Ensuring safe fire protection.

Ultra-reliable is the only standard acceptable when it comes to building, testing and maintaining water pumps for fire fighting. To ensure all of its pumps are fully able to provide maximum performance instantly, under all circumstances, Ruhrpumpen has built a dedicated fire pump centre in Lancing, West Sussex (GB) and fitted its test-rig with "the best torque sensors it could find on the market".

David Gentle, Ruhrpumpen Industrial Europa Product Line Manager for EU Fire Systems, says: “We are a very high tech industry, but there is also a lot of human intelligence and input into our operations. We really value the support from the team at Sensor Technology and know we will always get a quick response from them, no matter when we call. TorqSense transducers are lightweight, easy to use and we have recommended their adoption by our group subsidiaries around the world, all of whom are FM/UL certified."

Ruhrpumpen is a global leader in high technology pump systems and is a major player in industries such as oil and gas, water distribution, chemical production, continuous processes, and nuclear power. Identifying fire fighting as a crucial sector, it set up Ruhrpumpen Industrial Europa Ltd (RPIE) a Factory Mutual (FM) and Underwriters Laboratories (UL) certified manufacturing facility for fire water pumps in Britain. The FM and UL Approvals Bodies audit the facility quarterly, inspect calibration certification and carry out flow, pressure, power, NPSH (net positive suction head) and other relevant tests as required, ensuring that the facility maintains world-class standards at all times.

Ruhrpumpen Industrial Europa Ltd’s state-of-the-art fire pump manufacturing centre is fully equipped to design, assemble, test and package fire pumps for European market requirements. It can also produce standard and highly-engineered pumping systems for a wide range of other applications industries, often using the technical requirements of firefighting to set benchmarks in other industries.

In addition to pumps and systems for use in Britain and Europe, the facility also provides parts and support for highly-engineered pump equipment to other Ruhrpumpen companies around the world, and offers product and system testing, training and specialist consultancy services.

With the test-rig TorqSense transducers measure and record instantaneous torque levels in rotating pump drive shafts, with analysis of the data confirming real-time performance standards, in testing operations.

TorqSense comes in a range of sizes for measuring torque, both rotary and static, from 10mNm up to 13,000Nm. Different ranges are based on different technologies, including full four element strain gauge bridges and optical measurement. None of these require hard wiring with slip rings, instead being designed for use with wireless radio frequency pick-ups which make set up and adjustment fast and simple.

Working with clients, experts from Sensor Technology can recommend the best transducer for each application.

As is a requirement in all fire pump testing, the torque transducers are all regularly calibrated by an independent ISO 17025 accredited calibration laboratory.

There is also a full range of data display, recording and analysis interfaces. Again, it is the work of moments to integrate these with the sensor heads. However, with fire water pumps being such a specialised and highly regulated field, Ruhrpumpen decided to use bespoke data systems developed to directly address the needs of the industry. With these, data is recorded and analysed in Ruhrpumpen’s own performance test app before the final pump Test Report is made available. Naturally everything is tested and verified by qualified independent bodies on a regular basis.

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@sensortech @ruhrpumpen #Pauto

Intelligent grippers!

COVAL offers manufacturers a range of vacuum grippers suitable for handling of parts of various sizes, weights, and materials. This gripper range has been extended with the latest CMS HD series multistage vacuum pumps, developed by COVAL. With this enhancement, the new generation of grippers meets the demands of Industry 4.0 with greater robustness, communication, and modularity.

COVAL's range of vacuum grippers is based on two complementary solutions. The CVGL is characterized by its lightness and great adaptability. It is available as standard in several lengths, power ratings, and gripping interfaces.

A Vast Range of Applications With their great modularity and ease of integration in all contexts, CVGL and MVG vacuum grippers can be found in many industries: packaging, plastic, metal, and wood for handling porous and non-porous objects. Qualities that make the difference: • Solutions adapted to each process • Configurable vacuum grippers • Robustness, longevity, and economy of use • Vacuum grippers with communications capability for Industry 4.0

The MVG, on the other hand, offers the possibility of configuring the gripper to allow it to be perfectly adapted to each application by determining the length, width, gripping interface, and vacuum generator while guaranteeing extreme lightness. It offers a tailored solution that integrates perfectly with handling robots.

