will enable Domin to take its mission to ‘revolutionise the hydraulics industry’ to the next level. This strategic investment will significantly enhance Domin’s manufacturing capabilities, enabling the company to offer a wide range of high-quality parts and components to its customers. The RenAM 500Q system, equipped with four high-power 500W lasers capable of simultaneously accessing the entire Additive manufacturing technology upgrade investment to help ‘revolutionise the hydraulics industry’
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8 HYDRAULICS & PNEUMATICS June 2023 www.hpmag.co.uk RS, an omni-channel provider of product and service solutions including maintenance solutions and safety solutions, has released the ‘Industry in Motion’ 2023 Maintenance Engineering Report, in conjunction with the Institution of Mechanical Engineers (IMechE), based on findings from a survey that aimed to ‘take the pulse’ of the profession. The survey was conducted among more than 1200 IMechE members and the report focuses on the responses of almost 700 people in the UK and Ireland. The respondents were from sectors including manufacturing and are working in job roles like engineering manager. The resulting report covers five key areas: monitoring maintenance engineering, skills, the true cost of breakdowns, raising performance through stakeholder collaboration, and harnessing technology to improve efficiency. The top three challenges respondents cited as expecting to affect them over the next 12 months were attracting talent (47% inflation and higher costs (47%), and supply chain disruption (40 %). But the report also delves into a key issue: drivers of unscheduled downtime and its cost to a business. Ageing assets and mechanical failures are the biggest drivers of unscheduled downtime, and the report revealed: Nearly 20 hours are spent each week on unscheduled maintenance, compared with around 18 hours spent each week on scheduled maintenance The average hourly cost of downtime is £5121.81 (ranges from c. £1700 to £7.5k depending on size of business) The average weekly cost of unscheduled downtime is £100,371 Organisations need to get a grip on maintenance spend, as nearly a third of respondents do not know what proportion of their annual operating budget is spent on maintenance; 30% state approximately 5% – 10% is spent. Survey respondents cited the highest priority plans for decreasing unscheduled downtime as upgrading equipment (48%) and widening monitoring capabilities (46 per cent). In a bid to further tackle the issue, planned maintenance has emerged as the number one company strategy in place, deemed the highest priority by 53% of respondents. Emma Botfield, managing director for RS in the UK and Ireland, said: “The challenges facing businesses today mean that maintenance engineers are even more critical to manufacturing success, while under pressure to do more with their existing resources which often include ageing assets. They’re also firefighting because of the geopolitical environment and its effect on supply chains.” The issue of an ageing skilled workforce and a large age gap to the next engineers coming through was highlighted in the report. Meanwhile, Millennials – a group that made up more than half of the respondent pool – are reaching key decision-making positions within organisations. Botfield added: “These Millennials hold a real opportunity to affect change and should work with stakeholders and suppliers to find fresh solutions, and tackle maintenance problems that may be keeping them up at night head-on.” According to data from Engineering UK, people aged between 25 and 34 now constitute the largest single age group in engineering roles. Lydia Amarquaye, Professional Development and Education Policy Advisor at the IMechE, said: “Millennials have grown up with different technologies and they will be trying to implement some of these in their work to make life more efficient for themselves. I think we’re going to see the effects of this shift coming through in the way that businesses are conducted, as it plays into management styles. So, I think it is going to be exciting for the industry as a whole.” It is widely recognised that outsourcing maintenance requirements can help organisations overcome issues like skills shortages. The report found that more than 60% of respondents are outsourcing some form of maintenance requirement, with a gap in skills being the top two reasons. On digital transformation, only 16% of respondents stated they use Industrial Internet of Things (IIoT) and fewer than one in five respondents said their company is planning a digital transformation in the next 12 months. However, RS believes this is because terms like IIoT and digital transformation aren’t ones operational maintenance people use. Condition monitoring, which uses IIoT, is being employed, according to more than half of the respondents. The top two technologies are vibration measurement – used by 44% of respondents – and current monitoring, used by 