OEM Update October 2014 by I-Tech Media Pvt Ltd

OEM UPDATE

An I-Tech Media Publication

Welding

Automation

INSIDE Machine Tools

Newly Launched

SERIES- ADPRHT Aerosense Duct Mount Humidity Transmitter

TE-W

Aerosense Wall Mount Humidity Transmitter

Flow station

HUM-R

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ADPI-LED

T9002 Telaire Dewpoint Transmitter

HumiTrac Humidity Telaire Temperature Transmitter Series 477 Handheld

Psyclone Protimeter Thermo-Hygrometer

Digital Manometer

AS-500 Differential Pressure indicator Switch Transmitter

T5100 Telaire CO2 Transmitter

TTD1 Wall Mount Digital Temperature Transmitter Controller

T8700 Telaire Humidity Temperature Transmitter (Wall mount)

T8100

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CONTENTS Cover Story

MISSION ACCOMPLISHED �� 20

Quick Update

NI launches enterprise software solution for Industrial Internet �� 10 Rajesh Bhandari becomes MD of Gates India �� 10 Mobile surveillance apps for small systems �� 12 FARO releases Edge ScanArm HD with fast scanning speed �� 12 KEPL launches next-gen API steam turbine �� 14 ZF to acquire TRW Automotive �� 14 ExxonMobil celebrates 100th anniversary of its Equipment �� 16 Honeywell unveils solutions to boost oil and gas production �� 16 HARTING honoured Robotics China Excellence Supplier by ABB �� 18 CRI Pumps deploys 3DEXPERIENCE platform �� 18

Welding

Process automation boosting welding sector to a new high �� 26 Advance automation solutions for repair and maintenance welding � 32 Orbital welding for pipes and tubes �� 36 Orbital welding power source: Orbitron 5000 �� 36 Sandvik’s new super-duplex strip electrodes cut welding costs �� 38 FAPL assures ‘Fair Deal’ in welding equipment marketing �� 40 SigmaWeld: saving energy, increasing productivity �� 46

Automation Ultrafast Automation �� 48 Unlocking the potential of automation �� 50 Low-cost automation: a sticking trend �� 52 Indian market: a ‘hotspot’ for OMRON �� 54 Makino expects promising future for automation �� 56 Multiple needs driving automation �� 58 Automation industry needs more investment �� 60 KUKA: transforming the art of manufacturing �� 62 Staying ahead with robotics �� 66 3 ways to reduce machine design time �� 68 GE’s QuickPanel+ brings consumer technology to the factory floor � 70 Renishaw strengthens ASMPT �� 72 RELAYBILITY selecting industrial grade relays �� 74 Taking pelletiser technology to the next level �� 78

Machine Tools

Dürr builds energy saving paintshop for BMW in China �� 84 Fast, safe and quiet: igus expands P4 roller energy chain system �� 86 HMS expands Netbiter Remote Management offering �� 88 Pipeline alarm improvements through rationalisation �� 90

Brand Report Konecranes launches new overhead crane for emerging markets �� 92 Wohlhaupter: meeting boring requirements since 1929 �� 94 KHD Valves Automation: standardised for critical services �� 94 SML PEB: assured quality, timely delivery �� 97

October 2014 n OEM Update n 6

HIGH QUALITY FOR YOUR MACHINERY

MGM brake motor main features

VARVEL production lines

• TEFC 3-ph asynchronous brake motor (0.09kW-130kW) • AC 3-ph brake (no rectifier) or DC brake on request • Oversized brake disc for higher brake torque, longer life and reduced maintenance • Fine and easy brake torque adjustment (as standard) • Very quick brake reaction time • Frequent START/STOP cycle applications • Manual brake release (as standard) • Hexagonal hole on non drive end of the shaft for manual rotation • Single speed or two speeds motors • All motors designed for inverter duty

• RS-RT worm gearboxes: 28 to 150 mm centres. One stage worm, helical/worm and double worm. • RD helical gearboxes: 50 to 2300 Nm. Two and three stages. • RN parallel shaft gearboxes: 180 to 3300 Nm. Two and three stages. • RO-RV bevel/helical gearboxes: 180 to 3300 Nm. Three stages. • RG precision planetary gearboxes: 10 to 230 Nm. One and two stages. • VR dry friction speed variators: IEC63 to IEC90 1 to 5 stepless speed range, 300 to 1500 rpm. • VS planetary speed variators: IEC71 to IEC112 1 to 5 stepless speed range, 200 to 1000 rpm.

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Printed and published by Ms. Radha N. Poptani on behalf of I-Tech Media Pvt Ltd and printed at Print, Process Offset Printers, B-23, Royal Industrial Estate, 5-B, Wadala, Mumbai-400031 and published from 1, Gayatri, Karumari Amman, Chheda Nagar, Chembur (West), Mumbai- 400089. Editor: Ms. Radha N. Poptani. All rights reserved. While all efforts are made to ensure that the information published is correct, OEM Update holds no responsibility for any unlikely errors that might occur. The information on products and services / technology on offer is being provided for the reference of readers. However, readers are cautioned to make inquiries and take their decisions on purchase or investment after consulting experts on the subject. OEM Update holds no responsibility for any decision taken by readers on the basis of information provided herein. Tel.: +91-22-32682214/15, +91-9821667357

October 2014 n OEM Update n 8

Dawn of new beginning After the prolonged slowdown, the manufacturing sector in India is all set to witness the golden moment. The earlier government had set a target of six-fold growth for manufacturing sector by 2025, to $1 trillion, while creating up to 90 million domestic jobs. Taking a cue from this, the new government’s emphasis on bolstering manufacturing growth and eliminating bureaucratic roadblocks would give thrust in realising the above target. By 2020, India is poised to be the world’s third largest middle-class consumer market behind China and the US. By 2030, it is projected to surpass both these countries. This is going to create tremendous pressure on demand-supply chain, putting impetus on domestic manufacturing sector. Also to attract foreign investment and make India a manufacturing hub, Prime Minister Narendra Modi has launched the ‘Make in India’ campaign. Through this, the government promises easy and effective governance to ease doing business in India. This is expected to yield positive result in the long run. PM Modi’s recent visit to the US and his discussion with President Obama on industrial co-operation gives a new lease of life to the manufacturing sector. Obama and Modi mentioned that they would work jointly to “boost manufacturing and expand affordable renewable energy, while sustainably securing the future of our common environment.” The US can be a great partner in helping India achieve its manufacturing goal. It is for sure that the present government is leaving no stone unturned in redefining the Indian manufacturing sector. However, creating favourable policy alone cannot help Indian manufacturing sector achieve its desired goal. The manufacturers have to bring in advanced technology and create adequate knowledge-base to improve their productivity significantly, thereby capturing opportunity. Automation and IT are going to play key roles here. Please do send me your comments at editor@oemupdate.com

Quick Update

NI launches enterprise software solution for Industrial Internet Of Things N

I, a global systems provider for engineers and scientists has launched NI InsightCM Enterprise – a new software solution that helps companies gain insight into the health of their capital equipment for machine maintenance and operations. The software was launched on the eve of NI Days 2014 in Bangalore. The event was attended by more than 800 engineers, academicians and researchers. NI Insight CM Enterprise, a new software solution that helps companies gain insight into the health of their capital equipment for machine maintenance and operations. With more than 15 years of experience in condition monitoring, NI developed NI Insight CM Enterprise as its first end-to-end software solution that addresses big analog data challenges and builds on the industrial Internet of Things. Ultimately, it’s important for an organisation to gain insight into the overall reliability of its fleet of assets or plant and NI is excited to help facilitate these types of big analog data solutions.

The Internet has undergone various levels in its relatively short life span from consumer IoT to industrial IoT. This evolution will benefit individuals and businesses by removing physical barriers. Internet-powered technology innovation within the industrial operations space adds new dimensions to the technology space. Alex Davern, Chief Operating Officer, NI, said “With the tremendous amount of aging machinery in power plants, steel mills and factories in India, the Industrial Internet of Things is a critical element that will ensure the uptime and optimisation of these systems. We believe that NI Insight CM Enterprise that we are launching today will enable organisations to monitor critical machinery, analyse vast amounts of data and make meaningful business decisions.” NI Days 2014 witnessed participation from NI customers and Alliance Partners across a range of industries including academics, health care,

semiconductor, aerospace, automotive, life sciences, robotics and telecommunication. The application of the year was awarded to the team from National Aerospace Laboratories for their application titled Drishti Transmissometer.

Key benefits of NI Insight CM • Cost-effective: Lowers the instrumentation cost for monitoring both critical and other plant equipment at a fleet-wide scale • Open: Offers open software architecture to access data and gain interoperability with third-party enterprise software packages, such as CMMSs, database historians and prognostics tools • Easily scalable: Scales from one to hundreds of nodes per NI Insight CM Enterprise server and replicates one solution at multiple facilities • Flexible: Incorporates Compact RIO to adapt to changing sensory needs while maintaining the user’s investment in the platform. n

Rajesh Bhandari becomes MD of Gates India G

ates India announced the elevation of Rajesh Bhandari to the position of Managing Director with effect from September 1, 2014. In this new role Mr Bhandari will be leading all departments of Hydraulics business and will be responsible for the performance and growth of Hydraulics business in India. Mr Bhandari has been with Gates for 8 years and has over 24 years of experience in growing Gates Industrial businesses. Starting as lead in Sales and Marketing for the Hydraulics business, his last assignment was of managing commercial function of Industrial business of both hydraulics and power transmission. Gates India, the Indian subsidiary of Gates Corporation, USA, is an advanced and complete hose manufacturer.n

October 2014 n OEM Update n 10

Quick Update

Mobile surveillance apps for small systems Axis introduces mobile apps for Apple iPhone and Android devices for use with AXIS Camera Companion and hosted video solutions

stored to their mobile device and shared when needed.

uick and easy access to surveillance system from mobile devices is important for people on-the-go. Axis Communications, one of the world leaders in network video, has launched mobile surveillance apps for its AXIS Camera Companion and hosted video solutions. “By completing our offering with our own in-house developed mobile apps we can assure optimal performance and full compatibility with our vast product portfolio,” says Peter Friberg, Director Solution Management, Axis. “Providing easy remote access to high definition surveillance video gives our customers the tools they need to efficiently secure their operation wherever they are”.

To further strengthen its offering, Axis launches the mobile apps with the updated AXIS Camera Companion 2.2, with support for Axis Mobile Streaming. This technology is specially designed to give quick and easy access to live and recorded high definition videos even for installations where bandwidth is limited. The mobile surveillance apps allow the user to easily switch from live view to recorded videos from any location within their surveillance system. The integrated timeline notifies about triggered events and allows the user to take immediate action. Single images and video of interest can easily be

The apps are available for download free of charge and compatible with iOS and Android devices. The new app for AXIS Camera Companion is available to download. For more details and download links, visit www. axis.com/hosting/. n

FARO releases Edge ScanArm HD with fast scanning speed F

ARO Technologies, the source for 3D measurement, imaging, and realisation technology, announced the release of the allnew FARO Edge ScanArm HD (Laser Line Probe HD). The power of the new Laser Line Probe combined with the flexibility of the FaroArm creates the world’s most affordable, high performance contact/non-contact portable measurement system, the FARO Edge ScanArm HD. The ScanArm HD delivers rapid point cloud collection with extreme resolution and high accuracy – all in a compact, lightweight and easy-to-use system. The new functionalities enable users to seamlessly scan across diverse surface materials regardless of contrast, reflectivity or part complexity and without any special coatings or target placement. The ScanArm HD will be available for live product demonstrations in the Quality Assurance Pavilion at the 2014 International Manufacturing

October 2014 n OEM Update n 12

Technology Show (IMTS) at the McCormick Place in Chicago, IL from 8 – 13 September 2014 at booth N-6994. Kathleen J. Hall, Senior Vice President and Managing Director, Americas said, “The ScanArm HD delivers high-definition data with superior speed and surface coverage at an affordable price, enabling our customers to reduce on-site measurement times, to scan very challenging materials, and to meaningfully improve their products and processes.” The extra wide scan stripe and fast frame rate boosts productivity by increasing coverage and reducing scanning time. Intricate components can be captured in fine detail as a result of the 2,000 actual points per scanline and the new blue laser featuring noise reduction technology. Users can dramatically reduce required training time with the new crosshair feature and existing LED Rangefinder functionality, which provides real-time scanning feedback. n

Quick Update

KEPL launches next-gen API steam turbine KEPL becomes the first Indian company to develop steam turbines as per the American Petroleum Institute (API) specifications

EPL, one of the leaders in the manufacturing of API process pumps and API steam turbines, has announced the launch of India’s first indigenously-developed next generationAPI steam turbine ‘K-Tur’. KEPL is the first Indian company to develop the steam turbines in compliance with the American Petroleum Institute (API 611) specifications.

processing, oil and gas, fertilizers and chemicals industries, and water treatment plants and power projects. KEPL caters to various large public and private sector customers including Indian Oil Corporation, Bharat Petroleum Corporation, Hindustan Petroleum Corporation, Reliance Industries, Bharat Heavy Electricals and Essar Group companies, and many more.

K-Tur is built on the breakthrough technology developed by an Indian company. Appreciating the “Make in India” call, KEPL has developed K-Tur through its in-house capabilities and an intensive R&D programme.

KEPL is going to supply many pumps to global firms this year, including Saudi Aramco. KEPL has received more than 15 global customer approvals in last couple of years.

KEPL is a part of the Kirloskar Brothers, an engineering conglomerate and an Indian MNC. KEPL has more than 25 years of legacy and experience in the areas of engineering and manufacturing critical application pumps and turbines. The company manufactures complete turnkey Steam Turbine packages customised as per customer requirement. KEPL has already manufactured more than 200 steam turbines and supplied more than 9,000 components to the global steam turbine OEMs. KEPL manufactures complex pumps and allied products which are customised for critical applications in the hydrocarbon

Speaking at the occasion, Sanjay Kirloskar, Chairman & Managing Director, Kirloskar Brothers Limited (KBL), said, “The nextgeneration steam turbine is an effective alternative to imported ones and I feel privileged to announce that India has successfully developed the technology for commercial use. While the Indian industry is reeling under the pressure of abiding by the Past Track Record clause, I am proud to say that KEPL is the first Indian company to have developed the breakthrough technology and that too, as per international specifications. With the new government’s thrust on “Make in India” path, we look forward to introducing

many more indigenously developed critical application products. “ Aseem Srivastav, Managing Director, KEPL said, “The launch of “K-Tur” steam turbine is a major milestone for KEPL and is the testament of our commitment to deliver indigenous technology solutions. The journey of introducing indigenously-developed steam turbines has been exciting and it took us months to come up with this technological marvel.” K-Tur is among the most efficient single-stage turbines with a wide spectrum of interesting features such as Steam Shields, Blade-tip Seals and Reusable Bearing Liners. The steam turbine uses Profile blading, which helps in reducing the windage losses, thus improving its efficiency. K-Tur machine also has the facility of installing mechanical seals instead of the normal carbon rings. Currently, the K-Tur turbine is available in two frames. The first one (KT-B) is for the power requirements up to 1 MW and the second frame (KT-D) is for the power requirements up to 3 MW. The K-Tur Drive Turbines are also available in Condensing and Back Pressure Configuration. n

ZF to acquire TRW Automotive Z

F Friedrichshafen AG and TRW Automotive Holdings Corp. announced that they have entered into a definitive agreement under which ZF will acquire TRW. The combined company is poised to be a global leader in the automotive supplier business with pro forma combined sales of about $ 41 billion and 138,000 employees, stated a press release. The companies expect that together, ZF and TRW will be uniquely positioned to benefit from the megatrends of the automotive industry on a global basis, they said.

player in driveline and chassis technologies, whereas TRW is a significant supplier of active and passive safety technologies, including advanced driver assistance systems. Both companies have demonstrated a strong track record based on high product quality and continued innovation for their customers,” it said.

Both companies are working towards fuel efficiency, increased safety requirements and autonomous driving. “ZF is an important

Stefan Sommer, Chief Executive Officer of ZF said, “The acquisition of TRW fits perfectly into our long-term strategy. The transaction

October 2014 n OEM Update n 14

Globally, pro-forma combined R&D investments would amount to approximately $ 2.1 billion.

combines two highly successful companies that have remark-able track records of innovation and growth and solid financial positions. We are strengthening our future prospects by enlarging our product portfolio with acknowledged technologies in the most attractive segments.” John C. Plant, Chairman and CEO of TRW said, “This transaction provides significant benefits for our shareholders who will receive a full and certain value for their shares, as well as for our employees, customers and communities, all of which will reap the benefits of being part of a larger, more diversified global organisation.” n

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Quick Update

ExxonMobil celebrates 100th anniversary of its Equipment Builder Group Mobil-branded lubricants help the metals and mining sector in India increase efficiency, operate safely and lower environmental impact

xxonMobil Lubricants Pvt. Ltd., a subsidiary of Exxon Mobil Corporation, is celebrating the 100th Anniversary of its Equipment Builder Group, a diverse team of engineers and lubrication experts focused on helping manufacturers optimize the performance and efficiency of their equipment. Established in 1914, the Equipment Builder Group facilitates the designing and monitoring of innovative equipment testing programs with builders and ExxonMobil Research, evaluating lubrication approaches and carefully accessing equipment and lubricant performance. “We’re proud of our heritage of being one of the first lubricant manufacturers to dedicate resources specifically to building innovationcentred relationships with equipment builders. A lot has been achieved in the past 100 years and Exxon Mobil looks forward to our next 100 years together. Time and time again, we’ve had the privilege of seeing our partners bring to market some of the world’s

most advanced industrial machinery,” said Glen Sharkowicz, Industrial Lubricants Marketing Manager Asia Pacific, ExxonMobil Fuels and Lubricants. The company has also showcased its outstanding mining equipment lubrication products and lubrication solutions at the 10th edition of Minerals, Metals, Metallurgy and Materials international exhibition and conference (MMMM) held in New Delhi from 4– 7th September. ExxonMobil comprehensively elaborated on its safety, environmental care and productivity concept of sustainable development and practical experiences, attracting wide attention from participating companies and representatives at the MMMM. The mining industry is one of the most fundamental components of the industrial landscape and also one of the most challenging from a lubrication standpoint. “Advancing Productivity” focuses on how ExxonMobil’s innovative products and services help deliver tangible performance benefits in the areas of

safety, environmental care and productivity. Safety: Enhance mining equipment performance and reduce equipment failures and unscheduled downtime, thus lower maintenance requirements and the potential risks in safety of maintenance personnel. Environmental care: Improve energy efficiency of lubricant, reduce oil waste and environmental impact; improve mining equipment performance to strengthen the comprehensive utilization of mineral resources. Productivity: Improve mining equipment reliability, extend equipment life and ensure sustainable and efficient production. “With our comprehensive strategy, referred to as Advancing Productivity, we leverage our technology leadership and application expertise to help companies enhance their operational safety, achieve their environmental care-related goals, and maximise productivity,” said Shankar Karnik, Asia pacific, Mobil SHC brand manager, ExxonMobil Lubricants Pvt. Ltd. n

Honeywell unveils solutions to boost oil and gas production H

oneywell Process Solutions announced the release of digital suites for oil and gas, a set of software and services that can help oil and gas producers boost production performance by 3 to 5 per cent while improving operational safety. “The offering, which has been validated through customer testing, allows oil and gas producers to turn data into digital intelligence that helps operators make critical decisions faster by capturing, managing and analysing the right production information at the right time,” the company said. “Upstream oil and gas producers tell us they have access to more real-time data than ever, but access to that data alone is not enough October 2014 n OEM Update n 16

to improve performance – they also need digital intelligence to make sense of all the data being collected,” said Ali Raza, vice president and general manager, Honeywell Process Solutions. “By using these new tools, operators can get better productivity, higher uptime and more efficient remote operations, and they can produce a return on investment in as little as six months.” Honeywell leveraged its extensive experience in the oil and gas and related industries to develop this unique suite of solutions specifically designed for upstream operations. Digital Suites for Oil and Gas is designed to ensure that essential safety procedures perform as designed, operators are fully trained, alarms are managed and

enforced, and production performance is instantly available to detect and mitigate unexpected events. The solutions make collaboration through remote operations a reality, helping improve the safety of personnel, especially as upstream oil and gas production moves farther offshore and environmental conditions grow more risky. Digital suites for oil and gas is a fully integrated offering, but each suite is also available separately, letting customers address the specific issues they face. The six suites are: operational data, process safety, production surveillance, equipment effectiveness, production excellence, and operational performance. n

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Quick Update

HARTING honoured Robotics China Excellence Supplier by ABB China for ABB participated in the meeting and Kevin Sjoberg represented HARTING to receive the award. ABB is one of the leaders in China’s industrial robots and develops whole value chain business in China, from R&D, production, sales, engineering and system integration to service. On the other hand, HARTING is one of the market leaders in connectivity and industrial networks technology. It creates standards in the connector industry and provide connectivity and networks solutions for the transportation, factory automation, renewable energy, power transmission and machinery markets. n

ARTING (Zhuhai) Sales announced that the company has been honoured as an Excellence Supplier from ABB Engineering (Shanghai) Ltd Robotics BU on 9th September. HARTING (Zhuhai) Sales Ltd. and ABB Engineering (Shanghai) Ltd Robotics BU maintains a long term cooperation in terms of R&D, manufacturing and application of robotics. HARTING (Zhuhai) Sales won the award of 2014 Robotics China Excellence Supplier presented by ABB Shanghai among over 200 suppliers.

HARTING products have been widely used in the production of robots and robotic system and application solutions in ABB Engineering (Shanghai) Ltd Robotics BU. “As a professional connector supplier, HARTING provides a powerful support and guarantee for the safe and reliable production of ABB Engineering (Shanghai) Ltd Robotics BU with its excellent product range, customised solution and fastresponding service capabilities,” Harting informed issuing a statement. Kevin Sjoberg, Global Account Manager for ABB and Xiaolong Wu, Key Account Manager

Contact: HARTING India Pvt Ltd Abhishek Bimal Assistant Marketing Communications Manager 7th Floor (West Wing), Central Square II Unit No.B-19 Part, B 20&21, TVK Industrial Estate Guindy, Chennai - 600032 Tele: +91-44-43560415 Fax: +91-44-4356 0417 abhishek.bimal@HARTING.com www.HARTING.in

CRI Pumps deploys 3DEXPERIENCE platform P

ump manufacturer C.R.I. Pumps to deploy Dassault Systèmes’ 3DEXPERIENCE platform and its industrial equipment industry solution experiences. This will facilitate quicker response to customer requirements and standardisation of its entire design process. C.R.I. Pumps selected ENOVIA over key competition and it will be implemented across domestic pumps to begin with and later be rolled across C.R.I. Pumps’ entire product line. ENOVIA will help them improve data management,

October 2014 n OEM Update n 18

data and part reusability and project complexity.

(Engineer to Order) and ETM ( Engineer to Manufacture).

Dassault Systèmes, is the 3DEXPERIENCE company, which is one of the world leaders in 3D design software, 3D Digital Mock Up and Product Lifecycle Management (PLM) solutions. C.R.I. Pumps were keen to improve control over their product development processes and to address certain challenges including Data management, Data/Part reusability, Single Version of Truth, Project Complexity, ETO

Commenting on the deployment, C.R.I. Pumps said, “The entire approach, intelligence and the solutions offered by Dassault Systèmes will assist us in achieving a superior control over the product development process something that is critical to our business as we grow. Integrating ENOVIA and SolidWorks will strengthen our processes and our design excellence simultaneously.” n

Cover Story

MISSION ACCOMPLISHED Is India enough capable to do something which has not been possible for Europe, Russia or even the USA over the years? The answer is YES. And the whole world has witnessed the same recently on 24th September.

n the morning of 24 September, the Indian Space Research Organisation (ISRO) slowed down the spacecraft sufficiently so it could be caught in the orbit of Mars. And thus, it was successfully done. Yes, India created a history. ISRO showed the way how a dream can come true. Our scientists at ISRO made the Mars Mission possible making every individual of nation feel proud and extremely happy. India’s Mars mission had always been in the news or say, overall talk. Soon it turned into a hot topic not only for astronomy lovers

October 2014 n OEM Update n 20

or media but also for every Indian. Millions of prayers showed their positive effect and the spacecraft did an unbelievable job. Unbelievable because India became the first country in the world to have succeeded in putting a probe into Mars’ orbit on its maiden attempt. And this is something which was not possible for the USA, Russia and Europe also. A wonderful achievement made it all memorable.

MOM India’s Mars Orbiter Mission (MOM) – an indigenously made unmanned robotic mission weighing only 1,350 kg (less than an average SUV) was launched from the rocket port at Sriharikota on the coast of the Bay of Bengal

on a balmy afternoon on 5th November last year. Of the 51 Mars missions attempted across the world so far, only 21 have succeeded. However, India has nailed it, that too in very first attempt. At Rs 450 crores ($74 million) for 780 million km, the mission did cost about Rs 5.77 per km. MOM became the most cost-effective Mars mission to have ever been undertaken. Event the Hollywood movie ‘Gravity’ cost more than this Mars mission.

Objectives for marvellous Mars mission However, there were some specific objectives behind planning this ambitious mission. One of the main objectives is to

Cover Story develop the technologies required for design, planning, management and operations of an interplanetary mission. Also there have been some technological objectives as follows: • Design and realisation of a Mars orbiter with a capability to survive and perform Earth bound manoeuvres, cruise phase of 300 days, Mars orbit insertion / capture, and on-orbit phase around Mars • Deep space communication, navigation, mission planning and management • Incorporate autonomous features to handle contingency situations. From scientists’ point of view, the main objective of the mission was exploration of Mars surface features, morphology, mineralogy and Martian atmosphere by indigenous scientific instruments. This scientific objective will certainly help a lot our Indian scientists in many ways to plan such more missions in future.

