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Detection of gearbox damage during operation

Institute for Machine Elements at the University of Stuttgart detects smallest fraction on gear flank surface with the help of a SONOTEC ultrasound sensor.

The intelligent networking of machines plays a crucial role in Industry 4.0. As a result, many machines are equipped with condition monitoring systems. Sensor data recorded on the machine is used to make statements about the condition of the machine or individual critical components. Condition monitoring detects damage at an early stage, so that unexpected machine failures can be prevented. For machine engineers, this results in added value in terms of operational safety as well as a financial advantage.

A gearbox malfunction can lead to an entire machine coming to a standstill. For this reason, gearboxes are particularly suitable for condition monitoring during operation. The main failure mechanisms of gearboxes show a gradual progression of damage. It is therefore possible to detect damage early before it reaches a critical stage. As soon as damage has been detected and the condition of the damage has been identified, the remaining service life of the gearbox can be estimated.

The focus of current research at the Institute for Machine Elements at the University of Stuttgart is on pitting damage. In cooperation with SONOTEC, a measurement technology manufacturer specializing in ultrasound, pitting damage on gears was investigated. In the process, damage could be detected well before the failure criterion standardized in DIN 3990-5 which is of an area fraction on a tooth flank surface of 4%. This is possible with suitable sensor technology. In a series of tests, synthetic pitting damage with area fractions between 0.4 % and 2 % of the area of a tooth flank was examined. In addition to the size of the pitting damage, the speed, torque, and lubricating oil viscosity were systematically varied in the tests. In this way, the detection capability of the pitting damage could be tested under different boundary conditions. Different accelerometers were used to collect data. Compared to the accelerometers, the pitting damage is clearly visible in data of the T20 structure-borne sound probe from SONOTEC, particularly in the ultrasonic frequency range above 16 kHz. Thus, it is possible to reliably detect even the smallest examined pitting damage with area fractions of 0.4% of the area of a tooth flank.

testing gear 2 002

The T20 structure-borne sound transducer differs from classic accelerometers by its innovative transducer principle. At its heart is a piezocomposite material developed and manufactured in-house by SONOTEC, through the use of which an almost linear frequency response with excellent sensor sensitivity is achieved. Due to this principle, SONOTEC's structure-borne sound transducers are much better suited for the detection of smallest mechanical impulses than conventional accelerometers. In the case of slow-running rolling bearings or in gear drives, damage can thus be detected much earlier, which is of particular importance for successful condition monitoring.

The range of applications for condition monitoring with estimation of remaining service life is broad. One example is offshore wind turbines. Due to the difficult accessibility of the turbines on the open sea and the size of the gearboxes, maintenance is associated with high costs. Predicting the remaining service life as part of condition monitoring offers engineers the opportunity to continue operating the wind turbine until a predictable, economical maintenance date.

Belzona Provides Thermal Insulation Solution for Fortune 500 Oil & Gas Company

A leading oil and gas Company needed thermal insulation for a tank at one of its lubricant plants. The upper surface of the tank, which reaches a temperature of 110 °C (230 °F), serves as a walkway for operators. This creates a high risk of employees receiving contact burns from the hot substrate. Additionally, some pitting corrosion had occurred. Finding a solution that would lower the surface temperature to prevent burns and halt further corrosion was crucial. 


Unprotected tank’s upper surface, operating at high temperatures. 

What was the Issue? 

The high temperature of the tank causes a hazard for the employees walking upon it. According to the guidance set forth by the Occupational Safety and Health Administration (OSHA), the maximum temperature for exposed surfaces that an employee could come into contact with is 60 °C (140 °F), in line with ASTM C1055. Workers must be protected from exposed heated surfaces, so it was crucial to lower the surface temperature of this tank to eliminate this hazard. 

In addition to its high temperature, the metal tank surface had been experiencing pitting corrosion, necessitating pit filling and a protective coating that would prevent it from corroding further. 

Why was Belzona Chosen? 

Having previously used various Belzona products, this Customer had confidence in their Distributors’ recommendation that Belzona 5871 was the optimal solution.  

As well as offering thermal insulation to protect employees from contact-burn injuries, this product only needs two coats, enabling quick turnaround times. It also has excellent corrosion resistance which was essential as the tank top had been experiencing pitting corrosion. 


Protected from high temperatures with Belzona 5871. 

How was the Solution Applied? 

