Curtiss-Wright Industrial

New Penny + Giles Hall Effect Rotary Sensor Helps Geartonics Shift Up A Gear

Wed, Mar 27, 2013 Written by Cantillion Ki...

Penny + Giles, a business group of Curtiss-Wright Controls and designer and manufacturer of high precision sensing technology, is helping gearbox specialist Geartronics to significantly improve the shift times and reliability of its motorsport paddleshift system using Penny + Giles SRH280DP Hall effect rotary sensors.

Commenting on the change to Penny + Giles Hall effect sensor technology, Geartronics managing director Neil Wallace explains: “The strategy to successfully get out of one gear and engage the next as quickly as possible is not just a case of cutting the engine or blipping the throttle for a few milliseconds and hoping for the best!”

Gear up-shifts or down-shifts are essentially a two-stage process - first to disengage the current gear, then to engage the next gear. The times for both processes vary depending on complex dynamic factors acting on the vehicle at the time, which are impossible to model or predict.

The Geartronics 'closed-loop' control system uses a gearbox control unit (GCU) in conjunction with Penny + Giles SRH280DP sensor inputs to modify its own operation - in real-time. In the context of semi-automatic gear selection, the closed-loop system monitors the gear position sensor to determine the precise angular position of the gearbox selector barrel. This information is fed back to the GCU control algorithm so the pneumatic actuator, engine torque reduction or throttle blip can be turned on and off as necessary to effect the fastest and most reliable gear shifts.

Neil emphasises that a closed-loop system is absolutely reliant on receiving accurate feedback from the sensor, so the Penny + Giles SRH280DP Hall effect sensor is effectively the cornerstone of the system.

By contrast, an 'open-loop' system has no feedback mechanism, and simply relies on fixed timers to govern the various shift events. An open-loop system therefore applies the same engine cut or throttle blip duration for every shift, regardless of whether those times are appropriate for each individual shift requirement.

Geartronics’ sequential gearbox shift systems are used in extreme autosport environments such as formula and GT car racing and rallying, and, more recently, have been specified on the Ariel Atom V8 road car. Combining sophisticated electronic control and extremely accurate Penny + Giles rotary sensors, the pneumatic shifter mechanism directly controls the gearbox cam-drum or barrel, and eliminates the requirement for driver operated shift linkages.

A committed user of Penny + Giles SRS280 resistive rotary position sensors for more than nine years, Geartronics began specifying a competitor’s sensors following the introduction of Hall effect technology, but as Neil Wallace explains, they very quickly proved unreliable, were causing numerous problems, and in some applications, were failing within a couple of hours due to the high levels of vibration generated by V8 race engines.

“Fortunately, at around the same time we learned that Penny + Giles had introduced its own hall-effect sensor, the SRH280DP, so we began testing them on our shifter systems and saw an immediate improvement. In fact, when they were installed mid-season on two single-seat V8 racing cars, they proved 100% reliable for the remainder of the season.”

He says that the non-contact technology used in Penny + Giles Hall effect sensors is more reliable as it’s not affected by vibration – an important benefit compared to the wear experienced with resistive contacts, and adds that direct comparison is difficult as Geartronics hasn’t had a Penny + Giles SRH280DP fail.

Penny + Giles provides Geartronics with a mix of standard and bespoke SRH280 sensors including the special, double-output SRH DP versions that can be used to send separate signals to both the GCU and the engine management system (ECU) or data acquisition systems.

Summing up Neil Wallace says that for any semi-automatic shift system to work consistently and reliably under all conditions, the GCU needs, ‘as an absolute minimum’, to measure the gearbox barrel position, throttle position and engine speed, and that’s exactly what the Penny + Giles SRH280DP Hall effect sensors help us to do.

Geartronics provides its sequential gearbox shift systems to winners in a wide range of motorsport disciplines such as British and European Hillclimb Championships, open-wheel ‘formula’ racing, GT & sportscar endurance racing and rallying.

