Pneumatics pole position at new Formula One circuit

MAGAZINE FOR MOTION AND FLUID CONTROL SOLUTIONS
ENGINEERING A NEW
PARTNERSHIP - FAS & NORGREN
Pneumatics pole position at new
Formula One circuit - China
Engineered solution hits the spot in
laboratory automation
ISSUE 2 JANUARY 2005
ADVANTAGE | CONTENTS
ENGINEERINGADVANTAGE
This issue shows the results of Norgren people worldwide working in
close, practical partnerships with customers on a range of technically
challenging applications. Many demand inventive solutions and innovative
approaches to complex engineering and automation projects - often
involving the design and supply of fully integrated systems. These
examples demonstrate Norgren’s commitment to supporting customers in
helping them to improve efficiency and competitive edge, as their partner
in providing cost-effective motion and fluid control solutions.
NORGREN ADDRESSES THE NEEDS OF
THE ATEX DIRECTIVE
02
16
ENGINEERING A NEW
PARTNERSHIP
ATEX EXPLORED
GLOBAL
GLOBAL
04
NEW SOLUTIONS
18
TANKER SAFETY
AUSTRALIA
GLOBAL
06
IMPROVING THE AIR
20
PNEUMATICS POLE
CHINA
GLOBAL
08
HOME HUMIDIFICATION
22
MAKE THE DIFFERENCE
SPAIN
USA
10
EXPLOSION SAFETY
24
INNOVATION (RELIABILITY)
USA
GERMANY
12
THE RIGHT CONNECTION
26
APPLICATION SPECIFIC
IRELAND
UK
14
SWEEPING CHANGES
28
ENSURING FOOD HYGIENE
NETHERLANDS
UK
EDITORIAL
For further information on any of the stories please contact
Ian Jarrett.
Tel:
+44(0)1543 265000
Email: [email protected]
ADVANTAGE | GLOBAL
ENGINEERING A NEW
PARTNERSHIP
Fluid Automation Systems (FAS) is a high technology company
specialising in miniature solenoid valve solutions. In a move that
will strengthen both companies and creates an exciting new force
in the fluid power market, FAS becomes a part of the global
Norgren group where it will continue to play a leading role in the
development of innovative new solutions.
02
ADVANTAGE | GLOBAL
Operating from two sites near to Geneva and employing
a total of 263 people, including 45 engineers, FAS has
gained an international reputation for its innovative
spirit. A spirit of cultural diversity, combined with
effective concept sharing, confidence in experimentation
and initiative taking, encourages talent and leads to
successful solutions.
Its well-established user base includes customers in
the medical, printing, semiconductor, textile, sanitary
and instrumentation sectors. These represent an
excellent match with Norgren's chosen market sectors
and provide good opportunities for collaborative growth.
Having invested heavily in research and development
FAS has established a track record for technological
innovation especially in the area of customised
solutions. The company has grown organically and has
been consistently profitable since it was founded 30
years ago. Focused particularly on the fast growing
miniature solenoid valve market there is a perfect fit
with Norgren's existing solenoid capabilities
complementing the established Webber and KIP
ranges.
Just one example of Norgren's and FAS's common
vision in action is within the medical sector. Both
companies are already working together on joint
projects involving fluid control technology. Indeed the
medical sector is where FAS is very strong. As a leading
supplier of customised solutions for the medical sector
FAS prides itself on its medical device industry
experience and expertise. This knowledge is utilised to
provide solutions that will make a real difference for
customers.
FAS ENGINEERING SOLUTIONS INCLUDE:
Chipsol: 8mm width solenoid valves
Chipsol is a range of 2 and 3 way, subminiature
solenoid valves with superior performance. They are
designed to control pneumatic or medical microcomponents as well as industrial or portable
applications where energy consumption, size and
weight are an important design criteria.
High flow and high-pressure performance, along with
low electrical power consumption, fast response time,
high cycling rate, extreme reliability and a life
expectancy of hundreds of millions cycles are among
their key features. They are also remarkably quiet
during operation.
They are available in a large range of pneumatic
mounting patterns which adapt to most industrial
requirements. They can also be directly integrated into
manifolds with common supply, individual outlets and
common exhaust galleries.
Picosol: 10mm width solenoid valves
Picosol is a miniaturized series of solenoid valves and is
amongst the best performing valves currently on the
market. This series offers many advantages to
industrial applications that require the benefits of low
energy consumption combined with weight and space
savings. This series is available as 2/2 and 3/2 valves
that are normally closed, open or bistable (as in the
picolatch version which consumes almost no electrical
energy).
Microsol: 15mm width solenoid valves
Microsol has earned several awards and has gained an
international reputation as a result of its innovative
design and miniaturization. In a highly competitive
market Microsol makes a real difference in applications
that require high reliability, performance and quality.
Available as 2/2, 3/2 and 5/2 way valves this range is
extremely versatile making Microsol the ideal choice for
many applications.
Custom solutions:
Another strength for FAS lies in the provision of custom
solutions tailored to exacting specifications. Amongst
the capabilities are custom made manifold assemblies
with complex pneumatic functions either with or
without integrated electronics. Having developed close
working partnerships with many international
customers FAS have built a solid reputation for the
technical expertise they deliver through bespoke
custom solutions.
03
ADVANTAGE | GLOBAL
NEW SOLUTIONS EMBODY
ENGINEERINGADVANTAGE
At the heart of Norgren's recent growth has been the sustained introduction of new product
developments. With our global technical centres focused on engineering advantage for our
customers worldwide, 2004 has seen the introduction of many new and exciting engineering
solutions that are making a real difference in customer applications. Here we take a look at
some of the highlights.
VM15 VALVE ISLAND
MULTI POSITION AIRLESS CYLINDER
The new VM15 valve island builds on the
proven success of the VM10 and has been
developed to make a real difference in
applications that require cost savings and
reduced installation space.