The surface was prepared by vapour blasting the substrate to meet SSPC-SP10 (Near-White Metal) standards and was then degreased. Additionally, some corrosion on the top of the tank required pit filling with Belzona 1121 (Super XL-Metal) ahead of the coating being applied. 

With the surface prepared, the first coat of Belzona 5871 was then applied using a short-bristled brush. This product expands, reducing the number of layers which are needed, the first coat was applied at the target thickness of 1000 µm (39 mil) wet film thickness, which results in 3000 µm (118 mil) dry film thickness. The second coat was then applied using the same method six hours later. The tank was back to full service just 12 hours after the final coat was applied.


Surface preparation before application            
 Tank top after one coat of Belzona 5871 

What was the Result of the Application? 

This application successfully offered thermal insulation protection for a Fortune 500 oil and gas Company. Following the application of two coats of Belzona 5871, the previously dangerous temperature of 110 °C (230 °F) has been successfully lowered to a safe level—below 60 °C (140 °F).

This case study shows how Belzona 5871 offers thermal insulation and creates long-lasting safety and durability. The solution not only mitigated the risk of contact burns but also introduced a valuable layer of protection against corrosion. 

Want to Learn More About Thermal Insulation with Belzona?

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The importance of door maintenance

The fact that Hart Door Systems has built a reputation for quality and longevity of its wide range of industrial doors, the importance of door maintenance should not be understated says Keith Fisher, Hart’s National Operations Manager.

Servicing industrial doors not only improves their reliability and operational functionality but servicing is also a requirement under Health, Safety and Welfare Regulations  which protect people who come into contact with the doors. Indeed failure to maintain industrial doors could put the user in breach of Government legislation incurring liability in the case of an incident involving an industrial door which is non-compliant.

As essential support for our clients Hart has comprehensive Service & Maintenance assistance as a specialist department which delivers a range of repair and scheduled maintenance options for its customers to further extend the life of their doors.

Given the very wide variety of industrial classifications we supply doors and shutters to, the emphasis has to be on designing servicing and maintenance packages which are tailored to match the specific needs of our clients’ businesses and the arising usage patterns of the various doors/shutters.

A preventative Servicing and Maintenance Agreement ensures Hart’s servicing is carried out correctly and at the precise frequency thus complying with Regulations. Typically during a Hart servicing visit all mechanical and electrical elements are checked for missing parts, general wear and tear and Compliance issues.

Mechanical checks include inspecting parts such as drive chain tension, alignment and lubrication, bearing wear and tear, motor oil levels and fabric tension and electrical checks include limit settings, cable connections and safety devices.

Hart also has a legal responsibility to ensure doors are left in safe working order after servicing. Again the issues are wide ranging such as measuring the closing forces of automatic doors where safe contact is the main strategy to prevent hazards.

The closing force of a door ensures correct force limitation under EN 12978 which prevents injury and crushing. Testing should always be carried out with an annually calibrated instrument according to DIN 18650, EN 12453 or EN 12445.

On completion of a Hart service visit, a paperless electronic copy of the engineer’s report will be issued which may include additional recommendations necessary to ensure the doors are safe and compliant to relevant legislation due to changing ‘shop floor’ circumstances.

The sophistication of door systems such as Hart’s Speedor range or its Typhoon shutter range has changed significantly over the years to cater for changing needs by its customers across the globe and indeed by changing climate. To ensure hard working doors in busy industrial environments continue to make a significant daily contribution to efficiency and safety, planned maintenance is essential.

Sweet contract for Hart

Hart Door Systems has clinched a large order from a major UK producer of Syrup for a varied range of Hart’s industrial doors.

Doug Hart, Hart’s chairman, says the order covers a wide range of Hart’s doors from its Speedor Cleanroom and Speedor Mini doors to high-speed insulated roller shutters, pedestrian doors and fire shutters.

“This is a significant order across Hart’s product range. Being able to deliver doors from one manufacturer, as well as our acknowledged installation and service delivery as a single source of supply, were key to our success,” says Mr Hart.

“Our ability to advise the client throughout the time-sensitive project, which involved the client relocating to new premises, was also important in Hart’s success.”

Mr Hart adds: “This was the wide-ranging package from a single supplier, involving over 40 doors, finished in food-grade paint where appropriate. Brian Woodcock, our regional sales manager for the Midlands/South West, advised throughout.