Major challenges Well, whenever such a huge mission is designed and planned to execute, it faces number of challenges in its way. Number of factors need to be taken care of in order to reach the success. Some of the major challenges faced are as follows: • Thermal environment • Radiation environment • Communication systems • Power system • Propulsion system.

Appreciation Yes, ISRO definitely deserved that. Right from Indian PM to NASA professionals, all who witnessed this achievement something as

Mars Orbiter Mission Spacecraft attached to the 4th stage of PSLV-C25 and ready for heat shield closure

never before, appreciated genuinely. It was a proud moment for every Indian when the spacecraft entered into Martian orbit. Prime Minister Narendra Modi congratulated ISRO scientists as he said, “History has been created. We have dared to reach out into the unknown.” Even NASA professionals twitted to congratulate India. The twit says, “We congratulate ISRO for its Mars arrival! Mars orbiter joins the missions studying the Red Planet.”

Prime Minister Narendra Modi addressing from ISTRAC as ISRO Chairman Dr K Radhakrishnan looks on

Mr Modi especially appreciated ISRO as he addressed, “Through your brilliance, and hard work, you have made it a habit, of achieving the impossible. The short form of this Mars mission is MOM, knew as soon as I heard this that MOM never disappoints.” No wonder that ISRO became the centre of attraction worldwide. Though having literally proved that even sky is not the limit as they went beyond it, the ISRO ‘magicians’ remained down to earth. “Our efforts have historically focussed on ultimate objective of nation-building. Of translating space technology into space applications,” said K Radhakrishnan, ISRO Chairman. “The entire nation has been with us on this mission and its success will make every Indian proud. It will also help inspire the younger generation take up science, technology, math and engineering.”

Mars Orbiter Spacecraft captures its first image of Mars. Taken from a height of 7300 km; with 376 m spatial resolution

21 n OEM Update n October 2014

Cover Story Cost of Indian space mission compered to other recent Mars mission 700 600 500 400 300 200 100 0

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Spacecraft and mission plan The spacecraft configuration was a balanced mix of design from flight proven IRS/INSAT/Chandrayaan-1 bus. Modifications required for Mars mission were in the areas of communication, power, propulsion systems (mainly related to liquid engine restart after nearly 10 months) and on-board autonomy. PSLV-C25, twenty fifth flight of PSLV was designed to launch Mars Orbiter Mission spacecraft from the first launch pad at Sriharikota. The challenging PSLV-C25 mission was optimised for the launch of Mars Orbiter Mission spacecraft into a highly elliptical Earth orbit with a perigee (nearest point to Earth) of 250 km and an apogee (farthest point to Earth) of 23,500 km with an inclination of 19.2 degree with respect to the equator. The launch vehicle PSLV-C25 injected the spacecraft into an elliptical parking orbit with a perigee of 250 km and an apogee of 23,500 km. With six liquid engine firing, the spacecraft was gradually manoeuvred

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into a hyperbolic trajectory with which it escaped from the Earth’s Sphere of Influence (SOI) and arrived at the Mars Sphere of Influence. When spacecraft reached nearest point of Mars, it was manoeuvred in to an elliptical orbit around Mars by firing the liquid engine. The spacecraft then moved around the Mars in the specified orbit. The mission consisted of three phases: Geocentric phase, Heliocentric phase and Martian phase.

End note India’s low-cost and quick turnaround satellite mission has been attracting a lot of global attention from the scientific community that seeks to better understand the mysterious Mars. Now that India has joined the US, Europe and Russia in an elite group of countries to have successfully undertaken a mission to Mars, this success will solidify India’s reputation as a competent and low cost base for sophisticated engineering. n

Some interesting facts about India’s Mars Mission Mars at Departure

Earth at MOI it orb ry h’s to Eart j ec tr a raft

Spacec

rs’ Ma i orb

Mars Orbit lnsertion (MOI) 24 Sep 2014 Trajectory Design

India becomes first Asian nation to reach Mars orbit. It also becomes the fourth country to place a probe in the Martian orbit after US, Europe and Russia. n Before India, different countries have launched Mars missions, but out of the 51 attempts, only 21 have been successful. n India’s $72 million Mars orbiter is the cheapest interplanetary mission ever. n Over the next 6 months, Mangalyaan will study the mineral composition on Mars and also look for the presence of methane, a chemical key to life on Earth. n The MOM mission in Mars orbit is open-ended and is expected to last about 160 days (March 3, 2015). n

Departure 01 Dec 2013

Vernal Equinox

Image courtesy: ISRO

October 2014 n OEM Update n 22

Industry hails Modi’s India Inc. remains expectant that Prime Minister Narendra Modi’s ‘Make in India’ statement materialises as the industry continues its recovery from a slump

The Make in India, launched by Prime Minister Narendra Modi is truely a “lion’s step” in making India a global manufacturing hub. Mr Modi’s assurance to the Indian and global investors that they would not lose and only gain by investing in the country will go a long way in instilling trust and confidence among all sections of the industry - Rana Kapoor, President, Assocham

We have embarked on the path for India to become a global manufacturing power. Never before have we seen so much focus and attention on the vital manufacturing sector. This mission is a tribute to millions of entrepreneurs who effortlessly work over years to show that India is a reliable source of high-quality state-of-the-art products that serve demand not only at home but all over the world. - Sidharth Birla, President, FICCI

October 2014 n OEM Update n 24

‘Make in India’ Vision Siemens India has been providing cutting-edge technology for India and the global market for over 150 years. India definitely has the capability, inclination towards innovation and the skill sets. Hence, we urge the world to come and make in India.” - Sunil Mathur, CEO, Siemens India

At ElectroMech we are highly excited by the opportunities that this wave will present to the entire manufacturing industry. After years of doldrums, we hope that the manufacturing industry gets some serious tail winds which will allow us to sail into the topmost echelons of manufacturing countries in the world. - Tushar Mehendale, Managing Director, ElectroMech

The “Make in India” initiative instituted by Prime Minister, Narendra Modi denotes his vision of making the country a manufacturing hub for the world. This is an echo of his intention, as enumerated during the 2014 election campaign. Among other things, it first gives a strong signal that the government means business and intends to deliver its promises. The more important implication will be on the economy as a whole as manufacturing growth has been negligible for the past two years and must be revived in order to scale up economic growth. - Sanjay Dutt, Executive, Managing Director, South Asia, Cushman & Wakefield

25 n OEM Update n October 2014

Industry Analysis

Process automation boosting welding sector to a new high Automated welding can provide large gains in productivity and profitability if one selects the same for right application. Process automation is playing a vital role today to benefit welding industry

elding is a common process that allows parts to be joined during product assembly. Many customers/ users have mastered the use of welding through its deployment in thousands of automation systems. It is part of production process, which is very much responsible for the production rate with desired quality. This helps to do precision job with quality and improve the efficiency of the equipment and process.

more creative tasks. The highest population of robots is in spot welding, spray painting, material handling, and arc welding. Spot welding and spray painting applications are mostly in the automotive industry. However, arc welding and material handling have applications in a broad range of industries, such as, automotive sub-suppliers, furniture manufacturers, and agricultural machine manufacturers.

Role of process automation in welding Also robot automation systems are rapidly taking the place of the human work force. One of the benefits is that this change provides the human work force with the time to spend on October 2014 n OEM Update n 26

Welding is arguably the most complex manufacturing process and is frequently the ignored or not paid required attention. Manual welding is still the best process for

A B Kulkarni, Head of Representation â&#x20AC;&#x201C; Technical Sales, Polysoude India

Indian industries are slowly switching towards the automated processes and the percentage is on the upward trend

Industry Analysis many parts. However, many parts/assemblers are undergoing automated welding systems to increase quality, productivity and profitability. “Not every welding operation is a good for automated welding. Applications will benefit most from automation if the quality of weld is critical; if repetitive welds are be made on identical parts; or if the parts have significant value prior to welding,” says A B Kulkarni, Head of Representation – Technical Sales, Polysoude India. “In the era of open economy one has to be priced competitive with high demand of quality standards and this can be achieved only by automation,” believes Dr Manish Samant, Vice President – Technical, FSH Welding India Pvt. Ltd. When it comes to robot arc welding, the station is comprised of a robot, a robot controller, arc welding equipment, a work clamp and motion devices to hold work pieces accurately in position (considering heat deformation), robot motion devices to move around the robot for a larger working range and better weld positions, sensors, and safety devices. “The number of arc welding automation robot stations is growing very rapidly. The two most common stations are the GMAW (Gas Metal Arc Welding) station and the GTAW (Gas Tungsten Arc Welding) station,” informs Vikas Mal, National Sales Manager, Kemper India. ”These two stations are the most common because they are so well suited to robot systems.” “The quality welder availability in India is a big concern and the other side the customer expectation on productivity, quality, consistency and value proposition in terms of techno economical affordability is very high and increasing day by day,” says V V Kamath, National Sales Director, Fronius India. “To meet these needs, the only option is to go for process automation vide special purpose machine (SPM) or by robotic automation. This SPM and robotic automation will be the feature and it assures all the above demands.” Welding automation can be divided into two basic categories and Mr Kulkarni describes the same as follows: • Semiautomatic: In semiautomatic welding, an operator manually loads the component to be welded into the welding fixture. A weld controller then controls the welding process, torch movement,

various power source controls with preset parameters. After the weld is completed, the operator removes the assembled or welded parts and reloads next part. If the parts to be welded are limited then in place of adopting a fully automated process, a semi automatic process can be recommended. • Fully automatic: In fully automatic welding, a custom built machine, all operations like loading / unloading of parts , indexing the part , Bringing torch into weld position start / stop of weld etc are automatically / sequentially controlled. Depending on the operation, an operator may be necessary.

Choice of welding type “During product assembly, there are often requirements to join two or more parts using a type of welding technology. The type of welding used hinges on the part material, joint strength, leak tight requirements, and numerous other factors,” says Rashmi Ranjan Mohapatra, National Sales Manager, Kemppi India Pvt. Ltd. In many cases, users/solution providers design and develop the process to account for part shape, joint definition, fixturing, and environment. Welding operations have been delivered on a wide range of automation platforms including rotary dials, power and free conveyors etc. As each welding process is a unique combination of tooling, part presentation, motion profile, and weld apparatus, user and the solution provider work closely with each other to develop the right welding recipe with appropriate process monitors to deliver the desired process robustness. Lack of skilled welder for critical application also plays a major role in opting for automation to maintain the quality and uniform standard in the product.

Rashmi Ranjan Mohapatra, National Sales Manager, Kemppi India Pvt. Ltd.

Indian industrial automation market is seeing a robust growth driven by increasing demand in the automotive, textile, pharmaceutical, material handling, water and waste water, process and food and beverage industries.

beginning to end of process automation) is now moving rapidly in the industry. The other sector which is moving on Automation is yellow goods, construction machinery, oil and piping industry also in the process of adopting process automation. Other target application sectors include agriculture, commercial vehicles, construction, electrical, industrial vehicles, railways, ship building, mining and defence labs. Also in the fields of nuclear applications, power sector, food/pharma plants manufacturing, and aeronautic industry etc. automated welding finds its applications. Automation requires a profound knowledge of sector specific technologies. It finds its uses in following fields as well: • Image processing (across industry sector) • Test engineering and mechanical engineering • Chemicals and pharmaceuticals • Materials and construction • Heat exchangers.

Target application sectors The automation in welding is essential and need of the hour. More often automation is implemented where there is a repetitive nature of job and needs high skill, stringent quality norms and productivity with minimum rejections. This is more often implemented in automotive industry, white goods manufactures, large equipment fabrication, piping etc. Automotive is the sector which is calling for more numbers and increase in demand and hence it is on the leading in shifting to process automation and line automation (from

Status of Indian industry By virtue of Indian population, labour is cheap and India has become hub for many export jobs for fabrications besides the demand of internal infrastructure development is very huge for welding. This is giving rise to demand of the skilled labour in welding as well. Hence this is being partly filled by the automation in welding. As far as automation in India, the development is at very low pace compared to developed countries like USA, Europe, China, Japan etc. and one of the reason is the investment cost (import technology) is huge, besides availability of cheap labour. 27 n OEM Update n October 2014

Industry Analysis of quality process automation solution providers. The young job aspirants are not willing to join these upcoming Integrators where they can have possibility to learn and grow their talent. Instead they bang on OEMs and corporate. If the picture changes, the automation industry will grow faster.” Vikas Mal, National Sales Manager, Kemper India

There has been an increase in the number of entrepreneurs adopting robotics techniques in manufacturing. Not only big players, small robotics start-ups and companies are also targeting the SME sector in India

“The automation in welding is the future and has now become the most important factor to remain competitive in this welding field,” says Dr Samant. In India still 60-70 per cent of welding is done manually with a SMAW process which is ideally suited for manual welding. Mig/Mag, SAW, TIG/PLASMA processes are ideally suited for semi automatic/automatic welding. “Indian industries are slowly switching towards the automated processes and the percentage is on the upward trend,” observes Mr Kulkarni. Whereas according Mr Kamath, “Indian industry is in the very early stage and many customers don’t have enough exposure to the process automation and they also don’t have any preparation of data and product design. On the other hand, there are limited number

Utilities 7%

Indian industry has now started accepting industrial robots for increasing production and improving quality and in areas where the process is humanly challenging like handling of hazardous or heavy material. “There has been an increase in the number of entrepreneurs adopting robotics techniques in manufacturing. Not only big players, small robotics start-ups and companies are also targeting the SME sector in India,” points out Mr Mal. Robotics companies have now targeted the SME sector of India. The new market for selling of robotics has emerged because the prices at which these are offered are also very low compared to the products offered by international players. These robotics arms and equipment can easily be introduced by SME companies. “Indian industrial automation market is seeing a robust growth driven by increasing demand in the automotive, textile, pharmaceutical, material handling, water and waste water, process and food and beverage industries. The market has been growing at a fast pace over the last two years at 12-15 per cent per annum,” observes Mr Mohapatra.

Distributors network The highlights of the distribution channel of the market are:

Solutions 7%

End Users 14%

System Integrator 7% Panel Builder 10% Rout to Market for Electrical + Automation Market

October 2014 n OEM Update n 28

The quality welder availability in India is a big concern and the other side the customer expectation on productivity, quality, consistency and value proposition in terms of techno economical affordability is very high and increasing

• There are around 500-600 distributors in India who sell industrial automation products (PLCs, drives, sensors etc.) in India. However, 30 – 35 per cent market is unorganised. • There is a strong connect with the Electrical Industry as the companies offering Industrial Automation also offer Electrical products (adjacent/overlapping end use applications) • 40 per cent of these distributors are dedicated with the leading 4-5 players and the others are either ‘sell all’ or with other companies • 50 – 60 distributors are the main ones who would contribute almost over 50 per cent of the channel business for industrial automation • Distributors account for almost 50 per cent of the combined electrical + automation market. For industrial automation alone, sale through distributors could be around 15-20 per cent. In addition, there are around 400 medium and large system integrators, with almost 70 per cent of these working with the top 5 companies in the Indian market.

Distributors 50%

OEMs 5%

V V Kamath, National Sales Director, Fronius India

Safety first Kemper India offers welding fume extraction for sound, safe and efficient metal fabrication and cutting processes. Welding and cutting fumes cause health problems and negatively affect production. The result is reduced capacity, re-occurring disturbances and eventually decreased profit. Not only welders are at risk in unsafe environments, but the production equipment as well as end products are negatively affected from the Contd. to 30

FAIRDEAL AGENCIES PVT. LTD. Authorised Distributor : Panasonic Welding Equipment Registered Office: Gala No. A-08, Plot No. J-7/8/9, Kohinur Industrial Complex, Opp. Hindalco, M.I.D.C. Taloja-410206, Dist-Raigad (Maharashtra), India. Tel. No.: +91-22-27401909, Cell no.: 09372740999/ 093238-18890, Email: mumbai@fairdealgroup.co, Gujarat Business Centre: E-11, Siddhi Vinayak Towers, S.G. Highway, Makarba, Ahmedabad - 380051 Corp. & H.O.: G.T. Road, Opp. Hero Cycles Ltd., Ludhiana-141010 (Pb.) India.

www.fairdealgroup.co

Industry Analysis 28

Contd. from

Dr Manish Samant, Vice President – Technical, FSH Welding India Pvt. Ltd.

In the era of open economy one has to be priced competitive with high demand of quality standards and this can be achieved only by automation

lack of adequate safety measures. Automated welding equipment such as robots and the operators can be subject to residual welding fumes and also need to be protected. For the purpose: • Improve workplace environment • Protect workers’ health • Protect equipment and processes

• Reduce production disturbances and improve profit.

for continuous brazing and pre-forms (such as rings) for robotic brazing.

“We carry out feasibility studies and planning for welding and metal fabrication industries. Installation work and commissioning are also parts of our services,” says Mr Mal. “Our after sales service encompasses everything from emergency repairs to scheduled maintenance of welding fume extraction system meant for robot application.”

Dr Samant assures, “Our consumables will help to eliminate human error in the precision and repetitive jobs and give high productivity without compromising in quality at competitive price.”

Contribution of current players Looking at the benefits offered by process automation in welding, it would be interesting to analyse the industry’s response to this technique. Let us see how the current industry players are taking their part in making the concept popular in market. FSH Welding’s motto is to invent quality consumables at competitive price for the automation being future of welding, market the consumables and remain single source for welding consumables. The company has developed consumables, such as Fluxcored wires, fluxes for strip cladding and submerged arc welding, Fluxcored wire

“We have a dedicated range of power sources which are compatible with any make of robots. This in turn helps in automation in various industries,” informs Mr Mohapatra. “We also conduct training programs to facilitate our users and prospects in the usage of our equipment along with robots.” Kemppi has also offered total welding quality management system. It provides welding solutions comprising of equipment, software and industrial services to its customers. It believes that its recently launched Kemppi Arc System 3 will go a long way to help the organisations in improving the systems. “We are in the process of providing our expertise through seminars, training programmes, and exclusive collaborations. We have introduced new features and technologies specific to metals that are offering quality, consistency, productivity and at the same time simpler plug and play automation,” informs Mr Kamath and also explains Fronius objectives as follows: • Shifting the limits by increasing the knowledge and awareness about the role of quality welding automation and its value proposition • Help Indian industry leverage cuttingedge welding automation technologies to be globally competitive there by moving up the value chain • Establish state-of-the-art welding technology in meeting the up quality, speed, consistency & techno economically affordable solutions amongst welding industry, robot OEMS and Integrators. “We at Polysoude do offer products for both semi automatic as well as fully automatic welding utilising mostly TIG / plasma process. To increase the productivity levels a hot wire TIG process is also used for both welding as well as cladding applications,” explains Mr Kulkarni. “Based on precise customer needs we offer a semi automatic (Orbital or a semi mechanised), fully automatic or even a robotic welding solutions by using our standard power sources/weld heads/automation tools.” n

October 2014 n OEM Update n 30

Technology

Advance automation solutions for repair and maintenance welding This article briefs about the necessity of different features in order to achieve the quality of weld joint for typical high deposition hard facing applications by automation systems Welding automation for maintenance application

repair

and

The critical challenges faced by maintenance manger before planning for any typical maintenance or cladding application for wear protection or corrosion protection are worth discussing and the advance machines and systems available now are quite sophisticated to reduce weld failure and are capable of achieving high degree of precision in welding and productivity.

Challenges in maintenance welding The first and far most challenge is to select the appropriate alloy according to the application requirements and base metal chemistry. The selection of appropriate alloy is subject in itself. The second most critical challenge is to take up the repair job within the time constraints of repairs of equipment shutdown which is directly linked to loss of revenue if the equipment is not made available within stipulated and estimated repair time. This article focuses on automation aspect and the advance systems and machines their features and expertise available in this field to facilitate maintenance personal to understand how these sophisticated semiand fully-automatic system can help them to achieve high degree of defect free weld deposit overlay, with remarkably higher deposition rate to reduce overall welding time with atomising every aspect of welding parameters. • Selection of appropriate welding process (Open Arc, MIG,MAG or SAW) • Selection of appropriate welding procedure, pre and post weld heat treatment and inspection requirements • Necessity of Higher deposition rate and productivity • Quality of welding by controlling key welding parameters • Completion time in accordance with critical equipment availability.

Automated welding systems The key to success of any Welding October 2014 n OEM Update n 32

Automation system built to facilitate repair or production application will depend upon quality of the components and the suitability of the design. Working closely with the customer at the initial stages and all through the built, the designers and engineers has to develop a clear understanding of the weld deposit requirements. Then, applying a combination of machine building experience, welding experience, and the design element, to ensure the application needs are fully met. It is important to mention that in order to achieve any automation in welding one has to use suitable process such as Open arc, MIG MAG or SAW process then adapt and design the equipment to achieve accuracy in all the aspects of welding, any system designed to facilitate automation should have computerised digital controls to monitor, deposition speed, arc gap, stick out adjustment and synchronisation between various axial movement of the welding torch. Pre-programmed, efficient and user-friendly controls are preferred to understand and monitor the welding. The system should have controls with the capacity to transfer the information about

the welding through compatible software, to PC or Laptop for analysis purpose.

Key features to achieve high degree of automation and time saving The availability of advanced features in these systems ensures the execution of critical welding perimeters in order to achieve the precise purpose of deposited alloys (wear protection or corrosion protection) by limiting the dilution and weld defect etc. Each underlined feature will contribute substantially to achieve quality weld (joint or overlay). The system parameter should be changeable during machine operation to give a constant weld deposit for complex work pieces such as cones and spirals. The system should have facility to display of the weld metal deposit rate. • Automatic adjustment of pre-set welding parameter and machine axis for ease of operation • Digital Pendant control to provide precise repeatable parameter settings, controlling each axis with aid of master module • Splash proof panel and keys. Flux

Technology Key Applications: That can be automated (Specifically in core sector where productivity is crucial) Industry Sector

Application

Key Intended benefits

Available solution

Key installations in India

Steel

CCS Roll Back up Rolls Mill Rolls

Hi deposition rate Advance N2 bearing alloys To reduce machine down time.

WA R-3000 WA R-6000 WA SCM

Bokaro steel Plant Corus Arcilor Mittal Steel

Cement

Vertical Mills (Raw and Cement) For Lime stone, Slag and Clinker

Hi Deposition rate 10 -12 kg per hr per welding head Welding on Hi chrome and Ni hard Forged rolls

WA –Portable Mill Kit With 4 welding head synchronized with each other to achieve simultaneous welding Up to 360 kg in 24 hr

Holcim ( ACCAmbuja) Lafarge Ultatech Grasim Chattinad Cement Madras cement Jindal

Cement

Roller press Rolls Bowl Mill Liners

Hi deposition rate Deposition of Ti-o2 alloy, On site profiling Rebuilding and Profiling

WA –Automatic gauging, Build up and profiling

Polysius KHD FL Smidth

Power

Coal Mill Grinding Rolls. of Vertical coal mills, Boll and Race Mills Boiler Penal Cladding

Hi deposition, Economical Efficient Accuracy and Efficiency Erosion protection

WA portable Mill kits, In house work station Boiler Penal Cladding machine

Alstom, Power corporation Japan,

Mineral processing

Conveyer Screw flights hard facing

Automation for complex geometry

WA Screw flight machine

Valve Cladding

Seat ring Base plate cladding

Corrosion protection Cladding on complex geometry Internal cladding

Valve cladding machine

Nicco Audco

Fabrication

Root pass And Filling Joining welding

Hi productivity x-Ray quality joint

WA customizable specifically designed m/c

Bouchmaster Austrlia CCC

Sugar Industry

Sugar Mill Roll Arcing

Gripping

Zukar

RB Resellers

Bodies of Armoured Vehicle Fabrication

• •

•

Zucar Machine

handling system options’ for submerged arc Motorised control of gun angle position to reach intricate corners Automatic stick-out adjuster to maintain constant set height of welding gun above the work piece in order to maintain consistent and required arc gap Programmer: PC uploads or downloads for analysis of weld programmed in spreadsheet format Able to store and retrieve the programmers whilst brings all weld parameter together Allow operator to sequence each weld step into an automatic programme

October 2014 n OEM Update n 34

•

Welding alloys Multisurfacer Screwflight Machine

Data logger records job details of weld parameter for easy traceability and to enhance quality assurance process with its download-to-printable format.

Laser profile scanner ideal but not essential for: • Complex surface scanned with accuracy • Automatic calculation of welded material required • Light-weight, battery operated design with LCD display • Pivoting capability up to 120 degree.

Conclusions •

Higher productivity possible due to automation

Scanning, cladding & machining Machine

•

• •

•

The constrains and challenges of maintenance manager for repair of critical application can be mat Technology available to manipulate, manoeuvre and monitor welding perimeters Tried and tested solution standardised by OEMs of large equipment suppliers of Steel and cement New advancement in valve cladding, internal pipe cladding Continuous development happening specially in Automotive sector for automation production lines Root pass, filling for joining welding for thick sections and large structures has great future possibilities. n

Brand Report

Orbital welding for pipes and tubes Orbital welding is a specialised area of welding whereby the arc travels circumferentially around the static work piece, in a continuous process without interruption Traditional welding of pipes and tubes One of the oldest methods of doing welding in piping and tubing is manual metal arc welding and manual TIG welding; in the latter the operator welds the job by holding the torch in one hand and filler material in another. Though manual welding is one of the preferred ways of doing welding it has limitations like: • Weld quality throughout all joints is not consistently same • No control on joint to joint penetration and HAZ uniformity • Inconsistent torch travel speed and filler wire feed speed • Difficulties in all position welding – high skill of welder required • No uniformity in weld bead formation in case of grooved pipe welding • No oscillation and side wall fusion control over multiple joints • Low arc on time and frequent stoppages and starts.

