News

Mills CNC, a machine tool supplier based in Leamington Spa, has chosen to use a laser triangulation sensor from Micro-Epsilon in one of its bespoke machine tool automation cells (SYNERGi) with a primary focus on inspecting large, hot rolled steel railway fishplates.

The triangulation sensor, which is mounted on a Fanuc robot end effector, intricately measures the contours – the ‘bend’ and ‘twist’ – of the fishplates to ensure they are within the required manufacturing tolerances. The automation cell then places the fishplates into a Mynx 5400 to be machined.

One of the fastest growing machine tool companies in the UK, Mills CNC is the sole provider of Doosan Machine Tools within the nation and has machines to suit all the manufacturing sectors including aerospace and defence, power generation, motorsport, oil and gas, medical, automotive and general precision component manufacture. The company’s reputation is built on the quality, reliability and performance of the Doosan machine tools it sells.

Established in 2018, Mills CNC Automation was created to project Mills CNC and its customers businesses forward. Mills CNC saw automation as key to increasing manufacturing productivity and output for all customers, both old and new. The division, which is located at Mills CNC’s Technology Campus facility in Leamington Spa, has two principal specialisms, Industrial Robots and Collaborative Robots. 

Chris Ingham, Controls & Systems Engineer at Mills CNC Automation comments: “At the Technology Campus, we’ve developed a number of automation systems and machine tool demonstrations for our customers to view. We are currently testing and commissioning an automation system for a customer who needs to inspect railway fishplates manufactured by a hot rolling mill. The project began in late 2020 and the inspection system uses a laser triangulation sensor from Micro-Epsilon.”

Fishplates are metal bars that are bolted to the end of two rails to join them together in a railway track. The hot rolling mill produces the high ductile steel fishplates in four different product groups that vary in length from 0.5m up to 1.0m. Mills CNC Automation has custom designed, and built, a fully automated machine tool pick-and-place system for inspecting the fishplates.

Easy integration was key

The optoNCDT 1750 laser triangulation sensor from Micro-Epsilon is mounted on a robot end effector in between two magnetic grippers. The laser sensor measures the fishplate in eight different positions (on average) and outputs this data via the Micro-Epsilon IF2030 EtherNet I/P module into the Fanuc robot controller.

This data is then utilised by Mills CNC’s own custom analysis software with the results displayed on the machine tool HMI. The data is used to verify that the fishplates are within tolerance in all three planes, including whether ‘bend’ and ‘twist’ tolerances have been exceeded.

As Chris Ingham explains: “If the measurement data shows that a fishplate is out of tolerance, the part is rejected before machining and returned to the rolling mill. The fishplates need to be within a tolerance of 2mm over a length of one metre, but we needed a sensor that was reliable and capable of communicating with our Ethernet I/P network. These factors, as well as a favourable price-performance ratio, were critical for us when searching for a suitable sensor solution.”

The optoNCDT 1750 is a laser triangulation sensor with integrated controller that is perfect for mounting on a robot end effector. It is also suitable for high speed distance, displacement and position measurements in a wide range of applications, including automation, machine building, electronics production, packaging, automotive and process manufacturing. Mills CNC is using a sensor with a measuring range of 750mm.

The optoNCDT 1750 series is also available in measuring ranges from 2mm up to 750mm. The sensor’s measuring rate is continuously adjustable up to 7.5kHz and can be individually adapted to suit each measurement task. Data output is via analogue or digital RS422 interface. Due to the Advanced Real Time Surface Compensation (A-RTSC) feature, the sensor operates almost regardless of the target material and colour. The exposure time or amount of light produced by the laser sensor is optimally matched to the reflection characteristics of the target surface, which enables reliable measurements even of difficult, changing surfaces.

