MechChem Africa April 2020

Level in the focus:- VEGAPULS 64 MechChem APRIL 2020 AFRICA

This month: Automated drives for materials handling at ports

Pneumatics and the IIoT

Wireless makes the connected mine possible – and powerful

Fit-for-purpose vibrating screens built to last

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CONTENTS POWER TRANSMISSION, BEARINGS, BUSHES AND SEALS 6 Power transmission solutions and high quality to price ratios Frans Odendaal, SKF product manager for Power Transmission, argues that the quality to price ratio of SKF-branded components and solutions is the lowest available. 8 Automated drives for materials handling at ports 11 Gearmotors and monorail system for automotive manufacture HYDRAULIC AND PNEUMATIC SYSTEMS 12 Pneumatics and the IIoT Emerson’s Enrico De Carolis, global technology vice president for Fluid Control and Pneumatics, explains how pneumatics is already established as an advanced technology that lends itself well to the Industrial Internet of Things (IIoT). 14 BI champions Berntel pneumatic and hydraulic solutions 15 Faster drilling and reduced fuel costs with DrillAir compressors AUTOMATION, PROCESS CONTROL, INSTRUMENTATION AND CAE 16 Wireless makes the connected mine possible – and powerful With the need for greater data access, real-time analytics, and autonomous systems and services, Rockwell Automation is realising the connected mine faster than some of its competitors. 17 Oval wheel flowmeters for multiple applications 18 Enabling the smart factory for smooth IIoT implementation 19 twisterband HD for rotary motion in very small spaces MINERALS PROCESSING 20 Fit-for-purpose vibrating screens built to last Kwatani CEO Kim Schoepflin and GM Operations Riaan Steinmann discuss how the company is leveraging years of experience in the field to bring fit-for-purpose products to clients. 22 Custom cyclone solution solves Zambian TSF challenge 23 Weir Minerals launches Linatex ® ceramic hose to meet global demand 24 Efficient milling productivity with FLSmidth trommel screens 25 TOMRA’s XRT sorting delivers high recovery rates on Chrome mine INNOVATIVE ENGINEERING 30 Captured CO 2 as a raw material for the chemical industry VTT and its business partners have launched a two-year project called BECCU to produce speciality chemicals from the CO 2 produced during bioenergy production. Regulars 2 Comment: The COVID-19 pandemic and the climate emergency 4 On the cover: VEGAPULS 64 secures raw material supply in the cosmetics industry Jürgen Skowaisa, product manager for radar at VEGA, shows by way of a success story, how to effectively deal with the replacement of an existing sensor. 26 Product and industry news 32 Backpage: Breath analysis: from smelling breath to sophisticated diagnoses

P U B L I C A T I O N S CROWN

Published monthly by Crown Publications (Pty) Ltd Cnr Theunis and Sovereign Streets Bedford Gardens 2007 PO Box 140, Bedfordview, 2008 Tel: +27 11 622 4770 e-mail: mechchemafrica@crown.co.za www.mechchemafricamagazine.co.za Editorial manager: Phila Mzamo e-mail: philam@crown.co.za Editorial consultant: Peter Middleton e-mail: peterm@crown.co.za Advertising: Brenda Karathanasis e-mail: brendak@crown.co.za Design: Darryl James Publisher: Karen Grant Deputy publisher: Wilhelm du Plessis Circulation: Brenda Grossmann The views expressed in this journal are not necessarily those of the publisher or the editors. P U B L I C A T I O N S CROWN P U B L I C A T I O N S CROWN 2015/02/10 01:17:09PM

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April 2020 • MechChem Africa ¦ 1

The COVID-19 pandemic and the climate emergency

A s from midnight of March 27, South Africa became the latest country to implement unprecedented restrictions on the move- ment of people. In the global effort to slow the ongoing spread of the new coronavirus, a third of thenationsoftheworldarenowlockeddown,confined to staying home and forbidden to travel or socialise. Restaurants, cafés, theatres, cinemas, clubs and bars are closedandall gatherings of twoormorepeople are being vigorously discouraged and, in many countries, enforced by police and soldiers. Only essential services such as food shops and pharmacies remainopen and all but themost essential businesses have been told to shut their doors to the publicand,wherepossible,forstafftocontinuetofunc- tion remotely fromhome. Theeconomic consequences for businesses and individuals is enormous, leading to huge stimulus packages being put into place to assist millions of employees forced to stop working. The enemy? A very infections flu virus – every carrier is estimated to infect two other people. Now officially called ‘severe acute respiratory syndrome coronavirus 2 (SARS-CoV-2)’, the high transmission rate is thought tobebecause, while thevirus takes hold and becomes transmittable relatively quickly, carriers do not begin to experience symptoms for five or more days after becoming infected. In addition, many carriers experience mild symp- toms and can recover without the need for medical intervention. In elderly people and those with pre- existing health conditions such as diabetes, heart disease or asthma, however, SARS-CoV-2 can cause coronavirus disease (COVID-19), which is a severe and often fatal respiratory condition. Simply put, the disease is largely spread by the relatively young and healthy, but it is their frail and elderly parents that are most at risk. As of March 27, 540 832 people from every corner of the world have been tested positive for the virus and 24 293 are known tohavedied. There arenow19737peoplewho are critically ill with the disease andup to25%of these are expected to die. And while the pandemic in China’s ‘ground-zero’ city of Wuhan and the surrounding Hubei province, which have been on state-imposed lockdown since January 23, is largely under control, almost all other countriesoftheworldarestillseveralweeksawayfrom peak infection rates.