With precision at the heart of the design the
new 8 position multi position airless cylinders
complement the existing range of pneumatic
actuators. Ideal for inclusion in applications
that require high speeds combined with
multiple position operation such as high
speed insertion equipment in the packaging
and semiconductor manufacturing sectors,
automatic test, printing and medical
industries.
VM15 offers unsurpassed flow rates of 1,000
l/min. Previously to achieve this flow rate
customers would have had to opt for a more
expensive larger footprint valve solution.
04
FD67 DISTRIBUTED I/O
VS18/VS26 VALVE RANGE
PNEUFIT C/M FITTINGS
Suitable for use in fieldbus systems the
modular FD67 has been developed to deliver
real competitive advantage to OEMs who are
looking to simplify and reduce costs of the
entire electrical installation of machine and
systems. The FD67 allows the machine
design engineer to universally standardise
the machine design around one I/O system
and there are a wide variety of fieldbus
protocols available.
This new range of plug in sub base valves
features flexibility and configurability at the
heart of its design. The new VS series fulfils
the requirements of a wide variety of markets
such as packaging, paper and printing,
materials handling, machine tools and the
automotive industry. We have developed the
VS series to provide competitive advantage
through its wealth of features including high
flow, long life and I/O capabilities.
To give the customer more choice the Pneufit
C range has been quadrupled to deliver 1,200
different variants. The range has been
extended even further with the addition of the
ultra compact Pneufit M fittings with sizes
down to M3. The competitively priced Pneufit
series offers customers rapid assembly
combined with choice.
05
ADVANTAGE | GLOBAL
IMPROVING THE AIR WE
BREATHE
Manufacturers are currently working towards
reducing the levels of emissions in
accordance with the Euro 4 and US 07
directives. The Euro 4 legislation comes into
force in October 2005 and simply states that
all new commercial vehicles entering into
service must comply. Diesel engine
technology is the dominant engine technology
within the arena of commercial vehicles and is
likely to stay for many years to come. When it
comes to diesel engine technology there are
many advantages such as fuel economy and
reliability, however there are also
disadvantages such as higher exhaust
emissions of particulate matter and nitrous
oxides.
Reducing emissions
In conjunction with some of the worlds
leading power train manufacturers Norgren
has been developing innovative engineering
solutions within this sector for a number of
years. When Norgren develops any new
platform technology the focus is always on
providing the customer with an advantage that
will help them reduce costs, improve quality
etc. Norgren engineers are knowledgeable in
the latest issues that affect the power train
industry. This knowledge is utilised to great
effect with the development of cutting edge
solutions that go along way in tackling the
latest legislation requirements head on.
In conjunction with some of the world's
leading diesel engine manufacturers Norgren
have developed a range of solutions to
address the needs of the emissions levels.
Included amongst the innovative power train
solutions are:
06
Fluidtronic/Mechatronic valves
Facilitating compliance with Euro 4 and US 07
legislation these proportional solenoid valves
communicate with the engine electronic
control unit via a sensoric/electronic control
device. This aids the optimisation of engine
performance and improves the exhaust gas
re-circulation rate. A simple software
parameter change allows modifications to the
exhaust or turbocharger control thus
achieving the desired engine performance.
Diaphragm actuators
Delivering actuation to the new fluidtronic
proportional solenoid valve, the diaphragm
actuators are critical in maintaining the
exhaust gas recirculation rate in line with
Euro 4 and US 07 emissions legislation.
Designed to successfully meet the demanding
challenges of environments that feature high
temperature and vibration the actuators are
expected to operate during the engines entire
life without failure.
Turbocharger applications
Norgren provides valve and actuation
technology for all current and future advanced
turbo control systems. Included here are
pressure modulating valves with or without
integrated pressure sensors and closed loop
electronic control, as stand alone designs as
well as manifolds. Actuators within this field
are top performers for HD applications with or
without position sensing systems to
optimise exhaust gas
re-circulation rates.
» In order to improve the quality of air, exhaust emissions are strictly regulated in most
countries. The legislation that applies directly sets and limits the NOx and particulate
levels of exhaust gases that vehicles may emit in terms of emissions. These emission
levels are constantly being lowered and truck manufacturers are under constant
pressure to improve existing technologies or to invent new ways in achieving the legal
levels for emissions.
07
ADVANTAGE | USA
HUMIDIFICATION
JUST-IN-TIME
08
ADVANTAGE | USA
WHEN FIELD CONTROLS WERE LOOKING TO UPGRADE AND IMPROVE ITS
THERMO MIST HUMIDIFIER THEY TURNED TO NORGREN TO DELIVER THE
ENGINEERING ADVANTAGE THAT THEY VITALLY NEEDED.
With 75 years of experience in the field of
humidification, Field Controls is a leader in
the design, manufacture and distribution of
DIY home comfort products. The Field
Controls Thermo Mist humidifier is a whole
house system that utilises the water supply of
the house. The unit is directly installed into
the dwellings existing ductwork. Control of the
humidifier is via a temperature sensor that
detects a rise in heat inside the plenum. Once
a rise in temperature has been detected the
humidifier will automatically release a fine
water mist into the ductwork, thus the heated
air is humidified and spread throughout the
whole house. When the boiler system is
deactivated and the temperature falls inside
the plenum, the Thermo Mist will
automatically switch off until the heating cycle
starts again.
Cost savings and performance improvements
The valve assembly installed into the
humidifier is the release mechanism for the
water flow to the mister. Field Controls were
simply looking for a valve supplier that could
deliver an overall cost saving to the project
and give them a competitive advantage in a
crowded market place. The original valve,
contained within the humidifier, featured three
separate components; a coil, the valve body
and a porex filter. Each component had to be
installed individually into the housing, and
connection wires for the valve had to be
trimmed by hand to fit. The Norgren solution
was to offer one of its KIP brand of solenoid
valves. The KIP valve encompasses all three
individual components with the valve itself and
features the correct length of wire for the
connection. This leads to a reduction in
manufacturing time, thus achieving vital cost
savings. The KIP branded valve also provides
superior performance with faster response
times and increased reliability.