Orbital welding is a specialised area of welding whereby the arc travels circumferentially around the static work piece, in a continuous process without interruption. In this mechanism the arc generated from the tungsten electrode rotates along the circumference of tube or pipe. The tungsten electrode is fixed on the rotor which is rotated by servo motor mechanism. This servo motor has a feedback encoder which detects the exact location of the electrode and controls the travel motion. These orbital welding power sources are either microprocessor or computer based programmable pulse TIG DC welding machines.

•

Advantages of using orbital welding •

Orbital TIG welding concept To overcome these limitations the concept of orbital welding system was introduced and is now becoming increasingly popular in India as well.

•

Programmable power source. The power sources are programmable. They can store many programs for weld schedules with multiple levels. The print out of weld programs can be taken any number of times for ease of traceability. The display boards of power source are user friendly with simple Graphical User interface (GUI). Better penetration and less HAZ. Being pulsed TIG welding machines the

•

heat input is controlled over a period of defined pulse width with the help of primary and background current settings. This fulfils the basic objectives of better penetration yet lower HAZ. Better quality and repeatability. The quality of first weld and last weld after several years will be identical with the proper weld schedule. Reduced skill levels risk. All the skills of certified welders are taken care by these welding machines. It is designed to take care of all safety aspects. Improvement in productivity. Due to repeatability consistency, and higher travel speeds, the productivity of automated orbital applications is significantly higher than manual welding productivity. Consistent torch travel speed and wire feed over the weld cycle. (a) Servo motors with encoder feedback mechanism for travel and wire for uniform weld bead formation. (b) Automatic arc voltage control (AVC) for avoiding arc extinguish and stub out problems. All position welding possible including 5G and 6G.

(Courtesy: Welding Technologies India)

Orbital welding power source: Orbitron 5000

niversal Welding Systems offers the indigenous orbital welding power source for tube-to-tube sheet welding.

Why orbital welding? • Productivity: An orbital welding system will drastically outperform manual welders, many times paying for the cost of the orbital equipment in a single job. • Quality: The quality of a weld created by an orbital welding system with the correct weld program will be superior to that of manual welding. In applications such as October 2014 n OEM Update n 36

semiconductor or pharmaceutical tube welding, orbital welding is the only way to reach the weld quality requirements. • Consistency: Once a weld program has been established an orbital welding system can repeatedly perform the same weld hundreds of times, eliminating the normal variability, inconsistencies, errors and defects of manual welding. • Skill level: Certified welders are increasingly hard to find. With orbital welding equipment no one needs a certified-welding operator. All it takes is a skilled mechanic with some weld training. There are other reasons too for the use of orbital equipment over manual welding. For example, inspection of the internal weld is not practical for each weld created.

Features • Compact design • New touch screen HMI • Segment wise programming with positional reference • In-built weld data logger with USB port either pen drive or printer can be connected • Password protected preset tables for different • Sizes of tubes, can be modified afterwards simple, user-friendly rugged and noiseproof design can run on generators • Specially tuned pulsed GTAW power source for orbital welding • Highly stable currents suitable for orbital welding • Auto tacking facility • Built-in water cooling for tong cooling. n

www.zeroseven.de

How can weld seams bolster your growth curves? Through intelligent automation. Perfected quality. Maximized productivity.

KUKA robots have perfected arc welding and contribute to the success of leading automotive brands and the components indus-try. Quality made in Germany: Our passion is finding innovative solutions to make even the most complex automation tasks simple. Use our edge to drive your success.

Discover the world of KUKA arc welding: www.kuka-robotics.com/arcwelding

KUKA Robotics India Pvt. Ltd., Office Number-7, German Centre, Level 12, Building No. - 9B, DLF Cyber City Phase III, Gurgaon - 122002, Haryana, India Tel.: +91 124 4635774- 776 ID-info@kuka.in, www.kuka.in

Technology

Sandvikâ&#x20AC;&#x2122;s new super-duplex strip electrodes cut welding costs Super duplex welding material offers technically favourable performance, especially in corrosive and erosive environments. With the introduction of a new super-duplex strip electrode, Sandvik offers the extra advantage of quick and cost-efficient surface welding.

andvik super-duplex stainless steel (SDSS) welding materials provide unique features compared to austenitic stainless steels and nickel base materials. SDSS exhibits excellent stress corrosion cracking resistance, provides higher mechanical strength and has very good chloride corrosion resistance. Other features of SDSS are good weldability and excellent resistance to erosion corrosion and to corrosion fatigue. The high corrosion resistance of SDSS makes it suitable for use in aggressive environments such as chlorinated seawater and acidic, chloride-containing media up to temperatures of 300 C (572 F). Typical applications are found in the oil and gas industry, desalination plants and other seawater applications, desulphurisation units and chloride-containing bleaching environments in the pulp and paper industry and chemical industry.

SDSS particularly suitable for corrosion resistant overlays deposited by welding. The low nickel content provides a more stable price level. The SDSS welding grades have so far only been available as wire (ER2594) and covered electrodes (E2594). Until now, SDSS wire has not been a productive alternative to austenitic stainless steels and nickel base alloys that are available as strip for deposition by submerged-arc welding (SAW) or electro-slag welding (ESW). The introduction of Sandvik 25.10.4.L strip makes SDSS radically better as an alternative for increased productivity.

Excellent weld strength Advanced testing of Sandvik 25.10.4. Loverlays deposited with ESW showed excellent results in terms of mechanical strength.

Lower welding costs SandvikSDSS is a cost-effective alternative to nickel base materials. The high erosion resistance, good weldability and a thermalexpansion coefficient similar to carbon- and low-alloyed steels make October 2014 n OEM Update n 38

Weld deposits displayed a critical-pitting temperature (CPT) of 45 C (113 F) and a PRE-value of â&#x2030;Ľ41and were essentially free of secondary-phases. The weld metal chemistry was within EQ2594

Technology Performs well in aggressive environments Sandvik 25.10.4.L is especially useful in applications where equipment is exposed to aggressive environments such as warm chlorinated seawater and acidic, chloride-containing media in temperatures up to 300 C (572 F). Hydrochloric acid, formic acid, acetic acid, caustic soda and sulphuric acid are other media where SDSS welding material has proven to be a favourable choice.

A manufacturer with control Sandvik offers a complete program of products for welding austenitic stainless steels, duplex stainless steels and nickel alloys. For most standard grades there are variants with both normal and high silicon content to suit different welding methods. Sandvik controls the entire steel making process â&#x20AC;&#x201C; from melt to finished product. This is why all Sandvik welding products are characterised by chemical composition within close tolerances and consistency between heats and batches, contributing to trouble-free welding and high-quality welding joints. n Contact:

composition and the ferrite content of ~30 per cent was measured according to ASTM E562 (50-60 per cent according to WRC-92). Mechanically, side-bend testing was approved. The impact strength was ~125 J at -46 C (-50.8 F) and tensile strength reached 830 MPa at 30 per cent elongation.

Mitul Shah Technical Marketing Manager- Welding Wire and Heating Technology Sandvik Materials Technology (India) Mobile: +91-9327002683 Email: mitul.shah@sandvik.com

Brand Report

FAPL assures ‘Fair Deal’ in welding equipment marketing The company has its own dedicated display, demonstration and technical training centre to conduct actual welding job trials and impart on the job training to clients on usage and maintenance of the welding equipment. It has service team to extend pre and after-sales service support to the users. FAPL has a large customer-base in automotive segment i.e. 2-wheelers, 4-wheelers, light commercial vehicles, heavy commercial vehicles manufacturers, construction and material handling equipment manufacturers. Most of the passenger and commercial vehicle manufacturers and their vendors have standardised Panasonic Welding Machines and Arc Welding Robot Systems for their excellent welding quality, increased productivity and ease of operation. Shipbuilding industry on Western Coast is the largest user segment of Panasonic Welding Equipment.

airdeal Agencies Pvt. Ltd. (FAPL), a trading house for industrial products marketing, deals with welding equipment, accessories and consumables. The company’s registered office is located in Mumbai whereas it’s corporate and head office is based in Ludhiana, Punjab. It has additional business centres at Taloja (Maharashtra), Ahmedabad (Gujarat) and Ludhiana (Punjab). FAPL’s present sales revenue is approximately Rs 50 crores and plans to double in three years. FAPL is a board-managed private limited company headed by Managing Director Girdhar Goyal and supported by visionary Joint Managing Director Madan Goyal and Directors Ishan Goyal and Vaibhav Goyal. FAPL is the authorised distributor for Panasonic Welding Equipment and Arc Welding Robot System. Panasonic stands for world-class quality welding equipment of high reliability. These are the products of latest design and technology with RoHS compliance. Panasonic Welding System Co. Ltd. offers total solutions in equipment, techniques and software to its customers through its distributor FAPL. Besides Panasonic Welding Equipment, FAPL deals in world-class products of international brands viz. Kaiyuan Autowelding System, ATTC-USA, Select-Arc France, Bosch-Germany and Coated and Bonded Abrasives of Norton. FAPL is now embarked upon expansion mode of marketing of additional products viz Kobelco Welding Consumables and special chemical sprays of Siliconi Italy. It is also planning to set up its manufacturing units for auto and bicycle components. FAPL has excellent market reach through its technically qualified and well-trained marketing team and wide spread dealers network at key consumption centres. To enhance users’ awareness, FAPL conducts spot demonstrations, seminars and participate in industrial products promotional events.

October 2014 n OEM Update n 40

On the other hand, bicycle industry is upgrading their manufacturing processes and adopting robotic and auto welding systems. FAPL is extensively supporting bicycle industry to implement this change over. Besides, FAPL has range of industrial products to cater to growing demand of power plants, petrochemical projects, refineries, railways, defence sector, structural fabrication, scaffolding and forming industry and small and medium industrial units. n

Brand Report

FIBROTOR: NNG launches new electromechanical navigation technology universal rotary tables

n a widespread country like India, the sheer number of roads and names of the same make navigating extremely tough.

n extremely long life time and shortest cycle time with an excellent precision and no need for maintenance - these are important aspects to any production line. FIBROTOR rotary tables combine all of them and offer as an additional highlight up to five years warranty.

New generation with 20 per cent energy savings Thanks to its completely new developed control cam, energy consumption drops by 20 per cent. Alternatively, higher mass can be moved, shorter indexing time can be realised or a smaller rotary table can be used. This effect is possible due to an optimisation of the control cam according to the energy efficiency-formula. In the process, the service life of the rotary tables amounts to 20,000 hours MTTF (Mean Time To Failure). Indeed, FIBROTOR rotary tables may be used as assembly tables; welding, positioning or storing tables; in packaging, printing, labelling or laser machines, as well as for chipping. n

The need of the hour for OEM’s in India was a single technology that raises the navigation software to a new level of usability, easy connectivity and feasibility. NNG realised this gap in the market and to address it, developed their groundbreaking new technology ‘iGO primo nextgen’, localising it to India. Designed specifically to cater automotive needs, using NNG’s nearly 10 years of industry experience and projects for over 30 car manufacturers, iGO primo nextgen features an adaptive HMI allowing easy customisation for different hardware, screen size and resolution, while also being platform-independent. Its easy adaptability is what makes it the perfect model for OEM’s as it saves time and resources while adjusting the same, thus providing affordable navigation solution to the automotive industry. Flexibility is also present in data entry modes, as iGO primo nextgen supports multimodal data entry, including touch screen, rotary controller, and voice control, as well as a combination of these technologies. n

Welding solutions from the Industry Leader A comprehensive range of welding products with on job support. The benefits of advanced technology, expert application assistance, robotised solutions, and gas manifolding system for uninterrupted stable gas requirements with total safety. For 5 decades you have come to expect nothing less than this from the welding products business of L & T.

Brand Report

Klinweld welding wires E

stablished in 1976, Klinweld offers best quality welding wires that are specially made for welding in all positions, in all Indian make and imported MIG/MAG/SAW welding machines with clean spatter less finish and deep penetration – continuous inline welding.

Applications • Automobile body, chassis, frames and brackets • Automobile silencers, petrol/diesel/gas tanks of all automobile, scooter, cycle spare parts and accessories • SAW Pipes, LPG Gas Cylinders, compressors, railway wagons, boilers, poles and steel towers • Steel furniture, scaffoldings and all other welding in general steel fabrication.

Quality 100 per cent fully guaranteed with test certificate and guarantee certificate and thoroughly checked before dispatch as per strict DNV ISO: 9001-2000 norms. All wires are electrolytic copper coated.

Production Total production capacity above 6,000 tons per annum. The company has dealers allover India and abroad to support the sales.

• • • • •

BHEL, Trichy L&T Ltd, Pithampur Mungi Brothers, Nasik, Pune ABB Ltd., Baroda Swaraj Mazda Ltd., Roper (Punjab)

Approvals Its welding wires are fully approved and being regularly used by many reputed companies such as: • Tata Motors Ltd., Pune • Hyundai Motors India Ltd., Chennai • Mahindai & Mahindra Ltd., Nasik • Suzlon Energy Ltd. Baroda, Gandhidham

Contact: Klinweld Wires Pvt. Ltd. Bandish Dodia (Sales and Marketing) 207, Timmy Arcade, Makwana Road, Marol, Andheri (E), Mumbai-400059 Cell: 9820134152, Tel: +91-22-28507504 klinweld@gmail.com, www.klinweld.com

EASEWELD: welding with ease

MMA

SAW

ASEWELD has started its journey in 1987 by setting up design, production and quality management facilities in Mumbai. With an experience of over threedecadesinweldingandcuttingtechnology,thepromotershavegreatly helped EASEWELD to establish itself in the Indian welding and cutting equipment market. Its technologically sound manufacturing unit features all requisite facilities to develop products in compliance with clients’ specific requirements. There is an integrated R&D to achieve design excellence throughout its product range. The latest arrival is complete range of IGBT inverter MMA/TIG/MIG/ SAW welders and plasma cutters.

EASEWELD products • • • • • • • • • • • • • • • •

ARC welding rectifiers AC DC pulse TIG welding set MIG welding machine Submerged ARC welding machine Plasma cutting machine Pug cutting machine Profile cutting machine Hydraulic pre-pinching machine Column and boom Rotators Electric winches Plate rolling machine Electrode/flux oven Welding cable Electrode Holder Cable couplers and SPMs.

EASEWELD exports its products to countries in Africa, Middle East and South-East Asia. The company is hoping to capitalise on the technology shift in terms of automatic and semi-automatic welding which sets to replace manual welding.

Application Automotive, chemical plants, construction, food processing and pharmaceutical industry, gas processing plants, metal fabrication workshops, oil refineries, power plants, steel plants, shipbuilding and offshore. n Contact: Easeweld Equipments India Pvt. Ltd. (An ISO 9001:2008 Certified Company) Tele: +91-22-2852 0692 E-mail: easeweld@gmail.com Website: www.easeweld.com

Brand Report

SigmaWeld: saving energy, increasing productivity Today more and more states are looking for ways and means to increase their energy availability by saving energy regulates the DC to give excellent welding characteristics along with an efficiency of over 85 per cent. Performance tests by independent consultants consistently confirm that replacing an old power source with an energy-efficient inverter provides a proven return on investment.

Quality of power: power factor Efficiency is only part of the savings equation. Equipment’s power factor also affects one’s energy usage. Power factor is defined as the ratio of real (working) power to apparent (total) power. In a purely resistive circuit, voltage and current waveforms are in phase, and the ratio of real power to apparent power is near to, or equal to one. In circuits with inductors and capacitors, the amp and voltage waveforms are out of phase, and not all of the power is available to do useful work; some of it is returned to the source. Although the power company charges for the apparent power, people are only receiving the benefits of the real power.

f India’s per capita (presently 40 kg) steel consumption is at par with Japan (944 kg), China (400 kg) or USA (330 kg), India would consume nearly 4,500 MW (3 per cent of Indian grid) from national grid for arcwelding process.

rates, decrease training time, and reduce weld defects and rework time. The inverterbased power sources can payback their costs within a year or so based on utility only by virtue of saving through energy and reduced rework.

“Chalta hai, chalne do” is a common practice. Unfortunately, it can lead anyone losing his or her money today. The good old rugged welding transformers and rectifiers may have stood the test of time. However, with the rising energy costs, these equipment can be termed as energy guzzlers when compared to today’s inverter-based welding equipment and the advantages it offers.

Why does the inverter consume less power than traditional equipment?

Inverter-based power sources provide many benefits that can help increase deposition

However, the welding inverter technology converts the incoming AC to DC and then

October 2014 n OEM Update n 46

Traditional welding equipment were based on transformer/rectifier technology which reduces the incoming AC voltage to weldable voltage levels via a transformer. This cannot operate at more than 65 to 70 per cent efficiency. Also, the efficiency varies across different current levels.

A high (close to unity) power factor will not only decrease energy usage, but increase you system capacity. Today’s leading inverters, such as SigmaWeld Welding power sources, offer power factors of 0.95.

Brand Report Today state electricity boards have bonus clauses for power factors of over 0.92 and penalties for poor power factors (typically below 0.9)

More for less For standard arc-welding process, the following equipment and connected loads are mentioned below:

to be scrapped costing time and money, which could better be spent elsewhere. Inverters, on the other hand, are much better suited to managing primary power fluctuations and better suited to handling a variety of power input. SigmaWeld welding inverters can keep welding output constant even if input power varies by +/- 15 per cent. This helps ensure that

Type of equipment

Transformer 400 amps

Rectifier 400 amps

SigmaWeld inverter 400 amps

KVA rating

27 KVA

18 KVA

13 KVA

Weight/machine

115 Kg

122 Kg

35 Kg

So in the same facility where 20 Welding transformers or rectifiers are being used, more than 40 welding inverters can be safely installed without changing the incoming load wiring or applying for additional connected load (power). This helps grow faster at lower costs. When working on project sites mobility of equipment does not require additional facilities like hydra, cranes etc., welding inverters can be easily portable from one location to another. Also on the same genset, more number of welding inverters can be used as compared to transformers or rectifiers.

Consistent performance fluctuations

under

power

Traditional power sources are tied directly to the input power, which means that a spike or dip in the power supply (such as when a large motor starts) can directly affect weld quality. This can lead to costly weld defects, which may need to be reworked, or cause the part

weld output remains consistent, improving weld quality.

Better quality SigmaWeld inverters also provide other advantages. Welders enjoy welding with them. The consistent arc starts, smooth and stable arc and improved puddle control make welding easier and often lead to better bead quality. With micro controlled-based systems, it is easily possible to incorporate better control features which help reduce dependency on skilled manpower. This allows the operator to concentrate on welding technique. With a welder shortage that is only expected to grow in coming years, features such as anti-stick and in-built hot start have shown to make it easier to train non-welders to produce quality welds.

Energy audits at works SigmaWeld has conducted energy audits at various plants across India. It is found that an average of 30-60 per cent energy savings

is possible by converting to SigmaWeld welding inverters from traditional thyristors or transformers. As per the trials, it was shown that if the arcing time per day is assumed at 10 hours and 2 hours of idle time, SigmaWeld welding inverters save almost 35 units of energy per machine per day. This results in an average of 300 (working days) x 35 (units saved) = 10,500 units of energy annually. At the current energy cost per unit, this can save up to Rs 73,500 per machine per year. These trials were conducted vis-a-vis the traditional machines at their works. Similar trials done with SigmaWeld SAW 1,000 Amps welding inverter the customer has saved close to Rs 5,00,000 annually, thanks to their continual production needs. SigmaWeld can also arrange for demonstration and energy audits at clientsâ&#x20AC;&#x2122; works. SigmaWeld welding inverters operate so efficiently that they easily create payback within 1-3 years. They produce high-quality weld beads consistently, reduce rework and are light enough to move around with great ease. Electronics Devices Worldwide Pvt. Ltd. is a leading manufacturer of inverter-based machinery since 1974. The company is a brand leader in induction cap sealing, induction heating machines, die-electric preheaters, SigmaWeld welding inverters for arc, TIG, MIG, saw and welding automation solutions. SigmaWeld welding inverters are 100 per cent indigenously designed, developed and manufactured by its own R&D team. Even PCBs are developed, designed and manufactured in-house. This ensures that SigmaWeld is able to provide prompt aftersales service as well as immediate supply of spares including PCBs. In fact, SigmaWeld is able to provide customisation. Continuing with the energy-saving power sources, SigmaWeld is happy to launch its SigmaTherm induction heater for welding preheating and post weld heat treatment with specially designed PLC interface for P91, P22 and other materials. It comes complete with temperature programming, temperature logging and audio/visual alarms. n Authored byâ&#x20AC;&#x201D; Nimesh Chinoy, Marketing Director, SigmaWeld

47 n OEM Update n October 2014

Technology

Ultrafast Automation

reACTION Technology reduces response times in industrial automation applications down to 1 µs. B&R has designed this new ultrafast control technology using standard hardware that can be programmed in accordance with IEC 61131 standards. The result is an immense increase in performance without the downside of additional costs

n many applications, control speed has a direct impact on product quality. “When forming PET bottles, for example, pressure must be controlled very precisely,” explains Anton Meindl, Manager of B&R’s Controls business unit. “The greater the control precision, the thinner you can make the wall of the bottle.” Other examples include the highprecision speed and position control required in injection molding applications. The printing industry is another area where high-speed control functions are essential. “When paper is fed into a machine, the edge needs to be detected at a very fast speed,” says Mr Meindl. The list of applications that could potentially benefit from ultrafast response times is virtually endless.

Advantages • Response time of 1 µs • Massive reduction of PLC load • IEC 61131 programming October 2014 n OEM Update n 48

• Centralised program management • Integrated parameter management. Conventional I/O technology operates with a minimum response time of around 1 ms. “A millisecond is no longer fast enough for some applications,” notes Mr Meindl. “In filling stations for bottled beverages, the control technology needs to process the signal from the fill level sensor faster in order to achieve optimal results.” Response times in a conventional solution are influenced by a number of factors such as network performance, or the number of nodes on the network, as well as network traffic and controller performance. With conventional signal processing, the input driver in an I/O module reads the input signal and converts it into a logic signal. This signal is then sent over the network to the central PLC. The PLC processes the signal and sends it back to the module. The output driver once again converts it and sends it to

where it is needed. With this approach, there is no way to achieve response times much below the millisecond range.

CPU

I/O

reACTION Technology always offers the same ultrafast performance. With signal processing directly in the I/O module, the response time is not influenced by the performance of the network or central controller

Technology 1 µs response time “When we developed reACTION Technology, our goal was to accelerate signal processing by integrating as much of it as possible directly into the I/O modules themselves,” says Mr Meindl. “At the same time, we wanted to do so without sacrificing the benefits of centralised software management.” This new B&R solution cuts the delay between the time the input signal is received and the time the control signal is sent down to 1 µs. The technology itself is based on I/O modules with integrated FPGA chips. “We used FPGA chips because of their ability to process signals quickly in parallel,” explains Mr Meindl. With around 10 connected function blocks, the processing time in the FPGA is around 0.8 µs.

“Using the same easy approach to software development that B&R customers are accustomed to, reACTION Technology opens up a whole new dimension of speed,” says Mr Meindl. In the interest of making applications as universal as possible, function blocks can be loaded to the modules at any time for local execution.

Flexibly faster with reACTION Technology reACTION Technology integrates signal processing directly in the module, taking the system bus and central controller out of the response time equation. “reACTION Technology always offers the same ultrafast performance,” says Mr Meindl. Other solutions on the market either don’t offer the same speed or impose unnecessary restrictions on the machine builder with regard to flexibility and programming.

FPGAs programmed quickly and easily One challenge B&R’s developers faced was the difficulty typically associated with programming FPGAs. “We found a very good solution to this problem,” says Mr Meindl. Machine builders can now manage and program FPGAs in the familiar Automation Studio development environment. They do so by developing programs and parameters in the form of IEC 61131 function blocks; communication between I/O and CPU tasks is handled conventionally through the exchange of process variables. Logical operators like AND, OR, XOR and NOT can be used, as can arithmetic operators such as ADD, SUB, MUL and DIV as well as flip-flops, PWM, comparator functions and counters. The connections created with function blocks can be tested just like regular control code. Simulation is possible by executing the modules on the controller. If everything works as planned, the software function is then assigned to the respective hardware component in the Automation Studio hardware configuration.

FPGAs are programmed using the function block editor in B&R’s Automation Studio engineering platform using corresponding reACTION libraries

“Distributed automation systems using reACTION Technology are advancing into a whole new dimension of high-speed control” Anton Meindl, Manager of B&R’s Controls business unit

With signal processing using reACTION Technology, the input driver samples the input signal with a resolution of 20 ns and converts it to a logic signal. The FPGA then processes the signal with a cycle time of up to 1 µs. The result is sent back to the I/O module’s output driver. The module converts it and generates a physical signal. In other words, the FPGA assumes responsibility for certain control functions and reduces the load on the PLC. “Since reACTION Technology takes on a significant portion of the processing load, a smaller PLC can be used,” says Mr Meindl. This means that machine builders can achieve microsecond control responses using a controller that operates in the millisecond range. “The user now decides the size of processor to be used based on the average load of the application rather than the peak speeds required by a few specific functions,” adds Mr Meindl.

