OEM UPDATE - JANUARY 2020

MAHENG/2009/33944 Vol 11 Issue 8 • Pages 68 • Mumbai • ISSN: 2456-7418 January 1, 2020 • Rs. 200 • www.oemupdate.com

Is the Budget 18-19 aimed to promote local manufacturing?

OEM UPDATE

Top Robotic Applications in the Automotive Industry

Also read: Investments in R&D transforming machine tools industry Reinstating the automotive sector with technology

Technology to transform metal forming and cutting Industry leaders talk about taking correct measures to deliver quality output and process throughout the production cycle in tooling, metal cutting and metal forming sector. /oemupdate /oemupdate oem-update OEM Update /oemupdate /oemupdate oem-update OEM Update OEMUpdate

| MW11-03E |

From compact to complex:

The scalable Beckhoff CNC. Servo drives Industrial PC

I/O system

www.beckhoff.co.in/cnc PC-based controllers from Beckhoff cover the whole range of high-precision CNC applications, from compact to complex.

Highly scalable: the TwinCAT software platform for engineering and runtime Highly scalable: the Industrial PC range with processors from Intel® Atom™ to many-core Highly scalable: the I/O system for all signals and fieldbus systems Highly scalable: the highly dynamic servo technology for all performance classes Highly scalable: the safety solution, from system-integrated I/Os to drives

Beckhoff Automation Pvt. Ltd. Pune – 411 001, India Phone: +91 (20) 6706 4800 info@beckhoff.co.in

CONTENTS INTERVIEW India can be a destination for prefabricated steel components for large OEMs

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Prashant Chaturvedi, General Manager – Oxyfuel Business & Marketing, Messer Cutting Systems India Private Limited

Embracing technology for progress

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Abhijit Kulkarni, Regional Manager Technical, North and West Region, DesignTech Systems Pvt. Ltd.

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Cutting-edge technologies for enhanced performance

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COVER STORY Technology to transform metal forming and cutting

Maulik Patel, Executive Director, SLTL Group

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Smart solutions to predict hydraulic health

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Sagar Chadala, Executive Director, Concord Hydraulics Pvt. Ltd.

Industry leaders talk about taking correct measures to deliver quality output and process throughout the production cycle in tooling, metal cutting and metal forming sector.

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Ashok P Chhajer, OE Sales, BKT Tyres

MAHENG/2009/33944 Vol 11 Issue 7 • Pages 52 • Mumbai • ISSN: 2456-7418 December 1, 2019 • Rs. 200 • www.oemupdate.com

Is the Budget 18-19 aimed to promote local manufacturing?

OEM UPDATE

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INDUSTRY ANALYSIS 22

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Targeting growth and success

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Investments in R&D transforming machine tools industry

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Top Robotic Applications in read: theAlso Automotive How automation Industry can complement hydraulics Ergonomic position for gears

heavy equipment

Slow but Steady Redoubling investment can be key strategy to counter the impacts of a downturn as empirical evidence indicates that public investments precede any pickup in economic activity. /oemupdate /oemupdate

AUTOMATION 24

Maximised precision and speed in laser cutting Cover Credit: Machhindranath Pawar ASSOCIATE EDITOR* Caroline Chorattil editor@oemupdate.com

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EDITORIAL Megha Iyer Liesha Tripathi

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January 2020 n OEM Update

23 - 28 January 2020, Bangalore, India

Quick update

Centre of Excellence to be established for next-generation transportation systems Institutes and research organisations. The centre would also invite partnerships from other industry and academic organisations as it develops in the future.

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he National Rail Transport Institute (NRTI), a deemed-to-beuniversity under the Ministry of Railways, signed a MoU with the University of Birmingham in Rail Bhawan, New Delhi on 18th December 2019 to set up its first Centre of Excellence for nextgeneration transportation systems. The MoU was signed by Vinod Kumar Yadav, Chairman, Railway Board and Chancellor of NRTI, and Professor Clive Roberts, Head of the Birmingham Centre for Railway Research and Education (BCRRE) at the University of Birmingham.

Indian Railways is a founding partner of this centre and would provide proprietary data, professional expertise, spare equipment and other available resources directly or through its Centralised Training

Moreover, this centre will be involved in promoting the development of the rail and transportation sector in India, which includes offering post-graduate, doctoral and post-doctoral programmes, customised training programmes for in-service professionals, undertaking joint research projects in areas such as signalling, communication, asset maintenance, traction and safety, and developing benchmarks, standards and certifications for specialised skills. It will also be involved in organising knowledge events, conferences, and workshops to disseminate trends, latest research, global best practices and developments in the transportation sector, accessible to industry and academia.

The establishment of this centre is yet another step towards building India’s capacity in the transportation sector, which would prepare the youth for participating in building and operation of national projects such as high-speed railways, modernising Indian Railways signalling systems, rolling stock, and operations. Its pedagogy would nurture creativity and entrepreneurship among NRTI students, providing them an opportunity to become best-in-class professionals, influential leaders, nation-builders, and value-driven citizens.

Global safety sensors and switches market to be valued at $30 billion by 2025

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ccording to the analytical research study performed by Persistence Market Research on safety sensors and switches, the global market is projected to expand at a meteoric rate to register a CAGR value of 10.7 per cent throughout the period of assessment, 2017-2025. In 2017, the global market for safety sensors and switches was valued at around $13.8 billion and is estimated to touch a valuation higher than $30 billion by the end of the period of forecast.

The fourth industrial revolution, Industry 4.0, aims at factory automation which removes human intervention. Autonomous robotics

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and sensor technology is expected to be implemented in industries by the end of 2025. The use of robots in the production line of the manufacturing sector would give a significant boost to the use of sensors and switches. These sensors are used to monitor the functioning of robots and machines, thus ensuring effective production with reduced errors and increasing profit margins. Several countries are opting for automation across various industries, implementing the Industry 4.0 concept. Moreover, they are looking forward to levy strict regulations related to safety in industries and commercial spaces with a view to avoid loss and damage to property or life under any circumstance. The growing industrial revolution has thus presented potential growth opportunities for safety sensors and switches market at a global level.

Emerging economies in Asia Pacific such as China and India are witnessing a huge drift towards rapid urbanisation coupled with increasing consumer disposable incomes. This has triggered the demand for emergency stop controls, pressure

sensing sensors and devices and other safety devices across various industries. Several projects in this region are encouraging advancements in the manufacturing sector. For instance, the “Make in India� project has encouraged the manufacturing sector to grow at a rapid pace by implementing automation across various enduse industries and also imposing strict safety regulations. This has given an accelerated push to the adoption of safety sensors and switches in Asia Pacific.

Industrial automation in Asia Pacific is at its peak in countries such as Japan, China, and South Korea. Other emerging counties such as India, Singapore, Malaysia, Thailand, and Vietnam are also witnessing increasing trends of automation across various sectors. For instance, the Digital India Campaign in India is a potential trend that is influencing the growth in use of safety sensors and switches. In addition, the concept of connected cities or smart cities is burgeoning in various developing countries. This has triggered the use of safety sensors and switches in the region.

January 2020 n OEM Update

Quick update

SCT current transformers complete end- to-end power measurement chain from the sensor to the cloud

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ith its SCT current transformers, Beckhoff makes it possible to implement reliable power sensor technology directly in the field as an integrated component of the PC-based control technology. Users can select from two device types, each available in various designs and performance categories that are highly scalable and therefore suitable for a great variety of applications. The SCT portfolio is extremely broad, ranging from low-cost 3-phase CT sets for building technology and standard industrial transformers for machines through to solutions for inspection and test stands with extra-high accuracy requirements.

The choice of product category depends on the type of use. While ring-type transformers are predestined for cost-effective and accurate data acquisition in new installations, the easy-to-install split-core CTs provide the ideal solution for trouble-free retrofit solutions.

With either solution, the integrated power measurement chain from the sensor to the cloud simplifies energy management and opens the door to improving the availability of machines and systems. Continuous, systemintegrated power measurement allows users to perform more efficiently.

India Cold Chain Show 2019 concludes on a high note supply segments and others were displayed at the show, which also witnessed a substantial increase in visitor footfall.

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ndia Cold Chain Show 2019, India’s leading trade show for the cold chain industry, was held from 4th to 6th December 2019 at the Bombay Exhibition Centre, Mumbai. Key buyers from pharmaceuticals, food processing, retail, meat and seafood, dairy, ice cream, cold supply chain and other end user industry segments flocked the venue to explore

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the best brands, innovative products, and market trends in the cold chain industry.

A wide and cost-effective range of products, solutions and technologies encompassing cold storage, refrigeration, ripening chambers, reefer transport, tracking and IoT, packaging, cold storage infrastructure, cold logistics, cold chain

The trade show was a converging point for exhibitors, influencers and decisionmakers to forge connections conduct business, gain insights, and network as well as reconnect. The “Cold Chain Summit” and “Pharma Distribution Conference & Workshop” brought together over 50 leading industry speakers from companies like Hindustan Coca-Cola Beverages, Modern Bazaar, BigBasket, Chaayos, Honeywell Voice Solutions, Reliance Life Sciences, Mother Dairy, Easyday (Future Group) and many more who shared insights on key topics. It successfully created a platform to learn, socialise and discover emerging trends in the Indian cold chain industry.

The 2019 edition of the India Cold Chain Show ended on a positive note, with a significant leap in the number of participants and visitors, as well as business and networking opportunities.

January 2020 n OEM Update

Cover Story

Technology to transform metal forming and cutting Industry leaders talk about taking correct measures to deliver quality output and process throughout the production cycle in tooling, metal cutting and metal forming sector.

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mong all the different sectors of the manufacturing industry, the sheet metal forming and machine tooling and cutting sectors are integral to the industry, as their applications in other sectors and industries spread far and wide. They form an important step in the manufacturing processes of various products, including automotive, construction, heavy engineering, industrial machinery, aerospace, defence and so on. As IMTEX celebrates these sectors in its latest edition that will be held from 23rd to 28th January 2020, we take a look at how these sectors are coping with the current challenges in the manufacturing industry, while utilising the upcoming opportunities to their advantage.

We also take a look at the new innovations occurring in this space.

Sheet metal forming The sheet metal forming process transforms the flat metal sheet to desired final product in one or more stages of forming operations, depending on part complexity using transfer and progressive dies.

The phases involved in sheet metal manufacturing include: • Product Design: Checking early manufacturing feasibility using one-step analysis • Costing: Blank nesting for cost reduction • Die Engineering: Die surface development, validation using incremental analysis for forming, drawing, spring-back analysis, die compensation, die structure analysis and die optimisation for weight reduction • Tryout & Production: Design of experiment, process optimisation for robust manufacturing process

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Sheet metal forming with varying properties and shapes are in great demand in various industries. However, it is a costly and time-consuming process, which makes it difficult for small manufacturers to complete this process at a low cost. In an era when staying lean and profitable is the norm, it is crucial for sheet metal manufacturers to deliver products at low costs while not compromising on quality.

Machining and tooling The machining and tooling sector, too, plays an important role in manufacturing. Efficient technologies used in this sector can make or break a company’s profitability. The right tools and machines can improve speed of operations, lower cost, contribute to optimal resource utilisation and thus affect the company’s bottom-line.

The sheet metal manufacturing industry is a key segment within the metal and tooling industry. To survive in the current demanding sheet metal manufacturing market, reducing the production cost by controlling the process and tool designing is essential. One of the key ways to achieve this is to reduce the scrap by improving material utilisation, as it would reduce the production cost considerably.

Status quo Although the manufacturing industry in India, primarily the automotive industry, is experiencing a slowdown, the sheet metal manufacturing and metal and tooling sectors cater to other industry segments such as heavy engineering, industrial machinery, power and energy and January 2020 n OEM Update

Cover Story many more. Abhijit Kulkarni, Regional Manager Technical, North and West Region, DesignTech Systems Pvt. Ltd., says, “The other industries in India are still doing relatively good. So while there are challenges in the domestic manufacturing segment, the sheet metal industry may still do well. Since they are not dependent on just one industry segment, i.e., automotive industry, and supply to other industry verticals as well, they are a little more insulated than the companies engaged predominantly in automotive manufacturing.”

Laser applications are sustainably increasing in lower thickness steel cutting, which also makes it certain that the laser market is poised for further growth in coming years.

He adds, “As per the data presented by the Indian Machine Tool Manufacturers’ Association on their website, machine tool exports from India have reached `355 crore during 2017–18 compared to `360 crore during 2016–17, registering an annual y-o-y growth decline rate of -1.4 percent. Metal cutting machine exports from India have reached `292 crore during 2017–18 compared to `297 crore during 2016–17, registering a y-o-y growth decline of -2 percent; while the metal forming machine exports from India remained at `63 crore during both 2017–18 and 2016–17. However, there is a good potential in the manufacturing industry for metal forming, as now OEMs are shifting to the high strength and lightweight material, DP grade. There is lot of demand for that from domestic as well foreign OEMs. The length and strength of these materials have been increased, which is encouraging Indian sheet metal suppliers to develop the capability to manufacture these parts. Many Indian sheet metal suppliers have developed this capability by doing virtual simulation and tryouts to meet the current industry needs.”

Today, companies have to embrace modern and advanced technologies that can help them do away with the traditional timeconsuming and iterative processes, and replace them with approaches that can significantly contribute in reducing the development time and costs.

Technology to the rescue Kulkarni states, “Precise sheet metal forming actually determines the quality of the output or product. There are sheet metal forming analysis technologies that can help companies achieve quality output with minimum wastage.” He adds, “Today, companies have to embrace modern and advanced technologies that can help them do away with the traditional time-consuming and iterative processes, and replace them with approaches that can significantly contribute in reducing the development time and costs. With the shrinking time-to-market cycle of OEMs, suppliers are also under pressure to perform and deliver within stringent timelines, without compromising on quality. The same is applicable for the sheet metal manufacturing industry.”