Just-in-time delivery
The engineering solution was only half the
story. As a supplier to some of the major DIY
stores across America, Field Controls is
required to deliver product on a just-in-time
basis. This means that they require all of its
suppliers to deliver on the same principle. To
this end, Norgren has specifically developed
tailored stocking principles to ensure that
Field Controls takes delivery of what they
want when they want it.
Contact:
Dean Frazier
Territory sales manager
Norgren US
09
ADVANTAGE | GERMANY
WITH A LONG STANDING RELATIONSHIP THAT CLEARLY
DEMONSTRATES HOW PROJECT COOPERATION CAN DELIVER MANY
ADVANTAGES NORGREN AND GRECON HAVE DEVELOPED A WORKING
PARTNERSHIP THAT GOES MUCH FURTHER THAN THE TRADITIONAL
SUPPLIER/CUSTOMER LINK.
THE RESULT OF SPARK IGNITION
10
ADVANTAGE | GERMANY
CLOSE COOPERATION
GUARANTEES EXPLOSION SAFETY
Explosion safety
Among experts worldwide the name
GreCon has become synonymous with
producing spark detection and
extinguishing systems. These systems
detect and automatically extinguish
sparks within extraction ducts therefore
reducing the risks of fires and
explosions. Fires and explosions often
occur in filters, silos and dryers and can
be dangerous to human life, cause
severe property damage and interrupt
production. To counteract this threat
GreCon design and build spark sensors
that are flush mounted on the walls of
the extraction ducts. These sensors
detect the infrared radiation emitted by
sparks in the transport air stream and an
extinguishing system is placed in the
extraction duct that provides a water mist
spray thus counteracting the spark and
the eventual fire risk.
The extinguishing device consists of a
special high speed Buschjost series
solenoid valve with one or more spray
nozzles. These are flush mounted to the
duct wall about 4 to 6 metres
downstream of the spark sensors. When
the sensor detects a threat
extinguishment is accomplished with
water being injected at high flow and
special nozzles spray a fine water mist
that covers the entire cross section of the
duct thus neutralising any potential
problems. With a properly planned
installation the ignition sources enter the
water mist and are effectively
SPARK EXTINGUISHING SUB ASSEMBLY
extinguished; the amount of water
released is sufficient to extinguish the
sparks. The valve closes after a preset
and adjustable time frame normally
about 5 seconds. This system can
effectively detect and extinguish ignition
sources without machinery shut down
which will interrupt the production
process thus resulting in costly
downtimes.
Joint development work delivers cost
savings
The association between Norgren and
GreCon is much closer than between a
customer and supplier. With a longstanding business relationship Norgren
has become a real partner for GreCon.
The connection between the two
companies started out in a relatively
modest way with the supply of the
solenoid valve. However this valve was
specifically developed for GreCon rather
than being an "off the shelf" standard
production item and it was through this
development that the technical
competence was demonstrated. The
original specification called for a valve
that featured highly accurate opening and
closing times and was suitable for
deployment with water applications.
Following on from these early foundation
stages Norgren demonstrated to GreCon
that they were a company that could
really add an advantage to its day-to-day
business activities. At this point in the
relationship the two companies began a
period of joint development work to
produce the complete spark
extinguishing sub assemblies rather than
just the valve. As it stands today Norgren
is manufacturing the third generation of
these devices for GreCon and the
solenoid valve and spray nozzle sub
assembly is supplied ready for
installation into the extraction duct.
Core competence focus
GreCon now have the advantage that they
can concentrate on its core
competencies such as sensor and
extinguishing systems know how whilst
Norgren as system supplier takes the
responsibility for jointly devised valve
systems.
"In every respect we have to be able to
rely on Norgren to be just like one of
GreCon's own departments" said Gunter
Hansch of GreCon. "Our partners at
Norgren are aware of what technical
innovations will give us a competitive
advantage in the future and we also profit
from being able to use Norgren's core
know how in relation to valves with their
engineers being at our disposal"
Contact:
Gerd Feldmann
Field service sales
Norgren Buschjost
11
ADVANTAGE | UNITED KINGDOM
MAKING THE RIGHT
CONNECTION
Representing a significant investment in new equipment Harwin has recently completed
and commissioned its new Jackscrew Datamate assembly machine for the manufacture
of high reliability electronic connectors. This cutting edge machine incorporates the latest
in pneumatic solutions from Norgren.
With unsurpassed experience and expertise in
the production of interconnect systems Harwin
has become renowned for its commitment to
developing and producing high quality connector
products. Featuring an extensive range of
standard products and the ability to offer
application-specific connectors Harwin serves
many different industry sectors including military,
aerospace, medical, automotive and consumer.
Jackscrew Datamate is the next phase in the
development of Harwin's high reliability range of
connectors for use in a wide variety of safety
critical applications. Customer demand has also
seen the company extend its 2.00mm pitch range
to include mixed technology connectors. The new
series combines a four finger Beryllium copper
contact clip and jackscrews to ensure contact
and termination reliability in applications where
connection security is paramount.
To incorporate this recent range extension
Harwin has designed and built an all-new
connector manufacturing machine that can cope
with the stringent production specifications of the
12
ADVANTAGE | UNITED KINGDOM
JACKSCREW DATAMATE
new series. Utilising the latest innovations in high
technology the new "Datamate" machine is highly
automated to achieve the high efficiency that is
required to manufacture components of this
nature cost effectively. The whole production
process has been optimised for minimal operator
interruption and maximum automation, thus
making the connectors both cost effective and
competitive to produce.
Latest technology
A large part of the machine is designed around
compressed air technology. In conjunction with
the distributor MB Air Systems Norgren is
supplying an engineering solution into this new
machine. With many years of experience in the
design and build of innovative pneumatic
solutions, Norgren is supplying the latest in valve
island technology combined with its cutting edge
series of FD67 distributed I/O Fieldbus systems.
Vital movements of the Datamate machine are
controlled pneumatically. Harwin were looking for
a solution to cut down on the number of
pneumatic stations needed to simplify the wiring.