Whocandenytheappropriatenessofthedraconian measures being taken to protect our loved ones? Compared to last-year’s almost forgotten climate crisis, Governments across the world have reacted much more strongly to the COVID-19 pandemic. Ironically, the decisions to ground aeroplanes, slow down public transport, stop people travelling and minimise workplace activity has impacted positively on emissions. NASA and European Space Agency imagery show dramatic reductions in nitrogen dioxide (NO 2 ) levels over locked down cities suchWuhan, where levels are estimated to have dropped by 30%. NO 2 is emitted by cars, power plants and factories and exposure to it can aggravate the symptoms of asthma, while longer term exposure causes people to be more vulnerable to the very respiratory infections that make them danger- ously susceptible to COVID-19. In Italy, thenear shutdownof cruise- andcargo-ship traffic around thenotoriously foul canals of Venicehas resulted in fish being visible in the lagoon and canals for the first time in decades, perhaps simply because the water is clearer, but potentially also because the waters are more life friendly. Birdsong is also being reported as a positive in Wuhan. “I used to think thereweren’t birds inWuhan, because you rarely saw them and never heard them. I now know they were just muted and crowded out by the traffic and people,” reports Rebecca Arendell Franks, who has been confined to her apartment for over eight weeks. Reducing CO 2 emissions is the immediate priority for overcoming the climate change crisis, however, whichmay not appear to be as dramatic as the current pandemic, but may well have life consequences that are as serious in the long term. In urging governments to tie any bailouts for the aviation and shipping industries to requirements for climate action, former Irish president and UN high commissioner for human rights, Mary Robinson says: “Governmentsneedtoputhugeamountsofmoneyinto trying to sustain jobs and livelihoods. But theymust do it with a very strong green emphasis. The threat from climate change is as real as the threat from Covid-19, though it seems far away.” Letususeourlockdowntimetogetusedtonewways of working and living: more safely, harmoniously and sustainably, with each other and our environment. q

Peter Middleton

Comment

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2 ¦ MechChem Africa • April 2020

VEGAPULS 64 secures raw material supply in the cosmetics industry

Pharmaceutical and cosmetics companies are often hesitant to replace existing sensors because the effort and expense of new approvals can be much greater than the costs of the sensors themselves. In this article, Jürgen Skowaisa, product manager for radar at VEGA, shows by way of a success story that there are other ways.

T he multinational company, Croda Ibérica SA, has long been supporting renowned companies in the beauty and personal care industries. The products usedmust bemade fromhigh-qual- ity raw materials that meet the high-quality demands of end users, while production pro- cessesmustalsobesustainable.Achievingthis requires, for example, the use of renewable energy, careful handling of natural plant raw materials and the use of certified, sustainable palm oil. Apart from effectiveness, compliance with quality assurance regulations plays an important role. Market analyses and regula- tory requirements must also be considered. A cosmetic product must undergo several tests before it can come onto themarket and, thereafter, nothing or hardly anything in the actualprocessmaychange.Thisalsoappliesto by-products, which aremanufactured in large quantities at Croda Ibérica’s facility in Fogars de la Selva, aCatalonian district of Barcelona. Croda Ibérica is therefore dependant on its long-established processes and measur- ing points. The company has been working with VEGA Spain for more than 10 years and

relies completely on the company’s level and pressure specialist in Schiltach, Germany, for levelmeasuringtechnology. Croda’sFogarsde la Selva factory houses about 200 sensors of different product families, including: pressure transducers; guided radar sensors; different limit detectors for liquids and solids; as well as various pressure transducers. A special feature of the measuring points is that they all used ATEX-certified VEGA measuring instruments and sensors. The only filling level measuring point at which no VEGAsensorwas installed is a reactor vessel, in which temperatures of more than 300 °C are required. This vessel relied on a weighing system to determine the liquid level. The VEGAPULS 64 radar filling level measuring instrumentwas launchedonto the market in 2016. These sensors are also now inuse at Croda Ibérica and aredemonstrating advantages in the measurement of a mixture of special detergent recipes and alcohols. Here, the sensors measure the raw material supplies in three tanks with heights of two, three and five metres. The result of these measurements is decisive, because the end products of the raw materials supplied from

The narrow radar beam of the VEGAPULS 64 radar sensor allows it to be installed in confined spaces with internal metal elements. these tanks into the downstream reactor vessel is present in about a quarter of total factory production. Since very reliable measured values are crucial, investment at thesemeasuring points was always high. At first, differential pressure transducers were used, but these led to the accumulation of deposits that clogged up the pipe system. The company then switched to guided radar as ameasuring principle, but the structure of the tankwith its built-inpipes led to heavy deposits on the inserted rod probe. Themediumwith its tendency to settle on the tank wall, along with the internal heating coils and pipework led to inaccuracies with the previously installed instruments. These problems were only resolved with the instal- lation of a VEGAPULS 64, which operates at thehigher frequencyof 80GHz (26GHzwere normal previously). Because the VEGAPULS 64 measures uses contact-free radar technology, prod- uct deposits are no longer an issue and the technology is ideal from a hygiene point of view. The front-flush, encapsulated antenna, for example, can be cleaned optimally and is insensitive to the extreme conditions of the SIP/CIP (sterilisation-in-place/clean-in-place) processes. Despite its shorter wavelength, the VEGAPULS 64 is also insensitive to deposits or the formation of condensation on its sen- sor face. This is achieved, above all, using distance-dependent dynamic adaptation, which reduces the influence of interference directly in front of the antenna system and, at the same time, enables very high signal sensitivity at greater distances. Reliablefilling

One of Croda Ibérica’s storage tanks fitted with the new VEGAPULS 64, which allows non-contact filling level measurement down to the bottom of the tank, despite various internal installations.

