Commenting for Curtiss-Wright, Senior Vice President & General Manager of the Industrial division, Kevin Rayment says: “The Industrial division has more than 50 years experience in providing control and feedback solutions for numerous applications and we’re no newcomer to high-octane and motorsport applications where custom sensors are often specified.”
Thanks to the experience gained from its aerospace businesses – where reliability under extreme and hostile conditions is paramount – Curtiss-Wright’s sensors have become a benchmark for motorsport applications and are used in numerous race series including the American Le Mans Series (ALMS), Formula One (F1) and Formula Student. In fact, from the moment a leading F1 team adopted a custom-engineered Penny + Giles sensor as part of its revolutionary active suspension system, to today’s unique Hall-effect position sensors, we can proudly boast to have been the first position sensor manufacturer to enter motorsport and have supplied every F1 championship winning team since 1986.
“With a performance to match today’s Formula racing cars, the single-seat Mono required an equivalent level of intuitive direct control, so BAC designers and engineers specified components that were themselves designed and engineered for the racetrack,” says Mr. Rayment.
With motorsport very much in mind during its evolution, Mono was the vision of BAC design director Ian Briggs. However, he also wanted the car to feel at home as much on country lanes as it does on the race track. Mr. Briggs noted, “I wanted Mono to be high tech and totally fresh in its approach. A car for people who want to feel a connection, and be really involved in the character of the car they drive. It had to be a car people would be consistently excited by, and would experience pride in owning. In short, Mono is a totally immersive experience, from start to finish.”
Operated via steering wheel-mounted paddles, Mono uses an F3-specification, six-speed sequential Hewland gearbox with an electronic/pneumatic semi-automatic, closed-loop gear selection system that delivers paddle-shift changes in 35 milliseconds. This is coupled to a 2.3 litre, 285bhp four-cylinder Cosworth engine enabling the Mono to achieve a 0-60mph time of less than three seconds.
The closed-loop control system on Mono uses a gearbox control unit (GCU) with inputs from a Penny + Giles gear position sensor to alter its own operation in real-time. During gear changes, the closed-loop system monitors the gear position sensor to determine the angular position of the gearbox selector barrel. Information from this is then relayed to the GCU to ensure use of the throttle blip, torque reduction or pneumatic actuator where necessary, to effect consistently quick and reliable gearshifts.
As BAC co-founder and technical director Neill Briggs explains, when a gear position sensor was required for the Mono’s gearbox, specifying Penny + Giles was the obvious choice. “Used to relay gear position feedback to the GCU, sensors were vital during BAC’s development of Mono and are as vital under normal and track day driving conditions in informing the driver of the car’s current gear. We therefore needed a sensor that was dependable, reliable and met our exacting requirements for Mono, so we called Penny + Giles.”
Standard Penny + Giles SRH280P rotary position sensors use a factory-programmable, non-contact Hall-effect sensor system to provide reliable and accurate rotary position measurement in extreme motorsport and industrial environments where shock and vibration can occur. Additional key features include single or dual output channels; total sensor measurement range from 0-20° to 0-360°; low noise level (1mVrms) on output signal; crush-proof mounting flange with steel inserts; and rapid availability.
Using the popular 38mm flanged housing and with an environmental protection rating to IP68, the sensors operate from either 5Vdc regulated or 9-30Vdc unregulated power supplies and are available with analog (0.5 - 4.5Vdc and 0.1 - 4.9Vdc) or digital (PWM) output signals. The sensor is factory programmable – allowing OEMs to specify the output signal type, measurement range (0-20° to 0-360° in 1° increments) and output direction (clockwise or anticlockwise) – has a 12 bit resolution (0.025%) over the selected measuring range, and operates from -40 to +140°C when powered at 5Vdc.
Curtiss-Wright’s Industrial division is a recognized leader in the production of critical controls and assemblies for specialty vehicles, including sensors, electronic throttle controls and joysticks. For further information about Penny + Giles products and other innovative solutions available from Curtiss-Wright’s Industrial division, please visit www.cw-industrial.com or call +44 (0)1425 271444.