VM10 COMBINED WITH FD67
Harwin achieved the overall objective by having a
highly innovative automated machine that
features leading edge diagnostic abilities
combined with reduced machine commissioning
times. Norgren’s solution was to utilise multipole
VM10 valve islands in conjunction with the FD67
wire technology distributed I/O.
Complete configuration
Due to its functionality the VM10 cuts down on
the number of individual valve stations needed
around the machine. The modular VM10 valve
island can be configured to provide up to 20
stations in one unit all delivering high
performance combined with interchangeable
Fieldbus protocols for applications that need this
high level of automation. The VM10 delivers
pneumatic control for all the cylinders that are
associated with the automated sequences of the
machine. Because of its flexibility and modularity
the VM10 provides an advantage through its ease
of installation and its reduction in component
count thus delivering a saving in system costs
and commissioning time.
FD67 DISTRIBUTED I/O MODULE
Reduced machine build times
In conjunction with the FD67 distributed I/O
system from Norgren the onboard PLC
continuously scans the in/out position signal from
each cylinder. When the PLC sees "the correct
position" it will go through an automated
sequence of events to assemble the finished
connector product. Providing communication
functions around the machine the FD67 I/O
transfers and receives vital system data. The
Datamate machine also required a solution that
will save space and with the FD67 Harwin have
cut down the number of individual connection
wires from 44 to 2 thus saving them vital
machine real estate. It is also very easy to install
which delivers advantages through reduced
machine build times.
Contact:
Charles Stevens
Area account manager
Norgren
13
ADVANTAGE | UNITED KINGDOM
JOINT CO-OPERATION BRINGS
SWEEPING CHANGES
WHEN JOHNSTON SWEEPERS, THE WORLD'S LEADING SUPPLIER
OF ROAD SWEEPING VEHICLES, WERE LOOKING TO IMPROVE BOTH
THE EFFICIENCY AND DESIGN OF ITS SYSTEMS LOCKER THEY
WERE LOOKING FOR A PARTNER THAT COULD DELIVER THE ALL
IMPORTANT COMPETITIVE ADVANTAGE THEY NEEDED.
14
ADVANTAGE | UNITED KINGDOM
Operating in a highly competitive industry, keeping the all-important
time to market to a minimum, is critical for Johnston Sweepers. With
the impending launch of its new modular 'V' series road-sweeping
vehicles, Johnston Sweepers needed to improve their production
processes, basically to improve the speed of build, thus improving
delivery times to give them a competitive advantage. One area that
they identified for possible improvement both in terms of engineering
and speed of manufacture was within the systems locker.
Customer configurable
The new systems locker needed to be fully customer configurable so
that it could be tailored to match individual customer requirements.
Within the old design configurability was difficult and lengthy in terms
of time. The new system needed to adapt a "plug and play" principle.
Connections to match the specification need to be made quickly to
ensure minimum production cycle times basically plug in plug out.
Efficiency, simplicity and effectiveness were all key words when the
specification for the new locker was formalised. The new vehicle also
operates within many different environments that can be a threat to
the vital components contained within the locker. Johnston Sweepers
therefore wanted to improve the overall IP protection rating of the
system for increased reliability.
The locker itself is at the heart of the vehicle controlling all of the vital
system functionality for the essential services. Mainly consisting of air
valves, hydraulic valves and water valves, the locker controls and
drives the sweeper brushes and the main cylinders that provide for the
emptying of the spoil collection hopper.
Close working relationships
One of the major strengths of Norgren is the fact that they pride
themselves on close working relationships with all of their customers.
With a proven track record of supplying pneumatic solutions to
Johnston Sweepers, Norgren were chosen to closely collaborate with
them on the design of the new system. So began a period of close
cooperation between the Norgren engineers and the design team at
Johnston Sweepers. It was imperative for this new design that both
teams of engineers worked together to achieve the competitive
advantage that Johnston were looking for. It was not simply a matter of
following instructions from Johnston but actively participating in the
whole design process and making recommendations that added value.
In conjunction with Johnston a new locker system was designed that
satisfied all of the main specification requirements with plug and play
configuarbility being at the heart. With the new plug and play system
the locker can be adapted easily to match individual customer
requirements. This ultimately means reduced production times, cost
savings and greater competitive advantage.
Dedicated manufacturing
Having achieved the basic specification guidelines there were still
improvements in production times that could be achieved. Using all of
its knowledge gained over many years Norgren were able to come up
with a fresh new approach for the manufacture and supply of the
systems locker. Norgren were already producing custom made
cylinders for Johnston Sweepers at its Farnham manufacturing facility.
The Norgren team hit upon the idea of taking over the full production
of the complete locker for Johnston Sweepers. To this end Norgren
have set up a dedicated manufacturing cell at Farnham. The cell is
completely responsible for every aspect of producing the new locker;
everything from component ordering through to build and system
testing.
The complete locker system is now delivered fully tested on a just-intime basis via Norgren's Lineside service to Johnston Sweepers facility
in Surrey. Johnston simply have to fit the system to the vehicle and
plug it in. They not only benefit from reduced production times but also
cost savings due to the fact that they do not have to carry stock etc.
Contact:
Ian Houston
Key account manager
Norgren
15
ADVANTAGE | GLOBAL
ATEX EXPLORED:
NORGREN ADDRESSES THE NEEDS OF THE ATEX DIRECTIVE
When it comes to the protection of people and material goods against the threat of
explosion, industry is strictly controlled by technical standards and Government legislation.
Equipment intended for use in a potentially explosive atmosphere falls within the scope of
the ATEX legislation. Combining two European directives ATEX 94/9/EC considers
potentially explosive concentrations of gas, vapour or mist in the air and dust. Taking into
account both electrical and mechanical sources of ignition it concerns the minimum
requirements for improving the health and safety protection of workers at risk from
explosive atmospheres. If you design, manufacture or sell any equipment intended for use
in potentially explosive atmospheres you must fully comply with the ATEX directive to
market said equipment anywhere in Europe. The directive covers a large range of
equipment within areas where potentially explosive atmospheres exist such as petrochemical plants, mines and flour mills.