The IF2030 module from Micro-Epsilon converts the sensor’s RS422 output for integration to industrial networks and is available for Profinet or Ethernet/IP. The IF2030 EtherNet I/P interface module is a single channel system that is compatible with Micro-Epsilon sensors that output data via their RS422 or RS485 interface. The interface module supports data rates up to 4 MBaud and can be installed in switching cabinets via a DIN rail.

“When I first contacted Micro-Epsilon, their application know-how and experience was evident. Once I had fully explained our application to Micro-Epsilon, they advised me on which type of measurement technique would be most suitable, in this case laser triangulation. From there, they advised me on which sensor product would best meet our needs. The only aspect of the sensor solution that we decided to carry out ourselves was to build a custom enclosure for the sensor that provides additional protection from machine tool coolant mist,” says Chris Ingham.

He concludes: “The sensor is performing well and is providing reliable measurement data. During the machine test and commissioning phase, the customer has been sending us different groups of parts to inspect and so we’ve really been able to put the sensor through its paces. We’ve been very impressed with the sensor and technical support when we’ve required it. We look forward to working with Micro-Epsilon again in the future.”

By Karl Lycett – Rittal UK Climate Control Product Manager

Finally! The temperature seems to be reducing to a more bearable level, the nights are slowly drawing in and… do I see a hint of colour change in the trees?

That’s right Autumn is upon us once again and that can only mean one thing… It’s time to stop, look back at the summer period and understand how things went.

Did you see –·

• Electrical equipment under stress?
• Unexpected breakdowns?
• Emergency repairs needed on critical equipment?

If any of this sounds familiar or has happened to you, now is the perfect time to put plans into place to make your life easier when next summer hits.

Servicing, upgrading or even specifying some brand-new Climate Control to protect your equipment is one of the most effective ways of creating a protective environment for your sensitive electrical equipment within your enclosures and ensuring it lasts for many summers to come.

Even if your cooling equipment is upto date, there is always an opportunity to make small improvements which will increase your overall efficiency.

A great example is the implementation of Industry 4.0 principles, simply put this is taking any data generated by cooling equipment and allowing it to be directly reported into your building management systems or straight to the relevant person in charge of managing the health of your electrical equipment.

This reduces the need for daily walk round with a clipboard, making notes of any issues. This old-style approach can result in things being missed and breakdowns occurring unexpectedly, however, with solutions now available you can choose to have e-mails sent directly to key personnel whenever limits have been reached and warning flags are showing. This means staff are utilised more efficiently and can be safe in the mind that they will be notified if any issues begin to arise.

Now never fear, we know that your sole focus doesn’t lie on Climate Control, you have more important things to worry about, mainly keeping your business up and running and producing for your customers.

That is where Rittal is here to help. Over the next three months we are going to cover a different theme related to Climate Control but with the focus on how you can utilise this information to get the most out of your equipment, by creating that protective environment and allowing it to thrive and stay healthy.

This takes the workload off you when the temperature starts to rise again and allows you to concentrate on more important matters on site while in the back of your mind knowing you have implemented systems to keep your equipment chugging along.

The additional benefits of undertaking this action is the reduction in energy usage and costs related to the replacement of spare parts etc. If items are tripping out every year, this causes a high level of wear on components which can result in more order being produced to replace burnt out cards etc.. All of these small changes are going to impact your bottom line and overall efficiency.

Resolve Optics offers an OEM design, develop and supply service for camera, instrument and sensor manufacturers looking to upgrade or replace hard to source or obsolete optical components.

To prolong the lifetime of a profitable product where key optical components are becoming hard to source – organisations are often faced with the challenge of finding a suitable replacement. At this point do you accept an off-the-shelf optical component that may compromise performance or require modification of your product or do you specify a bespoke component that fully meets your needs?

Choosing a new bespoke optical component for your camera, sensor or instrument not only gives you security of supply but also the opportunity to enhance performance thereby ensuring that your product remains competitive and successful.

Over the last 25+ years Resolve Optics has successfully developed high performance lenses for customers seeking to replace hard to source or obsolete optical components for their camera, sensor or instrument system.