4 ¦ MechChem Africa • April 2020

⎪ Cover story ⎪

The measuring uncertainties were resolved with the installation of VEGAPULS 64 radar level sensors, which operate with a high frequency of 80 GHz. These were simply fitted onto pre-existing nozzles.

There is not only a lot of pipework on the outside of the pharmaceutical plant; heating coils and installations also influence the measuring signals inside the reactors.

level measurement is therefore also possible during cleaning cycles.

Because of the much shorter wavelength of the 80 GHz signals of the VEGAPULS 64, these reflections are damped in the medium much more strongly than with 26 GHz sen - sors. The reflection from the bottom of the tank is therefore much lower. This results in the liquid levelmeasurement down to thebot- tomof the tankbeingmucheasier toestablish than with previous generation sensors. Fast commissioning Although the structure of the tank is com- plex, the conversion and installation of the VEGAPULS 64 was very simple and quick, becausetheexistingprocessconnectioncould be made available for use. This procedure has already proven effec- tive in other applications in the pharmaceu- tical and cosmetics industries. Plants and vessels have usually already gone through acceptance testing and constructional modi- fications, often at great expense. Thread sizes can be adapted with appropriate adapters, on clamp connections, for example. Other process connections are available for use in aseptic applications where only PTFE is may beused forwet-media contact. Theseprocess connections meet the requirements of 3-A and EHEDG approvals. Sensor integration and operation re- mained familiar because theVEGAPULS64 is also equippedwith the proven plics ® concept. ThePLICSCOMdisplayandoperatingmodule serves in exactly the same way as other solu- tions for the commissioning and operation of the sensors for displaying measured values on site. No additional PCs or special software are required. The display and operating module can be inserted into and removed fromthe sensor at any time, without interrupting thepower sup- ply. Wireless Bluetooth communication was also introduced last year. This is particularly useful where access is difficult or for rugged industrial environments and Ex areas.

Reduction of interference signals The structure of the tank with its complex installations now no longer has any influ- ence on the measurement either. This was achieved due to better focusing of the radar measuring instrument, which depends on the transmitter frequency and the effective antenna surface area. The three times higher transmitter frequency also enables smaller antenna sizes,whichstill achieve similar signal focusingtopreviousgenerationradarsensors. Anantennasizeofjust¾-inchisnobiggerthan a one-Euro coin, which enables much smaller process connections. This new antenna version has helped to reduce the interference signals in the near range considerably. Since the antenna system was integrated into the process connection, no antenna is required to protrude into the tank, so it is nowpossible tomeasure reliably right up to the process connection. The tank volume can thereforebeutilisedbetter, which results in more flexibility. Another positive aspect has emerged, which Croda Ibérica did not initially have in mindbutwhichturnedouttobeextremelyim- portant in practice. With the VEGAPULS 64, it is possible to measure right down to the bottomofthetank,evenwhenfilledwithquite different media. This is very advantageous in viewof the fact that the tankmust be emptied completely every two weeks. Withmediawith low relative permittivity, some signal pulseswill penetrate themedium and are reflected by the bottom of the tank. Two signals are therefore received, the actual filling level and the bottom of the tank. The signals from the tank bottom are greater when the relative permittivity of themedium is lower, andwhen the reflectivity of the tank is higher – when it has a flat metal bottom, for example.

Temperatures of more than 300 °C are required in this reactor, which processes a constituent that is present in about a quarter of the facility’s output. The VEGAPULS 64 module is downward- compatible and can be used with the entire installed base of plics ® sensors: in pressure and filling level applicationswith 70 different instrument types, without software update and with the proven operating structure. Users canconfigureandparametriseplics ® sensors from a safe distance with any iOS or Android Smart phone or tablet. Display and diagnostic functions are also available and all that Croda Ibérica’smaintenance teamhad to do was to install the sensor. In addition to reliable measured values, Croda Ibérica values the professional knowl- edge of the VEGA technician. They have had the same contact for years, who responds quickly to calls and has solutions to hand in the event of unforeseen incidents. Despite proven technology, Croda Ibérica is always interested in new, innovative solu- tions in filling level measuring technology, especially because these parameters play an important role in the company’s success. The company did not hesitate long when the VEGAPULS 64 came onto the market and these sensors have been supplying reliable level measurements ever since. q

April 2020 • MechChem Africa ¦ 5

Power transmission solutions and high quality to price ratios

Frans Odendaal, SKF product manager for Power Transmission, argues that the quality to price ratio of SKF-branded components and solutions is the lowest available, either making equivalent quality products more expensive, or similarly priced products inferior with respect to material and manufacturing quality.