16
The most important points for manufacturers to
consider with ATEX are:
•
•
•
•
•
•
•
•
•
The definition of equipment categories and assignment to
the hazardous zones
The regulation of Ex protection for dust
The inclusion of non-electrical equipment into the directive
The creation of an explosion protection document
concerning the safety of the workplace and materials by
the employer
The requirements for the formal assessment of the
explosion risks
The conformity evaluation process for the equipment by
the manufacturer or a notified body
The production of an EC declaration of conformity and the
affixing of the CE mark to the product by the manufacturer
The certification of the manufacturer's QA system
The provision of a mounting and operating manual with
the equipment
Classification of equipment and hazardous areas:
Equipment is divided into two groups and into
categories:
Group 1 is for the mining industry and group 2 for all
surface industries such as the chemical sector.
The categories M1 and M2 are for the mining industry
and categories 1,2 and 3 for all other industries.
Hazardous area in zones:
Equipment that is supplied to the industries must be
qualified for use to the various zone designations.
Basically only equipment that is approved to the
relevant zone level may be used. The zones and
descriptions are:
GAS, MISTS OR VAPOURS
Zone 0: An atmosphere where a mixture of air and
flammable substances in the form of gas, vapour or
mist is present frequently, continuously or for long
periods.
Zone 1: An atmosphere where a mixture of air and
flammable substances in the form of gas, vapour or
mist is likely to occur in normal operation only
occasionally.
Zone 2: An atmosphere where a mixture of air an
flammable substances in the form of gas, vapour or
mist is not likely to occur in normal operation but if it
does occur will persist for only a short period.
The requirements for ATEX equipment:
For each item of equipment the manufacturer must
produce a declaration of conformity in which is declared
that the equipment fulfils all the relevant safety
requirements. The CE mark is then affixed to the
product. If manufacturers wish to market equipment
within categories 1 and 2 an EC type test certificate
must be obtained from a notified body. If however after
an analysis of the explosion risk shows that no potential
sources of ignition exist then the equipment does not
fall under the ATEX directive.
The Norgren ATEX advantage:
Norgren has been one of the worlds leading partners in
explosion protection for many years. Our engineers are
knowledgeable in the latest legislation affecting industry
and the protection of equipment and personnel within
potentially explosive atmospheres is of the highest
importance to Norgren. We have strongly supported the
development of government regulations and technical
standards to ensure a high level of safety and have
developed a wide range of ATEX certified solutions.
Preventing explosions with Norgren approved
equipment:
As a manufacturer of engineering solutions Norgren
offers an extensive range of certified devices in
categories 2 and 3 for use in areas with potentially
explosive atmospheres containing gases and dusts and
for use in various zones.
Norgren devices conforming to ATEX include:
•
•
•
•
•
•
Fluid control valves
Pressure switches
Motion control valves/valve islands
Proportional valves - IP converters
Actuators
Airline equipment
Norgren is making great efforts to extend this range
even further. No matter which Ex zone is relevant for
your business Norgren will help you find the right
solution and support you with extensive documentation
and certificates of conformity all of which can be
downloaded on: www.norgren.com/atex/
DUSTS
Zone 20: An atmosphere where a cloud of combustible
dust in the air is present frequently, continuously or for
long periods.
Zone 21: An atmosphere where a cloud of combustible
dust in the air is likely to occur in normal operation
occasionally.
Zone 22: An atmosphere where a cloud of combustible
dust in the air is not likely to occur in normal operation
but if it does occur will persist for only a short period.
17
ADVANTAGE | AUSTRALIA
PERFORMANCE AND RELIABILITY
ARE KEY TO TANKER SAFETY
SAFETY RAILS DELIVER SECURITY
18
ADVANTAGE | AUSTRALIA
UP ON THE CATWALK, THE ROUTINE TASKS OF A TANKER DRIVER CAN BE
A HAZARDOUS BUSINESS. THE DANGERS OF STUMBLING OR BEING
KNOCKED OFF BALANCE ARE EVER PRESENT. NOW WITH THE AWARD
WINNING BOOTH SAFETY RAIL SYSTEM, ACTIVATED BY NORGREN
PNEUMATICS, THE UNPOPULAR SAFETY HARNESS CAN BE UNCLIPPED.
Booth Engineering in South Australia installed
the first safety rail system to bulk wine
tankers in 1997. This was in response to
increasing pressure on the tanker operators
from the major wineries and WorkCover (an
organisation managing workplace safety,
injury management and workers
compensation systems) to provide a safe work
environment on top of these vehicles. Wine
tankers have many loading points involving
more activity than usual on the catwalk. Since
that time hundreds of companies transporting
a diverse range of products have recognised
the need for safer tankers and have fitted the
Booth Safety Rail System.
Automatically raised and locked
The Booth Safety Rail System is constructed
from 304-grade stainless steel and is tested
and certified to exceed Australian Standard AS
1657-1992. This standard is relevant to
handrails and the loads they must be able to
withstand. A fixed rail installation on a tanker
could be vulnerable and prove to be an
obstruction when driving or manoeuvring. The
Booth Safety Rail however, when not in use, is
retracted to lie flat on top of the catwalk. Once
the vehicle is parked and in position, to take
on a delivery for example, the safety rail
system can be automatically raised and
locked. Pneumatic actuators power the action
that is started by the simple operation of a
pneumatic switch mounted by the access
ladder. When raised the stainless steel rails
stand at a height of 900mm on both sides and
the front of the tanker's catwalk providing
protection all the way back to the access
ladder at the rear. At half height, steel cables
provide additional restraint. Vehicle weight is
always a consideration when adding
enhancements. With this as an important
design feature the system weighs in at just
80kg.
Proven design
The rails are raised using Norgren
PRA/182000 series profile actuators operated
and controlled from high performance, proven
design, Super X valves. Using Norgren
components a choice of safety interlock
methods is available. The system can either
be connected to automatically apply the
vehicle's spring brakes when the safety rails
are raised or only allow the safety rails to be
raised if the spring brakes are already applied.
