Better braking – with modern hydraulics
SMC racks up success with its new thermo chiller
More flexibility for continuous casting machines
Haas makes 5-axis machining affordable
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The Lean Way of Parker Hannifin's Safety Culture
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CONTENTS SMC racks up success with its new thermo chiller4 The Lean Way of Parker Hannifin's Safety Culture 6 ACCURATE AND STEPLESS CONTROL UNDER PRESSURE WITH THE NEW SMC ITVH 7 More flexibility for continuous casting machines 8 Active Temperature Sensors for HVAC and Building Technologyl 10 All-new 20-channel temperature logger 12 Belden Partners with ASKOM in Test Lab for Automotive OEMs 13 Achieve Flow Tuning Excellence With the New EXTRUDE HONE™ MF PROGRESS™ 14 Wrapping Four Bottles Per Second 16
J uly - A ugust 2015/3 V ol.40 Publication T ype
: L ocal/Periodical
Y ay›n Türü
: (Y erel/Süreli)
Chairman
A hmet Pelit
‹ mtiyaz Sahibi
Editorial D irector
Editors
Expert Logger – the latest generation of stand alone data loggers 20 Gas mixer with remote control – new KM100-MEM+ unveiled 22
Erdem Ça€layan
Y azı ‹ flleri
A dvertising Sales Staff R eklam Grubu
Emel fienyüz F ahriye Z iyade H afise Ergün
D esign & Graphics
A jansM ik Co., L td.
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Compact Dewpoint Transmitter for OEM Applications 18
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COMBINED SOLUTION FROM EMERSON INDUSTRIAL AUTOMATION IMPROVES EXTRUSION 26 SCHEUERLE Highway Giant Dual Lane Trailer with integrated folding mechanism allows tremendous cost savings through approval-free empty runs 28 CREAFORM ANNOUNCES PIPECHECK 3.1: FASTER, EASIER TO USE AND NOW COMPATIBLE WITH ASME B31.8 STANDARD 30 DSM introduces high performance polyamides for improved reliability and
H ead Office / Y önetim M erkezi A jansM ik Publishing A dvertising Org.& T ourism I ndustry T rade Co., L td. Perpa T icaret M erkezi B B lok K at:11 N o:1928 Okmeydanı - fiiflli 34384 ‹ stanbul / T ürkiye Phone : +90 [212]222 93 71 Pbx F ax : +90 [212]222 93 74 E-mail : info@ ajansmik.com Web : www.ajansmik.com
safety in next-generation USB 32
R epresentative of Germany
Haas makes 5-axis machining affordable [approx. 350 words] 34
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Build Differentiated Machines, Faster, with Help from the Kollmorgen
F ax: +49 0228 65 00 76
Developer Network 36
R epresentative of I taly
New hazardous area flameproof enclosure with fully adjustable remote
EI SEN A CH ER M ED I EN Phone: +49 0228 24 99 860 • e-mail:info@ eisenacher-medien.de CA SI R A GH I I N T ER N A T I ON A L A D V ER T I SI N G V ia Cardano 81 - 22100 Como (I talia)
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New mounting system boosts Seco’s Square T4-08 Helical cutter strength, stability 38
R epresentative of T aiwan
NICOLAS SMDEL 4-67 semi-trailer with single telescopic function facilitates
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TESTING 42 Better braking – with modern hydraulics 44 Signage for an efficient turnaround 46
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I SSN 1303-636X ©T urkey I ndustry M agazine Publication D ate : 25 A ugust 2015 ‹ stanbul - T urkey B askı Y eri&T arihi: 25 A ğustos 2015 ‹ stanbul - T urkey A ll rights reserved. N o part of this publication may be reproduced or transmitted in any form or by any means, including photocopying and recording, without the written permission of the publishers.
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SMC racks up success with its new thermo chiller SMC is ‘racking up’ success with its new thermo chiller. Designed to comply with standard mounting dimensions, the peltier type chiller HECR Series can be mounted within a 19 inch rack system. This system not only saves space, as the HECR can be housed with other equipment in racks, but also saves installation and piping time. Aimed at the specialist medical, electronic, chemical and laser industries that require accurate temperature control, the HECR offers market leading temperature stability of ±0.01 to 0.03 °C. By optimising the machine’s performance, productivity and process quality is also increased. Thanks to its compressor-less structure there are no moving parts, reducing vibration and noise levels to as little as 49 dB. It can also control the number of fan rotations depending on the load, so the lighter the cooling load, the quieter the operation. It’s smaller in design than its predecessors, with an overall reduction in height of 55% and volume ratio of 36%. Further savings are achieved due to a simple threestep operation with self-diagnosis and check display that includes 14 different alarms. It has an additional automatic temperature control function managed by an external temperature sensor. Fluid can also be added without the need to remove the HECR from the rack and a drain pan removes the risk of fluid leaking onto other equipment placed in lower racks. Available in two sizes – HECR002 and HECR010 – this thermo chiller series is truly flexible
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with a cooling capacity of 200 W and 1 kW, heating capacity of 600 W and 2 kW and set temperature range of 10 to 60 °C. It’s also efficient to operate, consuming as little as 400 W and being refrigeration free, it’s environmentally friendly too. From its original pneumatics roots dating back to 1959, SMC now has a team of 1,400 R&D engineers and is recognised as the worldwide leading expert in the pneumatics industry. The company offers more than 12,000 basic products with
over 700,000 variations and has a diverse customer base covering all automation industries. For more information about SMC and its quality products visit www.smc.eu
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The Lean Way of Parker Hannifin's Safety Culture
Parker Sporlan accelerated its lean journey by switching from wood tables to adjustable workstations based on the IPS system of T-slot aluminum framing. Parker's Sporlan division uses lean organizational tools to improve visibility, standardization and, ultimately, safety. When a company's lean and quality journeys diverge, safety can be compromised. As a supplier to a wide variety of manufacturing organizations – and being one itself – Parker Hannifin developed sensitivity to the success and failure of lean philosophies many years ago. Early adoption of the lean structure had many organizations focusing on the 5S components: sort, straighten, shine, standardize and sustain. This philosophy is attractive and easy to adopt, but it can be hard to put into practice because,
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as with any great idea, timing is everything. Lean teams have found that if they don't achieve early implementation successes, their organizations can soon shift attention to competing priorities. "From my experience across Europe and the U.S., I've witnessed significant gains being postponed due to the time and the energy required to build the lean solutions teams designed for breakthrough improvements in safety, quality, on-time delivery or productivity," said JeanMarc Athanassiadis, lean manager for Parker's Electromechanical Division. "I long wished we had pre-made or modular solutions available to reduce our time from improve-
ments design to implementation." Safety improvements alone are a big enough challenge, especially in larger organizations, because different departments face different safety issues. That's why Athanassiadis believes such organizations should make safety the sixth S in their lean programs. Without it, none of the other five Ss matter. Parker itself is a large, diverse company with many divisions. The need for safety's fusion into lean programs started early in Parker's own lean journey. An example of that fusion can be seen in the collaboration between Parker's Sporlan Division located in Washington, Mo., and the Electromechanical Division's In-
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The IPS T-slot aluminum framing is used for assembling machine bases and frames to hold automation system components as well as for safety guarding, enclosures, worktables, material handling systems and signage.
