OEM Update April 2015

MAHENG/2009/33944

Vol 6 Issue 11 • Pages 60 • Mumbai

April 1, 2015 • `100 • www.oemupdate.com

OEM UPDATE

MINDING THE GAP Manufacturing skills gap is an issue that is being jointly addressed by the industry and the education system with a view to create a more skilled workforce

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MINDING THE GAP

OEM UPDATE

Manufacturing skills gap is an issue that is being jointly addressed by the industry and the education system with a view to create a more skilled workforce

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CONTENTS FEATURES

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Automation helping F&B industry scale new heights

18 Sliding and rolling: igus hybrid linear bearings in new sizes drylin double roller hybrid bearings now available for rail diameters of 10 and 16 mm

20 Ready-to-install parts straight from the press Combination of precision blanking and sheet metal forging reduces number of process steps as well as material and energy costs

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+ Context

+ Experience + Analysis + Conversion

BRIDGING THE BIG DATA CHASM How engineering and IT can work together to leverage test data

22 Flexible precision toolholder for automated tool grinding SCHUNK PRIMSO3 offers optimum preconditions for fully automated production grinding and resharpening of tools

26 New era in die mould with Mitsubishi Electric CNC Mitsubishi Electric CNC products are engineered with cutting edge solutions and technologies to meet the requirement of the precision industries

38 Optimising performance in industrial waste water treatment

SPEAK OUT

30

36

PSG pumps are optimised for management of industrial wastewater.

PSG pumps can work well in integrated waste water treatment systems where different types of equipment work in tandem

44 Hans Egermeier, B&R Automation

4

Ritwij Kulkarni, Honeywell Process Solutions, India

Team VEGA demonstrates innovation at BAJA India Bound by passion and need for endurance and speed, team VEGA, a group of budding engineers recently attended an event in NIT Jamshedpur under the name BAJA Student 2015

April 2015 n OEM Update

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Dear Readers, Welcome once again.

Shortage of skilled workforce has emerged as one of the key bottlenecks virtually for every sector across the country. From manufacturing to services, the employers are screaming hoarse about the skills gap. As the government is increasing its focus to make India as a manufacturing hub, there is a dire need to address the ‘skill gap’ issue without delay. Experts feel, for India to be a high-end manufacturing hub we should look at 20 per cent of workmen who can yield 80 per cent in returns, very similar to IT Industry.

This time, we have discussed on how to overcome the manufacturing skills gap, highlighting the roles that the government can play with a more proactive support from India Inc. With growing demand of increased productivity, enhanced quality and on-time delivery, advanced automation has become an integral part even in food and beverage (F&B) industry. We have analysed the role industrial automation can play in making F&B industry more efficient, highlighting the trends and technology.

Today, there is hardly any facet of manufacturing that is not touched by the computer numerical control (CNC) machining technologies. With the rapid change in computer-based technologies, machining technology is also evolving almost every day. As there is increasing focus on reducing operational costs and shortening lead times, new-age mission critical machines that can perform with greater efficiency are in demand. We have featured some of the innovative technologies in this front.

The issue has also given a loser look on the pumps, valves, and compressors (PVC) and die and mould industries. Hope you’ll enjoy reading every page of this issue.

Also, in June, OEM UPDATE will be celebrating its 6th Anniversary. On this occasion, we’ll be publishing an exclusive issue on ‘Make in India’. We’ll discuss on the roadmap to realise this ambitious mission along with the plethora of issues facing the manufacturing sector. We would like to invite you to be a part of this special issue.

Please do send me your comments at editor@oemupdate.com

April 2015 n OEM Update

Quick update

Egis awarded EPCM contract at Al Karaana in Qatar Located in the Al Rayyan region, west of Doha, the Al Karaana lagoon covers more than 4 sq.km and is raising serious environmental problems. Almost 60,000 cubic metres of untreated wastewater per day is discharged onto this site by tanker, most notably causing the contamination of the water table by infiltration, producing foul odours and creating safety risks connected with the transport of sewage.

The Public Works Authority of Qatar, Ashgal, awarded Egis with an engineering, procurement and construction management (EPCM) contract to rehabilitate this lagoon.

Ashgal wishes for the eradication of the lagoon and the site’s comprehensive overhaul, in continuance of the measures taken to date to mitigate its environmental impact.

Egis is an international group offering engineering, project structuring and operations services. In engineering and consulting, its sectors of activity include transport, urban development, building, industry, water, environment and energy. In roads and airports its offer is enlarged to encompass project structuring, equity investment, turnkey systems delivery, and operation and maintenance services.

This new contract gained follows another one awarded several weeks ago, also in the water sector: the extension of the Doha West waste water treatment and recycling plant.

The contract further bolsters Egis’ position in Qatar, where the Group generated almost 33 million euros of turnover in 2014 from a large number of infrastructure projects.

Egis’s responsibiilties at Al Karaana Teams from Egis will be tasked with identifying and qualifying the lagoon’s waters and sludge in order to appreciate the contamination of the water table and evacuate this waste to the appropriate treatment processes.

They will carry out the design of the wastewater treatment and the soil and water table decontamination, write the tender documentation, perform the design review of the plans and documents submitted by the selected contractor, and finally supervise the works.

Egis will consequently be mobilising all of its engineering capabilities for a period of 23 months to reduce to a minimum the environmental impact of this site, then redevelop it and convert it for new uses, in accordance with its sustainable development commitments. n

Emerson Climate Technologies unveils new products at Acrex Emerson Climate Technologies, a business segment of Emerson, recently launched three products for India market. The residential variable speed compressor and drives, multi compressor pack and semi-hermetic water cooled condensing units were unveiled at the prestigious ACREX India 2015 in Bengaluru.

Sridar Narayanswami, Vice President and Managing Director, Emerson Climate Technologies, India said, “As expectations for quality of life continue to rise, there is a growing need for reliable and efficient refrigeration technology to keep food safe during production, processing, transportation, and storage, leading to improved food quality and human health.”

Registration Solutions The Emerson Multi Compressor Pack (EMP) Refrigeration systems in 2, 3 and 4 compressor configuration comes assembled with a choice of compressor technology – Copeland Scroll and Semi–Hermetic compressors.

EMP also comes equipped with factory installed components that include HP/LP cut-out switches, Complete oil management systems and controls to ensure safe management of the systems.

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Emerson also launched the new Copeland Semi-Hermetic Water Cooled condensing unit with its range extending from 0.7 to 50 HP for low, medium and high temperature applications. These condensing units have been designed by employing the highly efficient shell and tube heat exchangers along with Emerson’s proven range of high efficiency Copeland Semi Hermetic compressors. These can be adopted as an option to air cooled units where its compact size allows for use in applications where space is a constraint.

Air Conditioning Solutions In the air -conditioning segment, the residential variable speed compressor was launched. These compressors offer customers environmentally responsible refrigerants. The Variable Speed compressor highlights were: • Expansive 900-7200RPM speed range for enhanced light load efficiency and dehumidification.

• Highest part load efficiency in its class enabling significant energy saving and future India inverter standards compliance • Patented 6 pole/9 slot concentrated brush-less permanent magnet motor enhances the energy efficiency • Use of variable volume ratio (VVR) Scroll sets boosts the system COP at both high and low pressures n April 2015 n OEM Update

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Quick update

Piaggio vehicles launches new model of 3-wheeler Piaggio Vehicles Pvt Ltd (PVPL), a 100 per cent subsidiary of the Italian Piaggio Group, announced the launch of new ape’ Xtra Dlx model.

While PVPL has already been marketing this vehicle successfully for some years, the new ape’ Xtra Dlx presents a series of enhancements in style and functionality, while continuing to offer exceptional reliability, fuel efficiency and comfort.

Hardip Goindi, EVP, Piaggio Vehicles Pvt. Ltd. and Stefano Pelle, CEO India, Piaggio Vehicles Pvt. Ltd. with the ape Xtra Dlx (L – R)

The changes introduced by PVPL on this successful vehicle reflect the evolving expectations of modern drivers.

The ape’ Xtra Dlx sheet metal body provides strength and stylish lines, together with a smart dashboard, new headlamps and new handlebar switch.

The ape’ Xtra Dlx also features a new paint treatment for added gloss and better colour retention, as well as higher rust prevention, thus ensuring an even longer life for the vehicle. The initial response of customers to these eagerly awaited changes has been excellent.

Explaining the Company’s new initiative, Stefano Pelle, CEO of Piaggio India Pvt. Ltd. said “Anticipating our new age customers’ needs, ape’ Xtra Dlx has been conceived as a modern, stylish vehicle with many new features and yet delivering its core values of exceptional reliability, fuel efficiency and comfort.”

With the new looks, style and features of ape’ Xtra Dlx, comes the same trust that over 19 Lacs customers have showered on the ape’ 3w passenger vehicles for more than 15 years. Today, the company is confident that apé Xtra Dlx in its new design would continue to enhance the lives of its customers and will help consolidate its leadership position in the 3 wheeler market.

Piaggio Vehicles commenced operations in India in 1999 with the launch of the 3 wheeler brand ape’.

The company has a manufacturing plant at Baramati in Maharashtra, with an installed annual production capacity of over 300,000 three-wheelers and 80,000 four-wheelers.

The company controls more than 33 per cent of market in the 3 wheeler segment in India, it said. n

Honeywell launches UniSim competency suite Honeywell Process Solutions (HPS) announced its new UniSim Competency Suite, which improves operator competency and helps prepare them faster through realistic training experiences for console and field operators in the process industries.

Leveraging more than 30 years of experience in process simulation and operator training, Honeywell’s new suite of simulation software offers an integrated, robust training experience that will help industrial facilities address a growing shortage of trained operators.

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accelerate knowledge transfer by consolidating an entire lifetime of experience into a concise process training curriculum; features realistic process, control and safety systems modeling UniSim Curriculum: Customizable competency model that aligns and assists in improving critical requisite skills and behaviors; tracks operator progress; built from Abnormal Situation Management Consortium’s research into operator competency to help businesses define, deploy and manage a structured competency program

“In the near future, many operators at industrial plants in developed countries will retire, while process industries in emerging economies will continue to face the challenge of critical skill shortages,” said Ali Raza, vice president and general manager for Honeywell Process Solutions Advanced Solutions business. He also adds, “The expanded UniSim Competency Suite helps our customers train its workforce faster in a more realistic environment to drive safe, incidentfree, efficient start-ups and ongoing operations.”

UniSim Tutor: Knowledge capture and propagation tool; provides a repository for domain knowledge and experiences; teaches and evaluates “what if” reflexes and diagnostic abilities

The UniSim Competency suite features proven simulation models as well as new technologies including: UniSim Operations: Operator Training Simulator (OTS), a dynamic plant simulation system that allows users to

UniSim 3D Connect: UniSim Operations simulator integration and connectivity to 3D virtual environment; provides credible and realistic experiences for field operator. n

UniSim Field View: Interactive, navigable, panoramic view for realistic field operator training; uses actual facility photographs and extends UniSim Operations simulator training to include field operators

April 2015 n OEM Update

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Quick update

NI announces Intel Xeon-based PXI embedded controller and highest bandwidth chassis NI, the provider of platform-based systems that enable engineers and scientists to solve the engineering challenges, announced the NI PXIe-8880 controller, which is based on the Intel Xeon processor, and the NI PXIe-1085 chassis.

The combination of the eight-core, server-class Intel Xeon processor E5-2618L v3 and full system bandwidth of 24 GB/s delivers breakthrough performance for computationally intensive and highly parallel applications such as wireless test, semiconductor test and 5G prototyping. Customers can take advantage of the flexibility of the PXI platform to replace previous generation controllers with the NI PXIe-8880 and see up to double the performance in their test and measurement applications.

“Over the past two decades, we have witnessed a gradual shift from traditional instrumentation in favour of the PXI platform for automated test,” said Jessy Cavazos, industry manager for measurement and instrumentation at Frost & Sullivan. “With the addition of Intel Xeon processor technology, we expect the adoption of PXI to only increase for high-performance applications.”

NI collaborated with Intel to deliver the server-class power of Intel Xeon processors to the test and measurement market. The embedded controller features eight cores, up to 24 GB of DDR4 memory and 24 lanes of PCI Express Gen 3 connectivity to the backplane. This provides engineers and scientists with up to twice the processing power and bandwidth compared to previous generation controllers.

In addition, the new 18-slot chassis incorporates PCI Express Gen 3 technology with eight lanes per slot for a matched total system bandwidth of 24 GB/s, so any test and measurement system can scale well into the future.

“The use of the latest Intel Xeon processors is a new milestone for our collaboration with NI,” said Shahram Mehraban, Director of market development for industrial IoT at Intel. “The Internet of Things requires the highest possible processing power to reduce time to market and lower the cost of test, and NI’s approach with PXI is critical toward that goal.”

When paired with LabVIEW system design software, this next-generation PXI controller and chassis combination empowers engineers and scientists to turn 24 GB/s of test and measurement data into readily usable insight. n

Power2SME ties up with NBFC Vistaar Finance to finance SME clients Power2SME has inked an agreement with non-banking financial company (NBFC) Vistaar Financial Services Pvt. Ltd., to finance procurement transactions of Power2SME’s SME clients.

The tie-up is in its initial stage and the pilot project is already underway in West India, with SME clients in Pune and Nashik hailing from the manufacturing sector. This first stage pilot project for NBFC funding will up to a credit limit of up to ` 25,00,000/-.

Power2SME, now in its third year of operation is committed to addressing the SMEs capital and cash flow issues and its tie up with Vistaar is a step in that direction. The tie-up will be particularly beneficial for SMEs seeking to scale up but lacking the wherewithal to do so. With hand-holding from Power2SME as required and a competitive funding option from Vistaar, SME clients will be in a position to expand their business faster.

Raw Material costs for Manufacturing SMEs ends up amounting to about 80 per cent of their recurring cost. With a registered user base of 30,000 SMEs, Power2SME is able to increase SME profit margins by 3-5 per cent per month by providing raw material to SMEs at competitive price points.

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The company has grown 50 per cent by the quarter with 70 per cent repeat buying behaviour.

Power2SME buys various materials (inks, chemicals, additives, polymers, textiles, steel, paints, cement, wood, electrical, etc.) from principal manufacturers and sells them directly to SMEs at competitive prices via its website and call centre.

Commenting on the tie up, R Narayan, Founder and CEO, Power2SME, said, “With Power2SME aggregating purchases on behalf of numerous SMEs, bulk buying ensures immense discounts and lower rates, which are passed on to SME clients. The tie-up with Vistaar will boost the number of annual transactions by facilitating faster and easier funding thereby providing an impetus to resolving cash flow related issues of SMEs.” Elaborating on the partnership, Brahmanand Hegde, MD and CEO, Vistaar, said, “With finance and cash flow problems, SMEs need more financial channels that create lending solutions for SMEs. The segment possesses tremendous potential to help fulfil the Government’s ‘Make in India’ campaign, provided adequate financing is available to them.

