Engineering Review - May 2016 by Divya Media Publications Pvt. Ltd.

CNC Servicing & Solutions (I) Pvt. Ltd. – A PHILLIPS CORP Group Company

Volume 16 No. 01 | May 2016 | ` 200 | www.engrreview.com RNI No. MAHENG/2004/15135

Industrial Matrix Drive U1000

Increase your green space with YASKAWA’s Industrial Matrix Drive (U1000), the product that that goes beyond conventional drives, providing outstanding harmonic performance and regeneration in a single stand-alone component. Enjoy extremely low harmonic distortion and regeneration in a space-saving design, completely without the need for additional components. Unlike conventional drives, YASKAWA’s matrix technology creates a variable output by switching directly from the input power (no DC bus). Additionally, the Matrix drive is a member of the YASKAWA industrial drive family, and provides the same user experience.

USING COMPLICATED SYSTEMS FOR LOW HARMONICS OR POWER REGENERATION?

TRY THE EFFICIENT WAY WITH THE U1000 INDUSTRIAL MATRIX DRIVE

12/18 PULSE SYSTEM 12/18 -Pulse Transformer

Input Fuses

Standard Drive U1000

ACTIVE COMPONENT SYSTEM Input Fuses

LC Filter

Active Rectifier

Standard Drive

PRIMARY FEATURES & BENEFITS • Full Regeneration • Low Input Distortion Across a Wide Load and Speed Range • IEEE-519 Compliant (<5% THD) • Eco-Mode to Achieve Near Across-the-Line THD • High Eﬃciency Design Provides Extra Energy Savings as Compared to Other Low Harmonic Solutions • Near Unity True Power Factor at Full Load • Integrated Input Fusing Provides 100kA SCCR • Compact Design • High Reliability with an MTBF of 28 Years

LESS SPACE, FASTER SETUP, HIGHER EFFICIENCY

• Embedded Modbus RTU Communications • Removable Terminal Block • Safe Torque Oﬀ rated for SIL CL3 and PLe • High Carrier Frequency (Low Motor Noise) Capability • 0-400 Hz Output Frequency • 120% Overload for 60 Seconds (ND) • 150% Overload for 60 Seconds (HD) • Multi-language LCD Display with Copy function • DriveWizard® Software • Start into Spinning Load (Speed Search) • Both Induction and Permanent Magnet Motor Control

415 V POWER RANGE • 2.2 – 220 kW (ND), 5 – 185 kW (HD) AMBIENT OPERATING TEMP • -10°C to 50°C (OPEN TYPE IP00) CERTIFICATION • UL, CSA, CE, RoHS STANDARD I/O • (8) Digital Inputs • (3) Analog Inputs • (1) Pulse Train Input • (2) Safe Torque Off Inputs • (4) Relay Outputs • Analog Outputs • (1) Pulse Train Output • (1) Safe Torque Off Output STANDARD COMMUNICATIONS • Modbus RTU CONTROL OPTIONS • Expandable I/O • EtherNet/IP • Modbus TCP/IP • Incremental Encoder • DeviceNet • Absolute Encoder • Resolver • Profibus DP • Profinet MECHANICAL OPTIONS • NEMA 1 Kit • External Heatsink

YASKAWA India Pvt. Ltd.

17/A, 2nd Main, Electronic city, Phase 1, Hosur Road, Bangalore 560 100 Tel: 080 4244 1900, Email: info@yaskawa.in / sales@yaskawa.in / service@yaskawa.in www.yaskawaindia.in

BUSINESS NEWS

» AUTOMATION

Beckhoff opens technology centre in “Silicon Valley” Beckhoff opened its new technology and visitor centre in Silicon Valley in San Jose in April 2016, located around 50 kilometres southeast of San Francisco. “This is precisely where technologies that shape all of our futures are conceived and developed. We want to contribute to this process through our automation technology,” explains Managing Director, Hans Beckhoff. “The ‘Valley’ is a hotbed for technology, with exciting customers and highly interesting business opportunities. Furthermore, the modern technology trends growing out of the Valley act as a driving force for automation in particular. We believe that we, together with our global

customers, can and must leverage these cutting-edge innovations. The convergence of technologies from the fields of automation, IT and Internet, a strategy consistently pursued by Beckhoff, will be especially visible in our San Jose branch.” As Aurelio Banda, President of Beckhoff North America, explained at the opening of the technology centre: “This is a major milestone for Beckhoff as a globally operating company, and naturally for Beckhoff USA as well, given that California represents one of the strongest economic regions in the US. Our goal is to establish even more extensive business relationships with the world’s largest technology companies. Growing our presence in Silicon Valley

Beckhoff opened a new Technical Center in Silicon Valley in April 2016 alongside high-profile research institutions and innovation drivers in the IT and high-tech industries. Thus, Beckhoff once again demonstrates the approach of leveraging the convergence of IT and automation technology for the benefit of industrial applications. – as a magnet for technology and our new office location – suits this strategy perfectly.” Strategically positioned for ease of access, the new technology centre features nearly 1,200 square metres of floor area and accommodates a showroom, sales offices, an engineering department and training facilities. In addition to the best-in-class technical

support Beckhoff will provide to the many customers based in this region, we also offer direct sales, technical services and customer training. With the opening of the Technical Center in Silicon Valley, Beckhoff now maintains seven regional sales and support offices in North America. For more information www.beckhoffautomation.com

Red Lion’s RAM 9000 Industrial Cellular RTUs Receive ATEX Zone 2, Category 3 Approval Red Lion Controls, the global experts in communication, monitoring and control for industrial automation and networking, announced its Sixnet® series RAM® 9000 industrial cellular RTUs have received ATEX zone 2, category 3 approval and are safe for use in potentially hazardous environments. This approval follows recent announcements that Red Lion’s rugged RAM industrial cellular RTUs support high-speed 4G LTE worldwide throughout the Americas, Europe and Asia Pacific. Ideal for deployment in industrial M2M networks such as oil and gas, water/wastewater,

ENGINEERING REVIEW

MAY 2016

utility and transportation applications, RAM 9000 cellular RTUs provide a seamless network extension to remote locations. With more I/O than many competitive offerings, the RAM 9000 serves as a robust control platform that enables customers to simplify remote site equipment by combining separate functions into one feature-packed cellular RTU. The secure all-in-one RAM 9000 platform combines built-in I/O, a powerful event engine and data logging capabilities to securely monitor and control remote devices via 4G LTE cellular communications.“Earning ATEX approval will allow the RAM

9000 to be deployed in even more hazardous and industrial environments,” said Denis Aull, vice president of products at Red Lion Controls. “As the Industrial Internet of Things continues to grow, approvals such as ATEX coupled with global 4G LTE communications will help connect critical data from rugged applications to next-generation IIoT platforms regardless of location.”