Drawing upon an experienced team of optical designers – Resolve Optics are able to quickly gain an understanding of the basic physics of the technology associated with your product enabling a novel, optimised and affordable solution to be proposed. A project engineer is assigned to closely liaise with customers at all points of a development to ensure complete satisfaction with the final lens or optical system.

Drawing upon the experience of its engineers and using the latest Computer Aided 3D modelling techniques – Resolve Optics has established an international reputation for creating innovative bespoke components optimised for its customer products.

Advanced optical manufacturing and CNC machining technology is used to produce the highest quality optical components. In assembly, Resolve Optics employs experienced workers to build complete assemblies with care and attention to detail. All OEM optical components and products are tested before leaving the factory to ensure your complete satisfaction. It is this blend of skills, experience and flexibility that have established Resolve Optics as a leading manufacturer of special OEM lenses and optical products for a significant and growing portfolio of small and large high technology businesses.

As runner blades are a critical component of water turbines, Rainpower has developed a new measurement tool – called a Flight Recorder – to accurately measure dynamic stress on these components, ensuring continuous operation under the harshest conditions.

The Flight Recorder is a battery-operated system, where all data is stored locally, negating the need for an underwater data transmission system. It measures strain on turbine blades, pressure distribution in the runner in different places, vibration on different locations and temperature on the runner surface, supplying data that is vital for calibration of data simulations and numerical analysis.

During development of the recorder, Rainpower approached test and measurement specialist, HBK for a solution on the Data Acquisition System (DAQ) part of the unit. HBK provided QuantumX units to collect data, along with a CX22 industrial computer/data recorder that contained a flash memory. The system, which runs with catman software, was mounted in a tailor-made framing system, then placed inside waterproof housing with waterproof subsea connectors.

Before testing, HBM strain gauges are applied to runner blades on predefined spots, and the other transducers are mounted on their appropriate places. All transducers are then connected to the Flight Recorder with watertight cables, and the unit is then mounted onto the hub of the runner. Before filling the turbine with water, the recorder is switched on and the catman program starts collecting data.

The QuantumX DAQ systems provides reliable data acquisition of different physical quantities and sensor technologies. It is also user friendly and portable, so is easy to move around and fit in confined spaces.

“As a company dedicated to testing, we needed to choose the right equipment for this project. So, following a market review, we opted to use HBM components. HBM provided us with excellent service and knowledge in the strain gauge market, which was an especially important aspect to us”, explains Kjell Sivertsen, Discipline Manager Lab Technology and Equipment, Rainpower AS, Turbine Laboratory, Trondheim.

With the development of the Flight Recorder proving such a success, Rainpower AS plans to undertake a further three to four tests later the coming year, both in Norway and Sweden.

Yokogawa selects global thought leaders to present successful transformations from industrial automation to industrial autonomy (IA2IA) at its global, virtual event, Y NOW 2021. Over November 2-4, 2021, leading experts such as Francisco Betti, head of Advanced Manufacturing & Production at the World Economic Forum, Michael Krauss, senior automation manager at BASF, Andreas Helget, president and CEO, Yokogawa Europe B.V., and Dr. Yu Dai, director and senior vice president, Digital Solutions Headquarters at Yokogawa Electric Corporation, will virtually share their expertise in focusing digital transformations to enable autonomous operations.

Expert panels will address the latest key topics in autonomous operations pertaining to several industries including oil & gas, petrochemical, chemical, renewable energy, food & beverage, and water & wastewater. Jac Opmeer, principal automation engineer at Shell Global Solutions B.V. and Dave Emerson, vice president, U.S. Technology Centre at Yokogawa Corporation of America, are hosting a ‘fireside chat’ on the Open Process Automation Standard. Yokogawa’s industrial cybersecurity expert, Matt Malone, will moderate a discussion on the emerging business risk management strategy for OT cyber security with Jerry Caponera, VP of Cyber Risk Strategy at ThreatConnect, Tom Finan, cyber growth leader at Willis Tower Watson, and David Llorens, director, Risk Consulting at RSM U.S.