Ultrafast modules, ultrafast control reACTION Technology is available on both X20 and X67 I/O modules, as well as on the new X20 compact controllers. Three

B&R offers reACTION Technology for the I/O modules in both its X20 and X67 series (photo), as well as the compact controllers in the X20 system

modules with different I/O configurations are available, including two X20 modules (X20RT8001 and X20RT8201) and one X 67 modules (X67BC81RT). IP20-rated X20 modules each have four digital inputs with variable input filters and another four configurable digital I/O points with a physical conversion time under 2 µs. The X20RT8201 module has two additional analog inputs (+/-10 V) with 12bit resolution and a 5 µs conversion time. The X67 module features IP67 protection and offers two 24 VDC digital inputs, three 5 VDC inputs and four configurable I/O points. In addition to the two analog inputs, an analog output (+/-10 V) with 12-bit resolution has also been integrated. B&R offers reACTION Technology on two compact controller models, the X20CP1381-RT and X20CP1382-RT. These compact controllers are available with 200 MHz or 400 MHz processors. Depending on the variant, up to 256 MB RAM and 16 kB nonvolatile RAM is available. A built-in flash drive is available to store up to 4 GB of application and data storage. The controllers come equipped with Ethernet, USB and RS232 interfaces. In both performance classes, integrated POWERLINK and CAN interfaces are also available. n Contact: B&R Industrial Automation Pvt. Ltd. 8, Tara Heights, Mumbai - Pune Road, Wakadewadi, Pune - 411003. Tele: +91-20 41478999 Fax: +91-20 41478998 Email: sales.in@br-automation.com www.br-automation.com 49 n OEM Update n October 2014

Speak Out

Unlocking the potential of automation “Bosch Rexroth is establishing itself as a supplier of first choice by providing comprehensive automation solutions, which can add value to customers’ expectations,” comments Dr. Johannes Grobe, Managing Director, Bosch Rexroth India

osch Rexroth India Ltd., a specialist in drive and control technology, supplies tailored solutions for driving, controlling and moving. In an interview with OEM Update, Dr. Johannes Grobe talks about the industry status, their position, key solutions they offer, and major achievements.

Industry status After a period of stagnation and fluctuation in the market we see now a recovery and increasing prospects in the industry and the market fluctuations have shifted the trends in market. Customers are increasingly looking for one single source that can cater their needs by supplying all drive and control technologies and offer automation solutions. Although cost plays an important role, quality, machine safety and energy efficiency coupled with productivity started dominating when a customer specifically goes for a solution. It is also much easier for a customer to ask for a comprehensive solution from a single source who can supply the whole range of drive and control technologies. This trend will persist and open new dimensions in automation segment.

OEMs understand the need In India, automation is growing in proportion to general market growth. The expansion of the product portfolio in the last few years has opened many new opportunities especially in mid-sized automation. In the past, customers were looking mainly on cost of investment and simple automation. Now, due to the strong demands from the October 2014 n OEM Update n 50

machine users, the OEMs understand the need for it. These demands request new solutions clearly driving the market to new investments.

Strength & Strategy Established in 1974, Bosch Rexroth in India as a part of Bosch Rexroth AG, is one of the leading specialists in the field of drive and control technologies, serve customers through manufacturing facility and technology centres at Ahmedabad and Bangalore with wide spread sales and service offices, dealers’ network spread all over India. It develops, produces and distributes its components and systems in the technology field of hydraulics, electric drives and controls, linear motion and assembly technology. These products are used in all major industries such as plastics, steel, (bulk) materials handling, railway, construction machinery, agricultural and farm machineries, cutting machine tools and presses, automotive, food and packaging, textile, etc. Machinery manufacturers and users require more engineering efficiency for a faster time to market and future-proof automation solutions in order to protect their investments. At the same time, they are looking for possibilities to customise their machines economically with new automation ideas for machine processes and functionalities to meet the needs of individual customers. This is how they can set themselves apart from the competition. As a result, the wish for more flexibility

to implement these customised concepts rounds out the list of new requirements. Rexroth meets these requirements with Open Core Engineering. Open Core Engineering represents Rexroth’s comprehensive package of solutions that increase engineering efficiency along the entire value stream for all drive and control technologies. Users benefit from accelerated engineering at lower cost and increased future readiness based on open industry standards. Thus, Bosch Rexroth is establishing itself as a supplier of first choice by providing comprehensive automation solutions, which can add value to customers’ expectations.

Major achievements Drive and control solutions from single source will always have an advantage by utilising synergies between technologies thereby achieving efficiency. A machine manufacturer will always look for energy efficiency and machine safety. This will ensure quality with productivity and reduces cost burden. Bosch Rexroth as a drive and control solution provider offer such concepts e.g. Rexroth 4EE (energy system design, efficient components, energy recovery, energy on demand) thus optimising energy efficiency in all phases of machine life-cycle. Take components from Rexroth range like axial piston motors which have got low coefficient of friction or servo motors which are highly efficient these will ensure peak performance. Moreover, energy efficient solutions from Rexroth ensures machines and plants run smoothly, Contd. to 52

Pneumatic Systems

Parallel Grippers

Angular Grippers

Three Point Chuck

Rotary Actuators

Grippers :  Various sizes available   Hard anodised aluminium body  Magnetic version as standard Internal or External gripping possible Rotary actuators : Key slot type and Flange type versions Sizes available Ø16, 20, 25, 32mm Choice of 90° or 180° rotation options Angle of rotation adjustable by 45° Magnetic sensing as standard

Range of products

Corporate Office : E-25, SIDCO Industrial Estate, Kurichi, Coimbatore - 641 021, INDIA. Tel : +91 422 2672800 Fax : +91 422 2672304 E-mail : janatics@md2.vsnl.net.in Web : www.janatics.com

Speak Out

Low-cost automation: a sticking trend “The concept of low-cost automation is quite refined now and the users of automation are also well versed with the functions and features offered by world-class automation products,” says Milind Kulkarni, Head - Business Development, Factory Automation – Siemens

he concept of low-cost automation for competitive manufacturing is gaining significance. Siemens has been offering Micro PLCs and Nano PLCs to cater to such lowcost automation products and solutions for the past few years. Milind Kulkarni discusses the advantages of low-cost automation and his company’s contribution in this spectrum.

How do you look at the concept of low-cost automation? Many SMEs and machine manufacturers today have understood the benefits of automation. However, each one is looking forward for state-of-the-art automation at affordable price. The concept of low-cost automation is quite refined now and the users of automation are also well versed with the functions and features offered by world-class automation products. The price adjustment in this segment to control the investments is mainly achieved by products that are functionally comparable to global products but have no global certifications like CE and/or UL, ATEX etc.

How can industrial manufacturing sector leverage low-cost automation to help increase their efficiency? Today besides improvement in productivity,

which is a main driver for choosing automation, everyone is looking at key performance indicators (KPI) like flexibility offered by chosen automation platforms, future proof investments etc. so that the deployed automation solution doesn’t become obsolete in near future. Additionally, scalability of the automation platform selected is also gaining importance. Monitoring and improving the Overall Equipment Efficiencies (OEE) is something each one is looking for besides investment protection.

What are the activities that can be optimised using low-cost automation products? Various activities can be optimised using lowcost automation. Some of the key areas being: • Material handling on shop floor • Remote monitoring and control of pumps • Unmanned distribution points for commodity • Accurate form fill and sealing in packaging • Automatic weighing and batching and many more.

Discuss on Siemens India’s contribution in the field of low-cost automation.

Some of the applications where low-cost automation is much sought-after include: • In production machines of packaging industries for F&B and pharmaceuticals, where single axis motion control is used • Substation automation • RTU applications cutting across various industries like Solar, Water and Waste Water • Tier 2 and 3 automotive machine manufacturers • Commodity distribution • Capital goods.

For the past few years, Siemens has been offering Micro PLCs and Nano PLCs to cater to such low-cost automation products and solutions. Recently Siemens has launched SIMATIC S7-200 SMART PLC to cater to such segments that need powerful micro PLCs at affordable prices. Additionally, in order to meet the low-cost requirements of operator interface for monitoring and control (HMI - Human Machine Interface), Siemens has also launched cost-effective key panels substituting conventional switches and announciators and second generation of basic panels for higher HMI requirements. n

Rexroth uses the Open Core Interface to connect engineering, which is based on the newest IEC standards. As a bridge between two separate environments, the Open Core Interface allows the integration of various device platforms into integrated automation architectures. Open Core Engineering and the Open Core Interface technology provide the basis for a variety of new solutions and

innovations. Rexroth offers the universal competence for functional safety at all levels of automation, as well as technologies thus establishing Rexroth Safety on Board path to intelligent and economical machine safety. As a drive and control company, Bosch Rexroth offers such innovative solutions which support in getting higher efficiency and fast operations. n

Could you name some of the sectors where lowcost automation can play better role?

Contd. from

e.g. Rexroth solution ‘Sytronix’ (Smart Interplay of Hydraulics and Electronics) combines the features and multiply the advantages of both the technologies i.e. hydraulics and electric drives and controls. This lowers energy consumption (up to 70%) and reduces noise considerably. The Open Core Engineering platform by October 2014 n OEM Update n 52

Crowcon presents Detective Net for wireless gas detection

THE BEST IN INDIA CONTROL PANEL ACCESSORIES FROM GERMANY

Detective Net Gas Pipelines

rowcon’s new Detective Net wireless module allows up to 25 Detective+ gas detectors to be linked without cables. It is suitable for use in the oil, gas, petrochemical and utility industries.

Innovative Locking, Latching and Hinging Systems including Quarter turns, Swing Handles, Handles, Rubber Profiles, Rod Latch Systems, Special Fittings for Industrial and Electrical Enclosures

The Detective+ is a free-standing, transportable multigas monitor that can be used individually or in groups to monitor up to four gases at once. By using the Detective Net module, up to 25 Detective+ units can be linked wirelessly and positioned as much as 100 metres apart. Should wireless connection between two of the detectors weaken, the RICOCHET wireless network will ‘self-heal’ and automatically re-route communications via alternative devices. This creates a mesh type network, ensuring greater reliability in safetycritical situations. Over a dozen gas sensor options are available with the Detective+, including infrared sensors for flammable gas that are immune to the poisoning effects which plague standard flammable gas sensors. If a dangerous gas level is detected, the Detective+ unit warns with a wailing 104 dBA siren and flashing, high intensity LED beacons which are visible from all angles. A signal is also sent to all the other units, alerting workers to the danger. In addition Detective Net transmits other fault information such as loss of signal or low battery power. The Detective+ is indeed ideal for confined spaces, ensuring safe gas levels before workers enter and monitoring continuously during welding and other repair work. With 60 hours of battery operation, work can go on with a minimum of detector recharging, keeping shutdown time as short as possible. In commissioning new liquefied natural gas (LNG) plants, the Detective+ can be placed along the pipelines to check for leaks, minimising explosion risks. The rugged tripod construction and raised profile keeps the Detective+ sensors away from obstructions and surface water. An integral safety cage gives extra protection in the event of the unit being overturned in chaotic work areas. An operating temperature range of -20 C to +40 C assures reliable detection in a variety of environments. Optional folding legs facilitate compact storage and transportation. Contact Sandip Diwate Tele: +91 22 6708 0400. E-mail: sandip.diwate@crowcon.com / salesindia@crowcon.com; www.crowcon.com

International Fittings

I N D I A

Panel Fittings Pvt. Ltd. For more Information, write to:

DIRAK India Panel Fittings Pvt. Ltd.

Plot No. 17 (i), II Floor, I ‘C’ Main Road, II Phase, Peenya Industrial Area, Bangalore - 560 058, India. Tel.: 080-28372980, 28372981 • Fax: 080-41492674 E-mail: sales@dirak.co.in

Visit us at www.dirak.com

Speak Out

Indian market: a ‘hotspot’ for OMRON “At OMRON, India is an extremely important market and hence is a part of our ‘Asia Hotspot’ strategy,” says Sameer Gandhi, MD, OMRON Automation, India

eadquartered in Kyoto, Japan, OMRON Corporation is a diversified company operating in industrial automation, electronic components, social systems, healthcare, and environment fields. Incepted in 1993, OMRON Automation in India caters to over seven industrial applications. In an interview with OEM Update, Sameer Gandhi talks about the industry trends and OMRON’s strength.

Industry status The current industry status seems extremely positive. The customers around the world have become extremely quality conscious. India is no exception to this. They want speed, precision, flexibility and connectivity. Most of them are looking for advanced automation and integrated technologies.

Penetration of automation in Indian industry In India, penetration of automation varies depending upon the industry type and the scale of operations but still there is a lot of potential to grow. With the growing demand for quality amongst customers, we feel several industries would be shifting to completely automated lines soon.

Indian market – a ‘hotspot’ for OMRON At OMRON, India is an extremely important market and hence is a part of our “Asia Hotspot” strategy. The reasons for the same include rapid growth in automation. October 2014 n OEM Update n 54

We believe that the manufacturing sector in India is on its way to witness a boost in investments in automation, with a growing focus on quality, efficiency and productivity combined with a shortage of skilled workforce. This is creating a requirement of additional production processes in the manufacturing world such as vision inspection (to improve quality). The huge population base of 1.22 billion people is another factor leading to a significant growth of the consumption in the country further causing an increase in mass production of foods, necessities, and expansion of related industries such as automotive, food and beverage, pharmaceutical, and textile. The potential of the automotive manufacturing industry is also huge. India stands at no. 6 in the annual production of automobiles. It is around 3.38 million cars as on 2013 and is hopeful of witnessing significant acceleration in the coming years. The investment in the social infrastructure of the country is also going up and shall continue to do so in the long-run. All these factors have a cumulative effect in increasing the requirement of automation in the manufacturing sector. Hence to leverage the same OMRON has launched its Automation Centre (ATC) in India. The main objective of the ATC is to understand

the customer’s challenges areas, work with the customer to develop the concepts, address the need of the hour and provide innovative solutions.

OMRON’s key solutions OMRON Automation in India caters to over seven industrial applications encompassing the wide requirements of packaging, automotive, material handling, food and beverages, textile and panel handling applications. In recent years the company has been concentrating on the solution business which provides “One Stop” solutions, improving the overall efficiency on diverse production sites. Focusing on the themes of quality, safety and the environment, they support manufacturing innovation worldwide with their unique sensing and controlling technologies.

Major achievements For a major manufacturer of rotary packaging machines, OMRON’s automation solution helped increase the speed from 900 PMM to more than 1,200 PPM with accuracy of (+/-) 1 mm sealing. Now, OMRON is working to achieve 1,500 PPM. Similarly, for a pharmaceutical company, the company has provided a Multi-camera Inspection System for vial inspection line resulting in improved line speed. The line Speed increased from 20 bpm to 150 bpm with complete solution for identification of defects and measurements with an accuracy of (+/-) 50 microns. n

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Speak Out

Makino expects promising future for automation “Presently, the penetration of automation in Indian industry is very limited and very much linked to maturity of manufacturing industry,” says M K Suresh, General Manager – Production Machinery, Makino India Pvt. Ltd.

oday, Makino is one of the leaders in metal cutting and manufacturing technology, sale and export of machine tools, CAM systems, FMS cutter and tool grinding machines and other equipment. Makino’s major product lines include horizontal machining centres, vertical machining centres, graphite milling machines, EDM’s, wire cut EDM’s, module MMC, turnkey solution and other machine tooling along with system engineering services. Makino India serves its customers supply of quality machining centres together with tooling up (fixtures and cutting tools) so that customers can enjoy a total solution. Mr Suresh, after analysing the present situation of automation industry in India, feels that the picture could have been more promising than it is today.

Still struggling Over the past 20 years, there has been extensive application of automation technology in Indian manufacturing industry. However, due to the cyclic nature of industry’s investment pattern, barring few niche areas, automation is still considered as a luxury and does not figure as a priority area. The current picture of automation industry in India, what is being observed today, could have been better in many aspects. “The automation industry is still struggling to find a foot hold in manufacturing, or October 2014 n OEM Update n 56

engineering industry,” says Mr Suresh. “The absence of opportunities has lead to limited players and limited activities thereby depriving the enormous productivity gain the industry could have derived.”

Limited penetration Presently, the penetration of automation in Indian industry is very limited and very much linked to maturity of manufacturing industry. Since Indian industry is still predominantly in low value and labour intensive manufacturing chain, the penetration is limited to certain foundry/ forging and casting industry which are necessitated by process and safety or in few other areas which are force driven like fabrication area.

Makino in market Makino’s participation in automation is more an auxiliary add with collaborative partners for automation on its CNC machines. In the early stages of manufacturing automation, the choices were limited. However, today there are a host of domestic and international companies offering very innovative solutions and competitive options. Almost all products offered by Makino can be easily tailored to suit automation equipment and interface so that customers can adopt very easily. Makino also shares and provides partnership to both customers and third party providers so

that customers can get the benefit of automation.

Solutions offered Makino offers a host of automation solutions to customers like gantry interface, robot interface, gantry and robot interface through feed systems, pick and place systems, built in work piece throw outs, module manufacturing cells with AGV’s etc. It is also important to take into consideration that there is wide variety of customer choices based on user industry, work piece material, type, size and weights, budgets, manufacturing process etc.

Notable achievements Globally Makino has few thousand installations with automation. In fact, it has a separate group working in Japan and US which focuses only on automation solution to customers. In India, due to the nature of user industry and tighter investment budget, there are not many installations with automation. “We have most of the types of the automation solutions installed at several customers’ plants,” informs Mr Suresh. “With a variety of solutions, Makino can offer one of the best, creative and innovative engineering automation solutions which will be able to add benefit as well as tremendous engineering interest and value.” n

Speak Out

Multiple needs driving automation “Till recently people wrongly believed that automation is done only to reduce labour. However, today automation is being driven by multiple needs,” says V Jayakumar, Founder and Director, Autosys Engineering Pvt. Ltd.

utosys provides solutions in green field projects – EPC/turnkey, fully automatic and semi automatic bagging/packing plants, lorry weighbridges, PLCs, SCADA, MES software, power, MCC and control panels, recron/fibre dosing systems for concrete mixing plants etc. Mr Jayakumar explains about the need of automation and how it is being encouraged by many factors today.

Current industry status The Indian manufacturing industry is moving up the value curve. The focus is shifting from volume to value, driven by quality and consistency. Setting up or modernising automated manufacturing plants on turn-key basis is a new trend,” says Mr Jayakumar. “After working with the industry across verticals for many years, we are leading this revolution with guaranteed performance metrics on OEE, throughput, quality and accuracy.”

Multiple drivers to encourage automation “Till recently people wrongly believed that automation is done only to reduce labour. However, today automation is being driven by multiple needs,” says Mr Jayakumar and explains the same: • Lack of skilled labour and unpredictability of skilled labour supply • Labour inputs and production output should be loosely coupled with asynchronous connections enabled by automation October 2014 n OEM Update n 58

• Need to compete with world class companies in quality and consistency • The need for traceability, poke-yoke etc. • Margin and ROI pressures. The need to monitor costs, productivity, plant load factor, equipment utilisation etc. on a moment to moment basis without waiting for manual logs and reports. These drivers are encouraging manufacturers to invest in modernisation of existing plants as well as go for a better design for new projects.

Autosys approach Long ago automation meant just the electronic systems or the PLC/DCS systems. Today customers need someone who can talk their language, help them in debottlenecking, capacity maximisation, OEE improvement and quality improvement. “Over the last 2 decades, we have evolved to a position where customers expect complete end to end systems (from mechanical, material handling and electrical systems to instruments, panels, PLCs and software) from a single company on a fixed price basis,” says Mr Jayakumar. Autosys does plant automation projects on turnkey/EPC basis or Build-Operate-Transfer basis (except civil/buildings) for a wide variety of verticals such as refractories, ceramics, animal/poultry feeds, food, nutritional supplements, ferro alloys, paints etc.

Key solutions The reasons for customers to go with Autosys are considered to be fixed price contracts, good domain/process knowledge across many industries and multi-disciplinary expertise in mechanical, electrical, electronics, instruments, PLCs, software. The company offers its services in the following areas: • OEE improvement, de-bottlenecking, modernisation and automation of existing plants • Automated material handling (raw materials to finished products) • Integrated container decanting and bagging plants for bulk materials • Instrumentation and remote monitoring for water and waste-water projects (distribution as well as treatment) • Automatic weighing, batching, dosing (grams to tons, solids and liquids) • Project management and consulting services

Major achievements The founding team of Autosys has worked together as a team for over 20 years, with experience in over 400 projects. “In the last 3 years Autosys has grown at a rapid rate of over 50 per cent per year,” assures Mr Jayakumar. “Marquee customers such as Ramco, Vesivius and Roca and large EPC companies such as Vatech and L&T are re-confirming their faith in our capabilities and strengths, by giving repeat business.” n

Technology

Customised surface inspection B

efore a workpiece leaves the production plant, it is subjected to rigorous inspection: because even the most infinitesimal fracture or impact point could diminish the reliability or durability of a component. And when it comes to safety-critical applications – such as in the automotive or aerospace industries – manufacturers can only use the most impeccable parts. But aesthetic aspects also count - for example, with ceiling panels or components for the cabin of the automobile. In order to check a component, manufacturers apply image processing methods. Multiple cameras take pictures of component surfaces from various angles, which are analysed by a software program.“Every material substance has its own unique surface structure. In order to evaluate its quality, the testing procedure has to be gauged precisely to these specific

Researchers at Fraunhofer Institute have engineered a high-precision modular inspection system that can be adapted on a customer-specific basis and integrated into the production process

properties,” explains Markus Rauhut of the Fraunhofer Institute for Industrial Mathematics ITWM. Even the size and shape of a component play a role – as well as the desired resolution of the images. Even though there is an array of surface inspection systems on the market already, these are only configured for specific materials and dimensions. Standard solutions cannot cover the entire spectrum of possible testing objectives. The researchers at ITWM have closed this gap: The scientists from Kaiserslautern engineered a modular inspection system they have dubbed “MASC: Modular Algorithms for Surface InspeCtion,” which can be modified to customer-defined specifications. “Our system is suited for the most diverse materials – like metals, leather, textiles or paper – and covers a size range from tiny components for medical technology through to entire sheets of rawhide or ceiling

panels,” Rauhut adds. MASC-STeX for the inspection of cover plates and MASCDehnzelle for the inspection of expansion cells are already in practical use in the industry.

Basic version with over 300 algorithms First, the surface of the workpiece is illuminated and scanned using multiple cameras set at a wide range of angles. “This is important, so that you can also pick up impact points or fractures that are only visible from one side,” explains Rauhut. With free-formed surfaces, regions are also recorded in this manner that are covered by curvatures or corners. The more complex the geometry, the more cameras are needed, as a rule. “To keep the costs within limits, we are concentrating on areas in a practical setting in which a defect would actually have negative implications,” the researcher said. For the analysis of the images, the scientists have developed mathematical evaluation algorithms and from this, built up a comprehensive software library. “For instance, one algorithm is programmed to find edges or certain colour points in the image,” explains Kai Taeubner of ITWM. The basic version of the software alone comprises more than 300 algorithms that could also be combined, depending on the testing task. One particular challenge includes those inspection procedures that require very high resolution. No surface is quite homogenous; indeed, they feature small scratches or fluctuations in brightness. For projects where resolution reaches the microscopic level, it becomes increasingly difficult to differentiate between anomalies in the surface texture and actual defects. The consequence: components that are actually free of defects get sorted out as defective. “With the aid of our algorithms, we can refine the analysis to such a degree that incorrectly identified flaws become virtually eliminated,” Taeubner indicates. Once all testing parameters are set, the procedure is integrated into the production process with the customer. The cameras are either installed directly on the assembly line for this purpose, or applied using robots. When a defect is found, the production process automatically stops; at the same time, the machine operator is notified. The detected defects are classified and the test object is divided into quality classes. n

October 2014 n OEM Update n 59

59 n OEM Update n October 2014

Speak Out

Automation industry needs more investment “Improvement in the investment environment will stimulate investment in manufacturing not only by multinational corporations but by domestic enterprises as well,” believes Manish Walia, Vice President (Industrial Automation Business Group), Delta India Electronics Pvt. Ltd.

elta India Electronics Pvt. Ltd. is a 100 per cent subsidiary of Delta Electronics (Thailand) PLC, a group company of Delta Group. Operating in India since 1992, Delta is one of the leading providers of telecom power solutions and a major source of industrial automation, display solutions, UPS, DC fans and blowers etc, Today, it provides solutions for telecom, IT, solar, power and industrial sectors offering its 12 product lines. Mr Walia believes the current automation industry in India is going to prosper more in future.