H eading up the Power Transmis- sion product line at SKF, Frans Odendaal says that SKF strives tooffer a completeand integrated range of high quality drive components and kits, includingbelts, chains, couplings, pulleys, sprockets, bushings and bearings. “Power transmission solutions are re- quired in virtually every industry to enable machinery tokeep running smoothly,” he says. “We believe that, by choosing SKF power transmission products, clients are investing in high quality, high performance solu-

“In addition, we are able to offer Tier 1 quality products at prices normally associ- ated with lower Tier equivalents,” he tells MechChem Africa . “We have never been box movers,” he continues. “For us, the SKF brand represents quality, but we do not believe that any of our competitors can better our quality to price ratio. While our quality is not in question, there are other brands that are also perceived as high-end, but the price of these top-end brands is significantly higher than quality-comparable SKF components. “Looking at this another way, if prod- ucts are compared based on price, we believe that comparatively priced

tions that will enable their machinery to runmore efficiently with less frequent failures.

competitor components are al- most always of inferior quality. And we can prove this. There are different manufactur-

ing procedures and standardsinvolvedin producingTier 1and Tier 2 transmission chain, for example. Our brand ticks the requirements for Tier 1,

while similarly priced equivalents tend to skip some of these key qual- ity manufacturing procedures,” he explains.

As evidence, he points to some of the key features of SKF Power Transmission chain components – inner and outer link plates, pins, bushings and rollers – and the associ- ated manufacturing processes. “A key mistake people make when comparing different drive component options is they lookat catalogueentries for load and power ratings. But it is seldom that a chain, for example, will fail due to load. The life of a quality component is more directly related to its wear resistance, and it is the more subtle aspects of material and design that govern a product’s wear life. “SKF’s published load ratings are exceptionally conservative as well, butwith respect to life, thema- terials used, the sealing and lubrication

The SKF Agri Hub is a virtually maintenance-free, unitised, sealed bearing unit that is greased and sealed for life. Due to its high stiffness, the risk for disc tilt is minimised, which further improves machine reliability. solutions and the robustness of the designs matter much more,” Odendaal says. As part of an innovation drive across SKF’s EMEA region, SKF South Africa is working on a number of new market offerings for the Agri industry to simplify and reduce the sea- sonalrefurbishmentcostsoffarmequipment,” Odendaal informs MechChem Africa . All farm equipment has to endure harsh conditions: mud, dust and debris; extreme Solutions for the agricultural industry

Field-testing of the SKF Agri Hub confirms that farmers can save as much as a half-hour of maintenance per day, per machine, compared to conventional bearing arrangements that require daily re-greasing.

6 ¦ MechChem Africa • April 2020

⎪ Power transmission, bearings, bushes and seals ⎪

heat and cold; rain and runoff; corrosive chemicals; and long periods of inactivity followed by intense periods of work. In addi- tion, rising fuel costs and new environmental regulations andhygiene standards complicate machine requirements. “SKF has long provided agricultural solu- tions for all types of farming equipment, which strive to achieve high reliability at low ownership and operating costs. These offer farmers a simpler and more cost effective way to keep equipment such tillers, planters and harvesters working when they are most needed,” he says, adding that components are available for different equipment brands and SKF agricultural solutions, including new initiatives, will offer the same highquality and lower cost promise that runs across theentire SKF range. While the Corona Virus pandemic con- tinues to force lock-downs across the globe, the farming community needs to carry on producing the food the world needs. “While we will be working much more remotely, we will continue to strive to understand and sup- port our customers’ needs and todevelop safe ways of reacting to the new normal imposed on us by the pandemic,” Odendaal assures. “We have a fantastic network and we can do a lot of our work remotely and online. Our modern condition monitoring systems, for

SKF’s published load ratings for its chain and other power transmission products are exceptionally conservative, but the materials used, the sealing and lubrication solutions, and the robustness of the designs matters much more.

“We know that there are some hard times ahead, butwe aredetermined toemerge from them stronger and wiser,” he concludes. q

example, enable us to remotely monitor cus- tomer equipment from safe offsite locations so that we can react quickly to emergencies.

SKF’s Tier 1 quality chain Inner and outer link plates: The shape of the inner and outer plates on SKF chains have been adapted to a wider waist link plate design. This provides increased fa- tigue strength. By subjecting the raw ma- terial to a series of cold rolling processes and stringent thickness controls, the plates achieve uniform thicknesses, which are critical to a smooth running chain. The plate’s endurance and strength is fully optimised via through hardening, shot peening and an aperture ball-burnishing process.

The assembled chains are then pre- stressed. This running-in of the chain not only avoids elongation, but it also improves the chain’s fatigue resistance. The final lubrication process provides SKF chains the lubricant they need for initial start-up. The lubricant also protects the chain against corrosion to significantly prolong shelf life. Connecting links: These links are used to connect two ends of a chain together. Both the spring clip and cotter pin type can be disassembled and replaced easily. The riveted type provides a very strong link and has a similar fatigue strength to the other links in the chain. q

the bushings are precision ground to im- prove service life. Rollers: SKF chains use solid rollers that are cold-drawn from bar stock to improve fatigue strength and resist the damag- ing effects of shock loads. All rollers go through a hardening process to improve wear resistance and increase service life. To reduce cracking, the rollers undergo shot peening, which significantly improves fatigue strength. The assembly process: The automated assembly process rejects parts that do not meet tolerance specifications, giving SKF chains a precisely spaced pitch and a near perfect fit. Every part and process is subject to tight quality controls with frequent checks to conformto tolerances and standards.