Features of the RAM 9000 include: • High-density on-board I/O: lowers total system cost with two digital inputs, two digital outputs, three analog inputs

and one relay output • Powerful built-in event engine: triggers actions based on real-time operational data • Detailed data logging capabilities: record I/O registers on SD Card or internal memory • Remote connectivity: securely monitors serial devices via separate RS-232 and RS-485 ports • Secure routing: enables reliable data exchange over 4G LTE cellular communication

For more information, Web: www.redlion.net

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BUSINESS NEWS

» AUTOMATION

Elmo Offers Gold Lion Motion Controllers for Harsh Environments Elmo’s Gold LION family consists of advanced network based, multi-axis machine motion controllers designed to withstand harsh environmental conditions Gold LION controllers can command over any multi axis scenario. From simple Point-To-Point, to complete multi-axis coordinated / synchronized motion. The GOLD LION series comes in two forms: -Rugged, Stand Alone, Ready To Use metal package -“Ready-ToUse” module that allows for a high-level of customization by embedding the unit on a PCB. This highly advanced motion control solution, with tremendous design flexibility and functionality allows significant space savings. Elmo’s GOLD LION multi axis controller is perfect for ruggedized applications operating in extreme and harsh environments requiring maximum performance. Suitable for applications such as unmanned robots, azimuthelevation systems, inertial stabilization systems, gun fire/ radars turret stabilizations, gimbals, radar tracking systems, ground based vehicle leveling, etc. Complete integration of the Gold Lion with Elmo’s advanced servo drives is extremely fast and simple, making it one of the best performing, highest reliability multi axis systems in the market. The GOLD LION high speed Compliant EtherCAT network is fast, deterministic with high communication reliability, and superior telemetry capabilities that are essential in Military solutions. The fast-real time deterministic operation of the GOLD LION over the EtherCAT network perfectly harmonizes with Elmo’s ExtrIQ servo drives

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Missiles launcher controlled by G-LION and 5X G-EAGLE 100A/ 800V servo drives application rapidly. within the system. Multi axis coordinated motion and system telemetry, on top of the highest servo control for fast and precise operation, all result in system performance levels never seen before. The wide variety of standardized and proprietary communication protocols between the GOLD LION Motion Controller and Host computer, PLC, or HMI enables fast and simple communications with 3rd party elements such as touch panels, teach pendant, PLCs, Computers etc., using standard “by the book” industry protocols. Host communication capabilities such as Ethernet, TCP/IP, and UDP Fast Binary Protocols Modbus and Ethernet/IP, allow simple and fast communication with almost any high level Host in the system. The GOLD LION enables rich, high-level, multi-axis programming in environments such as Microsoft . NET, IEC 61131-3 PLCopen, Native C/C++ programming using the PLCopen for Motion and Win32 C/C++. Elmo

supplies an enhanced Use of intelligent, simple to use Elmo Motion Block Libraries (EMBLs), machine templates, function, capabilities and libraries to operate under those environments. The EMBLs are complementary to the EASII (Elmo application Studio), a single tool that does it all - Configuration, Set-Up, Networking, Programming, Tuning, Load Identification, Multi-dimensional Control Optimization, Synchronization, Motion Blending and Transitions, Error mapping, ECAM, Gain Scheduling, Templates, Libraries, Scripts, Functions, Testing, Monitoring, Recording. Elmo developed numerous EMBLs to simplify machine development process. For example, Homing (all DS-402 methods and more), Output Compare (PEGS), Emulation, ECAM, PVT, Splines, Joystick etc. Elmo’s Philosophy is “Intelligence By Simplicity”, by applying ready to use motion function blocks and advanced tools to significantly simplify the development process of the

The Ultimate Network Motion Controller: • System Kinematics Support • Motion blending and superimposed motion • Coordinated group motion, blending and transitions • Polynomial motion segments, PVT and Spline support • EtherCAT master for distributed networking, with distributed clock management

Host communications and protocols: • Ethernet, TCP/IP, UDP (Fast Binary Protocols, Modbus, Ethernet/ IP) • USB 2.0 • Rich, high-level, multi-axis programming environment: • Microsoft .NET • IEC 61131-3, PLCopen • Native C/C++ programming using the PLCopen for Motion • Win32 C/C++ • Network statistics for diagnostics For more information Web: www.elmomc.com

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Contents MANAGEMENT

39 Customer delight : Moving to the right Rashmi Ranjan Mohapatra, Managing Director, Kemppi India

TECH UPDATE

152

Vol 16 Issue 01 | MAY 2016

COVER STORY

Legris India : Global Leadership in motion & control technology Mr. Balraj Raju, Regional Manager (WEST India) Legris India

The real game changer MACHINE TOOLS

BUSINESS NEWS INDUSTRY SPEAK

Tucson electric power seeks to elevate engineering efficiency by augmenting enterprise GIS systems

Farrokh Bhathena to spearhead Sales & Marketing at KSB Pumps Limited, India

50 Integration between CAD/ CAM & highly reliable design/ model for manufacture methodology will drive the industry in the future

TECH TREND

PRODUCTS

La Joliverie Haas Technical Education Centre : The realtime experience

253

PROJECTS 12

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MAY 2016

44 Mastercam : Technology leadership of CAM excellence Meghan Summers West, Chief Operating Officer, Mastercam

Pramet launched new chip breaker & wiper inserts

Haas launches new look International Website: HaasCNC.com

Vineet Seth, Managing Director – South Asia & Middle East, Delcam Ltd., UK

Hanna Instruments, Inc. IntroNew Milestones in duces new innovative HI9819 Microfinishing - Precision 4 Multiparameter, Waterproof engineered finish for & carriageable Meter automotive powertrain parts