Today, the modern technologies have evolved to an extent wherein the companies engaged in metal cutting and forming applications can now ensure maximum efficiency through compressed production time, minimum costs of development, and highest accuracy in their developing metal workpieces.

Some of the modern-day tools in metal formability analysis can address the most typical and challenging work areas such as: • Blank Development: It includes nesting operations for efficient and most optimum use of material, January 2020 n OEM Update

Prashant Chaturvedi, Messer Cutting Systems India Private Limited

Abhijit Kulkarni, Regional Manager Technical, North and West Region, DesignTech Systems Pvt. Ltd.

Larger industries are under immense pressure from the market to process sheet metal with lower prices and uncompromised quality.

Maulik Patel, Executive Director, SLTL Group

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•

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•

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thereby leading to cost-effectiveness.

Feasibility Analysis: It helps define the “manufacturability” of the sheet metal component for predicting failure or wrinkles on the component level.

Accurate die design: It helps in designing optimum die surface design for further validation of sheet metal forming.

Identifying wrinkles or tearing in the sheet metal Stamping Analysis: It helps determine the number of stamping stages required for deep drawing components.

Spring-back analysis and die compensation to get the desired output in terms of dimensions as per the actual component Bending or crash forming development Multi-stage simulation or elimination of stage if required for optimum forming/drawing process

Such tools can address some of the biggest pain areas of metal forming, including predicting failure, wrinkles, spring-back reaction, to material saving through blank nesting analysis. This can help companies save material, 11

Cover Story systems and processes ensures that the operations and workings on the factory floor are carried out smoothly and seamlessly with minimum to nil human intervention.

Industry 4.0 is an approach wherein all the systems on the factory floor will interact with each other through machine-to-machine interaction and collaboration, and carry out operations without any human intervention. It will be backed by Industrial IoT. He adds, “Human involvement would be limited to defining the preset protocols or logics, within which the machines have the flexibility to make adjustments, corrections or troubleshoot themselves to carry out the operations. These operations and processes would be completely automated, thus digitalising the entire management of the factories.

This is smart manufacturing.”

compress development time and expenses, while augmenting production quality. By incorporating forming analysis upfront, companies can save time and cost of tooling development. The quality of manufactured tools and parts improve as the iterative reworking gets reduced drastically.

A streamlined sheet metal stamping simulation software will thus help companies to: • Design better products with early check for forming feasibility • Reduce scraps and improve material utilisation • Improve productivity with accurate formability analysis • Optimise the process through single- and multi-stage virtual tryout Laser applications are another important technology that is being used in the metal cutting industry. Laser cutting technologies can speed up the cutting process, while lowering costs significantly. According to Prashant Chaturvedi, Messer Cutting Systems India Private Limited, “Laser applications are sustainably increasing in lower thickness steel cutting, which also makes it certain that the laser market is poised for further growth in coming years.”

Use of automation and IoT Advanced industry automation, leading up to smart manufacturing and Industry 4.0 backed by Industrial IoT (IIoT), is the next big trend in industrialisation.

Kulkarni says that IIoT helps companies predict machine performance issues and failures in advance, which can help companies reduce their downtime and thus achieve highest possible productivity. Advanced automation of 12

Automation and IoT give fabricators and manufacturers extra control over the sheet metal processing. Explaining this, Maulik Patel, Executive Director, SLTL Group, says, “With changing dynamics of the manufacturing industries, we at SLTL Group work rigorously to integrate advanced automation and IoT to increase the per sheet productivity by monitoring the processes very closely. With IoT, we are giving owners of our Laser Systems the power to oversee their machine and use the technology to increase their productivity, while maintaining the superior quality and keeping the cost down, which is the prime-time market demand. We are focused on listening to customers and understanding their main concerns. Thereafter, we prioritise the key areas and try to solve the problem using our industry-leading technology. We are consumed in creating a future where using these technologies is as easy as using an appliance to get unprecedented quality and productivity.”

He adds, “Sheet metal processing is one of the key aspects of the manufacturing industry, and when we invented fibre laser cutting for sheet metal, we took the standards to a whole new level. Larger industries are under immense pressure from the market to process sheet metal with lower prices and uncompromised quality. The domestic market is currently struggling and as a leading name, we think it’s our responsibility to give market options to continue operations and let it thrive. This year, our team worked closely with fabricators to figure out their core needs and worked to develop Laser Systems with the same quality at a practical price.”

Final note With such key players innovating and steering the industry to progress, there is no doubt that the sheet metal forming and machine tooling and cutting sectors will continue to grow and thrive. It is only a matter of time before the manufacturing industry as a whole adopts these smart technologies. As Kulkarni says, in the days to come, the metal and tooling industry too would be automated and digitalised in keeping with the trend of smart manufacturing. This will ensure strict check and conformance to quality, processes, and throughput, and as a result enhance the overall quality of the output and productivity of these sectors.

January 2020 n OEM Update

SPEAK OUT

India can be a destination for prefabricated steel components for large OEMs With increasing use of steel in infra and buildings, we see a very positive growth for steel plate processing equipment company like us.

Prashant Chaturvedi, General Manager – Oxyfuel Business & Marketing, Messer Cutting Systems India Private Limited

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iscussing the trends in the cutting tools sector, Prashant Chaturvedi, General Manager – Oxyfuel Business & Marketing, Messer Cutting Systems India Private Limited talks about how integrated Industry 4.0 and IoT can deliver enhanced solutions to customers, enabling digitisation of workflow and production process.

Current market size and trends in cutting industry When we talk about plate cutting equipment markets, there are two segments, Oxy-fuel plasma cutting machines, and laser cutting machines. We enjoy the leadership role in the first segment, along with holding a major market share in the industry. We are relatively new in the laser cutting machine segment, but we managed to make a significant progress in the laser cutting market in a short period. With increasing investments in infrastructure, steel and buildings, we see a positive growth in the coming years. Laser applications are sustainably increasing in lower thickness steel cutting, which also makes it certain that the laser market is poised for further growth in coming years.

Expanding end user applications and segments for your product With many architectural designs, new applications have increased. Increase of steel use in the construction segment has increased the cake size significantly.

Challenges faced by the industry Like any industry, we also have critical challenges such as increasing manpower cost, cost of services, need to reduce machine downtime by moving in virtual services, and staying competitive in the market, to name a few. Messer as a company is running almost 16 different initiatives to enhance customer experience.

The company is also investing in various business fundamentals like newer facilities, latest operating platform, and enhanced operating parameters to increase customer productivity.

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We also have our own challenges in terms of increased customer expectations and competition, but our 120 years of experience helps us to meet them.

Threat from foreign suppliers entering the Indian market Now, every new international player wants to have a share of the pie in India’s growth story, but we are the only player to invest in India. We have also invested in our state-of-the-art plant in Coimbatore, which helps us to ensure quality at all stages, which remains a big advantage when we need to deliver top-class services and have best spare part management. Yes, some customers get carried away with low-cost capital goods from our competitors, but the manufacturing compromise gets evidently visible in just 2-3 years, and machine dynamics gets disturbed and part rejections start bleeding you. We have machines running for at least 25 years in the industry.

India as a manufacturing hub for products of cutting industry With the increasing share of “Make in India” in Indian manufacturing, I think we will have a huge benefit, as we feed the pre-parts for manufacturing products that require steel and stainless steel parts. India emerging as the next best destination for manufacturing engineering parts will have a very positive impact for us.

Latest technological developments in your company’s basket Recently, our R&D team had developed Omnifab software.

This is an integrated Industry 4.0 and IoT solution for our customers, enabling digitisation of workflow and production process. Also, the customer gets all the details on his mobile or computer to track the production status.

The machines can now be connected to customer ERP as well. This will significantly increase the production monitor and scheduling remotely and help the client to become more and more competitive.

We have now come up with a totally automated material handling solution integrated with laser machine.

Improved databases have enhanced machine accuracies.

Moreover, automatic material and parts handling is the new thing customers are looking forward to.

Your innovations for display at IMTEX 2020 • We have the latest high-speed plasma cutting machine with many improved features to enhance quality of parts produced and productivity. Probably the best machine in this segment will be at display with live working.

• In the laser segment, we are displaying the latest fibre blade and laser cutting machine with integrated material handling solution.

January 2020 n OEM Update

Speak Out

Embracing technology for progress Advanced industry automation, leading up to smart manufacturing and Industry 4.0 backed by Industrial IoT (IIoT), is the next big trend in industrialisation.

Abhijit Kulkarni, Regional Manager Technical, North and West Region, DesignTech Systems Pvt. Ltd.

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bhijit Kulkarni, Regional Manager Technical, North and West Region, DesignTech Systems Pvt. Ltd. talks about the emerging technologies and solutions in the sheet metal manufacturing and metal and tooling industry.

What is going to be your focus in IMTEX 2020?

DesignTech will showcase leading technologies in the product design and development arena from world leaders such as CAD/PLM/IIoT/AR technologies from PTC, advanced product design analysis and simulation solutions, CAE solutions from Altair Engineering, 3D Printing and Additive Manufacturing technologies from Stratasys, advanced CAM solution HyperMill from OPEN MIND, and geometric dimensioning and tolerances solution from DCS. These technologies can help companies design robust and functionally superior products, establish optimised R&D workflows and processes that augment efficiency and productivity, and achieve a competitive edge.

We would focus on Augmented Reality (AR) and Industrial IoT solutions, which are the latest trends in the industry.

These technologies are predicted to revolutionise the way companies communicate internally and with their external stakeholders through AR, and redefine the way factories operate and manage functions through Industrial IoT. What kind of expertise is required to cater quality application for sheet metal forming?

Precise sheet metal forming actually determines the quality of the output or product. There are sheet metal forming analysis technologies that can help companies achieve quality output with minimum wastage. To survive in the current demanding sheet metal manufacturing market, reducing production cost by controlling the process and tool designing is essential. One of the key ways to achieve this is to reduce the scrap by improving material utilisation, as it would reduce the production cost considerably.

How is the sheet metal forming process serving the larger industries where speed and lower costs are crucial

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in reducing time-to-market issues?

Today, modern technologies have evolved to an extent wherein the companies engaged in metal cutting and forming applications can now ensure maximum efficiency through compressed production time, minimum costs of development, and highest accuracy in their developing metal workpieces.

Some of the modern-day tools in metal formability analysis can address the most typical and challenging work areas such as blank development, feasibility analysis, accurate die design, bending or crash forming development, and others. This can help companies save material, compress development time and expenses, while augmenting production quality. By incorporating forming analysis upfront, companies can save time and cost of tooling development. The quality of manufactured tools and parts improve as the iterative reworking gets reduced drastically.

Looking at the challenges in manufacturing, how do you see export potential for metal forming and fabrication?

Although the manufacturing industry in India, primarily the automotive industry, is experiencing a slowdown, sheet metal manufacturing and metal and tooling industry also caters to other industry segments such as heavy engineering, aerospace and defence, power and energy and many more, which are still doing relatively good. So the sheet metal industry may still do well.

OEMs are now shifting to the high-strength, lightweight material, DP grade. Indian sheet metal suppliers have developed this manufacturing capability by doing virtual simulation and tryouts to meet industry needs.

How are automation and Internet of Things (IoT) shaping the sector?

Advanced industry automation, leading up to smart manufacturing and Industry 4.0 backed by Industrial IoT (IIoT), is the next big trend in industrialisation.

Advanced automation of systems and processes ensures that the operations and workings on the factory floor are carried out with minimum human intervention.

Human involvement would be limited to defining the preset protocols or logics, within which the machines have the flexibility to make adjustments, corrections or troubleshoot themselves to carry out the operations.

This is smart manufacturing.

In the days to come, the metal and tooling industry too would be automated and digitalised in keeping with the trend of smart manufacturing. It will ensure strict conformance to quality, processes, and throughput, enhancing the overall quality of output and productivity as well.

January 2020 n OEM Update

Speak Out

Cutting-edge technologies for enhanced performance We work rigorously to integrate advanced automation and IoT to increase the per sheet productivity by monitoring the processes very closely Maulik Patel, Executive Director, SLTL Group

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aulik Patel, Executive Director, SLTL Group, discusses about a new launch at IMTEX 2020, namely a new cutting technology for a specific consumer set. He also talks about how IoT is increasing the efficiency of sheet metal forming.

What is going to be your focus in IMTEX 2020?

This year, SLTL Group would be focusing on empowering new fabricators and first-time fibre laser adopters by making our proprietary technology more affordable with them. Sahajanand Laser Technology Ltd. is one of the biggest players in the laser market and it is also one of the prominent participants in IMTEX. In IMTEX 2020, we are focusing on mostly cutting technology and are bringing in new technology designed for the specific consumer set. We are yet to make an official announcement about it. So, stay with us for the announcement at IMTEX.

standards to a whole new level. Larger industries are under immense pressure from the market to process sheet metal at lower prices and with uncompromised quality.

Looking at the challenges in domestic manufacturing, how do you see the export potential for metal forming and fabrication?

If you look at the manufacturing sector’s key players in the market, we are one of the top names and exports have been our key part of our business. The domestic market currently struggling and as a leading name, we think it’s our responsibility to give market options to continue and thrive the operations. Hence, our team this year worked closely with fabricators to figure out the core needs and worked to develop Laser Systems with the same quality at a practical price.

Exports are a key focus but we are not undermining the domestic market potential.

How is automation and IoT role in shaping the sector?

Automation and IoT give fabricators and manufacturers extra control over the sheet metal processing. With changing dynamics of the manufacturing industries, we at SLTL Group work rigorously to integrate advanced automation and IoT to increase the per sheet productivity by monitoring the processes very closely. With IoT, we are giving owners of our Laser Systems, the power to oversee their machine and use the technology to increase their productivity, while maintaining the superior quality and keeping the cost down, which is the prime-time market demand.

Since sheet metal forming is one of the key technologies in metal and tooling industry, what kind of expertise is required to cater quality application?

Well, I would say that perspective and focus is more important than the key technologies. Elaborating on the point, unlike other companies, at SLTL Group, we are focused on listening to customers and understanding their main concerns. We try to prioritise with the most effective solutions for trying to solve the problem through our industryleading technology. We are consumed in creating a future where using these technologies is as easy as using an appliance to get unprecedented quality and productivity.