COVAL's new generation of vacuum grippers now incorporate the latest CMS HD series of vacuum pumps. These pumps have a heavy-duty design for high reliability even in harsh environments (IP65), capable of ensuring 50 million cycles. A factor of the pump’s longevity is their modular design which allows specific configurations and targeted maintenance of specific parts to optimize repairability. As a result, the new generation of CMS HD multistage pumps adds to the vacuum grippers´ reliability and adaptability.

Vacuum Grippers Become Intelligent
The new COVAL vacuum grippers offer a choice of three multistage vacuum pump configurations, depending on the needs of the integrator or end user: non-piloted, piloted, and communicating.

The communicating configuration, which makes the vacuum grippers easier to use and parameterize, is obtained by integrating the CMS HD VX version of the multistage pump. The VX pump version features an IO-Link communication interface, compliant with the international IEC 61131-9 standard, for fast and cost-effective installation, continuous diagnostics, centralized parameterization, and efficient communication with higher-level protocols (EtherNet/IP, PROFINET, EtherCAT, etc.).

It can also support a Human Machine Interface (HMI) with NFC interface, enabling the operator to read and modify setup parameters and diagnostics from a mobile device (Android or iOS) using the dedicated COVAL Vacuum Manager app.

With these pump capabilities, the new generation of COVAL vacuum grippers become even more versatile and perfectly compatible with the robot systems at the heart of Industry 4.0.

@COVAL_SAS @mepaxIntPR #PAuto #Automation

Hydrostatic transmissions.

Danfoss Power Solutions has launched its PC-GO propel solution for single pump/motor hydrostatic transmissions. Comprising the new PC036 safety controller and PC-GO propel software, the ready-to-use platform cuts propel subsystem development time by up to 35% while simplifying compliance with environmental and safety regulations. The software is ideal for a wide variety of applications, including wheel loaders, telehandlers, dump trucks, street sweepers, and forestry equipment.

PC-GO is a fully developed propel system software solution that’s configurable using the Danfoss PLUS+1 service tool for quick and simple customization. Housed on the PC036 controller, the system is designed to work with Danfoss hydrostatic pumps and motors, offering easy and seamless integration of the entire propel system. This results in short and focused development cycles with fast machine startup.

“PC-GO’s validated software package and preconfigured parameters enable machine startup in less than three days. Comparatively speaking, it could easily take two years to write a program like this from scratch,” said Aaron Rodriguez, product application engineer, Danfoss Power Solutions. “Our plug-and-perform system embeds more than 30 years of experience in the automotive field so there’s practically zero development effort, which is highly beneficial to OEMs without large software engineering teams.”

PC-GO offers multiple adjustable drive modes, including an ECO mode feature that maintains the desired vehicle speed in transport mode while reducing engine speed. This reduces idle losses of the work function hydraulics, lowering fuel consumption and noise, and can allow for engine downsizing.

PC-GO offers numerous built-in protections, including engine overspeed protection, pump and motor overspeed protections, mode-dependent speed limitation, cold start protection, and temperature protection. In addition, the software includes pressure limiting, cruise control, and anti-stall, as well as robust error monitoring. With its PC036 safety controller, PC-GO is a PLd SIL 2 functional safety compliant system. It features fully integrated safety functions and has been tested, validated, and documented for compliance with international safety regulations such as Machinery Directive 2006/42/EC.

The PC036 controller’s robust housing offers reliable performance in harsh environments. It can be mounted inside the engine compartment or elsewhere on the vehicle, providing greater installation flexibility.

@DanfossPower @Danfoss @NapierPR #PAuto #Sustainability

Energy efficient motor-drive solution.

High efficiency, energy-saving motor with integrated fanless inverter suited to both new installations and retrofitting

The MPD Series inverter with motor, suitable for pump and fan applications has been launched by Delta. The new series delivers the benefits of energy efficiency, intelligent water supply and ease of operation by featuring a Delta MSI class IE5 energy efficiency synchronous reluctance motor coupled with a motor-mounted Delta MP300 variable frequency drive. This combination drives down the cost of daily operation, while the high level of integration supports decentralized solutions, reducing wiring and simplifying setup. Available in power classes from 0.75 to 22 kW, it features the IP55 construction that keeps out dust and jetted water from all directions. The fanless drive provides long-term reliability and low maintenance.