Improved organization of the final assembly cells resulted in better ergonomics. Workspaces are more efficient and back strains and eye injuries have been reduced dramatically. dustrial Profile Systems (IPS) product line, manufactured in two plants, located in Wadsworth, Ohio, and Rohnert Park, Calif. Sporlan, a provider of HVAC systems that Parker purchased in
2004, offers a broad selection of products in that category. Parker's IPS product line offers T-slot aluminum framing to help companies find quick ways to accomplish their lean goals in manufacturing, storage, assembly and shipping.
When Sporlan started reshaping its work environments, it did so with adjustable workstations, team scheduling boards, job tracking boards and cell communication boards – all based on the IPS system of T-slot aluminum framing. This also provided a ready platform to integrate mechanical or electrical interlocks, access control, light curtains, etc., without drilling or welding.
ACCURATE AND STEPLESS CONTROL UNDER PRESSURE WITH THE NEW SMC ITVH SMC has hit the target with its new ITVH electro-pneumatic regulator which responds to market demands for accurate and stepless high pressure control applications such as proof pressure testing or leak testers. Complementing SMC’s existing ITV Series, including the new, recently launched ITVX series which can assist gases by managing high pressure processes such as oxy-fuel welding or cutting, the new ITVH has been designed to perform under high pressure conditions and works either for air blowing or containment. It is able to control supply pressures reaching 3.0MPa and set
pressure ranges up to 2.0MPa. Although the ITVH can handle high pressure it also operates extremely efficiently, consuming no more than 3W. It’s compact and lightweight too, at just 122 mm high and 62 mm across, weighing in at just 630 g (without cables and brackets). SMC is the world-leading expert in pneumatics and offers over 12,000 basic products with over 700,000 variations. The company has a diverse customer base covering all automation industries. For more information, please visit SMC’s New Product Section at www.smc.eu.
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More flexibility for continuous casting machines
Rexroth's high-performance cylinder drive allows users to control all oscillation strengths during the casting process. High-performance cylinder drive from Bosch Rexroth optimizes mold oscillation Mold oscillation forms the basis for optimum steel surface quality and the productivity and cost-effectiveness of the entire continuous casting line. Continuous casting lines require not only precise oscillation but also a high level of flexibility in terms of stroke and frequency. Only state-of-the-art electro-hydraulics can provide the required precise movement of heavy masses with respect to all of the oscillation parameters. This is where Bosch Rexroth provides an all-in-one drive and control packa-
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ge made up of well-matched components that can be integrated into any control system: from oscillation cylinders right up to high-performance multi-axis control with software packages. The electro-hydraulic high-performance linear drive from Bosch Rexroth makes it possible to control all oscillation parameters while casting. Thanks to this flexibility in terms of control, various curve shapes can be implemented in order to optimize the oscillation. Both the stroke amplitude and the oscillation frequency can be varied during the casting process along with the casting speed. If no radial forces come into play, users can opt for Rexroth's cost-effective high-performance cylinders. The high-performance series of
cylinders are of modular design. The modular system comprises of five force levels from 16 to 250 kN with two predefined styles of mounting, those being "trunnion" or "head flange". The equal effective areas of the cylinder ensure good controllability, even with highly dynamic applications up to a maximum frequency of 50 Hz. The basic version of the high-performance cylinder is fitted with a connection block, associated valves, pressure accumulator, damper accumulator and measuring points. An integrated magnetostrictive position measurement system for position sensing is available as an option.
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Active Temperature Sensors for HVAC and Building Technology
The E+E temperature sensors are available with analog (0-10 V or 4-20 mA) or passive outputs.
The new temperature sensors from E+E Elektronik are now also available with 0-10 V or 4-20 mA outputs. The active sensors extend the portfolio of the Austrian sensor specialist in the field of HVAC and building technology. The compact, innovative housing and mounting concept with protection class IP65 / NEMA 4 facilitates extremely simple and fast installation of the sensors. The E+E temperature sensor range includes duct mounted types, sensors for wall mounting indoors and outdoors, a strap-on sensor
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for mounting on ducts and pipes, and a version with remote probe. Special immersion wells with innovative mounting spring turn the duct versions into immersion sensors for temperature measurement in fluids. The sensors offer outstanding accuracy and a wide temperature range. The measured values are available at a 0-10 V or 4-20 mA output. The factory scaling is freely selectable and can be subsequently changed by the user by means of an optional configuration kit and free configuration software.
The clever housing design offers a considerable advantage when it comes to installing the sensor. Thanks to the external fixing holes, the device can be mounted with closed cover, which keeps the electronics protected against construction site pollution. The new temperature sensor series from E+E Elektronik rounds off their existing product range of transmitters for humidity, CO2 and air velocity, thereby offering an extensive sensor package for HVAC and building technology.
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All-new 20-channel temperature logger
DATAPAQ TP3 20-channel loggers provide more detailed and higher-quality data to help users save time and boost productivity DATAPAQ TP3 for heat treatment, paint-curing, and ceramics processes Cambridge, UK – The new DATAPAQ TP3 data logger provides more measurement channels, connectivity options, and ease of use for profiling and surveying in hightemperature heat treatment applications. With a ±0.3 °C (0.5 °F) accuracy, the all-new logger surpasses the most stringent requirements. “We have worked towards this exciting launch for two years,” states Elie El Choueiry, Furnace and Kiln Product Manager at Datapaq Ltd., Cambridge, UK. “Compared to our previous, successful heat treatment solution TPAQ21, the new DATAPAQ TP3 provides even more detailed insight into high-tempera-
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ture processes. It is more resilient and includes numerous new features, such as full connectivity including Bluetooth, fully certified TUS capability for AMS 2750E and CQI9, integrated correction and calibration functions, and flexible charging with multiple battery options.” The new series comprises 20- and 10-channel loggers that store up to 3.6 million data points. One logger can perform up to ten measurement runs before data download. Thermal and ingress protection have been enhanced to ensure optimal performance in extreme applications, such as vacuum brazing, aluminum solution reheat, and water or gas quench. The DATAPAQ
TP3 logger is being released along with new, durable thermal barriers for use with the industry-specific temperature profiling systems from Datapaq: Furnace Tracker® for metal-working, Kiln Tracker® for ceramics, and Oven Tracker® AutoPaq® for premium paint cure processes in the automotive OEM assembly market. Each profiling solution includes Insight™ analysis software and thermocouples tailored to the application.
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Belden Partners with ASKOM in Test Lab for Automotive OEMs Strategic Partnership between Belden and ASKOM kommunikationstechnik Delivers Test Center for Factory Floor Communication Infrastructure
ting; Wolfgang Schenk, vice presi-
ger of ASKOM said: “This new test
Close Cooperation in Order to Respond to Automotive Customer Needs Belden Inc., a global leader in signal transmission solutions for mission-critical applications, and strategic partner ASKOM kommunikationstechnik, a specialist in communication technology, have opened a new test lab, located in the main building of ASKOM in Wolfsburg, Germany. The test lab is able to demonstrate a complete communication infrastructure around applications in the factory floor – and was established to meet the increasing demand for closer geographical support from Automotive OEMs and their suppliers - with a focus on the Volkswagen (VW) group.