This is the gap that the Power2SME-Vistaar tie-up will strive to fill.” n April 2015 n OEM Update

Quick update

Texas Instruments announces a new IDK named Sitara Texas Instruments (TI) announced the new Sitara AM437x Industrial Development Kit (IDK). Allowing developers to differentiate and optimize motor control industrial system design the AM437x IDK aids in the evaluation of the multi-protocol, industrial communication and feedback interface capabilities of the highly integrated Sitara AM4379 and AM4377 processors based on the ARM Cortex-A9 core.

As the trend of connected drive solutions continues, intelligent industrial systems are adopting digital motor feedback systems. This digitisation coupled with industrial Ethernet for communication provides higher efficiency in factory and energy sectors by reducing the latency between communications and control.

The AM437x IDK combines motor control feedback and certified industrial Ethernet protocols providing a singlechip drive solution for Inverter, servo drive or AC premium drive. In addition to motor control applications, the kit aids in the development of other industrial automation applications such as programmable logic controllers (PLCs) and Human Machine Interface (HMI) among others. The AM437x IDK integrates certified, production-

ready industrial communication protocols providing a developer friendly industrial system solution platform.

Punya Prakash, Marketing manager at TI, says “The Sitara AM437x processors, with the quad-core PRU, offer the highest degree of integration enabling multi-protocol communication and feedback interface for an industrial single-chip drive solution.”

Highlights of the Sitara AM437x IDK single-chip solution to bridge from motor control to higher level communications l The IDK combines feedback and industrial communication protocols on a single chip allowing for additional integration and a smaller footprint l The platform drives synchronization that aids in lower latency between communication and control l Support for certified multi-protocol industrial Ethernet through the programmable real-time unit (PRU) l Multi-protocol feedback interface for motor control though the PRU l Field-oriented Control (FOC) for variable-frequency drives n l A

SKF develops new technology to improve gearbox performance SKF, the knowledge engineering company, is continuing its partnership with Scuderia Ferrari in 2015, with the development of specialised components and systems to reduce weight and frictional power losses.

SKF has worked with Scuderia Ferrari to produce bearing sets manufactured from specially developed tool steel. By adapting the heat treatment process, SKF has been able to optimise the surface hardness properties. This makes each bearing extremely resistant to surface fatigue and able to withstand the exceptionally high contact stresses found in Formula One applications. As a result, bearings can be downsized without affecting performance or reliability.

The new bearing sets are now being used in the latest Scuderia Ferrari gearbox; where the ability to downsize has helped reduce overall weight by more than 20 per cent, the company claims. Gearbox performance is improved still further by the use of ceramic bearing rollers and optimised internal geometries; combined, these are making a significant reduction in frictional power losses.

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In a further development, Scuderia Ferrari is also using the latest condition monitoring technology from SKF. This is based on the company’s modular IMx platform, which has been re-engineered to meet the specific demands of the Team. In particular, SKF has adapted the hardware to enable it to process exceptionally large volumes of data at high speeds – typically up to 100 times faster than normally required in even the toughest of industrial applications.

Installed on Scuderia Ferrari engine and turbo test rigs, and using advanced SKF Observer software, the condition monitoring system provides asset protection, improved operational efficiency, preventive maintenance, and an increased speed of development.

Ing.Mattia Binotto, Power Unit Director of Scuderia Ferrari, explains, “SKF has played an important role in helping us develop the new 2015 Formula One car. The IMx solution is giving us fresh insight into how our engines perform, while the new gearbox bearings, along with specialised parts for our energy recovery and other critical on board systems, will be vital in helping us maintain a competitive advantage in the coming races.” n April 2015 n OEM Update

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Cover Story

MINDING THE GAP

Manufacturing skills gap is an issue that is being jointly addressed by the industry and the education system with a view to create a more skilled workforce

Manufacturing skills gap is an issue that the industry takes seriously and chooses to address. Skilled labour is still defined by educational curriculum and needs of the industry, though the priority of the industry is to stay relevant in a globally competitive business environment Manufacturing in India The manufacturing sector is growing at a phenomenal rate in India and expected to grow at three times at its current rate by 2022. The manufacturing industry, which spans several sectors, is rapidly shaping our country. The sector has some great and promising things in store. The manufacturing sector can grow with various government initiatives as well as an economy that complements its growth. Manufacturing sector is about to boom with foreign investors seeing interest in emerging economies like India.

Technologies are growing at a fast rate along with high adoption rate. India is using several technologies developed in the west. Many Indian companies are adopting these technologies created in developed nations. There are also a certain shortcomings in terms of what these technologies have to offer our country and our economy.

Challenges of obtaining skilled labour The Indian education system is known for producing talented engineers. However, globalisation has made the education system to catch up with the developed world as they offer courses that are tailor made for the industry.

However, this is a new trend. India produces lakhs of engineering graduates, and according to the industry they lack necessary skills that make them competitive globally. Though a section of Indian engineering graduates are driving innovation globally, a problem of skill gap in manufacturing needs to be addressed.

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Contribution to the economy Sadananda Koppalkar, Manager, Makino India, has interesting points to share on the state of manufacturing in the country, “Our country stands today as a strong one among the emerging economies of the world. A stable political environment and improvement in India’s macro economics – such as a sharp reduction in the Current Account Deficit (CAD) in fiscal 2014, a sharp decline in inflation in fiscal year 2015, and expectations of a return to over 6 per cent growth in fiscal year 2016 – have morphed into a significant ‘pull factor’ for capital flows.”

Mr Koppalkar says, “India’s manufacturing share [in GDP] is 13 per cent compared to China’s 32 per cent, Thailand’s 33 per cent and looking at developed countries, Germany is 22 per cent, Singapore is 20 per cent, Japan is 18 per cent.”

He adds “To achieve over 20 per cent contribution to GDP, manufacturing segment has to undergo a process change with regard to technology and support to customers. India stands a good chance in the global market, especially in

For India to be a high-end manufacturing hub, we should look at 20 per cent of workmen who can yield 80 per cent in returns, very similar to IT industry.

Sadananda Koppalkar, Manager, Makino India

April 2015 n OEM Update

Cover Story high-end manufacturing. However, we cannot compete with China as a mass production hub due to the sheer scale of investments that have been made in China.”

Communicating ideas effectively Ameer Ahamed Munaff, MD, FEIN Power Tools India, shares some interesting and compelling points on the manufacturing skills gap. He tells, “Manufacturing touches every aspect of our lives. Manufacturers must use creative solutions to improve the way they attract the new generation skilled workers. The severe shortage of highly skilled manufacturing work force is a significant issue that needs to be addressed.

A lot of experienced people who have worked in the manufacturing sector for many years are either of retirement age or moving to other avenues. The younger generation is moving towards white collared jobs.”

Focus on high-skilled workers for high returns Speaking of manufacturing in the Indian scenario, Koppalkar says, “The workers can be classified into four categories: low skilled, semi skilled, skilled and high skilled. To necessitate ‘high end’ manufacturing, we need to have well trained and highly knowledgeable manpower. Currently, we have lowskilled and semi-skilled category in 80 per cent. For India to be a high-end manufacturing hub, we should look at 20 per cent of workmen who can yield 80 per cent in returns, very similar to IT industry.”

Limiting his suggestions to the CNC machine tools industry, Mr Koppalkar says, “Across the industrial segment, the potential of the human resource versus its utilisation is only 30 to 40 per cent. This gap exists due to huge knowledge gap between the expert and operator. The industries have to come forward to establishing state-of-the-art technical centres for training manpower.”

Training programmes towards changing the scenario Mr Koppalkar speaks of Makino’s efforts in training unskilled labour. He speaks of the Makino Technical Training Centre in Bangalore. Mr Koppalkar says, “The training centre is an investment by Makino towards creating technical talent pool. This model has worked well for more than 8 years and we have trained and skilled people who are now placed at manufacturing industries in India and aboard.”

The candidates of the training centre undergo on the job

Manufacturers can point out that by using skills, employees get to use the latest innovations and cutting-edge technology to create tangible and meaningful products.

Ameer Ahamed Munaff, MD, FEIN Power Tools India

April 2015 n OEM Update

training at Makino facilities in India following critical parameters, including specific skill set to move up the value chain and learning curve. Each industry requires a specific skill set, and the curriculum should be tailored to suit the needs of the industry. Once we achieve where we have to be, we need to look into how to scale up this model. To this he adds “This way more industries will be benefited and bring the high-value manufacturing standards to global level.”

Speaking of skill development programmes, Munaff says, “Manufacturing companies must identify existing employees or recruit new people who could be trained to fill existing gaps. They must invest in training their employees. Capable employees lead to better production.

A talented workforce is necessary for a business to remain competitive.”

Government initiative towards skill development The National Skill Development Corporation India (NSDC) is a PPP model to promote skill development through funding initiatives for creation of large, quality oriented, profitbased vocational institutions. Its goal is also to enable support systems such as quality assurance, information systems and train the trainer academies either directly or through partnerships. NSDC helps in providing funding to enterprises, companies and organisations that provide skill training. It will also develop appropriate models to enhance, support and coordinate private sector initiatives. The goal of the NSDC is to create a large talent pool through creation of training institutes. These training institutes will create a talent pool in our country that will help in attracting private investment.

The goal of the NSDC is create a talent pool that matches to global standards by involving the industry and develop a solid framework for standards, curriculum and compliance.

The NSDC programme has already partnered with several private institutes involved in training to promote development of skills that contribute to our economy.

The NSDC has 31 sector skill councils (SSCs) with over 136 training partners spread across 2009 training centres. The NSDC has a training capacity of 15 million candidates in a year.

Calling for a change of perception Mr. Munaff says, “Manufacturers must be more proactive in communicating that this industry can be a desirable and rewarding career path. Manufacturers can point out that by using skills, employees get to use the latest innovations and cuttingedge technology to create tangible and meaningful products. Globally, there are countless number of workers who lack new skills and motivation to match up to global standards and they are not entirely responsible for it.”

On a more concluding note, it would be good to say that the manufacturing skills gap, which is a serious problem, is being addressed at all levels. Manufacturing skills gap is being addressed by the industry through training programmes. Also, another thing is that changes in the curriculum are required to address this problem. n 17

CNC Machine

Sliding and rolling: igus hybrid linear bearings in new sizes

drylin double roller hybrid bearings now available for rail diameters of 10 and 16 mm The double roller hybrid bearings in 10 and 16 millimetres complete the hybrid bearings range from igus (Source: igus GmbH)

igus,

The Cologne-based specialist for lubricant-free bearing technology, has expanded its range of double roller hybrid bearings with two new sizes. The range of hybrid bearings will now be completed with sizes of 10 and 16 millimetres. Lighter and quieter linear running on two rollers – also for applications with reduced installation space.

The quiet and smooth-running hybrid linear bearings from igus are used not only in camera technology, sliding doors or machine tool doors, but increasingly in cabins for construction machinery, or even for the individual hobbyist’s needs. To facilitate the design engineer in their selection, there is the option of two additional sizes of hybrid carriage. Behind the innovative concept of this bearing from igus is the combined advantages of plain and roller bearings. For extremely smooth and almost silent operation, the concept provides two angularly opposed rollers made of maintenance-free high performance plastics. The rollers take the weight in the main load and ensure low driving forces for manual operation. When misuse or moment forces occur, they will be absorbed smoothly over the sliding element, thus eliminating the risk of the carriage leaving the rail at the same time the movement of heavy loads becomes possible with minimal effort – all absolutely free of lubricant.

Suitability for the design of smaller installation sizes “The hybrid bearings available with 20 mm diameter have already proven themselves in practice,” says Stefan Niermann, head of the drylin linear and drive technology division at igus. “If only one guide rail is necessary, the user saves considerable space. In this aspect we have now gone one step ahead and offered the double roller hybrid bearings in new, smaller installation sizes of 10 and 16 millimetres.” These allow the design engineer now an even more flexible installation of the bearings, such as for control panels or stage setting installations on double rails and in combination with a complete carriage. Since the hybrid bearings encompass more than 180 degrees, they can also be used on simple shafts.

Ideally suited for manual operation Due to the low friction of the hybrid bearing, the required displacement force could be reduced by factor 5. They are therefore ideally suited for manual operation. Since loads up to 100 kg can be easily moved manually, they are ideal for applications in the furniture and office equipment industry (for example, sliding doors) as well as camera and monitor installations. The double roller bearings, which are priced lower than the common rolling solutions in the market, offer an efficient solution and can be ordered as a separate bearing carriage, or as a completely pre-assembled hybrid carriage. n Contact:

Behind the innovative concept of hybrid bearings is the combination of plain and roller bearings: offering quiet running and smooth motion at the same time (Source: igus GmbH)

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Vinayak Shetty Product Manager igus (India) Private Limited 36/1, Sy. No. 17/3, Euro School Road, Dodda Nekkundi Industrial Area - 2nd Stage Mahadevapura Post, Bengaluru - 560048 Tele: +91-80-45127800 Cell: +91-9341136381 vinayak@igus.in www.igus.in April 2015 n OEM Update

Wenli: one-stop-shop for machine tools from China

Wenli International is one of the leading exclusive distributors for machine tools in China. The company deals with some renowned machine tools brands such as Shenhuo CNC lathe machines. It also supplies all kinds of conventional machines such as instrumental lathes, vertical drills, surface grinders, and vertical and horizontal milling machines from China. To reach out to the local markets in India, Wenli had set up its branch office in Delhi 6 years ago.

ZheJiang Shenhuo Meter & Machine Tools Co. Ltd. has a stateof-the-art facility to manufacture XJ-milling machine, T21 dynamoelectric punches, CK numerically controlled lathe series with two types of popular CNC control like KND and GSK as per customers’ request.

Empowered with superior technology, the company has gained expertise in designing and producing machine tools. It posses efficient quality control technology and selects the best materials for manufacturing. ZheJiang Shenhuo follows the ideology of “quality first”.

Shenhuo series of machine tools has numerous advantages such as high quality, cost effective and rational structure. ZheJiang Shenhuo can produce customise machine tools according to the customers’ demand and specifications.

In India, Wenli International is already having successful installation of more than 100 CNC machines to various types of OEM industries like automobiles, fasteners, tool rooms for job works.

Wenli International also exports machines to countries like Bangladesh, Pakistan, Nepal, Turkey, Egypt, Vietnam, Indonesia, Thailand, and Syria.

Contact Yiwu Wenli Imp. & Exp.Co.,Ltd Yiwli Wenli Weaving & Zipper Machinery Co. Ltd Add: No. 1038-1043, Gate No. A8,1st Floor, Yiwu International Production Material Market, Zhejiang Province, China - 322000 Tele: 008657985793566/67/68 Fax: 008657985793588-0 E-mail: wenli@ywwenli.com April 2015 n OEM Update

19

CNC Machine

Ready-to-install parts straight from the press Combination of precision blanking and sheet metal forging reduces number of process steps as well as material and energy costs

Automotive

components are becoming increasingly complex: they are now expected to fulfil several functions at once in order to save weight. Until recently, such sophisticated parts had to be manufactured in several intermediate steps, pushing the possibilities of conventional forming processes to their limits.