245

BUSINESS NEWS

Maini Materials Movement (A Maini Group Company) launches 25-Ton Electric Tow TUG

FACE TO FACE

79 SBS Precision : The dynamic balancing & process control expert Mr. Rajesh Parsramka, Director, SBS Precision Systems (India) Pvt Ltd

PROFILE

Mastercam Programs 5 Machines at Sandvik Coromant Tech Days Event

Kennametal’s Cheryl Bush receives Women in Manufacturing STEP Award

SUCCESS STORY

60 Bright Roller Burnishing Tools for complete burnishing solutions

58 Garage to the Globe – The Saga of Grind Master www.engrreview.com

Contents

Vol 16 Issue 01 | MAY 2016

POWER

INDUSTRY SPEAK

PROFILE

BUSINESS NEWS

22 84 We need to revamp our transmission & distribution systems for improving efficiency & strengthening the grid Sameer Gupta, Chairman & MD, The Jakson Group.

TECH TREND

Geissel India – German excellence at home TEST & MEASUREMENT

Nucleus Marketing : Success through Innovation

Braco Electricals: Secure Connections

Mr. A N Arun, Founding Partner & Manager, Nucleus Marketing

Mr. Ramesh Sobhani, Technical Director (L) & Mr. Sunil Giasotta, CEO (R) Braco Electricals (India) Pvt. Ltd.

Committed towards a better tomorrow (L-to-R) Mr. Gautam Seth, JMD Mr. Lalit Seth, CMD, & Mr. Rishi Seth, JMD, HPL Electric & Power Ltd.

118

STEEL MART : The expertise with technology excellence

FACE TO FACE

INDUSTRY SPEAK

102 Power Industry demands efficiency & accuracy Mr. T.P. Singh, Country Manager, India-Instruments, FLIR Systems India Pvt. Ltd.

TECH TREND

104

“The infrared resolution is simply tremendous.”

110

Let’s breathe better……

118

Raytek, Ircon, and Datapaq join forces to create Fluke Process Instruments www.engrreview.com

174 In the days to come, all our compressors can also be controlled through a smart phone app making it easy to the operator as well as owners

170 GEM glistens in process cooling & drying Mr. K.P. Manoharan, Managing Director, Gem Equipments Pvt. Ltd.

PROFILE

Mahesh Nandurkar, Vice President & SBU Head-ACD, Kirloskar Pneumatic Co. Ltd.

176

Getzner displayed innovative anti-vibration solutions in POWER-GEN 2016

Henkel India embarks on a rural solar power CSR initiative

Mr. Juzer Faizy - Director, STEEL MART

AIR COMPRESSOR

INDUSTRY SPEAK

Vasudha Gel Earthing recieved National Award for innovation in Elecrama 2016

INDUSTRY SPEAK

188 Import substitution of gears & gearboxes to cater to niche markets is our prime focus today Debashis Chattopadhyay, Head-Sales & Marketing, Shanthi Gears Ltd.

177

Shavo Technologies offers high-tech tailor- made solutions

The budget has also given a huge boost to the Make in India program by correcting the inverted duty structure in 22 thrust sectors

Mr. Rushil Shah, Managing Director, Shavo Technologies Pvt. Ltd.

Santosh Kumar, Managing Director Instamod Airpipe Pvt. Ltd.

Airpipe: Zest for Innovation & Excellence

TECH TREND

180

POWER TRANSMISSION

FACE TO FACE

190

Sumitomo Drive : The legacy of technology perfection Mr. Chandrashekhar Paradkar, Country Manager, Sumitomo Drive Technologies, Pune, India MAY 2016 ENGINEERING REVIEW

Contents AUTOMATION

INDUSTRY SPEAK

FACE TO FACE

128

130 “We expect users in Indian market to shift towards premium mindset” Mr. Sridhar Nalluri, General Manager, InnoVista Sensors

Vol 16 Issue 01 | MAY 2016

WELDING

PUMPS & VALVES

INNOVATOR

INDUSTRY SPEAK

198

Testo : Trendsetter of smart & user-friendly technology

MEPL - The Leader in Resistance Welding

Mr. Kalidas Bhangare, Managing Director, Testo India Pvt Ltd

Gabin Kattukaran, Director, Mechelonic Engineers Pvt. Ltd.

INDUSTRY SPEAK

132 The field of robotics is in a massive growth phase similar to what IT was in late 90’s Arjun Prakash, Director, Effica Automation Ltd.

138

ROSS Controls: The Pneumatic Safety Expert Mr. Jay Dalal, Managing Director Ross Controls India Vice President Global Engineering, ROSS Controls

PROFILE

200 Innovation is a part of our culture Mr. Satish Bhat, Managing Director, Ador Welding Ltd.

Automation is the future of India P.L. Muthusekkar, Managing Director, Nord Drivesystems Pvt. Ltd.

TECH PROFILE

Mr. Prakash Patel, Founder & Director

TECH TREND

142 140 SICK continues to grow Markus Vatter, CFO

BUSINESS NEWS

Beckhoff opens technology centre in “Silicon Valley”

Elmo Offers Gold Lion Motion Controllers for Harsh Environments 14

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MAY 2016

Smart Factory - Industry 4.0 concept

144

Detectable plastics from igus for maximum safety in foods

146

Anticorrosive coatings protect train components

154

Why you should use Aditron Systems?

TECH TREND

217

FCRI’s large water flow lab – The largest in the world

222

136 Indus: Committing the green revolution

Yagnesh Buch, Dy. General Manager, KSB Pumps Ltd.