Pins: Pins are made from alloy steel that has been case hardened in rotary furnaces. These furnaces provide an even heat for a consistent and uniform case depth, which helps to resist damage fromshock loads and provide maximumwear resistance. Bushings: Cold rolling provides a uni- form wall thickness, which is extremely important in achieving a precise and con- sistent pitch. Precision curling units offer a uniformbushing roundness, inside and out, for an optimum bushing-link plate fit. The case hardening process provides the bush- ing with a wear-resistant case and a tough, impact resistant core. After heat treatment,

April 2020 • MechChem Africa ¦ 7

Vert Energy, the exclusive distributor for Leroy-Somer in southern Africa, offers environmentally-sound automated drive systems and engineering services for container, dry bulk terminal and port material handling. These solutions optimise the movement of containers and goods, at the same time maximising safety, energy efficiency and fuel savings. Automated drives for materials handling at ports

equipment automation solutions. “Customisedtechnicalservicesencompass consultation, installation, commissioning, training, maintenance and repairs, to ensure optimum performance of port equipment. The benefits of modular drives systems and advanced automation systems are vast and include fast turn-around of containers, bulk cargo or freight, by optimising the loading/ unloading and storage cycles. Intelligent and safe automation solutions enhance the efficiency of crane operators and also assist engineering andmaintenance staff to resolve and analyse faults.” Vert Energy’s LSdrives andmotor technol - ogy has specially designed features, to make port equipment safer. These include a range of motors and brake gear motors for static hold and dynamic braking and variable speed driveswithbuilt-in safety features for electric brake control and overspeed management. Leroy-Somer’sCraneManagementSystem (CMS), whichmonitors the physical andoper- ating conditions of port equipment on a real- timebasis, is used tooperate cranes, schedule maintenance, analyse faults, reconfigure the drives and provide crane production data. Single or multiple crane control systems communicatewith the remote cranemanage- ment system (RCMS) over fibre optic cables or via wireless communication systems to reduce equipment maintenance and down- time. RCMS can be used atmaintenance level for service monitoring, operations level for equipment availability andmanagement level for performancedata. Fault-tolerantmodular ac drive systems areused to control crane and handling equipmentmovements, withbuilt-in redundancy for continuous operations. The differential GPS control system (DGPS) is highly accurate and enables safe automatic steering for cranes and yard tracking systems with links with the terminal operating system. Leroy-Somer’s comprehensive hoisting induction motor range has features for im- proved crane performance, including high- speed for greater productivity and low inertia for smoother start/run/stop operations, as well as reduced maintenance requirements. Modular ac anddc drive crane systems can be set-up with an active front end (regenera- tivemode)where control of thebrakes via the drive software, and constant power hoisting via feedback from load-cells, prevents over- load/over-speed. During loweringoperations, the system is able to automaticallymove into regeneration mode to feed energy back into theportspowergrid,providingsignificantsav - ings in energy consumption.Where appropri- ate, energy on cranes can also be channelled into energy storage systems. Electric motors account for nearly 65% of the electricity used by the port logistics

L eroy-Somer’s drive systems for port logistic operations encompass variable speed modular drives, high- efficiency motors and a dedicated Crane Management System (CMS). These compact systems are installed at harbours around the world, with the necessary power and control to maximise the automation, speed and reliability of cranes and materials handling equipment. “In conjunctionwith Leroy-Somer special- ists, the Vert Energy team offers port opera- tors completely new equipment automation installationservices andalsohas theexpertise tomodernise existing port installed systems,” saysGrantRobertson,managingdirector,Vert

Energy. “This not only extends the lifetime of equipment and maximises benefits from the initial investment, but also increases safety on site and reduces operational costs. Furthermore, our eco-friendly fuel-saving solutions minimise environmental impact, by reducing CO 2 emissions and decreasing equipment noise levels. “Projects vary fromsmall logisticmachine automation to comprehensiveelectrical turn- key port automation solutions. Specifically, our port logistics services comprise advanced drive and motor technology and scalable automation solutions, which extend from simple drive and motor conveyor or hopper controls, to complete crane andport handling

Energy consumption and related costs can account for up to 60 % of a port’s operating expenses. Vert Energy’s Leroy Somer variable speed motor and drive technologies are combined to maximise energy savings and performance in accordance with global efficiency standards.

8 ¦ MechChem Africa • April 2020

⎪ Power transmission, bearings, bushes and seals ⎪

Above: Planetary gear motors with integrated brakes are equipped with a release system for free-slew mode. Centre: Features of Leroy-Somer’s hoisting induction motor range include: high-speed for greater productivity; low inertia for smoother start/run/stop operations; and reduced maintenance requirements. Right: Leroy Somer gantry crane drives feature helical geared motors with an integrated brake driven via a shrink disc.

industry. Leroy Somer drives and motors solutions aredeveloped together tomaximise energysavingsandperformance.Forexample, Dyneo ® permanent magnet solutions and IE2/3 induction solutions, combined with variable speed drive technologies, offer the highest levels of energy saving. In addition, the company offers a com- pact, energy and fuel-saving system called RISGA for diesel electric rubber tyre gantry

(RTG) and mobile harbour cranes (MHC). This system, which is easy to install in new or existing crane cabinets, is designed to manage the generator, allowing its speed to be reduced when idling, while still supplying auxiliaries such as lighting and heating. Fuel consumption savings of approximately 50% are achieved when the crane is idling. Other benefits include fewer refuel stops, reduced wear and extended life of the diesel engine,