India on positive note India’s industry sector is on a positive note. A stable government has helped in boosting the confidence of the industry and also the investors. The new government’s importance on manufacturing and export sector will help in augmenting the FDI and GDP. However, there are still many road blocks on policy front which needed to be addressed. Infrastructure is yet to be developed on international standard. India needs to improve its infrastructure by scaling up the capacity of its ports and improving the rail and road connectivity. Uninterrupted supply of high quality power, land-laws and unorganised SMEs are some other pain-areas government needs to attend on urgent basis. “Improvement in the investment environment will stimulate investment in manufacturing not only by multinational corporations but by domestic enterprises as well,” believes Mr Walia. October 2014 n OEM Update n 60

Automation sector growing fast The escalation in industrial investment has contributed to the growth of the automation market. With India’s industrial production continuing to expand at a dynamic rate, the challenge of meeting quality standards has become a priority. As the economy becomes more accessible to global market players, Indian manufacturers are realising they must modernise their production plants and processes in order to stay competitive. This applies to every facet of industrial automation. As a result there has been a dramatic increase in the demand for modern production technology and highperformance systems. Though the slowdown had affected the industry for sometime last year, but adaption of new technology for better accuracy and less wastage helped the companies to strengthen their competence. The robust investment in manufacturing industries pushed General Motion and drive Control (GMC) market growth worldwide. “India’s processing industry is growing by around 11 per cent annually resulting manufacturers in India need to spend significantly in production automation equipment and software,” observes Mr Walia. “The automation, instrumentation and control industry is one of the fastest growing industrial sectors in India today with a potential to sustain a growth rate of 10 per cent.”

Delta believes in promising future Delta’s product line focuses on three areas

of Drive, Control and Motion. Delta’s industrial technology and product offerings provide solutions for machine control and automation. “In recent times, we have started consolidating our presence in Tier-II and Tier-III cities as the companies are putting up their factories and manufacturing plants in these cities,” Mr Walia informs. On the product side, the company has developed new applications and introduced new range of HMI, servo motors, midrange PLCs and machine vision.

Solutions offered by Delta Over the years Delta industrial automation business has gained tremendous momentum with an increased market share rapidly in all three of product segments: Drive, Motion and Control. To enrich the product line, Delta continues to make more efforts on its research on the controller. Many OEM’s use its automation products for processing machines used in the food industry, textile industry, chemical industry, electronics industry, metal industry and plastic industry. Its automation equipment is also used in the pharmaceutical industry, printing industry, as well as for energy saving air-conditioning and water treatment facilities. In recent years, it has integrated its industrial automation products, developed industrial control networks, and offered integration services to its clients around the world. n

Voltas Material Handling to operate as KION India

orklift and material handling equipment manufacturer Voltas Material Handling Pvt. Ltd. has announced that it will operate under the name of “KION India Pvt. Ltd.”.

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Voltas Material Handling was launched in 2011 as a joint venture between the KION Group and Voltas Ltd. In November 2012 the KION Group – one of the world’s two leading suppliers of forklift trucks, warehouse technology and associated products – became the sole owner of the Indian manufacturer. The gross revenue of Voltas Material Handling for financial year ending 31st Mar 2014 was Rs 194 crore. With Kion taking over, the company plans to expand its reach to a wider consumer base and spread it wings to different geographies in the country. “KION in India has well spread sales and service network comprising more than 70 customer touch points and has combined market share of around 30 per cent. Voltas brand on standalone basis is holding no. 1 position in diesel forklift product segment commanding 53 per cent market share among Indian manufacturers,” the company said. “India is one of the fastest growing economies anywhere in the world and holds enormous potential, particularly in the manufacturing sector. We are confident that we will be able to market ourselves even more effectively under the new name and that it reflects our plans for future growth and innovation,” said C.P. Quek, Chief Asia Pacific Officer and Member of Executive Board, KION Group AG. KION India, part of KION Group AG, will continue to operate the Voltas Brand and Baoli Brand of Material Handling Equipment in SAARC Regions as earlier. It will also continue its manufacturing operations from its current production plant and corporate office in Pune. “The name change is symbolic of being part of the international KION family. While our company name is changing, all the core elements will still remain the same. We will still progress in our path to continually innovate and improve our products and services and to understand and meet the aspirations of our customers, employees, vendors and stake holders. KION India fully understands the market needs and plan to introduce series of new products with latest global technology while meeting customer desire of value for money. We will continue to invest in India during coming years, fully exploiting the potential of MH market in India,” said Sunil K Gupta, CEO and Managing Director of KION India. The KION Group – comprising the six brands of Linde, STILL, Fenwick, OM STILL, Baoli and Voltas – is one of the largest manufacturers of industrial trucks in western and eastern Europe. The Linde and STILL brands serve the premium segment worldwide. Fenwick is one of the largest suppliers of material handling products in France, while OM STILL is a market leader in Italy. The Baoli brand focuses on the economy segment, and Voltas is a one of the leading providers of industrial trucks in India. The KION Group is present in more than 100 countries and, in 2013, employed over 22,000 people and generated revenue of €4.5 billion. n

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KUKA: transforming the art of manufacturing

“Robotics players who have the right kind of organisation, right product, right service team, right after sales service are going to survive,” says Vikas Swami, Vice President, KUKA Robotics (India) Pvt. Ltd.

or many industrial manufacturers across the globe, the German brand KUKA is synonymous with robotics. It is the ubiquity of its machines in the manufacturing sector that has made it almost a generic name for robotics machines. With a vision to ‘service first’, the company is popularising robotics technology in India. In an interaction with Subhajit Roy; Vikas Swami, Vice President and Pradeep Shoran, AGM – Marketing of KUKA Robotics (India) Pvt. Ltd. talk about the industry trends and KUKA’s growth strategies.

As the new government in power, the economy is expected to surge. What kind of growth you see in the manufacturing sector? Vikas: With the new government coming

into power, everybody is quite hopeful. A lot of new projects are expected to come up and we feel that our industry will also be driven along with it. On other side, lot of subsidies have been extended till December for automotive industry and I am hopeful that it will go further to give us more opportunity. Many new projects in the automotive sector are also likely to come.

per cent. So everybody is looking forward to automation and talking about the automation.

How optimistic you are about the growth of robotics?

Second is the quality aspect. If you see the premium OEM manufacturers like BMW, Audi and Mercedes, they all have high growths in this market and they are looking forward to have an expansion in near future. Big players like high-end cars manufacturers are more quality conscious and are looking forward to the automation. So we can say automation will be the trend in future.

Vikas: Yes, we are optimistic because of two factors. Firstly, the labours are becoming more and more expensive and labour laws are getting very stringent. Global increase in salary rate is 3 to 4 per cent whereas in India the salary hikes are close to 10 to 15

Even in the logistics, F&B, and white goods sectors the volumes are increasing and they need automation. We expect that the Indian robotics market should grow by at least 1520 per cent in next 3-4 years. Pradeep: Also, the government has made an announcement to make India a manufacturing hub. It wants to promote the manufacturing activities and robotics is one technology that would be looked like as a whole.

Though India is no longer a ‘cheap labour’ country, the penetration of robotics or automation is very low. Why is it so? Vikas: There were not very good automation solution providers but as the economy is opening up, a lot of automation companies from Germany, Europe, China and Japan are coming to India. Apart from this many Indian companies have also gain expertise in specific fields where they can provide good robotics solutions. Many automation equipment October 2014 n OEM Update n 62

Speak Out manufacturers are setting up centre of excellence in tie-up with different universities. So the educational level of robotics has come to different stage in last two years. That’s the reason things are looking positive.

As the quality players are going to venture into the Indian market, you may expect the competition as well. So how are you going to deal with this? Vikas: Whenever the market grows the competition automatically comes in. However, the new entrants will also bring a lot of knowledge. One company cannot reach each and every corner of India, so every industry has to be educated on that. But at the end of the day, the best solution or service provider is going to survive. Robotics players who have the right kind of organisation, right product, right service team, right after sales service are going to survive.

What is the market size and what is your share? Vikas: As per the IFR figures around 1,700 robots were sold in the Indian market in 2013. KUKA is one of the major robot suppliers in the Indian market.

Are you also developing any product for the emerging market? Vikas: We already have few products that are specifically made for the Asian countries. For example, we have a special robot for welding applications that doesn’t need to have much of the features. It caters to the mid-market segment. In fact in India, sometimes we do not require over-featured product, which would be of course more expensive.

What you are doing to increase the knowledge of users? Vikas: We have a Training centre in Pune, which is in line with our training centre in Germany, called as KUKA College. We Train our customers or partners at this facility. However, there are different levels of trainings. We organise basic and advanced level of programming training, electrical and mechanical trainings, application-based training, simulations trainings and more customised trainings as per our customers’ requirements. Pradeep: We have to do a lot of activities in order to reach to the customers because every customer will not come down to our college. We participate in various exhibitions,

Pradeep Shoran, AGM – Marketing, KUKA Robotics (India) Pvt. Ltd.

LBR iiwa and an operator can together work in the same cell because of its human-robot cooperation features making it one of the safest robots.

conferences. We participate in number of industry seminars in order to reach to the endusers to make them aware that the available technology which could be beneficial for them.

Is automotive industry still ruling the robotic sector? Vikas: Yes, definitely it is still ruling and I

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Speak Out every strategic opportunity that is available for us. We expect automotive and Tier 1 business to grow in coming years. Apart from automotive, industries like foundry and forge, plastics, and metal are also expected to grow.

Did you launch any new product for Indian market? Vikas: We recently launched a new product called LBR iiwa. The product is mainly made to enable the direct cooperation between human and robot. The product was launched recently in Germany and would be available next year for sale in India. think in India, it will rule for another few years before few other industries catch-up.

robotics in India is driven by the automotive OEMs.

How this product will help you to expand?

Pradeep: In India, the industries buying maximum robots are driven by automotive sector. Last year most of the automotive OEMs said that they would like to invest less in robotics but they want their tier 1 and tier 2 suppliers to invest more in robotics. So ultimately it is driven by OEMs because the tier 1 and tier 2 suppliers can be flexible because one tier 1 can supply to different OEMs. Thus the utilisation of robots will always be there. Even if the production at some particular OEM is down, still the tier 1 can supply to other customers. So we can say that still

If you see the current statistics of last 3 months, there is an increase in the sales of passenger vehicles and commercial vehicles. Is it anyway increasing the demand for you?

Vikas: Automotive assembling applications right now are mostly manual in almost all the automotive OEM’s in India. LBR iiwa is the right product for such applications. We are very optimistic that LBR iiwa would easily cater this complex assembling applications.

Vikas: For sure. There are already some new projects declared by few big OEMs, which should be opening in 2015-2016. Actually 2015-16 is expected to be a big year for the new automotive projects.

Any particular project area that you are zeroing on? Vikas: We are focussing on each and

Pradeep: LBR iiwa and an operator can together work in the same cell because of its human-robot cooperation features making it one of the safest robots. LBR iiwa can also work as an assistant to the human beings for applications were required. We are sure that LBR iiwa will open many new avenues for the robot applications in the near future. n

LBR iiwa brings new forms of cooperation between humans and machines. LBR stands for Leichtbauroboter” (German for lightweight robot), iiwa for “intelligent industrial work assistant”. The robotic innovation with sensory capabilities for safety, fast teaching and simple operator control, opens up new areas of application in the vicinity of humans that were previously off-limits for robots. It has the safe torque sensors in every axis and is suited for tactile solutions and simple gripper systems.

October 2014 n OEM Update n 64

Brand Report

Cognex expands 3D sensor portfolio Three new models, ease-of-use software and vision tool advances for DS1000 series 3D laser displacement sensors

ognex Corporation, a provider of machine vision technology, has announced an expanded portfolio of 3D laser displacement sensors, an industrial vision controller, and powerful new 3D vision tools. The DS1050, DS1101, and DS1300 sensors address a variety of 3D applications that demand high resolution and expanded measurement range. The DS1000 series now comes bundled with the new Cognex VC5 vision controller, delivering a complete solution to meet the most challenging 3D requirements. The VC5 can control up to four 3D sensors, as well as factory-floor communications. It comes preinstalled with Cognex Designer, a new easy-to-configure software framework that simplifies the development of 3D applications and creation of a professional-looking graphical user interface. The DS1000 Series now also offers an expanded selection of advanced vision tools. In addition to 2D vision tools PatMax, IDMax, and OCRMax, the DS1000 Series now offers 3D tools such as 3D height, plane fitting, plane-to-plane angle, volume, and cross section. This combination gives the DS1000 series the power to perform virtually all 3D inspections – delivering sub-micron measurement

and addressing contrast-independent OCR and presence or absence applications. “Our expanded 3D sensor portfolio allows our customers to benefit from world-class Cognex 3D and 2D vision tools for higher resolution and larger field-of-view,” says Joerg Kuechen, Vice President and Business Unit Manager, Vision Products. “The Cognex Designer software turns complex machine-vision requirements into easily maintainable solutions and makes creating and deploying complete solutions for the most challenging 3D applications faster than ever without the assistance of a skilled programmer.” The DS1000 series of 3D displacement sensors uses laser triangulation to extract 3D information from the parts it scans. Displacement sensors allow precision inspection of parts regardless of contrast or lighting conditions. The DS1000 series is factory-calibrated for fast, consistent mounting and eliminates the need to go through a calibration procedure or pixel conversion process to acquire precision measurements in real-world units. n For more information, visit www.cognex.com.

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Expert Column

Staying ahead with robotics â&#x20AC;&#x153;The speed, repeatability, and efficiency that industrial robots provide can increase productivity, profits and reduce costs,â&#x20AC;? explains Rajan Goyal, Chief Manager, Motion Control Systems, Drive Technologies, Siemens Ltd.

ight from the emergence of industrial revolution, the motivation to improve the manufacturing process has continued and the drivers continue to be efficiency, speed and accuracy. A big part of the image of modern manufacturing is the idea of robots. A robot is a machine designed to execute one or more tasks, simple or complex, repeatedly, with speed and precision and that eliminates the human intervention and October 2014 n OEM Update n 66

effort. A robot can be controlled by a human operator, sometimes from a great distance. But most robots are controlled by computer. An industrial robot is an electro-mechanical machine that is controlled by a motion controller and driven by servo motors. One of the key applications of industrial robots is to perform repetitive motions with high accuracy. Such robots are extensively used

in automotive industry and for the packaging of manufactured goods. With advancements in robotics technology, more tasks are being performed by the robots in manufacturing. This not only ensures higher productivity but also minimizes human errors. The general types of robot configurations are articulated robots, SCARA robots, Delta robots and Cartesian coordinate robots (gantry robots or x-y-z robots).

Expert Column With more companies looking for lean manufacturing solutions, industrial manufacturing robots provide many benefits that companies require to stay competitive. The speed, repeatability, and efficiency that industrial robots provide can increase productivity, profits and reduce costs.

(robots with linear axes) are commonly used in manufacturing plants. An articulated arm is capable of performing a variety of tasks used in small machining cells and in assembly lines. These robots are flexible and consume lesser foot print, however limited by the number of machines it can cater to.

Productivity and Profits With no need to take breaks and the ability to work 24/7, a manufacturing robot can increase productivity dramatically. Higher rates of throughput mean higher profits. Manufacturing robots help produce products much faster than traditional manufacturing methods by decreasing part cycle times. The very nature of manufacturing robots lends itself to creating a leaner, more efficient manufacturing cycle.

Reduced Costs Industrial manufacturing robots do not require an hourly wage. Apart from the cost of maintenance, a company pays for a manufacturing robot only once. The initial cost of an industrial manufacturing robot can seem daunting, but the return on investment (ROI) can quickly be realised after implementation. A company can expect a ROI on their industrial manufacturing robot generally within a year.

Improved quality Also, manufacturing robots provide better quality parts. For example, an arc welding robot provides high-quality weld seams, making the weld strong and the part more durable. Because of high repeatability, reworking time is nearly eliminated when using manufacturing robots. According to estimates of the International Federation of Robotics (IFR), 1.66 million industrial robots will be installed worldwide by 2016. This would mean that approximately half a million more robots than in 2011 would be in operation by this time. The smooth inter linkage of the software and hardware of various components and machines is a prerequisite in order to be able to serve the growing market in an adequate manner. Thanks to the strategic cooperation between Siemens and KUKA, this requirement can be filled in a consistent manner.

Robots in machine tool industry Industrial robots are generally used on machining lines in the automotive industry; while articulated arm robots (robots with rotary joints) and gantry type robots

Gantry type robots are used for long machining lines with simple operation. In a machining line or a cell, these two types of robots are typically used for loading/ unloading operation. These two types of robots are selected depending on the parameters like investment per machine, type of machining line, and type of operation required. Robots are electrically interfaced to the machine tool controller using industrial communication bus protocols, the most widely used bus types being PROFINET and PROFIBUS. Other type of protocols are also used, in few cases even hardwiring is also practiced. In addition to the loading and unloading of machine tools these mechanical assistants can also perform machining steps such as polishing, deburring, drilling and milling. The extended functions provide additional fields of application in industries, in which robots are already active today - including the automotive industry, the plastics processing industry and also other fields such as the aerospace engineering and energy industries.

CNC systems, Siemens has introduced the feature SINUMERIK Integrate Run MyRobot. This simple and flexible solution allows the robot to be operated from the same user interface as that of the machine tool or CNC machine. The Run MyRobot technology package facilitates high-speed work piece and tool handling. Activities such as Operation, Retraction, Teach-in and Diagnostics can be realized from the CNC operator panel of the SINUMERIK 840Dsl, therefore increasing the efficiency and flexibility of the machine tool. As a consequence, the robot can be flexibly added to handle part loading and unloading. Just like every other unit at the machine, it can be operated from the SINUMERIK Operate user interface. This does not only make production automation really simple but also minimizes the loading or unloading time thereby increasing the productivity of the machine tool. Run MyRobot that is completely integrated in the SINUMERIK 840Dsl facilitates: • Viewing the machine including robots • Programming and operation • Diagnostics and display of robot messages.

Benefits

Industrial robot controllers

Robot loading and unloading has inherent advantages, such as: • Small space requirements as compared to gantry loading • Makes the handling flexible • Increases machine productivity • Lowers production costs.

Robots used in Machine tool industry are driven by commonly used synchronous Motors and drives, and an independent controller. Gantry type robots are controlled by general motion controller, where as the articulated arm robots require special motion controller that can handle noncartesian motion. This requires a different skill-set in terms of programming and diagnosing. So there is huge market demand for having seamless interface for both CNC controllers that control the machine tools and the robot controller.

These strengths can be fully utilized with SINUMERIK Integrate Run MyRobot. And the solution is scalable from the automation of individual production islands up to a completely networked system. As a consequence, the automation of the part flow at the individual stations, the complete production planning and control, the tool and resource management and also the maintenance can be optimised – achieving the highest degree of efficiency in production! n

Although at functional level these two types of controller can work differently, at the operational level both controllers could have similar look and feel. This also raises the efforts required for diagnosing the problem in an event of a break down. Attending to this market requirement, being a market leader in manufacturing

Authored by__

Rajan Goyal Chief Manager Motion Control Systems, Drive Technologies, Siemens Ltd. 67 n OEM Update n October 2014

3 Technology

ways to reduce machine design time Mechatronic design approach, EtherNet/IP and Accelerators offer machine builders simple ways to reduce the time it takes to design motion applications Mechatronic Technologies - Machine Example

Direct Drive Rotary Servo Motors Help boost machine performance and reduce design complexity for rotary loads.

Direct Drive Linear Motors Offer ultimate design flexibility and performance with speeds of up to 5 meters per second and accelerations up to 50G.

Electric Servo Cylinders Greater control, accuracy and repeatability than pneumatic cylinders. Also offer sustainability benefits.

achine builders know that the old saying “time is money” has never been truer than it is today. Getting a machine to market faster ultimately translates into an improved bottom line. As a result, machine builders often look to the design phase of machine development to save valuable time. In addition, a variety of external pressures also lead machine builders to be mindful of simplifying their design processes. Today’s end-users are demanding machines that run with greater efficiency, more quickly adapt to market changes and integrate with up and downstream operations. Global competition and tight regulations, meanwhile, put pressure on manufacturers to be more responsive and transparent. To help meet these new challenges, machine builders can turn to three time-saving methods: a mechatronic design approach, the EtherNet/IP network and Accelerators. Using a mechatronic approach, engineers are able to reduce design time through virtual prototyping. These digital simulations help engineers to quickly determine an optimized

October 2014 n OEM Update n 68

solution by finding errors early in the design process. Further, engineers can input design information in a familiar environment and understand how their design decisions affect the system as a whole, allowing them to quickly evaluate design alternatives and select the best one. EtherNet/IP gives machine builders a simplified network solution that can connect their motion application to the rest of their machine through one single channel, to other machines, to the entire line and even up into the business level. This streamlines the design phase because machine builders don’t need to consider separate network requirements and specifications when designing the motion application. The idea behind the DMAT (Drives and Motors Accelerator Toolkit) from Rockwell Automation is to help users quickly take care of the mundane, often time-consuming – but necessary – core tasks involved in the machine building process by providing easy to use modules which provide a solid foundation of functionality and features. This frees up

Direct Drive Linear Stages Help boost machine performance and reduce design complexity for linear loads. Also available as stacked stages for multi-axis applications requiring an off-the-shelf solution.

machine builders to focus on designing unique features and differentiating their machine. Therefore, a mechatronics approach during the design process helps machine builders ensure their machine is efficient and cost effective. EtherNet/IP can provide machine builders with the flexibility and performance required for demanding applications all on a single network architecture. Finally, Accelerators provide a programming backbone to get machines up and running faster. Every machine builder has an eye on reducing design time; these are three ways to get started. Authored by__ Mike Bayer, Commercial Engineering Manager, Rockwell Automation For more information: visit www. rockwellautomation.com or email at raindiamarketing@ra.rockwell.com. Customer Care (Toll Free): 18002000121 n (Courtesy: Rockwell Automation)

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Technology

GE’s QuickPanel+ brings consumer technology to the factory floor With faster processing speeds and increased memory, QuickPanel+ delivers lower total cost of ownership, speeds implementation time and time to market, and makes integration easy

E’s QuickPanel+ operator interface (OI) for the industrial Internet now features multi-touch technology, providing the same pinch-to-zoom functionality as today’s popular consumer touchscreen devices. Multi-touch and swipe viewing are a worldwide standard in consumer digital interfaces, so viewing system-wide details even on a 7-inch display is simple with the new QuickPanel+ multi-touch functionality. Double-tapping or pinching enables the interface to be enlarged to up to 400 per cent of its original size. Navigation between interactive schematics can be achieved by simply swiping the screen. Multi-touch and swipe also allows developers to build more intuitive HMIs by eliminating the need for a formal menu system. QuickPanel+ integrates process control, view and an option to run an embedded data historian in a single device with the latest touchscreen technology to provide the high performance, connectivity and user experience expected in today’s increasingly connected manufacturing environments. A October 2014 n OEM Update n 70

general purpose operator interface capable of connecting to a variety of industrial PLCs and PACs, the QuickPanel+ is designed specifically to take advantage of the industrial Internet. The latest in touchscreen technology makes it as responsive as a tablet or smartphone, yet robust enough to withstand industrial environments and applications, even if the user is wearing gloves. “QuickPanel+ is the first operator interface that is truly intuitive, empowering businesses to be more efficient and effective on the floor and in the field,” said Tom Craven, Product Manager for Operator Interface Solutions for GE Intelligent Platforms. “Today’s engineers and operators expect today’s technology to be available to them everywhere. QuickPanel+ was designed with the user in mind, to be crystal clear, fast, and highly responsive.” A plug-and-play operator interface, QuickPanel+ is not only compatible with GE systems but can also be integrated with a broad range of third-party controllers and I/O to meet customer and application

needs. It is available in 7-inch, 10-inch, 12inch or 15-inch screen sizes, and with faster processing speeds and more memory, QuickPanel+ delivers lower total cost of ownership, speeds implementation time and time to market, and makes integration easy. QuickPanel+ also offers a fully-functional browser and multimedia support with the Windows EC7 operating system. This functionality enhances customisation of the OI to user or customer needs: Users can pull up training videos, compile reports or access other necessary information like parts inventory to work efficiently. “With 50 billion machines connecting to the Internet in the next five years, the need for control system components that enhance performance without increasing complexity are critical,” said Craven. “Incorporating the latest in touch-screen technology for the ease of use and instant information expected in the smartphone era makes automation work better and add more value to the business.” n

PRE-ENGINEERED METAL BUILDING

Innovation

ASMPT, one of the world’s largest suppliers of wafer assembly and packaging equipment for the semiconductor industry, benefits from Renishaw’s innovative products

Renishaw strengthens ASMPT A

SM Pacific Technology Ltd (ASMPT) aims to offer complete factory automation solutions and satisfy customers’ needs through its innovative and cost-effective products.1 ASMPT has been using a range of Renishaw’s encoder, calibration and Coordinate Measuring Machine (CMM) products for more than 15 years. In 2011, ASMPT acquired the Electronics Assembly System division from Siemens SG and entered the surface-mount technology market for the first time. A variety of Renishaw encoders is employed in various ASMPT machines including incremental encoders (RGH series, compact TONiC series and SiGNUM series), the latest RESOLUTE absolute encoder range and the LM10 magnetic encoder system by RLS, a Renishaw associate company.

October 2014 n OEM Update n 72

Renishaw encoders are found in: • AB559 series wedge bonders, designed with a large aluminium bonding area of 8 inches x 4 inches and speeds to 4.1 wires/ sec • High speed MCM12 die bonders: a fully automatic multiple die, SMD, and flip chip bonding system, up to 14 types of picking tools and 12 inch wafer handling capability • SMD and flip-chip bonders with up to 300 mm wafer handling capacity • UV Cured Die bonders: used in image sensor applications with resolutions to 50 nm and speeds to 3.5 m/s in operating temperatures as high as 300 C.