From left to right: Steve Biegacki, senior vice president Belden sales and marketing, Andreas Schleicher, general manager ASKOM, Wolfgang Schenk, vice president of industrial sales Belden EMEA. dent of industrial sales Belden EMEA; Andreas Pilgrim, manager vertical sales Belden EMEA; and Alexander Maager, Belden sales manager automotive. Speaking at the formal opening, Andreas Schleicher, general mana-
The lab is equipped with a large range of products from various Belden brands, such as Lumberg Automation, Hirschmann, Tofino Security and Belden. They include EAGLE One security products; MACH4000, MACH1000 and MSP30 backbone switches; MS20/30 field switches; patch cord and IO box connectivity solutions; and HiVision software for industrial network management. The formal opening of the test lab was attended by Andreas Schleicher, general manager of ASKOM as well as Steve Biegacki, senior vice president Belden sales and marke-
lab allows us to offer a range of services to the automotive industry cluster in Northern Germany and enables us to respond quickly to customer needs. VW and other suppliers can rely on us to test their communication infrastructure networks intensively and train their employees in the most critical technologies for implementing the latest networks.” Speaking for Belden Wolfgang Schenk, vice president of industrial sales EMEA said: “Our partnership with ASKOM enables us to support VW with Belden technology as well as product training for automotive applications at a location that is very close to the production facilities of VW.”
Belden partners with ASKOM in test lab for automotive OEMs.
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Achieve Flow Tuning Excellence With the New EXTRUDE HONE™ MF PROGRESS™
New EXTRUDE HONE™ PROGRESS Fuel system manufacturers seeking the best fuel performance require flexible high-flow grinding and high-flow test capabilities to achieve finely tuned orifices in numerous design variations. To this end, Kennametal Precision Surface Solutions® is announcing EXTRUDE HONE™ MF PROGRESS™, the next generation of flow tuning and flow measurement featuring a flow targeting accuracy to +/-1% aimed at orifices 100-350 μm in parts
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less than 30 mm in diameter and flow rates up to 5 L/min. “Additionally, MF PROGRESS delivers another exclusive added value that we call Flexibility Through Modularity,” says Sharath Shankaregowda, Kennametal Precision Surface Solutions MICROFLOW product manager. “Customers benefit from a self-contained modular construction for each process (grinding, flush, flow testing, etc.) and configurable hardware (manifolds, frequency drives, etc.)”. Customers are saying adding such
advanced process options can help ensure components meet ever more stringent government regulations. From CAFÉ in North America, EURO6 and expected EURO7 in Europe, and PRC standards in Asia, all focused on reducing CO2 emissions, EXTRUDE HONE™ MF PROGRESS provides the perfect next step in upgraded manufacturing and finishing. In addition, this all takes place in a 25% reduced machine footprint, 50% less tool wear compared to previous-generation equipment, and depending on the
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application the output can be increased by up to 100%. MICROFLOW Explained • MICROFLOW is the real-time monitored flow of abrasive media through small passages, such as fuel-injector spray holes. • It achieves specific, repeatable processing results, including edge radius, micro-hole size and surface finish. These changes to small-hole geometry improve part function and performance. • Media flows in one direction, similar to part operation. • Increased flow is attributed to subtly changing the geometry of the opening entrance (opening exit usually is not affected).
• MICROFLOW processing involves pressure drop, flow rate, geometry, and fluid properties; machine design and dynamics; workpiece characteristics; media properties and processing procedures.
robotic or other handling system automation. The machine also comes with expanded on-screen maintenance capabilities and improved filtration to further pump and valve life.
• Exclusive range of standard and customized MICROFLOW media with specific properties perform a step beyond classical hydro erosive liquid.
Reliability being at the heart of production control requirements, EXTRUDE HONE™ MF PROGRESS provides for online monitoring and control of all relevant parameters. The online feature is also beneficial in delivering remote process demonstrations and gathering resulting data.
EXTRUDE HONE™ MF PROGRESS is available in various inside station layouts: flow tuning, media reclaim, flush module, test module, marking, thanks to the system’s modular design and construction. It is easy to configure and easy to fit into modern production lines ready for
For more specific information, contact Kennametal’s Precision Surfaces Solutions, AFM MICROFLOW Center of Excellence at: extrudehone.sales@kennametal.com
Comparison Kennametal MICROFLOW versus Hydro Erosive Grinding.
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Wrapping Four Bottles Per Second ding food and beverage, cosmetics and pharmaceuticals. “Through constant technological research, in conjunction with our clients, we are committed to finding solutions to our clients’ needs,” said Tagliaferro Silverio, owner of Clever Machines. So, when a client came to them with the need to reduce downtime on their Sleever Machine because of the time-consuming nature of maintaining slip rings, Clever contacted Rockwell Automation. Rockwell suggested they use ProSoft Technology’s 802.11n Fast Roaming Industrial Hotspot radios and a 5 GHz radiating cable as the antenna. The 802.11n Fast Roaming Hotspot supports Access Point, Repeater, Bridging and Client modes and delivers fast data rates up to 300 Mbps.
In Altavilla Vicentina, Italy, a Clever Sleever Machine places and shrink-wraps decorative sleeves on bottles at a rate of 18000 pieces per hour. That’s five pieces per second. So, imagine how much money would be lost every time they have to stop production to replace a damaged or broken slip ring. That was the problem facing Clever Machines.
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Clever provides a wide variety of sleever machines and heat-shrink tunnel applicators. These machines can perform every type of sleeve application required by the client, at different production speeds, including linear and rotary machines suitable to apply full and partial sleeves and safety seals. These machines can be found in many different packaging applications inclu-
“The Fast Roaming feature of this radio maintains seamless, high-speed connections particularly wellsuited for moving equipment like Clever’s Sleever Machine,” said Andrea Mazzucchelli, Regional Sales Manager for ProSoft Technology. “This was the excellent packetper-second performance and robust communications we were looking for,” said Andrea Parlato, Electrical Division Technical Manager for Clever. Now a CompactLogix™ L36, communicates to the Point I/O through ProSoft Technology’s radios, provi-
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ding fast and reliable data from their rounding tables which apply the label and heat-seal them to the bottles. The radiating cables essentially replace the slip rings, virtually eliminating the expensive downtime associated with maintaining them. A radiating cable is a long, flexible antenna with slots to radiate RF signals that can be installed around corners, along monorail systems and through tunnels to propagate wireless data signals in situations that are tough or impossible for traditional antennas. Since the radiating cable antenna can be mounted within inches of where the signal needs to be received, it isolates the wireless signal from going to other machines that may be on the plant
floor. And, the cable comes in multiple lengths to meet the needs of most applications.
solutions. These are found in applications spanning the industrial marketplace.
“The radiating cables have been specifically tested to work with the 802.11n radios,” said Mazzucchelli. “Making this a field-proven solution instead of those expensive-to-maintain slip rings.”
With 500 distributors and regional offices in Asia Pacific, Europe, Middle East, Latin America and North America, ProSoft Technology provide an unparalleled support to customers worldwide.