Compressed air to power the raising of the
safety rails is supplied from the vehicles
pneumatic braking system. Connections to
this use Norgren FleetFit fittings, specially
designed for use in commercial vehicle's
pneumatic systems. Good air quality is
realised using Norgren's 07 series
compressed air filters.
The local Australian Norgren specialist team
have been closely involved with Booth
Engineering from the beginning of this
product and continue to collaborate with
solutions to new applications such as Multirail systems, workshop systems, air loss
protection and more. The application has
grown from the original wine tankers to
supply protection to tankers in many other
industries, including dairy, petroleum, stock
feed, sugar, flour, aviation and chemical.
Proven in service
Over 1,000 Booth Engineering Safety Rail
Systems have already been fitted and the first
ones have successfully travelled millions of
kilometres. The importance of this product
and its contribution to operator safety is
reflected in the 1997 Victorian WorkCover
Award received for excellence and innovation
in Work Place Health and Safety.
Contact:
Darren Searles
Sales engineer
Norgren Australia
19
ENSURING PNEUMATICS
POLE POSITION AT NEW FORMULA
ONE CIRCUIT
20
ADVANTAGE | CHINA
PROVIDING A BRAND NEW PLATFORM FOR FORMULA ONE RACING THE
SHANGHAI INTERNATIONAL CIRCUIT IN CHINA WILL PLAY HOST TO THE
SPORT FOR THE FIRST TIME EVER IN 2004. HAVING TAKEN PLACE ON THE
26TH SEPTEMBER THE CHINESE GRAND PRIX WAS GRACED WITH SOME OF
THE WORLD'S LEADING MANUFACTURERS AND DRIVERS.
The Chinese Grand Prix will mark the fulfilment of a project
that began at the end of 2002 when initial preparation of the
site began. The distinctive 5.45 kilometre circuit will feature
the necessary infrastructure to accommodate the world of
Formula One and has been completed in just eighteen
months. There will be room for 200,000 spectators with
29,500 seats available in the massive grandstand stadium.
One of the new grandstand stadiums will feature a huge
sliding skylight and Norgren have been chosen to supply an
engineering solution into the open and close control
system.
Reputation for reliability
When the Shanghai Circuit officers were looking for a
supplier of pneumatic solutions the prime concern was to
specify a worldwide company that has built up a solid
reputation for reliability, safety and could offer the state-ofthe-art technology that this control system required.
Relationships with any new project are fundamental to the
smooth implementation. Norgren had built up a sound
relationship with the project team based on technical
expertise. The Shanghai project team needed to work with a
company that could deliver advantage through its
engineered solutions and knowledge to ensure that the roof
control system worked first time every time.
Innovative solution
Offering engineering solutions for many different
applications Norgren has built a reputation for innovation
and with Norgren's products reliability and safety comes as
standard. The first phase of the decision was to compare
various solutions from some of the world's leading
pneumatics companies including Norgren. Thanks to
Norgren's industry experience and innovative solutions the
company was chosen to be the premier supplier of
pneumatics to this exciting new project. Norgren will now
supply the circuit with RM/55463 actuators, V62C directional
control valves and FRLs. This new project clearly
demonstrates Norgren's ability to compete head on and win
through its focused commitment to offering reliable and
safe engineering solutions.
Contact:
David Dai
Direct sales manager
Norgren China
GRANDSTAND AT THE ALL NEW CIRCUIT
21
ADVANTAGE | SPAIN
ENGINEERING SOLUTIONS MAKE
THE DIFFERENCE AT CEHISA
AS ONE OF THE WORLD'S LEADING EXPERTS IN THE FIELD OF MOTION
AND CONTROL TECHNOLOGY NORGREN HAS BEEN SELECTED TO SUPPLY
A WEALTH OF INNOVATIVE ENGINEERING SOLUTIONS TO CEHISA.
Based in Spain and with representation
through out the world, Cehisa is a leading
supplier of edge banding machinery for the
wood working industry. Cehisa's range of
machines combines simplicity of design with
heavy-duty reliability. Ideal for small and large
wood machine shops, the range offers the
benefits of quality, performance and costeffective pricing. It is important to Cehisa that
they partner with companies that keep on
delivering the same benefits to them as they
deliver to their customers.
A particular speciality of Norgren is the supply
of custom solutions tailored to customers'
exacting specifications. The 400 series edge
bander takes advantage of this speciality
through the use of a cutting cylinder that was
specifically designed for Cehisa. Operating in
a similar style to an impact cylinder the unit is
used to cut plywood wedges. The winning
factor for this solution was its excellent
performance characteristics combined with
competitive pricing. This series also called for
a number of highly reliable directional control
valves and the V61 series from Norgren was
the ideal choice due to its solid tried and
tested reputation. Common to both machines
is the use of Norgren's air preparation
equipment which ensures high quality air
supply.
During the early design stages of their latest
machines, Cehisa were looking for a
pneumatics solutions provider that could
demonstrate a flair for innovation combined
with a tried and tested reputation Offering
engineering solutions that are making a
difference in many industry sectors
Cost and technical specifications met
worldwide, Norgren was the natural choice for
Cehisa operate in a highly competitive market
Cehisa.
place. Solutions that are incorporated into
their machines have to meet the desired
High performance demands
specifications and have to be competitively
The Cehisa Compact series of edge banders
priced. Norgren was able to meet their
takes advantage of the many features that
specifications both from a technical and cost
Norgren's VM10 valve island has to offer.
point of view and were able to deliver
Designed to be utilised in applications that
competitive advantage to Cehisa.
demand high performance, the VM10 is at the
heart of the machine delivering the high flow
Contact:
rates combined with modularity that this
Francisco Eqea
application called for. Installation times are
Sales engineer
also reduced through the use of VM10's
Norgren Spain
integral push-in fittings thus helping to keep
the time to market to a minimum.