About Curtiss-Wright Corporation
Curtiss-Wright Corporation (NYSE:CW) is a global innovative company that delivers highly engineered, critical function products and services to the commercial, industrial, defense and energy markets. Building on the heritage of Glenn Curtiss and the Wright brothers, Curtiss-Wright has a long tradition of providing reliable solutions through trusted customer relationships. The company employs approximately 10,000 people worldwide. For more information, visit www.curtisswright.com.
Established 50 years ago next year, Q8Research is part of the Kuwait Petroleum Corporation and a world leader in petroleum and refining research, achieving industry acclaim for its constant drive to ‘perfect petroleum’ and continue to benefit millions of people around the world.
The primary activity of Q8Research is supporting its sister companies within the Kuwait Petroleum Corporation group. However, due to its increasing cooperation with bodies such as trade organisations and Original Equipment Manufacturers, Q8Research is now undertaking further work on a selective basis with external partners and the company has produced a new 12-page brochure highlighting and promoting these capabilities.
The 40+ scientists and support staff working at Q8Research test 50,000 samples and conduct 350,000 analyses per year and are responsible for the specification of materials and products, legislation compliance and quality control. The facility also provides product testing, certification and quality control services to Q8’s refineries, which involves problem solving, optimising the daily operation of each unit and employing the latest test techniques.
Another Q8Research responsibility is the development of cost-effective product formulations for lubricating oils, prime products, aerosol propellant and bitumen. Many of these are derived from the Kuwait Export Crude (KEC) base stock – which boasts a consistency and quality that cannot be matched by any other company – and provides Q8 with the perfect feedstock for refining some of the world’s finest base oils and petroleum-based derivatives for the automotive, marine, industrial, metalworking and energy sectors. Q8Research is also an expert on the management of aviation fuels.
Commenting on the facility and its services, Q8Research coordinator Adri van de Ven says: “We have been perfecting petrochemical-based products for 50 years and our holistic approach to research and product development means that Q8Research is ideally placed to provide the very best support to customers in the 80+ countries worldwide where Q8 sells its products.
“Q8Research has an extensive reputation for influencing and creating pragmatic solutions for a range of industry issues and has, for many years, chaired leading industry bodies and has close working relationships with leading universities, technical institutions and OEMS such as Fives DMS, John Deere, Scania, Siemens and Volkswagen.” says Adri.
Q8Research sections work together to create a single unit of expertise and experience. Its laboratory services are complemented by the facility’s ability to transform chemical and physical elements into high-performing, cost-effective products. This wide-ranging expertise enables Q8Research to offer consultancy services for many other areas of the petroleum industry such as safety, health and the environment; market data; legislation; and training.
For further information and a copy of the new 12-page brochure email Q8Research@Q8.com.
Recognising that many customers are striving to reduce energy consumption and are committed to numerous environmental policies, Verco Limited – the leading supplier of refrigerated open-chill and glass-door cabinets for the UK convenience store sector – is introducing Energy Plus a low-energy, high-performanceoption for its Kingston and Verwood chillers.
Amongst it features, Verco’s Energy Plus includes a re-designed cabinet to improve airflow, LED lighting and specification of an R407f refrigerant such as Honeywell’s Genetron Performax LT. Its introduction has also been driven by the European Parliament’s recent ratification of a partial ban on F-gases, a regulation that has been introduced to control the use of refrigerants that have a detrimental effect on the environment.
As a result, Verco is initially introducing the low-energy, high-performance Energy Plus as an option for its Kingston and Verwoodmodels and plans to completely phase out the use of R404a in its range of open-chill and glass-door cabinets and replacing it with R407f.
Commenting for Verco, development director Mike Nicholls explains that Verco’s environmental policy includes a commitment to monitoring the development of environmentally friendly materials. “Following extensive testing, R407f has been selected for its combination of zero ODP (ozone depletion potential) and 53% reduction in GWP (global warming potential) compared to R404a.”
