Drives&Controls AUTOMATION FOR MANUFACTURING INSIDE Compact robots for small parts handling Oriental Motor presents powerful solutions for confined spaces Turn to pages 2 and 9 to find out more MARCH 2026 www.drivesncontrols.com FOOD AND BEVERAGE: How automation is helping to ensure food hygiene BEARINGS, BELTS & CHAINS: Which is a better for lubricating bearings: oil or grease? SAFETY AND SECURITY: Five tips to prepare for the EU’s Machinery Regulation
Electric grippers from the EH series by Oriental Motor enable robots to handle sensitive workpieces safely. The grippers are now also available in a three-finger version, allowing even complex objects to be picked up and moved with high precision. Until now, the EH series electric grippers were only available in the standard two-finger version. Oriental Motor (Europe) GmbH now also supplies the grippers in a 3-finger version: this model even allows complex, round and cylindrical workpieces to be gripped. The gripper can grasp objects with outer diameters between 2 mm and 24 mm and inner diameters from 14 mm to 36 mm, achieving a maximum gripping force of 50 N. With the help of electric grippers, robots can move objects with great precision, as they are driven by AZ stepper motors from Oriental Motor. The steppers have a battery-free absolute sensor, which ensures very accurate positioning of the gripper arm or end effector. In addition, Oriental Motor has integrated a special rack and pinion mechanism into the grippers, which allows for very sensitive handling of workpieces. Oriental Motor offers various mounting flanges for connecting the electric grippers to industrial robots. For more information, please visit: Oriental Motor UK +44 1256 347090 info@oriental-motor.co.uk www.orientalmotor.eu/uk Human-like hands The new 3-finger gripper moves even complex objects with precision and sensitivity
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 2026 NEXT ISSUE The April issue of Drives & Controls will contain a feature on machine vision, a section devoted to developments in conveyors and material-handling, and a look at what’s been happening in the machine-building sector. UPDATE 12 Comment 13 Back to Basics 45 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 34 24 22 5 48 DRIVES & CONTROLS MARCH 2026 Vol 42 No 3 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. 14 Technology Cutting-edge innovations in motion, power transmission, controls and related technologies. 22 Controllers Many factories still rely on fragmented, multi-controller architectures that create delays, inconsistencies and costly inefficiencies. An automation expert explains how next-generation single-controller systems are redefining what’s possible, and delivering multiple benefits. 24 Variable-Speed Drives The printer that produces Drives & Controls has slashed the annual energy bill for its dry waste extraction system by 62%. It has achieved this through a combination of measures, including replacing some of its fans and their motors, and introducing VSDs. 26 Food and Beverage We look at how hygienic design principles are being applied in food processing environments, and the vital role that automation plays in reducing the risks of food contamination. Plus sausage slicers that incorporate highspeed networking, and two ways that automation technologies are helping dairies to run more efficiently. 36 Bearings, Belts and Chains Advice on how to choose between using grease or oil as a lubricant for bearings. Plus a look at some of the techniques available for creating joints in fabric belts, with a summary of the advantages and disadvantages of each. 40 Safety and Security Tips on how to prepare the EU’s upcoming Machinery Regulation and Cyber Resilience Act. Plus a report on the how the global market for industrial safety technologies is expected to fare over the coming years, and news of a campaign designed to ensure switchboard safety. 42 45 Average net circulation January to December 2024 Subscribe for your FREE copy now 20,514 14 47
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NEWS n 5 FOUR COMPANIES – ABB, Phoenix Contact, WSCAD and the enclosure specialist, häwa – have demonstrated what they claim is the world’s control cabinet designed directly from a digital circuit diagram using AI (artificial intelligence). At the recent SPS show in Germany they showed WSCAD’s Electrix AI 2026 design software generating a productionready control cabinet layout automatically from a circuit diagram. This layout was then implemented in a real cabinet. Visitors were shown how a complete cabinet assembly can be created digitally from planning data within a few minutes. Then, on häwa’s stand, they could view a 3D model of the cabinet and experience the final design virtually via VR goggles. The partners are hailing the development as “a milestone for control cabinet building” and say that the technology will allow tasks that previously took many hours to be automated rapidly with the help of AI – cutting production times and workloads. WSCAD claims that it is the first CAD supplier worldwide to integrate foundation models and LLMs (large language models) into an E-CAD system. It uses these models to detect patterns, understand electrotechnical relationships and learn from user actions. While traditional CAD software operates according to fixed rules (using if-then logic), Electrix AI thinks ahead. It analyses circuit diagrams, and then generates complete control cabinet layouts including placement, wiring, labelling and thermal calculations. A further attraction is that it operates locally (not on www.drivesncontrols.com March 2026 the cloud), keeping knowledge within a company. At SPS, the software was shown converting paper, PDF and DWG circuit diagrams automatically into editable WSCAD projects. The AI recognises symbols, assigns components, retrieves component data, identifies connections, and reconstructs the entire circuit diagram. Proprietary AI models in the WSCAD software analyse the diagrams, identify components, select mounting panels and DIN rails, and position the devices. The models learn from a user’s