INDUSTRY SEPAK

INTERFACE

134

214 “Indian made Pumps and Solutions are steadily getting more and more acceptance and are becoming customers’ preference the world over”

202 “We need to churn out thousands of welding professionals to meet the growing demands of a burgeoning economy,” says R. Srinivasan, President, IIW Mr. R. Srinivasan, President, The Indian Institute of Welding

KEPL shipped API BB4 pumps to Mirfa International Power & Water Company

224

ValvTechnologies, Inc. Enhances ValvXpress® program to include three different options & meet customer demand

MATERIAL HANDLING

INDUSTRY SPEAK

226 “There is a growing appetite for automation in warehouse operations”

PROFILE

228 Materials handling equipment from Mahindra Stiller

S. Mohan, CEO, Materials Movement Pvt. Ltd. www.engrreview.com

BUSINESS NEWS

» AUTOMATION

RHEINTACHO’s new website with high-performance sensors & stroboscope product selectors RHEINTACHO offers a wide variety of different products in the speed sensor and stroboscope product selectors. This diverse range offers users the perfect product for almost any application. The important thing, though, is to find it quickly and reliably. So, in drawing up the initial designs for the new website, the integration of a product selector was already an important priority. Exactly what should such a selector be able to do? What questions does a potential customer ask when selecting a product? Which specifications are selection-relevant” and need clarifying in order to present the user with a really useful choice? Under the management of Isabelle Thumm, the RHEINTACHO project team closely examined, discussed and

drafted detailed concepts for these questions, until a good, workable solution had been found. The results can be seen at www.rheintacho.com. Two product-specific selectors with the same functional spectrum are currently integrated in the webpage. In the product selector for the speed sensors, users can find a sensor that perfectly suits their needs by using 14 search criteria to select from a current range of 111 sensors. The search criteria include: output signal, geometry, measurement principle, frequency etc. In the case of the stroboscopes, 23 models are offered in the selector, and the selection process can be effectively narrowed down according to 11 characteristics (for example: light source, brightness, illumination area

etc.). After having made the selection, the suitable products are shown in a list of results. Users can then compare up to 4 products from the list with one another and access the relevant data sheet online. There has been an extremely positive response from users. Meanwhile, the RHEINTACHO staff are making intensive use of this online application too. The selectors have already proven

their worth above all with regard to telephone enquiries: an interested customer can be directly talked through the different criteria, so that a product that is 100% suitable for the caller can already be identified on the phone. The investment in these functions has absolutely paid off from a business management viewpoint too. Thanks to the selector, RHEINTACHO is receiving markedly more knowledgeable and specific enquiries than before, as users now have a real chance of conveniently finding that famous needle amid a richly varied range of products.

For more information Web: www.rheintacho.com

Kontron announces new mITX-BW motherboard Kontron, a leading provider of Embedded Computing Technology (ECT), announces the immediate availability of a new mITX motherboard with Intel® Atom™ N3xxx System on Chip (SOC). With up to seven years long-term availability, the new Mini-ITX embedded motherboard with Intel® Celeron™ processor N3xxx SoC series is immediately deployable. Equipped with an ATX-compatible design, a large number of system components are already available, which reduces individual development effort to a minimum. The

ENGINEERING REVIEW

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embedded industry design differentiates the board significantly from commercial Mini-ITX offerings which are less robust and only available in identical configuration for short periods. This also has an influence on the interfaces. The board supports not only 2x Display Ports but also 24bit LVDS on the most performance Industrial Automation version.

And, besides the innovative IoT connection via 3G/4G SIM card-slot, serial interfaces are also available. The mPCIe slot supports mSATA or mPCIe extensions. The operating system and application code can be stored on the mITX-N3xxx on the optional on-board 16 GB-sized bootable NAND Flash memory (eMMC). Numerous standard interfaces, amongst others GbE, SATA, CAN, RS485 and USB, are also integrated on this new Mini-ITX motherboard. Reiner Grübmeyer, VP Product Management R&D explains, “Our customers are excited

about the release of a new paper thin motherboard. It allows for different types of development such as ultra-thin industrial Box PCs that are not as easily accomplished on a regular sized motherboard. The combination of this Kontron built form factor and Intel SOC, has long been awaited.” The mITX-BW is available immediately and can be ordered now.

For more information, Web: www.kontron.com

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High Definition Lenses for Machine Vision Applications

4.0µm

www.tamron.eu

Speciﬁcations

M118FM06

M118FM08

M118FM12

M118FM16

M118FM25

M118FM50

Imager Size

1/1.8"

Focal Length

6 mm

8 mm

12 mm

16 mm

25 mm

50 mm

Aperture Range

1.4 - 16

1.6 - 16

2.8 - 22

TV Distortion

< -3.0 %

< -2.0 %

< -1.2 %

< -0.7 %

< -0.2 %

<-0.1%

M.O.D

0.1 -

Weight

86 g

44 g

57 g

39 g

52 g

Tamron India Private Limited #801, 8th Floor, Time Tower, M.G. Road, Gurgaon-122002, Haryana, India. Ph.: +91-124-4116812 Email: cctv@tamron.in ENGINEERING REVIEW |

17 | May 2016

www.tamron.in

BUSINESS NEWS

» AUTOMATION

US President Obama & Chancellor Merkel visits HARTING stand Hannover Messe Strong interest in Industry 4.0 solutions in the United States Great joy at the HARTING Technology Group: The opening of the world’s largest industrial trade show saw US President Barack Obama visit the company’s stand together with German Chancellor Angela Merkel, with the Harting family greeting the two heads of state. The United States is this year’s partner country of the Hannover Messe. President Obama was accompanied by a large delegation. Together with Chancellor Merkel, the 44th US president learned about HARTING products and solutions, which are accompanying companies around the globe into Industrie 4.0. The HARTING MICA (Modular Industry Computing Architecture) has been developed for this digital transformation. The MICA is a mini industrial computer that is positioned as a neural interface between machine and Cloud, and enables systems and machines to function as part of the Internet of Things (IoT). President Obama

ENGINEERING REVIEW

MAY 2016

The Harting family greeting the two heads of state: Margrit Harting, Maresa Harting-Hertz, Dietmar Harting, Angela Merkel, Barack Obama, Philip Harting (from left to right). and Chancellor Merkel showed great interest in the presentation of the Rinspeed “Etos” car, in which the MICA captures drive and emissions data and transmits it to testing institutes for independent monitoring. The HARTING Technology Group is a leading driver and partner on the way to Integrated Industry, and its Industrie 4.0 solutions have been met with great

interest in the United States. The re-industrialisation of the nation is acting as a growth engine. This development has also benefited HARTING, which has operated its own production plant in Elgin (Illinois) for a number of years. Sales in the Americas have seen growth of a strong one-third over recent years. The 2014/2015 financial year alone witnessed an increase of more than 17 percent, to 61 million euros. The visit of Barack Obama is a notable highlight in the history of the HARTING Technology Group. The company is always represented with one of the most attractive stands at the Hannover Messe and ranks among the top 5 largest exhibitors. In addition, HARTING is one of the few companies which have been present every year since the trade show began

in 1947.