Benefits ASMPT’s equipment is renowned for high precision and high stability. Consequently, it demands reliable and high quality positioning

systems. Renishaw has a long history of developing high performance encoder products that are capable of meeting the diverse and demanding requirements of industrial automation. One good example of such requirements is the ‘dirt immunity’ capability, achieved with specially designed and patented optical schemes, which are built into every encoder readhead to withstand a variety of contaminants such as grease, dust, particles and scratches. ASMPT Technical Manager Dr. Joseph Choy noted, “The positive feedback from our customers has proven that Renishaw’s encoders have excellent dirt immunity and can run reliably with little or no maintenance.” Another requirement is size; most bonders from ASMPT are extremely compact in their design and have limited spaces for mounting encoders - each bonder can have up to 17

Innovation moving axes each requiring independent position feedback. Renishaw’s RGH24 and TONiC series encoders are well suited for this application and these compact readheads are used in conjunction with RGS tape scales, which are the lowest mass scales on the market weighing a mere 15 g/m with a thickness of 0.2 mm. “In many applications, the scale is the moving part with a speed of up to 3 m/s back and forth, so inertia is an important factor for the required acceleration and deceleration. Renishaw always keeps on the top of technology trends, delivering innovative encoder products to industries. We can concentrate our efforts on new product development as Renishaw’s technology always keeps pace with us. A good example is their latest RESOLUTE series,” adds Dr. Choy. Every Renishaw encoder is well-designed to meet the needs of the most demanding applications. Renishaw introduced the noncontact optical encoder with a set-up LED, for optimal installation with minimal effort. Dr Choy continues, “From RGH to RESOLUTE, we have experience with every generation of Renishaw’s encoders. Although the technology has been significantly enhanced, the installation is still as simple as ever. The set-up LED makes our job easier. Imagine how cumbersome it is when you have to tune more than 10 encoders per machine using an external plug-in device. Simple installation means cost reduction and greater efficiency in production which is absolutely essential for

maintaining our competitiveness and leading position in the market. Moreover, Renishaw’s TONiC DSi ultra-high accuracy rotary encoder system with dual readheads enables to us to eliminate the errors associated with rotor eccentricity, removing the need for compensation, which again reduces our costs.” Renishaw’s TONiC series encoders feature unique AGC (Automatic Gain Control) which maintains analogue signal amplitude of 1 volt to further enhance the accuracy and stability of the position feedback.

Custom-made solutions The semiconductor industry is fast-paced and competitive. Renishaw understands this and has supported the development of machines often by providing custom solutions to optimise the design, which in turn drives Renishaw to be innovative with its encoder products, illustrating the closed loop of innovation possible between Renishaw and its customers. Performance verification, inspection and service Overall machine performance also needs to be verified, and ASMPT has invested in several of Renishaw’s calibration products, including the XL-80 laser calibration system, RX10 rotary axis calibrator and QC20-W ballbar system. These are used by R&D engineers for performance verification of ASMPT’s machines, including positioning accuracy and dynamic characteristics, and by ASMPT’s production staff to regularly calibrate their Montage of all Renishaw encoders

ASMPT building

CNC machine tools to ensure the accuracy of manufactured parts. Jimmy Siu, ASMPT’s Maintenance Manager explained, “Many parts are made in-house. Our role is to ensure all the machine tools are functioning well every day. Before Renishaw, we used hand tools to perform the maintenance work but we have realised that the traditional methods no longer satisfy our needs as our production capacity expanded.” In its Huizhou’s plant alone, ASMPT has more than 400 machine tools. Additionally, hiring experienced employees is not an easy task in China. Renishaw calibration and ballbar systems allow ASMPT to identify potential errors early to minimise scrap and downtime. “It’s truly portable and the ballbar, especially, is much simpler than I imagined. I can operate it after one day of training from a Renishaw engineer,” adds Jimmy. ASMPT emphasises the quality control of all produced modules. Mr Lee, a Production Engineer at ASMPT explained, “We use the Renishaw XL-80 laser calibration system with an RX10 rotary axis calibrator to examine the accuracy of each direct-drive rotary (DDR) motor. The XL-80 complies with international standards and quality assurance. It is calibrated by recognised and traceable systems and methods, giving us confidence in the measured result. Renishaw has also done very well in support. When our XL-80 had been sent out for calibration, Renishaw provided us with a spare system for temporary use to avoid any stoppages in our production.” n 73 n OEM Update n October 2014

Expert Column

RELAYBILITY

selecting industrial grade relays This article outlines the 10 key factors that influence the performance of relay

n the first instance we may feel there is a spelling error in the topic of this paper i.e. a mistake has happened in the word “reliability”. But actually, the similar error may happen in the reliability of the electrical or electronic control system if we do not give a second thought while selecting a relay. After all a relay is a very simple product in which the coil changes the switch from one state to another when a rated voltage is applied to it. But the question is – Is it really so simple or we should give it a second thought. Many relay users take a standard product for all applications and more often than not they’re satisfied even if the relays are replaced frequently, much earlier than the actual electrical life cycle of the relay. This is due to the fact that not much time is spent on examining the important parameters necessary for optimum utilisation of these switching interfaces. For sure, a same relay may work for all applications but not for the same period of time. It may be that as the application is different, so is the requirement of a relay. Otherwise, the relays wear out very fast or sometimes even create problems like contact welding and arcing. PIC: Relay Contacts showing the effects of severe over current due to wrong selection

Factors affecting performance of relay Many internal and external factors influence the performance of relay and they can be broadly classified into 10 key types. Each of these factors affects the relays performance in some or the other way. Based on the application one must carefully analyse all these parameters and select an appropriate relay as its failure is immediately reflected on the control system reliability.

1. Contact material The contact material has the major influence on the relay performance when it is compelled to be used under high current, continuous operation and connected load. The correct contact material is like the correct tires for a race car, Rally tires on a F1 car are not so good. The same is true for relays, the wrong material will have a big effect on its performance. For example a relay with AgSNO2 contact material may be good for inrush current but over a period of use its contact resistance increases drastically. Where as a relay with AgNi contact material is long lasting for control applications. There is no universal contact which covers all applications. The selection depends on various factors like type of load, level of load, type of supply, frequency of switching etc. Four different contact materials are widely used today for relays and their use is depending on their properties. October 2014 n OEM Update n 74

2. Coil requirement A user should give emphasis to the minimum pick-up voltage and the maximum permitted coil voltage with respect to the ambient temperature. In some circuit’s leakage current or Transient EMF might have enough voltage to keep some coils energised, therefore not releasing in the intended way. Different manufacturers specifies different coil voltage ranges, usually a 24V DC relay has a working range of 0.80 to 1.1 times the nominal voltage UN.

3. Contact requirement As relays come in different configuration, thus several points of concerns arises in choosing the number of contacts required for the application. The question remains “How many poles (contact sets) does the user requires for the application?” Relays typically come in 1,2,3,4 poles and less main stream relays comes with more than 4 poles. The contacts can be understood on the basis of terminology of NO=Normally Open, NC= Normally Closed, CO=Change Over contacts (change from one set of contact to another) respectively.

Expert Column CO=Change Over contacts can further be described as SPST (Single Pole Single Throw), SPDT (Single Pole Double Throw), DPST (Double Pole Single Throw) and DPDT (Double Pole Double Throw). SPST is the simplest of all with only two contacts. SPDT has three contacts. The Double Pole versions are similar to Single Pole versions except there are two switches that open and close together. Special attention should be paid while selecting the contacts in accordance to the voltage and current requirements of the load.

4. Socket/ Base This is one of the most important and usually the mostly ignored parts of a relay used in a control system. The users must keep in mind that the relay can get only as good as its base or socket. The best of the relays will underperform if the mating socket is not optimised with respect to the relay. The important bit is quality of materials and plating’s in the base, the plastics need to withstand the heat generated from the contacts both in the relay, and the contact made between the terminal and the relay base, and the metal needs to have enough elasticity force to maintain its pressure on the terminals, usually this is where improperly designed bases/sockets fail and let down the

electrical system, the clamps in the base open up with heat and fails to return to its original position, and this reduce the pressure, and increasing heat, until a failure occurs. In all cases the relays and the bases/sockets should be made by the same manufacturer as per the specific mating requirements and considerations. The secret to a good electrical connection is the result of Area x Pressure. If a joint is made up with too little pressure, moisture and air will penetrate the joint and promote corrosion which raises resistance which increases heating which can accelerate corrosion.

5. Type of Load It is important to determine the parameters of relay in accordance with the type of load connected. Loads can be of different types example- Resistive, Inductive, Capacitive, Lamp Load, Motor Load etc. Some loads like Motor and Inductive loads have high inrush current and can damage the contacts of relay if not selected properly. An additional protective circuit may be required to overcome the ill effects of the using inductive loads and to increase the service life of the relay and the system. In industrial applications demanding switching high DC loads, a user has an option to connect two contacts in series to increase the switching capacity (as shown in the graph). A basic separation should be maintained between large AC and DC Loads. When switching large AC loads, the relay can be operated up to the mentioned voltage and current levels as the arc produced during the switching goes out in the next zero phase of AC cycle.

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Expert Column so as to efficiently work for a higher life span. This electrical life must be tested for a relay at the required ambient temperature which in Indian conditions are definitely above 40 C for air-conditioned environment and 60 C for uncontrolled environment. For records, it is important to check whether the relay selected has been tested for electrical life at the ambient temperature specified by the relay manufacturer in their data-sheet.

DC breaking current (A)

20 10 6 4 2 1

10. Service Factor

0.2 0.1 20

100 140 Voltage DC (V)

180

220

However while switching DC loads, due to non availability of zero crossing to extinguish the arc automatically, a standard relay can only switch relatively small DC load.

6. Insulation The main functions of a relay is to connect and disconnect different electric circuits, and usually, to maintain a high level of electrical separation between different circuits. It is therefore necessary to consider the level of isolation in accordance with the EN 61810-1 standards appropriate to the application and the task to be performed and relate this to the relay’s specification.

The Service factors are considered when there is a need to diagnose a fault in the relay and also the ease with which they relay can be replaced in an existing control system. It is very important to have indication for both - the coil actuation as well as the contact latching, so that the user can identify the nature of the fault. After the fault is diagnosed, the user needs an easy identification of the key technical parameters of the relay, so that the correct replacement can be ensured without looking at extensive documentation. For this purpose, it is important that the technical parameters are laser printed on the relay, as the ink printing normally wipes out over a period of time.

7. Temperature Temperature plays an important role in defining the electrical service life of a relay. The relay exposed to harsh ambient temperatures would lead it to work unreliably. While designing the system it is therefore necessary to take temperature as the main criteria. A typical Coil Voltage variation graph with respect to temperature is shown below.

Laser print

8. Type of Mounting Today depending on the application type, a user has different U 2.0 UN

Conclusion: The reliability of relay plays an Mechanical Flag important role in the For Contact availability of control system. For each application therefore the best relay shall be chosen based on different technical parameters. With the advancements in technology and the multiple options now available in these relays, the need of the hour is for optimisation of the selection parameters. This kind of design elevation if considered at the time of detailed engineering can help in: • Increasing reliability of control system • Reducing the cabinet footprint • Remove the wiring errors • Preventing additional heat generation inside the cabinet, • Saving space and optimising costs directly as well as indirectly by energy saving. n LED for Coil

1.5 1.0 0.5 -20

80 [ C]

DC coil operating range v ambient temperature 1 - Max. permitted coil voltage at nominal load (DC coil). 2 - Max. permitted coil voltage at nominal load (AC/DC coils U < 60 V). 3 - Max. permitted coil voltage at nominal load (AC/DC coils U>60 V). 4 - Min pick-up voltage with coil at ambient temperature. options for mounting the relay. The most common being the PCB version. These types of relays can directly be soldered on a PCB. In industries however Socket/Base mounted relays are preferred because of their modularity and ability to mount on DIN rails or screw mounting on panels. Third type of mounting is Flange mounting, which is used if there is no DIN Rail available.

9. Life Time For a reliable switching interface, a relay should typically have an electrical service life in few hundred thousands of switching cycles October 2014 n OEM Update n 76

Authored by__ Dr. Ashish Manchanda, Managing Director, Finder India Pvt. Ltd.

Case Study

Taking pelletiser technology to the next level

The DURO 2000 Belt Dryer model from MaagAutomatik gently dries thermoplastic compounds, resulting in pellets that contain an extremely low level of residual moisture

Soredi S.p.a. grows into a leading thermoplastic-compound manufacturer with the help of SPHERO 100 Underwater Pelletising Systems and DURO 2000 Belt Dryers from Automatik

ounded in 1983, Soredi S.p.a. – a manufacturer of thermoplastic compounds, has transformed itself from a small, family-run operation to a global dynamo that produced more than 16,000 tonnes of thermoplastics compounds in 2012. “We have a strong presence in several markets, including electrical, automotive, lighting, household items and furniture,” said Giorgio Ghidini, General Manager of Soredi S.p.a. “Currently, 65 per cent of our products are used in the domestic Italian market with 35 per cent exported, but we want to grow our export capabilities. We have confidence that our competitive advantages of flexibility in our production processes, along with the high quality of our products, will help us make

October 2014 n OEM Update n 78

our hoped-for expansion into additional global markets and regions a reality.” To make this goal a reality, as well as to meet growing production demands, Soredi has built on an area of 20,000 sq.m., 11,000 sq.m. of which are covered. Within those facilities, Soredi has completely automated all of its production cycles, including a battery of 18 silos for the storage of the raw materials, and also the use of modern software that manages all processes and operations, which gives Soredi the utmost control of product quality and quantity until delivery to the enduser.

Product portfolio In its operations, Soredi works with a number of polymer-based feedstocks that are used

to create specific thermoplastic-compound end-products, such as polypropylene (PP), acrylonitrile butadiene styrene (ABS), SAN, HIPS PC and PC/ABS blends, polybutylene terephthalate (PBT), PA 6 and 66, polyoxymethylene (POM). In all, Soredi produces 15 different thermoplastics products at its manufacturing facility. One of the more popular products that Soredi makes is polypropylene Niplene, of which it produces 23 different varieties. Polypropylene Niplene is a thermoplastic that contains resins that are used as fillers or reinforcing agents. The injection of these resins, or polymers, which are usually glass fibres, talc or calcium carbonate, or mixed fillings between glass fibre and different mineral fillers, produces a techno-polymer

Soredi S.p.A. works with a number of polymer-based feedstocks to create a wide array of thermoplastic-compound end-products

that offers greater stiffness, hardness and dimensional stability under heat to the user for several application in automotive, appliances, design furniture and electrical parts. “We produce polypropylene Niplene glass fibres, mineral fillers like talc and calcium carbonate, and/or fillings that can be mixed together, and are available in various percentages, generally from 10 per cent to 70 per cent,” explained Ghidini.

Improving the process In order for the polypropylene Niplene to provide the optimum stiffness or hardness levels to the thermoplastic, the granules or pellets, the injection of which are an essential intermediate stage in the thermoplastics production chain, need to be the perfect size and shape, or else the final product may be compromised. To produce the polypropylene Niplene granules, companies like Soredi employ pelletising systems that take difficult-to-handle melts and powders, which are the foundation of compounds like polypropylene Niplene, and turn them into the granular resins that are needed to produce the final end-product. Since its founding 30 years ago, Soredi has traditionally used dry-cut pelletising systems for the crucial granule-making process. It was not until the last few years, however, that Soredi discovered a more effective technology for this process: an underwater pelletising system. In particular, Soredi began deploying the SPHERO 100 model of Underwater Pelletising System from Automatik Plastics Machinery, a subsidiary of Maag, Oberglatt, Switzerland. Maag was established in 2010 through the merger of Maag Pump Systems AG with Automatik Plastics Machinery GmbH, Grossostheim, Germany, which is one of the world leaders in developing pelletising technology for use in the creation of thermoplastics compounds. In 2012, the newly created Maag became an operating company with the Dover Corporation’s Pump Solutions Group (PSG) Oakbrook Terrace, IL, USA. “We became familiar with the Automatik dry-cut pelletiser technology when we formed our company back in 1983, and in 2009 we were introduced to the underwater cutting system,” said Ghidini. “After watching the SPHERO 100 machine in action, we found that there was less wear to the equipment, it offered greater flexibility during production when we needed to change the colour of the granules, the granules produced were of a perfect spherical

Case Study Additional benefits of the DURO 2000 Belt Dryer are: • No movement of pellets against the dryer components • Long life span of all parts that come into contact with the pellets • Extremely gentle pellet-handling that ensures high product quality and keeps dust levels to a minimum • Reduced energy consumption with no additional heating required.

As a company that produces more than 16,000 tonnes of thermoplastics compounds annually, including polypropylene pellets, SorediS.p.A. has turned to Maag Automatik for pelletising systems and belt driers, both of which perform crucial tasks in the production of thermoplastics

size and there was a reduction in the amount of dust that was created during the cutting process.” The SPHERO 100 has been designed for use in compounding, recycling and master-batch applications and features a unique knife-head design and optimised water-flow conditions within the cutting chamber that combine to ensure the production of perfectly spherical pellets that are ideally suited for further processing. The system is also capable of producing high flow rates of up to 8,600 kg/ hr (19,000 lbs/hr) while the unit itself takes up minimal floor space.

•

• • •

• Operational benefits of the SPHERO 100 include: • A rugged design in which all components are arranged on a common supporting frame • Optimised melt-flow channels that reduce

SPHERO 100 Underwater Pelletising System from MaagAutomatik produces the perfectly spherical polypropylene Niplene pellets that SorediS.p.A. requires for its customers’ manufacturing processes

October 2014 n OEM Update n 80

•

the melt’s residence time and increase product quality Absence of an internal adapter, which results in a reduction of energy consumption A bolted-through diverter valve that connects directly to the valve plate, eliminating the build-up of polymer deposits Minimised cleaning, assembly and start-up times Lifetime cutting-tool performance Upgraded control panel with touch screen that provides fast start-up and maximum operational flexibility Single-handed opening and closing of the cutting chamber for quick, convenient and safe operation The availability of various die-plate options, including electric-heated, liquidheated and thermally insulated SuperFlow designs.

In conjunction to the SPHERO 100 Underwater Pelletising System, Soredi employs a DURO 2000 Belt Dryer from Automatik. The DURO 2000 gently and efficiently dries abrasive or brittle pellets, glass-fibre reinforced materials and other compounds with high chalk compositions, resulting in pellets that contain an extremely low level of residual moisture. This makes the DURO 2000 ideally suited for glass fibre-filled polymers, resulting in drastically reduced cost when compared to the operation of a centrifugal-style dryer. The DURO 2000’s small number of moving parts results in virtually no component wear, which also means quick and easy cleaning, especially during frequent product changeovers.

“We are extremely satisfied with the performance of the SPHERO 100 cutting system and DURO 2000 belt dryer,” said Ghidini. “More importantly, our clients are very satisfied to receive the type of granules that we are now producing, which flow very easily during their production processes. From our perspective, the flexibility of the SPHERO 100 and DURO 2000 reduces the amount of waste we experience during production changeovers while delivering high throughput and a lower need for system monitoring by the operator.”

Conclusion The success of any company or operation is in large ways ultimately determined by the ability of its channel partners to deliver equipment and system solutions that fill the needs of the manufacturer. Soredi S.p.a. found one of these reliable partners back in 1983 when it began using dry-cutting pelletising systems from Automatik Plastics Machinery. The performance and support that Maag has provided over the years to Soredi paid dividends when Soredi was looking for a better way to produce its polypropylene Niplene, and the company looked no further than Automatik for the solution: the SPHERO 100 Underwater Pelletising Systems and DURO 2000 Belt Dryer. “For us, it’s important that not only does the equipment work, but that there is reliable local post-sales and technical support, and we get that in an excellent way from Maag, usually by ClaudioBonafede, After Sales Manager in Italy,” Ghidini said. “We recommend the use of Maag Automatik equipment for thermoplastic-compound production because of the efficiency and trustworthiness of the machines. We will certainly continue to use Maag Automatik Pelletising Systems equipment in the future.” n About the author: Jürgen Skanda is Sales Manager Pelletising and Extrusion for Maag Automatik srl in Italy. For more information on PSG, visit www.psgdover.com.

Industry Analysis

Cutting tool industry getting enriched with latest innovations There is considerable activity on the front of development of new business of products in cutting tool industry and latest innovations are making the things easier

hen it comes to machining, a cutting tool is considered as a tool that is used to remove material from the work-piece by means of shear deformation. Cutting may be accomplished by single-point or multipoint tools. Single-point tools are used in turning, shaping and similar operations, and remove material by means of one cutting edge. Milling and drilling tools are often multipoint tools. Grinding tools are also multipoint tools. Each grain of abrasive functions as a microscopic single-point cutting edge and shears a tiny chip.

A good cutting tool Cutting tool must be made of a material harder than the material which is to be cut, and the tool must be able to withstand the heat generated in the metal-cutting process. October 2014 n OEM Update n 82

Also, the tool must have a specific geometry, with clearance angles designed so that the cutting edge can contact the work-piece without the rest of the tool dragging on the work-piece surface. The angle of the cutting face is also important, as is the flute width, number of flutes or teeth, and margin size. In order to have a long working life, all of the above must be optimised. To produce quality product, a cutting tool must have three characteristics: â&#x20AC;˘ Hardness: hardness and strength at high temperatures â&#x20AC;˘ Toughness: tools should not chip or fracture â&#x20AC;˘ Wear resistance: for acceptable tool life before needing to be replaced.

L Krishnan, Managing Director, TaeguTec India Pvt. Ltd.

The current focus is to upgrade geometries, improve coating technology and build on ideas that contribute to cutting down cost

Industry Analysis Latest innovations in the field Today, in the cutting tool industry, most innovation has to do with the ways to optimise existing resources concurrently with cutting costs. There is considerable activity on the front of development of new business of products. “The current focus is to upgrade geometries, improve coating technology and build on ideas that contribute to cutting down cost,” says L Krishnan, Managing Director, TaeguTec India Pvt. Ltd. “New materials are also looked upon from the point of view of cost-effective alternatives.” With over 100 years of development, the cutting tool is still one of the key elements inseparable from high-productivity, highprecision machining operations. Driven by advanced material processing and fabrications, cutting tools have been evolving to have some improvements like the hardest-ever coating and the smallest-ever configuration. “Many emerging machining technologies, such as micro scale machining, minimum lubrication machining, and machining of abrasive materials, etc., all require new cutting tools with performance uncharacteristic of conventional tooling,” informs Punit Koradia, Executive Head – Customised solutions, Jyoti CNC Automation Pvt. Ltd. “These cutting tools, either with unique materials or geometry, encounter sophisticated loading during machining and exhibit distinct thermo mechanical behaviour.”

Technology meeting modern challenges Currently if we observe carefully, in the metalworking industry, there is no other choice except to adopt advanced technology. The technology is getting consistently advanced to next levels and in turn helping to improve the productivity and efficiency of the processes in metal industry. Also these innovations help to complete the tasks in lesser time as they lead to achieve faster operations. The machining demands that are soon to come are so great that only advanced technology will be able to meet them. “The challenges in modern machining have mostly to do with increasing cost of raw materials and their availability in addition to uncertainty in demand and fast changing product and process technology,” says Mr Krishnan. Thus innovation and new product development are the only ways to keep pace with the times and trends.

According to Mr Koradia, “Two major cutting tool technologies or innovations in recent period provide us insights of how machining facilities now need to think about tooling differently.”

These two innovations are: • Use of cubic boron nitride (CBN) and polycrystalline diamond (PCD) materials for tools • Union of two cutting tool/combination tool: drilling and threading, for highproductivity. Difficult-to-machine materials like Inconel, are driving cutting tool manufacturers to develop innovative solutions to some of the most challenging machining problems. Working in concert with their customers and with the most advanced machine tools, cutting-tool manufacturers are developing strategies to meet demanding applications in aerospace, medical, oil and gas, and, increasingly, in the automotive industries. High temperature demands heat resistance which is a major strength of materials like titanium, Ti-alloys, Inconel, and nickel-based and cobalt-based superalloys. For example, the heat resistance of Inconel 718 delivers important performance characteristics in the hot zone of turbine engines. This same heatresistant characteristic can be detrimental during the machining process. If high heat is not effectively controlled in the cutting zone, it destroys tools, limits tool life, and reduces productivity. Strategies for removing heat through thermal management, and chip control through innovative insert design, figure prominently in solutions for machining these metals, and are additionally applied in the drilling and trimming of highly abrasive composite materials.

Contribution by current players It is clear that latest innovative yet cost-effective solutions are the need of an hour. Being aware of this, obviously it becomes interesting to see now what contribution is being given to the industry by current major players. TaeguTec believes that its strategies revolve around the introduction of new products towards increasing productivity and reducing cost. “We have always endeavoured to offer the best value proposition for our customers by innovating ingenious products and solutions with maximum cost efficiency,” assures Mr Krishnan. “We will continue to work towards strengthening our position as a preferred partner and supplier to our customers.”

Many emerging machining technologies, such as micro scale machining, minimum lubrication machining, and machining of abrasive materials, etc., all require new cutting tools with performance uncharacteristic of conventional tooling

Punit Koradia, Executive Head – Customised solutions, Jyoti CNC Automation Pvt. Ltd.

“We are concentrating on developing machines with high speed along with high torque. The combination of these two machining parameters will definitely help us to machine any difficult-to-machine workpiece,” believes Mr Koradia.