How is the sheet metal forming process serving the larger industries where speed and lower costs are crucial in reducing time-to-market issues?

Sheet metal processing is one of the key aspects of the manufacturing industry, and when we invented fibre laser cutting for sheet metal, we took the 18

January 2020 n OEM Update

Industry Analysis

Investments in R&D transforming machine tools industry

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achine tools industry in India is gearing up to be one of the world’s top five machine tools manufacturing countries in the world in next seven years; it is revisiting its capabilities and adding new products and solutions to meet cardinal demand. Industries are investing in R&D and innovation for developing sophisticated and high-precision technology to meet the requirements of India finding lucrative business overseas.

Role of machine tools in “Make in India” Machine tools industry is considered to be the “mother industry” for all manufacturing industries. Without a powerful machine tool industry, manufacturing excellence cannot be achieved. Government of India floated the “Make in India” initiative with a vision to make the country a global manufacturing hub. The machine tools industry is immensely contributing to the initiative by making the machines required for the manufacturing sector, including major ones such as automobiles, defence, railways, plastic machinery, white goods, and many more.

Machine tools industry has come a long way, where previous year’s import was 70 percent and only the rest 30 percent were Indian machines. This year’s ratio has changed to 50:50. This indicates the growth of the machine tools manufacturers.

Government is providing some assistance for R&D of machine tools, but this needs be stepped up. This will go a long way in aiding the “Make in India” initiative. It’s a long process to invent new technologies. Acquiring them or collaborating with foreign partners or taking over foreign companies is a faster way of doing it. Government should encourage such activities by supporting financially or subsidising such machine tool builders.

Ramesh TK, MD and CEO, Micromatic Machine Tools confidently says, “Consequently, via privatisation, Make in 22

India will get a boost, new manufacturing technology will come into the country and also appropriate technology in this area will develop with the help of joint ventures and tie-ups. Specifically, tier I and tier II will have to make a substantial investment, which will thereby help the machine tool sector.”

Machine tools companies will have to devise new processes which will be necessary to manufacture the new specifications on the part drawings that will come due to BS6 emission norms. E.g., the finish level and geometric accuracies on the engine and transmission shafts will be much higher and different than previous levels. “Grind Master has experience on working on such higher levels of finishing since we worked on such jobs from global auto OEMs outside India. Another thing is we need to handhold other companies including all the machine builders and end product manufacturers for developing new technologies. This will really make the machine tool industry grow in positive way and make “Make in India” a grand success,” concludes Mohini Kelkar.

Challenges to cater precise requirements The challenges faced by the Indian machine tool builders are countless. According to Mohini Kelkar of Grind Master Machines, “The list of challenges is long, but the main challenge in front of us is technology gap. There is clear-cut technology gap in terms of machines as well as processes. There are cases where sourcing of several items for regular use in defence sector can be sourced from MSMEs in India. It is also a government mandate to do so; however in practice, it is not happening.”

The materials or components which are required to be machined and processed in these sectors are much different than those in the engineering and automobile sector, for example, special alloys, titanium, special composites. All January 2020 n OEM Update

Industry Analysis Moving from the current BS4 to BS6 will most certainly entail significant changes to the manufacturing process of each platform for Automotive OEMs.

such materials need different processing methods. Here is the gap which we have to bridge.

Private companies will be able to innovate and produce defence equipment faster as well as better in the near future.

Announcement of the SP programme will create an efficient supply chain that involves tier II and tier III companies to be involved in the manufacturing process. Vineet Seth, Managing Director – South Asia and Middle East, Mastercam APAC says, “It is a known fact that we (India) are the largest importer of defence equipment (arms). It is no doubt a certainty that Make in India opportunities will increase significantly, as a result of this decision. Our dependence on imports and supply delays of the past will be overcome with this initiative.”

Vineet Seth, Managing Director – South Asia & Middle East, Mastercam APAC

The precision challenge demanded by the sectors can’t be achieved by the current range of machines tools made in India.

Mohini Kelkar, Director - Sales & Marketing, Grind Master Machines Pvt. Ltd.

Major challenges are faced when handling and processing such materials. The machine tool builders constantly feel pressurised to stay updated in the market; the need to invent and build new machines and new tools which will be suitable for these components. The next challenge is precision which demanded by these sectors can’t be achieved by the current range of machines tools made in India. We need to build high quality machines by high quality workmanship. Many times, the processes such as deburring are neglected but in these sectors, even these processes matter a lot.

The impending technology gap and transfer of technology In terms of manufacturing technology, we are a mature nation. We have access to the best manufacturing technology in the world through companies that now

Tier I and tier II companies will have to make a substantial investment to help the machine tool sector.

Ramesh TK, MD and CEO, Micromatic Machine Tools

have direct presence in the country. One of the key challenges, however, in the Indian industry scenario is that technology is not easily shared. But another issue to address is that we are far behind on the technology front compared to our international counterparts.

Our MW/MS Series Twin and Single spindle automated turning machines and MD series turning centres have more than 10,000 installations worldwide. We are proud to say that, "MURATEC MOVES YOUR CAR".

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January 2020 n OEM Update

23

Automation

Maximised precision and speed in laser cutting

Eagle cutters use fibre lasers as their light source, which enables burr-free cutting of metal sheets of varying thicknesses with precise and narrow kerfs.

D

ue to the outstanding quality characteristics of its beam, the fibre laser has become the technology of choice in the fine-cutting of metal sheets. It delivers highly precise cuts with very narrow kerfs and operates with outstanding contouring speed. In order to deliver these features, Polish manufacturer Power-Tech employs fibre lasers in its laser cutting machines and relies on powerful automation technology from Beckhoff for machine control.

Eagle laser cutters can cut virtually any shape out of metal sheets. They use fibre lasers as a light source, which ensures burr-free edges on sheets of varying thicknesses as well as precise and narrow kerfs. Power-Tech makes three variants of laser cutting machines: the Esmart model with a working area of 1,500 x 3,000 mm, as well as the Evision and the Inspire models with working areas of up to 2,500 x 6,000 mm. All cutters feature easy operation, high reliability, and compact dimensions. Equipped with special high-performance Eagle laser heads, they cut through sheets with thicknesses of up to 60 mm. Customers can select the laser power that best fits their needs — the higher the power, the faster the cutting speed.

Speeds of up to 150 metres per minute Power-Tech has continuously improved the performance of its laser cutters. In 2013, the company introduced a machine with a 6 kW laser to the market. In 2016, it followed up with a 12 kW machine, which increased the production efficiency regarding material thickness and cutting speed significantly. “With the Inspire 1530 developed in 2018, we have introduced a laser cutter with a top performance of 15

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Beckhoff’s automation technology for machine control allows high-tech laser cutters to deliver high-precision, highspeed fine-cutting of metal sheets, ensuring quicker and easier operations for manufacturers in the sheet metal forming industry. kW that makes dynamic cutting processes with a speed of 150 m/min possible,” says Power-Tech Managing Director Janusz Marcin Ejma. “We work constantly on making our lasers more powerful, because these improvements have such a decisive impact on a cutter’s productivity. A machine with 15 kW cuts out four times as many shapes per hour as a machine with 4 kW, which reduces the manufacturing costs per workpiece dramatically.” To achieve the necessary machine parameters in terms of motion speed and accuracy, Power-Tech employs powerful control and data communication systems.

PC- and EtherCAT-based control as integrated control platform Power-Tech has worked with Beckhoff since 2010. “After a careful analysis of the market, we picked Beckhoff as our control system supplier,” says Marcin Masternak, who is in charge of CNC/PLC systems at Power-Tech. “The deciding factor was EtherCAT. The high-speed fieldbus system, which Beckhoff introduced in 2003, has become a global standard because of its performance. Many suppliers of other components used in our machines also use on EtherCAT, which gives us great flexibility in component selection.”

Furthermore, Power-Tech uses the Beckhoff Industrial PC and TwinCAT automation software as the standard control platform in all its machines. “The openness and modularity of the PC-based control system allow us to expand each machine’s functionalities with great flexibility, for example, by integrating the CNC interpolation. We can also integrate our own solutions, such as the visualisation system, which is based on our own proprietary solution,” explains Masternak.

January 2020 n OEM Update

Automation The Inspire 1530 laser cutter uses a C6930 Industrial cabinet PC equipped with an Intel® CoreTM i7 processor as its control platform. To control the axes via three AX5000 EtherCAT Servo Drives (single- and dual-channel), the X-, Y- and Z-axes are linked via CNC interpolation (the X-axis is implemented as part of the gantry system).

Various machine modules such as the laser beam source, cutting head, vacuum suction system, etc. are integrated via analogue and digital EtherCAT I/O modules with IP20 and IP67 ratings. Process and machine parameters are processed in real time, with data exchange taking only microseconds. The integrated safety solution was also implemented with Beckhoff components. “With EtherCAT, we are able to meet the high requirements regarding the high-speed exchange of large data volumes during laser cutting at speeds of up to 150 m/min. With the great support we received from the Beckhoff control specialists, we were able to achieve a single-axis positioning speed of 4 m/s and a speed of 5.6 m/s for all axes simultaneously.

Our fastest machines feature an acceleration rate of 6 g, which is top-of-the-line in the laser cutting industry,” summarises Masternak.

Trouble-free loading and unloading system integration The laser cutters are optionally equipped with semiautomatic or fully automatic loading and unloading systems. The Crane Master, a fully automatic and fully integrated system, picks up the sheets via a loading frame and places them on the cutter’s pallet changer while the cut parts are removed with a comb conveyor.

The loading and unloading system is connected to the

January 2020 n OEM Update

The C6930 cabinet PC delivers the computing power that is necessary for the high performance of the Eagle laser cutters.

cutter’s controller via the EK1100 EtherCAT Coupler, which simplifies data communication,” explains Masternak.

For more information, contact: info@beckhoff.co.in Compiled by: Ajey Phatak Picture proof, picture credits/Copyright: Pictures: Power-Tech, Poland

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Speak Out

Smart solutions to predict hydraulic health Presently, a hydraulic system’s health and its continuous and smooth running is a completely predictive term.

Sagar Chadala, Executive Director, Concord Hydraulics Pvt. Ltd.

I

n a discussion, Sagar Chadala, Executive Director, Concord Hydraulics Pvt. Ltd. explains how changed is the hydraulic system as of now health and its continuous and smooth running has become predictive term, and not like the past when the hydraulic system is considered to be leakage prone, unsafe and nonproductive operating system, with certainty of failure at any time and moment.

What smart industry solutions are being provided in hydraulics and pneumatics?

Hydraulics and/or pneumatics are currently serving the industry as a backbone in the contemplation, design and application for the most intricate and complex motion and power control problems, which many a times are found difficult to be handled by pure mechanical or electrical systems alone.

Hydraulic/pneumatic systems are broadly divided into industrial, mobile, defence, marine, and aviation segments, and the product selection for each is based on its environmental safety norms, noise and vibration control, contamination control, risks and hazards, and the technical capability of individual products that apply to the making of the systems for each of the above segments.

Thus, the smart solutions provided currently for industrial applications alone in hydraulic/pneumatic systems are broadly based as follows: • The optimisation of control to provide for the correct application need • Product selection for ease of maintenance, longer life span of equipment and bigger intervals in maintenance schedules • Lightweight, compact, highly integrated but sturdy designs for systemised power units and control stands • Ergonomical design of system based on manufacturer and acceptable quality norms, with/ without data acquisition system embedded for

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• •

diagnostic approach System design even in its conceptual stage based on low contamination generation techniques Industrial Internet of Things and integration with digital technology to give proper diagnosable and controllable system with online and offline maintenance support, with periodic and predictive maintenance as a main driving element to give zero downtime in productivity.

What kind of testing and analysis is done for hydraulic fluid? How is the state of a hydraulic fluid monitored?

Hydraulic systems currently in the industry use many types of system fluids, including mineral oils, phosphate esters, water glycols, and even plain tap water. Hydraulic systems can be made extremely reliable and highly productive if the fluid used to operate it is kept in the best of its health and continuously monitored to stay that way throughout the life of the equipment.

The product’s capabilities are enhanced by making it operate at elevated pressures like 350 bar instead of 210 bar as was 15 years ago. This pressure capability rise will further increase to, say, 400 bar in the near future, by having appropriate materials available now in the industry to make hydraulic products.

This high-pressure capability calls for compact and lighter design and necessarily tighter tolerances in manufacturing to give better result and longevity of product under continuous running at elevated pressures. Surface clearances like 3-5 microns are now becoming common in many products, which are brought in the market with higher capabilities. To cater for such fine tolerance zone and without damage to the product’s structured design, the oil used must be correctly selected, monitored and maintained with perfect contamination control.

Oil is tested by a manufacturer in many ways, namely for its viscosity, operable temperature range, solid, liquid and gaseous contamination available prior to dispatch, and anti-oxidation and anti-foaming properties.

But when it comes to supporting the hydraulic system in its end user’s equipment, the only way to control its health is to use a proper filter at proper location, of proper size, proper type and proper micronic filtration capability.

To monitor the health of oil, following methods are used: • The colour of oil is direct visual information to user to indicate contamination. Darker the oil colour, higher is the contamination.

• The viscosity of oil can be checked by sending the January 2020 n OEM Update

HYDRAULIC POWER PACK

CUSTOMISED HYDRAULIC SYSTEMS

HYDRAULIC VALVE STAND

HYDRAULIC VALVE ASSEMBLIES

HYDRAULIC & PNEUMATIC CYLINDER

PORTABLE OIL FILTRATION UNIT

HYDRAULIC FITTINGS & FLANGES

FIELD PIPING WORK

Speak Out

•

sample to the manufacturer or laboratory.

Amount of solid contamination available in the oil can be easily monitored by using particle counter machines or patch kit sampling devices which are available in many designs or can be custom-built or tailor-made for specific application.

