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Please download and print any .pdf files that are of interest to you
Design, development and manufacture of bespoke circuit boards:
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Title: ‘Developing a networked process control board’
Subject: Circuit board for controlling electrical IR lamps providing process heating in multi-station linear indexing machines for resin impregnation of electric motor components
Content: Logic + power PCB; analogue + digital signals; ProfiBus + DeviceNet + CANopen + MODBUS networks; harsh operating conditions; cost reduction; PCB manufacture
Client: AWE Newtech Ltd, Newark, Nottinghamshire, UK, for machines supplied worldwide
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Title: ‘Web guides for softgel capsule machines’
Subject: Circuit board for controlling stepper motor driven mechanism for guiding gelatine webs, retrofitted to rotary die encapsulation machines in various locations worldwide
Content: Logic + power PCB; analogue + digital signals; PCB manufacture
Client: N/A
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Title: ‘Developing a motion controller: why?’ (see below also)
Subject: Networked circuit board for controlling up to 65,535 stepper motors used for varying length of yarn paid out on a carpet tufting machine, for creating different patterns
Content: Logic + power PCB; analogue + digital signals; bespoke network MCSNet supporting up to 65,535 nodes; PCB manufacture; appraisal of why the board was developed
Client: THOM Engineering Ltd, Blackburn, Lancashire, UK, for machines supplied worldwide
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Title: ‘Developing a motion controller: how?’ (see above also)
Subject: Networked circuit board for controlling up to 65,535 stepper motors used for varying length of yarn paid out on a carpet tufting machine, for creating different patterns
Content: Logic + power PCB; analogue + digital signals; bespoke network MCSNet supporting up to 65,535 nodes; PCB manufacture; appraisal of how the board was developed
Client: THOM Engineering Ltd, Blackburn, Lancashire, UK, for machines supplied worldwide
Drives + control systems, programming, networks and software:
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Title: ‘Reaching new heights in the world of film and TV’
Subject: Trailer mounted, remote-control telescopic mast for lifting TV camera to 30m/100ft
Content: Mixed electrical / hydraulic system; 6-axis motion controller; VSDs in flux vector + servo modes; battery powered operation; regenerative braking
Client: Cammotion Ltd, Marlow, Buckinghamshire, UK
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Title: ‘Needling machine for carbon disc brakes’
Subject: Designing, making + commissioning programmable X-Y table; writing CAD software for generating + downloading programmes to controller via LAN
Content: 2-axis ballscrew mechanism; servomotors + drives; motion controller; CAD software
Client: Dunlop Aerospace Braking Systems (part of Meggitt plc), Coventry, W Midlands, UK
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Title: ‘Programming a push-pull machine’
Subject: Programming a machine for assembling automotive drive shaft with constant velocity (CV) joint then testing the integrity of the assembly + process monitoring
Content: PLC; servomotors + intelligent servo drives for torque/load + position control; HMI; ProfiBus + CAN networks; PC-based software for data acquisition, storage + analysis
Client: GKN Driveline (part of GKN plc), Erdington, Birmingham, W Midlands, UK
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Title: ‘Pathology lab sample preparation machine’
Subject: Designing, making + commissioning prototype control system for new lab machine
Content: Multi-axis motion controller; 8 stepper axes + 1 servo axis; HMI
Client: Genial Genetic Solutions Ltd, Upton, Wirral, UK
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Title: ‘Hybrid centre/surface winder for metal foil’
Subject: Designing, making + commissioning control system for foil converting machine
Content: PLC; VSDs for speed + torque/tension control; HMI; CAN network
Client: Machinery Development Services Ltd, Whitminster, Gloucestershire, UK
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Title: ‘Bottle Capping Machine’
Subject: Designing, making + commissioning capping machine for automated bottle filling line
Content: Torque-controlled mechanism for screwing caps on bottles; 2 servomotors + drives, one drive operating in torque control mode; CAN network
Client: Olympus Life and Material Science Europa, Co. Clare, Republic of Ireland
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Title: ‘15-axis Taping Machine for large diameter pipes’
Subject: Designing, making + commissioning control system for pipe wrapping machine
Content: PLC; geared servomotors + drives; network; wireless communications; PC-based software with graphical interface for generating + downloading recipes to machine
Client: Ridgway Machines Ltd, Anstey, Leicestershire, UK for a customer in China
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Title: ‘Taping Lines for Copper Conductors’
Subject: Designing, making + commissioning modular control system for taping machines
Content: PLC; servomotors + drives; network; HMI; PC-based software for generating + downloading recipes to machines
Client: Ridgway Machines Ltd, Anstey, Leicestershire, UK for a customer in India
Gefran’s famous ‘No-fix No-fee’ breakdown call-out service:
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Title: ‘No-fix no-fee breakdown call-out service’
Subject: Gefran’s famous ‘No-fix No-fee’ breakdown call-out service
Content: Examples of clients helped; details about our expertise + equipment we support
Client: Various
Machinery upgrades:
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Title: ‘Giving an old machine a new lease of life’
Subject: Upgrading a 3-axis CNC grinding machine with a new controller and servomotors
Content: 6-axis motion controller; servomotors + drives
Client: Bondabelt Ltd, Telford, Shropshire, UK
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Title: ‘Breakdown support: first aid for machinery’
Subject: Retrofitting a linear servomotor and drive to replace obsolete equipment
Content: Linear servomotor + drive
Client: Cuxson Gerrard Ltd, Oldbury, W Midlands, UK
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Title: ‘Servos revolutionise packaging machinery’
Subject: Upgrading a mechanical flow wrapping machine to full servo control
Content: Servomotors + drives; multi-axis motion controller; operating software + high level Software for creating and storing recipes; HMI
Client: Daco Engineering Ltd, Westbury, Wiltshire, UK for machines supplied worldwide
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Title: ‘Automating production of savoury pancakes’
Subject: Programming + commissioning food production machinery; on-going support + control system upgrades
Content: 12-axis motion controller; servomotors + drives
Client: Findus Ltd, Longbenton, Newcastle-upon-Tyne, Tyne & Wear, UK
Technical training:
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Title: ‘Specialist training for your technical staff’
Subject: Training for technical staff in implementation, programming + fault analysis of modern drives + control systems specific to customers’ own plant + machinery
Content: Training course for contact lens manufacturer Bausch & Lomb Scotland Ltd, covering the main features of the multi-axis motion controllers used in their own machines
Client: Various
Energy saving and cost reduction:
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Title: ‘Variable speed drive reduces energy costs’
Subject: Application of VSD for driving dust extraction fan, to reduce energy consumption
Content: Inverter; cost saving calculation
Client: Peter Grant Papers Ltd, Telford, Shropshire, UK
Key to abbreviations:
| CAD | Computer Aided Design |
| CNC | Computer Numerical Control/Controller |
| HMI | Human-Machine Interface (a.k.a. MMI: Man-Machine Interface) |
| IR | Infrared |
| LAN | Local Area Network |
| PC | Personal Computer |
| PCB | Printed Circuit Board |
| PLC | Programmable Logic Control/Controller |
| VSD | Variable Speed Drive (generally for AC induction motors, including soft starters) |
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