All iglidur materials are tested by igus in its own 3 800m 2 test laboratory usingmore than 15 000 application-related tests per year.Thecollectedfindingsareincorporated in the online selection aids such as the igli- dur expert. In the test laboratory, iglidur E7 was impressive in the pivot test at a speed of 0.01 m/s under a load of 1.0 MPa on all shafts, with a very low coefficient of wear of 0.3 to 0.8. Currently, iglidur E7 is available as a plainbearing in12 standarddimensions, but customised designs according to customer specifications are available on request. www.igus.de generator and electrical auxiliaries. Emission and noise levels are also reduced. Through Vert Energy’s comprehensive range of high-performance products and extensive experience in port equipment automation solutions, the company is able to offer port operators faster turn around and delivery of cargo, while increasing productiv- ity, improving safety and enhancing energy efficiency. q

iglidur E7 polymer material used in plain bearings Motion plastics specialist, igus, is expanding its plain bearing rangewith its newand very abrasion-resistant material, iglidur E7. further development of thematerial for igus’ plain bearing range.

The iglidur E7 bearing is specifically designed for low to medium loads in pivot- ing movements and can withstand surface pressures of up to18MPa inmotion. “Due to the very low coefficient of friction of iglidur E7, the drive energy is reduced, saving costs for the user,” explains Stefan Loockmann- Rittich, business unit manager of iglidur plain bearing technology at igusGmbH. The new plain bearing material is ideal for flap or sensor bearings and other suitable ap- plications can be found in packaging, textile machinery and furniture technology.

With specifications such as low coef- ficient of friction and excellent vibration dampening, the tribo-polymer, iglidur E7, has already proven its strengths in the sliding elements of drylin linear technology from igus. Now the plastics specialist has also included the material in its plain bear- ings catalogue. This allows users to benefit from iglidur E7’s low energy properties for rotating or pivoting applications. The low coefficient of friction of the material ensures smooth movements, reduces the required drive energy and saves additional costs. In times of advancing automation, du- rable, cost-effective and, above all, energy- efficientmachine components are called for. igus has been developing tribo-polymers for plain bearing technology that are free of lubricants – and therefore free of main- tenance – since 1983. Iglidur E7 is among a total of 57 iglidurmaterials for various appli- cations in the company’s product range. The tribo-polymer has been used in the sliding elements of drylin linear systems since2012 andhas been available indryspin lead screw nuts since 2018. E7 has already proven itself in ap- plications such as camera lenses, train doors and even 3D printers. Above all, the vibration-dampening specifications of the tribo-polymer are convincing, leading to the

Proven and new at the same time: the vibration-dampening and abrasion-resistant iglidur E7 tribo- polymer from igus is now also available as a plain bearing. Pic: igus GmbH

April 2020 • MechChem Africa ¦ 9

⎪ Power transmission, bearings, bushes and seals ⎪

A leading systems integrator for the automotive industry has adapted a MAXOLUTION ® electrified monorail system (EMS) and 23 HK Series gear units from SEW-EURODRIVE for its overhead trolley systems for a major local expansion project. Gearmotors and monorail system for automotive manufacture

A ccording to McCormick Engi- neering owner, Vaughan Pike, his project house was approached by a local automotive manufacturer to optimise its existing system to cater for a capacity increase and newmodels. “Wewere contracted to redesign the system in terms of these specific parameters.” Themainproject had two components, the first for delivering engines and gearboxes to themain line, anda second transfer systemfor moving ahalf-built chassis overhead fromone floor conveyor to another. McCormick Engineering systemdesigner, JacoViljoen, approached SEW-EURODRIVE to become involved upfront in the gearbox and drive selection for the project. It pro- vided expert assistance in calculating the correct speed needed to accommodate the capacity increase, which in turn affected the gearbox selection. All of this information and parameters were fed into an actual simula- tion of the final system to demonstrate how it would operate. “On the hoist drives themselves, we needed a great deal of control due to the high level of accuracy required,” Viljoenpoints out. TheHK Series consists of special gearmotors with integrated couplings, making them ideal for overhead trolley systems such as those deployed by automotive manufacturers. NineHKSeriesgearunitswereusedonthe first part of the project, and 14 on the chassis transfer system. These trolley and hoist units operate seamlesslywitheachother across the entire EMS system at the plant. Whentheautomotivemanufacturercalled for secondary hoist brakes to be installed for added safety precautions, SEW-EURODRIVE was able to prove to its client that its pre- cision-engineered and highly-controllable technology was perfect for the application. This resulted in a significant cost-saving for the client, and demonstrated the close work- ing relationshipwithMcCormickEngineering indesigning, installing, andcommissioning the upgraded system. “Themajor benefit of our state-of-the-art technology for the client is that the drive and automation specialist is able to supply the complete system, from the stationary control level to the sensors themselves. MAXOLUTION ® allows for highly accurate simulation for trouble-free start-up, produc-

SEW-EURODRIVE has supplied a MAXOLUTION monorail system and 23 HK Series gear units to a systems integrator in the automotive industry.