Particle counter machines are the best solution to check, continuously monitor and maintain proper oil condition to run the system for a long time without failure.

Contamination to even 3 micron size can be detected in these machines and the values of actual solid contamination numbers obtained in 5 micron/10 micron/15 micron size from the oil can be used to produce its ISO grade which is internationally accepted and implemented by all users, designers, manufacturers, and consultants. Comparing results of oil samples taken and checked for its ISO grade from time to time can maintain the system health to its best, as it maintains the oil condition to the required tolerance limit and grade.

Around 90 percent of failures in hydraulic systems are attributed to contaminated oil, and nowadays the industry has fine micronic graded, high-pressure and advanced filters to safeguard oil, reduce downtime and maintenance costs, and get higher productivity from machines.

Proper sampling of oil from various locations in the oil hydraulic system can give a proper health record of the oil in order to ensure well-maintained overall hydraulic system health.

Which automation technologies are in place to tackle common service and maintenance tasks?

Presently, a hydraulic system’s health and its continuous and smooth running is a completely predictive term, and not like in the past when the hydraulic system was considered to be a leakage-prone, unsafe and non-productive operating system, with certainty of failure at any time.

28

The same stands true even today if some basic conditions of operation are not monitored and maintained. They are as follows: • Common servicing and maintenance task in hydraulics is mainly related to the cleanliness of the system fluid — oil. Oil is kept clean in hydraulic systems by using proper filters. Once the filters are selected and properly placed in the system, the next task is to check their health periodically so that they work diligently to keep the oil clean.

• Automated particle counter system or online oil monitoring system is an answer to it. This system can be hooked to any hydraulic system and programmed to give periodic oil sampling tests and diagnostic records to see how the oil is being contaminated and also kept clean. This reduces cost of maintenance drastically.

• Other automation technologies employed are to monitor the oil level in the tank, and on reaching the minimum acceptable set level for minimum oil in the tank, the alarm is sent to operator as well as the control PLC or system to stop or trip the system to avoid further damages to important hydraulic products like pumps, etc.

• Another technology employed is to monitor and take proper care of the oil temperature. Systems are equipped with water or air in oil cooling circuits or are provided later once the rise in temperature is established and data record reveals that oil cooling is necessary. Many oil hydraulic systems have inbuilt programmed temperature signalling to start or stop water or air supply for cooling oil.

• Today, Internet of Things is coming in a big way with the digital technology platform to enhance the predictive and progressive maintenance mode for online monitoring of system health to operate with zero downtime. This calls for new products, sensors, bus systems to connect the entire product for data logging techniques, and using appropriate data for maintaining and servicing of system.

• Many software-driven systems are in the market to pick up data from the hydraulic system like oil level, temperature, pressure, noise, etc. which can be converted into electrical values and are transmitted to the mobile app to reproduce the result in exact physical values of the entity measured to give the person or service station, who may be away from the system, the exact nature of working parameters on his desktop or hand-held mobile device.

• Noise level in the hydraulic system is also very annoying, and safe and silent systems are always welcome to enhance the environmental condition around the system where people are working.

Monitoring noise from 1 meter distance and recording the noise level of pump is also considered important to know its health and judge longevity of major maintenance breakdowns. The pump is the heart of any system to safeguard its working life; this small but important monitoring is an essential requirement and can be embedded into automation system for periodic maintenance.

January 2020 n OEM Update

Safe area. Strong solution. Best outlook.

Experienced system planners and design engineers know the score: the monitoring of danger zones is just as indispensable for automation as protection is on the mountain. Risks must be detected immediately and processed reliably. Based on many years of experience in the field of optoelectronic sensors, Pilz is now taking the next step. With a new product group: flexible, configurable safety laser scanner for productive area monitoring, including in series. Play it safe: sensor technology, control technology, drive technology and visualisation. A one-stop shop. The complete solution from Pilz.

For further information on safety laser scanner from Pilz, visit: www.pilz.com/scanner

Pilz India Pvt. Ltd

Pune 411042

+91 (0) 20 49221100

AD_PSENscan_Mountain_Tent_210x297_UE_2017_05.indd 1

info@pilz.in

www.pilz.in

10.05.19 11:46

Automotive

Targeting growth and success It is necessary to arrest stagnation and create opportunities.

Ashok P Chhajer, GM – OE Sales, BKT Tires

I

ncepted in 1987 and headquartered in Mumbai, Balkrishna Industries Limited (BKT) is a leading manufacturer in the off-highway tyre market. Ashok P Chhajer, GM – OE Sales, BKT Tires, talks about BKT’s expansion plans in India and his belief that a turnaround in the health of the construction sector is eminent.

Please tell us about your expansion plans.

Our top management is overlooking the implementation of the expansion plan. It will include end-to-end automation, right from raw material handling to production of the end product. Nevertheless, it is expensive and ambitious, but we have been known to do things differently. The existing Aurangabad plant will be relocated to a new location to bring this expansion plan into action.

So, you are saying that the relocation has begun. Have you finalised everything?

Yes, everything is done and the work is on in full swing.

The new site is based in Aurangabad itself. But the location is different; the location is bigger and can help in achieving the desired capacity augmentation.

15 percent. Yes, India as a market fits into our global aspirations. We are growing and will continue to grow.

With your global expertise in place, what are your key focus areas?

Initially, our sole focus was on the domestic agricultural market. In the last four years, we have become even more aggressive about it. This has a lot to do with the response to our COMMANDER range of tyres. At the same time, we remain bullish about product offerings in the construction and mining sector, which includes the OTR tyre range.

As one of the key industry players, do you have any feedback for the government?

Nitin Gadkari, Minister for Road Transport & Highways of India, in his inauguratory Excon speech, covered all the areas. He laid out the government’s plans with regards to construction and infrastructure. This has added a lot of faith in the minds of the participants at Excon. These projects have a lot of business potential and we are all keen to capitalise.

So, are you very happy with the way things are going currently?

I agree that the construction sector is not in the best of health. Having said that, it is necessary to arrest stagnation and create opportunities. After listening to Nitin Gadkari, I believe that the government remains optimistic and is keen to ensure that the sector flourishes. So, I am banking on the promises which have been made and hopefully everything will be in place.

Something like the facility you have in Bhuj?

No. Bhuj is a massive property of about 350 acres and this one is relatively smaller. From the existing facility that is spread across 15 to 20 acres, we are going for a facility which will be spread across 30 to 35 acres.

Does this capacity expansion cater to the Indian market or the international market?

BKT caters to a global market. And now we have started addressing the needs of the Indian market too. It is needless to say that BKT is a global brand. So, whatever we do, we keep in mind the needs and requirements of our global product market.

BKT is a global player and much of its market is overseas. At the same time, the market share of BKT in the domestic market has increased from 8 percent to

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January 2020 n OEM Update

Automotive

Automotive industry leaders discuss the visible growth in the automotive industry along with reaping the benefits of the emerging industrial trends with latest technologies.

Reinstating the automotive sector with technology

A

utomation has been keying the industry to take leaps in automotive manufacturing. Adoption of indigenous manufacturing and latest technological innovations have nurtured the sector’s overall financial growth. However, with the invention of sophisticated technologies like automation, IIoT and 3D technology, among others, the Indian automotive industry is reaching new heights. With intensifying demand in the automotive industry, it is now imperative to have an uninterrupted supply.

Trends in automotive sector shifting with advanced automation If you look at the history of automation in the automotive sector, the first areas that got automated were hazardous sectors like painting and welding. This has largely to do with reducing the hazards and number of people with a speed which is fairly well-settled now, as most of the painting/welding activities has been largely automated.

The second aspect of automation is the line assembly and automation of assembly itself, where the product moves from station to station. On this note, Ramesh TK, CEO, Ace Micromatic Machine Tools Pvt. Ltd. says, “The work that needs to be done now is connectivity and data analytics. This data analytics is not from the market perspective, but from the management perspective, ratability or right from assembling and final dispatch; because they all come from the safety aspect, this is the area where automation is happening towards its end.

We still need to have active involvement of automation in the designing perspective, as the designing remains to be a non-automated process largely. ” The entire automotive system has been divided into subsystems, where you have transmission systems, cabin interiors, stylish dashboards and engines, among others. These systems are completely independent and easy to access. The design and tools that control the designs must be modular, as it supports the entire functionality of a vehicle. Babu further says, “With the mixture of modular tools and modular designs, we can obsolete the previous and existing car models quickly, whilst introducing the new car variants in minimum time frame. This further helps in rearranging the entire supply chain ecosystem for smooth delivery of new orders. This is the need of the hour and the entire automotive industry is transforming with this scheme in its own way.”

Automation also allows a common assembly line for different models to be managed by various sets of robots. The most important thing is to use a common assembly line for multiple models managed by different set of robots with least human intervention to ensure compatibility. The modular approach and common assembly line driven by tools and automation is helping the automotive industry to combat slowdown and ensure growth.

Continued to 34

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g

January 2020 n OEM Update

Brand Report

Harnessing the wiring industry with Bright Cords charging variants

B

right Cords Pvt. Ltd., established in 1996 in New Delhi, is a prominent and leading manufacturer, supplier and exporter of Car Phone Charging Socket, Car Power Socket, and Automobile Power Socket. They offer a wide range of products that are highly durable, convenient to use, strong, reliable and of premium quality, robust design and elegant functionality. They are fabricated using premium-grade materials and cutting-edge tools and technology.

With the capability to undertake development of wiring harness and sheet metal components, the company does the assembling of various types of wiring harness.

The company has an expertise in assembling various kinds of wiring harness. They also have the capability to undertake development of tooling for components as per given customer specifications. The company has set up a modern and advanced infrastructure that is equipped with cutting-edge tools and machines to fabricate these products in a smooth manner. Owing to the modern set-up, they have the capacity to manufacture in bulk to process huge customer orders on time. They keep on fabricating products with innovative and impeccable design.

The company is committed to quality, cost, and timely delivery as the key business approach. Their expert team of quality controllers inspects the entire product range on various parameters of quality to ensure that it complies with the universal quality standards.

For more information contact, E-mail: brightcords@yahoo.co.in

Manufacturer Of Power Socket,Auto Switches, Wiring Harness & Deep Draw Components

BRIGHT CORDS PVT. LTD. AN ISO 9001: 2015 CERTIFIED COMPANY

A-5-A/10-C, Janak Puri, New Delhi -110058 • Ph.: 011-25612123 Cell: 9811014332 • E-mail: brightcords@yahoo.co.in

January 2020 n OEM Update

33

Automotive 32 f

Reinstating the automotive sector with technology

I think automotive designing still remains to be a nonautomated process at large, and automation can reinstate designing with a single touch.

Ramesh TK, CEO, Ace Micromatic Machine Tools Pvt. Ltd.

Precision in the automotive industry is driven by tools where human intervention has to be low.

Sharadhi Babu, Chief Executive Officer, AXISCADES

The modular approach, automation, and common assembly line is helping the automotive industry to take leaps in industrial growth.

Sameer Gandhi, MD, Omron Automation, India

Elaborating on the capabilities of automation, Sameer Gandhi, MD, Omron Automation, India feels that the auto manufacturing sector is driven by varied KPIs like design and energy optimisation, finest asset utilisation, big data and analytics (connected supply chains and shop floors), worker and machine safety and zero-defect production, and has shown good adoption rates for varied automation technologies falling under the ambit of Industry 4.0, IoT and robotics.

One of the notable applications amongst these is the total traceability solution. It renders the ability to trace and verify the history, location, or application of an item by means of documented recorded identification. Having a close interface with IIoT, this solution holds lot of significance for the automotive industry.

Improving precision manufacturing One of the major advantages of automation is that it is very durable with variability, which is not the case with humans. From the western perspective, automation is a basic necessity owing to the unavailability of required manpower. But India has surplus manpower, so automation has to be applied in ways where manpower is not affected.

In fact, we should update our manpower to automation.

Everybody from the world is coming to India with the expectation to grow. We need to support that.”

However, according to Babu, “Precision in the automotive industry is driven by tools where human intervention has to be low. Different level of precision applies to different equipment. I would say that automation is a requirement born out of precision and human fatigue point of view.”

With automation liberating some tasks, humans obtain more scope and freedom to focus more on higher-level and creative tasks that demand more complex skills, and for this a well-structured plan to evolve and upgrade their skill sets is also needed. Noting the same, Gandhi says, “Automation helps improve the precision and repeatability of a given task. But, the idea is to achieve the best harmony between humans and machines, between the power and precision of automation or robots and the problem-solving ability of humans to achieve greater productivity and achieve something which is beyond human capabilities.”

3D printing in automotive 3D printing is an absolutely different application with a different perspective, and today it is predominantly used for prototyping. It is said to be the best fit in certain areas, but it is yet to meet the requirements of the industry in terms of real application. 3D printing involves both design and manufacturing and is a different aspect of both, where an assembly or a component is completely resigned to a system.

Babu states, “We have executed several projects by redesigning fuel injection pump, hydraulic manifold, among others. Moreover, 3D printing has eased the assembling process by cutting down the requirement of 30 parts to almost 6. Still the composition of material and purchasing of adhesives and laser must comply with 3D printing standards to use them in an extended market.

Predominantly, hydraulics used in block manifolds is delivered in 3D printing and in several automotives.”

To sum it up, usually, aftermarket and spares for automotive parts is a major market, while the repair market, especially for automobiles, is enormous. This is a market additive manufacturing, which is being added to the aftermarket for providing value-added services to consumers. Apart from these spares, especially for replacements in case of damage or fault, there is a budding market for customised components where consumers are also willing to pay a premium.

Discussing the significance of the human factor, Ramesh asks if everything is mechanised, then what will people do and where will the PPP offer be applied? He says, “From the Indian perspective, we still have a large population that needs manufacturers to do certain manual content, which is the livelihood and also increases the PPP of our country.

Whether it is the automation or mass manufacturing industry, the process of eliminating people must be stopped.