22
ADVANTAGE | SPAIN
23
ADVANTAGE | USA
FINAL TOUCH 101
INNOVATION AND RELIABILITY
FEATURE HIGHLY IN NEW
PCB ROUTING MACHINE PROJECT
VM10 IDEAL FOR SPACE CRITICAL APPLICATIONS
24
ADVANTAGE | USA
WHEN PRECISION PCB PRODUCTS NEEDED TO REDESIGN THEIR PCB
ROUTING MACHINES THEY TURNED TO NORGREN FOR THE LATEST IN
PNEUMATIC TECHNOLOGY.
High speed PCB depanilisation
Precision PCB Products manufactures a
range of depanilisation routers for use
within the circuit board assembly market.
Drawing on over twenty years of
experience in this market the latest
generation of their routing machines is
the Final Touch 101. This new machine
has been developed to emphasise ease
of operator use, routing speed, accuracy
and more importantly reliability. The new
machine comes in a single or dual
spindle configuration in either a standalone or in an in line automated variation.
Offering increased productivity the
machine allows the operator to rout both
straight and geometric cuts at feed rates
up to 300 IPM.
When Precision PCB were looking at the
pneumatic requirements for the system
they turned to Norgren for design
assistance and guidance. Norgren
engineers are knowledgeable in the
latest issues that affect industry as a
whole and are ideally placed to offer
design advice at all levels. Initially
Norgren engineers sat down with the
design team at Precision PCB to get a
full understanding of what was actually
required in terms of specification. When
selecting the right solution for this
particular application the team had to
take into account factors such as flow
rates and size limitations. One critical
factor for the overall design is reliability
therefore Norgren had to be able to
deliver a solution that was tried and
tested and would offer improved figures
thus giving Precision PCB maximum
machine uptime. Norgren also needed to
recommend a solution that would satisfy
the budgetary objectives that had been
set by Precision PCB Products.
Flexibility combined with reliability
The solution for this project was to utilise
Norgren's innovative range of VM10 valve
islands. Flexibility is at the heart of the
design of the VM10 and it was able to
deliver the three different pressure
ratings that this project required. When
machine manufacturers are looking for
advantages in space savings the VM10
valve island is the ideal choice due to its
compact design. However this compact
design does not degrade performance
and the VM10 features the ability to
handle the most demanding project
specification combined with superb
reliability figures. Norgren's tried and
tested range of EXCELON 72 series FRLs
were chosen for the air preparation and
round line actuators were also utilised
within the automation of the router. The
machine has the ability to be either
manually loaded or automatically loaded.
When the autoloader option is added it
utilises 2 Nugget 30 5/2 valves which
have a reputation for quality and
performance.
Norgren USA puts together the
engineering solution into kit form,
assembles the air preparation and
installs pneumatic fittings. This goes a
long way in reducing Precision's machine
assembly time thus giving them a
competitive advantage through lower
manufacturing costs and reduced time to
markets.
"Precision PCB Products is using
Norgren as a major supplier of
pneumatic solutions on all models of our
routing machines" said Joseph Drier
President of PCB Products. "This
industry requires us to work with
suppliers that can offer innovative
solutions combined with highly reliable
products and we are also able to take
advantage of the costs savings that can
be made by purchasing from one
supplier. Precision PCB also get the
benefit of dealing with a supplier that
offers very good technical support and
fast response times"
Contact:
Mike Gibbons
Direct sales manager
Norgren US
Reducing machine assembly times
However this project goes beyond just
supplying correct product solutions.
25
ADVANTAGE | IRELAND
ENGINEERED SOLUTION
HITS THE SPOT IN
LABORATORY AUTOMATION
Deerac Fluidics™ is a global leader in the development
and production of reliable, robust and user-friendly
liquid handling solutions, enabling the addition and
transfer of micro litre and nano litre volumes of a wide
range of fluids. Employed within its range of Equator™
bench top liquid handling products Deerac Fluidics™
utilise a proprietary non-contact low volume spot-on™
liquid handling technology. Utilised within the
disciplines of drug discovery, genomics, proteomics and
diagnostics the spot-on™ technology brings significant
improvements to existing assays by assisting in the
increase of throughput and the decrease in assay costs.
At the core of the spot on technology is a unique
pipetting tip that enables volumes to be dispensed in
the range of 50nL to 20uL. This utilises a pressure/time
valve mechanism based on the real time feedback
control of the movement of a magnet boss that is held
in the tip body. The magnet movement is actuated by
applying a current through an electronic coil assembly
situated outside the tip.
Customised solutions
An integral part of the spot-on™ pipetting mechanism
is a pneumatic reservoir that maintains the correct
pressure holding of air to facilitate the aspiration and
dispensation of liquid in to the system. This function is
performed by a series of valves connected to a sub
base. Ensuring that the pneumatic pump is not in
operation all the time the valve sub base incorporates a
reservoir to hold air. This reserve maintains the
pressure needed in the system to facilitate the efficient
running. The system simply draws on the air contained
in the reserve as and when it is needed and the
26
pneumatic pump tops up the air levels when required.
However this valve system and block was not an "off the
shelf item". Deerac needed to partner with a motion
and fluid control specialist that could design and build a
suitable solution for the Equator's™ pneumatic needs.
Norgren engineers have many years experience in the
design and build of customised engineering solutions
and were able to take Deerac's design ideas and turn
them into reality.
Tried and tested performance
The solution was to utilise Norgren's tried and tested
Webber EXCEL. The Webber EXCEL series is mounted
onto a sub base system and in conjunction with Deerac
Norgren engineers modified the sub base to include
vacuum and pressure chambers thus delivering the
reservoir of air that the system called for. Also due to
the fact the Equator™ series is a bench top instrument
Deerac needed a design that was compact because of
the lack of installation space. The Webber EXCEL series
from Norgren creates competitive advantage for Deerac
thanks to its compact form and ease of installation.
Deerac now have a solution that meets the desired
specification and was easy to fit.