43%. The main benefits cited from using these technologies are understanding asset health (68%) and better prediction of failures (53%). Botfield concluded: “This report shows that in the face of a multitude of challenges, maintenance engineers are keeping the wheels of UK industry turning and facing up to these challenges. They should aim to bolster efforts by working with trusted suppliers who understand what they are trying to achieve and where the pain points lie. This will allow them to achieve the best value for money for the organisation.” The RS and IMechE ‘Industry In Motion’ 2023 Maintenance Engineering Report,’ can be downloaded in full at: https://uk.rs-online.com/web/content/m/ imeche-report collaborations with Renishaw as we continue pushing the boundaries of what is possible through precision additive manufacturing.” The partnership with Renishaw is a continuation of Domin’s growth in UK engineering. The collaboration will create job opportunities, providing employment opportunities for skilled professionals in the engineering and manufacturing fields, and developing new ideas, techniques, and solutions. NEWS powder bed surface, achieves remarkable build rates surpassing those of previous systems. Bryan Austin, Director of AM Sales at Renishaw, explained: “The valves manufactured by Domin require high precision machining, tight tolerances, and accurate positioning, utilising high-grade materials to ensure robust chip shear and durability. With the RenAM 500Q, Domin can meet these demanding requirements while manufacturing at scale.” By integrating Renishaw’s RenAM 500Q system, which incorporates an intelligent gas flow system that reduces process emissions from the build volume, we can achieve a stable processing environment that further enhances quality standards. “We are thrilled to partner with Renishaw in acquiring the RenAM 500Q”, explains Marcus Pont, CEO of Domin. “This strategic investment will enable us to provide our customers with even more advanced solutions. We anticipate future ‘Industry In Motion’ 2023 Maintenance Engineering Report published
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NEWS 10 HYDRAULICS & PNEUMATICS June 2023 www.hpmag.co.uk A&S International appointed as a master distributor for Hosepatch A&S International has been appointed as a master distributor for the Australian company Hosepatch. The A & S team has been in the distribution business for 47 years and already sells a wide range of machinery lubrication and bioremediation solutions to multiple industries, with more than 50 distribution arrangements in over 40 countries. The strategic vision of Hosepatch is to expand its overseas distributor network & the new agreement with A&S is an important development in this strategy. Chris Turner, MD of Hosepatch commented: “We were made aware of the quality of the A&S distribution business and the reach that it has across the globe. Hosepatch is a proven temporary repair solution for hydraulic hose applications with significant worldwide sales potential. We are really looking forward to working with the A&S International team to grow the business as more of their distributors start to offer the Hosepatch brand to their loyal clients.” Angus Macdonald, one of the Directors at A&S, added: “Our new representation of the Hosepatch brand is an exciting opportunity for our company & our global network of distributors. It is a simple & effective temporary hydraulic hose repair solution for mobile operators in the field that will help them significantly save time & money. We believe that it will be an ideal fit for many of our distributors around the world as most have clients with mobile fleets.” A&S International is also looking to appoint a network of UK resellers from the hydraulics sector. Schaeffler completes acquisition of Ewellix The Schaeffler Group has completed the acquisition of Ewellix. This starts a new era for Ewellix being part of a large industrial group with a strong focus on industrial applications. Ewellix will be operated as an additional business that works closely with the Schaeffler Industrial team. “This will enable us to continue our agile way of working in the future”, says Daniel Westberg, CEO of Ewellix.? The two companies highlight how they complement each other: “This is particularly true in the high-growth areas of electromechanics, efficiency optimisation, automation, and robotics”, says Dr Stefan Spindler, CEO Schaeffler Industrial. Being one team means that Schaeffler and Ewellix will bring their expertise together and continue to develop as a company. Schaeffler will support the Ewellix team in executing the major growth plans, leveraging synergies in every step along the common journey. Daniel Westberg added: “We will continue to bring the best support and service level for our products that our customers have come to expect.” “Together, we will form a global leader in linear motion and electromechanical actuation”, concluded Ralf Moseberg, Head of Industrial Automation at Schaeffler. RIGHT: Daniel Westberg, CEO of Ewellix