“Whether targeting residential areas, commercial buildings, or factories, pump system manufacturers can be sure of delivering their customers’ significant energy savings. Additionally, thanks to the integrated monitoring system the drive can handle the conditions that lead to mishaps such as flooding and production delays in the pump system. With support for IEC standard motor flanges, the MPD Series is ideal for both new installations and retrofitting,” said Martien Heesterbeek, Product Manager of Industrial Automation Business Group, Delta Electronics EMEA region.

Energy-efficient and fully featured.
With energy costs rising, the efficiency of water pumps during operation is of growing importance. Thanks to the use of a high-efficiency motor coupled with the latest variable frequency drive technology, the MPD Series fulfills efficiency class IES2 according to IEC 61800-9-2. The motor-mounted Delta PLC supports 14k steps to implement a range of multi-pump operating modes, such as alternating operation to facilitate maintenance and extend equipment life, constant pressure mode for energy-efficient staging, and redundancy.

A sleep mode can automatically detect falling water demand, entering a hibernation mode to avoid frequent switching on and off. The integrated clean function removes foreign objects from the blades and minimizes extended periods of no operation. Scheduling can also be defined to improve overall energy efficiency. Further protection mechanisms, such as burst pipe and high/low pressure detection, limit property damage by stopping water flow and providing an alarm output. Should the water supply be cut off, the pump slows to a stop to avoid damage. Cavitation events are also monitored: If small vapor-filled cavities form in the pump, the inverter can give an immediate warning in order to increase reliability and reduce wear.

System integration through smart communication.
The MPD Series offers an in-built RS-485 communication interface for easy integration into existing control systems. If required, optional communication cards are available for EtherNet/IP, DeviceNet, and PROFINET DP. An optional Bluetooth communication interface is also available for more efficient commissioning and maintenance. When coupled with the Android app, smartphone users can access operational information via a dashboard, configure pump operating parameters, and are provided with handling guidance on error messages. If desired, the motor drive, MP300, is available separately for use with alternative motors.

@mepaxIntPR #deltaww #PAuto #Water

Pump for polyurethane processing.

Pump technology plays a central role in processing reactive polyurethane components, where precise metering, reproducibility and efficiency are key. The new 'HX' pump series, an in-house development by Hennecke's polyurethane experts, marks an important milestone in polyurethane processing, just like the invention of the first high-pressure mixhead by Hennecke. It is the very first axial piston pump produced exclusively for polyurethane applications, offering Hennecke's customers real added value in polyurethane processing.

A wide range of first-class pumps in different series, which are perfectly matched to the respective application and in particular to the required output is available. As a global market leader in PU technology, Hennecke gives its customers highly specialized solutions for pump technology, just like with its mixhead portfolio, and ultimately making production even more competitive using their mixing and metering technology. Concentrating on processing aspects and market requirements, Hennecke's application experts have developed a completely new pump generation in the last two years, which is to be manufactured at the company's site in Germany. Here, the focal point is a precise, highly efficient, and future-fit metering line,

The enhanced pump housing design has a new bearing seating which allows for maximum flow around the bearing. This ensures efficient heat dissipation whilst at the same time preventing a rise in the reactive media temperature. Multiple tests have shown an effective flow of heat between the functional surfaces and the pump housing, even at maximum operating points, which is demonstrated by a clearly measurable temperature gradient. Comparable measurements from conventional pumps on the market show that heat often builds up even at room temperature and that comparatively high temperatures are reached inside and around the housing. The new HX with effective built-in cooling offers decisive advantages even in unfavorable operating conditions with comparatively high ambient temperatures.

The pump's pressure resistance reaches up to 16 bar with open circulation. This is up to 60 percent higher than comparative models by competitors. Operating with open circulation brings a clear advantage in terms of process technology. Combined with the open pump construction and resulting improved suction, this is particularly beneficial when using highly viscous polyols. And it may even mean that pre-pumps are not required, depending on the application.