For enthusiasts requiring more information, a YouTube video (Search: Steiner Marcel La Roche 2011) shows an under bonnet view of a system operating real time in a Steiner Motosport Osella FA30.

Penny + Giles’ popular SRH280 contactless rotary position sensors use a factory programmable non-contact Hall effect sensor system. The SRH280P & SRH280DP provide reliable and accurate rotary position measurement in extreme motorsport and industrial environments where shock and vibration can occur. These sensors use the popular 38mm flanged housing with an environmental protection rating to IP68.

SRH280P & SRH280DP operate from either 5Vdc regulated or 9-30Vdc unregulated power supply 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 you to specify the output signal type, the measurement range (0-20° to 0-360° in 1° increments) and the output direction (clockwise or anticlockwise). It has a 12 bit resolution (0.025%) over the selected measuring range, and operates from -40 to +140°C when powered at 5Vdc.

Key Features include contactless Hall effect technology; single or dual output channels; 5Vdc or 9-30Vdc supply; total sensor measurement range from 0-20° to 0-360°; analog or digital (PWM) output; 12 bit resolution over selected measuring range; low noise level (1mVrms) on output signal; operating temperature -40° to +140°C; environmental protection to IP68; crush-proof mounting flange with steel inserts, and rapid availability.

Fleet Services Vehicle Security Conversions Use Build-To- Last Solenoids from Penny + Giles

Published in Curtiss-Wrigh...

Tue, Feb 26, 2013 Written by Cantillion Ki...

Fleet Services Vehicle Security Conversions Use Build-To- Last Solenoids from Penny + Giles

Penny + Giles – a business group of Curtiss-Wright Controls and designer and manufacturer of high precision joystick controllers, sensors and solenoids – is supplying its door-lock and shot-bolt solenoids to Preston, UK-based Fleet Service for use by the company’s Fleet Care division, which specialises in commercial vehicle security, cash-in-transit (CIT) and cash & valuables in transit (CVIT) vehicle conversions. The company is also diversifying by offering similar solenoid-based locks for buildings and facilities applications.

Today Fleet Service has developed a full service for the commercial vehicle, CIT and CVIT industry, which continues to maintain vehicles in the field and, having gained a broad range of experience of different conversions and system types, now carries out full vehicle conversions and installations as well as designing and integrating complex control systems. It also offers a wide range of security products to organisations whose business involves transporting valuable goods or cash securely or eliminating opportunities for fraud.

Commenting for Fleet Service, technical director Darren Clayton explains: “We started out as a repair service for several cash management specialists, and whilst we were carrying out regular routine servicing and repairs to the vehicle fleets we experienced many breakdowns relating to the conversion of the cash-in-transit fleet. Eventually we were asked to review the control systems and repair other issues with the conversions.”

Most of the security locks used by Fleet Service are controlled by solenoids and where possible, the company has always specified Penny + Giles (formerly Mechetronics) solenoids.

Fleet Service’s controls are industrial PLC-based systems that provide the driver with feedback via a cab-mounted graphical user-interface, enabling them to interact and control different vehicle operations, including the solenoid-based locking systems. Penny + Giles is currently supplying Fleet Service with two solenoids types, the SB291 (previously the MS SD291) power-to-unlock 90° door-lock and a bespoke version of its SB244 (previously the MS SD244) shot-bolt, the latter featuring a shaft specifically machined to a unique angle for Fleet Service.

Currently being assembled into locks which secure heavy-duty floor-to-ceiling roller/shutter doors, the Penny + Giles SB244 solenoid shot-bolt features a bolt with a chamfered edge that is mounted into a steel housing installed into the back of the vehicle. When the shutter door is closed, an integrated arm on the door itself locks behind the solenoid.

This system is used on multiple vehicle types, from small box vans to 26 and 33 tonne dry freight box trucks, and is proving extremely durable and reliable under the extremely harsh operating conditions. In fact, Fleet Service reports that some solenoids are still operational after more than twelve years and have even been recycled and reused after the original vehicles on which they were installed have reached their end of life!