About HARTING: HARTING Technology Group is one of the world’s leading providers of industrial connection technology for the three lifelines of “Power”, “Signals” and “Data” and has 13 production plants and branches in 43 countries. In addition, the company also produces retail checkout systems, electromagnetic actuators for automotive and industrial series use, as well as hardware and software for customers and applications in automation technology, robotics and transportation engineering. In the 2014/15 business year, some 4,200 employees generated sales of EUR 567 million. For more information Web: www.HARTING.com

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BUSINESS NEWS

» POWER

Vasudha Gel Earthing recieved National Award for innovation in Elecrama 2016

When Benjamin Franklin first gave the concept of electricity, little did he know that it would become one of the basic needs of the 21st century? With electricity integrating itself in each and every aspect of our life, it has also carved a path for the introduction of modernization via electrical automation in households. However, the downside of electric automation includes electrical damages and risks in safety. A solution to this problem is EARTHING. Earthing has been used in electrical appliances since ancient times as a safety measure against the downsides of using electricity. However, the conventional earthing systems has many limitations to cater to the needs of the 21st century. We at Shree Vasudha Group strongly believe that Innovation is described as a novel service that creates value for the customers.

ENGINEERING REVIEW

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Keeping this in mind, we have developed a unique product – ShockPro, which is the only ready to install earthing kit in India. ShockPro has been devised in a way that can accommodate the needs of each and every customer. It has efficiently resolved the cons of the conventional earthing system, thus providing more consistency, less maintenance and more longevity. ShockPro could prove to be a breakthrough in earthing field. The product has a potential to rise above its contemporaries due to the novel concept of GEL EARTHING used in its making. The use of metal alloys and natural chemical compositions has given the Gel earthing electrode an ability to provide a multifaceted proactive earthing protection. ShockPro—an eco-friendly earthing solution kit comes equipped with a Rod-in-Pipe technology, along with clamps,

lugs and couplers. Economical yet efficient, this futuristic technology is best suited for SOHO segment. Overcoming the limitations of the prevailing ordinary technologies, our product has proven to be a quanta in the earthing field due to its novel properties like corrosion resistance and ease of installation. A bio-degradable tube surrounding rode and pipe filled with hygroscopic material contains graphite and other minerals which enhance soil condition, lowers the ground resistivity. Recently, ShockPro made its first appearance at ELECRAMA 2016, the most colossal showcase in the world of electrical and power sector. The product garnered unprecedented level of interest by both, Indian as well as global industrial leaders. However, the highlight of the success was the number of orders received by the company for the product. A marvellous addition to

our recent achievements is the prestigious national award for Innovation from Productivity Council of India rewarded by honourable Mr Kalraj Mishra, Minister for MSME, Government of India. The award has come as a recognition for our efforts and as a source of encouragement to move further towards our goal. The company has doubled its efforts to make ShockPro a country wide phenomenon by making it available in maximum areas of the country. We hope that this becomes a stepping stone to establish a strong dealer and distribution channel network at national level. The bookings for first 500 units of ShockPro will be opened from 4th April 2016 and the bookings will be opened for Indian market only.

For more information www.vashudhaearthing.com

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BUSINESS NEWS

» POWER

Getzner displayed innovative anti-vibration solutions in POWER-GEN 2016 The Austrian vibration isolation specialist Getzner displayed its innovative products at the POWER-GEN trade show in New Delhi held from 18-20 May 2016 (booth 1120+1120A, hall 11). “We had a focus on the so called table foundations, a solution for the low-cost and effective mounting of foundations on point bearings”, explains Sanjay Risbood, CEO of Getzner India Pvt. Ltd. “Typical applications for this solution are gas and steam turbines, generators, pumps, compressors, fans or blowers.” The table foundation bearings are based on Sylomer® and Sylodyn®, the in-house developed, proven polyurethane (PU) materials from Getzner. Getzner has developed a special steel-PU product for the elastic bearing of table foundations (TFB), allowing optimal vibration isolation as well as transmission of high horizontal loads. “In addition to this innovative steel-PU product, the total package includes the calculation and material selection, the installation supervision and the associated quality control measures”, states Mr. Risbood. In the R&D process,

A clever solution for the mounting of foundations on point bearings: The Getzner table foundation bearings (TFB).

Image source: Getzner Werkstoffe, may be used free of charge

Getzner was able to rely on its expertise as a manufacturer of a comprehensive range of PU materials and its know-how in the field of building design and construction. Long-standing partnerships with specialized engineering consultants complete the Getzner package.

Low maintenance, long service life The Getzner TFB products convince with a long service life, low investment costs and damping elements that need very limited maintenance. They are easy to install and can be used for various types of foundations and load ranges. Mr. Risbood: “We have combined our many years of experience in point bearings with proven systems developed in the field of structural steel engineering to create a unique and innovative solution.”

In the GMR Group power plant in Raipur, Getzner isolated 14 machine foundations to restrict the flow of vibrations to other structures. Image source: Getzner Werkstoffe, may be used free of charge

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Getzner experts installing the innovative table foundation bearings at the Interlaken Heliport in Switzerland. Image source: Getzner Werkstoffe, may be used free of charge

Big demand for vibration isolation In general, vibration isolation solutions get more and more important in the Indian power generation sector. “The Indian power sector booms, as new power plants are being built throughout the country. At the same time, the awareness for the importance of vibration isolation is growing rapidly”, says Mr. Risbood. Vibration transfer of machines, pumps, turbines and generators cause noise and damage. This is not only harmful to the immediate surrounding area, but also negatively affects manufacturing and quality processes in the vicinity and disrupts the neighborhood and environment. The hightech materials Sylomer® and Sylodyn® are ideal to reduce such vibrations. The benefits are manifold: Elastically mounted devices are more cost-effective and efficient in the long term. Vibration protection increases the value of office space, production processes and adjoining residential buildings. “Last but not least,

optimum vibration solutions usually account for less than 1% of the initial cost, whereas solutions that are added later are expensive and less effective”, explains Mr. Risbood.