With Energy Plus already standard on the Quebec range of glass-door cabinets – including the single-door Q1XL, two-door Q2CC and three-door Q3CC – Verco has turned its attention to the open-chill Kingston and glass-door Verwood models. Already re-engineered to accept the optional Energy Plus and available to order now are the company’s range-topping Kingston K250 (2500mm wide), single-door Verwood V1CHM models. These will be closely followed by the 1950mm wide Kingston K195 and two-door Verwood V2CHM models by this summer.
“Customers specifying the Energy Plus option on Verwood models can expect significant energy savings of up to 33% at chill temperature” says Mike.
The introduction of R407f also addresses the ATEX directive covering potentially explosive atmospheres or areas and the use of hydrocarbon-based refrigerants (such as R1270), which states that system designers follow the principles of the ATEX 95 equipment directive with regard to area classification and avoidance of sources of ignition.
In glass-door cabinets as an example, even a minor leak of hydrocarbon refrigerant cannot dissipate and a potentially explosive atmosphere could be created and persist. The inability of the explosive atmosphere to dissipate substantially increases the risk of ignition, therefore bringing the ATEX directive into effect.
Looking to the future, Mike says: “It is becoming increasingly difficult to anticipate and satisfy safety requirements where hydrocarbons are used so, while Verco has committed to standardising on the use of non-flammable refrigerants such as R407f in its glass-door cabinets, we will continue to offer the option of R407f or R1270 on open-chill Kingston and Cambridge models.”
He goes on to say that, with a growing preference for ‘natural refrigerants’ Verco will keep under review the use of hydrocarbons in glass-door cabinets until such time as equipment is available to ensure their safe use and compliance with regulatory requirements.
For further information on Verco’s Energy Plus or its range of open-chill and glass-door chiller and freezer cabinets, call +44 (0)1491 839966, email sales@ver.co.uk or visit www.ver.co.uk.
Penny + Giles, a business group of Curtiss-Wright Controls and designer and manufacturer of joystick controllers, solenoids and high precision sensing technology, is supplying its TPS280DP throttle position sensors to UH Racing, the University of Hertfordshire’s Formula Student racing team.
Used as a testing ground for the next generation of world-class engineers, Formula Student challenges university students from around the world to design and build single-seat racing cars with the aim of inspiring the next generation and addressing the all too apparent skills shortage in engineering.
Commenting for UH Racing’s Formula Student team, engine specialist Craig Brant says: “The 2011 season has been one of the toughest yet, but UH Racing was named top UK team and achieved an overall third place at the Formula Student UK event held at Silverstone. We were also awarded top UK team and overall seventh place at the Formula Student Germany event.”
Like many other racing formulas, vehicles entering the Formula Student event are subject to restrictions, including a maximum 600cc engine size and air restrictors to the engine. However, Formula Student is one of the most open formulas in the world with teams able to choose single cylinder or v-twin engines, many derived from powerful, high-revving motorbike units. UH Racing’s car – dubbed UH14 because it is the University’s fourteenth combustion-engine vehicle since entering the event in 1998 – uses a 600cc, four-cylinder, four-stroke Yamaha engine.
For 2011 many teams have taken a different approach, opting for a lightweight design with very small wheels and a single cylinder engine to give them an advantage on the skid pad and sprint course.
However, as Craig explains: “With UH14, UH Racing has continued the approach of using a more powerful but slightly heavier engine, but has also started to adopt Formula One technologies including the use of a carbon fibre body, tyre pressure monitoring systems and tyre temperature. We have also been lucky to have students in work placements with Cosworth Racing who, through sponsorship, have offered technical advice and supplied useful equipment.”
He goes onto say that because the track for the 2011 endurance event was tight and twisty, UH Racing wanted to replace its usual gear lever with a paddle shift system to enable drivers to change gears more quickly, easily and safely, and in turn improve lap times.
