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.
Advanced Insulation (www.aisplc.com)
Since its formation in 2007, Advanced Insulation has become a single source provider for insulation and fire protection systems to the oil and gas industry, and represents one of the most respected and progressive names in topside and subsea insulation worldwide.
Advanced Insulation offers a wide range of products to meet the growing demand for fire protection and thermal insulation systems adaptable for elevated service temperatures and pressures.
AL-KO Kober (www.al-ko-co.uk)
Since 1931, AL-KO Kober has been manufacturing premium, high quality components used in the Automotive, Commercial and Leisure industry.
The extensive range of chassis components, premium accessories and spare parts are engineered to last, ensuring whatever product you have purchased, you will benefit from the generations of development and enjoy a lifetime of service.
Arc Energy Resources (www.arcenergy.co.uk)
Arc Energy Resources is one of the UK’s leading specialists in weld overlay cladding and fabrication for the oil & gas industry. The company’s expertise provides protection against corrosion and wear for a variety of process and pipeline equipment for use in any hostile environment.
The company recently made a major investment in two new Rotating Head welding machines costing £500,000. This has increased productivity and extended the size and scope of work it can handle, which now includes complicated component geometries for the full or partial cladding and fabrication of a huge range of component sizes weighing up to 15 tonnes. The company’s in-house designed cladding workstations feature state-of-the-art control systems developed to suit its customer’s specialised engineering requirements, and can clad bores up to four metres diameter and areas of restricted access within bores as small as 20mm diameter. Arc Energy also offers in-house test weld, heat treatment, PMI and NDT facilities.
Industry certifications include ISO 9001:2008 quality management, ISO 3834-2 fusion welding of metallic materials, and the internationally renowned ASME U and R Stamps, as well as ISO 14001:2004 environment management, Investors in People and OHSAS 18001:2007 Health & Safety management system.
Curtiss-Wright Industrial Group, which includes the legacy brands of Arens Controls, Penny & Giles, PG Drives Technology and Williams Controls, is a recognized leader in providing components and sub-systems which enable customer specific solutions for on- and off-highway vehicles. These include medium- and heavy-duty trucks, buses and motor coaches, construction and agricultural vehicles, materials handling, and other specialty vehicles, as well as sophisticated wheelchairs and scooters for medical mobility.
We are a leading provider of electronic throttle controls, transmission shifters and sensors for commercial off-highway equipment and heavy trucks, so helping to address the long-term trend towards attaining higher fuel efficiency and lower emissions. We also supply operator controls and advanced motor controllers for hybrid and electric vehicles, such as buses, forklift trucks, pallet stackers, wheelchairs and rehabilitation chairs.
With a proud legacy spanning more than 85 years, Curtiss-Wright 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, we have a long tradition of providing reliable solutions through trusted customer relationships.
Further information is available from the Curtiss-Wright Industrial website (www.cw-industrialgroup.com) or by calling +44 (0)1202 034000.
Euchner (UK) Limited (www.euchner.co.uk)
Safety for people, machines and products has been the maxim of this family-owned company since 1953. Stefan Euchner is the third generation to take the helm.
As specialists in industrial safety engineering, Euchner develops and manufactures products and solutions tailored to the requirements of customers from a wide range of sectors. Using its guards on machines and installations helps to minimise hazards and risks, which in turn protects people and processes. For its 800 employees around the world, safety is the watchword.
Further information is available from the Euchner (UK) Limited website (www.euchner.co.uk) or by calling +44 (0)114 256 0123.
Industry Superstore (www.industrysuperstore.co.uk)
Industry Superstore is a one-stop-shop for a wealth of budget-friendly, high-quality products tailored to industry!
Further information is available from the Industry Superstore website (www.industrysuperstore.co.uk) or by calling +44 (0)1892 664499.
Exmac Automation Limited has many years experience in the design, manufacture, and installation of unit conveyors, conveyor systems and associated materials handling equipment for most industry sectors.
Exmac Automation is part of the MacDonald Humfrey group of companies and are market leaders in the supply of automated materials handling equipment to the automotive, aerospace, white goods, warehouse & distribution, nuclear, pharmaceutical and food & beverage industries.