“Progress towards industrial autonomy will bring benefits in many areas of the value chain”, stated Andreas Helget, president and CEO, Yokogawa Europe B.V. “With autonomous operations, customers can rapidly adapt to market disruptions and benefit from improved safety, higher reliability, increased efficiency, reduced costs, and expedited time-to-market.”

According to a global survey conducted by Yokogawa, a majority of companies expect to deploy autonomous operations by 2030. The survey found companies are planning significant investment in three key areas, cyber security (51%), cloud, analytics, and big data (47%), and artificial intelligence (42%). This will enable organisations to make better decisions across a greater span of control. The Y NOW 2021 virtual event will serve as a guide to the realisation of autonomous operations. For more information on Y NOW 2021 and to register for free, please visit https://www.ynowlive.com/.

Charcroft Electronics, a specialist distributor and manufacturer of electronic components, has appointed Roger Tall as Director, after seven years with Charcroft as Business Development Manager, Product Specialist and Sales Manager.

“Roger Tall has helped to steer our customers through the unusual times that the industry has experienced recently,” explains Paul Newman, Managing Director. “The significant technical expertise and problem-solving that he has provided have contributed to the high level of customer support and continued growth.”

The knowledge and experience gained by Roger Tall has been acquired through five years in management roles for Charcroft’s franchised supplier, TT Electronics. The experience also covers four years as Sales Manager for RS Components and two years as an Applications Engineer for Power Integrations. Roger Tall also spent one year as a Regional Manager for a not-for-profit social enterprise which supports the homeless in getting back into employment and self-sufficiency.

“This is an exciting time for Charcroft customers,” says Roger Tall. “The combination of UK-based manufacturing and stock-holding gives customers a clear advantage. Buying from UK-held stock overcomes the delays and extra paperwork required to buy from organisations which ship into the UK from centralised European warehousing.”

“The UK-based in-house manufacturing is being extended with the recent acquisition of ClarityCap Audio-grade Capacitors and ICW Film Capacitors, and all technical support is provided by a UK-based team. This compares to most other distributors and component manufacturers where the teams cover customers across Europe.”

“The solutions that we define for customers are often found by thinking out-of-the-box and as part of a long-term relationship with the customers and suppliers. There is also the determination to find solutions for customers in the defence, space, specialist automotive, instrumentation and high-end audio sectors which are not typically a focus for high-volume distributors. As a privately-owned company, Charcroft has the flexibility and agility to respond to our customer needs.”

For many years the AQE (Air Quality & Emissions) and WWEM (Water Wastewater & Environmental Monitoring) events have been important dates in the diaries of anyone with an interest in environmental monitoring. In 2021 (13/14 Oct.) WWEM and AQE will both take place online, providing registered participants with free, exclusive access to both live and recorded presentations from the comfort and convenience of their own PC, tablet or smartphone.

WWEM and AQE visitors can now register (free of charge) for the virtual conference and exhibition at www.ilmexhibitions.com.  Pre-registration will provide free access to a comprehensive conference programme that will address all of the most topical environmental monitoring issues. Virtual attendees will be able to dip in and out of their chosen presentations, as well as visiting the virtual booths of the world’s leading organisations in air quality, emissions, water and wastewater monitoring, and related products and services.

The event platform will provide networking and match-making opportunities for all visitors, speakers and exhibitors, with facilities to quickly and easily arrange appointments/ meetings/ calls with exhibitors or other visitors in advance of the show. In total, there will be over 60 hours of free LIVE technical content, virtual exhibits from over 150 world-leading organisations, and technical experts will be available on the virtual exhibition booths to answer questions and provide demonstrations. Registered visitors are therefore urged to pre-book appointments with their chosen exhibitors.