One possible solution is the combination of precision blanking and forging in a single die.

The PSK precision blanking and forming presses of Schuler subsidiary Gaebener Pressensysteme are ideally suited for this task

“At present, components which have different material thicknesses in different areas are generally produced by joining several individual components,” explains Schuler Managing Director Jochen Frueh, who heads the company’s Industry division. “Long process chains to produce these components and additional steps for storing, separating and loading – as well as the necessary joining processes – all result in high part costs.”

In addition, surfaces often have to be reworked, e.g. to remove the burr. Shortening process chains including all press operations for producing components in a single press therefore offers a huge potential for savings.

Schuler’s sheet metal forging process for progressive or transfer dies has been developed to facilitate the economic production of components with varying material strengths.

First, a pre-form shape of the component is produced in a classic sheet metal forming process. Next, one area is thickened or embossed by means of cold forging, e.g. to increase rigidity. Such parts can be produced with a

high level of repeat accuracy and close tolerances. For components requiring a higher degree of deformation, Schuler offers hot forming processes.

Toothed flange produced in one pass In the case of a flange component, for example, the required torque transmission in the toothing can be achieved by increasing the sheet thickness from 3.1 to 5 mm. First, the component is pre-formed in a progressive die before the sheet thickness is increased over several stages. Next, the collar is drawn, perforated and thickened in further steps by means of upsetting. Once the component has been cut from the strip, the downstream transfer system takes it, turns it by 180 degrees, places it in the bending station and after that in the station for precision blanking.

Precision blanking – also a development of Schuler – guarantees a high smooth cut ratio and rounds off the burr in the same process. With the aid of additional functions integrated into the press – so-called Servo Modules – a smooth blanked surface is created which is free from fracture and tearing and which can fulfil functions without the need for reworking. As a result, the manufactured components are ready to install.

“The PSK precision blanking and forming presses of Schuler subsidiary Gräbener Pressensysteme are ideally suited for the production of such complex components,” says Schuler Managing Director Jochen Frueh. The line features a servo knuckle-joint drive which allows greater productivity than conventional knuckle-joint presses thanks to its freely programmable stroke heights and movement sequences. It also means that a variety of processes can be integrated – from drawing, bending, embossing, precision blanking and calibrating to welding and joining. The high system rigidity of the PSK presses guarantees close component tolerances while at the same time protecting the die by reducing the cutting impact. n

The combination of precision blanking and sheet metal forging makes it possible to produce highly complex parts

20

Blanking edges of various materials (clockwise from upper left: 1.4301, S 235, S 700, high-manganese)

April 2015 n OEM Update

CNC Machine

Flexible precision toolholder for automated tool grinding

The SCHUNK PRIMSO3 tool grinding toolholder convinces with a broad clamping range, optimised interfering contours, and a so-phisticated clamping principle. It offers optimum preconditions for fully automated production grinding and re-sharpening of tools PRISMO3 Anwendung

PRISMO3

The new generation of SCHUNK PRISMO tool grinding toolholders promise more efficiency during production grinding and re-sharpening of tools. PRIMSO3 directly clamps every shank diameter between 3 mm and 20 mm fully automatically without using collet chucks or intermediate sleeves on the fly at a run-out and repeat accuracy of less than 0.005 mm. The tool shank is automatically centered in the toolholder during the clamping operation. An optimized interfering contour ensures a better interference between the grinding wheel and the toolholder even in case of demanding operations.

“Compared with conventional multi-range grinding toolholders, the set-up time with PRISMO3 is lowered up to 70 per cent,” the company claims. “Moreover, the users don’t have to invest in intermediate sleeves and collet chucks.”

Since the X axis is independent from the tool diameter and does not change, every type of chuck jaw can remain at the same axial position, which allows unmanned machining of various drilling, reaming, and milling tools in small quantities without having to re-program the L1 dimension around the clock. Expensive additional programming and the danger of a crash are now a thing of the past.

Compact dimensions and robust design The constructional design, the basic sleeve, and the robust nature give a particularly high rigidity to the toolholder. Its stable jaw guidance avoids a swing up of the grinding wheels, and completely

22

avoids tube imbalance. The hard coated chuck jaws are particularly robust and durable. If damage should happen, the complete set of chuck jaws can be exchanged. The toolholder is rinsed with clean oil during the grinding operation which prevents pollution, and a consistently high precision is achieved. No matter if axial clamping cylinders, radial power chucks, or an individual machine interface is concerned: PRISMO3 is compatible with the grinding machines of renowned manufacturers. The compact dimensions of 125 mm x 125 mm leave enough space for the tools during the grinding process and loading operation. The tool grinding toolholder will be available in the fall of 2014. n Contact: Satish Sadasivan Schunk Intec India Pvt. Ltd. No 80 B, Yeshwanthpur Industrial Suburbs, Bengaluru – 560022 Tele: +91-80-40538999 Fax: +91-80-40538998 Email: info@in.schunk.com www.in.schunk.com

To share your article or case study in this section,

write us at editor@oemupdate.com Next issue focus: pdate.com

`100 • www.oemu

DATE OEM UP March 1,

l Automation & CAD/CAM Solution l Machining Process l Milling technology l Water treatment

10 Vol 6 Issue

4

• Pages

2015 •

52 • Mumbai

2009/3394

MAHENG/

Create botiCs Can ro turing manufaC jobs? turing in manufac While robotics concept utopian is not a conceptualised, vity e producti otherwis all about they are they could to and what turing manufac

manufacturing for efficient Material handling of welding The future Indian market its focus on Henkel sets towards growth BITZER: inching

INSIDE

An I-Tech

tion Media Publica

April 2015 n OEM Update

FIBRO INDIA PRECISION PRODUCTS PVT. LTD. (Formerly FIBRO INDIA STANDARD PARTS PVT. LTD.)

Plot No: A-55, Phase II, Chakan MIDC, Tal: Khed, Pune - 410 501. INDIA. Tel: +91-2135-33 88 00 / 03 Email: info@fibro-india.com, Web: www.fibro.com

CNC Machine

CNC system with enhanced interoperability production dashboard software. NUM was one of the first CNC manufacturers to offer an MTConnect compliant interface for an entire product range which does not require the use of third-party or custom adapters. The company originally introduced the interface on its Axium product line in 2008 and is now making it available as an option across its entire range of CNC systems.

NUM

has developed a new communications interface option for its CNC systems that fully complies with the open MTConnect interoperability standard.

Known as NUMConnect, the interface can be fitted to new or existing systems and simplifies the integration of CNC machine tools with third party manufacturing management software. It enables users to implement powerful productivity-enhancing real-time data collection and retrieval facilities for production monitoring and analysis purposes.

Manufacturers are increasingly making use of data retrieved from CNC machine tools on the shop floor to improve the efficiency of their production processes.

However, until recently, the lack of a vendor-neutral data communications standard within the industry meant that CNC machine tool companies could only provide their customers with proprietary solutions for collecting and retrieving manufacturing data.

To compound the problem, most CNC systems have a closed architecture and only provide a data link via their PLC, limiting data collection to the PLC’s scan rate.

The inflexibility of this approach – which also demands custom client software for each machine type – drove an industry initiative to bring Internet style connectivity to manufacturing equipment.

MTConnect is an open, royalty-free communication standard that can be used by anyone and it is rapidly becoming the preferred choice of the machine tool industry. The standard is managed by the MTConnect Institute – a not-for-profit organisation that seeks to improve the use of real-data in manufacturing industries.

A growing number of machine tool manufacturers are adopting the standard, which is also now supported by many leading suppliers of enterprise resource planning (ERP), manufacturing operations management and

24

The underlying technology of the MTConnect standard is the same as that used by the World Wide Web. It is based an Extensible Markup Language (XML) for capturing data that is readable by both humans and machines, with the format of all data transfers defined by hypertext transfer protocol (HTTP). NUM’s open architecture CNC systems already use similar software technology for their humanmachine interface (HMI), which is based on HTML and JavaScript and employs standardised server functions to facilitate the exchange of data between the CNC kernel, PLC, drives and motors. As a consequence, NUMConnect can read anything that is capable of being displayed on the CNC system’s HMI, regardless of whether it is in analog or digital format. Even detailed low level machine data, such as motor, drive or encoder error messages, can be retrieved and used for monitoring machine performance, preventative maintenance or diagnostics.

Developed by NUM Corporation in the US, NUMConnect is fully compliant with the latest 1.3.0 version of the MTConnect standard and is available ready fitted or as a retrofit option for all of the company’s Axium, Flexium and Flexium+ CNC systems, as well as its earlier generation Power 1000 series. The software can be installed on any standard PC equipped with Windows XP or later, and it runs in the background on any NUM industrial PC panel.

As a member of the MTConnect Technical Advisory Group (MTCTAG), NUM Corporation is committed to keeping NUMConnect up-to-date with the latest developments in the standard and to helping machine builders best exploit its benefits.

The NUMConnect software interface essentially comprises two main components: an MTConnect Adapter and an MTConnect compliant information provider or lightweight webserver known as an ‘Agent’. The Adapter collects data from the CNC system, associates it with defined MTConnect data items, filters out any duplicates and then pushes the data to the Agent, where it is held in a buffer store until overwritten by fresh information. To help minimise response times, MTConnect does not require the establishment of a formal data transfer session, and under normal use there are no log-on or log-off sequences.

When the Agent receives a request for information from any client application software, it transfers the appropriate data over the network, using HTTP. The system is inherently secure; MTConnect is a read-only standard designed to facilitate the retrieval of data from manufacturing equipment – it does not control or instruct a CNC machine tool to take action. n April 2015 n OEM Update

Die & Mould

New era in die mould with Mitsubishi Electric CNC

Mitsubishi Electric CNC products are engineered with cutting edge solutions and technologies to meet the requirement of the precision industries

With the sophisticated technologies Mitsubishi Electric India has developed as a total factory automation manufacturer, we attain advanced machining control and contribute to the highest accuracy and productivity of manufacturing worldwide.

Mitsubishi Electric CNCs change machine tools, machining and manufacturing. As a global CNC provider as well as the best partner, we provide optimum technologies and supports for the users making a step toward the future.

Mitsubishi Electric CNCs create new values in cooperation with the users. Providing prompt responses, solid technologies and user-friendly supports, we continuously improve our after-sales service quality for users in the world so that they choose Mitsubishi Electric CNCs again.

In India high-end technologies, precision engineering and metalworking industries will continue to grow. Fully developed nano-machining technology ensures the highest level of precision and resulting in the need of high performance and automated production facilities will continue to increase.

Mitsubishi Electric CNC products are engineered with cutting edge solutions and technologies to meet the requirement of the precision industries.

Here we discussed on the best surface finishing of the die mould machines. The technology of “SSS” (Super Smooth Surface) control provides an optimal speed control function for machining die mould with smooth surface.

Tolerance

Command shape

Conventional problem As for the mould machining of three-dimensional shape, the smoothness of the machined surface (surface accuracy) is important. In recent years, even at the case of more than 5m/min feed speeds, the request of high surface accuracy in several μm or less has increased especially. In this case, the quality of instruction shape described in the machining program is often regarded as a problem.

Generally, in CAM to create a machining program, the motion curve of the tool relative to the workpiece is calculated by approximating the minute line segments.

Therefore small error is more or less included in the data of minute line segment. For example, as shown in Fig.1, there are many cases like the minute error of the zigzag shape or the shape of a level difference is contained within the limits of the permissible error (tolerance) on CAM processing, to form the process originally.

In NC, it’s essential to have the process of determining the rate at which moves according to the shape in order to maintain the trajectory accuracy. If some errors are included in the instruction shape, it is difficult to calculate the accurate determination of the appropriate speed movement. Especially in scan line machining, there are some cases that the fluctuation occurred in the trajectory of movement of the machine and scratch Original shape

Fixed shape (a) Example of improving accuracy by fixing command shape

Fixed shape A A

Original shape

D

End of full line

Fig.1 Example of the shape containing error

Command shape

B

Command shape Original shape

C C

D D

(b) Example of worsen accuracy by fixing command shape

Fig.2. Example of improve accuracy or worsen by fixing shape

C

26

April 2015 n OEM Update

Die & Mould streaky occurred in the machined surface when the magnitude of the error contained in the instruction form by path difference.

In order to cope with such problems, is developed Fairing Function to correct shape in the NC Conventional, so as to reduce the error and it has been used in (Fig.2 (a)).

However, at first glance zig-zag shape or a minute level difference which seems to contain an error, it is difficult for NC to distinguish whether it is a thing with the sense which should be processed essentially. Especially the program die-mould machining consists tens of thousands of blocks of minute line segments, as for at least several positions, the part which cannot restore the exact shape correctly and where sufficient accuracy is not acquired in many cases.

Since shape correction was performed as shown in Fig. 2 (b), it is shifted to the contrary original form, and there was also an example for which accuracy gets worse (A to D part in a figure).

SSS Control Here, we discuss of different way from such shape correction in which potential risks are hidden. In the process of determining the movement speed depending on the shape, the process is not affected by the error contained in the directive shape and it can generate the stable and optimal pattern of speed, it is possible to obtain a smooth cutting result even if the pattern and magnitude of the error included in the instruction by the path shape are different. The “SSS Control” was developed so as to realise the speed control method in this way. The following original processing modes are adopted in SSS control.

• The global shape judgment based on prediction of instruction form determines the optimal feeding speed • Efficient acceleration and deceleration without waste even in shape • Processing a uniform that does not depend on the speed and shape instruction.

As a result, the following effects can be obtained in the SSS control.

A stabilised and high-quality processing is realised • Irrespective of the speed and shape command to achieve high quality processing in a stable.

• There is no streaks on the processing surface even in the command shape that changes consecutively Reduction of processing time • Conventional ratio 5:30 per cent of time reduction (comparison with the same accuracy) • Especially the effect is remarkable when feed rate is higher.

Easy parameter setting • Parameter adjustment for correction of shape is not required • Easy adjustment such as efficiency-oriented and accuracy-oriented.

April 2015 n OEM Update

Sample of processing results Three samples processing of SSS Control are: Dome-shape worked sample (Fig 3): This is the sample shape consisting of the upper half and plane part of hemisphere. This is processed by the scan line processing of the left-right direction (round Fig.3: Sample of dome-shape processed trip). The tool used in this processing is Ball end mill of diameter 4 mm, feed speed is 2m/min and shaft rotation speed is 12,000 min-1.

By the SSS control, beautiful and shiny processing surface which does not include fringes caused by vibration and streaks are realised in both the part of hemisphere and plane portion. Furthermore, also at the boundary portion both hemisphere and plane portion, excellent accuracy is obtained without any streaks.