“It is a clear message that Hart is a market leader which has the ability to take on complex projects and deliver a first-class service every time using doors from our comprehensive range such as Hart’s Speedor high speed doors to roller shutters such as our Typhoon and Terror Screen range and more.

“In particular it was important that our Speedor Cleanroom was part of this project as it is designed to work in strictly controlled environments where high hygiene standards are required including protection against dust and dirt for example.

“The fast opening and closing feature helps to control airflow, reducing contaminants as a result,” says Mr Hart.     sales: +44 (0)191 214 0404

Work smarter. Label right where the work happens!

Work smarter. Label right where the work happens!

Print bigger, clearer messages. Go edge to edge. Design and print on the fly, or a PC. Plus, share files, import data and connect up to 5 users simultaneously. Discover innovative M511 labeler from Brady!


Communicate better with the Brady M511’s edge-to-edge printing and on-demand labelling. Ideal for big, bold, easy-to-read safety messages. Perfect for text-heavy labels for the lab or compliance. With the M511, you print right where the work happens, skipping rework and saving time. Its Bluetooth capabilities connect more users in more ways to ensure you move through work faster.


Label creation is just a tap away - you can seamlessly design, view and print labels right from Brady's industry-leading app. The Brady M511 Printer paired with Express Labels mobile app provides a seamless on-demand experience for maximum on-site efficiency.


Key features & benefits:

  • Ideal for larger applications – print up to 38.10 mm labels
  • Less waste – go edge to edge with text, graphics and barcodes
  • Longer battery life with an internal Li-ION battery – 8+ hours of work; 1,000 labels on a single charge
  • More durable – resists 1.8 m drops, shocks, 115 kg crushes and blowing sand and dust (MIL-STD-810G)
  • Prints anywhere – Bluetooth 5.0 (20 m range); connects up to 5 users simultaneously
  • Uses label creation software – Express Labels app via Bluetooth on a phone/tablet; Brady Workstation on a PC
  • Saves time; saves space – features an auto label cutter and prints upright or on its side


Enerpac Cuts the Cord with Portable Cordless Bar Cutter

The Enerpac highly portable EBC-Series Cordless Bar Cutter quickly and easily slices through number 6 rebar or similar metal bar up to 20mm in diameter within seconds. The battery-powered cuter is designed for those who work in environments without access to on-site power. It is a convenient, and safe solution where external power is not available or where spark risk is a concern.

Portable, self-contained, and convenient 
Whether cutting rebar for residential or commercial construction or cutting steel and aluminium bars (round, hexagonal, or square) in industrial applications, the cordless technology in the Enerpac Cordless Bar Cutter provides complete freedom of movement. Because it has self-contained power, no external power source is required. This makes the tool completely portable. Another convenient feature on the cutter is a 360-degree rotating head that allows the tool to either be positioned flat on a work surface, where metal bar can be fed through the blades from a comfortable working position, or rotated in any orientation needed to finish hard-to-reach cuts on the job site. 

Another way Enerpac makes the tool convenient is by supplying it with two batteries and a charger so the operator can keep working when the first battery needs to be charged.

Precise Speed
The cutter offers a controlled, shear cut that is repeatable—unlike rotating cuts that tend to walk or slide on the bar—providing a uniform precise cut every time. Able to quickly cut through up to #6 rebar in 5 seconds, the Enerpac EBC-Series Cordless Bar Cutter has highly durable blades for thousands of cuts, with up to 125 cuts on a single charge.

Minimises Safety Risks
The Enerpac Cordless Bar Cutter is designed to minimise safety risks. Gas saws, angle grinders and cut-off tools are among the most popular solutions for cutting metal bar today, however, these tools are also the leading causes of injuries to an operator’s hand, arm or face. With the cordless bar cutter, the bar is held in place behind a protective guard, while a Trigger Guard helps prevent accidental activation. While the cutter’s controlled cutting action ensures there are no shooting sparks, exploding blades or exposure to high RPM cut-off wheels. 

To learn more about the Enerpac EBC-Series Cordless Bar Cutter, visit

ABB, Boliden and LKAB complete successful testing of industry-first automated robot charger for increased safety in underground mines


  • Technology leader working with the major Swedish mine operators to advance automation and robotics for safer working environments
  • ABB Robot Charger detects drilled holes in a rock face and installs explosive charges during mining operations, removing the need for human presence
  • Technology development will end this year with control of the robot handed over to the customer to run the blasting sequence

ABB has successfully completed testing of the industry-first automated robot charging technology for underground mines in partnership with mine operators Boliden and LKAB. The goal is to make mines safer by automating one of few manual processes left in mining: charging the blasting holes with explosives.