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January 2020 n OEM Update

Brand Report

Corvina cloud 1.0 completes IoT security

C

orvina cloud 1.0 is the EXOR international system for remote control and tele-assistance, based on secure VPN and web access. The user interface is incredibly clean and easy to use.

Being web-based, it allows all your remote devices, networks and users to communicate seamlessly and securely.

Corvina cloud 1.0 can be offered as an on-premise cloud infrastructure that delivers the uptime and performance needed for industrial applications and control services at any scale. It is a powerful and highly scalable system that offers advanced VPN capabilities with a simple web-based interface.

Industry standard encryption technology ensures that your data stays protected in transit for complete IoT security. Security is further enhanced with granular role-based access permissions that allow users to only gain access to required resources and nothing else.

Besides security, one of the most common challenges industrial networks face is the problem of multiple locations having the same subnet, making it impossible to implement a central VPN management tool without significant intervention. Yet, Corvina cloud 1.0 is the only solution on the market that can seamlessly resolve this routing nightmare, allowing your deployment to go smoothly.

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January 2020 n OEM Update

35

Special Report

Automation: The prevalent trend in cutting and welding industry

A

pt adoption and application of automation in the welding sector can boost the overall efficiency and growth of the sector. Automation paves the way for the industry to boost product performance and deliver uncompromised quality results to the consumers. Implementing advanced welding processes can further improvise on the delivered quality for greater productivity and welding quality in minimum investment.

In a recent announcement, the government announced allotting of Rs. 100 crores for the welding sector. Today, a lot of sectors like power, defence, and railways are being opened to the private sector and public enterprises. This opening will give rise to a large amount of manufacturing activity. The Infrastructure and Transportation Ministry is planning to use the large coastal area of the country for ease of transportation. It plans to develop more ports — big as well as small — for shipping requirements.

This is all basically the new vision of the country and if we are to reach $5-trillion economy by 2025, these investments are mandatory. Because our Prime Minister’s vision is that India will be a $5-trillion economy by 2025, we hardly have 5 years to go.

We are now a $1-trillion economy; we have to increase fivefold.

Rakesh Pachpor, Proprietor, Root Machinery LLP says, “With today’s innovations, I think, human intervention should be equally critical to address the safety aspect. Welding and cutting industry incurs critical applications that take place within a short period of time with intense protection.” Automation will facilitate in creating and maintaining the records of the production and achievements of the industry, whilst insisting on quality with minimum risk.

Aniruddha R. Vilekar, Head - Operations & Marketing, Ador Welding Limited, says, “Advanced welding processes can deal with issue like deformation, spatter, travel speeds and other factors, which can minimise rework, increase production and offer a competitive advantage. With the ‘Make in India’ initiative, the thrust in achieving world-class standards along with Industry 36

4.0 revolution in automated welding and cutting becomes more crucial as our answer to these challenges.”

R Srinivasan, Chairman, Indian Institute of Welding Technology, says that automation is very important. “Today, there is a wrong notion that automation is going to cost or reduce the use of manpower. However, that is not the case. Automation is needed in India to meet the market challenges and keep quality consistency. The manual work a welder does can use automation or can be programmed; when it is programmed automation, the repeatability of the task is promptly achieved; thus, the success rate is high. At the same time, the amount of manual labour required to programme automation such as studying and designing the programme, coding the programme, and so on is enormous. So here, not only the welders or the welding industry is involved, but the electronic industry comes into the picture as well.”

Oxy-fuel and plasma cutting for metal forming The choice between the two processes can be made based on which process will ultimately yield the lowest cost per cut from amongst oxy-fuel and plasma after considering all possible variables. The basic nature of each process immediately dictates some choices when you are purchasing a new automated cutting table or retrofitting an existing one.

Vilekar says, “The restraint of oxy-fuel is that while it is relatively cheaper, the cost of plasma cutting equipment is up to 3 times more than oxy-fuel systems to install. As compared to plasma cutting, it cannot be used to cut aluminum and stainless steel.

Conversely, the high-precision plasma process works with any electrically conductive material, making it suitable for cutting steel, stainless steel, and aluminum.”

The speed of cutting also plays a vital role. While oxy-fuel cutting can reach speeds of up to 750 mm per minute, the plasma process can reach speeds of up to 200 mm per minute. This January 2020 n OEM Update

Special Report Advanced welding processes can minimise rework, increase production and offer a competitive advantage.

is true especially for lower cutting thicknesses of up to 40mm where plasma cutting pierces and cuts exceedingly faster than the conventional oxy-fuel process.

Vilekar says, “Modern CNC machines have up to four oxyfuel torches and two plasma torches on the same gantry, giving the process versatility and flexibility. An oxy-fuel cut will have a heat-affected zone that is five to ten times larger than a plasma cut.

Aniruddha R. Vilekar, Head - Operations & Marketing, Ador Welding Limited

Automation will help the welding and cutting industry achieve the desired production target with desired quality.

Oxy-fuel cutting has involvement of gases, and their surface finishing is quite rough. It is generally used where one does not need good surface finishing or in places where surface finishing is done after cutting. Pachpor says, “Choosing a process needs the right selection of material, desired surface finishing, economical process, and the frequency of cutting.”

Rakesh Pachpor, Proprietor, Root Machinery LLP

Today, there is a wrong notion that automation is going to cost or reduce the use of manpower. However, that is not the case.

Risk assessments in the welding and cutting process Carrying out risk assessment during welding and cutting process is paramount for all industries. However, there is still a lot to be desired. Proper safety equipment must be used with these equipment like flashback arrestors, etc.

Also, standard products should be used since any leakage might lead to big accidents.

It is always said that “safety is the first priority” for any process. Pachpor says, “During the welding and cutting process, many risk factors are involved; it is always good to understand and do safety exercises to prevent the measure of risk in the process.” Risks involves electric and noise

R Srinivasan, Chairman, Indian Institute of Welding Technology

hazards, exposure to fumes and gases, burns, welding and cutting safety precautions, lack of appropriate training, ensuring your workplace is well-ventilated and free of flammable materials. It is always the first priority to check these factors once before, during and after the welding and cutting process.

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37

Speak Out

Digitisation to solve operational constraints in lubrication practices With ExxonMobil’s MSLA programme, operators can now look forward to increased productivity and performance from their equipment.

Shankar Karnik, General Manager Industrial Lubricants, ExxonMobil Lubricants Pvt. Ltd.

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hankar Karnik, General Manager - Industrial Lubricants, ExxonMobil Lubricants Pvt. Ltd., discusses how IIoT and automation are transforming the industry, especially in lubrication sector, to improve operational efficiency.

How does the future look for Industrial Internet of Things (IIoT) in manufacturing?

IIoT has become the buzzword for many industries, ranging from telecom, logistics, manufacturing et al.

As these industries evolve, the need for accelerating the efficiency and productivity of various operational processes is relatively rising.

Talking specifically about manufacturing, we see a lot of manufacturers adopting IIoT-enabled technologies.

A recent survey, “Data’s Big Impact on Manufacturing”, revealed that 67 percent of the 200 manufacturing executives plan to invest significant resources in data analytics technology in the near future.

IIoT helps in catalysing and transforming various industrial operations. It is of paramount importance in bringing about the revolutionary benefits of predictive and proactive maintenance, real-time monitoring, resource optimisation, efficient diagnosis and much more. It enables a connected, smart manufacturing enterprise by enhancing decision making, increasing security and productivity, profitability as well as improving overall collaboration across the enterprise.

It provides the right information at the right time to optimise operations.

Moreover, with the government laying impetus on domestic manufacturing during the 2018 budget announcement, entrepreneurs are being encouraged to lead more manufacturing ventures in the days to come.

Hence, given the promising offerings of IIoT and the overall government agenda of boosting the 38

manufacturing sector, I foresee increased investments in IIoT-related technologies. It has become essential for the sector to invest in efficient technologies and automation solutions now, in order to be in sync with the dynamic needs of the new age customer.

Which industries will drive IIoT adoption in 2019?

According to a latest research, the Internet of Things (IoT) market is projected to grow at a CAGR of 28.2 percent during 2016–22. The Indian IoT market is largely dominated by Industrial IoT followed by Consumer IoT. Higher use of automation and data exchange in any specific industry will enhance efficiency, improve profitability, foster innovation, and allow smart management of safety, performance, and environmental impact. As a result, companies across India and the globe are increasingly turning to IIoT to avail these benefits. The IIoT segment, hence, is registering a remarkable growth.

The government’s “Digital India campaign” is also a driver in spreading awareness and adoption of IoT amongst end users.

With the mounting emphasis laid on factors such as operational efficiency, optimal outcomes, and effective resource management, multitudes of industries are deploying IIoT-aided automation technologies for their industrial units. These technologies bring together the physical and digital world to enable man and machine make informed, real-time decisions, delivering a safe, efficient and sustainable environment.

The sectors adopting IIoT technologies at a relatively faster rate include energy, manufacturing, plastics, steel, mining, and infrastructure as these sectors are the propellants of economic growth and development in the country.

Could you discuss about your company’s preparedness in this front?

ExxonMobilTM has always played a part in the progress of the industrial revolutions, where industrial lubrication ensured optimum equipment performance.

For over 150 years, innovation has been our core focus in providing the best lubricant solutions for manufacturers, where ExxonMobil continues to make breakthrough innovations that redefine the power of lubrication.

One major issue that has been pertinent for the manufacturing sector is the performance of heavyduty machinery. Lubricants play a crucial role in ensuring consistent protection and performance of equipment to minimise financial losses. That said, January 2020 n OEM Update

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Speak Out oil health analysis becomes a quintessential programme that ensures reduced downtime and increased reliability of equipment.

However, the traditional oil analysis process is laborious and costly, and may cause unscheduled downtime, production delays, and reduced operational efficiency. Furthermore, the diagnosis from the analysis could also impact their productivity, safety, and environmental goals.

Industrial lubricant and grease makers are, therefore, shifting towards digitised lubrication practices. ExxonMobil, with a long history of working with equipment manufacturers, worked to develop a modern, app-based platform. A model of ‘Mobil going Mobile’ was developed to reach every end user through a regular and convenient operational interface.

Mobil ServSM Lubricant Analysis (MSLA), a mobile-enabled used oil analysis programme, was launched in 2016. MSLA is designed to enhance efficiency and simplify the oil health analysis process by replacing a paperwork-heavy approach

with a simple, intuitive, mobile-enabled service platform that reduces the number of steps involved in the used oil analysis process. MSLA is a solution that manufacturers need to take to move towards Industry 4.0 and digitisation.

The platform streamlines the entire oil analysis process — from initial sample gathering to final reporting, with QRcoded scan-and-go sampling bottles that deliver used oil samples to ExxonMobil’s oil analysis laboratory. Customers can also leverage application-specific analysis options that allow them to access results and perform customised equipment recommendations directly on their mobiles or tablet devices, saving them from unnecessary downtime that could affect production output and delivery deadlines.

With ExxonMobil’s MSLA programme, operators can now look forward to increased productivity and performance from their equipment — the analysis helps identify issues that can be mitigated with minimal downtime, reduce the amount of lubricant needed to operate machinery, and improve and extend overall machine life.

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We have state of the art manufacturing unit with world class machinery, tool room and processes. We have our own inhouse product testing to assure that our clients get high quality customized products adhering to national and international requirements and standards. Our aim and vision is to be the

42

We have been manufacturing all types of silicone hoses used in automotive, marine or industrial equipment. Our cutting edge technology and a professionally managed team is our main strength. Through our services and cutting edge technology, we have created a niche in domestic and international market.

Why Indee Industries?

We have all facilities for state of the art in our manufacturing unit with world class machinery, tool room and processes. To assure the best and high quality products to our customers, we have our own in-house product testing and we also manufacture customized products adhering to national and international requirements and standards. We bring forth for our clients a comprehensive range of Silicone Hoses. Our hoses are suitable for cooling systems, charge air systems, induction systems and pressure signal lines. With its’ temperature range stability, flexibility, longevity, thermal, and electrical insulation properties, silicon polymers have emerged as miracle of engineering material science.

Our range includes silicone radiator hoses, blue and red silicon hoses and silicone turbo hoses. All our hoses are manufactured from high grade silicone polymer and reinforced with a high strength fabric.

This gives a minimum/ maximum operating temperature range of -40ºC to +380ºC. For more details, visit: www.indeeindustries.com January 2020 n OEM Update

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Market Update

Rockwell Automation inaugurates first Digital Transformation Experience Centre in India

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ockwell Automation launched its first Digital Transformation Experience Centre in India, a stateof-the-art, collaborative hub, designed to inform and inspire Indian businesses about creative ways to spark productivity gains using automation.

The Gurugram-based centre is the first of its kind in India to fully demonstrate the integration of key technology platforms for IT-OT convergence, enabling customers to understand the benefits of the Connected Enterprise and the positive impact that it can have on their business. The centre also illustrates how solutions and services offered are entirely scalable and can be tailored to businesses.

Inaugurating the centre, Rockwell Automation CEO Blake Moret said, “This is a hugely exciting time for a whole range of industries in India who stand to unlock trillions of dollars in value over the next decade as a result of rapid advancements in automation technology. It’s also a complex moment, when leaders have an exceptional number of decisions to make about how and where to invest their resources to achieve best results. With this centre, we’re inviting businesses across the country to come and get informed and inspired about what the future could look like and how to get there.”

Dilip Sawhney, Managing Director, Rockwell Automation India said, “We believe that embarking on the journey of digitalisation and the Connected Enterprise is key for 44

businesses to realise their full potential. Our new Digital Transformation Experience Centre enables us to show, rather than tell our customers, how our technology can help to bridge the gap between traditional plant floor technologies (OT level) and enterprise level demands (IT level). Using our technical expertise and industry knowhow, we can demonstrate how we can help our customers maximise performance, advance innovation, and drive growth by unlocking new business models and adding value to existing products.”

Visitors to the centre can experience first-hand the synergy of key technology platforms such as network, cybersecurity, industrial data centre, machine learning as well as augmented reality (AR) and virtual reality (VR).