previous projects and can generate a production-ready layout in seconds. It is claimed to improve its results with every project. Previously, panel-builders and maintenance technicians have had to work with static PDFs or binders full of diagrams. WSCAD’s Cabinet AR App gives them direct access to circuit diagram pages, 3D views, and spare parts data via a QR code. Any changes made via a redlining function are transferred automatically back into the documentation, ensuring that a digital twin of the project remains up-to-date at all times. “An AI-generated control cabinet that connects every process step from engineering data to real-world assembly is a genuine milestone,” says WSCAD’s partner manager, Christian Rathgeber. “We are demonstrating live how future projects can be realised with fewer errors, greater speed and improved resource efficiency.” “The future of control cabinet building lies in the intelligent and efficient combination of data from engineering, with manual and automated production,” adds Sophia Hardeck, director of product marketing for industrial cabinet systems at Phoenix Contact, which oversaw the production of the physical cabinet at SPS. “The combination of WSCAD’s engineering expertise and our know-how in detailed planning and production creates real added value for our customers.” In a second exhibit at SPS, WSCAD displayed a Schneider Electric cabinet containing its new TeSys Deca Snap-In motor management system, demonstrating how digital product data from a Schneider configurator at wscaduniverse.com and calculations from Schneider’s ProClima software (which calculates and configures climate control and airflows inside a cabinet) integrate into the AI-driven planning process. The Schneider system uses Weidmüller’s Snap In connection technology, said to result in time savings of up to 75% compared to screw connections. www.wscad.com/en AI turns circuit diagrams into control cabinet designs in seconds Above: The SPS demonstration showed how a control cabinet can be created automatically from a digital circuit diagram, powered by AI. Right: WSCAD’s software uses AI to analyse circuit diagrams, identify components, select mounting panels and DIN rails, and position devices.
March 2026 www.drivesncontrols.com 6 THE VALUE OF THE UK’S MANUFACTURING output increased by £21bn in 2025, despite a workforce reduction of more than 36,000 people and 2,500 fewer manufacturers, according to an analysis of ONS data by FourJaw Manufacturing Analytics. It reports that 2025 marked the fifth consecutive year of growth in output and productivity for UK manufacturing. The total value of factory production in 2025 (£55bn) was 27.8% higher in real terms than it was in 2020. According to FourJaw’s analysis, factory output grew by 3.4% to nearly £639bn last year, driven by output and productivity gains in aerospace (£6.7bn), chemicals and pharmaceuticals (£4.2bn), metals and machinery (£2.6bn), and computers and electrical products (£1.9bn). After adjusting for inflation, FourJaw estimates that UK manufacturing productivity was £8.9bn (1.4%) higher in 2025 than in 2024. The average output per manufacturing employee rose by 2.9% (around £7,000) in real terms year-on-year. Automotive manufacturing, including motor vehicles and trailers, declined by nearly £5.4bn (7%) in 2025. The industry faced challenges including reduced domestic demand, export tariffs, trade uncertainty and disruption of Jaguar Land Rover’s operations by a major cyberattack. “UK manufacturing is proving that resilience and innovation are winning the day,”comments Chris Iveson, CEO of FourJaw Manufacturing Analytics. “To deliver £21bn more in output is a phenomenal achievement given current workforce challenges and points to a sector successfully embracing continuous improvement and productivity-enhancing technology. “The resurgence of UK manufacturing is down to smart, efficient production and maximising the output of every machine and every employee,” he adds. p Optimism among UK manufacturers hit a 17-month high in January, as output, new orders and exports all accelerated, according to the latest S&P Purchasing Managers’ Index analysis. The PMI rose to 51.8 (up from 50.6 in December). Production climbed for the fourth month in a row, and at its joint-quickest rate since September 2024. The expansion was driven mainly by larger manufacturers, with SME output falling for the third month in a row. Employment levels in the sector also fell. Some 58% of UK manufacturers expect their output to rise in the next 12 months. p PCE Automation is reported to be making up to to 60 redundances at its Beccles headquarters in Suffolk. The cutbacks follow the closure of its Lutterworth, Leicestershire, branch in January. PCE also has operations in Lincolnshire and Ireland. p Germany’s Hoerbiger group is acquiring the precision motion and positioning technologies business Physik Instrumente (PI) for an undisclosed sum. PI will form the basis for a new positioning division in Hoerbiger, and will operate as a standalone business, keeping its name. Previously familyowned, PI has 1,900 employees and nine production sites worldwide. Its portfolio includes piezoelectric drives, linear actuators and rotary tables. p An initiative to accelerate digital transformation for manufacturing SMEs across the island of Ireland has been launched, backed by the Advanced Manufacturing Innovation Centre (Amic) at Queens University Belfast and Irish Manufacturing Research. The cross-border initiative, called Datum, will provide a practical path to help SME manufacturers to move from digital readiness to real implementation. https://datumdigital.org p The US motion control specialist Aerotech is expanding operations at its Fürth site in Germany. In addition to a previously announced laser laboratory, it also plans to assemble control components there, focussing initially on its XA4 series servodrives and motion controls. The aim is to achieve greater production flexibility, help stabilise supply chains, and increase product availability in Europe. Aerotech has a longterm strategy to develop its European operations. p