The locks are also proving so successful that one Fleet Service customer is retro-fitting them to existing vehicles and specifying them on trucks designed and manufactured by other conversion specialists.

The Penny + Giles’ SB244 power-to-activate shot-bolt solenoid can also be used in a variety of industrial security applications including machine tool guards, security doors and gates, and for general interlock applications. It features a 15mm stroke and 50% duty rating from 24 Watts rated power, and is available with a variety of optional bolt ends. Additional features include a high side-load capability and optional operating voltages.

The Penny + Giles SB291 power-to-unlock 90° locks are being used as slam locks on cab doors and for sliding, side-load doors on vans. They are specified because vehicles needed a more robust system than the magnetic solenoids previously used.

The SB291 solenoid activated 90° lock can be energised to unlock in a variety of industrial security applications including machine tool guards, security doors and gates, and for general interlock applications. It offers a 16mm stroke and 100% duty rating from 40 Watts rated power, with features including optional operating voltages, high side-load capability and bolt position sensing.

Summing up, Darren says: “Over the years we have used many different solenoids and seen most fail when bolt-ends and bushes wear and coils fail or become lazy. But the quality of Penny + Giles solenoids is second-to-none, they are designed for heavy-duty applications, are much better built and built to last. This was always important when we were maintaining vehicles and repairing them on the road, and is especially important now that we are designing and manufacturing our own control systems and converting our own vehicles.”

For further information call Penny + Giles on +44 (0)1202 409499, email sales@pennyandgiles.com or visit www.pennyandgiles.com

Penny + Giles Solenoids Clear the Lanes for Ten-Pin Bowling

Published in Curtiss-Wrigh...

Wed, Apr 27, 2011 Written by Cantillion Ki...

Penny + Giles Solenoids Clear the Lanes for Ten-Pin Bowling

There are more than 200 tenpin bowling centres in the UK, averaging 24 lanes per centre. These include chains such as First Bowl, AMF and Hollywood Bowl; independents and many British and American military bases.

Penny + Giles Controls, a business unit of Curtiss-Wright Controls and designer and manufacturer of high precision joysticks, sensors and solenoids, has developed a number of bespoke solenoids to activate and control the specialised machinery that cleans and oils the busy lanes in tenpin bowling centres throughout the UK and Europe.

The solenoids are manufactured for Canterbury based Embassy Services, a company that specialises in the servicing, repair and refurbishment of tenpin bowling machinery, which is predominately supplied from the USA.

Whilst laminate has replaced traditional timber as the material of choice for bowling lanes, they are still oiled with a special low-friction lubricant to help protect the surface and control the path of the ball as Stuart Munnings of Embassy Services explains: “If it is thrown properly a bowling ball is spinning when it leaves the hand. No matter how fast it is spinning, the ball will slide through the first heavily-oiled twenty feet of the lane. It then has a degree of guidance in the middle section where the oil is shaped and tapered, before reaching the final section, at which stage the lane is almost dry because the oil has been stripped off. At this point stored energy in the ball is released, creating the correct hooking action on the bowling lane.”

He adds: “Game play can be significantly affected by the length and depth of the coating applied to the lane, hence the need for the development of an accurate and reliable solenoid to ensure that the machine correctly controls the flow and shape the oil.”

During tournaments, officials measure the amount of oil used to ensure that it meets strict rules governing both the amount applied, and to what portion of the lane it is applied. The more games played on the lane the more the oil degrades so the oiling machine is usually employed twice a day in reasonably busy centres and up to ten times a day during tournaments.

The wheel-mounted machines begin their 3-stage process at the bowler’s end of the lane, where a cleaning head applies a detergent to convert the degraded coating of oil into an emulsion. This is then removed by a vacuum head and the machine begins to deposit a new coating of oil, which is built up in layers by moving the machine up and down the bowling lane. When the process is completed the machine is moved to the next lane. Typically, a machine takes 30 to 60 seconds to strip and oil an entire bowling lane.