Fig. 4: Sample of corrugated plate type processed

Corrugated plate type processing sample (Fig 4): Fig.5: Noh mask-type processed sample This is the sample shape which contains the convex portion, concave portion and the sharp edge portion. Scan line processing was implemented from the lower left side to upper right direction (one way) in the figure. The tool used in this processing was Ball end mill of diameter 4 mm, feed speed is 1 to 8m/min and shaft rotation speed is 20,000 min-1. Even in the part where the command speed is increased up to 8m/min, it is appropriately controlled at a required speed in order to maintain the accuracy. Therefore, the command speed is even location of 8m/min, a sharp edge (concave portion, convex portion) and a smooth curved surface without streaks is obtained. In addition to sample, the characteristic type of plastic, there is the point where the shape is continuously changes little by little, without shape changes discontinuously along the way, natural processing shape was obtained.

Noh mask-type processing sample (Fig 5): This is the example of sample which contains various part of shape such as the concave portion, the convex portion, edge portion, plane portion and so on. This was processed by the scan line processing from lower left to the upper right direction (round trip). The Tool used in this processing was Ball end mill of diameter 6mm, feed speed is 2m/ min and shaft rotation speed was 20,000 min-1. Even in such complex shapes, by SSS control can be realised the beautiful working surface with shiny overall is obtained. n Authored by__ Sandip Chakraborty, Manager-Planning, CNC- Factory Automation & Industrial Division, Mitsubishi Electric India

27

Automation

Xchanging’s automation services give it a clear edge A key reason for our winning performance especially in the Indian manufacturing industry is our constant endeavour on customizing our services, to address the automotive industry’s requirements.

Rakesh Pandey, Manufacturing Global Business Unit Head, Xchanging

Rakesh

Pandey, Global BU head, speaks of the services that Xchanging offers for a variety of sectors. He also speaks of innovative technologies, about the ‘Make in India’ movement and other global and domestic factors that are shaping the industry.

Give us a Profile of Xchanging and the various product offerings that Xchanging has?

Xchanging provides business processing, technology and procurement services across industry verticals in a number of geographies. In India, Xchanging’s sales focus is primarily into Engineering and Product Lifecycle Management (PLM) services targeted at the manufacturing, retail and pharmaceutical sectors; and our Learning platforms focused on the education sector.

Through our Engineering and PLM services, we help design systems/sub-systems, end-to-end product life cycle support for discrete manufacturing companies, especially for the automobile sector, in India and globally as well. In India, we have worked with two of the top five commercial vehicle manufacturing companies. In the virtual analysis space, we have started work on an analysis tool, for a UK-based university.

28

product development and specification management process.

In addition, we have done global specifications management, artworks and labelling and even sourcing management for both discrete and process manufacturing companies in India.

What about Crash Testing?

At Xchanging, we have a team of experts who support companies in crash testing. Since the ABS safety system has become mandatory for commercial vehicles, we are helping an auto company change their entire interface. We have engineers who help generate data virtually through a crash test. We draw the parameters for a testing process and the parameters that will matter after the testing is over.

What do you think of the Make in India initiative by the Narendra Modi government?

Prime Minister Narendra Modi has given us a vision and inspired us that nation building is a collective effort. A large number of technology companies globally have Indians driving the engineering processes. So why can’t we have it all here in India? If we need to compete at the highest levels, we need to apply the most sophisticated cutting edge technologies. We need to bring those technologies to India, without breaching the IP rights.

Technology is changing rapidly and the next generation must have the ability to learn, unlearn and relearn. We don’t need to reinvent the wheel here. We need to learn from these ideas, take what works and remove the unnecessary ones. These concepts may be anything from stem cell technology in the US or in the field of education. We need the knowledge, and the required skill sets and ideas should be welcome from all.

Do you think India will become a global super power like China?

India will definitely become a superpower. However, having said that China is still ahead of India in a lot of aspects. But what works for India is our free economy and democracy.

Once we start opening-up, learning things and implementing them, we can achieve what we’ve set out to do.

A key reason for our winning performance especially in the Indian manufacturing industry is our constant endeavour on customizing our services, to address the automotive industry’s requirements. We manage the entire product lifecycle for clients and also provide simpler solutions. If an Indian company wants to supply automotive parts to the top three American automotive giants,they need to follow TS16949 processes. We have made an entire layer of these industry-specific processes like APQP, PPAP, DFMEA, PFEMA, and PCP on top of the PLM platform; and this helps us implement solutions faster.

Do you think American companies will be trend setters in technology or even Indian technology companies can set trends?

Presently, American companies are at the forefront of setting technological trends. But over the past one year, more and more of Indian companies are being acquired by American companies. We have the brains, what we do not have currently is a conducive environment to flourish. Once we have that, there will be no holding back. Bengaluru is at the forefront with a large number of start-ups and big and small technology companies.

We are also collaborating with some of the leading process manufacturing companies in India in the pharmaceutical and CPG space to digitize and thus streamline their entire new

The Indian e-commerce companies are challenging the global giants. The government too now is providing a conducive environment for business. n April 2015 n OEM Update

Automation

HARTING to demonstrate Integrated Industry at Hanover research project conducted within the framework of the ‘it‘s OWL’ leading-edge cluster, with system integration solutions on the basis of SAP. “With this production line we have also included the aspects of the Smart Factory, the internet of things and services, and the Industrial Internet,” Claus Hilger, Managing Director HARTING IT Services said.

At the Hanover Fair, HARTING will be featuring the Integrated Industry Demonstrator, which addresses the topics holistically.

Integrated Industry will feature as the HARTING Technology Group’s key topic at the Hanover Fair (Hall 11, Stand C 13) from 13 to 17 April. HARTING will be presenting live on the fair stand a production line demonstrating solutions for Integrated Industry.

The Espelkamp family company is thereby positioning itself as a trailblazer for technological change. “Integrated Industry will change almost all industrial companies in coming years.

We offer customers tailor-made solutions and accompany them along the way,” as Dr. Volker Franke, Managing Director, HARTING Applied Technologies, emphasises.

The HARTING production line, as an Integrated Industry Demonstrator, presents the topic holistically and combines elements such as the flexible assembly system FlexiMon, a

April 2015 n OEM Update

Consequently, a Plug&Produce modularisation concept based on the Han-Modular standard was implemented in the demonstrator, for example. The production unit with three production cells is linked into the fabrication environment via a smart infrastructure solution. n 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

29

Automation

“B&R Automation Studio is extremely flexible”

The size of the automation solution doesn’t make a difference. Whether you’re working with a small machine or automating an entire plant, you can still work with the same tool.

Hans Egermeier, Business Unit Manager - Automation Software, B&R

B &R’s Automation Studio engineering software is a universal tool for every phase of an automation project – from development and commissioning to maintenance and diagnostics. Hans Egermeier, Business Unit Manager - Automation Software, B&R, speaks about current challenges facing the automation industry and the new functions available in Automation Studio.

The contribution of software engineering to the development of new machines and systems is constantly increasing. What challenges face engineering platforms such as Automation Studio in relation to Industry 4.0?

The demands facing machines and systems are on the rise: improved product quality, faster production speeds and series production with a batch size of one are just a few examples. No matter what, the software has to be able to handle increasingly complex tasks.

We need tools that can master this complexity. At the same time, ensuring an environment that fosters innovation is a must. New systems, machines and applications have to be developed and set up quickly.

This also means that software like Automation Studio must provide the maximum possible degree of flexibility.

What functions have been implemented in Automation Studio to meet these challenges?

It’s not really the individual functions that make Automation Studio an ideal engineering platform.

The entire concept is much more important. That’s why anyone who uses B&R technology to automate their machines only needs a single tool: Automation Studio. This one development environment handles all essential product types – from the controller and HMI systems to motion control and even safety technology, everything is fully integrated. The size of the automation solution doesn’t make a difference.

Whether you’re working with a small machine or 30

automating an entire plant, you can still work with the same tool. Whenever you develop a new variant of an existing machine, it’s possible to reuse a large part of the software.

For machine manufacturers, engineering is only part of the job. What do things look like after development is finished?

Development is only one part of Automation Studio.

This software can also be used to manage all other tasks, including commissioning, troubleshooting and service. In addition to the advanced simulation tools also integrated in Automation Studio, its modular and object-oriented approach to programming ensures that software is simple and clearly structured, regardless of the degree of complexity.

Is all of this enough to keep development going at the required rate?

No, it is also necessary to stop developing the mechanical, electronic and software components of a project separately. Automation Studio makes it possible for these three engineering disciplines to be worked on simultaneously to a very large degree, which saves quite a lot of time. Even more time is saved when the software is developed in modular units.

Isn’t it much more complicated to work on multiple areas at the same time?

Yes, it’s more complicated, but structured and modularised software development and clearly defined interfaces allow software to be reliably developed and tested in self-contained modules. It even allows for improved software quality. With the mechanical components, modular machine concepts have already more than proven their worth. Whereas the traditional approach has been to develop an entire machine generation in one fell swoop, it is now possible to develop upgraded versions of individual components April 2015 n OEM Update

separately. This evens out the load on the development team and relieves the pressure associated with notoriously tight completion deadlines. We are now applying this kind of modularisation to software development.

Do developers need to receive extra training for parallel development?

Automation Studio is extremely flexible. We rely on widely used standards such as IEC 61131 and C/C++, which allows everyone to program in their preferred programming language and software to be easily reused and swapped out. Special training for parallel development is not needed.

Automation Studio’s flexibility is also evident in other areas.

For example, it is easy to link defined interfaces and formats from other engineering software, such as simulation tools from MATLAB and MapleSim or E-CAD applications from EPLAN Electric P8.

Additional interfaces on the controller also make it easy to establish database and Internet connections. Of course, all common fieldbus systems are also supported. OPC UA, TCP/IP and UDP can be used to connect directly to the supervisory level. And by combining the real-time Ethernet POWERLINK protocol, openSAFETY and various conventional fieldbus systems, we can offer a complete portfolio when it comes to communication.

THE BEST IN INDIA

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

Automation Studio is constantly being further developed.

What are the latest innovations?

We have implemented many improvements that make it even easier to develop new software. This includes simplified hardware configuration using a virtual control cabinet and integrated drive sizing. We have also introduced unit testing, a feature that provides a structured test for software that goes a long way to ensuring total quality assurance.

Another advancement is the implementation of OPC UA, which allows the highest level of integration directly on the controller. In addition, we have implemented a wide range of technology solutions for the printing and process industries, for example. These packages include complete solutions for typical application tasks in a certain industry, allowing for much easier and faster development.

About B&R A global leader in industrial automation, B&R provides complete solutions for machine and process automation, motion control, HMI and integrated safety technology for every industry. With industrial fieldbus communication standards like POWERLINK and openSAFETY as well as the powerful Automation Studio software development environment, B&R is constantly redefining the future of automation engineering.

B&R India has its head-office at Pune, Maharashtra and four other offices in India. B&R is fully equipped to cater application, supply and support requirements right in India.

The global headquarters as well as the manufacturing centre is at Eggelsberg, Austria.

For more information, visit www.br-automation.com or email us at sales.in@br-automation.com April 2015 n OEM Update

International Fittings

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 31

Automation

Automation helping F&B industry scale new heights

Improvements in industrial automation coupled with a growing demand for packaged food presents a great opportunity for the automation industry.

As packaged food fly off the shelves, automation will only have a more important role to play

Modern

lifestyle and retail has contributed to the growth of the food and beverage (F&B) industry. The F&B industry is growing steadily. Though, when it comes to packaged food, the industry is dominated by few players.

Packaged food such as bakery products, dairy products, canned beverages, aerated drinks and much more are in increasing demand. The F&B industry is also expanding with foreign brands that are coming to India as they see India as a growing market for their products.

The Global Industrial Automation Market research report on the F&B industry 2014-2018 forecasts the global industrial automation market in the F&B industry to grow at 9.37 per cent CAGR over the period 2013-2018.

Growth of F&B industry Improvements in automation have helped the F&B industry to evolve. As there is a demand for packaged food items of several sizes and drinks of several shapes and sizes, much effort goes into designing and packaging of the products. With an increasing focus on design, the storage boxes and containers of several products are being designed keeping in mind the competitive environment created by several foreign brands. Also retail strategies and retailing has added to the admiration and excitement, brands focusing even more on packaging and design. This represents a great opportunity for packaging automation.

A growing industry of F&B is set to spur the growth for automation. Indeed, both F&B and automation will complement each other as developments and innovations continue to happen in both.

Automation in F&B industry has been a topic of interest

32

and still remains when it comes to brands like Coca- Cola, Pepsi and Lays. This is primarily to aid, mass production of food. Several Agro companies also use automation technology to process varieties of rice. Automation technologies are not only limited to large conglomerates but also used by SMEs and SSIs (Small Medium Enterprise and Small Scale Industries). A few years ago, there was reluctance from the food industry to adapt to technology but now that has somehow disappeared and the F&B industry is embracing technology. Today, automation is increasingly penetrating F&B processing space due their user-friendliness.

Automation is doing its wonders for F&B industry Large quantity production of F&B for a large market needs to be ensured. To meet a large supply in order to meet large demand, we require automation machines that allow meeting this demand. The F&B industry is classified into several segments - dairy products, cheese, chocolates, pasteurisation of dairy products, brewing, mixer and cooking. The purpose of automation is to create products that are made to keep up with trends in food industry. Automation helps in a great way to create new products and to create quality products. Research and development in science has helped people to improve quality of life while also helping to reduce costs.

Automation technologies with cutting edge innovations are helping the food industry to drive growth. Without automation technologies in place, it is implausible that food production will be able to meet up to demands while keeping up with the quality of food. The food industry has embraced technology, allowing it to become more profitable. The convergence of food technology with automation helped to focus on issues like hygiene and food safety.

April 2015 n OEM Update

Automation Companies like Amul Coop, HUL, P&G, SM food, Lays, Nestle and several others are deploying the best automation technologies. Several popular food brands are using these technologies to provide the best products to keep up with the demand. This also allows food companies to increase the production while cutting costs. Automation is being primarily used for production of milk products, chips and bakery products like biscuits. Automation is also being used for sealing soft drink bottles and cans.

Thanks to automation, these companies have been able to increase their production and meet the demands.

Also while much of the leading automation technologies for F&B industry have had their inception in the west, a more customised version of the automation is today made for India. Some brands emphasise on the principle “Untouched by hand”, though the concept is not entirely applicable to the Indian food industry. After studying the Indian market, the players in automation have made these technologies suitable for Indian ecosystem. Much of this is done keeping in mind, the Indian demographics, and consumption patterns. The food industry is very large and consists of several segments. A large number of eateries and food courts too are using automation technology in a big way. For example, automation equipment are used at small stores for dispensing soft drinks and sodas. They are also used when serving ice creams.

Global players in automation for F&B industry Global players in automation for F&B industry are ABB, B&R Industrial Automation, Bosch Rexroth, Emerson Process Management, GE Intelligent Platforms, Eurotherm, Invensys Operations Management, Mitsubishi Electric, Panasonic Electric Works, ProLeiT, Rockwell Automation, Schneider Electric, and Siemens.