The initial student-designed system involved steering wheel mounted paddle switches actuating a solenoid attached to the engine block, which in turn moved a gear selector on the engine to change gear. However, tests revealed that the system’s ECU read the gear position based on the wheel speed of the car and the data couldn’t accurately provide drivers with a dashboard display showing which gear was selected.
To achieve a more definitive gear position the team decided to monitor the barrel of the engine using a sensor installed on the barrel position of the gearbox. Now, when it moves the selector forks to change gear, the rotation is changed and the team is able to determine exactly which gear has been selected.
UH Racing’s Yamaha-based engine has its gearbox mounted to the engine, making it a very compact unit. However, the sensors mounted on the engine block and gearbox barrel are subjected to extremely high levels of shock and vibration over long periods, so the team needed a sensor that would withstand the mechanical abuse from the engine/gearbox configuration.
Having already partnered Active Technologies (AT Power) in developing a Formula Student throttle body, the University of Hertfordshire again approached the company for advice. AT Power had themselves recently begun using Penny + Giles throttle position sensors on its own throttle bodies and after further testing and discussions with Penny + Giles engineers, the same advanced TPS280DP sensors were also specified for use on UH Racing’s gear position system.
As Craig explains: “Previously, we had used potentiometer-based sensors from another manufacturer, but we decided that for this season a more advanced sensor was needed. As AT Power had recommended the TPS280DP for the throttle bodies, we approached Penny + Giles to source the same sensors for our new gear position system.”
Penny + Giles tailored the throttle position sensor to UH Racing’s specifications and the team designed its own mounting bracket for the engine. The sensor was then factory-programmed with a 360° rotation to allow it to read the full range of gears. The throttle position sensors are now connected to the gear position barrel and provide feedback on the exact position of the barrel and therefore the exact gear number.
The Penny + Giles TPS280DP uses a factory programmable Hall effect sensor with two outputs that can be programmed individually for angular range, output range and direction. It has no contacting sensor parts, which ensures zero signal degradation over the lifetime of the sensor, and has a tested life of more than 60 million operations – more than 18 times the life of an equivalent potentiometer. In addition, when powered with 5Vdc, the sensor has an operating temperature range from -40 to +140ºC.
The TPS280DP has been specifically designed to work in harsh motorsport environments and has excellent shock and vibration resistance. Its drive and body are IP69K-rated to provide excellent protection against the ingress of dust and fluids. It is also mechanically interchangeable with many existing potentiometer-based throttle sensors using 32mm mounting centres, and is designed to interface with most common throttle body D type spindles.
“The new setup works very well.” says Craig. “Instead of the ECU trying to calculate the gear position, the TPS280DP now provides us with an exact position, ensuring that the correct gear is displayed on the dashboard. In endurance events this helps the driver to prepare the car for the course ahead while navigating the tight and twisting courses.”
The updated throttle bodies and new gear position system have been thoroughly tested on and off the track, on cars from both the 2010 and 2011 seasons, and have proved very reliable.
Summing up the Penny + Giles contribution Craig Brant says that while the team’s engines aren’t too highly stressed they are run very hard and adds: “We expected the sensor to last the life of the engine and therefore the season, and we haven’t been disappointed.”
With a legacy spanning more than 50 years, Penny + Giles is a recognised leader in the design and manufacture of joystick controllers, sensors and industrial solenoids. It has extensive experience in providing solutions for monitoring and control under extreme operating conditions.
Contactless Rotary Position Sensors
The company’s extensive range of rotary position sensors offer angle measurements from 10° to 360° and use Hall effect, inductive or potentiometric technologies, all packaged in compact or rugged housings, with environmental protections to IP68 and IP69K. Its dual-output, contactless range has been specially developed to meet the operating requirements of many industrial position sensing applications in the general engineering, automation and process control sectors.
Designed with 21st century applications in mind, Penny + Giles contactless rotary position sensors use the latest advances in 12bit Hall effect sensing technology and are factory-programmed to provide OEM’s with a variety of previously unavailable options. These include single- or dual-redundant outputs, clockwise or anticlockwise rotation and measurement angles from 0-20° to 0-360° in 1° increments.