DigiKey, the global distributor of electronic and automation products, added more than 108,000 new in-stock products for same-day shipping in 2025. In total, it added more than 1.6 million new items to its system, as well as 364 new suppliers. In the fourth quarter alone, DigiKey added 25,653 new stocking parts and 89 suppliers. NEWS BRIEFS The UK manufacturing sector raised its output and productivity for the fifth consecutive year in 2025, despite fewer workers (Source: Office for National Statistics and FourJaw Manufacturing Analytics) n NEWS UK manufacturing output soared by £21bn in 2025 despite industry cutbacks SCHNEIDER ELECTRIC HAS appointed David Hall as president of its UK and Ireland (UK&I) region, succeeding Kelly Becker who has held the position for the past five years. Hall will spearhead the strategic growth in a region that Schneider regards as being pivotal to its ambitions in Europe. He will report to Laurent Bataille, executive vicepresident of Europe operations. Hall and Becker will work together to ensure a smooth transition. Schneider is announcing Becker’s next role separately. “Kelly leaves a lasting legacy of transformational impact across the UK and Ireland and more widely across Europe, and we are deeply grateful,” says Bataille. Hall, an electrical and electronics engineer, has held senior positions at Schneider Electric for nine years, most recently as global senior vice-president for industrial automation strategic accounts. Before this, he led the UK&I Power Systems business, overseeing the shift to renewable generation, EVs, electric rail and shore-to-ship electric charging. Before joining Schneider, Hall held senior roles in energy and utility companies including Engie, SSE, E.ON, Severn Trent Water, AES and RWE npower. Schneider names David Hall as president of UK & I
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n NEWS THE MANUFACTURING TECHNOLOGY CENTRE (MTC) has released a White Paper arguing that the UK should learn lessons from abroad on how to accelerate its adoption of robots and autonomous systems (RAS) to unlock economic and industrial benefits, and to boost productivity. It suggests a path to speed up adoption of these technologies, build a strong base of RAS businesses to boost investor confidence, align regional priorities, and lay the groundwork for a coordinated national action plan. Called Global Robotics Clusters Study: A Blueprint to Accelerate the UK Adoption of Robotics & Autonomous Systems, the paper examines how high-impact robotics clusters have been created in other parts of the world – including Denmark, Germany, Singapore and the US. The report goes behind the scenes of these hubs to uncover how they work. It explores how long-term investment, shared testbeds, and targeted adoption programmes are helping businesses to move from pilot projects to deployed systems. It highlights how robotics clusters are not just collections of companies, but carefully nurtured systems that connect industry, academia, government, and investors around a shared mission. The report contrasts the success of the overseas clusters with the situation in the UK, highlighting some of the barriers that are slowing the transition from research to widespread industrial use. These include: n the relatively low number of robots in the UK; n slow uptake among SMEs; n skills shortages; n unclear routes to market; n fragmented support; and n short funding cycles. By comparing these issues with global best practice, the report identifies where the UK’s efforts are diverging, and outlines a coordinated national and regional blueprint that, it argues, could close the gaps and drive faster adoption. The report calls for a UK-wide action plan to align government activity in areas such as adoption, standards and technology translation. Regionally, it recommends establishing a small number of robotics clusters that would act as vendor-neutral proving grounds, offering shared testbeds and early-stage procurement routes to help businesses deploy mature technologies more quickly. “What stands out from the most successful global clusters is that businesses thrive when the pathway to adoption is simple, proven and properly supported,” says the MTC’s chief automation officer, Mike Wilson. “Too often in the UK, companies are left to navigate fragmented advice and short-term initiatives, which slows momentum and adds risk. “This blueprint is about giving businesses a clearer route: consistent support, access to trusted technology partners, and environments where solutions can be tested before committing to capital,” he adds. “This shift will give organisations the confidence to adopt robotics, helping to shorten adoption cycles, reduce costs and make automation a realistic step for businesses of every size while improving productivity across the UK.” www.the-mtc.org/insights/global-roboticsclusters-study-blueprint-accelerate-ukadoption-robotics-autonomous March 2026 www.drivesncontrols.com 8 MTC: UK should learn lessons from abroad to boost its use of robots The MTC report argues that the UK could learn from the Odense Robotics hub in Denmark, which has more than 300 member companies Yasa, the UK designer and manufacturer of axial-flux motors owned by Mercedes-Benz, has appointed Andy Morley as its chief commercial officer. He is returning to Yasa after nine years with the gearbox manufacturer Hewland, where he was managing director for the past five years. Morley previously worked at Yasa from 2013 to 2016, playing a key role in its early development. His appointment strengthens Yasa’s leadership as it expands its powertrain systems portfolio and accelerates growth with third-party customers. HepcoMotion has appointed David Steele as its production director. He will oversee all aspects of production both at its Tiverton, Devon, headquarters and at Hepco Europe in Veghel in The Netherlands. He will also support the development of apprentices and emerging leaders in the company. Steele joined Hepco as an apprentice 26 years ago, and has held a variety of roles in the company. Nearly a third of Hepco’s management team began their careers as apprentices with the company. EVENTS MACH 2026 20–24 April, 2026 NEC, Birmingham The manufacturing technologies event, organised by the Manufacturing Technologies Association (MTA), has sold more than 90% of its floorspace. More than 30,000 members of the UK manufacturing community are expected to attend. Spread across five halls will be a series of interactive Knowledge Hubs providing visitors with impartial advice. One Hub will be dedicated to Automation and Robotics; another will focus on Data and AI. https://www.machexhibition.com 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. 