ProSoft Technology® designs industrial communication solutions that connect automation products seamlessly. ProSoft Technology is a highly diversified, customer intimate, global organization with a focus on quality and ease-of-use. Their products include in-chassis communication modules for PLC/PAC controllers, standalone protocol gateways, and a wide range of robust, field-proven wireless
www.prosoft-technology.com
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Compact Dewpoint Transmitter for OEM Applications
Compact EE355 dewpoint transmitter for OEM applications. The compact EE355 dewpoint transmitter measures dewpoint temperature with ±2°C accuracy across the entire working range. The unit offers an optimal priceperformance ratio for OEM applications in compressed air systems, plastic dryers and other industrial drying processes. With the new EE355, E+E Elektronik expanded its range of dewpoint products with a transmitter for the range -60…+60°C Td at an operating pressure up to 20 bar. Same as other E+E dewpoint transmitters, the EE355 features a special auto-calibration procedure which leads to ±2°C Td accuracy, and employs E+E
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polymer humidity sensors, which are condensation resistant and highly long-term stable. The measured values for dewpoint, frost point or ppm volume concentration are available on the analog 4…20mA and on the digital Modbus RTU outputs. Integration into the measurement task is simplified considerably by the compact design and the robust stainless steel enclosure. With the free configuration software and the optional Modbus to USB converter the user can scale the analog output, set up the Modbus communication and adjust the transmitter.
E+E Elektronik manufactures various models of dewpoint measuring instruments, from compact OEM transmitters to high-end devices for demanding process control, and covers with these a wide range of applications.
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Expert Logger – the latest generation of stand alone data loggers With its Expert Logger, Delphin Technology AG introduces a new generation of data loggers that combine the latest communication technology with advanced measurement technology. The device is being launched in three versions, capable of processing 16, 32 or 46 analog input channels. Up to 8 digital inputs/outputs and one SDI12 interface are also available depending on the version. The main areas of application include product testing, environmental measurement technology, laboratory data acquisition, research and development, and trials and testing. All analog inputs are galvanically isolated from each other. A 24-bit A/D converter ensures fast, precision sampling rates of up to 50 measurements per second per channel. The devices are maintenance and noise free due to the absence of electromechanical components (such as relays) that are prone to
wear and tear. All Expert Loggers are equipped with internal 4 GB memories that can independently store up to 100 million measurement values with date and time stamps. Storage capacity can be extended as required via external USB or LAN storage (NAS). Online measurement data or the contents of the data memory can be transmitted to the internet via an integrated WLAN or UMTS module. The Expert Logger is also equipped with an energy-saving “sleep functi-
on“ for automated switching off during breaks in measuring. Independent operation is possible using batteries, rechargeables or solar panels. The Expert Logger can communicate as standard via CanBus, ModBus and ProfiBus. Internal software channels such as calculation channels, limit values and integrators enable online evaluation of measurements and the logging of meaningful data. Users can quickly and effectively operate the Expert Logger using the powerful ProfiSignal Go software that is included free in delivery. ProfiSignal Go can be used to portray measurement data in trends and to carry out detailed analyses. The software also enables fast ASCII exporting of measurement data for MS Excel™ or for conversion into TDM format.
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Gas mixer with remote control – new KM100-MEM+ unveiled When it comes to gas mixers, the company Witt-Gasetechnik is always the first to spring to mind: The market leader is proud to present its truly state-of-the-art mixing systems for up to three gases … the KM100-MEM+. And it can be operated remotely. This latest device uses electronically actuated valves, a further leap forward in the technology. And it’s not only the gas mixture setting that is extremely precise in comparison to manual setting. The target values can also be reproduced exactly, even after changes in use. The speed is tremendous too. "It usually takes just a second to get the gas mixture flowing", stresses Witt Managing Director Martin Bender, "no matter which target values you set". TOTAL REMOTE CONTROL What is more, the latest Witt development provides the option of remote control via processor technology and electronic motor-operated mixing valves. It can be driven via PC, PLC or a machine control system. All parameters can be conveniently called up, set, queried and documented. "That means the mixer can be integrated seamlessly into any of the user's existing infrastructure", states Bender. A new feature of the KM100-MEM+ is an additional touchscreen display. The
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user can utilise this to check the current settings or change the device parameters. The gas mixture can generally be set in increments of 0.1 percent and maintained with maximum accuracy. At its maximum 20 bar inlet pressure and 10 bar outlet pressure, the system generates a gas mixture output of up to 544 Nl/min (air equivalent). All technical gases (apart from toxic and corrosive gases) and combinations of combustion gas with air, O2or N2O can be blended – including mixtures of up to three gases. In conjunction with a gas tank, the mixer is suitable for both continuous and batch gas blending. Pressure is accurately controlled using dome pressure regulators which com-
pensate for any fluctuations in the gas supply pressure. The integral gas inlet monitoring system ensures extra safety, by emitting an alarm and/or alarm signal if the pressure is too low. The device can be combined with other modules, such as on-line analysers. Witt has enclosed its product in a splash-proof stainless steel housing with compact dimensions of only 330 x 485 x 445 mm (HxWxD) and weighing a mere 22 kg. The new mixer is available now. Further information is available at www.wittgas.com.
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COMBINED SOLUTION FROM EMERSON INDUSTRIAL AUTOMATION IMPROVES EXTRUSION The manufacturing site of Clariant at Izmit, Turkey, has adopted the latest high performance Emerson Industrial Automation technology to help it overcome issues surrounding maintenance and inefficiency. Control Techniques’ Unidrive M, in tandem with a Leroy-Somer Dyneo® permanent magnet synchronous motor from Emerson Industrial Automation, is being used on a process-critical extrusion machine in order to help boost both the efficiency and accuracy of its work for customers in the plastics and chemical industries. Clariant, one of the world’s leading speciality chemical companies, was experiencing issues with its previous DC motor and drive system on an important extrusion machine at its Izmit facility. The plant, located around 70 km east of Istanbul, centres on colouration solutions for plastics and polymer products, as well as a host of other products ranging from PVC stabilisers to waxes for polyolefin compounds. The motor and drive package had been in service for many years but was now ageing and proving inefficient. Furthermore, frequent maintenance was required and, as a result, the facility sought an alternative solution. Having researched the market, Clariant opted to move away from its previous supplier of motors and dri-
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ves in favour of a complete drives and motors solution from Emerson Industrial Automation.
Dyneo®. It also supports simple positioning without the need for encoder position feedback.
“Aside from new technology and increased energy efficiency, the choice was based on the user-friendly and easy-to-use parameters of the Unidrive M600,” said Serdar Kiyi, technical manager at the plant. “We are now using the package to leverage more efficiency, accuracy and reliability from the extrusion machine than was possible using our previous systems.”
The Unidrive M600 also offers a high performance onboard PLC with a real-time task that can be used for straightforward logic control, speed following and digital lock to enhance drive application capability. The drive also features CODESYS technology for machine control programming.
Among the main technical features of the Unidrive M600 that appealed to Clariant was its ability to support sensor-less open loop control. This mode offers impressive dynamic performance and enables more compact and higher efficiency motor technologies to be used, such as
“We really like the user friendly menu and parameters, as well as its compact, slim design,” says Mr Kiyi. “Since installing the new solution from Emerson Industrial Automation, the extrusion machine has been working with markedly higher efficiency and precision, and our total throughput has increased by around 10 per cent.”