They can also experience scenarios showcasing how a business could fix problems faster and with less disruption to production by combining data on machinery faults, production commitments, and availability of parts along with insights into how long it would take a technician to fix the problem with the support of AR. The centre will also demonstrate how Rockwell Automation integrates solutions seamlessly from the plant floor up through the enterprise in collaboration with Strategic Alliance Partners like PTC, Cisco, Microsoft, and Endress+Hauser to accelerate innovation and convergence for operational and information technologies through digital transformation.

January 2020 n OEM Update

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Guest Column

VASIMR engine to help man reach Mars in 39 days

General arrangement of VASIMR engine

D

uring more than 40 years of space flight, a lot of things have changed. Today’s spaceship is a luxury ship compared to the capsule that carried the first man to space. One thing that has changed very little, however, is today’s spacecraft that is still travelling at about the same speed as in 1962 when John Glenn became the first man to orbit Earth. One major goal for futuristic spacecraft is that it should be able to move in deep space more quickly, enabling man to venture into deep space. One possible way to change that would be to use the Variable Specific Impulse Magnetoplasma Rocket (VASIMR) for deep space flight. It has got the potential to reach Mars with astronauts in 39 days.

There are two main types of propulsion systems, namely chemical and plasma propulsion systems that are used to lift the payload from Earth’s surface to space. The conventional system uses chemical rockets to burn a tremendous amount of fuel to launch the spacecraft.

Whereas the other system developed recently uses plasma thrust generation and is very cost-effective.

Chemical rockets are suitable for only short-range trips like lifting the payload from Earth’s surface to an orbit round the Earth. But they are impractical for deep space exploration due to very high fuel requirement which would make it too heavy to be lifted into the orbit economically. On the contrary, plasma rocket is not used for launching payload into space, but for carrying payload that has already been lifted in the orbit for onward journey in deep space. This is called “in-space propulsion”. It will save thousands of litres of fuel and millions of dollars.

VASIMR is a plasma-based propulsion system. Electric power is used to ionise fuel into plasma. Electric fields heat and accelerate the plasma, while magnetic fields direct the plasma in the proper direction as it is ejected from the engine, creating thrust for the 46

spacecraft. The engine can even vary the amount of thrust generated, allowing to increase or decrease the acceleration. It even features an “afterburner” mode for additional speed, while of course sacrificing fuel efficiency. Hydrogen, helium, deuterium or any other gas can be used as fuel.

Expeditions to the outer solar system have been mostly “rocketless” affairs, because most of the fuel is typically expended in the first few minutes of operation, leaving the spacecraft to coast for the rest of the journey to reach its goal. Rockets using plasma as a propellant generate much lesser thrust compared to their chemical cousins, but their extremely frugal consumption of propellants allows them to operate for much longer periods and reach greater speeds or braking as necessary to achieve the desired trajectory.

Vehicles using a plasma rocket system are highly efficient even when using only one-tenth of the fuel compared to chemical rockets.

Kinds of plasma propulsion • Ion drive: A couple of dozens of ion drivers are currently operating in most of the communicating

Conceptual cross-section of VASIMR engine

January 2020 n OEM Update

Guest Column

Morphology of the VASIMR engine satellites in the geosynchronous orbit for controlling their position and altitude. It was first used in space applications in 1964. It can handle power about 7 kW and generate a thrust of 20–50 mN. •

•

Hall thruster: Its production started in the 1970s.

Generally, it cannot handle power more than 10 kW and can generate a thrust of about 6 N. It is mainly used for satellite propulsion as a main propulsion engine for space probes, medium-size robotic space vehicles, etc.

Magnetoplasmadynamic thruster (MPDT): Although its development started in the 1960s, its progress has not been satisfactory. A powerhungry driver having an efficiency of about 40– 60 percent, it can generate a thrust of 2.5 to 25 N and can handle about 100–500 kW of power.

Japan launched a MPDT-propelled space vehicle in 1995 which is still the only operating one.

All these three engines are basically low-powered engines delivering a small amount of thrust and are too small to undertake interplanetary manned missions.

coupler. The primary purpose of the first RF coupler is to convert gas into plasma by ionising it, or knocking an electron loose from each gas atom. It is known as ‘helicon’ section because its coupler is shaped such that it ionises gas by launching helical waves.

Helicon couplers are a common method of generating plasma. After the helicon section, the gas is now “cold plasma” even though its temperature is greater than 5800K, which is the temperature on the surface of the Sun. The newly formed plasma containing a mixture of electrons and ions carry charge and may then be contained by a magnetic field shielding the rocket core from the high-temperature plasma. The second coupler is called the ‘Ion Cyclotron Heating (ICH)’ section. ICH is a technique used in fusion experiment to heat plasma to a temperature of 10 million K that is found in the Sun’s core. The ICH waves push only the ions as they orbit around the magnetic field lines, resulting in accelerated motion and higher temperature.

The thermal motion of ions around the magnetic field lines is mostly perpendicular to the rocket’s direction of travel and must be converted into directed flow to produce thrust. VASIMR uses a magnetic nozzle to convert the ion’s orbital motion into useful linear momentum, resulting in ion speeds on the order of 1,80,000 km/hr.

The VASIMR engine uses radiofrequency (RF) waves to create and energise the plasma within its core.

Hence, the VASIMR engine has no physical material electrodes in contact with the hot plasma. Hence, no plasma erosion of the electrodes happens, which means greater reliability, longer life and a much higher power density than other plasma devices.

It can process a large amount of power needed for interplanetary manned missions. This technology is highly scalable, meaning that higher power versions can be easily designed.

Scientists have dreamt of sending man to Mars and back in 39 days. To achieve this goal, a new generation of plasma propulsion system is to be developed which can sink 25–50 MW of power. A 39-day mission would require about 200 MW of input power driving 4–8 units of a yet-to-be-designed plasma engine, which will alone handle 25–50 MW of power.

In 2015, NASA awarded a $9-million contract to Ad Astra Rocket Company as a first step to achieve the goal. The best engine which has got the potential to meet the requirements is the VASIMR. To fulfil their side of the deal, Ad Astra needs to make their VASIMR engine fire at 100 kW for 100 hours continuously. They have fulfilled this milestone and hope to achieve the final goal in a couple of years.

Basic principles of operation The propellant is injected into a hollow cylinder surfaced with electromagnets and is first heated to a cold plasma by a helicon RF antenna also known as a January 2020 n OEM Update

Isometric cut way view of VASIMR

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Guest Column

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Manned spaceship with VASIMR engine to Mars

Morphology of the VASIMR engine There are four successive processes, i.e., ionise, energise, accelerate, and detach. The VASIMR is a radio frequency (RF) driven device wherein the ionisation of the propellant is done by ionising antenna, known as helicon, in the first phase. In the second phase, the plasma ions are further energised

by Ion Cyclotron Resonance Heating (ICRH), a wellknown technique used extensively in magnetic confinement fusion research, and accelerated. Finally, it is detached through the nozzle generating thrust.

Power required for this device would be generated by a container-sized fusion reactor for interplanetary manned missions, then converted to RF power by RF generator and fed to both helicon and ICRH antennae for energising plasma. High-temperature superconducting magnets surround the helicon and ICRH devices. These magnets generate a B-field that guides the plasma through the helicon and ICRH boosters without touching their ceramic body. Thus, they are not subjected to plasma corrosion.

VASIMR structure The VASIMR engine consists of three main sections: • Injection stage (helicon discharge): Helicon is a low-frequency RF electromagnetic wave which excites the plasma through radio frequency heating. The presence of the magnetic field creates higher ionisation efficiency and greater electron density. The engine uses radio antenna instead of physical electrodes which heats the plasma like a microwave oven heats food. The helicon waves are electromagnetic oscillations of 10–50 MHz, which in a magnetic field energises the free electrons in a gas. The electrons quickly multiply by liberating other electrons from nearby atoms in a cascade of ionisation.

• ICRH stage: In the next stage, energy is fed to the system in the form of a circularly polarised RF signal tuned to the ion cyclotron frequency.

ICRH heating has been chosen because it 48

transfers energy directly and primarily to the ions, which maximises the efficiency of the engine. An important consideration involves the rapid absorption of ion cyclotron waves by the high-speed plasma flow. The thrust/specific impulse ratio control in the engine is achieved by the selective partitioning of the RF power to the helicon and ICRH systems, with proper adjustment of the propellant flow.

Nozzle: The vacuum chamber in the nozzle captures the hot gas as it escapes magnetic confinement. Axial momentum is obtained by the adiabatic expansion of the plasma in the nozzle. The ions are immediately ejected through the nozzle before the ion distribution has had time to thermalise. A divergent magnetic field is needed to convert the plasma’s thermal energy into directed kinetic energy, while also confining the energetic plasma away from the surface of the thruster.

Human mission to Mars There is no major technical problem in sending man to Mars. NASA is aiming at 2030 as the date of crewed surface landing on Mars using VASIMR propulsion. This technology sustains propulsions over the entire journey and accelerates gradually, reaching 50 km/sec over 30 days, i.e., four times as fast as any chemical rocket could travel, thereby saving at least six months off a trip to Mars and minimising breakdown of any equipment, radiation exposure to crews, bone loss, muscle atrophy, etc. The option of spacecraft propulsion is available anytime, so it is possible to change the course whenever required. The projected Initial Mass in Low Earth Orbit (IMLEO) of the spacecraft has been estimated to be about 190 mt, which includes the weight of the Earth return vehicle (approximately 30 mt), propellant (approximately 30 mt), landing craft (approximately 60 mt), and fusion reactor (approximately 40 mt). At the 200 MW power level provided by a fusion nuclear reactor, with a specific mass of 1 kg/kW, a human mission to Mars can be accomplished with VASIMR propulsion in 39 days.

A number of 40 MW VASIMR engines would be provided to get the required thrust. Each engine would be consuming about 40 kW/N. Another option is to use a lower capacity power plant. A 12 MW nuclear power source with a moderately aggressive technology advancement that assumes a specific mass of 4 kg/kW yields a 3-month human mission to Mars with approximately the same initial mass as a chemical mission. With this new technology, it is now possible for humans to travel to Mars and beyond safely.

Manned spaceship with VASIMR engine to Mars For more information, contact: Rathindranath Biswas rathinb7175@yahoo.com January 2020 n OEM Update

Brand Report

Functional safety in electrohydraulics Atos’ SIL & PL certified digital proportional valves

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tos is the only worldwide manufacturer offering a full range of proportional and conventional valves designed for functional safety and certified by a notified body.

The Machine Directive 2006/42/EC with relevant harmonised standards — IEC 61508 Safety Integrity Level (SIL) and ISO 13849 Performance Level (PL) — define the general principles concerning machine safety, which manufacturers have to consider to limit risk related to machine operation.

Atos-certified proportional valves meet these standards by performing the safety function in addition to standard axis motion control. By keeping the on-board diagnostics active when removing solenoid power, Atos valves confirm when a safe spool position has been reached.

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The valves are certified by TÜV in compliance with ISO 13849 up to category 4, PL e and IEC 61508 up to SIL 2 / SIL 3. Atos safety valves help in limiting potential risks to equipment or operators, preventing dangerous movements of electrohydraulic axes during production cycles or emergency conditions.

Certified safety valves eliminate the need for machine manufacturers to validate such components as they comply with the applicable safety standards. This saves considerable amount of time during the machine design phase and the system certification process.

Of course, actual system SIL and PL levels do not depend only on the characteristics of single components, but also on the hydraulic system architecture and diagnostic coverage.

Atos specialists are available and ready to support customers in the tuning of the best safety electrohydraulics solution for their application.

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January 2020 n OEM Update

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Smart Factory

Smart factories to revolutionise global manufacturing practices

As smart technologies and smart factories become the name of the game in manufacturing, Schneider Electric’s new smart factory launch in Bengaluru shows how businesses can constantly improve their processes and products and keep up with the changing times.

“S

mart” is now the keyword in manufacturing. From smart technologies to smart cities and smart factories, companies are going the smart way to ensure that they stay at the top of the game. Recently, Schneider Electric launched its second smart factory in India at Bengaluru. The newly inaugurated facility demonstrates how the company’s EcoStruxure architecture and related suite of offerings drives process automation, increases operational efficiency and reduces costs in the industrial environment. Having two smart factories located in India reinforces Schneider Electric’s contribution to the Indian government’s “Make in India” programme that is designed to facilitate investment, foster innovation, enhance skill development, and build best-in-class manufacturing infrastructure in the country.

Talking about the need for smart factories, Javed Ahmed, Senior Vice President – Global Supply Chain – India, Middle East & Africa, Schneider Electric, said, “Today, the manufacturing segment contributes about 17 percent of our GDP. If we want to accelerate the growth of India and bring in more productivity and efficiency in the country, this rate has to rise from 17 percent to 35 percent. These technologies which are being implemented aim to showcase how to retain your customers by increasing productivity, efficiency, and validation of your business that will set the required pace and allow customers to explore more and more, because today we see India improving on a lot of parameters.”

Delving further on how Schneider Electric’s technologies are contributing to making smart factories a reality, Mourad Tamoud, Executive Vice President – Global Supply Chain, Schneider Electric, added, “Our technologies are providing

“One of the key benefits of our factories is that we are able to gain energy efficiency.

Javed Ahmed, Senior Vice President – Global Supply Chain – India, Middle East & Africa, Schneider Electric

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a lot of efficiency and productivity to businesses. Schneider has increased its patents from 142 to 6,070. We work on the technologies and manufacturing practices that are being implemented outside in order to contribute to the global building blocks of manufacturing. Our products compete at the global level and symbolise trust and confidence. This is not only helping our partners, our ecosystem and India’s growth, but also us.”

At present, Schneider Electric has 24 factories in India. The company is designing global factories for global markets as well as the Indian market. Some of the factories like the one in Hyderabad meet global standards. With this kind of measures, the company has built an excellent manufacturing platform to serve Indian customers. It is pertinent for other companies too to develop smart factories so that they can harness the opportunities of economies of scale, efficiency, productivity, and stringent quality checks. In order to grow your business, it is vital to take advantage of the new, upcoming technologies and concepts such as smart factories.