Blasting schedules in underground mines can vary, but the process takes place up to 15 times per day in larger mines as miners expand the chambers to extract mineral and metal ores. ABB Robot Charger automatically detects boreholes and fills them with charges without the presence of humans, removing the need for people to be near the unsupported rock face during blasting sequences.

The completed testing phase confirms the effectiveness of integrating the robot charger with a carrier vehicle, communication with bulk emulsion and vision systems and incorporation of a second robot arm to assemble prime and detonator. It ensures full reach to all borehole levels and areas of the rock face and remote control for operators.

The program has been undertaken at Boliden Garpenberg, which is the world's most productive underground zinc mine and is located 180 kilometers northwest of Stockholm.

ABB is now embarking on the final stage of development that aims to execute the full blasting sequence in the underground mine with full control of the robot handed over to the customer. ABB is also starting discussions with other mine operators to eventually join the co-development project, so that the technology can be tested in different mine environments and in regions beyond Northern Europe with varying climate and rock composition.

“This is a significant technology development for ABB and the wider industry where safety is part of overall ESG commitments,” said Vedrana Spudic, Head of Technology, Business Line Mining, ABB. “The robot locates the drilled holes on the rock face using a vision system, and these recent tests show all can be reached and charged with the cycle fully automated. This removes the need for human operators in a small, unsupported area right at the face.”

ABB developed the robot charger technology with vision systems and automation solutions to communicate with the truck, crane and ABB industrial robotic arm. The solution can be retrofitted to any truck.

ABB draws on 130 years of experience in the mining industry and is a pioneer in the integration of electrification, automation and digitalization in mining.

ABB’s Process Automation business automates, electrifies and digitalizes industrial operations that address a wide range of essential needs – from supplying energy, water and materials, to producing goods and transporting them to market. With its ~20,000 employees, leading technology and service expertise, ABB Process Automation helps customers in process, hybrid and maritime industries improve performance and safety of operations, enabling a more sustainable and resource-efficient future.

ABB is a technology leader in electrification and automation, enabling a more sustainable and resource-efficient future. The company’s solutions connect engineering know-how and software to optimize how things are manufactured, moved, powered and operated. Building on more than 140 years of excellence, ABB’s ~105,000 employees are committed to driving innovations that accelerate industrial transformation.




Easily improve safety and optimise performance of any workplace

Colour your way to an improved workplace with the S3700 Sign and Label Printer. With multicolour print and shape cutting capabilities, this printer creates impactful identification that fits your application and workspace needs.

Because safety and efficiency are the pulse of your operations, you need an industrial label printer that delivers both. Put multicolour brilliance, transformative shape cutting, and seamless create-and-print capabilities at the heart of your labelling. Empower any user to make signs, labels, and tags for just about any application. Let your labelling take shape with the BradyPrinter S3700 Multicolour & Cut Sign and Label Printer.

Put colour at the core of your labelling for safety, Lean and work-in-process visuals that truly pop. Auto-adjusting multicolour panel ribbons last up to 60% longer and print colour labels on a single cartridge.

Enjoy straighter lines, smoother curves and tighter connection points thanks to the precision XY plotter cutter. Plus, stack pipe markers and pack multiple shapes per label to minimise waste.

Create and print faster than ever before with time-saving onboard templates, intuitive PC labelling software and a mobile app, plus 20-second material changeovers and 127mm-per-second print speed.

Watch the video and discover the S3700 Sign and Label printer from Brady!

Hart Storms for Caribbean airport A typical Hart’s Speedor Storm

Hart Door Systems of Newcastle upon Tyne, has completed the installation of four Speedor Storms at a major international airport in the Caribbean, bringing the number of international airports globally which have Hart door installations to over 40.

In respect of the recently completed Caribbean contract, John Loftus, Hart’s Export Manager, says the high-speed Speedor Storms have been installed in the baggage area of the airport. 

“The doors, our best-selling Speedor version, will work together as two entry doors and two exit doors. The Speedor Storm is a robust, rapid roll, low maintenance door delivering exceptional wind resistance in exposed areas, ideal for this application,” says Mr Loftus.

“While its high-speed opening and closing action improve the environment of the baggage area, the efficiency of the ‘Storm’ will help to  control internal temperatures as well as reducing external noise.”