Successfully installed all over India Three years ago, Getzner started its work for a thermal power plant with the capacity of 2x685MW, built by India’s GMR Group. In the facility in Raipur, Getzner isolated 14 machine foundations having machines like pumps (Motor Driven Boiler Feed Pumps) and fans (Forced Draft fan, Primary Air fan etc.). Sanjay Risbood: “The basic need for our vibration isolation systems was to restrict the flow of vibrations to nearby structures and to bring down the size of the foundation as the subsoil shear modulus was very high.” Getzner solutions have proven themselves in power plant projects all over India – from Bihar and Rajasthan to Gujarat, Tamil Nadu, Karnataka and Madhya Pradesh. For more information Web: www.getzner.com

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BUSINESS NEWS

» POWER

Henkel India embarks on a rural solar power CSR initiative

Henkel Adhesive Technologies India Private Limited (Henkel India), a fully owned subsidiary of Henkel AG & Co. KGaA, the leading solution provider for adhesives, sealants and functional coatings, has taken a big step towards sustainability with its CSR project, ‘Lighting Lives’. This project, which is in line with the global Sustainability Strategy for 2030, aims to provide electricity to villages in Maharashtra by installing solar panels. The company also reached the interim targets of its Sustainability strategy, setting new milestones for 2020 and published its 25th Sustainability Report.

‘Lighting Lives’ Project in India As part of 2015-16 budget speech, Finance Minister Arun Jaitley has set a deadline of May 1, 2018 for “100 per cent village electrification”. Under the ‘Deen Dayal Upadhyaya Gram Jyoti Yojana’, the ministry has allocated a fund of Rs 8,500 crores to achieve this key target of rural electrification. As a sustainability leader, Henkel through ‘Lighting Lives’,

ENGINEERING REVIEW

MAY 2016

intends to contribute to this development story of India while continuing to shape the business responsibly and increase economic success. This noble initiative, currently in the pilot phase, has seen installation of solar cells in three villages situated in the Palghar district of Maharashtra. The solar power generated has successfully supplied electricity to the homes of 150 people and to the schools attended by about 1,600 children. The project will be expanded to include other villages and public facilities.

Interim targets achieved – new ambitions for 2020 Achieving more while using less resources and tripling the efficiency by 2030 – that is the goal of Henkel’s Sustainability Strategy.

The company has made great progress and has surpassed its interim targets for 2011 to 2015: • Energy efficiency improved by 18 percent • Water use by 23 percent • Waste volume by 17 percent • Occupational safety by 33

percent and • Sales by 11 percent Overall, Henkel has improved the relationship between the created value and the environmental footprint by 38 percent.

The new targets By 2020, the company intends to reduce Carbon Dioxide emissions, water use and waste volume at production sites by 30 percent per ton of product compared to 2010. Occupational safety is to be improved by 40 percent and sales by 22 percent per ton of product. The achievement of these targets would result in an overall efficiency improvement of 75 percent by 2020 compared to 2010.

School project reaches around 63,000 children As a company, Henkel aims to create more value with a reduced environmental footprint. It also encourages others to offer contributions for more sustainability; this goes beyond dialog with suppliers, customers and consumers. Henkel’s employees are at the

centre of the Sustainability Ambassador program. As a part of the program, the company’s school project initiative continued to grow in 2015: Henkel’s employees receive training so that they are able to explain the importance of sustainable behaviour to others, including schoolchildren. Since 2012, around 6,200 Henkel employees have become Sustainability Ambassadors, and the program has reached around 63,000 schoolchildren in 43 countries. Besides this, Henkel in India has an “Edu-care” project, which focuses on providing infrastructure support to needy government/ municipal schools located close to our plants/ offices. Henkel’s achievements in sustainability were once again honored in 2015 by various sustainability ratings and rankings. Henkel was included once again in the “Global 100 Most Sustainable Corporations in the World” Index and was rated “Gold” by EcoVadis. The company also received RobecoSAM’s Silver Class award. For more information Web: www.henkel.com

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BUSINESS NEWS

» MACHINE TOOLS

Pramet launched new chip breaker & wiper inserts Pramet’s range of turning tools for stainless steel has been further extended with the launch of a new chip breaker and wiper inserts. The NMR chip breaker provides a reliable option for longitudinal and face turning with high stock removal in medium and roughing operations. This new geometry further enhances Pramet’s range of double-sided chip breakers for all turning stainless steel applications, which already includes NM for medium turning and NF for finishing to medium turning. NMR’s positive geometry offers increased reliability through its strong cutting edge, which features a protective peripheral land. It is ideal for heavy machining and less stable conditions, with higher metal removal rates and predictable insert behavior providing increased tool life and productivity. The NMR chip breaker is available for many types of Pramet inserts, including

CNMG, DNMG, SNMG and TNMG. Meanwhile, Pramet has also launched a new range of wiper inserts for turning. Compared with standard inserts, the W-FM and W-NM wipers promote increased productivity by supporting higher feeds, as well as high quality machined surface, due to its new wiper edge. In straight turning and facing operations, the smoothing effect of the wiper results in improved quality of surface roughness. If used properly, it can prevent the need for additional grinding operations, saving further costs. Single-sided positive inserts with the W-FM positive geometry are suited to machining stainless steel and steels. The double-sided negative inserts with the W-NM highly positive geometry are ideal for machining stainless steel and low carbon steels. Both feature a positive front land which further promotes smooth machining. An overview of all new products launched

by Dormer Pramet in April is available in its latest 2016.1 brochure. To order a printed copy or for more information contact your local Dormer Pramet sales office. Watch the new range in action on our YouTube

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MAY 2016

channel (www.youtube.com/ dormerpramet). Pramet is a product brand of Dormer Pramet.