These are some of the leading players in the market among others.

Eurotherm by Schneider has developed automation technologies for the F&B industry. The automation technologies are run by a computer. The automation technology can also generate reports based on several filters and parameters. The automation machines can set temperatures that are sensitive to the food that is being processed. The automation process is integrated with several features that it takes care of the whole process involved in food production. The automation machines also are accurate and can follow time very accurately. The process can also control pH levels.

Several such other features have been integrated and accommodated into the process that allows food to be manufactured according to the needs of the market to which they cater.

Siemens has some innovative solutions for F&B industry. Some of the processes that Siemens follows include ‘Totally Integrated Automation’. Totally April 2015 n OEM Update

Integrated Automation takes care of the product right from production to the ERP level. It is also suitable for the ‘Just in Time’ concept. The automation allows the production of small and large batches all with the press of a button. It is extremely energy efficient. The automation tools allow the user to compile data on the processes. ERP connectivity allows interconnection of the automation level with the management level.

Line monitoring system (LMS) allows automatic real-time acquisition and analysis of production of relevant data for continuous optimisation of plant performance. Line visualisation (HMI) allows fast overview of operation-relevant data using preconfigured templates. Line control unit (LCU) ensures optimal line utilisation by coordinating the speeds of all machines. Plant data interface – fast, standardised integration of machines Kuka provides tailor-made solutions for every requirement. Kuka’s automation systems emphasise on packaging. Kuka’s palletising robots are fast, powerful, compact and cost efficient. Based on their specification, Kuka’s robots can manage a variety of loads.

ABB’s automation solutions give users the advantage of flexible, cost-effective production systems needed to manage your risks and gain the most from today’s trends.

Several automation systems worldwide use and deploy robots in the food industry including MAR Australia.

Robots are used in several processes like picking, packaging and labelling. They are guided by a vision sensing system. Large food processing units use expensive automation to produce the best products.

Palletising technologies are used to pick all types of cartons. Some palletising technologies are efficient enough to work throughout the day with little time needed for rest.

CRM software is paving a new way for F&B Seema Batavia, Global Brand Manager, Fazlani foods has some interesting points to share on the growth of the F&B industry. Batavia says, “Technology has facilitated the growth of F&B industry. Technology and media have contributed to this growth. New media and technologies have helped companies to understand the tastes of customers. CRM or Customer relationship management software has helped the industry. F&B companies are using these technologies to market their products effectively. Companies are adapting more automated services to streamline their supply chain processes. ERP or Enterprise Resource Planning systems allow the companies to monitor and link their finance, management, and supply chain procedures. It has also helped in better management of human resources.

New technologies are allowing companies to diversify their portfolio and tap into new markets, reaching new customers who are interested in trying unique products.” n 33

Automation

BRIDGING THE BIG DATA CHASM How engineering and IT can work together to leverage test data + Context

+ Experience

+ Analysis

+ Conversion

A measurement from the physical world + an digital conversion = Data Data + analysis = Information used to confirm assumptions, communicate results, prove hypothesis, improve performance etc.

Information + Experience = Knowledge Knowledge + Context = Wisdom which is the collective application of knowledge in action to make wiser decisions.

Unlike the big data typically associated with traditional IT data sources such as social media and enterprise applications, Big Analog Data solutions represent a vastly untapped well of information and insight that test and measurement companies can use to identify and create competitive advantages in data-centric engineering. This is no small feat considering the IDC estimates that only 5 percent of the data collected today is even being analysed.

In this push to better acquire, store, and leverage Big Analog Data solutions, specifically for test data, as it is known in automated test, engineers must start by recognising the role that IT plays in managing it. At present, the sheer amount of data being generated by engineering departments is causing a chasm between IT and engineering. Unless these groups work together to develop tools and methods to better use the data, this chasm will grow deeper.

The first step to cohesion is understanding how big data is classified: structured, unstructured, or semi-structured.

Historically, most big data solutions have focused on structured data. Defined by the user, structured data embodies a distinct relationship to the user, who inputs numerous values (name, birthday, address) as raw data.

Unstructured data contains no metadata, schema, or other pre-assigned, established organisation.

The third category, semi-structured, is influenced by the dramatic increase in the amount of test data being

34

Competition, market forces, and new innovations require companies to evaluate the people, processes, and technologies used to develop products and services. For test and measurement companies, that evaluation is being driven by the emergence of the Big Analog Data problem, which includes collecting and analysing the raw data from the physical world around us collected. As more test systems are deployed for 24/7 test data collection, the volume of test data will soon surpass that of human-generated data. Because test data yields so much information, assigning structured value to each and every byte is difficult. Creating hierarchies of data provides structure and makes mining the data after capture easier. This semi-structured test data is typically marked with a timestamp and then analysed across a set time period or for a set stimulus/ response event.

Most companies suboptimally implement their solutions for test data because they haven’t anticipated how valuable the correlation of the information gleaned from this stimulus/response data might be at the time of implementation. The most effective methods to combat this issue combine test data analytics with traditional IT tools, but this architecture requires new approaches to data integration and management. This includes new infrastructures and skills to store, mine, and analyse the information-rich data collected. These solutions need to be designed to analyse new data sources and integrate with existing data stores.

Though IT departments haven’t traditionally included test data from engineers and scientists in their overall objectives, they now see the compelling business value to applying analytics and algorithms for exploiting this mountain of data and driving new business opportunities. But making this challenging transition requires asking the following questions: • Is more than half of your analysis manual?

• Does your team spend more than five hours a week searching for data trends?

• How much data are you actually analysing? Is it less than 80 percent of the data you’re collecting?

• Do you have a streamlined process across departments? Or are different teams using different tools?

April 2015 n OEM Update

Automation Form a cross-functional data management team To effectively transform into a test data-centric organisation, a crossfunctional team should jointly test solutions and ensure compatibility. This team should include a representative from IT, an engineer tasked with data collection, a data scientist, and a manager with a high-level view of how new solutions will roll out to other departments.

Additionally, an executive should have a vested interest in the outcome of the inclusion of test data analytics to ensure key members of the crossfunctional team are held accountable for progress.

Don’t expect results immediately Many companies make the mistake of expecting a full data analytics solution in an unreasonable amount of time. Underestimating the effort required to align multiple teams while trying to overhaul existing workflow processes usually leads teams into proposing solutions without understanding their true data needs.

This results in an unusable solution that end users don’t adopt.

A full data analytics solution for test data involves smaller, incremental steps and builds momentum for end users, IT professionals, business leaders, and so on.

Best-in-class companies often run an internal pilot within a single department before documenting data analytics requirements. This pilot typically includes integrating a data storage mechanism specifically for test data into existing IT infrastructure, testing multiple data analytics software packages, and defining a process to analyse data from start to finish.

This allows key stakeholders to understand the flow of the collected data and identify data bottlenecks. It also gives the IT department time to learn the differences between traditional big data and test data and to pinpoint strategies for adopting the different tools required for the successful implementation of test data solutions. Addressing bottlenecks also improves yield, quality, and time to market as well as prevents sending inadequate products to market by catching more errors or tests out of specification. These benefits will increase the company’s overall profit.

Architect for expansion Companies need to keep the big picture in mind when starting pilot programs in test automation.

April 2015 n OEM Update

They need to remember that solutions architected for certain groups won’t scale when rolling out test data analytics solutions to different departments. In addition, companies can send their engineering and design teams weekly reports to identify key trends for avoiding failures or tightening margins. This can jump-start a redesign process that addresses all possible scenarios.

By prioritising a long-term vision when designing a test data analytics solution architecture, companies can set tangible goals for expansion and IT can plan accordingly and add more servers as the solution is implemented across multiple departments.

The “Edge” in the graphic depicts the point where data must cross the chasm from the data acquisition and analysis node to IT infrastructure where the data can then be mined and analysed efficiently, providing the basis for key engineering or business decisions.

Invest now for enormous payoffs Implementing a test data solution can add tremendous value to an organisation by enabling a more productive workforce while lowering costs and increasing profit.

The companies that choose to make the shift to datacentric organisations will be market leaders with access to up to 95 percent more data than competitors, which can make them 20 percent more cost-efficient. Forming a strong relationship between IT and engineering to meet these test data challenges is critical for extracting not only the analytics but also the knowledge in large test data sets.

Authored by__

Stephanie Amrite, Product Marketing Manager, National Instruments 35

Automation

Instrumentation’s Next Great Leap

The need for instrumentation is not only limited to process automation but also to enhance safety, reliability, security and productivity of a plant.

Ritwij Kulkarni, Business Unit Head, Field Products, Honeywell Process Solutions, India

H oneywell Process Solutions (HPS) is a business unit serving the process industries across the segments.

In an e-mail interaction with OEM Update, Ritwij Kulkarni talks about the technology transformation in field of instruments and measurement products.

Importance of instrumentation in process industry Instrumentation plays a crucial role in various process industries for controlling and monitoring of various operations. Instrumentation and process control systems can be used to measure and control process parameters like pressure, temperature, flow, density of different fluids, gases, etc. that are used in different process industry verticals like refining and petrochemicals, oil and gas, minerals and metals, chemicals and life sciences, pulp and paper, etc.

Over the years instrumentation through control systems like Distributed Control Systems (DCS), and Programmable Logic Controllers (PLC) have helped traditional manual processes to become fully automated to the highest standards.

Further, the need for instrumentation is not only limited to process automation but also to enhance safety, reliability, security and productivity of a plant.

Key functional areas of instrumentation and control In a modern plant, the instrumentation and control models are linked to the systems and components where all the plant feeds are collected giving the operator a holistic picture of the plant processes. The instrumentation model’s primary function is to control the processes and procedures of the plant, measure the protection of the plant and lastly update the operator of any kind of abnormal activity happening in the plant.

All these functions help plant managers and engineers run the plant in the right way.

36

The requirement of instrumentation and control model is different during a maintenance stage from that of a project implementation stage and this differs from project to project or plant to plant. The development department of any plant here plays a crucial role by understanding a customer’s project planning, functionality of the project and accordingly create a sustainable instrumentation and control model that would run for a long time.

This would help increase plant’s life and at any given point of time the plant can implement any up gradation to the technology on the existing platform making the plant more efficient. The instrumentation model has to be developed in such a way that it is aligned to the IT development and people can use it on the current platform such as HTML and other internet languages.

But while designing the models, it is important that these models are incorporated into various stages of instrumentation so that, whatever solutions are being used are safe, reliable and provide good productivity to the plant.

Latest innovation There are many aged plants that need renovation and modernisation along with new plants that look for latest innovation and technology and that meet the four main pillars: safety, reliability, efficiency and sustainability.

Technology in field instruments and measurement products has taken a great leap from conventional to wireless, SIL (Safety Integrity Level) based, complying with different latest standards like 61850 and protocols like foundation field bus, Profibus etc. The control systems have become fully open for unification of businesses and processes with appropriate cyber security solutions to protect the hardware and software.

Virtualisation is the latest technology innovation in process automation which helps energy conservation, April 2015 n OEM Update

Automation lowered power consumption and makes systems platform independent. There is a lot of focus on operator effectiveness who control the plant through an innovation of right abnormal situation management processes. To extend the life of the equipment, innovative asset management tools are available.

Honeywell’s key offerings in industrial instrumentation and process control Honeywell’s offerings in the industrial instrumentation and process control are divided into following categories: L1 Segment (FATE) This segment mainly consists of field instruments such as Smartline Transmitters and Wireless Transmitters which help tackle critical industrial challenges in the areas of reliability, safety and process efficiency. The key features of these transmitters help determine a customer or a plant manager to run the plant by guiding them through the planning stage, explaining the features and benefits they will receive from instrumentation

at each level till the maintenance stage highlighting the reliability, safety and cost effectiveness of the transmitters.

L2 Segment (Control Systems) This segment mainly consists of new trends in cyber security which can be implemented at every stage of the project, giving customers the insights into the crucial activities happening and alerts them of any abnormal situations. The most important part at this stage is the human factor which is getting into the control system and improving the productivity of a plant operator, supervisor or maintenance engineer. This not only helps improve the productive output but also improves a plant’s assets.

L3 Segment These solutions mainly focus on process optimisation, real time data based management systems, etc.

L4 Segment These solutions focus on unification of businesses and processes. n

Red Lion launches new 8-port unmanaged Gigabit Ethernet Switch R ed Lion Controls, the global experts in communication, monitoring and control for industrial automation and networking, announced the addition of the N-Tron series 1008TX unmanaged Gigabit Ethernet switch to its industrial networking solutions portfolio.

The new industrial switch, which offers eight 10/100/1000Base-T(X) ports with support for jumbo frames, features an extended operating temperature and wider power input range than most competitive offerings.

Red Lion’s1008TXis a plug-and-play, unmanaged Gigabit Ethernet switch housed in a hardened, metal DIN-rail mountable enclosure designed to provide cost-effective, reliable performance in the harshest industrial environments. Ideal for use in missioncritical data acquisition, security and surveillance, control and Ethernet I/O applications, the 1008TX delivers low latency and high bandwidth to industrial networks.

“Faster, high-volume data and video applications are becoming the norm in industrial networking,” said Diane Davis, Director of product management, networking at Red Lion Controls. “Users implementing Gigabit Ethernet networks to manage this flow of information will find that our new N-Tron series 1008TXswitches cost-effectively deliver reliability and April 2015 n OEM Update

high performance in a rugged, space-saving package.”

1008TXswitch features include: • Compact design: 4.6”x 1.5” x 4.0” packaging is ideal for spaceconstrained applications • Hardened metal DIN-rail enclosure: Built to last in the toughest industrial environments with unmatched tolerance to 50g shock and 200g vibration • Extended environmental specifications: UL Class I, Div. 2 listing, CE and IEC 1613 compliance and a wide -40 to 85 C temperature range guarantees reliability in Red Lion N-Tron extreme locations Series 1008TX • Redundant power inputs: 10-49VDC keeps devices online in the event of a power supply failure. n

For more information, visit www.redlion.net/1008TX 37

PVC

Optimising performance in industrial waste water treatment PSG pumps are optimised for management of industrial wastewater. PSG pumps can work well in integrated waste water treatment systems where different types of equipment work in tandem in industrial applications contains some level of solid particles. It goes without saying that these particles should not be consumed, but particle-laden water also can’t be used, for example, in a boiler that provides steam to a turbine during power generation, lest the turbine become fouled and damaged.

Abaque skid-system As a supplier of all of the pumping and polymer makedown equipment needed for a watertreatment system, Neptunes has the capability to create pre-wired and prepiped skid-mounted arrangements.

Since the beginning of

Abaque Peristaltic (Hose) Pumps play a pivotal role in sludge removal during a wastewatertreatment operation thanks to their ability to run dry and effectively handle abrasive, particleladen materials.