NEWS 12 HYDRAULICS & PNEUMATICS June 2023 www.hpmag.co.uk ERIKS UK has launched an APP that enables its customers to digitally replenish their stores ensuring that they experience fast, efficient and reliable next day delivery with full digital traceability. For applications at point of use or open industrial stores the App is specifically to help ERIKS’ customers replenish their stocks. It’s a simple tool that allows them to create their own QR/bar codes, scan QR/bar codes, select the right quantities of product they wish to order and to complete an order in the ERIKS web shop. The QR codes generated can be affixed on a customer’s racking, boxes or wherever their machine is, and their process is then fully integrated into the ERIKS web shop. The App also allows people to search for products, to set up a favorites list and to build a shopping cart – much as most people do when they use Amazon or other web shops. As with those, it’s simple to check out and a full order history is available to view. An important feature of the App, given the supply chain difficulties that most industrial businesses have experienced in the last few years, is that lead times for products are shown when searching and products are picked, dispatched and delivered in 24 hours to most of the UK via ERIKS’ Fulfilment Centre of Excellence in Oldbury in the West Midlands. Mick Holland, ERIKS Chief Product Officer commented: “The App removes the challenge of distance and allows customers to interact seamlessly with our IT system in a way that adds genuine value and a great deal of process efficiency. It’s important to note that this is a replenishment process – it's not vendor managed inventory, it’s not an inventory management algorithm and it’s not stock control – it is however what most people need.” ERIKS says its App is simple but powerful and once downloaded customers have all their product and order information in their pockets. The company says that by using the App there is less chance of making mistakes when ordering with no more writing down or copying item numbers or quantities. It all provides faster and easier ordering. Another major advantage of using the App is that it is possible to specify a PO number that applies to a selection or all of the customer’s maintenance products. This allows the busy buyer to give autonomy to their engineers to buy products up to a certain spend limit and then receive all the spending information on one invoice at the end of the month – which obviously makes life much simpler for them in terms of vendor management and budget control. “The launch of the Digital Replenishment App” says Mick Holland, “is the start of a journey and our first venture in providing our customers with a fully digital experience – it's a big focus for us. The user interface means that customers will control all aspects of their digital experience with ERIKS. The objective is to make us easy to work with as we become almost invisible to the buyer.” The ERIKS App can be downloaded from the Apple App store or from Google Play, just search “ERIKS App”. Digital replenishment App launched
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KNOWLEDGE BASE The manufacturing industry has pioneered global shifts in commerce and trade since the first industrial revolution brought affordable, mass-produced consumer products to the market. The advent of automation, a commonplace feature in factories and production plants for generations, increased efficiency, delivered better value to customers, and placed safety at the forefront of the workplace. But today, assailed on all sides by the global disruption of a prevailing pandemic, regionalised geopolitical 14 HYDRAULICS & PNEUMATICS June 2023 www.hpmag.co.uk complexity including the Ukraine conflict, supply chain disruptions and everchanging customer demands, manufacturers face a considerable number of new challenges. Overcoming them isn’t about a complete revolution - as was the solution to mounting globalisation in the 19th century, but it will call for a similar leap of faith in new processes and technologies. In an era of business uncertainty, industry 4.0 has a leading part to play in the next seismic technology shift that addresses today’s global challenges. For manufacturers, there’s no doubt about technology’s role in delivering continuity and resilience against what may come, but also in helping them to thrive. If manufacturers want to emerge ahead of their competitors from today’s challenges, here’s the top three industry 4.0 technologies they should be paying attention to. The influence of the cloud on modern manufacturing First and foremost, manufacturers must pay attention to the evolution of cloud The Industry 4.0 technologies that can help manufacturers remain resilient to global uncertainty Greg Moyle, Head of Energy & Discrete Industries, SAP UKI, discusses the Industry 4.0 technologies that manufacturers must embrace to remain resilient to global uncertainty.