For more information Web: www.dormerpramet.com

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BUSINESS NEWS

» MACHINE TOOLS

Haas launches new look International Website: HaasCNC.com

The international website of Haas Automation, Inc., has been re-designed and re-launched, in line with the company’s U.S. website, which itself was re-launched at the end of 2015. The all-new international site, available in 11 languages, is simplified and easier to navigate than the site it replaces, allowing visitors to more quickly learn about new Haas products and technical innovations. The home page has just four headings – CNC Machines, Customer Services, What’s New, and Contact Haas –each with a drop-down menu. Perhaps the biggest and most notable change to the new site, however, is the inclusion of video tutorials and product videos, some which the company produces

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MAY 2016

and publishes daily, on social media platforms. “Videos are an increasingly important part of the way we communicate with our customers,” says Haas General Manager Bob Murray. “They’re a quick, easy, and clear way for us to show customers how to get the best from their machines and options. They’re also a great way to demonstrate new products, and show how customers around the world are already using their Haas machines.” Haas Automation is well known for it’s full line of CNC products; the company produces many of its machine models in multiple sizes and specifications. According to Mr. Murray, one of the primary goals with the new website was to present the company’s

expansive product line in an easy-to-navigate format, where visitors to the site can find a product with as few clicks as possible. “Our product line has expanded a great deal over the past few years,” he says, “as we’ve launched new products and extended the lines of our core machines, including, for example, our CNC vertical machining centres. We think we’ve managed to design a site that is uncluttered, informative, and easy to navigate.” Also accessible through the main website is diy.haascnc. com, where customers can access an enormous amount of pertinent information about their Haas CNC machine tools – everything from Routine Maintenance to FAQ and Video Tips of

the Day! There’s also an introduction to the next generation Haas control. “We’re always aiming to make communications with our customers smoother and more time-effective,” Mr. Murray concluded. “They want to be kept in touch via their handheld devices and smart phones, as well the usual channels. Our general marketing and the new international website are designed for the digital age, where facts, figures, and information change continuously, and customers want to be kept informed.”

For more information Web: www.HaasCNC.com

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BUSINESS NEWS

» MACHINE TOOLS

Mastercam Programs 5 Machines at Sandvik Coromant Tech Days Event

Kennametal’s Cheryl Bush receives Women in Manufacturing STEP Award

CNC Software, Inc., producers of Mastercam CAD/CAM software, participated in a 3-day Sandvik Coromant Tech Days event held in Sandviken, Sweden where over 350 attendees from area manufacturing companies participated. The three day event featured industry and technical presentations, and live machining demonstrations where Mastercam was used to program five of the six DMG Mori machines highlighted at the event. Mastercam’s industry-leading Dynamic Motion technology was chosen for both milling and turning demonstrations in various materials ranging from Sandvik Sanmac 316L, Ovako IQ Steel 159 and M-Steel MW, and aluminum En6082. CNC Software’s co-participation in the event reflects the technical partnership and cooperation between the two companies. The event drew attendees from across Sweden and other Scandinavian countries, and was held in cooperation with DMG Mori, Ovako, Sandvik Material Technology division, and AME,

The STEP Awards recognize women at all levels, from the factory floor to the C-suite, who have demonstrated leadership excellence in modern manufacturing. The awards are part of the larger STEP Ahead Initiative, launched to examine and promote the role of women in the manufacturing industry through recognition, research and leadership for attracting, advancing and retaining strong female talent. “My career in manufacturing has linked my enthusiasm for science and math to creating tangible products and services that make a difference in people’s lives,” said Ms. Bush. “Manufacturing offers vast opportunities for innovation and value creation in allaspects of product development through delivery. Having a career in manufacturing has been quite exciting and rewarding for me.” Ms. Bush joins three other women from Kennametal, Helen Patricia, Colleen Cordova and Martina Igel, who received the honor in 2013 and 2014. “We are thrilled to have Cheryl represent Kennametal at this year’s STEP Awards,” said Colleen Cordova, Kennametal Vice President, Industrial North America and former STEP Award recipient. “Through her leadership and invaluable contributions to the company, particularly in process management, Cheryl serves as an inspiration to the nextgeneration of women in the industry and demonstrates the

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MAY 2016

the distributor of Mastercam in Sweden and Norway.

About Mastercam Developed by CNC Software, Inc., Mastercam is Windows®based CAD/CAM software for 2through 5-axis routing, milling and turning, 2- and 4-axis wire EDM, 2D and 3D design, surface and solid modeling, and Swiss machining. Privately owned and founded in 1983, CNC Software provides CAD/CAM solutions to more than 211,000 installations in 75 countries in industries including moldmaking, prototyping, automotive, medical, aerospace, consumer products, and much more.

For more information, Web : www.mastercam.com

endless opportunities available to females in manufacturing.” The Manufacturing Institution will recognize Ms. Bush and 130 other honorees during a special STEP Awards reception on April 21 in Washington, D.C.

The Manufacturing Institute The Manufacturing Institute (the Institute) is the 501(c)(3) affiliate of the National Association of Manufacturers. As a non-partisan organization, the Institute is committed to delivering leadingedge information and services to the nation’s manufacturers. The Institute is the authority on the attraction, qualification and development of world-class manufacturing talent.

Kennametal: At the forefront of advanced materials innovation for more than 75 years, Kennametal Inc. is a global industrial technology leader delivering productivity to customers through materials science, tooling and wearresistant solutions. Customers across aerospace, earthworks, energy, general engineering and transportation turn to Kennametal to help them manufacture with precision and efficiency. Every day nearly 12,000 employees are helping customers in more than 60 countries stay competitive. Kennametal generated more than $2.6 billion in revenues in fiscal 2015. Website: www.kennametal.com

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BUSINESS NEWS

Maini Materials Movement (A Maini Group Company) launches 25-Ton Electric Tow TUG Maini Materials Movement (MMM) launched its 25-ton Electric Tow Tug for aviation support applications at India Aviation 2016, held at Begumpet airport, Hyderabad from 16th to 20th March. The 25-ton Electric Tow Tug is designed to tow small aircraft, ground support equipment, baggage trolleys and air cargo containers, among others. The Tug has been tested rigorously in the Indian environment at various airports and military bases. All the aviation support equipment manufactured by MMM is designed to the specific requirements of the customer with inherent flight safety features. MMM is proud to be the first mover in this product range as a ‘Make in India’ initiative and will soon launch the 15-ton class of tow tugs. Mr. G V Sanjay Reddy, Vice Chairman, GVK, launched the Tug at the event, said “I am so happy and proud to know that Maini has come up with electric

tug for the aviation industry. It shows that good Indian companies can come up with fantastic design and compete with the best in the world” Mr. Reddy went on to wish success on this amazing ‘Make in India’ initiative by Maini Materials Movement. Mr. Sandeep Maini, Managing Director, Maini Materials Movement Pvt. Ltd. said, MMM has many firsts to its credit in the Electric Equipment space. The company with more than three decades of experience and expertise on cutting edge technology always focuses to

in this product range and have leveraged our present pan-India after sales network to mitigate this pain point of domestic stake holders

meet the requirements of the domestic market. We believe, today an indigenous electric tug is one of the most needed equipment for the Indian aviation sector. I am happy that we are launching the product during ‘India Aviation 2016’. We have recognized the severe impact of long lead times for spares and after-sales service