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 CWIEME Berlin / EEMODS 26 19-21 May, 2026 Berlin, Germany The world’s largest coil-winding and electrical manufacturing exhibition will host the biennial EEMODS (energy efficiency in motor-driven systems) conference for the first time in 2026. The conference is expected to attract experts and policymakers from around the world to discuss efficiency and regulatory issues regarding motors, pumps and compressors. 2026 also marks CWIEME Berlin’s 30th anniversary. https://berlin.cwiemeevents.com/home Smart Manufacturing Week 2026 3–4 June, 2026 NEC, Birmingham Smart Manufacturing Week (SMW), described as the UK’s biggest festival of advanced manufacturing and engineering, will have a fresh look and new features for 2026. It includes Drives & Controls, Smart Factory Expo, Maintec, Design & Engineering Expo, the Manufacturing Digitalisation Summit and The Manufacturer Top 100 Awards. New attractions for 2026 include fighting robots, extra showfloor theatres, and Future Stage – a window into the future of industry. www.smartmanufacturingweek.com Hillhead 2026 23-25 June, 2026 Hillhead Quarry, Buxton, Derbyshire The UK’s largest quarrying, construction and recycling equipment exhibition takes place every two years in a working Derbyshire quarry. It includes live demonstrations of quarrying equipment. Across its three days, the show is expected to attract around 600 exhibitors and nearly 20,000 visitors. Hillhead 2026 is on course to be the largest event in the show’s 44-year history. www.hillhead.com
While classic industrial robots are often designed for larger workpieces and open work areas, they are only suitable to a limited extent for handling small parts in confined environments. The new compact robots in Oriental Motor's OVR series fill this gap: they are available as SCARA and palletising robots. With the MRCU controller, the robots can be programmed and integrated into the application without any prior knowledge. The new small robots in the OVR series are based on powerful standard components from Oriental Motor. At the heart of the robots is a highly efficient AZ stepper motor with a battery-free mechanical absolute encoder. This eliminates the need for additional external sensors, significantly reducing the amount of cabling required. "Oriental Motor's strength lies in its high flexibility in automation and robotisation," says Daniel Schönfelder, Manager Sales Strategic Department at Oriental Motor. "With the OVR series, we are opening up new possibilities for our customers: a compact robot solution based on proven AZ drive technology that is consistently simple yet delivers maximum precision and performance." The robots in the OVR3 and OVR4 series are available in various designs: The OVR3 SCARA models combine a particularly flat design with high accuracy and flexible variants up to 360° rotation and a payload of 10 kg. The OVR4 robots with parallel kinematics offer stable horizontal transport and are ideal for palletising tasks up to 5 kg. In addition, all drives consist of standard components that can be replaced by the customer themselves thanks to the simple structure of the OVR series. All robots can be programmed with Oriental Motor's MRCU controller and MRC Studio software without any prior knowledge – up to eight axes are supported. The controller is designed for AZ series drives and automatically performs complex kinematic calculations. In addition to applications for the OVR4 palletising and OVR3 SCARA robots, the controller also supports other applications such as delta robots, gantry systems and X-Y-Z portals. The OVR robots can be expanded with a variety of end effectors and gear solutions from Oriental Motor's product range. As an additional component, the company is providing an electric column unit (EL series), which extends the robot's degree of freedom with strokes of up to 300 mm in the Z direction. The electric column unit allows precise height adjustment of the OVR robot and can be seamlessly integrated into the MRCU control system. The OVR series from Oriental Motor thus offers a comprehensive solution for compact, precise and flexible automation tasks. From simple integration to intuitive programming, the robots can be quickly and costeffectively integrated into a wide variety of production environments. The series opens up new possibilities for companies to economically automate even confined workspaces without compromising on precision or performance. ADVERTORIAL For more information, please visit: Oriental Motor UK +44 1256 347090 info@oriental-motor.co.uk www.orientalmotor.eu/uk Compact robots for small parts handling Oriental Motor presents powerful solutions for confined spaces