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KNOWLEDGE BASE 16 HYDRAULICS & PNEUMATICS June 2023 www.hpmag.co.uk computing and understand how it can continue to make an impact in the future. While most manufacturers have embraced the cloud in some capacity, research suggests that some remain concerned about legacy integration and the performance of applications in the cloud. This indicates that there may still be some hesitancy to go ‘all-in’ and this could be a concern as the industry looks to thrive, not just survive, in the current business landscape. Cloud computing is not just the enabler of industry 4.0 but also wider digital transformation. It is the foundation in which most advanced technologies, such as the IoT and realtime data analytics, operate, and can be scaled up or down to manage shifting project workloads, react to demand and improve visibility across the business. In the context of the supply chain crisis, this can have a real positive impact. For instance, the shortage of cars has been a permanent fixture on the news agenda over the last two years, with long waiting times in production. For many original equipment manufacturers, the cloud has been a game-changing solution in maintaining levels of customer experience. It has facilitated greater end-to-end visibility of the supply chain, meaning faster and more accurate customer communications, as well as the capacity to forecast demand, plan in advance and improve the efficiency of the production line. The power of the Industrial Internet of Things At a time where the future of industry remains in flux, determined by the outcome of global events, the Industrial Internet of Things (IIoT) has a critical role to play in supporting manufacturers to be agile to change. Unlike the IoT which is commonly used as an umbrella term for connected consumer devices, like a smart watch, the IIoT uses connected machines, devices and sensors in industrial applications such as robotics. These devices produce large volumes of data that when analysed, can improve efficiency, productivity and visibility, both in manufacturing and along the supply chain. To explore this further, the IIoT is pioneering a concept called smart factories. While the concept of automation has been in use in manufacturing for decades with barcode scanners, cameras and digitised production equipment, those devices are rarely interconnected. Instead, the people, assets and data management often operate in isolation and must be processes at an exorbitant cost to read and analyse this data, but this is no longer necessary. During a crisis or business uncertainty, manufacturers need to move fast and make smart, accurate choices. Slow, costly data insights could be the difference between making the right or wrong choice. Through machine learning and real-time analytics platforms, manufacturers can accelerate connectivity across the business, collecting and analysing data at speed and scale. In practice, this means they can pivot faster to changes in trading conditions or identify and address issues before they reach the customer. This could be machines in need of repair, maintaining field equipment or adjusting their supplier based on the availability of chips or raw materials. Helping companies meet their sustainability targets Innovative companies are now able to drive comprehensive sustainability agendas while boosting their bottom line and market share – but how are they doing this? Conscious that all stakeholders, from investors to end users, are asking companies to reduce their carbon footprints, forward-thinking enterprises are specifically targeting manufacturing processes to make sustainability improvements. In fact, Industry 4.0 is specifically able to enable this by improving operating efficiency, optimising cost and eliminating sustainability issues right at the point of product design. By harnessing the power of automation, augmented reality, AI/Machine Learning and the IoT, Industry 4.0 can promise improved methods of production and enhanced business models. With Scope 3 emissions accounting for 80-90% of your total emissions, this can be a game-changer for organisations with their eye on the environment. Ultimately, the manufacturing industry has experienced greater disruption and challenge in the last decade than the previous three combined. As before, manufacturers looking to resurface ahead of competitors need to be bold and take a leap of faith on embracing new technologies and processes. It’s here that they must recognise the role of industry 4.0 technologies, in the cloud, IIoT and Big Data with real-time analytics, in helping them to successfully navigate the ongoing supply chain crises and geopolitical complexity, while maintaining business continuity and a level of service end-customers have come to expect. For further information please visit: https://www.sap.com/uk manually coordinated and integrated on an ongoing basis. Through the IIoT, manufacturers are able to build an interconnected factory by collecting disparate sets of useful data across the business and supply chain. This can then be stored and actioned to inform product development or quality control. Moreover, in the case of global challenges such as the blockage of the Suez Canal in 2021 or the start of the conflict in Ukraine, the IIoT allows manufacturers to be proactive, as opposed to reactive, to crises. Spotlighting the Suez Canal blockage, for instance, during the period of severe supply chain disruption - it was the IIoT that supported manufacturers with contingency planning, understanding where raw materials were and which suppliers had them, enabling them to mitigate against disruption. Managing the tide of data While large quantities of data at your fingertips is paramount, it can easily go to waste without the ability to effectively manage and analyse it in real-time. This is where Big Data management, machinelearning and real-time analytics play an important role in supporting industry leaders to glean the best insights from their data, and inform smart strategic choices. Typically, manufacturers will produce vast amounts of both structured data and unstructured data. Structured data is the simplest to organise and search, and can include financial information and machine logs, like an Excel sheet - that can be easily categorised and doesn’t require intensive resources to manage. Unstructured data, on the other hand, typifies the volume of information produced by connected machines, and isn’t as easily captured. Today, manufacturers still use laborious manual Greg Moyle