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ultrasonic joining solutions. Emerson brands include Appleton, ASCO, Branson Ultrasonics, Browning, Control Techniques, Kop-Flex, Leroy-Somer, McGill, Morse, Numatics, O-Z/Gedney, Rollway, SealMaster, and System Plast. For more information, visit www.EmersonIndustrial.com About Emerson
About Control Techniques
www.ControlTechniques.com
Control Techniques, a business unit of Emerson Industrial Automation, is a world leader in the design and production of electronic variable speed drives for the control of electric motors. The company’s strategy is to concentrate on delivering drives and servo products that enhance the productivity of its customers’ machines and processes.
About Emerson Industrial Automation
For more information, visit
Emerson Industrial Automation, a business of Emerson, is a global technology provider that enables productivity, efficiency and quality gains for customers across a spectrum of industries. Its products include alternators, electric motors and drives, electrical distribution devices and mechanical power transmission, fluid automation and
Emerson (NYSE: EMR), based in St. Louis, Missouri (USA), is a global leader in bringing technology and engineering together to provide innovative solutions for customers in industrial, commercial, and consumer markets around the world. The company is comprised of five business segments: Process Management, Industrial Automation, Network Power, Climate Technologies, and Commercial & Residential Solutions. Sales in fiscal 2014 were $24.5 billion. For more information, visit Emerson.com. For more information, visit www.Emerson.com
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SCHEUERLE Highway Giant Dual Lane Trailer with integrated folding mechanism allows tremendous cost savings through approval-free empty runs With the development of Highway Giant Dual Lane Trailer, SCHEUERLE has raised dual-lane technology to a completely new level with the first vehicle having been recently delivered to the first customer, Sterett Crane & Rigging in Owensboro, Kentucky (USA). A special feature on the SCHEUERLE Highway Giant, among other things, is
the integrated folding mechanism which allows the complete trailer to be transported in a folded state on low-level platform semi-trailers (flat-bed trailers) with road use authorization. Thus, inexpensive approval-free empty runs can be carried out resulting in huge costsavings.
Due to its low tare weight - which happens to be the lowest on the market - the SCHEUERLE Highway Giant Dual Lane Trailer has been approved for use in most US states, and was specially developed as a flexible vehicle concept in order to fulfil the wide range of requirements found in the North American market. The design not only accom-
Ingeniously simple, simply ingenious: the SCHEUERLE folding technology allows the aproval-free transport of the SCHEUERLE Highway Giant on standard flat-bed trailers.
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The SCHEUERLE Highway Giant during a successful test drive near to the SCHEUERLE factory premises.
modates the variable vehicle widths (16', 18', 20'/ 4.8m, 5.4m, 6m), but there is also the possibility to safely widen the vehicle under load. Adapting to meet the different regulations in the states to be crossed can therefore be easily and economically made with just one vehicle. Thanks to the folding technology, the trailer can also be inexpensively transported over long distances when folded up - regardless whether it is delivery to or returning from a transport assignment. In order to achieve an optimum payload/tare weight ratio, the chassis is manufactured using a stable lightweight construction. As a connection to the towing vehicle, a gooseneck or drawbar can be used whilst equipment such as spacers or deck can easily be fitted. The centrepiece of the Highway Giant features the proven pendulum axle technology from SCHEUERLE. The hydraulic cylinders in the pendulum axles have
the largest displacement volume in the market thus facilitating driving under and picking up loads. The SCHEUERLE pendulum axle mounting guarantees, in connection with the precise and smoothlyoperating steering system, easy manoeuvring even when negotiating tight bends. On request, the Highway Giant is available as a PowerBooster (PB): with this version, an additional aggregate provides extra thrust when driving and allow the use as a self-propelled vehicle without a tractor. Thus, under certain circumstances, a second tractor is not required during the transport assignment and the cargo can be shunted into position at the final destination even in confined spaces.
(Precision Enterprise Inc., Cocoa, FL), RGS (Rigging Gear Sales Inc., Dixon, IL), TSP (Transport Systems and Products Inc., Stamford, CT) (in alphabetical order). Based on their long-standing business relationship with the TII Group, they provide all services in the area of sales and after-sales for TII Group vehicles in the US market.
SCHEUERLE is part of the world´s leading manufacturer of heavyduty vehicles, the TII Group. Customers of the TII Group profit from three authorized sales and service partners in North America - PEI
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CREAFORM ANNOUNCES PIPECHECK 3.1: FASTER, EASIER TO USE AND NOW COMPATIBLE WITH ASME B31.8 STANDARD
The pipeline integrity assessment software for NDT service companies is now more powerful than ever Creaform, worldwide leader in portable 3D measurement solutions, 3D engineering services, today announced the release of Pipecheck 3.1, its pipeline integrity assessment software that is now compatible with the ASME B31.8 in-
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dustry standard. With Creaform’s metrology-grade scanners and sophisticated algorithms, strain-based assessment is now possible and accessible to everyone! There is no software capable of performing quick and easy calculation processes for strain-based assessment of mechanical damage. This type of assessment usually re-
quires a high level of expertise. Being able to choose the points used in the calculation process is not only unique but extremely intuitive thanks to the powerful pipeline integrity assessment solution available for NDT service companies. Several other enhancements have been added to this version of Pipecheck, including:
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• Scan edition: The scan module of Pipecheck has been improved to allow operations on the scan surface. Operations, such as increase/decrease resolution and delete permanently scanned surface, are now available. • Clustering definition: It’s now possible to define “cluster” types in Pipecheck to enhance the ILI correlation module. • Manual selection of corroded features: This tool is designed to evaluate the burst pressure over a specific scanned region. Pipecheck software will first run a complete assessment over the entire scan
and then focus on the specific regions to determine repair actions over long features or enhance ILI correlation. • Volume of material loss: Pipecheck will now calculate the volume of material loss per feature and over the entire scanned region.
and sells 3D portable measurement technologies and specializes in 3D engineering services. The company offers innovative solutions, such as 3D scanning, reverse engineering, quality control, non-destructive testing, product development, and numerical simulation (FEA/CFD). Its products and services cater to a variety of industries, including automotive, aerospace, consumer products, heavy industries, healthcare, manufacturing, oil and gas, power generation, and research and education With headquarters and manufacturing operations in Lévis, Québec, Creaform operates innovation centers in Lévis and Grenoble, France, and has offices in the United States, France, Germany, Brazil, China, Japan, India, Korea and Singapore.
Pipecheck 3.1 is available by contacting Creaform or a member of its vast network of distributors.
Creaform is a unit of AMETEK Ultra Precision Technologies, a division of AMETEK Inc., a leading global manufacturer of electronic instruments and electromechanical devices, with 2014 annual sales of $4.0 billion.
About Creaform
www.creaform3d.com
• Optimized targets: This feature has been completely revamped for increased performances.