Most models can withstand operating temperatures between -40°C and +140°C (+170°C for 72 hours for NRH/TPS models); are tested to resist severe shock and vibration; and have an EMC immunity of 100V/m.
The sensors are designed to operate from a 5Vdc regulated or 9 - 30Vdc supply; and outputs can be PWM or analog voltage (nominal 0.5 - 4.5Vdc) over the measurement range, with clockwise or anticlockwise shaft rotation. A choice of 341 different electrical angles from 20° to 360° are possible and 12bit resolution (0.025%) is available over the selected measuring range with a non-linearity better than ±0.4% and temperature stability better than ±50ppm/°C. The sensor’s analog output option has a very low output noise level of less than 1mV rms.
Contactless Tilt Sensors
The company’s STT tilt sensor range uses solid-state 3D-MEMS technology to measure the sensor's inclination relative to earth's gravity. By using solid-state system-on-chip technology, the STT series provides distinct advantages in reliability, stability and compactness over fluid-based, electrolytic and pendulum operated sensors. For maximum flexibility this new range has a low power requirement of less than 6.5mA, so it can be used in hard-wired or battery-powered wireless systems.
The IP68-rated STT280 is supplied in a compact 28mm diameter corrosion-resistant body with crush proof inserts in the mounting flange. The larger STT500 is supplied in a rugged, marine grade cast aluminium housing with a protection rating of IP69K.
Both sensors can withstand operating temperatures from -40°C to +125°C and have been tested to withstand a 3m drop onto concrete (maximum 20,000g). They are available with a choice of measurement ranges from ±10°, ±20°, ±30° and ±60° and can operate from a 5Vdc regulated or 8 – 30Vdc unregulated power supply.
Contactless Linear Position Sensors
Penny + Giles’ comprehensive range of linear position sensors use non-contacting technologies and cover measurement ranges from 10 to 5000mm. A choice of models and mounting configurations, including embedded in-cylinder linear transducers, suit a wide range of hostile industrial applications.
The company’s SLT190 is designed to provide reliable, fit-and-forget position sensing (up to 500mm) within a compact transducer size for the most arduous operating environments. It can withstand operating temperatures from -40 to +150°C, has been tested to withstand shocks to 10,000g and, with EMC Immunity of 100V/m, the SLT190 is suitable for the harshest of applications.
To minimise size and the impact on the overall system, separate signal conditioning electronics (EICT or EICTM) are housed in rugged IP66 or IP68 rated enclosures. The electronics module can be located up to 10m from the transducer, away from any hostile conditions (vibration, mechanical impact, temperature) that the position transducer may encounter during operation. The result is a more reliable transducer solution, easily installed and adjusted and more flexible in the choice of outputs - including voltage, current and digital PWM.
The Penny + Giles SLH100 has been specifically designed to provide precision, cost-effective position sensing using the contactless Hall effect principle, with the sensing system comprises only two parts: the sensor and the magnetic activator. As a fully encapsulated electronic device it is intended to compete with sealed potentiometers and inductive sensors.
This robust, maintenance-free and easy-to-fit sensor can be used for a variety of control applications and its durable design and absence of mechanical linkages makes this sensor attractive for use in harsh environments - where particles, moisture, temperature and vibration can be present.
Sensors In Action
For a recent application, Penny + Giles is supplying its STT280 tilt sensors and SRH280DP rotary Hall effect sensors to Sarclad Ltd to provide critical measurements for an In-Chain Strand Condition Monitor – a precision, online measurement system used to monitor continuous casting machine rolls used in the steel making process.
The In-Chain Strand Condition Monitor (In-Chain SCM) is permanently installed in the steelmaking process to enable automatic fixed-roll alignment and roll-gap measurements to be performed at the beginning of every casting, without affecting production activities. The Penny + Giles sensors were specified to meet the stringent requirements of a system that is robustly engineered to endure the extremely hostile casting environment.