One of the key aspects of Schneider Electric’s smart factories is that it has deployed several technologies to ensure that they are smart and digitalised. Smart factories can help businesses stay connected to their customers using digital tools, even for placing orders, increasing visibility for the customers and so on.

Also, with respect to logistics and order shipments, Schneider provides continuous status updates to its customers as to whether the order is packed, shipped, whether the invoice has been raised, etc. Javed Ahmed explains, “Our customers like the complete end-to-end visibility and transparency we have with them as it enables them to manage their planning centre, so that they too can plan their functions around those deliveries. In case there is a delay, we also send alerts to our customers.

Moreover, for each order, they are able to rate the different aspects of our service, in terms of delivery, transportation, packaging, related paperwork and other issues. We use this information and analyse it to make improvements so that we can serve our customers better.”

January 2020 n OEM Update

Smart Factory He adds, “This is one aspect of how we are connected to the world. We have a deep understanding of our customers’ needs and of how we can serve them much better. Talking about our operations, one of the key benefits of our factories is that we are able to gain energy efficiency, for which we have deployed our EcoStruxure architecture. And we have been able to achieve almost 50 percent of energy savings year-over-year for the past 3-4 years.” Another key result area that can be addressed using smart factories is the operational efficiency of a product. Schneider has the necessary infrastructure to ensure that the company’s uptime is up and it is able to track its downtime and bottlenecks, and thereby improve the efficiency of its manufacturing plan. Javed Ahmed says, “We have quite a lot of digital tools for training too. We have deployed virtual training in our warehouses to allow our operators to function better. Before they start working, they can virtually learn how to use the different drivers, testing stations, etc. so that they go on to the plan and do their jobs in a much better fashion.”

Moreover, Schneider Electric promises a 99.95 percent uptime to all its customers, setting its technologies a class apart. There are almost 100 check points for each product before it leaves the factory. So at any point of time, the team can quickly go back and see which process worked better for a product, what kind of quality checks were done, etc. If it needs to improve on any aspect, it can quickly get the relevant feedback.

Thus, it can be seen that smart factories are essential to moving into the digital world, where companies and customers can stay connected to each other, allowing companies to develop processes, products and services that cater to the needs of the latter better and meet global standards and competition. Live status updates given to the customer also help the companies earn and retain the customer’s trust and loyalty. Companies can also train their employees using virtual tools, reducing the risk of accidents and errors.

With technology constantly disrupting our way of functioning, it has become necessary to harness the benefits of smart factories to ensure that businesses stay ahead of the competition and become more efficient, profitable and sustainable, while meeting global standards and improving manufacturing practices.

Smart factories also promote the sustainable use of resources. For example, waste water collected from Schneider’s factories is used for washing vehicles, etc., thereby making the company part of a circular economy. It also has a centre of digital innovation, where a group of people all over the world who are connected as a community are looking at technologies that can be deployed and can help with functional areas such as quality, productivity, and training to improve the processes.

“Our technologies are providing a lot of efficiency and productivity to businesses.

Schneider Electric is ranked number 11 in the global supply chain. Achieving this was no easy feat, as the company has deployed several quality tools through which the traceability of components, supplier management, process parameters and set-up are monitored. Smart factories allow businesses to collect and use such data to improve their processes, functions, and technologies.

WERING PO

SIN

CE 1992

Mourad Tamoud, Executive Vice President – Global Supply Chain, Schneider Electric

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January 2020 n OEM Update

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Brand Report

Plasma nitriding for effective surface treatment

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lasma nitriding (ion nitriding) is a plasma-supported thermochemical case hardening process used to increase wear resistance, surface hardness and fatigue by generation of a hard layer including compressive stresses.

Application & materials Typical applications include gears, crankshafts, camshafts, cam followers, valve parts, extruder screws, pressure die-casting tools, forging dies, cold forming tools, injectors and plastic mould tools, long shafts, axis, clutch, and engine parts.

Plasma nitriding and plasma nitrocarburising are often preferred to the corresponding gas processes if masking is required.

Plasma nitriding is suitable for all ferrous materials, including sintered steel with higher porosity, cast iron and high alloyed tool steel even with chromium contents higher than 12 percent. Stainless steel and nickel-based alloys can be plasma nitrided and keep most of their corrosion resistance if low temperatures are applied. Special applications include plasma nitriding of titanium and aluminium alloys. For heavy loads on large machine parts such as shafts and spindles, the use of special chromium and aluminum alloyed nitriding steel gives a huge benefit, as plasma nitriding generates surface hardness of more than 1,000 HV. Process details Plasma nitriding/nitrocarburising is a modern thermochemical treatment, which is carried out in a mixture of nitrogen, hydrogen and an optional carbon spending gas. In this low pressure process, a voltage is applied between the batch and

the furnace wall. A glow discharge with a high ionisation level (plasma) is generated around the parts. On the surface area that is directly charged by the ions, nitrogen-rich nitrides are formed and decomposed, releasing active nitrogen onto the surface. Due to this mechanism, shielding is easily done by covering the concerning areas with a metal blanket.

Plasma nitriding allows modification of the surface according to the desired properties. Tailor-made layers and hardness profiles can be achieved by adapting the gas mixture from a compound layer-free surface with low nitrogen contents up to 20 microns thick, to a compound layer with high nitrogen contents and an add-on of carbonic gas (plasma nitrocarburation). The wide applicable temperature range enables a multitude of applications beyond the possibilities of gas or salt bath processes.

Benefits The advantages of gaseous nitriding processes can be surpassed by plasma nitriding. Particularly when applied to higher alloyed steels, plasma nitriding imparts a high surface hardness which increases resistance to wear, scuffing, galling, and seizure. Fatigue strength is increased mainly by the development of surface compressive stresses. Plasma nitriding is a smart choice whenever parts are required to have both nitrided and soft areas. The possibility of generating a compound layer-free diffusion layer is often used in plasma nitriding prior to PVD or CVD coating, and customised layers and hardness profiles can also be achieved.

Authored by: Ankit Gupta, Director, Modern Metals India Pvt Ltd Mobile Number: +91 9910012626 Email: info@modernmetalsindia.com

Infinity F1 for 2D sheet metal cutting and tube cutting

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he market today is flooded with fabricators who wish to make a mark in the manufacturing industry by offering superior quality, productivity, and affordable operating cost. To achieve these standards, SLTL Group has developed Infinity F1, a fibre laser cutting system with Modular Product Architecture (MPA).

This system is designed to provide the best throughput with effective and efficient operations.

Infinity F1 is the best-selling product in the market and has been chosen as the industry’s favourite since its inception. With MPA, the machine can be integrated with different modules to perform productive operations and achieve new tasks. Therefore, with MPA, the machine can be upgraded as per future needs. Infinity F1 can do 2D sheet metal cutting as well as tube cutting. 2D cutting 52

allows us to operate on various thicknesses and materials like aluminium, brass, copper, mild steel, galvanised iron, titanium, and stainless steel. With an adjustable four-jaw chuck system to hold the different tube shapes, it can process various shapes like circular, rectangular, triangular, and square. It is also equipped with a double servo motor for accurate movement of the tubes. This will help fabricators bring in variety into manufacturing. It is highly productive for micro, thick and thin cutting.

Equipped with features and options to perform numerous tasks, the machine is designed to meet the needs of speed, quality, and productivity. It can achieve a butter cut finish with integrated software and hardware and has a robust machine structure to ensure maintenance-free work. The in-house research and development team has created a complete system for fulfilling the demands of the industry.

For more details, visit: www.sltl.com January 2020 n OEM Update

advertorial

ISRAEL’s Patented BATTERY REVIVAL CLEANTECH TECHNOLOGY in INDIA (Faridabad-Haryana)”

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he technological solutions and the refurbishing process offered by the patented BSI leads to the following results: • Battery refurbishment at a very low-cost process with a huge profit margin • Reducing the environmental impact by extending the battery lifetime • Saving around 30–50 percent on battery budget for the end user • Proven technology and process for battery refurbishment • An attractive Clean-Tech market with rapid growth globally • A relatively short period for the return of investment (ROI) • A relatively short period for break-even point • A small-mid initial business with a great growth potential • Gradual and controlled business growth ability • Worldwide support for all aspects of the business • A complete environment-friendly process which reduces the environmental pollution of battery waste • A crazy market growth horizon for the Electric Vehicle (EV) battery (Lithium Ion and NiH).

BSI has established a successful track record in its international chain of battery refurbishment facilities, with a global presence in countries like India, Bangladesh, Chile, Egypt, Ghana, Oman, Myanmar, Kenya, South Africa, Vietnam, Slovenia, Poland, and Ukraine.

Below are the potential advantages and prospects for the customers of the refurbishing business: • Refurbished batteries in a similar quality as brand new batteries in a significant lower price (30-50 percent) • The possibility to receive continuous support and

January 2020 n OEM Update

• • •

maintenance for a large amount of batteries at a relatively low cost, reducing the battery budget by 25–55 percent A warranty for the refurbished battery similar to that of a new battery (free replacement) All components are refurbished, which eliminates the need for waste disposal One-Stop Shop services by BSI.

First time in India (Since 2017)

Cleantech Sustainable Solution from ISRAEL, NOW in Delhi NCR YES to OLD BATTERIES Revival , NO to RECYCLE Provides Optimum BATTERY RECOVERY PROCESS DOUBLE YOUR BATTERY LIFE @ 1/5 th cost of NEW Battery SAVE ENVIRONMENTAL POLLUTION FROM HIGHLY HAZARDOUS LEAD ACID BATTERIES 100% POLLUTION FREE (ZERO LEAD & ACID DISCHARGE)PROCESS We do Revival/ Life Longevity of Nicd Batteries also.

Soon Coming up with Li Ion Batteries Life Longevity (ELECTRIC CAR BATTERY & STORAGE) Solution

EFFULGENT BR RESOURCES LLP Greater Faridabad , Haryana Contact: 9810635349/9650993990 Email: support@voltaredox.com vcare@voltaredox.com

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Brand Report

Gandhi Automations received WASME Award for warehouse and logistic innovation

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orld Association for Small and Medium Enterprises (WASME) is a global non-profit organisation that has been spearheading the cause and development of small and medium enterprises (SMEs) the world over since its inception in 1980.

Speed Doors - Prime Reset, High Speed Doors - Prime Internal Doors, Industrial Sectional Overhead Doors, Dock Levelers, and Isotherm Rolling Shutters are some of the fast-moving innovations and products that have changed the landscape of logistics and warehousing automation.

Warehousing and logistics are crucial factors for companies to gain a competitive edge. With the advent of modern manufacturing, which combines smart and effective products with advanced and innovative technologies, the very definition of warehousing and logistics has evolved to a much larger and integral concept.

Quality is a key driver of progress for Gandhi Automations and is an integral part of every process it undertakes, from R&D to product delivery. Its quality policies are constantly upgraded to exceed customers’ requirements and expectations. Gandhi Automations is committed to delivering high-quality products and services to its customers and continuously strives to improve in all aspects. Its products and services are geared towards ensuring that every delivery to the client passes through its stringent quality measures.

This policy has engendered a work culture that exhibits a no-compromise attitude towards quality.

As the logistics and manufacturing sectors move beyond the rudimentary manual operations in the supply chain, Gandhi Automations’ range of entrance automation and loading bay range of products has revolutionised traditional warehousing powered by advanced engineering technology, thereby not only impacting logistics but the supply chain as a whole. For its advanced tech innovation, Gandhi Automations Pvt Ltd once again bagged the WASME Award of Warehouse & Logistic Innovation Award, which was presented by the Hon’ble Minister of State for Health and Family Welfare, Ashwini Kumar Choubey.

Gandhi Automations has successfully evolved into an innovative company catering to all kinds of needs. It has an extremely talented in-house research and development team which designs customised solutions for its customers.

Its product engineering team uses the latest software in combination with technologically advanced machinery to provide customers with an unmatched experience in entrance automation and loading bay equipment.

Gandhi Automations has made significant improvisations and innovations to its loading bay equipment range of products as well as high-speed doors. The new Forklift Roll-off Barrier lip Dock Leveler, Prime Cold Reset, High 54

Gandhi Automations is known for its research and development, quality and commitment towards customers. The material handling industry is responding with new equipment, technology, and systems that enable complete supply chain visibility, thus allowing customers to see how their investments are impacting their overall operation. The demand for material handling automation and equipment has increased exponentially over the past few years because of increasing production capacity, reducing man-hours, and meeting deadlines. Now, with more and more companies streamlining their processes, use of material handling equipment for any industry is a must. Demand for such automation is the need of the hour, even to deliver faster, hassle-free loading/unloading functions to reduce supply chain operating costs.

To know more about Gandhi Automations products, visit: www.geapl.co.in January 2020 n OEM Update

Brand Report

B&R to showcase automation technologies for plastic industry

P

lastivision 2020 will be held from 16th to 20th January 2020 at the Bombay Exhibition Centre in Mumbai.

At this leading exhibition for plastics, B&R’s entire product range will be on display in Hall 1 Booth C4-2.

The highlights will be B&R’s state-of-the-art solutions for machine builders, end users and system integrators in the plastics industry. These innovations from B&R are opening new opportunities for them to build and strengthen their competitive edge.

“In our opinion, India’s plastics industry is always keen to try new technologies and appreciates the benefits of our completely integrated automation solution. With the extraordinary scalability of our products, machine builders can easily and cost-effectively tailor their solutions to meet their customers’ demands,” says Dharmendra Patel, plastics industry expert at B&R India. “From control and HMI to drives, motors and safety technology, B&R offers the entire spectrum of machine and factory automation solutions and is always leading the industry with innovation.”

APROL to increase efficiency of entire plant Faced with enormous cost and quality pressure, users are seeking solutions to reduce maintenance costs and downtime while optimising availability and utilisation.