Creaform develops, manufactures,
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DSM introduces high performance polyamides for improved reliability and safety in next-generation USB
DSM introduces high performance polyamides for improved reliability and safety in next-generation USB. Royal DSM, the global Life Sciences and Material Sciences company, says its high-performance polyamides, Stanyl® and Stanyl® ForTii™, have been approved by global producers for use in the next generation of USB Type-C connectors. DSM’s materials answer the need for improved levels of safety and reliability. The company highlighted its various solutions for mobile devices at Chinaplas 2015 in Guangzhou on May 20-23. USB is the industry bus standard used for transferring data and power to and from digital devices. Device charging over USB has become a major consumer feature in recent
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years. USB is by far the most popular and successful means of connecting peripherals, with some 5 billion ports being produced every year The introduction of the USB Type-C connector is the result of the need to reduce electronic waste. Legislation in Europe, for example, is enforcing the use of a standardized charging interface, so that one charger and its associated cable can be used for multiple devices. As a result, the USB Type-C connector will be obligatory from 2017. Some electronics OEMs, including Apple and Google, have already launched equipment that incorporates TypeC ports.
The Type-C connector overcomes an important draw-back that has traditionally been associated with USB. Until now, numerous different types of plugs and sockets have been available, so, for example, charging two different mobile phones often requires two different sets of chargers and cables. In addition, “in” and “out” connectors have different shapes. The new USB type-C standard is the first USB connector with reversible design allowing it to function perfectly whether you plug it in right-side up or upside down, Moreover, with wall thicknesses at only 25% of previous generation connectors, they are much smaller.
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With USB Type C connectors being so small, the performance properties of the materials used for their housings are especially critical. Stanyl (polyamide 46) and Stanyl ForTii (polyamide 4T) have high CTI (Comparative Tracking Index) ratings well above 400V, which are a measure of their ability to provide electrical insulation. Alternative materials show a short break during CTI testing, resulting in a serious performance and safety issue for the complete device when in use and exposed to particles, moisture, sweat or other pollution due to electrical tracking. DSM high performance polyamides offer an ideal balance of toughness and stiffness. Furthermore, the flame retardant additive systems that they incorporate to provide a UL 94 V-0 rating contain no halogens. In addition to ensuring high output rates, the excellent processability of Stanyl and Stanyl ForTii also provides connector designers with flexibility in component structure and tooling design. Stanyl and Stanyl ForTii can be used to produce connectors with wall thicknesses as
thin as 0.12 mm and which still have the required high mechanical properties. Their high flow in combination with high weld-line strength ensure the required high pin pull-out strength—the force needed to pull metal contacts out of the housing—parts successfully pass durability tests that involve mating and unmating plugs and sockets more than 10,000 times. Bright color is becoming more and more popular in electronics devices enabling fancy designs and product differentiation for OEMs, so connector materials also need to be easy to color to the exact shade required by the customer. DSM polyamides are available in a broad color portfolio, and specifiers can make use of the company’s color matching service to obtain exactly the color they want. Further important advantages for DSM high performance polyamides in this application include their ability to withstand the very high temperatures used in lead-free reflow soldering processes used to assemble components on printed circuit boards, as well as their compatibi-
lity with ultrasonic welding (used for joining separate connector components together in some designs). They also have very good wear resistance which is essential to meet the high mating/unmating cycles of manufacturers. Stanyl ForTii and Stanyl are already approved by global producers for the use in USB Type-C, among them Acon based in Taiwan. According to a spokesperson at Acon: “We are getting great performance from DSM materials, and DSM also provides excellent technical support and service, as well as strong application expertise, all of which together have helped us develop and put into production high performance USB Type-C connectors in a very short time. In specific we value the high CTI of DSM materials which allows us to provide OEMs with higher end product safety against potential fire hazards caused by electrical tracking. We have now started mass production and are winning new business from many OEMs.”
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Haas makes 5-axis machining affordable [approx. 350 words] mount tool changer swaps tools quickly to reduce non-cutting time. Furthermore, high speed 61 m/min rapids combine with high acceleration rates to shorten cycle times and increase throughput. Adding the Haas TRT-100 dual-axis rotary table to the DT-1 provides high speed, accurate, 3+2 positioning and full 5-axis machining of small, complex parts. Fast indexing speeds ensure short cycle times, while impressive braking capability on both axes guarantees extreme accuracy.
With ever more components requiring the application of 5-axis machining techniques to minimise set-up and cycle times, Haas is able to present a highly cost effective solution that brings 5-axis machining within the reach of shops that perhaps wouldn’t normally have the necessary budget. The combination of a Haas DT-1 drill/tap centre and TRT-100 dual-axis rotary/tilting table can deliver both 3+2 and full 5-axis machining from just €70,180! The DT-1 is a compact, high-speed drill and tap machine featuring a generous 508 x 406 x 394 mm work cube yet maintaining a very small footprint. The powerful BT-30 taper spindle spins to 15,000 rpm, and allows rigid tapping to 5000 rpm. The machine provides cutting feed rates to 30.5 m/min for high speed milling, and the machine’s 20+1 side-
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The TRT-100 uses powerful brushless servomotors to provide 47 Nm of spindle torque on the tilt axis and 22 Nm on the rotary axis, with indexing speeds of 1000 deg/sec on both axes. In addition, the unit offers ±120 degrees of tilt and 360 degrees of rotation to position parts to almost any angle for mac-
hining. The precision-ground 100 mm platter features multiple bolt patterns and a precision through-bore for versatile fixturing, and will swing parts up to 213 mm diameter. In terms of platter capacity, the maximum weight is 6.8 kg for 3+2 machining, and 2.25 kg for 5-axis machining. At just 508 mm wide and less than 330 mm deep, the TRT-100 is the perfect complement for the high speed DT-1 Drill/Tap Centre, and can easily be removed when not needed. Ultimately then, an extremely competent, versatile and affordable 5-axis machining centre is now available to machine shops everywhere.
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Build Differentiated Machines, Faster, with Help from the Kollmorgen Developer Network KDN is an online knowledgebase that helps OEMs spend less time troubleshooting and more time developing superior performing machines Kollmorgen introduces the Kollmorgen Developer Network (KDN). Located at http://www.kollmorgen.com/kdn , KDN is an interactive knowledge base where Kollmorgen customers can learn from one another, receive expert advice from Kollmorgen application engineers and customer support staff, and delve into rich technical information with just a
few clicks. "KDN was developed to help machine designers spend less time troubleshooting and more time building awesome machines that differentiate them from their competition," says Mark Duckwitz, Technical Communications Manager. "This online community is an interactive resource where OEMs can ask questions and quickly get answers,
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provide insights to other Kollmorgen customers, review sample projects, readily access the latest Kollmorgen firmware, software and technical documentation and suggest future product features. Customers who register can also create a personalized content area that will help save even more time and focus resources by bringing together the-
ir most frequently accessed content in a single area." KDN content focuses on AKD® servo drives series, AKD® BASIC drives, AKD® PDMM, Kollmorgen Automation Suite™ (KAS), and Kollmorgen servo motors. The site also provides information and support for Kollmorgen legacy products.