n NEWS March 2026 www.drivesncontrols.com 10 AROUND ONE IN FIVE UK manufacturers have reduced or stopped exporting to the US as a result of the trade tariffs introduced by President Donald Trump in the past year. A survey of 119 UK manufacturers has also revealed that 23% have shifted their export focus to non-US markets, such as the Asia-Pacific region. The figures come from new Make UK / DHL Express study –International Trade Trends 2026: UK Manufacturers in Global Markets – which reports that the US remains a key export destination for British manufacturers, with six out of ten currently trading with the US. However, the impacts of tariffs are being felt. One in four manufacturers are linking balance sheet losses to the added costs arising from the US tariffs. And nearly a quarter reveal that they accelerated their exports to the US in early 2025 to try to beat the anticipated increases. As well as the one in five manufacturers that have already curbed their exports to the US, a further 16% say they are planning to do so. But a quarter of exporters haven’t changed their US trade plans at all, highlighting the varied impact across the sector. Beyond the US, the research highlights wider structural barriers to international trade. Around 80% of UK manufacturers have been hit by some form of tariff. And 58% cite tariffs and trade rules, including rules of origin, as being a major obstacle to exporting. Half also point to customs delays as being a significant challenge, with businesses facing extra paperwork, inconsistent processes and a lack of guidance. Turning to the EU, more than half of manufacturers report that either that their trade with the EU is now higher than it was before Brexit in 2020 (42%) or that it A fifth of UK manufacturers have curbed their exports to the US LESS THAN 100 HUMANOID robot developers will progress beyond experimenting with proof-of-concepts by 2028, with 20 or fewer using them in real manufacturing and supply chain applications, according to the business and technology insights company, Gartner. It suggests that“the hype surrounding humanoid robots is outpacing their readiness for large-scale deployment,”and predicts that by 2028 most production deployments of humanoid robots will be limited to tightly controlled environments, rather than dynamic, high-throughput operations. “The promise of humanoid robots is compelling, but the reality is that the technology remains immature and far from meeting expectations for versatility and cost-effectiveness,” says Abdil Tunca, a senior principal analyst in Gartner’s Supply Chain practice. “CSCOs (chief supply chain officers) must carefully evaluate readiness and avoid overcommitting resources to solutions that cannot yet deliver on their potential.” Although humanoid robots that replicate human shapes and movements, and incorporate heads, arms and legs, might offer some advantages, Gartner suggests that alternative designs – such as hybrid robots equipped with wheels or sensors in unconventional placements – may provide superior performance and adaptability. Humanoid robots, it argues, face significant barriers to adoption, including: n Technological limitations Current models lack the dexterity, intelligence and adaptability needed for complex, unstructured environments such as mixedSKU picking, trailer unloading or exception handling in high-velocity warehouses. n Integration complexity Compatibility with existing systems and workflows remains a challenge. n High costs Substantial upfront investments and maintenance costs need to be weighed against uncertain returns. With the current technology and costs, humanoids cost many times more than task-specific robots, while delivering lower throughput and uptime. n Energy constraints Limited battery life restricts operational time for highmobility tasks. Unlike humanoids, hybrid robots are optimised for flexibility without being constrained by a human-like design. For example, a robot with wheels and a telescopic arm can move boxes, pick cases, scan inventory and perform inspections, usually with higher uptime and using less energy than a humanoid attempting the same tasks. Such robots can incorporate functions that enhance their efficiency and durability, making them better suited for dynamic environments. is now similar to pre-2020 levels (15%). But 19% report that trade with the EU has fallen and stayed lower, while 9% say that Brexit has had no impact at all. A third of firms report that their trade with non-EU markets has increased since 2020. UK manufacturers remain cautiously optimistic. Almost eight in ten say they are confident in the UK’s trade prospects, signalling a continuing ambition to compete globally, even in a fragmented and uncertain trading environment. The manufacturers also believe that Britain still has a strong manufacturing reputation globally, with 85% of them saying they that emphasise the “Britishness” of their products or business. “UK manufacturers’ ability to trade goods and services globally is under growing strain from a combination of higher tariffs, geopolitical pressures, and the need to adapt to a rapidly changing global environment,”comments Make UK’s CEO, Stephen Phipson. “Tariffs and trade friction in global markets are creating uncertainty and disrupting long-standing customer and supply chains. Many businesses are responding by diversifying exports, adjusting supply chains, or scaling back activity to manage rising costs and delays. “Despite these challenges,” he adds, “manufacturers remain ambitious and outward-looking. We fully support the Government’s strategy to adopt a trade approach that strengthens the UK’s global competitiveness and supports more seamless and certain trading relations with our long-term partners.” Reported changes in trade with the EU since Brexit (percentage of respondents) Source: Make UK/DHL Many humanoids will stall at pilot stage, with hybrid robots benefitting
NEWS n ABB IS NOW OFFERING ITS magnet-free synchronous reluctance motors in IE6 efficiency versions as standard in ratings from 100kW to 450kW, promising a 76% improvement in energy savings over IE4 machines. The IE6 Hyper-Efficiency motors, in frame sizes 280 and 315, operate at speeds of 3,600 rpm. In 2024, ABB claimed to be the world’s first manufacturer to be offering magnet‑free IE6 SynRM motors. It has now made IE6 ratings its mainstream option, ahead of the anticipated IE6 Hyper‑Efficiency standard. ABB says that over a motor’s typical 20-year service life, the savings of upgrading from IE4 to IE6, will amount to €51,200 – with a 92,200kg reduction in CO2 emissions. This represents an additional 76% improvement over IE4 and can result in ROIs as short as eight months. Viewed another way, the savings are equivalent to removing 21.5 petrol-powered passenger vehicles from the roads for a year, according to ABB. The calculations are based on a 110kW application running for 