Commenting for Sarclad, In-Chain SCM manager Richard Cowlishaw says: “With a continuous cast system able to produce in excess of $1million worth of steel a day time is of the essence, so interrupting production to measure the condition of the casting machine could cost steelmakers huge amounts of money. Installing a Sarclad In-Chain SCM system ensures that measurements are taken automatically at the start of every cast, so that costly downtime is avoided and quality of product is maintained.”
The Penny + Giles STT280 tilt sensors are fitted to the In-Chain SCM to measure the fixed-roll alignment of the casting machine using spring-loaded blades that tangent pairs of rolls to measure the angles between them. The data is then processed to identify rolls and segments that are out of position relative to other rolls within each segment.
Sarclad had previously used inclinometers, but specified the Penny + Giles tilt sensor because its compact size and extremely robust construction proved more effective and robust for the application. In addition, because measurements are taken while the continuous cast system is moving, inclinometers were prone to resonate or create a spike output. In contrast, the STT280 tilt sensor features 3D-MEMS technology, which provides a naturally-damped response that is unaffected by knocking or vibration. This feature is especially important for continuous steelmaking operations where accurate measurements are vital, as Richard Cowlishaw explains.
“The steel making process involves pouring molten steel into a caster mould and oscillating the mould to prevent the liquid steel sticking to the sides while it solidifies. The vibrations from the action of the oscillator affects the measurements taken with traditional inclinometers, by producing spiked rather than smooth outputs, which corrupts the measured data.
The caster operates from ninety degrees vertical to zero degrees horizontal, so in order to accurately measure between the two angles it is necessary to measure beyond them. Penny + Giles were able to customise the STT280 sensor to measure between 92 degrees and -2 degrees, providing the calibration points we needed outside the measuring range.”
He goes onto say that Sarclad was so impressed with the Penny + Giles sensors that they have also been installed on its traditional Strand Condition Monitor, which is the offline equivalent of the online In-Chain system.
Sarclad also uses Penny + Giles SRH280DP rotary Hall effect sensors to measure gap displacement on the In-Chain SCM system, replacing the rotary inductive position sensor (RIPS) used in the original design.
Says Richard: “The RIPS were too big, were influenced by forces exerted on the shaft and used a technology that proved to be unsuitable for the application. Axial loads on the RIPS shaft also caused the output to fluctuate even though it wasn’t being rotated.” He adds that potentiometers also proved problematic because the application only needed a small length of track, which meant that the conductive grease degraded prematurely, causing spikes in the signal.
When Penny + Giles introduced the SRH280 rotary Hall effect sensor to provide uniform feedback, Sarclad immediately realised its benefits even though it was only initially launched as a single channel sensor. However, the range was programmable, which allowed the company to get the maximum resolution from the 30 degrees rotation output they required. Sarclad now fits the recently developed Penny + Giles SRH280DP two channel version, which can be configured with both channel outputs increasing with clockwise or anti-clockwise shaft rotation, or one clockwise with one anti-clockwise.
“Being a non-contact Hall effect sensor, any pressure applied to the shaft in an axial direction does not affect the output.” says Richard. “It is also available as a regulated or unregulated version, is very stable and not affected by heat or shock, which is a real bonus for this particular application.”
The SRH280DP is fitted as part of a gap transducer, which has a spring-loaded rotary arm that extends out to contact the caster rolls to provide an absolute measurement for the distance between the pair of opposing rolls.
New levels of sophistication
The latest developments in sensing and control system technology are bringing a whole new level of sophistication to monitoring and control, resulting in much more efficient operation. Highly reliable signals from the latest sensor developments, combined with intuitive control system software, mean that process control equipment can be tuned to optimise performance to individual applications. At the touch of a few buttons, routine operations can be performed throughout the process to deliver considerably better productivity.
Involving component suppliers such as Penny + Giles at the earliest possible stages of development often produces the most cost-effective solution in the shortest possible development time. This is achieved by combining Penny + Giles’ vast experience of the type and layout of equipment controls with the more subjective input of OEM engineering and marketing departments.