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New hazardous area flameproof enclosure with fully adjustable remote controlled electronic controller Quintex have developed and produced a new electronic thermostat contained in a flameproof Ex d type enclosure that can be fully controlled via an infra-red remote control without having to open or switchoff the unit. This gives the user full flexibility to operate and adjust process or maintenance temperatures when switched on or energised, exactly matching required site conditions and set parameters. A common problem for electronic type controllers located in hazardous area environments is adjusting and setting the temperature and alarm points. Adjustment normally requires the power supply to be switched-off before opening the flameproof enclosure housing, which then makes setting accurately on site a near impossible task. Having to remove the complete unit to a safe area location before making adjustments and the re-installing is not an acceptable approach. Quintex have now thoughtfully eliminated this problem by introducing their EXTC 100 electronic temperature controller in an Ex d housing to the market. This is controlled and adjusted by means of an in-
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neously. In addition either a high or low temperature alarm point can be pre-set for remote monitoring. Detection and sensing are carried out with 'Ex' type PT100 temperature sensors.
trinsically safe remote control infrared beam. All settings are securely kept and stored, only being accessible via a 4-digit password. All settings are fully legible through a large inspection window with the operating and actual temperature set points being displayed simulta-
Electric Trace Heating circuits can be directly connected and operated via the 16A switching capacity of the SPST contacts. Not only is this hazardous area thermostat used for electric trace heating circuits, it is also ideally suited for other process, thermostatic and heating control applications requiring quick and easy site adjustments and operation. Our first home public release of this new controller will be at ACHEMA, Frankfurt, from 15th to 19th June 2015, where we can demonstrate to you many operational functions. We challenge you to come up with new applications and ideas by visiting us and discussing your future requirements for this new product. If you require free entry tickets to this exhibition these can be requested directly from us via our contact page/website.
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New mounting system boosts Seco’s Square T4-08 Helical cutter strength, stability Seco recently expanded its Square T4-08 Helical milling cutter line to include a new innovative insert mounting system for specially designed inserts with four cutting edge capabilities. The product line also now includes a new MS2050 insert grade. Ideal for 2D directional contour milling applications, the Square T408 Helical excels in machining challenging materials such as cast iron, steel and stainless steels. Its strong, reliable pocket seats combined with multi-edge inserts optimise cutting stability and allow for clean 90-degree walls. The inserts mount tangentially in the cutter so that the cutting forces impact the thickest parts of the inserts, allowing manufacturers to achieve the required levels of strength for increased depths of cut with small diameters. In addition to its high metal removal rates and cost effective operations, users will also benefit from the Square T4-08 Helical’s versatility. Variations include normal pitch for slotting and contouring operations and close pitch for contouring only. The Square T4-08 is available in M08 and MD08 insert geometries, and four grades including the new MS2050, which joins the MP3000, MK2050 and F40M options. Various mounting types include Seco-Capto™, Weldon, Arbor and Combimaster™ heads. The tool has cutting diameters that
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range from 25 mm (1.0") to 54 mm (2.0") and depths of cut between 22 mm (0.87") and 64 mm (2.52"). Corner radii ranges from 0.02" (0.4 mm) to 0.063" (1.6 mm). Furthermore, the entire Square T4-08 Helical range has integrated throughcoolant channels to provide extended tool life. For more information on the Square T4-08 Helical, please contact a local Seco representative or visitwww.secotools.com/squaret4/h elical. Headquartered in Fagersta, Swe-
den and present in more than 50 countries, Seco Tools is a leading global provider of metal cutting solutions for milling, turning, holemaking and toolholding. For more than 80 years, the company has provided the technologies, processes and support that manufacturers depend on for maximum productivity and profitability. For more information on how Seco’s innovative products and expert services bring success to manufacturers across all industry segments, please visit www.secotools.com.
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NICOLAS SMDEL 4-67 semi-trailer with single telescopic function facilitates transport of 73 m long rotor blade Although LM Wind Power had sent enquiries to a number of providers, Mammoet Wind Brande A/S was the only one which could carry out the assignment without requiring any costly moving procedure using two cranes, thanks to the company´s NICOLAS SMDEL 4-67 5-axle semi-trailer complete with its single telescopic function. The vehicle from the French special vehicle manufacturer NICOLAS Industries SAS part of the TII Group, the world´s leading manufacturer of heavyduty vehicles - offers high axle compensation, a large steering angle and a strongly pre-loaded centre beam which, in this case, was extended even further by means of two so-called spacers. As a result, it has a high ground clearance and can drive over obstacles such as roundabouts that other vehicles cannot negotiate. In addition, the blade can be positioned directly on the extra-low gooseneck in order to save space. With a total combination length of around 100 metres, "manoeuvrable" is hardly the best description and, without the availability of the SMDEL 4-67, the transport of the 73 m long blade would have been far more expensive and complicated. The route itself provided enough
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The NICOLAS SMDEL 4-67 in front of the Bellacenter in Copenhagen. Due to the lack of a suitable turning area, this meant that several kilometres had to be overcome in reverse gear before the return journey could begin. challenges along the way. Initially, the transport went via Lunderskov (Jutland) on the E45 in the direction of Germany in order to branch off after 40 kilometres towards Copenhagen. Unfortunately, the direct route was blocked by some unfavorably-positioned concrete pillars. In the meantime, Mammoet Wind Brande A/S operates NICOLAS vehicles with over 200 axle lines in total and will continue to add to this. "Since 1989, together we have been moving the wind industry - in the true sense of the word - and with our safe and efficient vehicles, Mammoet Wind Brande A/S will maintain its leading position in the
future", according to Lars Schoedt, Area Manager Sales at TII Sales, the joint sales and marketing arm of SCHEUERLE, NICOLAS and KAMAG. After the EWEA Offshore Wind trade show finished, where the rotor blade has been exhibited, the driver faced a nerve-racking ordeal: the lack of a suitable turning area meant that several kilometres had to be overcome in reverse gear before the return journey to Lunderskov could commence. Here, the NICOLAS SMDEL 4-67 scored thanks to the precise control and good directional stabilit
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PRECISION CONTROL MAKES EMERSON FIRST CHOICE AT ADVANCED FURNITURE TESTING A leading furniture testing specialist is now among the increasing number of industrial companies benefitting from variable speed drive solutions from Emerson. Advanced Furniture Testing of Holland, Michigan has established itself as a market-leading furniture testing specialist. It performs a full suite of rigorous tests, and builds automated furniture testing machines that can be installed directly in customer laboratories. While many of the tests prescribed by Business and Institutional Furniture Manufacturers Association (BIFMA) are straightforward, the ability to perform seating, casegoods and finish tests with a high level of accuracy and repeatability requires in-depth knowledge of the industry and the equipment being used. To meet these challenges, Advanced Furniture Testing developed specialised machines for tests that include chair back durability, drop impact and load ease, multi-task furniture, dual arm durability and universal cyclic testing. For a brand new multi-axis chair testing machine, the company is now using the Control Techniques Unidrive M range of drives. The drive’s precise control and accuracy was identified as critical for a brand
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new machine designed to test chair strength and rigidity. The machine is designed to complete multiple, repetitive cycles of pulling on the back of the item and pushing on its seat. The pull is completed using a motor that controls an electromechanical actuator, while the push on the seat again is completed using another electromechanical actuator that pushes a load on to the seat. Millions of cycles can be performed to replicate the sit, lean and recline process. Advanced Furniture Testing ensures each test is performed to the highest level of accuracy and repeatability. The company’s machines use load cells to ‘close the loop’ between the machine and the product under test. In practice, this means that Advanced Furniture Testing does not just trust a theoretical load applied with