8,760 hours a year at 75% power, with energy assumed to cost €0.2/kWh. The IE6 SynRM motors have been designed with sustainability in mind. They contain no permanent magnets or rare-earth materials, are 98% recyclable, and have Environmental Product Declarations (ISO 14025 Type III). They are the same size as standard induction motors, allowing simple drop‑in replacements for fans, pumps, compressors and other applications. “The IEA’s World Energy Outlook 2025 reinforces energy efficiency as one of the fastest, and most cost‑effective levers for industrial productivity and decarbonisation,” says Stefan Floeck, president of ABB’s IEC LV Motors business. “In line with our Engineered to Outrun philosophy, the IE6 Hyper‑Efficiency SynRM motors are designed exactly for this moment. Customers can now access world‑leading efficiency across a wider power range, often achieving payback in just months, while moving closer to their sustainability targets.” ABB makes IE6 efficiency standard for its SynRM motors, slashing energy use by 76% ABB’s IE6 Hyper-Efficiency SynRM motors are available in ratings from 110–450kW Al v lways impro give y ving to more plu you us va wit LA ria th AR up to 120% higher th n flex PERFORMANCE O gths OF T ants, enables machine design h new motor sizes, active leng RGE PRODUCT RANGE ion. han previous gener + xibility. and winding rat TMB technology access is reduced with TM RS COST OF OWNER applications. ible for many MB+ making direct drive hig SHIP on controllers and to moti ETEL is 100% dedicated gh-end motion system products Our w ology. o direct drive techn provides a portfolio to meet yo ide range of linear and torque m ur needs. motors, position and ETEL Torque Motors ar HEIDENHA buted in the UK by re distri E T: 01444 2477 • AIN GB Limited sales@heidenhain.co.uk • 711 www.etel.ch
OPEN SDA: A WAY TO BREAK FREE FROM PROPRIETARY LOCK-INS? Schneider Electric has been laying out its vision of a form of industrial automation that frees customers from being locked into closed, proprietary architectures from a single vendor. At an recent event in London, it argued that such systems are costing manufacturers dearly as a result of factors such as increased downtime, operating inefficiencies and compliance issues. Research conducted for Schneider last year by Omdia concluded that closed automation systems are costing mid-sized manufacturers around £8m a year, while for larger enterprises the bill could be £33m. The study suggested that these systems add 4.5% of the average turnover of a manufacturing enterprise – with the total cost to industry amounting to around £8.4bn. Smaller companies are bearing the brunt, losing up to 25% of their revenues through a reliance on closed proprietary automation systems, the study estimated. The answer, according to Schneider, is to adopt an open form of softwaredefined automation (SDA). It differentiates this from other forms of SDA, promoted by some vendors, which simply separate control logic from hardware. The open version of SDA is based on open standards and protocols, allowing devices and systems from different manufacturers to integrate and interoperate with each other. Neil Smith, president of Schneider’s global CPG (consumer packaged goods) business, likens the open approach to the way recorded music can now be played on a variety of different platforms, from CDs to streaming services, allowing users to access playlists from anywhere and on different devices. Open SDA, he argues, “allows manufacturers to use the best tools for their specific business challenges, integrate new capabilities quickly, and evolve at ‘software speed’, rather than being bound by legacy systems.” Schneider’s vision of open SDA is being backed by a non-profit association, called universalautomation.org, which was established in 2021 by nine founding members including Schneider, Yokogawa and Intel. It now has more than 100 members including suppliers (such as Phoenix Contact, Honeywell and Omron) and end-users (including Nestlé and Hyundai). So far, universalautomation.org has not attracted any of the other big players in the industrial automation world, which would give added weight to the concept. But Schneider is building up a solid base of users, ranging from an Italian coffee roasting business called Zicaffe (which is using open SDA to give it better control of its processes and materials) to the city of Conroe in Texas, which is using the technology to keep water flowing to its 115,000 residents. It reports that open SDA has delivered a 70% improvement in engineering efficiency, 80% faster recovery times after system faults, and a reduction of time spent on manual data collection of more than 50 hours per week. Schneider may be taking the lead in the campaign for open softwaredefined automation, but if it can demonstrate that businesses that adopt the idea are experiencing the benefits that it claims, it could be onto a winner – and the other major players may have to adopt a similar approach. Tony Sacks, Editor n COMMENT pot en ti a l o f y o Are you inve our workforce? esting in the mproves Comp Creates an Adaptable a ncreases Productivi mproves Safe W Industry recognised co I I a I any Reputation nd Flexible Workforce y and Performance orking Practices ourses from the BFPA W t a p Please call 01608 6479 00 or bfpa.co.u RITISH FLUID POW B email enquiries@bfpa.co.uk k/training WER ASSOCIATION / Drives&Controls Follow us on LinkedIn @Drives & Controls Join us on Facebook Drives & Controls Follow us on X @DrivesnControls For the latest news visit www.drivesncontrols.com Drives& Controls