As well as its extremely broad application range, the HX series features state-of-the-art sensor technology. The integration of digitalized smart features within the metering line was an extremely important aspect in the pump's development process. To ensure for example that process parameters can be recorded 'on the spot', Hennecke's engineers have incorporated pressure and temperature monitoring into the pump housing. The pumps also have additional internal sensors. These include a distance sensor for monitoring the pump bearings, an important feature for predictive maintenance work. The company's clear, long-term goal is to expand the use of intelligent sensor technology, for example to advise of upcoming maintenance measures in advance.

The increased efficiency of the pump is ultimately conveyed through an optimized energy balance in the entire system. Chemical systems using bio-based and recycled content polyols can also be easily processed. Low noise emissions during operation are another plus point for the pump.

Real added value is available when both the pump technology and the metering function are solid. Secure and calculable service measures are crucial, for example, particularly for complex application scenarios or high production volumes. This includes the easy-to-service design with integrated safety valve as well as the guaranteed long-term supply of spare parts.

The new HX series is available now in sizes HX06, HX12 and HX28, exclusively for Hennecke's new generation metering machines. The HX portfolio will be extended in the future to include even more sizes. 

@HenneckeGroup @PresseBox #PAuto 

Digital Displacement pump wins Agri award.

The Danfoss DDP096 Digital Displacement® pump has been named a winner of Agritechnica’s prestigious Systems & Components Trophy 2022. Presented by DLG, the German Agricultural Society, the award recognises the inventive spirit of industry suppliers and their importance to agricultural technology. The Digital Displacement pump triumphed as one of three winners from among 20 nominees.

Alasdair Robertson, director of product portfolio and marketing for Digital Displacement, Danfoss Power Solutions, accepted the award at a virtual event held February 8 as part of the Agritechnica 2022 digital program.

“We are excited and honored to win this prestigious award,” Robertson said. “The fact that industry development engineers recognised our product as an outstanding innovation makes it even more significant and highlights the advantages Digital Displacement can bring to OEMs in the agriculture sector.”

Delivering hydraulic fluid power with both high efficiency and controllability, the Digital Displacement pump uses solenoid valves to control each cylinder on a shaft-turn-by-shaft-turn basis. The technology offers a fast response rate and reduces energy losses by up to 90% compared with conventional pumps. Additionally, it is possible to bring groups of cylinders out to the endplate for independent control, creating a multi-service pump in a compact package. Original equipment manufacturers can take advantage of up to three separately controllable outputs from a single pump body.

This level of innovation caught the eye of the awards jury, which comprised development engineers from leading agricultural OEMs. Judging criteria included practical significance and benefits to profitability, processes, environment, energy use, workload and safety.

@Danfoss @AGRITECHNICA @DLGeV @NapierPR #Agriculture

Predictive maintenance in pumps.

Omni recently installed a pair of pumps and wanted to monitor vibration as an indicator of their operating condition. The goal was to integrate the measured signal into the existing BMS system to provide predictive maintenance reporting to the service team in order to avoid unplanned downtime.

While choosing a sensor, it was determined that a combined vibration/temperature sensor could be obtained at a small additional charge to add temperature monitoring as well. The logical location for the sensor was at the most likely point of failure, the drive motor end bearing. Fitting the sensor was straightforward. The problem then became how to integrate the collected data into the BMS.

Contemporary Controls was approached with the problem and suggested a solution utilizing the BAScontrol22 unitary controller which supports BACnet/IP and Sedona using a 2-port Ethernet switch connection. The controller complies with the B-ASC device profile having a convenient mix of 8 universal inputs, 4 binary inputs, 4 analog outputs and 6 relay outputs. Unique to the unit are 48 web components which link Sedona wire sheet readable/writeable data to web pages, and 24 virtual points which link Sedona wire sheet readable/writeable data to a BACnet client.

The sensor’s 0 to 10VDC temperature and 4 to 20 milliamp vibration outputs were easily input into the BAScontrol. The free Sedona drag-and-drop programming methodology of assembling components onto a wire sheet was then used to create the application.