a pneumatic cylinder to a pre-set air pressure, for example. Nor does it apply a cyclic dead weight load that may oscillate wildly and apply more loading cycles. Instead, electromechanical actuator/servo systems are deployed similar to
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we now plan to use M700 drives for all future machines, and will upgrade our own in-house test machine to feature this innovative technology.� About Emerson Industrial Automation
those used by industrial robots. This strategy helps to apply a load within two per cent accuracy, far exceeding BIFMA standards which require five per cent accuracy. The Unidrive M700 drives used on the new machine control the motors, which in turn control the electromechanical actuators. Unidrive M700 offers comprehensive position feedback and high performance control of dynamic permanent magnet servo motors, as well as onboard Ethernet, which gives Advanced Furniture Testing more flexibility, remote programming and data
logging. The drive is paired with a Control Techniques MCi210 machine control module, which adds a powerful, second on-board microprocessor for high performance IEC 61131-3 based machine control. Douglas Woodard, UL Furniture Division Leader at Advanced Furniture Testing, said: “M700 is just a beautiful machine that delivers everything we need. We selected the Unidrive M for its precise control and accuracy, on top of its reliability and simplicity. We haven’t been disappointed. Furthermore
Emerson Industrial Automation, a business of Emerson, is a global technology provider that enables productivity, efficiency and quality gains for customers across a spectrum of industries. Its products include alternators, electric motors and drives, electrical distribution devices and mechanical power transmission, fluid automation and ultrasonic joining solutions. Emerson brands include Appleton, ASCO, Branson Ultrasonics, Browning, Control Techniques, Kop-Flex, Leroy-Somer, McGill, Morse, Numatics, O-Z/Gedney, Rollway, SealMaster, and System Plast. For more information, visit www.EmersonIndustrial.com
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Modernisation project by Ruppel Hydraulik in a general foundry
Better braking – with modern hydraulics Author: Christoph von Haaren, Project Engineer, Gerhard W. Ruppel Hydraulik Modernisation of the hydraulic drives in the cooling station of a foundry means that the user can now handle the chill-moulds, weighing several tonnes, more accurately and more quickly. Ruppel Hydraulik was not only responsible for the full engineering of the new control blocks, but was also in charge of installation and commissioning, ensuring these were to deadline in a very short lead time. There are several reasons why hydraulic power is the preferred drive form in foundry engineering. The environmental conditions are harsh: all foundry plant components have to be able to work reliably in all conditions, including dirt, dust and high temperatures. In such cases, hydraulic drives perform better than their electro-mechanical counterparts. In addition, for many process sequences, drives with a high power density are needed. This is true for the actual founding process, as well as for other support and preparatory processes, such as conveying the chill moulds (foundry moulds), as well as the production and automatic insertion of the cores needed for forming the cavities and undercuts in cast parts. The task: new drive technology for the cooling station Because foundry technology ma-
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View of the cooling station in the foundry. Here the job of the hydraulics is to ensure the containers with their loads of cast parts or chill moulds are braked to a standstill at just the right time. The containers weigh up to five tonnes. on. This is the area where, after rekes the casting of highly complex ceiving the casting material, the shapes possible and the combinachill moulds are cooled until the tion of materials and processing cast parts can be removed from result in a high degree of ductility, the moulds. iron and aluminium alloy casting is the method of choice in the manuOriginal condition: long pipe runs facture of high-quality chassis and large cross-sections components for cars, trucks and Here the main consumers of mobile construction machinery, hydraulic energy are various cylinfor instance. ders of 100 mm piston diameter Safety components of this type and 1827 mm in length. It is their are part of the product range of a job to brake to a standstill the chill general foundry in the German femould conveyor trucks, which are deral state of North Rhine-Westppowered by electric wheel motors halia that has recently modernised and weigh up to five tonnes. They the hydraulics of its cooling statihave to do this at the right time and
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The control blocks are now arranged in distributed fashion near the cylinders. In addition, the diameter of the pipework has been reduced, with the result that the system is quicker to respond and easier to control. The upgrade was able to be completed on time – to a very tight schedule.
Given that the overall cooling station comprises up to 23 chill mould conveyor containers per individual line and there are six lines in total, the conveyor technology involved is complex. In view of the great weights of up to five tonnes per container, precise positioning of the units is of particular importance.
rapid feed function can be activated. This ensures more rapid deceleration, resulting in increased throughput on the conveyor section. This function is implemented using cartridge valves. Another additional function implemented has been to integrate actuation of the lifting tables in the control blocks. These tables manage the difference in height between the cooling station and the downstream conveyor section. It proved possible to retain the original hydraulic unit, which works with a mineral oil-based medium. Commissioned “just in time”
Engineering and pre-assembly of the control blocks in the Ruppel factory in Bad Münder was followed by installation on site. Here there was another challenge: the cooling Integration of additional station is a central station in the Work in progress on the user’s premises. The functions distributed layout of the control blocks also overall process chain of the foundry enhances the performance characteristics of To ensure seamless and for this reason could only be the hydraulics. out of action for a brief period. Alworkflows and improve ready from the outset the timetabpositioning accuracy, Ruprate, thereby positioning them at pel Hydraulik has implemented an le had been tight, but it got even the desired location. additional function in the control tighter for Ruppel’s fitters, as the The as-is analysis showed that thefirm responsible for prior installatiblocks – by connecting the oil flow re was indeed a need for optimisaon of the steelwork needed more on the piston side and ring side, a tion. The cylinders were connected time than had been schewith a central control block via piduled. Even so, the Ruppel pework of relatively large cross-secteam was able to meet this tion. The centralised layout resulstill tighter deadline. The ted in correspondingly long pipe plant system was compleruns and, although their large ted on time and commiscross-sections did mean low flow sioned jointly with the forates, this also resulted in inadeundry technical staff. It has quate oil replacement and a slugbeen running ever since to gish drive system. the full and complete saNew plant system with distributisfaction of the operator. The new hydraulics of the cooling station feated control blocks tures an uncluttered design and various addiThe engineers from Ruppel tional functions. The system allows dynamic Hydraulik first of all altered the baoperation of the brake cylinders as and when sic layout of the hydraulic system. needed.
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Signage for an efficient turnaround Field operators in the physical plant often face a labyrinth of pipes and instruments relying solely on past training and experience to know where they need to be. To easily navigate the ever evolving COG physical plant, Brady offers durable signage solutions for a more efficient turnaround. Durable Brady signage can be used in a number of ways to support field operators. Gauges and fluid containers can be marked to show allowable ranges or levels, lubrication points can be identified and equipment labelled with a barcode linking to maintenance history or supplier information to easily re-order parts. Checklists and procedures can be attached to the equipment itself to optimise compliance, and pipe contents, flow direction, source and destination information can be displayed where they are needed.
Printable Onsite Durable Brady signs can resist UV exposure, weathering, extreme temperatures and chemicals and can be printed on-site using a Brady printer and pre-defined templates. The BBP™85 Label Printer can print the largest signs on-site.The BBP33 Sign and Label Printer is especially useful for a multitude of smaller si-
ze COG identification applications. A Brady printer on-site eliminates the need to order new signage at the last minute and instead enables you to quickly print additional identification when needed. With great signage, plant operability, maintainability and reliability can be improved. Contact us at emea_request@bradycorp.com and read all about it in our white paper ‘Equipment visuals for process operations’.
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