The group supplies to most industry sectors and have over 250 employees with many years experience in the design, manufacture and installation of unit conveyors, conveyor systems and associated materials handling equipment.
Projects have ranged from individual standard conveyors and bespoke handling applications, through to complete turnkey contracts involving conceptual and process design, installation and commissioning.
We are ISO 9001 accredited and constantly strive to achieve continuous improvements in the overall quality of our products and service.
Exmac Automation has has established a reputation for supplying high quality, robust systems at competitive prices.
In-house resources enable us to provide clients with a single source for complete systems integration including simulation, engineering, machining, fabrication, assembly, controls, installation & commissioning and after sales service.
Our 70,000 sq ft facility in Worcester has extensive design, manufacturing and assembly resources. Our skilled team of customer focussed automation professionals offers a broad base of knowledge and experience in a wide variety of industries.
A large workshop enables us to carry out comprehensive pre-installation assembly and factory acceptance tests on all projects.
Fulton Limited (www.fulton.co.uk)
The Fulton name has been synonymous with steam since the company first introduced the vertical tubeless steam boiler in 1949 and Fulton was established in Bristol in 1966. Fulton is still one of the world’s leading manufacturers, producing an unrivalled range of multi-fuel steam boilers. But increasingly these are ordered by customers as part of bespoke turnkey systems designed to meet exacting specifications.
Today Fulton Limited is an important design and manufacturing base in Fulton’s global network that also includes production facilities in the USA and China. The company’s UK facility makes it possible to manufacture products more efficiently and assemble completed units for whenever and wherever they are needed throughout the UK and in export markets.
Once just a steam boiler manufacturer, Fulton now specialises in ready-to-ship skid mounted and fully packaged boiler plant rooms to meet the current demand for off-site fabrication. The company puts great emphasis in providing sales and application advice and a full commissioning and after sales service to a growing customer base in hospital and healthcare facilities, food and beverage processing, laundries and other applications.
Design and manufacturing resources are shared and coordinated around the world, but no matter where your product originates, it will always be produced to the highest quality in a facility that is wholly owned and managed by the Fulton Group, which remains a privately owned family business.
Fulton’s heating and hot water systems can be delivered as fully prefabricated plant rooms or complete skid-mounted units, built to fit a prepared location and connect direct to your services.
Using the latest CAD equipment its design team can accommodate the most sophisticated engineering specifications in surprisingly compact spaces, locating components in the best possible position to suit the installation.
In every sense, today’s Fulton boiler systems are solutions that fit the requirements of the modern age of steam.
Gast Group (www.gastmfg.com / www.jun-air.com)
Since 1921, Gast Manufacturing, Inc. has been designing and manufacturing quality air-moving products. Our vacuum pumps, compressors, air motors, gear motors, vacuum generators, regenerative blowers and Smart Air technology meet the many challenging applications of OEMs and end-users worldwide.
For industrial manufacturing, health care lab, or environmental cleanup applications, Gast provides a full range of ideally suited and cost-effective solutions to any pneumatic problem.
Monodraught (www.monodraught.com)
In the current climate of soaring energy prices and the fear of global warming, increasing attention is being focused on Monodraught’s range of energy-free products.
Monodraught has always sought to invent, explore and develop innovative technologies that harness the wind and sun. Products include Windcatchers, Sunpipes, Suncatchers, Sola-vents, Sola-boosts and Cool-phase.
Nexen Lift Trucks (www.nexenlifttrucks.com)
Disillusioned with the ever-increasing complexity of new forklift trucks and the failure of the major manufacturers to provide a high level of support to their dealer networks, the decision was taken to develop its own range of forklifts.
In 2003 Nexen Lift Trucks was established with the vision to design and manufacture its own range with a combined 70 years experience of the lift truck rental industry. Nexen's ultimate goal is to build worldwide brand recognition based on its product's design and build quality as well as outstanding reliability at competitive prices.
In 2007 Nexen completed the purchase of the second largest lift truck manufacturer in Taiwan, creating the Nexen Motor Corporation. Initially the existing models were improved whilst a European based design team was established to develop a completely new range of trucks from the ground up to meet Nexen's standards.
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.