As well as controlling the supply of oil and lowering the buffing brushes and cleaning vacuum heads to the lane prior to the application of each new coating, the Penny + Giles solenoids also play an important role in shaping and tapering the finished coating.

In total, twelve solenoids are fitted to each machine. A pair of larger Penny + Giles solenoids is connected to cantilevers to raise and lower the three heads that individually operate the cleaning, vacuuming and oiling functions. Control of the six oil tanks fitted to each machine is operated by smaller Penny + Giles solenoids.

Based on their positive experience with the solenoids developed for the cleaning and oiling machines, Embassy Services invited Penny + Giles to develop a robust, accurate and reliable solenoid that is an integral part of the complex pinspotter mechanism, which operates in what is arguably the most arduous environment in a bowling centre.

Pinspotter mechanisms are used to assemble and place the ten pins upright onto the lane surface, register the first bowled ball, and sweep away the fallen pins after picking up the remaining standing pins. Swept pins are automatically lifted inside the machine, sorted and placed, ready to be ‘spotted’ for the next game by a table mechanism on the lane. The table is moved to one of two different heights by the specially developed Penny + Giles solenoids, which are either engaged or disengaged.

The solenoid that the Penny + Giles unit replaces was an upgraded version of an archaic US-manufactured component, which was dual 50/60 Hertz and tended to run very hot in a bowling centre environment, making them very unreliable. Various alternatives were developed by manufacturers in Europe – some with oversized heat sinks, others with various coatings to try to dissipate the heat, but not one of them was fit for purpose or particularly successful.

Commenting for Embassy Services, Stuart Munnings says: “The solenoids had become unnecessarily complicated over the years, but fortunately, when we invited Penny + Giles to look at the problem they very quickly produced a thoroughly developed product that we were able to use straight away, which is impressive when you consider that typical US bowling equipment is based on 40 year-old technology. Their engineers are very knowledgeable regarding the electro magnetic fields (EMF) that can be generated within the solenoids.”

He adds that it was refreshing to find a company in the UK that would work with them to develop a product specifically for the application and says that Penny + Giles worked very closely with them and provided a lot of very good feedback and technical help, which is a rarity these days.

The solenoid developed by Penny + Giles was wound specifically for the pinspotter machine’s Hertz/voltage requirement which also means that reliability and general performance is greatly improved.

The solenoid is mounted on the machine using a laser-cut bracket, which positions it accurately for operation.

Penny + Giles Joystick Controller Provides Superior Functionality for New Dynapac Cab Control System

Published in Curtiss-Wrigh...

Thu, Sep 27, 2012 Written by Cantillion Ki...

Penny + Giles Joystick Controller Provides Superior Functionality for New Dynapac Cab Control System

Penny + Giles - a business unit of Curtiss-Wright Controls and a designer and manufacturer of position sensors, solenoids, and joystick controllers – is supplying its JC6000 joystick to Dynapac in Sweden, for the company’s new CA5000 range of Soil Compactors.

The order is the latest in a seven year relationship that began when Dynapac, part of the Atlas Copco Group and one of the world’s most experienced manufacturers of compaction and paving equipment, first approached Penny + Giles in 2005 with an invitation to join a competitive tender to find a new joystick controller for a new 7 to 12 tonne range of tandem rollers.

The tender also required a change from mechanical to electronic joysticks, prompted by some issues with the driver controls in earlier cabs. These were resolved by the selection of the Penny + Giles JC6000 joystick, which was first specified as part of the new cab control system for a Tandem Asphalt Roller. The cab and JC6000 have since been rolled out across many new models, new platforms and other, larger machines, ranging from seven to twenty tonnes operating mass.

Commenting for Dynapac, electrical development engineer Markus Karlowsky says that while price was an important issue, the Penny + Giles JC6000 is a very robust joystick that best met the specification and helped to resolve the control issues.