Utilizing the BAScontrol22’s BACnet/IP interface, the data was then available to the BMS. By operating at the BACnet/IP level, the BAScontrol22 can share the same Ethernet network with supervisory controllers and operator workstations. The unit can be configured for a fixed IP address or can operate as a DHCP client receiving its IP address from a DHCP server. A real-time clock with a supercap backup allows for creating local schedules.

The customer then created graphics and alarms. Manufacturers data confirmed that the bearings should be serviced at 40°C., so an email alarm was set to alert the maintenance team if this value was reached. The vibration data was more about degradation of the data trends, so again an alarm was set slightly above the average value. A second alarm at a higher value was set for both the above to allow the operators to monitor a value that had gone over the first limit as well as a backup alarm for a critical failure.

Predictive maintenance techniques are designed to help determine the condition of in-service equipment in order to estimate when maintenance should be performed. This approach promises cost savings over routine or time-based preventive maintenance and avoids a “run to failure” approach by being more proactive.

#CControls #PAuto 

Mini-vacuum pump.

After the launch of the LEM, a new generation mini vacuum module integrating, in a smaller size, all the functions of the vacuum pump, COVAL has entered a new phase with the LEMAX. Emphasis with this new product is on energy saving through continuous monitoring and regulation.

Areas of use COVAL recommends using the LEMAX for gripping airtight pieces in the following materials: glass – plastic – treated wood – sheet metal … Industries concerned are: Packaging - Robotics - Plastics Applications: Clamping, transfer. What makes the difference • ASC technology : energy consumption reduced by 60 to 97% • Integrated regulation : energy savings, reduced consumption and noise level • Reduced size : assembly near the suction cups for better efficiency • Holding time : Two times faster than multi-stage technology • Non-clogging : Thanks to the through-type silencer, no maintenance necessary

With this new mini-pump, the guiding principle is energy saving. The LEMAX integrates ASC (AIR SAVING CONTROL) technology for the very first time. It generates energy savings of between 60 to 97%, depending on the applications.

Air is only consumed to create the vacuum and to enable gripping and moving the piece. Once the regulated vacuum level has been reached, a valve closes, enabling the piece to be held without any consumption of energy. If the vacuum level drops, an air intake is generated until it returns to the initial value.

The ASC analyses the application and adapts to airtight or porous pieces in order to optimize energy use and consumption.

Compactness: the LEMAX integrates all the main functions in a single module: pressure control, pilot solenoid valves, non-clogging through-type silencer, electronic vacuum switch, M8 connector (Plug & Play direct connection), and adjustable blow-off. Its reduced size and weight (130 grams) enables it to be connected as close as possible to the suction cups for reduced gripping time without drop in pressure.

Communication: The LEMAX supplies accurate information to the user at each operation phase. It has a dialogue façade which operates directly on the electronic card, controlling the main functions and settings.

Modularity: the LEMAX adjusts itself to the needs of the integrator and user. It is available in 6 configurations: three standard nozzle diameters (1; 1,2; 1,4 mm) allowing an intake flow of 29 à 70 Nl/mn (90% maximum vacuum).

It can be provided with a normally closed (NC) or normally open (NO) solenoid valve. This alternative is recommended for applications where safety of the gripped piece must imperatively be ensured during an inadvertent power failure, this even in the case of leakage (fail-safe).

It is possible to combine several LEMAX on island assemblies with a single pressure supply.

@COVAL_SAS #PAuto

PLC support helps pump OEM create application-specific water pressure boosting systems.

The easy configurability of ABB's AC500 PLC range is helping the specialist pump OEM, Plad Equipment, to rapidly produce application-specific pump systems for boosting water pressure in high-rise buildings.

Plad's dual- and triple-pump systems are widely used for pressure boosting. However, virtually every application in the buildings market demands a degree of customization, both operationally, and in form factor - to fit into the spaces available and interface to pre-determined inlet and outlet piping. To simplify the operational configuration of pump control, Plad decided to standardize on ABB PLC control for water pressure boosting systems.

Before the switch, Plad had used ABB drives for a long time, but tended to buy its PLCs from different suppliers, and to integrate the control system in house. This multi-supplier approach had led to the occasional system integration problem in the past. So, when ABB approached Plad to talk about its ongoing development of a new modular 'water library' of PLC software - which features a large range of relevant pump control and data collection functions - Plad became interested.