Drives&Controls & BACK TO BASICS n SPONSORED BY Data centres should prevent harmonics at their source Data centres are hotbeds of harmonics. While there are various ways of mitigating them, stopping them at the source can help to enhance reliability and reduce the risk of downtime, as Scott Birchall, HVACR global application engineer at ABB, explains. Data centres are incredibly power-hungry, and the emergence of AI means that facilities and the server racks that fill them have become larger and more densely packed to handle the trillions of computations required every second. This has led to vast increases in power demand. The power supplied must also be clean and high quality, with the lowest possible harmonic content. Any data centre downtime can incur huge fines and reputational damage and must therefore be avoided at all costs. And since data centres are essentially packed from floor to ceiling with harmonic-generating electrical devices, effective harmonic mitigation is essential. One way of addressing the high harmonic content is by oversizing equipment such as transformers and back-up generators. If you’re using a six-pulse drive in a data centre – as opposed to an ultra-low harmonic (ULH) drive – then you’ll typically have to oversize your generator by around 50%. As well as sending costs skyrocketing, using oversized equipment reduces system efficiency. In addition, it not only potentially takes up precious space that could otherwise be used for more computing equipment, but also generates more heat. Harmonic filters are another option, and are typically used on EC fan systems or drive systems with no built-in mitigation. However, filters create additional power requirements, and are also an additional point of failure. If your filter goes down then so too does your mitigation, which can lead to major issues across the facility. Installing filters as and when you need them means that you are already risking downtime. Conversely, if you use ULH drives instead, this prevents the problem at the source, so that even if one drive fails, the remaining drives will still continue to provide mitigation – more than enough to prevent any downtime. For more information about ABB’s ultra-low harmonic drives, search for “ABB ULH”. ABB will be showing its ULH drives at Data Centre World, from 4-5 March, at Excel, London.
n TECHNOLOGY March 2026 www.drivesncontrols.com 14 SCHNEIDER ELECTRIC CLAIMS to have developed industry’s first open, software-defined DCS (distributed control system). Called EcoStruxure Foxboro Software Defined Automation (SDA), the platform is said to deliver openness, embedded cybersecurity, and real-time intelligence, and will modernise operations “without compromise”. Schneider says it will offer flexibility, scalability and cost efficiency, without sacrificing reliability. Developed in response to end-user challenges such as ageing systems, rising costs, and the need to do more with less, Foxboro SDA decouples hardware from software to protect existing investments and enable a smooth, lower-risk modernisation path. The result, according to Schneider, is simpler workflows, faster insights and sustainable performance gains. “EcoStruxure Foxboro SDA marks a defining moment for industrial automation,”says Hany Fouda, senior vice-president in Schneider’s Process Automation business. “By embracing openness and software-defined architecture, we’re giving our customers the agility to modernise without compromise, protecting their investments while unlocking future-ready capabilities. This evolution is a strategic enabler for digital transformation.” As the first software-defined DCS, Foxboro SDA enables interoperability, rapid deployment, and fit-forpurpose configurations, while maintaining high availability. It ensures digital continuity by keeping data connected and consistent throughout the plant lifecycle – from design to production and maintenance. According to Schneider, this will enable automated workflows, improved product quality, and easy integration with analytics for smarter, real-time business decisions. Customers will also benefit from future-ready upgrade paths, built-in cybersecurity, and simplified operations that support IT/OT convergence and advanced technologies such as AI and machine learning. Schneider is promising a control system that is “unbounded by hardware, engineered for agility and empowered by data”. Key characteristics of the new system include its: n Open, software-defined architecture Foxboro SDA decouples software from hardware to deliver vendor independence and interoperability, enabling flexible, scalable architectures n Cybersecure and future-ready capabilities The software is built on secure-by-design principles and IEC 624433-3 compliance, delivering a platform that enables IT/OT convergence, AI/ML integration, and autonomous operations for Industry 4.0 and energy transition. n Simpler operations and lower costs Users can lower their CapEx and OpEx, streamline deployment with intuitive tools, and reduce downtime by avoiding obsolescence and enabling predictive maintenance. The importance of open industrial systems was highlighted in a recent Schneider Electric research report with Omdia, which revealed that closed systems were costing mid-sized industrial companies around 7.5% of their annual revenues through downtime, inefficiencies and compliance retrofits. Commenting on the launch of the new system, Craig Resnick, vice-president at the ARC Advisory Group, says that it “marks a major milestone in the evolution of process automation. By decoupling control logic from hardware, Schneider Electric is providing manufacturers with the agility to scale, adapt, and simplify their operations. “This software-defined approach helps to reduce maintenance costs, protect legacy automation investments, and ensure digital continuity throughout the entire plant lifecycle,” he adds. “With cybersecurity built into its core, and a commitment to open, interoperable standards, Foxboro SDA enables manufacturers to modernise at their own pace, accelerate IT and OT convergence, and increase their adoption of next generation technologies, such as AI, edge computing, and autonomous operations.” A US SPECIALIST IN safe controls for robots and mobile machines has launched a SIL3 safety-certified wireless device designed to prevent accidents and increase uptime. Fort Robotics says that its wearable Wireless E-Stop Pro device puts failsafe control in operators’ hands, allowing them to send certified stop commands to machines up to 200m away. Philadelphia-based Fort argues that as industry adopts increasing numbers of mobile and autonomous machines, legacy safety systems such as fixed e-stop buttons are proving to be less effective. “Safety shouldn't be a restraint on productivity, it should be the catalyst for it,” says Fort’s head of product, Amod Damle. “With the Wireless E-Stop Pro, we've eliminated the compromise between risk and throughput. “We are redefining the relationship between human and machine, giving operators the green light to move at full speed and the power to dominate their workflows with total flexibility.” Since Fort Robotics was founded in 2018, it has been awarded 27 patents and has deployed around 12,000 products to a global base of more than 600 customers. https://fortrobotics.com/wireless-e-stop-pro Failsafe wireless e-stop can halt a machine from 200m away ‘First’ open, software‑defined DCS reduces modernisation risks Schneider Electric’s Foxboro SDA platform decouples software from hardware