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APPLICATIONS 18 HYDRAULICS & PNEUMATICS June 2023 www.hpmag.co.uk With a low maximum operating temperature, the new Kick and Drop coils from Bürkert are said to enhance safety and remove the potential of electrical overheating. The 3-in-1 design, covering various voltage inputs, also streamlines inventory management. The coils can also be used across a range of Bürkert solenoid valves, including pneumatic, plunger, servodiaphragm, and servo-piston, as replacement demand or retrofit. Covering a variety of inrush and holding powers, each 3-in-1 coil covers DC, AC 50Hz and AC 60Hz, spanning 24V to 240V inputs, this flexibility reduces storage and handling requirements. Energy efficiency The device optimises energy efficiency by utilising a high initial voltage to move the valve into position. After just 500ms, the New coil technology for solenoid valves can increase energy efficiency by up to 80% Kick and Drop valve coils from Bürkert are saving significant costs by reducing energy use and extending service life according to the manufacturer. The increased efficiency also optimises environmental sustainability. With a low maximum operating temperature, the coils are said to enhance safety and remove the potential of electrical overheating. The 3-in-1 design, covering various voltage inputs, and also streamlines inventory management. H&P takes a closer look. desired position is reached, and the coil wattage is reduced to a lower level that holds the valve position. This makes the coils well-suited to applications with long duty cycles. The increased ‘kick’ force is also useful for applications where the valve is required to open against a high-pressure differential. The design includes two coil windings encapsulated in a single epoxy coil, with both coils powered in series. The first winding delivers the ‘kick’ that moves the plunger, while the second winding ensures the ‘drop’, and holds the plunger in position. The overexcited inrush winding generates a very high starting power, creating a strong magnetic field using 85% power Kick and Drop coils can minimise the overall energy demand by up to 80% The design includes two coil windings encapsulated in a single epoxy coil, with both coils powered in series
www.hpmag.co.uk HYDRAULICS & PNEUMATICS June 2022 19 Bürkert Fluid Control Systems manufacturers control and measuring systems for fluids and gases. The products have a wide variety of applications and are used by breweries and laboratories as well as in medical engineering and space technology. The company employs over 2200 people and has a comprehensive network of branches in 35 countries world-wide. Think BIG, or small. Fast, precise, elegant, servo-hydraulic control. BIG or small, get your next project running more quickly than you thought possible. One axis or fifty; position, velocity, force, or position-pressure/force, look to Delta RMC Motion Controllers and graphical RMCTools software to make complex motion easier, smoother, and more precise. RMC200 Standard (Up to 50-axis) RMC200 Lite (Up to 18-axis) RMC75 (1 to 2-axis) CCSLN.com 44(0)1926 485532 Distributor to quickly move the plunger, but just 15% to hold it in position. In contrast, a standard valve coil produces a continuous magnetic field to move the valve into position and hold it over time. As a result, Kick and Drop coils can minimise the overall energy demand by up to 80%. Improved sustainability Reducing solenoid valve energy use can also make a significant contribution to improved sustainability. Taking an installation of 8,000 solenoid valves, Kick and Drop technology can save 114MWh per year and a CO2 reduction of 830 tons, based on 485 g/KWh. Decreasing the continuous current requirement also extends the coil’s lifespan, reducing the total cost of ownership. For water applications, the Kick and Drop coils can also help to prevent the challenge of calcification, caused by hard water with high lime breakdown. Higher temperatures speed up the lime breakdown process, but below 60°C, the process is so slow that it doesn’t create a problem. The Kick and Drop coils only heat up to a maximum of 55°C, which removes the challenge. As the coils only heat up to this lower maximum temperature, this increases safety by reducing the risk of burns. Kick and Drop coils can be used in insulated systems or housings, and the low operating temperature also prevents electrical overheating, with testing according to EN 60730-2-8. The coils provide these advantages within a compact footprint, comparable to a standard coil, and they can also be used in close proximity to other electrical equipment as a result of noiseless EMC (electromagnetic) compliance. http://www.burkert.co.uk