ABB proposed a new pump control solution based on the continued use of ABB's ACS550 variable speed drives, but with control provided by the AC500 PLC. To demonstrate the effectiveness of the drive and PLC combination, ABB developed a flexible control program, which utilized many pump control functions from the development version of its Water Library software.

It was clear to the OEM that this proposed solution offered a great deal of flexibility, allowing Plad to configure one master software package for dual or triple pump systems, as well as select other operational parameters required for different types of high-rise building water pressure boosting.

ABB's example design also provided a number of technical advances over Plad's own previous control system arrangements. The use of Modbus RTU networking eliminated equipment cabling and simplified system assembly. The ABB PLC’s high level Function Block library for communications also simplified data exchange with the ABB drives, speeding control development and simplifying maintenance tasks on Plad systems.

The proposed control solution, combined with ABB's obvious willingness to provide in-depth support on control matters, proved very attractive for Plad. So, Plad made the switch and now specifies ABB PLC and drive systems for all of its pumping systems for the building market.

"We are pumping specialists first," says Robert Delisle, director of Plad Equipment, "so, standardization on a single control systems supplier makes a lot of sense. It means that we sidestep any potential system integration problems. However, the key deciding factor in choosing ABB as our supplier was its willingness to act as a technical partner and provide in-depth support. If a user needs new functionality we can always call on ABB experts to discuss or help us implement a change. This partnership becomes very attractive for a mid-sized OEM like us - allowing us to focus most of our technical resources on our core pumping technology and applications know-how - and I believe it will help us to expand our business."

"Having a strong relationship with a customer makes it easy for us to invest our own time - to ensure that our products are used in the most efficient way, and to use our control systems expertise to help clients meet new challenges," adds Patrice Bélec, a PLC Product Specialist with ABB Canada.

The pumping systems that are used for water pressure boosting in high rise buildings can be configured in many different ways depending on factors including the water pressure available, the size of the building, the spaces available for risers and equipment such as valves and break tanks on higher floor levels. To deal with this complexity and match the solution to the application, Plad offers a broad range of pumping systems with many configuration choices such as the ability to have dual or triple pumps to meet varying demand levels and for reliability, variable speed operation, local or remote instrumentation. Systems are also typically assembled on small skids, which allow a great deal of flexibility over the size and shape of the finished system. The pumping action required from each system can also vary greatly in complexity depending on the application and the needs of the user, and custom-made control panels are fitted to almost every system shipped.

The combination of the proven ACS550 drives and AC500 PLC in this application add - on top of energy efficient operation - flexibility and connectivity to Plad's pump product lines. This facilitates simple maintainability and ensures that future requirements can be incorporated with minimal engineering efforts by a PLC engineer. The AC500 also acts as the central interface for several pumps or ACS550 drives to the system's CP600 HMI panel, enabling open interaction, monitoring and visualization of single pumps, as well as the whole pump-set configuration.

European pump conference!

WEG is to sponsor the Europump Conference which is to be held at St. Andrews in Scotland in May 2014.

As part of its involvement in the event Mr Siegfried Kreutzfeld, Managing Director- Motors Division for WEG is to deliver a paper to the delegates that will address the market trends for alternating current, permanent magnet and synchronous reluctance motors. WEG is of course well-placed to deliver a research paper on these subjects as a global leader in energy efficient motors.

This conference is hosted this year by the British Pump Manufacturers Association (BPMA) conducts vital work for the pump industry on legislation and standards and is a combination of presentations, working groups and committees and networking meetings.

Commenting on the decision to invite WEG to sponsor the conference for 2014, Steve Schofield, Director of the BPMA said, “The work that takes place during the conference is vital to the well-being of the pump industry in Europe and of enormous value. We were pleased to align ourselves with WEG as the sponsor, as the company has an outstanding reputation for pushing the boundaries in motor and automation technology.”

Commenting on the sponsorship Marek Lukaszczyk, Marketing Director for Europe for WEG said, “Obviously the pump industry is closely aligned with WEG as a manufacturer of electric drives and motors commonly used within the fluid movement industry. The opportunity to help facilitate the Europump conference and to help make the event a success, is something we are proud to be able to do.”