The air quality conference will address three major themes: air quality regulations; air quality and climate change, and indoor air quality and public health.

The emissions conference will also address three themes: the measurement of low emissions; biogenic carbon measurement, and mercury monitoring.

The three main themes of the analytical conference will be the challenges involved with the laboratory analysis of microplastics, PFAS, and coronaviruses in wastewater.

The WWEM instrumentation conference will cover highly topical issues in the water sector such as pollution control in receiving waters, CSO spills, data management, climate change and stakeholder engagement.

By pre-registering for either of the virtual events (www.ilmexhibitions.com), visitors will be able to assimilate all of the latest findings from some of the world’s leading researchers, and at the same time be able to discuss the practicalities of environmental testing and monitoring with some of the sector’s leading experts.

Measurement of electrical signals, voltage, and current is one of the most important methods used by researchers to characterise electronic materials. But electrical signals are often at very low levels and in the presence of noise — which can be as large as or even larger than the signal itself.

Because DC measurement instruments cannot easily extract the signal from the noise, AC measurement techniques are often used. They can modulate the signal with a frequency to measure the signal in the presence of less noise. The lock-in amplifier can perform such a measurement and is one of the best methods for measuring amplitude and phase of AC signals. For these reasons, it is the instrument of choice for low-level measurements of AC signals.

A better way to extract your signal from the noise

The new app note discusses lock-in amplifiers in general and examines how the lock-in technology employed in a new, modular source measure architecture deals with removing the effects of noise from the measurement. It details how the new M81-SSM architecture offers:

• Filters designed to remove noise and decrease measurement time
• Multiple measure options, with the flexibility of measurement configurations
• Multiple source modules, which can be matched to measurement requirements

Download the app note here.

One of the most unique features of the new modular Lake Shore MeasureReady™ M81-SSM synchronous source measure system is its patent-pending MeasureSync™ signal synchronisation technology. This real-time sampling architecture enables simultaneous source module update and measure module sampling timing across all channels, regardless of signal types for frequencies up to 100 kHz.

Because MeasureSync samples all channels at precisely the same time, it ensures that multiple devices under tests (DUTs) are tested under identical conditions, so you obtain consistent measurement data. In addition, the architecture allows each source and measure amplifier module to be physically co-located as near as possible to the DUT to further minimise noise pickup from ambient, thermal, ground loop, and other common interference sources.

The technology explained

Amplitude and frequency signals are transmitted to/from the remote amplifier modules using a proprietary, real-time analogue voltage method that minimises noise and ground errors while ensuring tight synchronisation of all modules. This analogue interface keeps noisy digital circuitry away from the modules’ sensitive analogue circuits. The signals are digitised by a dedicated converter for each channel, which are synchronised by the shared MeasureSync clock. Each rising edge of the clock triggers every ADC to take a reading and triggers each DAC to update its output. In between clock edges, all of the data is transferred from ADCs to the controller and each DAC is preloaded with a value that is applied on the next edge. Unlike multiplexed systems, this maintains total synchronisation and continuous sampling of each channel. Digital signals are generated or processed by a configurable DSP core.

Each measure channel can be configured to perform DC, AC, or lock-in measurements. The core processes the individual readings collected at 375 kSa/s and produces fully processed and calibrated readings at up to 5 kSa/s. These readings can be observed on the front panel and collected via the remote interface.

The multiple parameter query structure allows a single data query to return multiple readings in one query, which maintains synchronisation. Additionally, the configurable data streaming interface can be used to provide a continuous stream of synchronised data at a fixed, regular time interval, or a burst of high-speed collection. This combination of an analogue interface to the distributed modules, a centralised simultaneous acquisition clock, and a unified remote interface provides end-to-end signal synchronisation that cannot be easily achieved with separate instrumentation.

For more information, visit the M81-SSM webpage and watch the video.

Also available to view, a recording of a related webinar.