In industrial applications, for instance, water can be taken from a nearby river and used for boiler or cooling-tower makeups. In the oilfield, water that is used or produced during the drilling and recovery process can be treated and sold to farmers for use in field-irrigation activities.

time, people have had the need to treat the water they consume, and use it for cooking, bathing and washing their homes and cooking utensils.

They have also needed to find ways to properly treat and dispose of the water that has been fouled through the course of its use - in latter centuries most commonly during industrial production activities.

When people hear the phrase “water treatment”, the first thought that comes to mind is taking water that will be used in domestic settings and removing any impurities, in the process making it safe to drink, cook with, bathe in and wash clothes with; in other words, “municipal” water treatment.

But from a broader perspective, the term water treatment can have a number of completely different meanings.

This article illustrates the use of an integrated waste water-treatment system, with many different types of equipment working hand-in-hand - specifically metering and peristaltic (hose) pumps, and polymer make down systems - can be used in a straight-line treatment process. This will deliver the most costeffective and efficient way to treat industrial waste water, all while making it safe for disposal or reuse in any number of additional activities.

The Challenge Most of the water used or produced

Recognising the presence of particulates in water and successfully removing them, however, are two different things. Some of the particles—which can be anything from bacteria and plant material to dirt or minuscule pieces of crushed stone—are so small that their response to gravity is very low. In other words, they don’t fall through water at a consistent rate because their mass is so small and not impacted by gravity. This means that it may take many hours, days or even weeks for the particles to settle as little as a foot. This is an unacceptable, and unpredictable, settling rate for a water or waste water-treatment system, so the particles need some help in settling or clumping.

To speed along the settling or clumping process, the water-treatment facility must turn to the introduction of a coagulant or flocculant that helps the tiny particles clump together in a mass that is called a “floc,” which is easier to remove. Two of the more popular types of coagulants/flocculants that are used in water and waste water treatment are: • Alum: A more economical way to say “hydrated potassium aluminium sulfate,” alum has been used since Roman times to aid in the purification of drinking and industrial-process water. Alum coaxes negatively charged colloidal particles to clump together so they will be able to be more easily removed from settling basins.

• Ferric chloride: Another name for Iron (III) chloride, ferric chloride undergoes hydrolysis when dissolved in water, which gives it the ability to sufficiently form suspended solid particles into flocs.

While quite effective in creating flocs, the flocs that are formed by alum and ferric chloride are held together rather loosely, which means that they can break apart if agitated as they settle in the clarifier or settling basin. Eliminating this break-up potential requires the introduction of a polymer solution that helps form more efficient flocs. The polymer takes the neutralised solid particle clumps and binds them together more tightly.

The clumps that settle in the basin form a material that is called “sludge.” The use of alum by itself leads to the generation of a large amount of sludge; the introduction of polymer helps further coagulate the sludge. However, 40

38

g

April 2015 n OEM Update

PVC 38

f

the sludge that is produced still needs to be removed and disposed of. Accumulated sludge can be collected and sent away to someplace like a centrifuge, or just piled up on the ground outside the water-treatment facility, allowed to dry and then removed via front-end loader and dump truck.

Neptunes 7000 Series Mechanical Diaphragm Metering Pumps are ideal for dosing alum and ferric chloride because they do not feature contour plates on the liquid side of the diaphragm, resulting in a simple, straightthrough valve and head design that allows improved flow characteristics.

3

dynaBLENDs Liquid Polymer Blending Systems from Fluid Dynamicss, a division of Neptunes, feature a non-mechanical mixing chamber that allows an unequalled degree of reliability when activating all types of liquid polymer for use in water or wastewater treatment.

Removing the sludge from the water requires a pump that can run dry and won’t be bothered by abrasive materials. In other words, a pump that has the capability to take whatever flows into it—no matter its makeup—and deliver it out the discharge side in that same form.

The Solution Industrial water or waste water treatment, then, is a threestage process that must work hand-in-hand: Initial floc formation with alum and ferric chloride, clump strengthening with polymer, and removal and disposal of the sludge. Not all manufacturers of waste watertreatment equipment are able to offer full lines of pumping and polymer-blending technology for the required watertreatment applications.

However, PSG does feature full lines of pumping and polymer-blending technology for industrial water or waste water-treatment applications. This allows the water-treatment facility access to a “One Company. One Source.” solution that covers its needs from start to finish.

Specific water-treatment technology from PSG includes: • Neptunes 7000 Series Mechanical Metering Pumps: Ideal for dosing alum and ferric chloride, these mechanically actuated pumps eliminate the use of contour plates on the liquid side of the diaphragm, resulting in a simple, straightthrough valve and head design that allows improved flow characteristics. They have been designed to handle clear liquids with viscosity ranging from water-like to 5,000 cPs, making them ideal for use in industrial water and waste water-treatment applications. The capacity of the 7000 Series pumps is manually adjustable via micrometer dial while the pump is running. This allows the pump to produce flow rates ranging from 10 gph to 450 gph (38 L/ hr to 1,710 L/hr) at head pressures up to 150 psi (10 bar). The pump’s liquid ends are constructed of PVC, 316 stainless steel or Kynar. Wash down-duty and explosion-proof motors, as well as variable frequency drive options, are also available. The pumps are also self-priming.

• Fluid Dynamicss dynaBLENDs Liquid Polymer Blending Systems: Fluid Dynamics, which is a division of Neptune, has designed the dynaBLEND with a nonmechanical mixing chamber that allows it to deliver an unequaled degree of reliability when activating all types of liquid polymer for use in water or waste water

40

treatment. The system’s injection check valve has been designed with easy disassembly and inspection in mind, eliminating a maintenance concern that troubles other systems. These features allow the dynaBLEND to apply ultra-high mixing energy at the point of initial polymer and water contact to prevent polymer gelling and agglomeration. The prolonged turbulence that the dynaBLEND process creates allows the polymer to complete the blending process gently and fully.

Finally, after the polymer is initially activated, the dynaBLEND’s gentle mixing energy does not break the fragile long polymer chains that have been formed.

• Abaque Series Peristaltic (Hose) Pumps: Featuring a design that ensures that “whatever goes into the pump comes out of the pump,” Abaque pumps can handle solid particles up to 18 mm (0.7”) and soft particles as large as 31 mm (1.2”), making them a top choice for sludge removal. They feature a seal-free design that eliminates leaks, which enables them to handle the waste water industry’s toughest pumping applications, from abrasive and aggressive fluids to shear-sensitive and viscous materials. The pumps, which can run in either forward or reverse, are selfpriming, dry-running and offer suction-lift capabilities to 9 meters (25.5 feet), as well as the ability to run dry continuously without adversely affecting the pump’s performance. Ductile-iron and steel construction lets the pump produce discharge pressures as high as 16 bar (232 psi). The Abaque’s pump hoses are available in three materials of construction: natural rubber, EPDM and Buna N. Conclusion A wide variety of industries use untold millions of gallons of water and produce untold millions of gallons of waste water each and every day. Properly handling and disposing (or reusing) this waste water requires a number of stages that must work together seamlessly, from alum and ferric chloride introduction, to polymer injection, to sludge removal. Each stage requires a different type of technology, which can often have the waste water-plant operator moving in many different directions to identify a solution. PSG offers a one-stop shop for industrial waste water treatment, with a ready supply of metering pumps, polymer make down systems and peristaltic pumps, all of which have been designed to work in hand-in-hand to create the most efficient and cost-effective industrial waste water-treatment process. n Authored by__

Greg Kriebel, Sales Manager, Fluid Dynamicss and PSG

Ravi Prasad, Director of Sales, PSG India

April 2015 n OEM Update

PVC

Zero Discharge RO plants Ahura

Aqua Treat, a company certified with ISO 9001:2000, CE, Crisil offers recovery of ‘treated ETP water’, thus heading towards ‘Zero Liquid Discharge’. The company specialises in manufacturing water treatment systems like zero liquid discharge with help of elaborate pre-treatment + UF + resin columns + 2 RO plants of different types, and effluent treatment plants. It also manufactures deioniser/ de-mineralising systems, sewage treatment plants, water softeners, pure water systems, etc.

Ahura Aqua Treat manufactures RO plants to remove variety of contaminants from water, which are present in the conventional industrial effluents. “It is the best and most economical method towards Zero Liquid Discharge,” the company claims. “Since the output is reused, it reduces the demand for in-feed water and reduces the load on

ETP systems – this contributes to major cost saving and improves quality.”

Ahura Aqua Treat designs and provides systems for different industrial sectors like metal-plating or finishing, cosmetics, beverages, textiles, plastics, paper, pharmaceuticals, bulk drugs and chemicals, etc. It also has expertise in storage and distribution loop for pharmaceutical and food industries, SS tanks and pipelines, chemicals for cooling towers, chillers, boilers, RO systems, etc. n

Contact: Ahura Aqua Treat Tele: +91-22-28770033, 28768636 Mobile: +91-9920120120 Email: ahuraaquatreat@gmail.com

Uninam offers complete range of industrial valves Uninam Industrial Marketing, an ISO 9001:2008 certified organisation, has emerged as one of the pioneers in providing complete analogue and industrial products.

Industrial products Uninam is an authorised distributor-dealer and importer for industrial valves serving over 500 customers all over the country. The company has around 2,000 products in its range in the range of pneumatic and electrical actuator operated ball valve , solenoid valve, instrumentation manifolds valves, 2-way and 5-way valves, butterfly valve, Y-type strainers, sluice valve, gate globe check valves, boiler mountings, S.S. pipes and valves , plumbing and industrial valves, antivibration mountings, HVAC mounts or rubber expansion joints and S.S. bellows etc. from leading companies such as Zoloto, Amco, Fouress, Atam, Sir, Parker Legris, and Resistoflex for life-long trouble free service.

Uninam has extensive experience and catering to diverse engineering needs of the key sector such as power, oil and

gas, refineries, petrochemicals, mining and metals, process chemicals, pulps and paper, pharmaceuticals, infrastructure, constructions etc.

Uninam has years of experience in providing comprehensive technical solutions in industrial applications. The company’s endeavour is to offer advanced technological solutions in collaboration with its alliances, backed by robust service support.

Uninam provides value-added engineering services to its clients. Over the past 15 years, the company has devoted itself to understand the nuance of industrial products. Today it has its presence across the industries and are serving chemical and petrochemical, power, oil and gas, refineries, pulp and paper, pharmaceuticals, food processing, mining, cement plants, plumbing and construction ,steel plants, breweries, textiles plants, sewage and water works, airconditioning plants, fertilizers, dairy, infrastructure paint and heavy-engineering etc. n

KBL i-NS range of pumps are made for Indian consumers The

“i-NS” pump is packed with innovative features that make it ideal for use. Its integrated design for major components (Stator Housing / Upper Bearing Holder, Mechanical Seal Housing / Lower Bearing Holder and Motor End Cover / Cable Gland) reduces the total number of parts and minimizes the fasteners. This integrated design product has 13 basic models with 49 hydraulics and 206 frames. Due to fewer components and integrated design concept, the pump has better assembly and dismantling lead time than its competitors.

KBL’s “i-NS” pump’s stationary installation arrangement is simplified with single guide pipe system. It introduces the innovative modular concept for interchangeability of components. Its Cable Bracket design for wrapping the

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cable around the body helps in avoiding cable damage, and its Potting Cup design helps in restricting the entry of water inside the pump. Its integrated design also eliminates most of the potential leakage and short circuit issues typically faced by the end-users in the water and waste water treatment industries, sewage, building & construction and other allied segments.

Range of i-NS pumps : i-NS pumps has a delivery size of 40 to 150 mm with a capacity of maximum of up to 300m3/hr. It has a head of max up to 50 meters with a Rating: 2.2 to 22 kw. It has a Nom RPM of 1450. The i-NS pumps are available in three unit sizes of 2.2KW/4P to 5.5KW/4P, 7.5KW/4P to 11KW/4P, and 15KW/4P to 22KW/4P. n April 2015 n OEM Update

Brand Report

Team VEGA demonstrates innovation at BAJA India Bound by passion and need for endurance and speed, team VEGA, a group of budding engineers recently attended an event in NIT Jamshedpur under the name BAJA Student 2015 this competition is on safety, good engineering practice, engineering design and education of the participating students.

Team VEGA’s buggy at BAJA India

BAJA Student India (BSI) BAJA Student India is a student design competition which follows the standards of the international BAJA SAE competition held all over the world. The BAJA Student India is an event for the undergraduate engineering students, organised by the Delta Inc. The BAJA SAE Series for the undergraduate engineering students is organised globally by the Society of Automotive Engineers, USA. The event originated in the name of Mini - BAJA, in the year 1976 at University of Carolina. Since then, the event has spanned across six countries – USA, Mexico, South Africa, Korea, Brazil and India. The BAJA Student India tasks the students to design, fabricate and validate a single seater 4-wheeled off road vehicle to take part in series of events spread over a course of 4 days that test the vehicle for the sound engineering practices that have gone into it, the agility of the vehicle in terms of gradability, speed, acceleration and manoeuvrability characteristics and finally its ability to endure that back breaking durability test. Focus of

Objective Several factors contribute to making a winning buggy.

First and foremost the buggy has to meet the strict specification of the rule book. The teams still need to build a simple all-terrain vehicle for recreation purpose that is aesthetically and ergonomically sound while still being a fun and durable machine in the real world conditions. The evaluation process for the BAJA Student India is a twofold process and students have to clear the virtual rulebook quiz round before they start manufacturing their buggies for the main events.

The evaluation process in the main event is a different ball game altogether and the students finally got to showcase their finished buggies to the judges. In the static tests the buggies are evaluation on various factors such as cost, aesthetics and the quality of the fabrication. There are also many dynamic tests such as acceleration. Braking, manoeuvrability over all terrain and a hill climb test. But none of these tests are more gruelling than the endurance race where the drivers and buggies are pushed to their limits till a winner emerges.

The hill climb and the obstacle course are just some of the dynamic tests that the buggies have to endure to make it to the finish line.

During event Nearly 100 teams from various colleges participated in the event. The event saw some imminent personalities from the world of motor sports. Steve Fox, the chief design judge FSAE Michigan, USA and Peter Jones were on the panel of judges.

The team qualified the technical inspection .Out of those 100 teams, Team Vega secured 28th position. Judges also appreciated the suspension system used in car. Apart from technical inspection, business presentation was also organised. In the same, the Team Vega secured 7th position. The results were overwhelming.

Team VEGA at BAJA India

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As the journey does not end here, team VEGA continues to enhance knowledge and explore more in the field of automobile engineering. n April 2015 n OEM Update

The international meeting place for warehousing, logistics & supply chain

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Brand Report

Finder’s lighting control components for energy savings the light sensing element may be integral with the relay itself, or it is remote. The latter allows the light sensing to be more closely linked to the light entering an open area or a warehouse roof- light for example, or allows it to be less affected by the internal artificial light. This is important to avoid any “hunting” effect of the LDR due to artificial light feedback. An alternative way of achieving a decoupling of the sensor from the artificial light is to use special versions where the LDR’s micro-processor measures and then calculates for the effect of the artificial light and makes automatic correction for this (Finder 11.41 and 11.91 – Series).