The Speedor Storm has been developed by Hart for challenging applications where reliability is essential. As Hart’s best-selling high speed doors they are in operation on a daily basis throughout the World.

Hart Door Systems is oldest British manufacturer of industrial high speed doors and shutters and the only British manufacturer to offer two years warranty as standard on all its doors.

Hart’s range of specialist doors for airports is focused on baggage management on conveyors, fire security and high speed access controls for vehicles, baggage and people.

Hart’s largest order from an international airport was for 177 fire and security shutters for a baggage conveyor system at King Abdulaziz Airport, Saudi Arabia.             

Belzona Announces New Swedish Distributor

Belzona, the global designer and manufacturer of repair composite materials and industrial protective coatings, has announced a new partnership with Svensk Kompositteknik AB, based in Karlstad, Sweden. Svensk Kompositteknik AB will serve as Belzona’s sole Distributor for Sweden going forward.

New Swedish Distributor Image 1 002

 Mikael Ringsåker, CEO and Niklas Blom, Business Manager outside the new Svensk Kompositteknik AB headquarters

Founded in 2023, Svensk Kompositteknik AB is built on the wealth of expertise of its founders, boasting a combined experience of over 200 years. The team, led by CEO Mikael Ringsåker, has been working with composite materials and epoxies in the region since the early 2000s, across a wide range of industries. Over the past decade, they have been working with Belzona products with a particular focus on the steel, pulp and paper, and chemical production industries.

Their extensive knowledge and years of experience working with Belzona has culminated in the official appointment of Svensk Kompositteknik AB as the authorized Distributor of Belzona’s range of protective coatings and repair composites in Sweden. This partnership shows how Belzona is expanding strategically in the Nordic Region, providing Swedish customers with enhanced accessibility to its innovative solutions.

In a joint statement, Mikael Ringsåker, CEO and Niklas Blom, Business Manager at Svensk Kompositteknik AB said: “We are delighted to to be entrusted with the management of Belzona’s strong brand in Sweden. Our organization is well prepared, and we are actively expanding our sales and installation network to ensure its continued success.”

New Swedish Distributor Image 2 002

 Niklas Blom, Business Manager opening the door of their new Headquarters in Karlstad

Jeremie Maillard, Export Sales Director at Belzona said: "Belzona is very excited at the prospect of working with Kompositteknik AB to support industrial customers across Sweden. Their experience with composite materials and strong network of partners throughout the country will allow Belzona to strengthen its presence. Most importantly, end users in Sweden will be able to confidently rely on Belzona solutions to extend the life of their assets.”

To find out more about Belzona, please visit


Lumens vs. Candela, what is the difference?

When it comes to lighting, lumens and candela are the two metrics that are often confused. In this article, we’ll explain the differences and how this will help you select the perfect light for the job.

Lumens: Total Light Output

Lumens are the most common unit for measuring all the visible light from a given light source. Imagine the bare bulb or LED from a light inside the center of a large sphere. When all the light is measured inside the sphere it gives you the total lumen value of that light source. If the goal is to light a large area, lumens is the crucial metric for selecting the correct light.

Candela: Peak Beam Intensity

Candela is the standard unit for measuring peak beam intensity. Let’s imagine the large sphere from the previous example. Now, instead of the light being projected evenly over the entire surface inside the sphere, focus all that available light onto a specific section. This gives you the candela rating. If you need to project light in one direction or over a long distance, then candela is the crucial metric for selecting the correct light.

For example, sporting arenas use very high-lumen lights to bathe the playing field with a complete blanket of even lighting with no focused “hot spots.” The opposite end of the spectrum would be a police cruiser spotlight with a very high candela rating to pinpoint a suspect or a distant dark corner.

Choosing the Right Light for You

If you need even light distribution in an area, you should primarily consider lumens. On the other hand, if you require a focused, directional light source, then candela becomes a more critical factor. The ideal situation would be to combine both lighting styles into a single product. These types of lights are referred to as dual-light products. A spotlight features a tight, focused beam for distant illumination (candela) and a soft flood light to illuminate the area directly around you (lumens).

The Original Dual Light

Nightstick, a provider of professional LED products for industrial environments, firefighting, and law enforcement worldwide, created the original dual-light product in 2007. Often imitated but never equaled, Nightstick dual light products are the gold standard by which all others are measured. Visit to find the perfect dual light for your job site.


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