The joystick’s primary function is as a speed controller – pushing the handle forward moves the machine forward and the farther it is pushed the faster the machine accelerates. Pulling back provides the same function in reverse. In addition, the JC6000 also features a ‘friction-hold’ mechanism that allows operators to maintain the vehicle at a constant speed when the joystick is released, and leaving them free to steer with a conventional steering wheel while monitoring the progress of the operation and focusing on other functions. For example, one of the functions available via buttons on the joystick controller’s handle is the control of jets, which are used to water-lubricate the drums to prevent them sticking to the material being compacted.

Penny + Giles engineers also fulfilled the force level requirements specified by Dynapac for the joystick friction-hold feature, rather than a conventional spring-loaded lever that automatically returns to a neutral position when released.

The superior functionality of the new cab control system is partly due to the variety of operations that can be configured via buttons on the JC6000 handle and partly due to the versatility of the handle itself.

A further, and not insignificant, benefit of the JC6000 joystick controller is its full-grip handle, which is similar to that fitted to mechanical joysticks and therefore familiar to operators, making it easier for them to switch to the Penny + Giles electronic controller.

The contract negotiations were carried out through Penny + Giles’ local distributor Christer Houbaer at AB Elwia, whose input ably demonstrated the local service available through Penny + Giles’ international network.

Since 2005 Penny + Giles has supplied Dynapac with several thousand JC6000’s. Initially, the joystick controllers were delivered to the Dynapac plant in Sweden and more recently have been supplied to Dynapac’s after sales division in Belgium and, since Dynapac began manufacturing in China, have also been supplied to the plant there.

Penny + Giles’ JC6000 joystick controller is designed for demanding operator control applications for off-highway vehicles and other man-machine interfaces, including operator controls on a wide range of off-highway vehicles such as cranes, loaders, excavators, access platforms, tractors and harvesters.

It is available with single- or dual-axis configurations and can be supplied with non-contact Hall effect sensors or long life potentiometer tracks. The compact size, high lever strength and superb proportional control of the JC6000 joystick controller makes it ideal for applications where strength, reliability and handle functionality are important. Features include a rugged design with superior lever strength, a range of ergonomic handle designs, analog or CAN outputs, sealing above panel to IP66 and safety features including switch/logic functions.

2012 Formula Student Winners Opt for Penny + Giles Sensor Technology

Published in Curtiss-Wrigh...

Tue, Nov 06, 2012 Written by Cantillion Ki...

2012 Formula Student Winners Opt for Penny + Giles Sensor Technology

With regional support from its Swedish distributor AB Elwia, Penny + Giles – a business group of Curtiss-Wright Controls and designer and manufacturer of position sensors, solenoids, and joystick controllers – has supplied its SRH280DP rotary position sensors and TPS280DP throttle position sensors to the Chalmers Formula Student team, which competes in the Formula Student racing car series. This testing ground for the next generation of world-class engineers, challenges university students from around the world to design and build single-seat racing cars with the aim of inspiring each new generation, and addressing the all too apparent skills shortage in engineering.

The Formula Student team, from Chalmers University of Technology in Gothenburg, Sweden, consisted of 24 members, five trainees, five supervisors and a project manager and, unlike many of the teams taking part in the event, ensures that the majority of the team of project engineers (those who design and manufacture the car) are changed every season.

Against fierce competition from 130 other teams, Chalmers Formula Student finished this year’s UK event (the largest in Europe) with 850.5 points to win the 2012 Formula Student title. The team were also placed third overall in the German competition.

Explaining the specification of the Penny + Giles sensors being used for its gearbox and throttle body applications, Chalmers Formula Student’s Andreas Andersson – a project manager with responsibility for Vehicle Electronics – says: “Sensors installed inside a gearbox need to be rugged and robust to cope with the arduous environment caused by hot oil and vibration. The SRH280DP rotary position sensor, which was fitted to the closed-loop control system on the 600cc Yamaha engine and gearbox at the start of the 2011 competition, provides feedback to the engine management system and monitors gear position and selection on the team’s electronic gearshift system to ensure that, as shifting occurs, the ignition is cut to create as short a shift time as possible. While other sensor solutions that we tested meant gear shift times were slow, adopting the SRH280DP and introducing a closed-loop system has eliminated the preset times and means the team can achieve the shortest shift time possible, making the system more dynamic.