18 Series

From a company formed to exploit its founder’s patent for a lighting control relay, Finder SpA has since grown to be a renowned name for such products and today offers reliable, rugged, superior electrical life, high inrush current handling capacity for lamp loads and high temperature withstand capability to control over lighting circuits and in doing so, save energy.

Special time switches: In addition to a wide range of 24hour, daily or weekly programmable time switches, Finder offers more specialised versions.

Special light dependent relays: LDRs (light dependent relays) will, as the name suggests, switch according to the ambient light levels irrespective of the time of day or when the sun officially rises or sets. Fundamentally a simple device, there are a few refined version available where

Whilst there are some applications where the use of electricity is fundamentally a function of the time of day and the particular day(s) of the week (such as water heating), the control of other applications – such as external lights - may be more relevantly determined by switching times that vary throughout the year and day-by-day. For these cases it may be better to use an Astro time switch (Finder’s 12.81), where the switching times Time Switches are linked, not to fixed time of day, but to the sunrise and sunset times experienced at the place of installation. This will be dependent on the seasonal time of year and the longitude and latitude - set by entering the geographical coordinates. Whilst the switching action of the control is primarily determined by the sunrise and sunset times, there is also the useful facility to advance or retard the switching about these astro times by as much as 90 minutes (in 10 minute intervals).

“Zero hysteresis” version (Finder 11.41) incorporates special measures to overcome the natural instability that would normally result when having the ‘on’ and ‘off’ switching thresholds at the same level. All these fine tuning measures allow the threshold at which the lighting switches on and off to be more finely set, again contributing to optimising energy saving.

LDRs with time override Applications like this can be implemented on a simple case by case basis, and they are probably better served by using a simple stand-alone control component rather than trying to integrate within a wider system or network.

New application-specific movement detectors Based on new innovative electronics and optics Finder has added three new application-specific movement detectors to its 18 Series range.

Specifically for sensing within larger rectangular areas such as hotel lobbies and long corridors, the 18.41 surveys an area up to 15 metres either side of the device, giving

Sometimes the need exists for lighting to be controlled according to the ambient light level as well as an overriding time requirement.

Although one could of course use a LDR and Time switch in combination, Finder’s 11.91 is a dual-function device, where it is possible to provide an output when the light level requires it, but subject to certain time considerations. As an example, a shop window display lighting may be required only when the ambient light level is below the set value Light Dependent Relays but overridden to shut off when it is past midnight – when potential window shoppers are expected to be off the street.

But it might also be required that the shop sign, or perhaps low level security lighting, remains on for the full time of darkness. In this instance a second output contact is available which is purely dependent on the ambient light level.

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April 2015 n OEM Update

Brand Report

High temperature abrasion resistance coating environmentally friendly water based system that offers high abrasion resistance even at 1,000 C and above.

Loctite PC 7000 HTARC offers twice the protection compared to conventional methods, leading to almost double life for the burner tip. This results in sustained boiler efficiency and lesser downtime as well as associated production losses, making it a cost effective solution. It is easy to apply on most substrates and does not require skilled labour.

HTARC Product Image

Henkel offers Loctite PC 7000 - High Temperature Abrasion Resistant Coating (HTARC) that is designed to protect industrial processing equipment like coal tip burners in boilers and furnaces, against harsh temperature and abrasion environment.

Traditional coal tip burners are prone to wear due to exposure to high heat from furnace flame and erosion caused by coal particles in high velocity air stream. High levels of erosion lead to deformation of the coal burner tips that instantly and negatively impact the boiler efficiency.

To overcome these shortcomings and provide a reliable, cost efficient solution to burner tip wear, Henkel has introduced Loctite PC 7000 High Temperature Abrasion Resistant Coating (HTARC).

This is a unique three-component rapid setting silica-based composite coating system. It is designed to protect industrial processing equipment like coal tip burners in boilers and furnaces, against harsh temperature and abrasion environment. Loctite PC 7000 HTARC is an innovative 46

Benefits • Up to 2 X protection from wear • Lesser production loss • Cost effective – almost 29 per cent cost saving over conventional methods • Laminar flow of coal-air mixture for optimum efficiency.

This product has already been tried and tested in operating conditions by a leading natural resources mining & extraction company in India. They have verified that Loctite PC 7000 HTARC was intact on the burner tip even after more than 12 months of continuous operation.

In addition to coal burner tips, Loctite PC 7000 HTARC can be used on baffle plates of coal burner tips, aluminium and steel smelters, flue gas ducts, coal burner pipes and refractory brick structure of chimneys and kilns. n For more information, contact at marketing.ag@henkel. com or visit www.henkel.in/enquiry

f

an extensive total detecting zone of 30 metres long by 4 metres wide, from just a single unit.

Central to the 18.51 is an advanced lens and electronics system that achieves two detecting zones with different sensitivities. The central 4 x 4 metre zone responds to very small movements, able for example to pick-up on the presence of a person quietly working at his workplace.

But additionally, within an extended 8 x 8 metre zone, it will also respond to normal movements. This product is particularly targeted at offices, control rooms, warehouses and the workplace in general.

“Twin-Mirror” technology gives the 18.61 its exceptionally wide viewing angle of 180-degree. Specifically designed 48

Features • Unique three-component rapid setting silica-based composite coating • Environmentally friendly water based system (resins and filler mixture) • High abrasion resistance up to 1,100 C • Bonds well to porous substrates like concrete, refractory bricks etc (metal substrates need metallic mesh reinforcement).

for fitting into new or existing wall boxes, the 18.61 can be installed in corridors along with the 18.41 but is equally suited to small spaces such as bathrooms or passage areas.

Essentially it can be installed as a direct replacement for a wall mounted light switch board.

All three models share the common characteristics of a wide 110 to 230 V AC power supply range, a 10A rated ‘no’ output contact, adjustable ambient light intervention threshold and a light-off delay adjustable from 12 to 35 minutes.

Depending on the type, these new products can be installed on the ceiling, in suspended ceilings or in recessed or flush mounting boxes. n April 2015 n OEM Update

JOIN US FOR THE BEST OPPORTUNITY IN SHEET METAL WORKING INDUSTRY!

Pre-register your visit now

www.blechindia.com also see latest exhibitor list with profile

Exhibition for Sheet Metal Working Media Partners:

22-25 April 2015 | Mumbai | India Join for the best opportunity in sheet metal working industry and accelerate the business growth!

Get one to one interaction with the leading national and international suppliers.

Exhibition Highlights:

Exhibition Schedule & Venue:

• A highly focussed B2B trade exhibition for Sheet Metal Working.

• 150 leading manufacturers/ companies from China, Finland, France, Germany, Greece, India, Italy, Switzerland, The Netherlands, Taiwan, Turkey, UK and USA. • Hi-tech machineries on display and live machine demonstrations.

• Extensive range of Sheet Metal Working Solutions.

Wednesday Thursday Friday Saturday

22 April 2015 23 April 2015 24 April 2015 25 April 2015

10:00 - 17:00 hours 10:00 - 17:00 hours 10:00 - 17:00 hours 10:00 - 17:00 hours

Organiser:

Hall 1, Bombay Exhibition Centre, Goregaon (East), Mumbai, India For exhibit space, contact: E: sales.blechindia@interads.in T: 0124-4524220

Fasten the business opportunities in Fastener Industry!

Pre-register your visit now

www.fastenerfair.com also see latest exhibitor list with profile

Media Partners:

Exhibition for Fastener and Fixing Technology 23 – 24 April 2015 | Mumbai | India To fasten the business opportunities in fastener industry, do visit Fastener Fair India 2015 and interact with leading suppliers.

Exhibition Highlights:

• A comprehensive range of industrial fasteners, construction fixings, assembly & installation systems as well as fastener manufacturing technologies on display.

• 125+ companies from China, France, Germany, India, Italy, Malaysia, Taiwan, UK and USA

Exhibition Schedule & Venue:

Thursday 23 April 2015 10:00 - 17:00 hours Friday 24 April 2015 10:00 - 17:00 hours Hall 6, Bombay Exhibition Centre, Goregaon (East), Mumbai, India For exhibit space, contact: E: sales.ffi@interads.in T: 0124-4524228

Organiser:

For more information, please contact:

Inter Ads-Brooks Exhibitions (India) Pvt. Ltd., Plot No 859, Phase-V, Udyog Vihar, Gurgaon-122 016, Haryana, India.

THEMES: 2483: 2015

Brand Report

FIBRO Gas Springs: safe and reliable The

extensive range of FIBRO gas springs constitutes an ideal supplement to and expansion of the traditionally used spring elements such as helical springs, disc springs and elastomer units.

safety standards as well as the requirements of the BAK requirement specification.

When analysing the risks of what could happen when using a gas spring, three failure possibilities have been identified; over-stroke (S > Max), over-load (V>Max) and overpressure (P>Max). These features have been implemented in FIBRO gas springs to increase the safety level. n

With their minimal space requirement, gas springs close a gap wherever the accent is on accommodation of the utmost force component within a minimum of space or where exceedingly large travel is demanded.

FIBRO Gas Springs

FIBRO gas springs take care of both demands, even in combination. Their self-contained nitrogen charge makes FIBRO gas springs completely autonomous devices. Feeder pipes or storage vessel are not required.

FIBRO gas pressure springs: safety comes first FIBRO considers safety and reliability as its topmost priority. This particularly applies to its gas pressure springs which are subject to the pressure equipment directive.

Equipped with unique and innovative safety features such as over stroke, return stroke and overpressure protection, FIBRO gas pressure springs fulfil the highest

Contact: FIBRO India Precision Products Pvt. Ltd. (Formerly FIBRO India Standard Parts Pvt. Ltd.) Plot No: A-55, Phase II, Chakan MIDC, Taluka Khed, Pune - 410 501, Maharashtra Tele: +91-2135-338800 E-mail: info@fibro-india.com

BASF binder for automotive lightweight composites BASF plans to launch a new binder, Acrodur Power 2750 X, designed for the production of natural fibre composites for automotive lightweight applications such as interior car door panels or shelves.

BASF will present a functionalised natural fibre lightweight composite based on Acrodur Power 2750 X at the JEC Composites Show, scheduled to be held in Paris from March 10 to 12

50

As a low-emission alternative to formaldehyde-based reactive resins, Acrodur Power 2750 X gives natural fibre composites high mechanical stability. At the same time, the product offers thermoplastic processability and, unlike traditional thermoplastic binders based on polypropylene, it allows the use of up to 75 per cent natural fibres in lightweight components.

Environmentally-friendly, health-compatible “Due to the use of Acrodur Power 2750 X, natural fibre components are up to 40 per cent lighter than conventional plastic products. This results in cars that consume less fuel and have fewer carbon emissions,� explains Claus Dallner, Head of Marketing for Dispersions for Fibre Bonding at BASF.

The water-based binder Acrodur Power 2750 X is a healthcompatible alternative to conventional formaldehydebased reactive resins: Neither during processing nor as part of the final product does it release any organic substances.

This offers greater safety at work for the user, who no longer needs to invest in exhaust air treatment systems. In addition to this, the binder helps to improve the ambient air quality inside cars.

Making it easier and cost-effective Natural fibres bonded with Acrodur Power 2750 X can be processed using traditional thermoplastic cold-forming methods and be combined in one single process step with complex plastic elements such as reinforcing ribs or supports. The product helps to save both system and process costs. Acrodur Power 2750 X combines these benefits with great mechanical component stability.

Furthermore, the pre-impregnated natural fibres boast a long shelf-life.

The low-emission Acrodur binders are used to reinforce natural fibre composites before these can be processed into moulded components. They are also used for the production of high quality lightweight applications in the furniture and automotive industry. Due to their 3D plasticity, the binders help create attractive design options with a natural fibre look and feel. n April 2015 n OEM Update

Event

Rockwell Automation, Cisco to help industry improve business performance “Rockwell Automation on the Move 2015 is a commitment to help manufacturers gain the competitive advantage they need to succeed and grow”

US-based Rockwell Automation with over $6.62 billion dedicated to industrial automation and information is focussing on further expanding its global footprint on the major emerging markets like India, China and South East Asia. Rockwell Automation employs over 20,000 Professionals globally, with almost a thousand based out of India.

Dilip Sawhney, Managing Director, Rockwell Automation India, emphasised, “Increasing awareness of automation benefits in manufacturing shows a lot of scope for automation in manufacturing as the industry is realizing the vast benefits of automation. Also, as the penetration of automation in manufacturing in India is low, this leaves vast potential for industry to adopt automation for increasing productivity, improving decision making, quality, and innovating processes. In the light of ‘Make in India’ vision of government, manufacturing will be getting a boost thus giving scope to more adoption of automation in manufacturing for industry to remain competitive also.”

Modern automation technology, from an engineer’s perspective, now broadly encompasses mechanical engineering, electrical engineering, electronics engineering, good amount of instrumentation, communication engineering and lots of real time software (IT). The revolution in the Enterprise Area, the emergence of IT in manufacturing, information systems and MES to connect automation to enterprise and finally the role of social, media, mobility, analytics, cloud (SMAC) has changed the way the manufacturing and automation companies look at automation.

RAOTM brings industry together Rockwell Automation has recently organised RAOTM (Rockwell Automation On the Move) event in Bengaluru. It is an exclusive annual event that brings together the best and brightest thinkers, practitioners, and innovators from business and academia to accelerate the market adoption .The theme of Rockwell Automation on the Move 2015 is “The Connected Enterprise”. Rockwell believes, “The implementation of the Connected Enterprise will drive more change in industrial operations in the next 10 years than in the past 50 years.”

“Rockwell Automation on the Move 2015 is a commitment to help manufacturers gain the competitive advantage they need to succeed and grow. Every manufacturer shall enter and progress 52

through the stages of The Connected Enterprise that is most appropriate for it, at a pace determined by its own needs, infrastructure, readiness and resources.

It is critically important for Rockwell’s customers (manufacturers) to experience what its offerings are, and hence looking at creating customer briefing centers to take its solutions closer to their hearts,” said Mr Sawhney.

Strengthening partnerships On the backdrop of hosting RAOTM event, the company announced its partnership with Microsoft and Cisco for joint solution development and integrated solutions and services. These collaborative efforts shall result in better asset optimisation and broader risk management for industrial companies, the company said.

Commenting on the occasion, Mr Sawhney and Dinesh Malkani, President, Cisco India and SAARC said that both the companies are committed to being the most valuable resources in the industry for helping and guarding manufacturers to improve business performance by bridging the technical and cultural gaps between plant floor and higher level information systems and enterprise. This would result in increased profits and job opportunities. It was further emphasised that “Manufacturing is tightly linked to overall business processes for the enterprise.