n TECHNOLOGY March 2026 www.drivesncontrols.com 16 PHOENIX CONTACT HAS ANNOUNCED a new way of tackling the challenge of integrating a variety of signals in small, decentralised control cabinets, and connecting them to higher-level controllers via industrial Ethernet. Even for applications with small numbers of I/Os or low levels of complexity, many companies currently use unnecessarily powerful remote I/O systems, it says. Phoenix Contact’s answer is a remote relay system with flexible channel assignments that is intended to be a cost-effective alternative for small, remote applications. The modular, networkable PLC-Interface Ethernet Gateway system enables space-saving implementations either of new designs, or of extensions to existing PLC-Interface relay systems. Phoenix claims the new approach can cut panel space by up to 65%. The system is designed to optimise simple applications using up to 56 individually configurable I/O channels. The modular, networkable system allows installations to be tailored precisely to the application. It is compatible with common controller software and various communications protocols (including EtherNet/IP, Modbus and Profinet Class C and S2 redundancy), offering a high level of flexibility and intuitive network integration. The system allows flexible channel configuration with digital and analogue inputs and outputs, as well as temperature modules and Ex modules. It is particularly suitable for simple applications with small to medium numbers of channels housed in decentralised control boxes. Digital and analogue signals are recorded reliably, while temperature and analogue values are processed with a 10-bit resolution (in the range 0–1,000). A network module supports multi-protocol connections. Compatibility with existing controller software simplifies integration with the control level, and saves time. Firmware updates will allow functions to be extended, and performance to be optimised. Compatibility with Phoenix’s PLC-Interface relay system enables simple extensions to existing systems, with functions ranging from simple coupling relays, to relay modules with integrated circuit breakers. The system supports a future-proof automation strategy for simple applications. There is a choice of remote I/O options. For example, PROFIsafe modules can be used to implement safety applications without needing a safety controller, using Phoenix’s SafetyBridge technology. For decentralised automation without a control cabinet, you can use I/O modules with a block design. Applications can be extended using digital I/Os, an IO-Link master and IO-Link devices. www.phoenixcontact.co.uk Decentralised relay system can cut panel space by up to 65% FLIR HAS ANNOUNCED A MWIR (mid-wave infrared) thermal imaging technology for continuous monitoring of industrial automation, process control and testing applications. The A6450 Long-Life Cooled MWIR cameras have been designed to overcome existing barriers to using cooled thermal cameras in production environments. “Historically, the timing and cost of maintaining cooled thermal cameras limited their use in production-line applications,” explains Flir’s global director for automation, Matthew Hasty. “With the A6450, we’ve fundamentally changed that equation, delivering long-life cooled MWIR performance that manufacturers can confidently deploy across continuous production processes.” MWIR cameras operate in the 3–5μm wavelength range to detect thermal emissions from objects, differentiating them from SWIR (short-wave, 1–3μm) and LWIR (long-wave, 8–14μm) infrared cameras. MWIR cameras capture heat signatures, making them ideal for applications such as monitoring industrial machinery, where higher temperatures contrast with cooler backgrounds. MWIR cameras also offer superior performance with hotter targets. At the core of the new camera is a MWIR detector paired with a linear cooler, capable of operating lives of up to 27,000 hours. This reduces the need for maintenance. By cutting downtime, service costs and operational risks, Flir says the A6450 will transform cooled MWIR cameras from specialised inspection tools into reliable, long-term automation assets. The camera is aimed at applications where timing is critical. With a 125Hz frame rate, it can capture fast thermal events and subtle temperature variations on moving products, for applications such as nondestructive testing and quality assurance. The camera’s high thermal sensitivity can detect early-stage defects, material inconsistencies or deviations, helping to cut scrap, reworking and downtime. The A6450 camera supports GigE Vision, GenICam and other standard protocols, for easy integration into automation systems. Plug-and-play compatibility with Flir’s Research Studio software allows users to test, tune and validate inspection set-ups before system integration. The new camera offers flexible, highperformance optics. Users can store hundreds of calibration profiles onboard to support multiple products, materials and inspection scenarios. www.flir.com/en-gb/home MWIR cameras tackle barriers to 24/7 monitoring of production lines Phoenix Contact says its remote relay system will “re-invent” automation
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