He adds that other sensors can cope with these applications but the team opted for the Penny + Giles SRH280DP sensor because it has the advantage of contactless Hall effect technology, which is ideal for such arduous environments.

The Penny + Giles SRH280DP contactless rotary position sensor features a factory programmable non-contact Hall effect sensor system and provides reliable and accurate rotary position measurement in extreme motorsport environments where shock and vibration can occur. They are factory programmable to allow users to specify output signal type, measurement range (0-20° to 0-360° in 1° increments) and output direction (clockwise or anticlockwise); operate from either 5Vdc regulated or 9-30Vdc unregulated power supply; and are available with analog (0.5 - 4.5Vdc and 0.1 - 4.9Vdc) or digital (PWM) output signals.

Commenting on the change to the Penny + Giles TPS280DP sensors for the 2012 season, he says: “In previous seasons we had experienced multiple sensor failures and vibrations problems with the throttle position system, so having successfully integrated the SRH280DP into our 2011 vehicle, and knowing just how rugged they are, we decided to replace the existing sensor in the throttle body with the Penny + Giles TPS280DP throttle position sensor.”

As well as being more durable than any throttle position sensor the team had used previously, integrating and mounting the Penny + Giles TPS280DP in the AT Power throttle body also proved easier than previous sensor types because it is smaller. This meant the sensor didn’t have to be mounted in a specific way to make it work; and the team could choose a throttle body and sensor combination based on performance and not just fit!

The Penny + Giles TPS280DP sensor is 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. It 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.

Summarising, Andreas says that both Penny + Giles sensors have performed extremely well and the team didn’t experience a single sensor failure throughout the 2012 season, which includes the competition and several months of arduous testing. “We have even stressed the SRH280DP sensor by shortening the shaft and adjusting the housing to ensure a snug fit within the gearbox, but it has still outperformed every other sensor we have tried from rival manufacturers.” he says.

For the 2013 competition, Chalmers is entering two vehicles. The first is a development of its winning 2012 vehicle; the second will use an electric drive-train in the hope that the team will be fully electric for the 2014 competition.

For further information call Penny + Giles on +44 (0)1202 409499, email sales@pennyandgiles.com or visit www.pennyandgiles.com.

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Q8Oils (www.Q8Oils.co.uk / @Q8OilsUK)

Q8Oils has become a major player in the global lubricants market. Our success is founded on significant corporate resources, a commitment to product development and uncompromising standards of quality and service.

Q8Oils has a unique and innovative approach producing some of the world´s finest quality lubricants. Manufactured in its state of the art plant at Leeds, West Yorkshire, Q8Oils represent the very best and latest in lubricant technology. With over 1000 grades of finished lubricants, base oils, process oils, extracts and waxes.

We are dedicated to serving the needs of our customers by striving to understand, anticipate and satisfy their needs faster and better than our competitors. To achieve this our objective is to develop and supply products and services which reflect customer demands in each of our market sectors.

TLV Euro Engineering (www.tlv.co.uk)

TLV Euro Engineering UK is part of TLV, an internationally-established designer, manufacturer and provider of steam traps, condensate recovery pumps, pressure reducing valves and other specialist steam solutions. The company plays a leading role in the promotion of efficient energy systems and increased environmental conservation on a worldwide scale through its products and consulting and engineering services.

Rockatek (www.rockatek.com)

Cheltenham-based Rockatek Ltd is an engineering consultancy that offers design, analysis and physical testing services that set it apart from others. Its directors have over 40 years’ experience in complex engineering product optimisation and development; and its engineers specialise in engineering solutions for harsh environments and value improving reliability and performance.

Verco (www.ver.co.uk)

Founded in 1965, Verco quickly built a reputation for supplying quality refrigerated glass door and open chill cabinets to supermarkets, convenience and forecourt stores. Verco is now a leading supplier of retail refrigeration and the largest UK manufacturer of glass door cabinets.

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