This has manifested itself in a convergence of IT and automation technologies, driving real time decision making from demand fulfilment back through the supply chain. We have seen great gains in productivity as a result- smart manufacturing is a fundamental need for all manufacturers.”

R&D Centre The R&D Centre under the OES Group started in March 2010 with 5 ASIC Engineers is head quartered in Bengaluru. Today it has grown to a 33-member team with over 6 functions including ASIC, ECAD, PCB Schematic and Layout, Signal Integrity, Component Engineering and Engineering Data Management.

The R&D Centre also has 4 Process enabled IA stations- each fully capable to run Process core and IA Programs.

Speaking about the Rockwell R&D facility in Bengaluru, Mr Sawhney added, “The only R&D centre of Rockwell is based in Bengaluru because of the cross-cultural nature of the city, high performance, quality chip design ability, power electronics, signal detection, easier to wrap up and scale up.” n April 2015 n OEM Update

OEM

MART Dushyant R. Dalal 09820443020

INTERNATIONAL AUTOMATIC Mfgrs. of: Precision Turned Parts, Studs, Threaded Bars, Automotive Fastener Sp. in CNC Small Components A/11-B, Pravasi Industrial Estate, Off Aarey Road, Goregaon (E), Mumbai-63.Tel.: 022-6694 0899 Telefax : 29271881 Email: intdalal@hotmail.com

www.indiamart.com/internationalautomatic/

Book Space Now 09821575178 or 022-32682214 / 15 Visit: www.oemupdate.com 54

April 2015 n OEM Update

COMMERCIAL PARTNERS Ace Micromatic Group ................................................................21

igus India Pvt Ltd .......................................................................25

Ahura Aqua Treat .......................................................................54

Ingersoll Rand ..........................................................................IBC

B&R Industrial Automation Pvt Ltd ............................... Cover strip

International Automatic ...............................................................54

Dirak India Panel Fittings Pvt Ltd ...............................................31

John Enterprises ........................................................................54

Dormer Tools India Pvt Ltd .........................................................13

Mettler-Toledo India Pvt Ltd........................................................BC

Dover India Pvt Ltd .....................................................................11

Omron Automation Pvt Ltd ......................................................IFC

Fibro India Precision Products Pvt. Ltd.......................................23

Paramount Machine Tools ..........................................................54

Filtra Consultants & Engineers Ltd .............................................41

Rockwell Automation ...................................................................7

Finder India Pvt. Ltd ..................................................................58

Schuler India Pvt Ltd .................................................................15

Gati Kintetsu Express Pvt Ltd ......................................................5

Uninam Industries.......................................................................54

Harting India Pvt Ltd ..................................................................29

Wenli International Trading Pvt. Ltd.............................................19

Henkel Adhesive Technologies India Ltd .....................................3

Wohlhaupter India Pvt Ltd.............................................................9

UPDATE

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New Projects

Metallurgical Industries

Cement

Engineering

Ashok Iron Works is planning an expansion of its CI (SG) grade casting unit in dist. Belgaum, Karnataka.

Location: Belgaum, Karnataka.

Status: Planning Stage Office: Mazagaon Road, Udyambag, Belgaum, Belgaum - 590008, Karnataka, India.

Tel: 91-831-2442599.

Fax: 91-831-2441899.

Email: corporate@ashokiron.com Website: www.ashokiron.com

Jaiprakash Associates is planning an integrated cement project in dist. Sonbhadra, Uttar Pradesh.

Location: Sonbhadra, Uttar Pradesh.

Status: Planning Stage Office: Dalla Cement Factory, Dalla, Robertsganj, Sonbhadra - 231207, Uttar Pradesh, India.

Contact: Manager Environment Department.

Tel: 91-5445-265778/ 265801/ 265802 Fax: 91-5445-265776 Email: dalla.environment@jalindia.co.in Website: www.jalindia.com

Taikisha Engineering India is implementing an expansion of its sheet metal products manufacturing project in dist. Pune, Maharashtra.

Location: Pune, Maharashtra Office: Br 2/ 301/ 302 B Wing, 3rd Floor, Jai Ganesh Vision, Akurdi, Pune - 411035, Maharashtra, India.

Contact: Secretary, CEO Tel: 91-20-46703056/ 46703059 Website: www.taikishaindia.com www.taikisha-group.com

Chemicals

Power Generation

Chemicals

Astrica Laboratories is implementing a synthetic organic chemicals manufacturing project in dist. Medak, Telangana.

Location: Medak, Telangana Status: Under Implementation Office: Flat No. 19, 1st Floor, Sony Business Complex, Prashanti Nagar, Kukatpally, Hyderabad, Hyderabad 500072, Telangana, India.

Contact: Director Email: astricalabs@rediffmail.com

Karnataka Power Corporation is planning the Ghataprabha hydel power project in Karnataka. The project is waiting for environmental clearance.

Location: Belgaum, Karnataka.

Status: Planning Stage Office: Shakti Bhavan, 82, Race Course Road, Bangalore, Bangalore - 560001, Karnataka, India.

Tel: 91-80-22269931/ 22269932 Fax: 91-80-22252144.

Email: cccm@karnatakapower.com Website: www.karnatakapower.com

Gujarat State Fertilizers & Chemicals is planning a melamine manufacturing project in dist. Vadodara, Gujarat.

Location: Vadodara, Gujarat Status: Planning Stage Office: Fertilizernagar, Vadodara, Vadodara - 391750, Gujarat, India.

Tel: 91-265-2242451/ 2242651/ 2242751 Fax: 91-265-2240119/ 2240966 Email: info@gsfcltd.com Website: www.gsfclimited.com

Petroleum refining

Textiles

Engineering

Bharat Petroleum Corporation is planning a Diesel Hydro Treatment Unit (DHT) & associated facilities in dist. Mumbai Suburban, Maharashtra.

Location: Mumbai Suburban, Maharashtra.

Status: Planning Stage Office: Bharat Petroleum Refinery, Mahul, Chembur, Mumbai Suburban - 400074, Maharashtra, India.

Contact: Officer Operations Department Tel: 91-22-25524888/ 25524999 Fax: 91-22-25542970 Website: www.bharatpetroleum.com

Kerala State Co-Operative Federation For Fisheries Development is implementing an fishing net factory in dist.

Thiruvananthapuram, Kerala.

Location: Thiruvananthapuram, Kerala.

Status: Under Implementation Office: Kamaleswaram, Manacaud PO, Thiruvananthapuram - 695009, Kerala, India.

Tel: 91-471-2457172/ 2457756/ 2458606 Fax: 91-471-2457752 Email: matysafed@asianetindia.com, mfedho@yahoo.com Website: www.fisheries.kerala.gov.in

Taikisha Engineering India is implementing an expansion of its sheet metal products manufacturing project in dist. Pune, Maharashtra.

Location: Pune, Maharashtra Office: Br 2/ 301/ 302 B Wing, 3rd Floor, Jai Ganesh Vision, Akurdi, Pune 411035, Maharashtra, India.

Contact: Secretary, CEO Tel: 91-20-46703056/ 46703059/ 46703146 Website: www.taikishaindia.com www.taikisha-group.com

Drugs and Pharma

Sugar

Power Generation

Divis Laboratories is planning a bulk drug manufacturing project in dist. East Godavari, Andhra Pradesh.

Location: East Godavari, Andhra Pradesh Status: Planning Stage Office: Divi Towers, 7-1-77/E/1/303, Dharam Karan Road, Ameerpet, Hyderabad, Hyderabad - 500016, Telangana, India Tel: 91-40-23731318/ 23731760/ 23731761/ 23786300 Fax: 91-40-23733242/ 23786460 Email: mail@divislaboratories.com Website: www.divislabs.com

NSL Sugars is planning an expansion of integrated sugar complex in dist. Mandya, Karnataka.

Location: Mandya, Karnataka.

Status: Planning Stage Office: 4th Floor, NSL ICON, D. No. 8-2-684/ 2/ A, Road No. 12, Banjara Hills, Hyderabad, Hyderabad - 500034, Telangana, India.

Contact: Deputy General Manager Tel: 91-40-30514444.

Fax: 91-40-23327919 Website: www.nslsugars.com

New Delhi Municipal Council is implementing rooftop solar power projects in dist. New Delhi, Delhi.

Location: New Delhi, Delhi.

Status: Under Implementation Office: New Delhi Municipal Council, Palika Kendra, Parliament Street, New Delhi - 110001, Delhi, India.

Tel: 91-11-23360065/ 23742451/ 23743579 Email: chairperson@ndmc.gov.in Website: www.ndmc.gov.in

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

56

April 2015 n OEM Update

Tenders

Port Trust Company Name: Chennai Port Trust Tender Detail: Call for expression of interest for sale and redeployment of tugs and launches owned by Chennai Port for carrying out the shipping operations under Private - Public Participation (PPP) mode.

Location: Chennai Documentation Sale from: 11-December-2014 Documentation Sale to: 07-May-2015 Closing Date: 07-May-2015 Address: Marine Department, 6th Floor, Centenary Building, No: 1, Rajaji Salai Chennai Port Trust, Chennai – 600 001, Tamil Nadu, India.

Tel: 91-44-25360833 Email: 91-44-25384012 Website: www.chennaiport.gov.in Contact Person: Mr. Kesavaraman Designation: Administrative Officer Mobile: 91-44- 25362201 Company Name: Kandla Port Trust Tender Detail: E- Tender cum E – auction for the allotment of 04 Nos. plots between Kandla and village Jungi for production of salt on 30 years lease on as is where is basis.

Location: Kandla Documentation Sale from: 04-February-2015 Documentation Sale to: 17-April-2015 Documentation Fees: ` 5000/Closing Date: 17-April-2015 Address: Business Development Cell, P.O. Box 50, Administrative Building, Gandhidham, Kutch, Gujarat - 370 201, India.

Tel: 91-2836 – 239055 Fax: 91-2836 - 238055, 239055 Email: bdc@kandlaport.com Website: www.kandlaport.gov.in Contact Person: Mr. Rajesh Gupta Designation: Divisional Accountant (Estate Division - Administration Department) Mobile: 9408529119 Company Name: Kolkata Port Trust Tender Detail: Shore handling operation at berth No. 2 & 8 Of Haldia dock complex including supply, operation and maintenance of different cargo handling equipment.

Location: Haldia Documentation Sale to: 17-April-2015 Documentation Fees: ` 5,000/EMD: ` 27,62,000/- if the bidder bids for one berth, ` 55,24,000/- if the bidder bids for two berths Closing Date: 17-April-2015 Address: Operational Building, Chiranjibpur, Haldia Dock Complex, Haldia Dist. East Midnapore-721604, West Bengal, India.

Tel: 91-3224-252559

Email: sksaharoy@kopt.in Website: www.kolkataporttrust.gov.in Contact Person: Mr. S. K. Saha Roy Designation: GMIC (General Manager in Shipping) Mobile: 9434063719 Company Name: Kolkata Port Trust Tender Detail: Supply, operation and maintenance of different cargo handling equipment primarily at berth No. 2 & 8 of Haldia Dock Complex, Kolkata Port Trust.

Location: Haldia Documentation Sale to: 16-April-2015 Documentation Fees: Rs. 5,000/EMD: ` 24, 35,000/- for one berth, ` 48,70,000/for both the berth Closing Date: 16-April-2015 Address: Operational Building, Chiranjibpur, Haldia Dock Complex, Haldia Dist. East Midnapore-721604, West Bengal, India.

Tel: 91-3224-252559 Email: sksaharoy@kopt.in Website: www.kolkataporttrust.gov.in Contact Person: Mr. S. K. Saha Roy Designation: GMIC (General Manager in Shipping) Mobile: 9434063719 ELECTRICALS Company Name: Transformers and Electricals Kerala Limited Tender Detail: Design, manufacturing, supply, erection, testing and commissioning of 135/30 Ton EOT Crane and 270 T Swl balancer complying as per specification below.

Documentation Sale from: 21-February-2015 Documentation Sale to: 22-May-2015 Documentation Fees: ` 1, 05,000/ EMD: ` 5,00,000 /- Closing Date: 22-May-2015 Address: Angamaly South, Kochi, dist. Ernakulam - 683573, Kerala, India.

Tel: 91-476 – 2686722 to 2686733 (12 lines), Website: www.telk.com Contact Person: Mr. Hari Krishnan Designation: Engineer (Contracts & Materials) power Company Name: Rajasthan Rajya Vidyut Utpadan Nigam Limited Tender Detail: Online tender for (1) TN-2307 CHP removal of residual coal from emptied railway.

Wagons after unloaded from wagon tipplers and transportation thereof. (2) TN-2308 CHP unloading of coal rakes, feeding of coal & coal cleaning work of coal handling system of STPS, Suratgarh.

Location: Suratgarh.

Documentation Sale from: 21-March-2015 Documentation Sale to: 21-April-2015 Documentation Fees: For TN-2307- ` 500/-, For TN-2308 - `1000/EMD: TN-2307- `1,15, 500/-, For TN-2308 ` 7,27,300/Closing Date: 21-April-2015 Address: Suratgarh Super Thermal Power Station, Room No. 306, Service Building, Suratgarh, District. Sriganganagar- 335804, Rajasthan, India.

Tel: 91-1509-245252, 9413385188 Email: cestps@yahoo.com Website: www.rvunl.com Contact Person: Mr. Keshar Singh Designation: Superintending Engineer Mobile: 9413385345 Company Name: Madhya Pradesh Power Generating Company Limited Tender Detail: E-Procurement of 11 KV, UE, XLPE, HT aluminium cable of size 3Cx180 mm2 for construction power supply at 2x600 MW SSTPP MPPGCL Dongalia Distt Khandwa Madhya Pradesh.

Location: Dongalia Documentation Sale from: 27- April-2015 Documentation Sale to: 27-April-2015 Documentation Fees: ` 525/- Inclusive of VAT EMD: `20,000/Closing Date: 27-April-2015 Address: Office of the superintending engineer (P&W) Shree Singaji Thermal Power Project, Dongalia Dist. Khandwa, Madhya Pradesh, India.

Email: sepnw.sstpp1@gmail.com Website: www.mppgenco.nic.in Contact Person: Mr. Narendra Gupta Designation: Superintending Engineer (Purchase) Mobile: 9425611006 Company Name: Power Grid Corporation Of India Limited Tender Detail: Turnkey tower packages TW01, TW02 TW03 associated with NER power system improvement project (Intra-State Nagaland) Location: Nagaland Documentation Sale from: 17-March-2015 Documentation Sale to: 01-May-2015 Documentation Fees: ` 25,000/EMD: TW01 - ` 1,57,41,000 /-, TW02 – ` 1,68,67,000/-, TW03 - ` 77,38,000 /Closing Date: 01-May-2015 Address: Saudamini, Plot No 2, Sector-29, Gurgaon-122001, Haryana , India.

Tel: 91-124-2823312/2351 Website: www.powergridindia.com Contact Person: Mr. Manu Designation: Manager (CS-G4)

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

April 2015 n OEM Update

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