HK Series gear units from SEW-EURODRIVE consist of special gearmotors with integrated couplings.

tion support and project acceptance. Tailor- made for specific production requirements, the modular EMS is integrated seamlessly

into the existing system,” concludes SEW- EURODRIVE sales representative, Philip Steyn. q

April 2020 • MechChem Africa ¦ 11

Emerson’s Enrico De Carolis, global technology vice president for Fluid Control and Pneumatics, explains how pneumatics is already established as an advanced technology that lends itself well to the Industrial Internet of Things (IIoT). Pneumatics and the IIoT

S ensors have become smaller, more lightweight, and easier to use in vari- ous pneumatic components, allow- ing measurement of temperatures, pressures, flow rates, cycle times and valve response rates. Even the simplest devices can provide crucial information. Machine builders in many industries are responding to the IIoT’s growth by adding data gathering sensors to their equipment, with the resulting data made available for analysis and, as systems become more ad- vanced, converted into actionable informa- tion. Rather than a revolution, manufacturers arefinding that the IIoT ismore a gradual evo - lution toward smart components, machines and systems that has been taking place over the past few years. Pneumatics is already established as an advanced technology that lends itself well to these new capabilities, giving companies a deeper understanding of their equipment’s actual operational performance. For example, OEMs can use pneumatic capabilities to monitorapneumaticsystem’soperatingstate, analyse that data, and report on its operation, resources used, energy efficiency, and much more. The same sensors can also provide reliable information on actuators, valves, and other devices without involving the machine controller. In addition, machine builders can lever- age IIoT capabilities to improve pneumatic

components’ extensive diagnostic abilities to measure critical parameters including cylinder velocity. This provides predictive maintenance information to prevent un- planned downtime. Pneumatics offers several key benefits in an IIoT environment, including: • Predictive maintenance is where pneu- matic IIoT capabilities truly shine. By using appropriate data from IIoT sensors’ analyseddata,forexample,technicianscan predict that a shock absorber at the end of an actuator is deteriorating by noting an increase in its stroke speed, even if only by a fewmilliseconds. • With respect to safety, the IIoT is enabling pneumatic systems tousenewcapabilities in tracking and measurement. These pro- vide great insight into machine operation and component and subsystem perfor- mance.With these insights comes a richer opportunity to monitor machine safety and better protect people and equipment from harm. • IIoT-enabled control components such as smart pneumatics generate component- level data that makes calculations of a production system’s overall operational efficiency (OEE) and total cost of owner - ship (TCO) more accurate. • Energy efficiency is a critical component of IIoT’s appeal to manufacturers. An IIoT edge gateway helps users determine the

A smart pneumatics monitor module, this one from Aventics, provides users with reliable information on the state of wear of pneumatic actuators, valves, and other devices, as well as the energy efficiency of pneumatic systems. locationof possible leaks and todetermine the optimal operating point, matching the work to be carried out with the appropri- ate amount of energy supplied. • More and more businesses support late customisation of their products. Changeovers and product variations are more frequent and this calls for manufac- turing equipment that can changewithout sacrificing quality. Machinery can be designed to easily and seamlessly supply different pressures for different tooling positions and sequences, enabling various parts be processed on the same machine. IIoT sensing and measurement Pneumatics circuits already contain sensors for feedback, but now they can bemonitored by IIoT-enableddevices. Sensors canmeasure temperatures, pressures, flow rates, cycle times, position, valve response rates, and more. IIoT-enabledsensors canmeasurepres- sure losses, for example, and sendalertswhen leak rate exceeds a predetermined value. The highest levels of manufacturing quality require constant monitoring and re- lentless control over every production step. Companies building automotive components want to know the exact forces, pressures and positions of a pneumatic cylinder driving a bearing installation tool. Theywant sequenc- esdocumentedso they candeterminemonths later if components are being made with the same precision as the first ones off the line. Open, high-performance, globally avail- able communication protocols are vital for the IIoT. Deterministic control protocols have been around for decades. However, these protocols were designed for real time I/O (control) data, not necessarily for diagnostic

Pneumatics lends itself well to new IIoT capabilities. For example, it can let packaging companies know more about the performance of pneumatic equipment on the packaging line.

12 ¦ MechChem Africa • April 2020

⎪ Hydraulic and pneumatic systems ⎪

and prognostic information generated and used by IIoT devices. OPCUnifiedArchitecture (OPCUA) is the OPCFoundation’s data exchange standard. It builds on previous OPC protocols to ensure secure, reliable manufacturer- and platform- independent information transfer. OPC UA allows easyaccess tovarious devicedata from authorised applications without disrupting the network infrastructure’s deterministic real time I/O (control) data. Now standardised in IEC 62541, OPC UA architecture is particularly versatile and flexible and offers access to data carrying his - torical information, along with base services for data access, alarms, andevents. These ser- vices can be supplemented with information models (forfluid technology, for example), and for custom, manufacturer-specific functions and information. Pneumatics manufacturers such as Emer­ sonhavealsodevelopededgecomputinggate- ways that aggregate, analyse and report key performance metrics from several pneumatic devices.Thesecanbeusedbyend-usersandof- fers competitive advantage tomachineOEMs by letting them use their equipment’s IIoT- support capabilities anywhere in the world. Edge computing gateways make it easier to implement IIoT solutions by operating independently fromtheexistingcontrol archi-

This Aventics ASCO 502 Series valve could be the basis for a host of IIoT applications as it is modular design with all relevant fieldbus protocols, consistent communication up to the valve, and an integrated web server. tecture and usingOPCUA, MQTT, e-mail and other pathways to deliver prognostic alerts forsystem-anddevice-levelperformancedata to a local server or an offsite cloud. Bringing IIoT to life By accessing the electronics on valves an IIoT gateway lets pneumatic manufacturers evaluate valve life by tracking the valve’s cycle counts. A cycle-counter algorithm can then be used to determine what percentage of a valve’s life cycle is gone and predict how much is left. This lets proactiveusers schedule predictivemaintenance and avoid unplanned downtime. Pneumatic cylinders often use external shock absorbers, especially when quickly moving large loads. Butworn shock absorbers can increasewear and vibrations in pneumat- ics. An IIoT edge computing gateway can use