Promising future Machine tools are certainly evolving along with technology advancement. Accordingly the machines are getting faster and more accurate as well. However, it is observed that the work-pieces themselves are not just evolving in the same incremental way, they are fundamentally changing. Machined workpieces today are not just defined by more demanding accuracy, delivery and quality requirements, but increasingly they are also made of difficult-to-machine materials that many shops have never faced before. These materials include titanium alloys, nickel-based alloys and compacted graphite iron (CGI), and of course the engineered composites in the growing number of cases where composites are replacing metal. Also, tool wear monitoring using new sensor technologies, tool life management and tool life predictions using neural network approaches etc. are equally important to advance the overall production and manufacturing systems. Overall, it could be said that the future seems to be much promising and more technology friendly in order to come up with more wonderful innovations in the field. It is going to definitely serve the industry better and in more precise manner. That would, of course, help a lot to meet the ever-growing challenges of 83 n OEM Update n October 2014

Brand Report

Dürr builds energy saving paintshop for BMW in China D

ürr, a mechanical and plant engineering group, builds a particularly resourcesaving Eco+Paintshop for BMW Brilliance Automotive Ltd. (BBA) in Dadong in China. This paint shop will feature a wide range of the technological innovations Dürr offers for economically friendly, sustainable automotive painting. Pretreatment and electrocoating are implemented by means of the rotary dip painting system called EcopaintRoDip M. Making use of the rotation movement of the car bodies, this technology allows for designing a dip tank without inlet or outlet slopes. This results in a significantly smaller footprint and a reduced consumption of energy, water and chemicals by reason of the smaller bath volume. The fully automated IPP (Integrated Paint Process) is another technical feature which proves that the plant has earned the name

“Eco+”. The IPP eliminates the need for both aprimer and a drying phase. The spray booths are equipped with Dürr’s innovative EcoDryScrubber. This technology binds the overspray without water and chemicals. Using large-scale air recirculation, energy savings of up to 60 per cent are possible. Currently, the EcoDryScrubber is in use or under installation in more than 70 painting lines on four continents. The car bodies in Dadong will be painted by 36 Dürr paint robots of the types EcoRP E033 and EcoRP L133. They are equipped with the EcoBell3, an atomizer of the new generation characterized by a significantly higher atomizer performance. Thanks to their compact design, the atomizers of the EcoBell3 family are suited for exterior and interior painting. Combined with the linear color changer EcoLCC, the EcoBell3 is an extremely efficient and compact, yet easy to operate application system for all types

Dürr EcoDryScrubber – at work at BMW’s in Regensburg – saves up to 60 per cent energy in the paint booth

October 2014 n OEM Update n 84

of use. It reduces the paint loss during color change to a minimum and greatly accelerates the color change process. Eight robots of type EcoRS are used for automatic seam sealing with 3D applicators. Four of them are equipped with highly precise tandem piston dosing units for sealing the seams from above. The use of heat wheels for recovering heat from supply and exhaust air is another feature which protects the environment. The waste heat from the ovens is also recovered via waste heat boilers. The exhaust air flow from the clear coat booth is purified before exiting the system. Membrane technology in pretreatment, electrocoating, and a wastewater treatment plant help to reduce the water consumption and thus the volume of waste water. n For more details, visit www.durr.com

Brand Report

Fast, safe and quiet: igus expands P4 roller energy chain system Rollers ensure very low friction and energy efficiency for long travels

In the P4 system the rollers (marked in green) of the upper run do not run onto the lower ones, but are staggered to run through them and supported by comb-shaped autoglide crossbars (also in green). The coefficient of friction when rolling drops by around 75 per cent when compared with gliding friction, which enables energy savings of up to 57 per cent required to drive the chain. (Source: igus GmbH)

he Cologne-based plastics specialist igus has expanded its comprehensive range of P4 roller energy chains system, now offering guide troughs for the P4.80. With it, a complete range of guide troughs are now available for all P4 roller energy chains from stock. Due to its special design, the P4 system can achieve travels of 800 metres or more in a very energy efficient way. Long travel lengths, high dynamics and high cable fill weights are extremely important not only for crane and conveyor energy supply systems. Speed and acceleration are important even in other sectors such as the automotive industry. For this reason, igus GmbH developed its innovative roller energy chain system which has been providing power and data reliably and safely on hundreds of cranes and other material handling systems for more than 15 years. Rollers made of special tribo-polymers provide a virtually maintenance-free operation. They reduce abrasion and wear of the energy chain considerably thereby increasing the service life of the system. As the coefficient of friction is about 75 per cent less with integrated rollers than with the normal gliding contact friction, up to 57 per cent less energy is required to drive the energy chain system.

High speed, long distance The roller energy chain system is constantly evolving. The P4 system is designed specifically for long travels up to 800m, high travel speeds over 10 m/s and high October 2014 n OEM Update n 86

fill weights of up to 50 kg/m. The rollers of the upper run do not run on the lower rollers, but are staggered to run between them. This is also supported by the use of autoglide crossbars with “combs” that keep the energy chain gliding in a straight line. The small pitch and uniform size of the chain links - with and without the rollers - causes the polygon effect to decrease and the chain thereby rolls smoothly and quietly. The chain is also shaped to offer a wide continuous running surface for the rollers to run on.. Guide troughs also assist in the safe and reliable operation of the e-chain. Wear pads integrated into the chain side links ensure a long service life when in contact with the guide trough.

Strong and stable Achieving exceptional stability at high speeds and accelerations is one of the objectives of the P4 system from igus. The links in the e-chain include a double “stop-dog” system, and tight tolerances allow a low clearance motion which enables high acceleration. The large pin and bore connections in the side links also provide stability, as does the “tongue and groove” design which interlocks the chain links together. The P4 roller chain is offered with a range of inner widths from 100 to 400 millimetres and inner heights of 32, 42, 56 and 80 mm. Three different bending radii for each type ensure flexibility in matching the cable minimum bend radius requirements. The load capacity of the roller chain can be increased further by using extension links to build a wider system.

Each extension link can carry up to 50 per cent higher fill weight, increasing the overall capacity. A double lock on the crossbar, which can still be opened quickly and easily with a screwdriver, holds the cables and hoses securely in the energy chain, even with large fill weights.

Everything from one source The P4 system is offered by igus as a modular system from a single source. As a readychain, the roller chain can be supplied as a fully assembled energy chain complete with cables, connectors and equipped with interface components such as floating towing arms and even electronic condition monitoring systems. These are delivered ready for installation together with the trough system. Before specifying the roller energy supply system, the igus installation team design the system, including all drawings and layouts. By working directly with the customer the individual system requirements can be fully met. n Contact: Harish Booshan Product Manager E-ChainSystems & ReadyChains igus (India) Private Limited 36/1, Sy. No. 17/3, Euro School Road, Dodda Nekkundi Industrial Area - 2nd Stage Mahadevapura Post, Bangalore - 560048 Tele: +91-80-49127809 (Direct) Email: harish@igus.in www.igus.in

dry-tech: ®

dry-tech® [ˈdraɪ]-[tekˈ] The lubricant-free, low-cost way to swivel, rotate, oscillate, move and achieve linear motion ... construct sustainably with dry-running polymer bearing solutions from igus . ®

.in/dry-tech24h

igus (India) Pvt. Ltd. 36/1, Sy. No. 17/3 Euro School Road Dodda Nekkundi Industrial Area - 2nd Stage Mahadevapura, Bangalore - 560048, Karnataka, India Phone +91-80-45127800 Fax +91-80-45127802 info@igus.in plastics for longer life ®

Product Launch

HMS expands Netbiter Remote Management offering H

well as powerful multi-site management with multiple users for larger installations. Netbiter can now meet even more demands for putting field equipment online, realising the Internet of Things.”

MS Industrial Networks expands the Netbiter Remote Management offering to include three different services catering for different user needs. The services enable both quick connections to a single remote machine, as well as advanced projects including multiple installations and users. HMS also presents a new Netbiter EasyConnect gateway (EC310) which communicates via Ethernet only. Three different services Netbiter is a cloudbased solution for remote management of equipment such as power generators, PLCs, sensors, tanks etc. Users connect a Netbiter gateway to their equipment and log in to the online data centre Netbiter Argos (www.netbiter.net), where they can access their devices online. Netbiter now includes three different services: • Remote access: Free and included with a Netbiter gateway Opens up a secure tunnel to a PLC or machine. This enables configuration, programming or debugging of almost any industrial device from any location. Users utilise their regular configuration software just as they would if they were on site. • View and control: Free and included with a Netbiter gateway Allows users October 2014 n OEM Update n 88

New gateway

to manage a single installation remotely. Online dashboards, alarms and trend graphs provide full insight from any location. • Manage and analyse: Subscriptionbased service for large-scale, multiple installations with several users. Users can customise the Netbiter Argos interface and integrate data into their own system with the Netbiter Argos API.

Realising the Internet of Things “With this new service offering, we take another step in making it easier for our customers to access their field equipment online,” says Henrik Arleving, Product Line Manager at HMS Industrial Networks. “We can now offer a quick and easy solution for monitoring a single installation online as

HMS also offers a new gateway, the Netbiter EC310, which sends data from the remote site via Ethernet only. This is a complement to the EC350 which communicates both via the mobile phone network (3G/GPRS) and via Ethernet.

What is Netbiter? Netbiter is a remote management solution for monitoring and controlling industrial equipment online. A Netbiter gateway connects to the remote equipment in the field and sends data to the Netbiter Argos data centre. This cloud-based server collects and stores the data from the field equipment and enables users to get statistics and reports on the performance of their devices. At www.netbiter.net users can see the status of their devices and can monitor and control equipment in a graphical dashboard. n For more details, visit www.netbiter.com.

BIG AND LITTLE

BROTHER ECONOMICAL SOLUTION WITH 12 CUTTING EDGES FACE MILLING CUTTERS WITH INSERTS

Dormer Tools India Pvt Ltd B 64-65, Sushant Lok -1 Gurgaon 122001 (Haryana), India www.pramet.com

Tel.: +91 124 4703825, 26

www.pramet.com

HNGX 09 & HNGX 06

Case Study

Pipeline alarm improvements through rationalisation The case study shows how Access Pipeline’s alarm management improved by implementation of proper and effective alarm management system

eadquartered in Calgary, Canada, Access Pipeline Inc. was established to construct, operate and manage the two corporations’ joint pipeline system assets. The Access Pipeline system accommodates two steam-assisted, gravity drainage, and heavy oil-producing facilities in the Christina Lake area of northeastern Alberta, where two heavy oil batteries are connected to the pipeline. Pipeline field operations are based out of the Sturgeon Terminal, 13 km east of Gibbons, Alberta. Additional resources are located in the Conklin area to assist with northern operations. Pipeline and facilities are monitored and controlled remotely via a Supervisory Control and Data Acquisition (SCADA) system. Local and remote computer systems provide necessary safeguards to operate the pipeline in accordance with Alberta Regulatory requirements. • Access Pipeline’s alarm rationalisation program has helped reduce configured alarms and improve the alarm rate at its Christina Lake, Alberta site. The work addressed the SCADA alarm system and controllers, ensuring ownership of the alarm problem at the operational level. During this project, strategies were developed to minimise the rationalisation effort, maximise the use of participants’ time, and still deliver expected results.

Benefits Rationalisation is a key stage in the alarm management lifecycle defined in ISA-18.2, which forms the basis for implementing an alarm configuration and optimising the performance of the alarm system. Access Pipeline’s initial alarm rationalisation effort produced noteworthy results. Overall, rationalisation reduced configured alarms by 65.7 per cent. This included reductions in configured highpriority alarms by 26.2 per cent and configured medium-priority alarms by 35.2 per cent. At the same time configured low-priority alarms increased by 26.25 per cent. Access Pipeline also gained many valuable insights from its work with Honeywell on alarm rationalisation. For example, the company found that the success of alarm rationalisation projects depends on detailed preparation, careful evaluation of the alarm system, and implementation of the right process pertaining to its business. Creating buy-in is essential, too, as it requires open discussions with alarm rationalisation professionals and listening to all feedback. Other “lessons learned” in developing the Access Pipeline alarm rationalisation process: October 2014 n OEM Update n 90

• • •

Don’t overlook the alignment of SCADA and HMI philosophies with alarm strategy Evaluate alarm descriptions and create a standard format providing sufficient detail for operators Avoid manual creation of alarm rationalisation spreadsheets Use Honeywell’s automated alarm management software package to generate required alarm rationalisation forms (two initial sites were manually prepared and rationalised in approx. 260 hours; all 37 remaining sites were completed in approx. 300 hours after purchasing alarm management software).

Challenges At modern industrial sites, poor performing alarm systems can overwhelm operators with alarm floods and hinder their ability to effectively manage process upsets. Time is the most critical factor in dealing with abnormal situations. Personnel must be able to take action within seconds in order to safely mitigate the impact of an upset. Most pipeline operating companies equate alarm management with reducing alarms, however, this is only one piece of the puzzle. Operations staff needs enough information to prevent abnormal situations — and prohibit the escalation of situations that cannot be avoided. Alarm management is a comprehensive process by which alarms are engineered, monitored, and managed to ensure safe and reliable operations. Industrial facilities focus on rationalising alarm systems so control room personnel can effectively manage the process and not just respond to alarms during their shift. Alarm rationalisation involves reconciling individual alarms against the principles and

Case Study has cleared removes one more issue requiring their attention. Honeywell also proposed solutions for reducing Access Pipeline’s alarm count, including: • Weekly review of top 10 most frequent alarms with goal of resolving issues prior to the next review (provided immediate reduction in alarms and improves alarm rate for operators) • Focus on tags producing high number of alarms or with chattering alarms • Prioritise groupings of correlated alarms once significant progress is made in eliminating unnecessary alarms.

requirements of the alarm philosophy. Relevant data for each alarm is documented to support other stages of the lifecycle. Unique metrics can be used to measure alarm system performance in a process industry facility. Typical key performance indicators (KPIs) include: • Total alarms generated by the system • Total alarms presented to the controller • Chattering alarm occurrences • Total alarms configured on the system • Alarms not in service (disabled or inhibited) • Duplicate alarms.

Further confirmation and review of alarm priority distribution data Honeywell’s specific alarm system recommendations were: • Rationalise top 10 alarms • Analyse root causes of alarms • Avoid alarm suppression to eliminate annunciation of alarms to control room operators • Modify control system to remove alarms in a managed and documented manner • Review and delete non-essential, operator-settable alarms from the list • Review relational alarms and determine if redundancy is required • Eliminate alarms that serve no additional purpose other than information. Finally, Honeywell recommended a review of the SCADA design basis and addition of topics such as: lifecycle, roles and responsibility, training, management of change, alarm system performance monitoring, and scheduling a full rationalisation for all alarms. n

Solution In 2008, Access Pipeline’s automation team and control centre operators identified the need to better control and manage more than 11,000 control system alarms. Several small and successful initiatives were undertaken during the following year. This included introducing alarm masking to reduce alarm flooding, adding first-in first-out (FIFO) sequence of events (SOE) routines to increase accuracy of the time stamp and cause of the SD, and eliminating latched alarms that didn’t activate an automated SD. In October 2010, Access Pipeline decided to build upon its previous alarm project by incorporating a comprehensive alarm rationalisation process. Honeywell was engaged to perform an analysis comparing existing alarm performance with alarm management best practices. The project team determined that the Matrikon solution would be used to achieve its alarm management objectives. The alarm analysis identified opportunities to reduce nuisance and redundant alarms, and determined that the overall SCADA alarm rate was unacceptable (approx. 40 alarms per hour during normal operating conditions). Based on the results of its analysis, Honeywell recommended that Access Pipeline’s status alarm latch functionality be reviewed and modified. Under the original system, operators could only tell if an alarm had cleared by sending a request to reset. Having an indication to inform operators that an alarm 91 n OEM Update n October 2014

Product Launch

Konecranes launches new overhead crane for emerging markets K

onecranes has introduced a new overhead crane, CXT UNO, in Pune to serve the needs of emerging markets. The new crane is primarily intended for companies operating in manufacturing, construction, and logistics. Capable of lifting loads up to 10 tonnes up to 9 metres off the ground, the CXT UNO features a 2-speed hoisting and travelling design with a fixed pendant controller, tagline festooning, and compact singlegirder construction, and can operate over spans of up to 20 metres. According to the company safety, high-quality, high-productivity, low power consumption and easy maintenance – are some of the key features of CXT UNO.

2-SPEED TRAVELING AND HOISTING MOVEMENTS

Talking about the significance of Indian market for the company’s global business Pekka Lundmark, President and CEO, Konecranes said, “India is key to our growth targets and we are very optimistic about Indian market. We have invested Rs 120 crore for our Jejury plant near Pune. The plant has a capacity of manufacturing 1,000 cranes annually.” Saeesh Nevrekar, Country Manager, India adds, “The current industrial cranes market in India is around EUR 500 million and we have a market share of 10 per cent.”

PROFILE GIRDERS allow for optimized use of steel.

PENDANT FIXED ON THE HOIST OPTIMIZED USE OF SPACE IN END CARRIAGES

LIGHTER STRUCTURED TAGLINE POWER SUPPLY

Small, compact bridge panel and tagline power supply attached directly onto the end carriage.

with round cables is a simple and dependable way to supply power to the hoist.

October 2014 n OEM Update n 92

“CXT UNO expands our product offering into a segment where we haven’t been present before,” says Jukka Paasonen, Vice President, Head of Business Line Industrial Crane Products, Konecranes. “The CXT UNO offers customers in this category access to Konecranes’ quality and reliability in what we believe is a very attractive and competitive overall package.” He claimed that the new crane is 20 per cent cost-efficient and more importantly delivery time is only 3-4 weeks.

CXT UNO is Konecranes’ second product to be launched for emerging markets this year and follows the BOXHUNTER, an innovative new type of RTG for ports and terminals. In 2013, the group sales totalled EUR 2,100 million. It has around 12,000 employees at 600 locations in 48 countries. In India, Konecranes has two manufacturing facilities and employs around 700 employees.

Empowering SMEs

Across India

India’s Largest SME Gathering On Engineering & Manufacturing

PUNE

CHENNAI

31 Oct - 03 Nov 2014

20 - 23 Nov 2014

LUDHIANA

AHMEDABAD

12 - 15 Dec 2014

13 - 16 Feb 2015

Exhibitors’ Proﬁle • Auto Components

• Instrumentation

• Power

• Automation & Robotics

• IT Products & Services

• Process Plant Machinery & Eqpt

• Bearings

• Light & Medium Industries

• Pumps & Valves

• Castings & Forgings

• Logistics & SCM

• Safety & Security

• Chemical Process Machinery

• Machine Tools & Accessories

• Special Purpose Machines

• Die & Mould

• Manufacturing Aids

• Testing & Measuring Instruments

• Electrical & Electronics

• Material Handling

• Water Treatment Products

• Factory Interiors

• Metal & Steel

• Wheels & Castors

• Hand Tools

• Packaging Machinery & Equipment

• Wires & Cables

• Hydraulics & Pneumatics

• Pipes, Tubes & Fittings

• Industrial Maintenance Products

• Plastics Machinery & Equipment

and many more…

For Details Contact : +91 9819552270 | engexpo@network18 publishing.com An Event By

Supported By

In Association With

BOOK

YOUR STALL

Consortium Of Ludhiana Machine Tools Manufacturers

Online Partners

Magazine Partners

Media Partner

Hotel Partners

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N OW !

Brand Report

Wohlhaupter: meeting boring requirements since 1929 P

recise quality products are day in and day out job in the manufacturing sector now. Boring, as one of the last operations in hole making, is very critical as even an error in microns can reject the component which is time and money loss in strict target. Wohlhaupter helps to meet the quality and precision hole making requirements in a lesser cycle time. Wohlhaupter is a renowned name when it comes to boring and since 1929 companies across the globe rely on Wohlhaupter as one of their preferred boring solutions providers. It has been serving the Indian customers for more than 20 years now. To strengthen the support activities, Wohlhaupter India Pvt. Ltd. as the 100 per cent subsidiary of Wohlhaupter GmbH brings the Wohlhaupter quality and its innovative products closer to Indian market. With tools ranging from hole size 0.4mm to 3,255 mm and productivity improving tools enabling roughing and finishing in one go, Wohlhaupter has the right solution to offer.

• • • • •

Range of products •

MultiBore: Modular connection boring

•

systems, enabling a range of sizes to communise the solutions Combiline: Roughing and finishing in one go UPA: Facing and boring heads EK: Grooving head Customised solutions: Solutions as per your exact requirement Clamping elements: Machining centre holders for various spindle types Replaceable inserts: ISO and

special inserts of different grades and geometries. n Contact Khurram Iqbal Asst. Manager- WApplication and Business Development Wohlhaupter India Pvt. Ltd. B-23, B Block Community Centre, Janakpuri, New Delhi-110058

KHD Valves Automation: standardised for critical services

HD Valves Automation Pvt. Ltd. is an ISO 9001:2008, ISO 14001:2004 and OHSAS 18001:2007 company. The company is mainly in the manufacturing of industrial valves for the past four decades. Each and every valve of KHD passes through stringent quality control tests at every stage of production and each valve made perfect in all respect. Each valve is tested on in-house modern test bed as per the latest Indian BS,

October 2014 n OEM Update n 94

ASA standard for hydraulic and pneumatic testing.

Valves has computerised most of its activities from designing to marketing.

Standardisation of valves components manufacturing ensures easy interchangeability and hence maintenance becomes easy.

KHD Valves Automation has been standardised for critical services by many renowned establishments. n

KHD Valves Automation has experience of two decades in manufacturing of precision industrial valves and has created its position in terms of quality and reliability across the process industries and other vital industrial units.

Contact

The company has required infrastructure for manufacturing, testing, designing, and development and quality control. To keep pace with the fast changing world, KHD

KHD Valves Automation Pvt. Ltd. Jogani Industrial Estate, Bldg. No: 9, Gr. Floor, Unit No. 7, V.N. Purav Marg, Chunabhatti (E), Sion, Mumbai – 400022 Tele: +91-22-24051234, 24055678 Fax No: +91-22-24055678 Mob: +91-982 111 6437, 8108450450 Email: khdhemant@gmail.com www.khdvalvesautomation.com

Brand Report

Aerosense differential pressure indicator and transmitter

Applications Aerosense differential pressure indicator or transmitter (Model ADPI-LED) finds extensive application in pharma clean rooms, HVAC, environmental, pharma machinery, across ﬁlters, hospital isolation rooms, operation theatres and laboratories. Precision of measurement in HVAC duct pressure application makes this instrument suitable for optimisation of energy and thereby its conservation in ventilation systems. Analog output and RS 485 communication lead to easy integration with

Variable Frequency Drives and SCADA or BMS systems.

Unique features • Outstanding accuracy of +/-0.5 per cent F.S. for positive, negative or differential pressure • Front Key selectable any 2 engineering unit selection • Large and easy to read 7 segment LED display • Install in any position without losing readout accuracy

• Optional analog output of 0-10V.D.C. or 4-20mA • Integrated buzzer alarm for Hi and Lo alarm limit violation • Display Blink in case of alarm to alert operator • Optional RS485 Modbus communication for SCADA or BMS integration • Flush mount provision with stainless steel front plate for Clean Room. n For more details, visit www.aerosense.sg or mail at sales@aerosense.sg

McPherson Strut Bearing Unit A new generation of suspension bearings to extend product lifetime in diverse driving conditions

he environment for driving in India can be very tough and demanding, not only on the driver but equally demanding on the vehicle also. Today, it is important that automotive manufacturers focus on building platforms that will survive the tough environmental conditions in emerging markets. As a result, the suspension bearings need to meet these new market requirements, being able to support high loads, external pollution and have improved reliability.

SKF’s role SKF’s experience and understanding of the suspension application enable them to develop products and solutions that are robust and reliable. This can reduce manufacturers’ risks when launching a new product, helps reduce warranty costs and minimise the number of field returns. SKF October 2014 n OEM Update n 96

Superior suspension means robust solutions that improve performance and minimise cost. SKF’s engineering excellence enables them to provide the customers with robust and reliable MacPherson strut bearings and shock absorber seals.

• It comes with a new ball set to increase radial capacity, provide lower radial clearance and increase overturning moment • The metallic spring seat has been overmoulded to lower deformation and stress • Seals have been designed to combine a full protection against external pollution, providing low friction torque.

Benefits

Key features

• The downsizing and integration of components of SKF MacPherson strut bearing units reduces weight and size • Provides more space for surrounding components • Reduces fuel consumption • Withstands severe environmental conditions

MSBU has been developed for specific applications in terms of loads, geometry of housings and protection from surrounding environment and has the following key features: • Enables coil spring or complete suspension to rotate during steering movements with low, constant friction torque • Enables spring rotation during normal suspension movements and transmits suspension loads to chassis. n

bearings and seals help increase the service life of the suspension.

Brand Report

SML PEB: assured quality, timely delivery

M. S. Saxena, Chairman, Saxena Marine Tech Pvt Ltd

SML PEB business has become synonymous with providing nonresidential PEBs to client with a comprehensive offering of design, manufacturing and erection services having all facilities under one roof.

axena Marine-Tech Pvt. Ltd. (SML) has been serving the nation since 1973, when it started its journey by associating with the indigenisation process of Ministry of Defence. SML has come a long way since then. SML PEB business has become synonymous with providing non-residential PEBs to client with a comprehensive offering of design, manufacturing and erection services having all facilities under one roof. The company consistently sets new standards in building technology, with continual improvement and assimilation of new concepts, products and practices. Its products are backed by superior quality assurance practices to ensure that every SML building shall perform equal to the best in the world. SML buildings are custom-designed using state-of-the-art engineering software so as to meet customers’ exact specifications. Its construction approach ensures that the

buildings are comparatively economical and delivery is faster. SML is equipped to meet the demand for environment friendly, energy efficient design as well as contemporary construction practices to ensure that the buildings perform well during the expected life. SML PEB has product approval from Military Engineering Services (MES).