Production processes generate huge amounts of data, which helps generate valuable reports about equipment utilisation, asset availability, productivity, and energy efficiency. Real-time data acquisition with APROL enables complete online performance monitoring and January 2020 n OEM Update

visual overviews that make it possible to track quality for the entire manufacturing process and plant. The ready-to-use solutions available with B&R’s APROL process control system for energy monitoring, condition monitoring, advanced process control, and process data acquisition provide higher benefits and strengthened core competencies.

Optimum quality with machine vision B&R will also be exhibiting its machine vision solution, which is fully integrated into the automation landscape.

“In the plastics industry, our vision solution is best for quick qualitative analysis where processes are complex.

In the production process, our integrated machine vision system can be deployed for applications such as calibration, measurement, orientation, inspection, barcode reading, locating, positioning, preprocessing, and comparison. Defective products can be immediately rejected, which saves raw materials and makes it possible to rectify problems at the same level, resulting in increased quality and productivity,” says Patel.

All visitors to the B&R booth will also be able to experience ABB products and services for the plastics industry, which help manufacturers achieve higher quality, comply with standards, and become responsive to the challenges of global markets.

For more information, visit www.br-automation.com 55

Advertorial

TIPL completes 60 years of operations

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oshniwal Industries Pvt. Ltd. (TIPL), a manufacturer of process instrumentation products and solutions in India, was incorporated by Dr. GR Toshniwal and his brothers in 1959. It offers a wide range of products, systems and solutions, including process control instruments, surveillance systems, test and measurement, condition monitoring, environmental solutions, and process optimisation and safety.

This year, TIPL is celebrating its 60th year of incorporation.

As part of these celebrations, the company organised several events and activities like a blood donation drive in partnership with JLN Hospital, a tree plantation drive, inspirational talks for business, spiritual and thought leaders, a musical performance by a well-known New Delhi rock band, and sports events. The celebrations culminated with a mega event called “Utkarsh” at Mayo College, Ajmer.

The event was attended by over 1,000 guests, including eminent citizens of Ajmer, the company’s overseas partners from the US, Japan, Europe, and China, as well as major customers, suppliers, and the entire TIPL family.

A product expo will was held at the TIPL office as well, which showcased the company’s entire range of products, systems, and solutions. It was attended by more than 100 business delegates from the steel, cement, power and projects industries.

from the first to the second generation. Approximately 12 percent make it to the third generation, and only 3 percent of all family businesses successfully transition to the fourth generation and beyond. TIPL is among this small minority of businesses that has made it to the fourth generation. This has been possible because of the values that have been embedded in the organisation by the leaders of the Toshniwal family over four generations.

According to Rajeev Toshniwal, Managing Director, TIPL, “It is not hard to make decisions once you know what your values are. We are what we are because of our values. Our stated values are Knowledge, Ownership, Speed, Trust, and Transparency. Over the last few years, we have consciously embedded these amongst all employees. I can confidently say that every employee of TIPL is aware of our values and are encouraged to practise them.”

Abhinav Toshniwal, CEO, TIPL, added, “Our team is the single most important asset of our organisation. We believe in building people, and people build businesses.

My endeavour is to build a world-class company in Ajmer and create a professional work culture for the youth of Rajasthan and India.”

Moreover, TIPL recently signed a joint venture with KE Electric, Shijiazhuang, China, a leading player in the field of design, manufacturing, research, and maintenance of the entire scope of electrical power distribution and metering. The new venture is called Toshniwal Electric Works Pvt. Ltd. and it will manufacture and market smart meters in India. The venture has already bagged an order of 4,00,000 electric meters.

According to the Family Business Alliance, about 30 percent of all family-owned businesses make the transition 56

January 2020 n OEM Update

Proven / Reliable Soft Starters for LT/HT Pumps/ Compressors

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he complex process of starting an induction motor is intelligently controlled, simplified and a smooth jerk-less start with reduced starting current is achieved with Jayashree HFSR Soft Starters.

Jayashree is a pioneer in the design and manufacture of harmonic free series reactor type Soft-Starters.

With continuous upgradation and adoption of new techniques, our Soft Starters are most ideal for starting induction motors.

The latest models incorporate an HMI control which shows the starting/running performance of the motor and keeps log of motor performance and parameters.

• Available for 415V/3.3/6.6/11 KV with motor rating up to 35 MW • HMI/PLC control with data logging • CPRI tested and approved • Ideal for pumps/compressors/crusher • Can reduce starting current up to 1.5 X FLC • Thousands of units in operation over last 3 years.

For more details, contact: Jayashree Electron Pvt. Ltd EL-12, J Block, MIDC, Bhosari, Pune 411026 Phone: 020 46768998 E-mail: sales@jayashree.co.in

January 2020 n OEM Update

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advertorial

Walpha Engineering: the honour for technology excellence

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alpha Engineering, established in 1975, is the brainchild of Amardeep Patheja, a wellexperienced technocrat and a qualified mechanical engineer. The company was established with an aim to develop and manufacture electromagnetic and mechanical clutches and clutch plates for machine tool application.

A small seed planted in 1975 for developing and manufacturing of electromagnetic and mechanical clutches and brakes for the first time in India has grown into a wellestablished and highly successful industry. Backed by a highly qualified and efficient team of technocrats, Walpha is the first Indian company to have successfully developed about 600 different types of clutches, over 3,000 types of clutch plates and 50 types of current supply brushes. Walpha Engineering is well known for successfully import substituting multidisc electromagnetic clutches and brakes. The company manufactures clutches equivalent to those manufactured

by Siemens Germany (EK1 to EK60 Series), Moninghoff, Ortlinghaus, Binder Magnet, Heid, Stromag, Warner and various other makes.

Walpha is also one of the leading manufacturers of single disc (dry) clutches and brakes, fail-safe brakes, mechanical clutches, clutch brake combinations, clutch plates, telescopic brushes and friction material since over 35 years.

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With its expertise and experience spanning over 3 decades, Walpha is in a position to develop and manufacture any type of clutch/ brake and clutch plates used by the machine tool industry. The very fact that Walpha is the original equipment supplier for several machine tool manufacturers like Hindustan Machine Tools (HMT) speaks volumes of its quality assurance and reliability.

Other than this, Walpha supplies clutches to almost all the industries such as manufacturing, packaging, textile, mining, pharmaceutical, automobile, power transmission, etc. The company also supplies its products to defence and railways and has a strong presence in the international markets. Walpha’s efforts towards import substitution and innovation were well recognised by the Government of India and the company was awarded the national award for import substitution on 26th January 1979. The promoter, Amardeep Patheja, who is the company’s guiding force, has been honoured with several awards and recognitions for his personal contribution to the Indian machine tools industry, for excellence in import substitution, for his entrepreneurship and marketing skills, the quality of his products and his contribution to the society. “Walpha” is recognised as a trusted and recommended brand name and is in a position to develop and manufacture any type of industrial clutches to the entire satisfaction of its customers.

Even a small-batch quantity is accepted by the company.

The company is well-equipped to export industrial clutches, brakes, and clutch plates and also has an open mind to join hands with like-minded competent companies to expand its existing business. The main motto of the company is “customer satisfaction and only customer satisfaction”.

For more information: R-235, M.I.D.C., T.T.C. Area Pipeline Road, Rabale, P.O. Ghansoli, Navi Mumbai 400 701. India Tel.: 022-6457 2442/3/4/5 Fax.: 022-2769 2761 Cell.: 9769109989/8850606313/9769109988 Email: sales@walphaengineering.com mktg@walphaengineering.com Web: www.walphaengineering.com

January 2020 n OEM Update

Belimo ultrasonic flow sensor for accurate measurement

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elimo’s in-line flow sensors utilise ultrasonic transit time technology to provide accurate, repeatable measurement for any HVAC application. The innovative measurement method features patented glycol compensation logic to automatically detect, monitor and compensate the glycol concentration in the system at all times.

• • • • • • •

Trusted flow measurement with +/- 2 per cent accuracy and +/- 0.5 percent repeatability Multi-point wet calibrated to ensure accuracy and repeatability Only one-flow sensor is required for all glycol concentration of up to 60 percent Low pressure drop for pump optimisation for miximised energy saving Low power consumption of 0.5 W saves energy and transformer capacity Accurate results without drift Ease of installation and energy efficiency.

For more details, visit: belimo.ch Email: info.india@belimo.ch

January 2020 n OEM Update

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Brand Report

Customised wear-resistant parts by Speedigus

Speedigus: Wear-resistant special parts made quickly and individually with different igus services.

I

n order to be able to quickly supply and install the right plain bearing solution at all times, igus keeps more than 12,000 different iglidur plain bearing types made of tribo-polymers in stock. These are prototype and high-volume production made of tribo-polymers that are manufactured quickly using various manufacturing methods.

But sometimes, customers demand plastic components which are not in the catalogue. For this purpose, igus manufactures customised parts using different methods. The type of production is determined by the motion plastics specialist according to the required quantities.

For large volumes, starting at 500 pieces, the in-house tool manufacturer constructs application-related moulds made of steel, which are then used in the injection moulding machines. For small batches up to 500 pieces or prototypes, igus offers another solution for wear-resistant special parts via the speedigus production service.

The speedigus services are divided into the speedimold, speedicut and speedifit divisions and the 3D printing service, according to the method that is most suitable. In the video, Gerhard Baus, Vice President New Business Development, tells you what is possible with the different methods: https://youtu.be/x8H9WISW9gQ.

Low-cost process automation with lubrication-free drylin linear robots from igus of programming effort. igus’ lubrication-free linear axes are developed in several stages.

S

imple, precise, fast processes: these are the requirements of Cartesian robots.

They are used for such things as pickand-place applications, sorting systems, and medical technology. igus has now developed a linear and room linear robot for large workspaces. The two new kinematics systems allow users to move up to five kilogrammes.

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Both linear robots are available directly from stock. They can also be customised to suit the customer application in question, with no minimum order quantity. For years, Cartesian robots have been the means of choice in automation technology. They allow users to complete their tasks quickly, easily and costeffectively. All that is required is a little bit

Low-cost automation with lubrication-free linear robot solutions The two linear robots consist of pre-configured linear modules, aluminium linear axes, NEMA stepper motors, and encoders. The new line robot can transport loads of up to 50 N in a workspace of 800x500mm at a maximum speed of up to 1 m/s. “The investment risk for the line robot is manageable, so that our automated pick-and-place applications for assembly tasks pay for themselves in less than six months.

This means that decision makers have a low level of risk,” says Alexander Mühlens, Head of Automation Technology at igus. The new room linear robot is a good option for more complex tasks. It can transport loads of up to 50 N in a workspace of 800x800x500mm at a maximum speed of 0.5 m/s. Two ZLW toothed belt axes and one GRR gear rack axis ensure precise guidance and lubrication-free operation.

For details, visit: www.igus.in January 2020 n OEM Update

Brand Report

Filtration unit Double filter, triple control This filtering unit provides double filtering for oil and diesel fuel and absorbs any water and impurities.

The unit features a supply and suction pipe with integrated bottom valve.

Features • Sturdy wheeled structure • Large-diameter wheels • Flow rate 56 l/min.

• Filtering capacity – first stage 30 µ with water absorption, second stage 5 µ for impurities.

• Rate up to 56 l/min • Two-step filtration • Continuous AC operation 230 V • Duty cycle 30 min DC version For further details, contact: Toshniwal Hyvac Pvt Ltd., 267, Kilpauk Garden Road, Chennai - 600010.

Contact: +91 44 26445626 /8983 sales@toshniwal.net www.toshniwal.net

Flow transmitters

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he flow transmitters are a new series introduced with the only two moving parts, i.e., Oval Wheels. The dry sectional parts like transmission gear assembly is totally eliminated in this flow transmitter where wear and tear is totally nil. These transmitters are maintenance-free. This is fixed with a weigh and wire sensor to give direct pulse output for rate of flow indication/totalisation.

Salient features • Higher reliability, therefore longer product life • Simper signal conditioning circuits, no or little lower component count, lower system costs and higher system reliability

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• •

No false pulse counts Lower system power consumption, therefore longer product life for battery-powered designs.

For more information, contact: M/s Toshniwal Hyvac Pvt Ltd., No.267, Kilpauk Garden Road, Chennai – 600 010.

Tel.: +91-44-26445626 / 26448983 Fax: +91-44-26441820 Email: sales@toshniwal.net Web: www.toshniwal.net January 2020 n OEM Update

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The Best Tools is the ideal purchase for keeping hands away form danger during use with items such as a Slogging spanner

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OEM UPDATE Worm Gear Boxes Helical Worm Gear Box Worm Geared Moter Worm & Worm Wheels Worm Helical Gear Box Shaft Mounted Strip Mill Special Gear Box Plastic Extruder Gear Box NMRV Aluminium body gearboxes Helical Geared Motor Bevel Gearboxes

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January 2020 n OEM Update

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OEM

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Pvt Ltd...............................

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Bhagyashree AccessoriesPvt Pvt.Ltd................................................

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Mercantile Pvt. 63 AtosElectronics India Hydraulics Modern Metals IndiaLtd...............................................

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B&R Industrial& Automation ...................Cover13Strip

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January 2020 n OEM Update

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Yes Prosper Spinning Technologies ...............................47

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Created Within the X Platform High User Interface Experience From Shop Floor to Cloud / Big Data Great HTML5 interface with JM4web Data Acquisition,Trends, Recipes, Multilanguage, Javascript, User management More than 200 communication protocols with gateway function Optional Integrated PLC runtime include full support of networked I/O Canvas and custom widgets, Browser widget email , Media Player , RSS feed OPC UA, MQTT Full Compatibility CODESYS V3 with Ethernet I/O Stacks Industry 4.0 Product Concept

Exor India P. Ltd

exorint.com

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Tel: (022) 27840422 / 27840423 / 27840424 / 49766424 | sales.in@exorint.com, support.in@exorint.com

exorint.com

All-steel casing Extra-long tread life Excellent traction Superior stability Steel belts

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