The Aventics ASCO 502 Series valve can process a large variety of signals, including analogue and digital I/O modules, analogue combination modules, control modules, and pressure measurement modules. end-of-stroke sensor signals to evaluates cylinder deceleration. Now, customers no longer need to replace shock absorbers simply as a precaution. As soon as a critical value is reached, an alarmmessage is sent out triggering maintenance to replace the shock absorberbeforeitfailsandaffectsproduction. Data is only useful when it becomes infor- mation that provides insight, guides decisions, or helps justify investments. To achieve IIoT’s full potential, component manufacturers, OEMs, and end-users must communicate and collaborate for the common good. The ultimate result: a data-rich environment established by IIoT-enabled technology that provides real-world, real-time, actionable in- formationaboutmanufacturingand industrial systems, information that is readily usable to help solve challenges and better satisfy busi- ness goals. q

April 2020 • MechChem Africa ¦ 13

Hudaco Group company Berntel is expanding its footprint by offering its extensive range of pneumatic products through the Bearings International (BI) branch network. This, in turn, expands BI’s value proposition to its own customer base by offering a wider range of complete solutions for different market segments. BI champions Berntel pneumatic and hydraulic solutions

Berntel General Manager Neil Champion.

A cquired in 2014 as a complemen- tary company to pneumatic and hydraulic automation solutions provider Ernest Lowe, Berntel ex- pands theHudacoGroup’s industrial offering in pneumatic, hydraulic, vacuum, process and automation solutions. It alsomanufactures its own pneumatic cylinders, anddesigns, builds, and commissions control systems, including PLC programming. In addition, Berntel represents a range of well-known brands, including JELPC, JORC Industrial (condensate drain manage- ment), VMECA (water-free units), Belef (actuation), Ober (air tools, air motors, and automation), Piab (vacuum technology), and

BOGE (compressors and dryers). Targetmarkets are foodandbeverage, automotive, general industry, sugar, pulp and paper, OEMs, machine builders, and agriculture. “AdedicatedBerntel teamsupportsBI, allowingBerntel to begin growing its cus- tomer base countrywide,” says GM Neil Champion, whohas beengrowingBerntel product sales through the Ernest Lowe branch network in the past five years. Involved in the pneumatics industry since2001, ChampionoversawtheKwaZulu- Natal branch before being appointed sales director prior to Berntel’s acquisition by the Hudaco Group. Champion reveals that in 2020, Berntel will introduce its latestOber agency, an Italian designer andmanufacturer of portable pneu- matic tools, motors, automated machinery, and systems for drilling, tapping, threading and screwing, including power screwdriv- ers with electronic torque control. Another new agency is BOGE, a German producer of reliable compressors that has been operat- ing for over 110 years. The Piab agency has also extended Berntel’s offering into smart vacuum solutions. “Our value proposition lies in our capabil- ity to offer complete solutions,” Champion

of Pneumatics; Pneumatic Components; and ‘Designing On/Off Manual Pneumatic Systems to Achieve Given Functions’. “The training proved highly valuable in improving the trainees’ understanding of how pneumatic components work and how to integrate them to make a functional system,” explains Thomas Mbugua, Sales Manager, Bosch Rexroth Kenya. All suc- cessful candidates were issued with the Bosch Rexroth Certification for Pneumatic Training. Bosch Rexroth Kenya is in the process of registering this pneumatic course with the Engineer’s Board of Kenya, which will accord successful trainees with nationally recognised CPD points. q The JELPC range of pneumatic control components from Berntel. stresses. These range from the efficient generation of clean, dry compressed air to condensate drain management, pneumatic, vacuum, process, and industrial components, and designing and programming control sys- tems with PLC integration. Being part of the broader Hudaco Group allowsBI to leverage synergies across a broad range of companies, meaning it can offer a complete product basket through its exten- sive branch network countrywide. “BI is a house of world-class leading brands, and we are working closely with our suppliers and the larger Hudaco Group to penetrate new market segments and grow through innovative marketing initiatives,” BI offer marketing manager, Victor Strobel concludes. q

Berntel supplies BOGE dryers and compressors.

Pneumatic training rigs installed for Coca-Cola bottler The first on-site Bosch Rexroth pneumatic training rigs have been installed in Africa. The rigs were supplied to Nairobi Bottlers Ltd, the base for Coca-Cola Beverages Africa Kenya, by Bosch Rexroth Kenya, in collaboration with Bosch Rexroth South Africa’s Training Department.

The pneumatic rigs were manufactured and supplied by Bosch Rexroth Germany and assembled at the local Bosch Rexroth plant in Nairobi prior to installation and commissioning at Nairobi Bottlers in August 2019. The training rigs are now a permanent installation atNairobi Bottlers and are used to conduct pneumatic training for Coca- Cola Beverages Africa Kenya employees. The first such training was a three-module training course for Coca-Cola East Africa’s technical personnel covering the Theory

One of the two Bosch Rexroth pneumatic training rigs that were commissioned at Nairobi Bottlers, during a demonstration.

14 ¦ MechChem Africa • April 2020