Contact:
Dave Whelan
Field sales manager
Norgren Ireland
NORGREN HAS DELIVERED AN APPLICATION-SPECIFIC SOLUTION
TO DEERAC FLUIDICS™ TAILORED TO MATCH THEIR INDIVIDUAL
SPECIFICATION REQUIREMENTS.
27
ADVANTAGE | NETHERLANDS
ENSURING FOOD HYGIENE
STANDARDS
28
ADVANTAGE | NETHERLANDS
Located in the southern part of the
Netherlands in a town called Oss, Townsend
Engineering developed a continuous sausage
manufacturing system based on the coextrusion principle. Compaxo a producer of
meat delicacies in Gouda ordered two of these
co-extrusion systems for the manufacturing
of a wide range of sausages. The same
company also bought in two sessions a
number of sausage curing/fermenting
systems.
The history of Townsend started in the 1940s
when Ray Townsend, who was working in his
father's blacksmith shop, was on occasion
asked to do custom fabrication at a local meat
packing plant in Des Moines, Iowa. Ray
observed that it took many people to remove
skin from various pork cuts, and he developed
a machine to remove the skin mechanically.
Continuous production
Townsend developed a continuous sausage
manufacturing system based on the coextrusion principle. The main difference
compared to more traditional ways of sausage
making is, that the tubular (natural,
preformed or cellulose) casing literally does
not exist. The casing material comes from
selected cattle hides, as an in acid swollen
collagen fibre paste manufactured according
to a special process.
Hygienically safe
Pneumatic cylinders often come near the
process of manufacturing food products. For
this reason there are strict requirements
concerning corrosion resistance, non toxic
and non absorbing of the used materials.
Norgren's pneumatic cylinder series
KM/55001/M, with a smooth surface, is
About 20 years later, in 1962 the first semispecially designed so that it can be cleaned
automatic sausage linking machine was
properly. These cylinders are specially
introduced by Townsend Engineering. Since its developed for areas where food is processed
introduction the sausage making industry has according to HACCP / EN 1672-2 and are
seen remarkable developments. The most
aggressive detergent resistant. In the above
recent and far reaching development is comentioned sausage curing/fermenting
extrusion to overcome the negatives related to systems a large number of the Norgren
traditional sausage making.
Pneumatic cylinders are in operation. In each
system 64 of these cylinders are being used,
40 with diameter Ø100mm, 12 with Ø40mm
and 12 with Ø32mm.
Product availability
Norgren Press-lube is used for the lubrication
of the various systems conveyor-chain that
have a length of 700m. In a stainless steel
cabinet a patented micro-fog lubricator is
mounted. From this pulverized aerosol oil
cloud only the finest particles smaller than 2
micron are air born. This method of central
lubrication is the solution for complex or long
networks with compressed air. With this
lubricator the oil particles can be transported
over 300m. Norgren is a truly international
company with a guaranteed product
availability and local support anywhere in the
world, via a global service network of Norgren
Market Companies and independent
distributors. This was an important reason for
Townsend to choose Norgren as their supplier
for pneumatics and industrial automation.
Today, Townsend equipment is being used in
over 100 countries throughout the world.
29
AUSTRIA
Tel: +43 22 36 63 520
Fax: +43 22 36 63 520 20
[email protected]
DENMARK
Tel: +45 44 91 41 66
Fax: +45 44 91 15 60
[email protected]
INDIA
Tel: +91 11 2681 7933
Fax: +91 11 2681 7932
[email protected].
NETHERLANDS
Tel: +31 20 6822751
Fax: +31 20 6820983
[email protected]
SPAIN
Tel: +34 93 748 9800
Fax: +34 93 783 0838
[email protected]
AUSTRALIA
Tel: +61 3 921 30 800
Fax: +61 3 921 30 890
[email protected]
FINLAND
Tel: +358 95 712 140
Fax: +358 95 712 1440
arki@imi–norgren.fi
IRELAND
Tel: +353 1 8300 288
Fax: +353 1 8300 082
[email protected]
NEW ZEALAND
Tel: +64 9 579 0189
Fax: +64 9 526 3398
[email protected]
SWEDEN
Tel: +46 40 59 51 00
Fax: +46 40 49 50 90
[email protected]
BELGIUM & LUXEMBURG
Tel: +32 2 333 44 11
Fax: +32 2 376 26 34
[email protected]
FRANCE
Tel: +33 1 60 05 92 12
Fax: +33 1 60 06 08 52
[email protected]
ITALY
Tel: +39 039 60 631
Fax: +39 039 60 63 301
[email protected]
NORWAY
Tel: +47 67 90 82 01
Fax: +47 67 97 06 24
[email protected]
SWITZERLAND
Tel: +41 71 973 82 00
Fax: +41 71 973 82 01
[email protected]
BRAZIL
Tel: +55 11 5698 4000
Fax: +55 11 5698 4001
[email protected]
GERMANY
Tel: +49 2802 49–0
Fax: +49 2802 49356
[email protected]
JAPAN
Tel: +81 6 6876 8913
Fax: +81 6 6876 8929
Japan@imi–norgren.com
POLAND
Tel: +48 22 518 9530
Fax: +48 22 518 9531
[email protected]
UK
Tel: +44 1543 265 000
Fax: +44 1543 265 811
[email protected]
CHINA
Tel: +86 21 64 85 69 09
Fax: +86 21 64 95 60 42
[email protected]
HONG KONG
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Fax: +852 2498 5878
[email protected]
MALAYSIA
Tel: +60 3 5121 9255
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Tel: +65 6862 1811
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CZECH REPUBLIC
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Fax: +420 465 612 908
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HUNGARY
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[email protected]
MEXICO
Tel: +52 55 1500 64 00
Fax: +52 55 5565 70 72
[email protected]
SLOVENIA
Tel: +386 4 531 7550
Fax: +386 4 531 7555
[email protected]
Supported by distributors worldwide
www.norgren.com
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© IMI Norgren Limited 2004.
Due to our policy of continuous
development, Norgren reserve the right to
change specifications without prior notice.
z6744_IPS EN 01/05
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