Focus on customer In India, penetration of PEB concept and its components has increased tremendously during the past 10 years. It has found application in 5-Star hotels, green buildings, shopping malls, residential accommodation, high rise buildings, cold storages, steel and cement plant sheds in addition to the conventional uses like warehouses and industrial buildings.

• • • • • •

Roofing and wall cladding Cold form Z and C purlins Metal decking or mezzanine system Roof rafter system Insulated roofing or cladding system Louvers.

SML products are produced using virgin carbon steel and aluminium alloy based materials for PEB. SML is having vast experience of over three decades in fabrication and manufacturing. It started PEB business vertical in 2001. Today the company is offering versatile solutions to building industries which include design, engineering, development, and execution of complete metal building.

PEB as concept has great future. Today, SML is covering entire range of application of PEB concept except residential buildings.

SML steel building manufacturing facility has four semi-automatic, computer aided manufacturing lines. SML strives to exceed the expectations of its valued customer by virtue of having assimilated the stringent Military Standards. n

SML product range

Contact:

•

Pre-engineered building systems Saxena Marine-Tech Pvt. Ltd. B-15, Site – C, Industrial Area Surajpur Greater Noida – 201306, UP Mobile: +91-9818189271 Tele: +91-120-2560600, 601 Fax: +91-120-2560600 Email: sales@smlpeb.com, info@smlpeb.com www.smlpeb.com 97 n OEM Update n October 2014

Brand Report

Cost-effective pumping solution New rotary lobe pump needs 10 % less energy and can be used in wide range of applications

n order to meet the growing pressure to achieve efficiency in process sectors, new generation rotary lobe pump TORNADO T2 has been developed. Conventional design principles were comprehensively reworked on the basis of established displacement technology, so as to reduce service times, increase operational reliability and lower both materials and energy costs. Pumps in the processing industry must operate in a pressure-stable, constant and smooth way â&#x20AC;&#x201C; but at the same time they should also be low-maintenance and have reasonable operating costs. Positive displacement pumps have already proved their worth over a long period of time in a variety of fields of application. They achieve high pumping capacities, are self-priming, are resistant to dry-running and convey without strong pulsation or shear forces. They are suited to low to high viscosity, abrasive media, either containing solids or gases, lubricating or non-lubricating. It was essential to keep these typical characteristics when reworking the pump and in addition to increase the efficiency still further through design modifications.

Saves energy and reduces wear Reversing the materials in the pump chamber represents a crucial innovation. Instead of elastomer lobes rotating in a steel chamber, light hollow rotary lobes made of steel or stainless steel are used here running in a housing lined with a specially shaped elastomer insert. The particular advantage of this is that the thin-walled rubber skin of the insert is less seriously affected by temperature fluctuations than the relatively thick rubber layer of the previous rubber lobes. This means that expansion and contraction are easier to control, which enables significantly tighter tolerances in the manufacture of the elastomer components. For a radial gap actually to develop, a far greater amount of elastomer would have to be worn away from the whole radial area of the insert than on the lobe tips of the October 2014 n OEM Update n 98

previous rubber lobe design. The clearances can therefore be reduced to the minimum which is technically feasible and this increases the overall level of efficiency. In addition, it was ensured that only steel and rubber surfaces come into contact at any time anywhere in the pump chamber. To achieve this, a precisely dimensioned elastomer insert was vulcanised onto the edges of the rotary lobes, so that there is not only a hard-soft contact between lobes and housing during rotation, but also on the contact surfaces of the lobes with one another. This structure reduces friction and thus power loss as well. The new design was able to lower energy consumption by around ten percent overall in comparison to previous models. In addition, this mix of materials means less wear and greater preservation of materials in general. Until now, elastomer lobes have been exposed to strong dynamic forces when in operation and these accelerate the ageing of the material. In contrast, steel is resistant to motion for a considerably longer time, which means lower costs for maintenance work and spare parts. Conversely, when signs of wear appear, the new elastomer housing insert can be replaced considerably more quickly and at a much lower cost than the standard wear plates. The special

geometry of this casing with its machined-in pockets also reduces pulsation, which means the TORNADO T2 with straight bi-lobe rotors achieves similar low pulsation values to complex spiral lobe designs.

Critical applications The slim design of the new TORNADO T2 makes it far more compact and around 30 percent lighter than comparable models and it can therefore be used for mobile applications with any problem. It is suitable for sensitive foods such as edible oil as well as for aggressive chemicals, such as highly abrasive concrete primer for example. There is also an all-metal model for particularly challenging media. The all-metal pump is available in stainless steel, special steels or also with coatings, so that it is resistant to chemically aggressive media, high temperatures or abrasive media too. An electropolished model is also available in the market. n Contact NETZSH Pumps & Systems, NETZSCH Technologies India Pvt. Ltd. No.39, 2nd Street, Spartan Nagar, Mogappair, Chennai - 600 037 Tele: +91-44 4296 5100 Email: info.nti@netzsch.com www.netzsch.com

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Co2 MIG Welding Wires SAW Welding Wires For strong & spatterless welding of Automobiles Frames, Body, Chassis, Silencers, Spiral & Longitudinal Pipes Cylinders & all general Steel Fabrication.

Sales Network all over India. Manufacturers & Exporters:-

WIRES PVT. LTD.

An ISO 9001-2000 Certified Company

207, Timmy Arcade, Makwana Road, Marol, Andheri (E), Mumbai - 400 059. Tel: +91-22-2850 4848, 2850 7501, 2850 7502 Fax: +91-22-2850 7503 E-mail: klinweld@gmail.com Cell: 98201 34152 Website: www.klinweld.com Authorised Distribotor ( Bombay ) Fiszaz & Sons 08108366364 Landline 022-25394212

October 2014 n OEM Update n 102

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103 n OEM Update n October 2014

Event

Technologies to address India’s mega-water cleaning needs to be showcased at IFAT 2014 IFAT India 2014 to provide an excellent platform and larger participation from both India and international, showcasing environmental technologies and services

he Indian edition of the world’s largest trade exhibition on environmental technology; IFAT India 2014 will be hosted from 9 – 11 October, 2014 after the successful debut of its first edition. IFATIndia2014 is the largest trade exhibition in this segment with a focus on environmental technology, the need for which is paramount, for a growing economy like India. Providing a unique opportunity to showcase a range of world-class products and services in the environmental industry, IFAT India 2013 had been successful in inviting participation of over 130 exhibitors from 17 countries and attracting close to 5000 trade visitors reaping benefits of largest exhibition on environmental technology. This exhibition would infuse the most updated technologies with a great amalgamation of superior quality services across sectors of the environment industry. The exhibition encapsulates sectors of water, sewage, refuse, recycling and energy conservation.

IFAT India 2014 will again be supporting the Indo-German Environment Partnership (IGEP) of the GIZ. The Government at the Centre has also constituted the newly set-up Water Resources Ministry to look at the Ganga Rejuvenation Project, where the Minister has also gone on record stating that they will be able to rejuvenate the river in a period of three years. This ominous task will mean multiple mega-projects will be rolled out in water and other allied technologies along the length of the river. The “Clean Ganga Award”, a special prize for reporting on the rejuvenation of the Ganges, will be presented by Michael October 2014 n OEM Update n 104

Steiner, the German Ambassador in India. Parallel to the exhibition there will be various conferences like professional training in the water sector, training for wastewater treatment plant operators in India, green jobs in India in the water sector, training in the textile industry in Bangladesh. Eminent speakers from the industry like Dr. Helmut Schnurer, former Director General, Federal Ministry for the Solid waste regulation in India and Germany Environment, Nature Conservation, Building and Nuclear Safety, Dr. D B Boralkar, Former Member Secretary, Maharashtra Pollution Control Board Industry representative are expected to be present at the event. The efforts towards water protection, waste management, pollution control, clean air, are much demanded for a better tomorrow. The government will focus more on infrastructure, public transport, solid waste disposal, sewage treatment and drinking water. According to the Government of India statistics, about 42 million metric tonnes of solid waste is generated per year in urban India with per capita waste generation rate ranging between 0.2 and 0.6 kg per day. Bhupinder Singh, Deputy CEO, MMI India said, “The trade exhibition would offer an opportunity for foreign water treatment, recycling, sewage companies to collaborate with Indian players and generate revenues in the lucrative Indian market. International exhibitors will present futureorientated innovations for sustainable use of resources in the industrial nations as well as adequate technologies for the developing countries. Conferences, symposia and workshops will complete the exhibition program. IFAT India is a platform

that provides Municipal and Government bodies or authorities to witness the solutions for environment technology under one roof. Both, national and international players of this segment are present at the trade-fair”. Saurabh Shah, Vice President at Excel Industries Ltd, India said, “IFAT India 2014 provides a high quality platform for innovations in environment technology. We are pleased to participate in IFAT India 2014 because it helps us to showcase our technology in this environmental sector”. Sunil Bhor - AGM - Environmental Sales & Marketing at Endress+Hauser India

IFAT India 2014 Expectation • 4,924 trade visitors • 131 exhibitors from 17 countries • Innovation exchange forum

Pvt. Ltd, said, “Industrial sector increase from 6 per cent to18 per cent. Issue and challenges for water and waste water industry in India are Burgeoning demand for water, regional disparities, groundwater depletion and contamination & Inefficiencies in usage. Hence there is an urgent need for efficient water management, enhanced water use efficiency and waste water recycling. Trade fairs such as IFAT India have been a great platform for bringing international key decision makers, customers, and solution providers under one roof.” n

COMMERCIAL PARTNERS Ace Micromatic Group ................................................................85

Kuka Robotics India Pvt Ltd .......................................................37

Ace Weld Engineers....................................................................99

Linear Systems .........................................................................103

Ahire Machine Tools Pvt. Ltd.......................................................81

Mather & Platt Pumps Ltd ..........................................................23

ALM Engineering & Instrumentation Pvt. Ltd ...........................IFC

MGM Varvel Power Transmission Pvt Ltd.....................................7

Apurva Water Management Systems........................................101

Omron Automation Pvt Ltd ...........................................................5

Associate Flexiweld Pvt Ltd ......................................................102

Power Build Ltd ........................................................................IBC

Autosys Engineering (P) Ltd .......................................................57

Radiant Engineers ......................................................................65

Avians Innovations Technology Pvt. Ltd. ....................................13

Red Lion Controls .......................................................................63

B&R Industrial Automation Pvt Ltd .............................................15

Rockwell Automation ..................................................................11

B. R. Kumar & Sons ...................................................................35

Rtex Connectors........................................................................103

Dirak India Panel Fittings Pvt Ltd ...............................................53

Sandvik Asia Pvt Ltd......................................................................9

Dormer Tools India Pvt Ltd..........................................................89

Saxena Marine Tech (P) Ltd........................................................71

Electronica India .......................................................................102

Skaf Enterprise...........................................................................69

Electronics Devices.....................................................................31

U K Systems................................................................................91

Ewac Alloys Ltd...........................................................................41

Universal Welding Systems ........................................................43

Fairdeal Agencies Pvt. Ltd...........................................................29

Vermani Enterprises ...................................................................39

FRONIUS India Private Limited......................................... Gatefold

Welding Technologies India.........................................................45

Gati Kintetsu Express Pvt. Ltd ....................................................19

Wohlhaupter India Pvt Ltd..........................................................BC

Genesis Membrane Sepratech Pvt. Ltd. ..................................100 Graebert India software Pvt Ltd ..................................................61 GreenEclipse Technologies India Pvt. Ltd ................................108

SPRAY BALL

FULL VIEW T.C

igus India Pvt. Ltd........................................................................87 Impex Engneering & Equipment Co..........................................103 IMTMA ........................................................................................17

DIAPHRAGM VALVE

ACTUATED BALL VALVE

T.C. 1-PC BALL VALVE

3-WAY T.C BALL VALVE

DEAD LEG VALVE

T.C. TEE

FLUSH BOTTOM ‘Y’ TYPE

TC. 3PC BALL VALVE

TRYCLOVER CLAMP

FLUSH TYPE BALL VALVE

Janatics India Pvt. Ltd ................................................................51 Jayesh Group .............................................................................33 KHD Valves Automation Pvt Ltd................................................104 klinweld Wires Pvt Ltd ..............................................................102

BUTTERFLY VALVE

rd STRAINER

105 n OEM Update n October 2014

New Projects

Cement

Drugs and Pharmaceuticals Lupin plans a Darunavir Ethanolate manufacturing unit in dist. Vadodara, Gujarat. The drug is used to treat HIV infection. Location: Vadodara, Gujarat. Status: Planning Stage Contact: Lupin Limited, Registered Office: 159, CST Road, Kalina, Santacruz East, Mumbai Suburban - 400098, Maharashtra Tel: 91-22-66402323 Fax: 91-22-66432051 Email: corporateoffice@lupinworld.com Website: www.lupinpharmaceuticals.com

Tamilnadu Newsprint & Papers plans an expansion of its cement manufacturing project at Kagithapuram, dist. Karur, Tamil Nadu from 600 TPD to 900 TPD. Location: Karur, Tamil Nadu Status: Planning Stage Contact: Tamilnadu Newsprint & Papers Limited, Plant Add: Kagithapuram, Karur - 639136, Tamil Nadu Tel: 91-4324-277001/ 277002/ 277003/ 277004/ 277005. Fax: 91-4324-277025/ 277026. Email: it.fo@tnpl.co.in,mktg.fo@tnpl.co.in Website: www.tnpl.com

sugar Aakriti Sugar Mills, plans an expansion of its sugar manufacturing unit at Village Tumda, dist. Narsinghpur, Madhya Pradesh. The existing capacity is 1,200 TCD. Location: Narsinghpur, Madhya Pradesh Status: Conceptual Stage Contact: Aakriti Sugar Mills Private Limited, Registered Office: F-11,206, Shristi Complex, M.P Nagar, Zone-1, Bhopal - 462011, Madhya Pradesh Tel: 91-755-2573954/ 2763653. Fax: 91-755-4270084. Email: adplbhopal@rediffmail.com Website: www.ag8.in

Chemicals India GCI Resitop plans a resin coated sand & phenolic resin manufacturing project at Oragadam, dist. Kanchipuram, Tamil Nadu. Land acquisition is in progress. Location: Kanchipuram, Tamil Nadu Status: Planning Stage Contact: India G C I Resitop Private Limited, Plant Add: S. F. No. 429/4, 429/6, Sriperumbudur Taluk, Mannur, Kanchipuram - 602105, Tamil Nadu Website: www.gunei-chemical.co.jp

Textile Murugan Textiles is implementing a 70,000 spindles cotton yarn spinning project at Palladam, dist. Coimbatore, Tamil Nadu. A 1 MW rooftop solar plant and a warehouse facility will also come up in the same location. Location: Coimbatore, Tamil Nadu Status: Under Implementation Contact: Murugan Textiles Private Limited, Administrative Office: 84, Trichy Road, Palladam, Coimbatore, Coimbatore - 641664, Tamil Nadu Tel: 91-4255-252552.

Chemicals Bhuruka Gases plans a compressed oxygen project in dist. Pune, Maharashtra. Land is yet to be acquired. Location: Pune Status: Conceptual Stage Address: Bhuruka Gases Limited, Registered Office: Whitefield Road, Mahadevapura Post, Bangalore, Bangalore - 560048, Karnataka Tel: 91-80-41818200. Fax: 91-80-28524243/ 41148753. Email: info@bhurukagases.com Website: www.bhurukagases.com

Textile The Cotton Corporation Of India plans a cotton bale ginning & pressing project in Telangana. Work will commence after completion of the companyâ&#x20AC;&#x2122;s ginning and pressing unit to come up in Andhra Pradesh Location: Telangana Status: Conceptual Stage Contact: The Cotton Corporation Of India Limited, Registered Office: Kapas Bhavan, Plot No. 3-A, P.B.No : 60 Sector 10, CBD Belapur, Navi Mumbai 400614, Maharashtra Tel: 91-22-27571368/ 27579217. Fax: 91-22-27576030/ 27576069/ 27579219. Email: headoffice@cotcorp.com Website: www.cotcorp.gov.in

Metallurgical Industries Gerdau Steel India is implementing a coke plant at Village Jambulapadu, dist. Anantapur, Andhra Pradesh. Location: Anantapur, Andhra Pradesh Status: Under Implementation Contact: Gerdau Steel India Limited, Corporate Office: 304/305, World Trade Center Bangalore, No. 26/1, Dr. Rajkumar Road, Malleshwaram (West), Bangalore, Bangalore - 560055, Karnataka Tel: 91-80-30262205. Fax: 91-80-30262241. Website: www.gerdau.in,-www.gerdau.co.in

Automotive components Neel Metal Products, is implementing a 2-wheeler motorcycle parts and accessories manufacturing project at Village Vithlapur, dist. Ahmedabad, Gujarat. The project is scheduled for completion in 2015. Location: Ahmedabad, Gujarat Status: Under Implementation Contact: Neel Metal Products Limited, Plant Add: Sector-36, Mohmmadpur Jharsa, Near Khandsa Village, Gurgaon - 122001, Haryana Tel: 91-124-4032011/ 4767800. Mobile: +91-9711169788,+91-9711169789 Website: www.jbm-group.com

Metallurgical Industries Bhushan Steel is implementing an expansion of its Cold Rolling Mill (CRM) at Meramandali, dist. Dhenkanal, Odisha. Location: Dhenkanal, Odisha Status: Dhenkanal, Odisha Contact: Bhushan Steel Limited, Plant Add: Narendra Pur, P.O. Shibapur, Meramandali, Dhenkanal - 759121, Odisha Tel: 91-6762-300000. Email: bssldhenkanal@bhushansteel.com Website: www.bhushan-group.org

Note: Above information is the sole property of domexinfo.in and can not be published without prior permission.

October 2014 n OEM Update n 106

Tenders nPorts

Company Name: Paradip Port Trust Tender Detail: Consultancy Services to Study for Improvement of Operational Efficiency of Paradip Port. Location: Paradip Documentation Sale from: 16-September- 2014 Documentation Sale to: 30-October-2014 Documentation Fees: ` 5,000/EMD: ` 50,000/Closing Date: 31-October-2014 Address: Iron Ore Handling Plant, Administrative building, Paradip Port, Paradip, Jagatsinghpur – 754142, Odisha. Tel: 91-6722-222078 Fax: 91-6722-220287 Email: bipin_sai07@yahoo.co.in Website: www.paradipport.gov.in Company Name: Kolkata Port Trust Tender Detail: Tender For Repairing Of Damaged Wearing Course On Deck Surface Of Berth No.4b In Patches At Haldia Dock Complex, Haldia. Location: Haldia Documentation Sale from:19-September- 2014 Documentation Sale to: 20-October-2014 Documentation Fees: ` 600/EMD: ` 16,000/- Closing Date: 21-October-2014 Address: Haldia Dock Complex, Jawahar Tower, Haldia Township, East Midnapore - 721607, West Bengal. Tel: 91-3224-252118 Fax: 91-3224-263255 Email: bsengupta@kopt.in Website: www.kolkataporttrust.gov.in

noil & gas

Company Name: GAIL (India) Limited Tender Detail: E-tender for time charter hiring of LNG vessels Location: New Delhi Documentation Sale from: 01-August-2014 Documentation Sale to: 30-October-2014 Documentation Fees: ` 1,20,000 Closing Date: 30-October-2014 Address: 16, Bhikaiji Cama Place, R.K.Puram, New Delhi – 110066 Tel: 91-11- 26172580 Fax: 91-11-26185941 Email: shalder@gail.co.in Website: www.gailonline.com Company Name: GAIL (India) Limited Tender Detail: Rate Contract for SITC of GPRS Based Communication System for GMS Location: Uttar Pradesh Documentation Sale from: 4-September- 2014 Documentation Sale to:17-October-2014 Documentation Fees: `1686.00/- (` 1500/+Service Tax @12.36%)

Closing Date:17-October-2014 Address: Jubilee Tower, B-35 & 36, Sector-1, Noida – 201301, Gautam Buddha Nagar, Uttar Pradesh. Tel: 91-120-2446400, 2547855 Fax: 91-11-26185941, 26182126 Email: rps04536@gail.co.in Website: www.gailonline.com

nthermal power

Company Name: NTPC Limited Tender Detail: Air Conditioning and Ventilation System Package for Lara Super Thermal Power Project, Stage-I (2X800 Mw) Located at Lara, District Raigarh, State of Chattisgarh. Location: Raigarh Documentation Sale from: 18-September- 2014 Documentation Sale to: 20-October-2014 Documentation Fees: ` 6,750 + Bank Charges EMD: ` 3,719,000/Closing Date: 20-November- 2014 Address: NTPC Limited, Sixth Floor, Engineering Office Complex, Plot A-8A, Sector-24, Noida, Gautam Budh Nagar-201301 Uttar Pradesh. Tel: 91-120-4948678/ 4946663 Fax: 91-120-2410359/ 2410011 Email: dinkarsingh@ntpc.co.in / jsbhal@ntpc.co.in Website: www.ntpctender.com

nConcrete Pavement

Company Name:Government Of Karnataka, Directorate of Municipal Administration Tender Detail: Providing concrete pavement to Prapade Jalligudde 3rd Cross Road of 17 Derebail North ward in MCC Limits. Location: Karnataka Documentation Sale from:17-September- 2014 Documentation Sale to: 20-October-2014 Documentation Fees: ` 500/EMD: ` 29,550/Closing Date: 20-October-2014 Address: Mangalore City Corporation, M.G Road, Lalbagh, Mangalore -575003 Karnataka. Tel: 91-824-2220316 Fax: 91-824-2220309 Website: www.mangalorecity.gov.in

ntyers

Company Name: Indian Air Force Tender Detail: RFP Floated on LTE basis for tyres for MIG-27 A/c to registered firms. firms to abide to the provisions of the DPM-09 as amended. Location: New Delhi Documentation Sale from: 07-August-2014 Documentation Sale to: 27-November-2014 EMD: ` 2,575,200/Closing Date: 27-November-2014

Address: Room No. 278, Directorate of Proc Air HQ (VB) Rafi Marg, New Delhi-10106. Tel: 91-11-23010231 Fax: 91-11-23012934 Website: www.indianairforce.nic.in

nPower

Company Name: Power Grid Corporation of India Limited Tender Detail: Substation package ss01 for 765/400 kv Chittorgarh (New) substation and extension of 400kv Chittorgarh (rvpn) substation associated with Green Energy Corridors Inter-State Transmission Scheme (ISTS) Part A Location: Chittorgarh Documentation Sale from: 04- September- 2014 Documentation Sale to: 20-October-2014 Documentation Fees: ` 25,000/- EMD: ` 20,541,000/Closing Date: 21-October-2014 Address: Saudamini, Plot No-2, Sector-29, Third Floorgurgaon, Gurgaon - 122001 Haryana Tel: 91-124-2571700-19, 2822339, 2822376, 2823313 Fax: 91-124-2571 831 Website: www.powergridindia.com Company Name: Karnataka Power Corporation Limited Tender Detail: Dismantling of existing 350 NB Motor operated cast steel gate valves, supply, erection & commissioning of new 350 NB Motor operated cast steel gate valves –2 Nos. for Nagjhari Power House. Location: Uttara Kannada Documentation Sale from:17-September- 2014 Documentation Sale to: 28-October-2014 Documentation Fees: ` 550/EMD: ` 50,000/Closing Date: 28-October-2014 Address: No. 01, KPCL, Ambikanagar, Uttara Kannada - 581363 Karnataka, INDIA. Tel: 91-8284-258626 Email: seenambica@yahoo.com Website: www.karnatakapower.com Company Name: Power Grid Corporation Of India Limited Tender Detail: Tower Package-Tw01 for 765kv D/C Chittorgarh-Ajmer Transmission Location: Chittorgarh to Ajmer Documentation Sale from: 11-September- 2014 Documentation Sale to: 27-October-2014 Documentation Fees: ` 25,000/EMD: ` 43,019,000 for package TW01, ` 44,557,000 for package TW02, ` 49,059,000 for package TW03 Closing Date: 28-October-2014 Address: Saudamini, Plot No-2, Sector-29, Third Floor, Gurgaon - 122001, Haryana, Tel: 91-124-2571 700-19, 2822336, 2822383 Fax: 91-124-2571 831 Website: www.powergridindia.com

Note: Above information is the sole property of domexinfo.in and can not be published without prior permission.

107 n OEM Update n October 2014

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Wohlhaupter India Pvt Ltd. B-23, 2nd Floor, B Block community Centre, Janakpuri, New Delhi-110058, India Phone: 011-32227044, 41827044 Mobile: 9810405242, 8447398786 Email: info.in@wohlhaupter.com, keshav.khurana@wohlhaupter.com, Challenge us at:- www.wohlhaupter.com, www.wohlhaupterindia.in 110

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Address: Survey No. 28 / 2,3,4,Sahil Park, Near Raghunandan Mangal Karyalay, Tathawade, Tal. Mulshi, Dist. Pune - 411 033. Contact: VG Patil (Director) +91 9823443601 SP Patwardhan (Director) +91 9422082829 Tel : +91 - 20 - 651109 Email : aceweld2008@rediffmail aceweld2008@gmail.com Website: www.aceweld.in 99 n OEM Update n October 2014