HYDRAULICS 20 HYDRAULICS & PNEUMATICS June 2023 www.hpmag.co.uk Identifying a hose that can deliver on all fronts has historically proved challenging. The issue is compounded when trying to find a supplier that can match product excellence with high levels of customer service and engineering support, while simultaneously demonstrating an ethos of continuous improvement in R&D, production and testing. Although opinions vary when it comes to stating the leading factor that influences the purchase of a hydraulic hose, many machine builders look carefully at fatigue life. Luca Pozzi, Product Manager Hoses, Polymer Hose Division Europe, Parker Hannifin explains that they want a hose that lasts for a long period as it can serve as a machine USP (unique selling point) for the sales team, while also reflecting well on their brand and market reputation. For the end user, hose longevity saves the inconvenience and cost of frequent hose replacements, production downtime and corresponding loss of productivity. Tired of short hose life? So, what governs the fatigue life of a hydraulic hose? Pozzi says that so-called impulse testing is a key indicator of hose life. Impulse testing involves the pressure cycling of hose often up to 133% of working pressure, at frequencies up to 1.3 Hz, with the hose held in either a 90° or 180° configuration. Typically, an EN or ISO standard defines the minimum performance parameters for a hose. A design engineer seeking a hose, suitable for their project, can view the impulse test parameters associated with these standards and the number of fatigue cycles claimed. Ahead of the curve Another increasingly significant factor in choosing a braided hydraulic hose explains Pozzi, is the bend radius. Unfortunately, he says hose selection is often an afterthought: “Today’s design focus for off-highway and construction vehicles centres on size and weight, without compromising power or performance. A more compact, lighter machine will yield lower fuel consumption: a factor even more pertinent in the current inflationary cost climate.” However, Pozzi adds that while Long fatigue life and low bending radius: Meeting the need for braided hydraulic hoses There are several individual prerequisites when it comes to selecting a braided hydraulic hose, including working pressure, fatigue life, bending radius, abrasion resistance, construction integrity, corrosion resistance, chemical/fluid compatibility, temperature resistance and flexibility. H&P takes a closer look.
www.hpmag.co.uk HYDRAULICS & PNEUMATICS June 2023 21 designing a compact machine makes clear economic and environmental sense, the need subsequently arises to source a hydraulic hose with a low bend radius in order to be able to install in tight and confined spaces. Although he says engineers should, of course, consider the hose at the time of system design, it is now possible to source a robust, long-life braided hydraulic hose that also offers low bending radius. In turn, machine designers can create more compact units. Covering all bases Beyond long, quantifiable fatigue life and low bending radius, Pozzi comments that OEMs should also seek out a hose with high levels of abrasion resistance, as in many applications it is impossible to avoid contact with other machine elements: “Look for a manufacturer able to offer a range of different cover compounds. If the application is particularly challenging, some of the more advanced cover compounds available today can offer up to several hundred times more abrasion resistance than a hose with a standard rubber cover.” Another important point he makes, is that the selected hose will require validation with the fittings: “Only hoses with approved fittings will provide a safe and reliable assembly. Again, a reputable supplier will be able to offer expert advice.” Further factors influencing hose selection decisions include fluid compatibility. Here, Pozzi says to try and source a hose that is not only highly The one touch push-in con昀guration allows instant tubing connection. Made from NSF & ACS approved nontoxic materials, the smaller 昀ttings feature wider working pressure & temperature ranges for maximum versatility. Available in metric & imperial. For water, food, air, vacuum, liquids, and selected gases. Call Tom Parker Ltd, or request a brochure. Fluid昀t is perfect for water, food & air tube connections Connect & disconnect quickly, easily & reliably & 01772 255109 sales@tom-parker.co.uk REQUEST A BROCHURE cdc1@tom-parker.co.uk suitable for conventional mineral-based hydraulic oils, but also the latest environmentally friendly biodegradable oils. Pillar of support Of course, finding the ideal hose for a specific application is one thing explains Pozzi, but will it come with the required levels of support? It is easy to treat a hydraulic hose as a commodity item, purchased from a catalogue or website, but this will likely come without customer or engineering back-up. A far wiser strategy he says, is to buy from a reputable manufacturer, particularly one that can demonstrate its credentials in R&D investment, engineering innovation and worldwide laboratory resources. Seek out a supplier with global customer and technical support, perhaps even one prepared to develop, manufacture, test and approve a hose (in one size) for a specific application. Not every hose manufacturer has the structure and flexibility to offer such a comprehensive service. Choosing a supplier that works to international standards in production, quality and testing, is another clear benefit in support of hose reliability and safety. A leading hose manufacturer will likely have representatives from its engineering team on the steering committees of standards development agencies. As a further point of note, he highlights that you should always partner with a supplier that can demonstrate continuous improvement and regular investment in the latest hose manufacturing technologies.
HYDRAULICS 22 HYDRAULICS & PNEUMATICS June 2023 www.hpmag.co.uk When Rapid Solutions, the global provider of electrical, instrumentation, hydraulic and mechanical engineering services required some dedicated pump training for staff working on a project in Baku, Azerbaijan, the BPMA was quick to act. With local engineers already booked on to the maintenance project, flying them to the UK was not an option, and the e-learning offering did not quite provide the required content. However, on understanding the importance of providing the correct training modules ahead of the project work being undertaken, a bespoke training course was created, and then delivered by a BPMA lecturer in Baku. Specific to the eventual work being carried out, the specially configured course drew on elements contained in the BPMA’s established Pump Fundamentals, Testing and Systems, and Pump Repair courses, whilst also covering the presence and implications of viscosity on the behaviour and performance of rotodynamic machines, along with any system pipe losses. The training included modules that covered the classification and specification of machines for API 610 and 685. Details of the design changes that are expected in API compared to standard industrial and utility pumps were addressed, outlining where the design is more robust, whilst being able to maintain dimensional standards. Additionally, the importance and impact of critical machine clearances, how to maintain the clearances and the opportunities with new non-metallic materials to reduce the clearances and recover the efficiency and performance of the machines were also included. The course was designed and formatted inside two weeks, to accommodate the client’s requirement of commencing site work by the 1st May, with an added level of complexity caused by the staging of the Azerbaijan Formula 1 Grand Prix over the weekend of 28th30th April in Baku. Full details on the full programme of training courses offered by the BPMA can be found on its website: https://www.bpma.org.uk Framo orders FPSO-bound coolers Marine and offshore pumping system supplier Framo has contracted Hydroniq Coolers to deliver tube coolers for use in Framo’s hydraulic pump units that will be supplied to four newbuild FPSOs (floating, production, offloading and storage vessels). Under the contract, Hydroniq Coolers will supply eight large tube coolers – two for each of the four FPSO-bound hydraulic pump units. The coolers will be integrated with Framo’s pump skids and utilised to cool down the oil in the hydraulic pumps. Alfa Laval-owned Framo will supply the hydraulic pump skids to four undisclosed FPSO projects. Lars Elling Gloppholm, aftermarket sales manager at Hydroniq Coolers, commented: “We are delivering our standardised tube coolers that are certified for offshore use, with necessary documentation, test and certification requirements. We have extensive experience from supplying oil coolers for lube oils, hydraulic oils and thermal oils, and we look forward to supporting Framo on these projects.” Hydroniq Coolers will manufacture and assemble the eight tube coolers at the company’s headquarter at Ellingsøy outside Ålesund, Norway, and deliver them to the Framo Fusa manufacturing plant for marine pumping systems, located southeast of Bergen, Norway. Hydroniq Coolers has specialised its production of heat exchangers to enable customised solutions based on standard heat exchanger models. The company offers more than 200 standard models of shell and tube heat exchangers with cooling surfaces from 0.2 to 350 square metres. BPMA delivers bespoke pump training in Baku
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