Maini Materials Movement Pvt. Ltd. A member of the Maini Group, Maini Materials Movement Pvt. Ltd (MMM) designs, manufactures and markets electrically-operated material handling equipment, in-campus people movement vehicles and aviation support equipment. The company’s capabilities in design and customer-specific product customization continue to be pivotal in the Maini brand equity’s growth across industry verticals. Leveraging its technological capabilities, MMM initiated the indigenous manufacture of electric tow tugs in 2014. With its established, allIndia presence and after-sales network, MMM is confident to meet customer expectations.

For more information Web: www.mainigroup.com

ENGINEERING REVIEW

MAY 2016

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BUSINESS NEWS

Tucson electric power seeks to elevate engineering efficiency by augmenting enterprise GIS systems

Tucson Electric Power (TEP), the largest corporation headquartered in southern Arizona, are enhancing their engineering design capability by integrating best-in-breed network design software with their existing enterprise GIS. TEP is completing deployment of Bentley OpenUtilities to complement their Smallworld GIS with on-the-fly cost estimation and engineering workflow management. TEP expects to save time with the ability to refine designs for cost savings more rapidly. Automatic

compatible unit assignment and comprehensive unit data support in Bentley OpenUtilities will enable TEP to produce detailed labor and material cost breakdowns faster without time-consuming cycles between their GIS and enterprise work management system (WMS). This provides the ability to explore options quickly, find the least-cost design, and to submit designs within budget the first time. TEP also expects to reduce project delays with the ability to better manage work requests

from directly inside their GIS design environment. The configurable design workflow engine in Bentley OpenUtilities will work in concert with TEP’s WMS, enabling managers to assign, manage, and approve work orders. This will allow TEP to avoid open-loop processes with status notifications, approval requests, and e-mail integration as well as track project status and progress using dashboards and reports. Jeff McConnell, GIS supervisor, Tucson Electric Power, stated, “The ability to

integrate Bentley OpenUtilities with our existing enterprise GIS made it possible to upgrade key components of our engineering design process. We found the cost estimation and design workflow management capabilities in Bentley Open Utilities designer to be best suited for our demanding environment and anticipate these capabilities will advance our design efficiency.”

Farrokh Bhathena to spearhead Sales & Marketing at KSB Pumps Limited, India In a fierce competitive environment, when sustaining market leadership is one of the most important goals of KSB Pumps Limited in India; Mr. Farrokh Bhathena has been handed over the responsibilities of Director – Sales & Marketing from April 2016. With his over 25 years of experience in Sales and Marketing, Mr. Bhathena is all poised to strengthen the position of KSB in India. Mr. Bhathena is a graduate in mechanical engineering

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Mr. Farrokh Bhathena, Director – Sales & Marketing, KSB PUMPS LTD.

and a certified Marine Engineer. After a stint of 10 years in the Merchant Navy, he joined KSB India in 1990 as an Executive Officer and was a part of the

team handling pumps for refinery, petrochemical and fertilizer industries. Before taking over as Director – Sales and Marketing, Mr. Bhathena held senior positions as Head of Product Management and as the Head of Energy Business. At the time Mr. Bhathena has taken over the responsibilities of Sales and Marketing of the Indian arm of KSB; he is all set to steering this over Rupees. 8000 Mio company today; to beyond Rupees 10000

Mio, in the next few years! Today, KSB in India offers solutions through Pumps; Valves and Services; to customers from Power; Oil and Refinery; General Process Industries; Construction; Water and Waste Water segments. KSB in India is a part of KSB Ag.; an over 2.3 billion Euro. multinational conglomerate whose headquarters are in Germany For more information Web: www.ksb.com

MAY 2016 ENGINEERING REVIEW

BUSINESS NEWS

Hanna Instruments, Inc. Introduces new innovative HI98194 Multiparameter, Waterproof & carriageable Meter Hanna Instruments is pleased to announce the release of HI98194 Multiparameter, Waterproof & Carriageable Meter. Hanna Instruments is pleased to announce the release HI98194 with new innovative features. The HI98194 is a waterproof portable logging multiparameter meter that monitors most important water quality parameters like pH, mV, ORP, EC, TDS, Resistivity, Salinity, Seawater σ, DO, Atmospheric Pressure, Temperature. This meter has digital probe which directly measure pH, EC, TDS and then meter calculate other parameters. The probe transmits readings digitally to the meter, where data points can be displayed and logged. The complete system is simple to setup and easy to use. The HI98194 is supplied with

for pH, conductivity, and dissolved oxygen. Rugged thermoformed carrying case - The HI98194 meter, probe, and all accessories are supplied in a rugged carrying case designed to provide years of use.

all necessary accessories and packaged in a durable carrying case.

Features at-a-glance: Backlit Graphic LCD Display - The HI98194 features a backlit graphic LCD with on-screen help and the capability to display up to twelve parameters simultaneously.

About Hanna

Waterproof Protection - The meter is enclosed in an IP67 rated waterproof casing and can withstand immersion in water at a depth of 1 m for up to 30 minutes. Quick Connect Digital Probe - The HI7698194 probe features a Quick Connect DIN connector that makes a waterproof connection with the meter.

Auto-sensor Recognition - The probe and meter automatically recognize the sensors that are connected. Automatic temperature compensation - Integrated temperature sensor allows for automatic temperature compensation of pH, conductivity, and dissolved oxygen measurements. Automatic Barometric Pressure Compensation - The meter features a built-in barometer with user-selectable units for dissolved oxygen pressure compensation. Standard or Quick Calibration - Quick Calibration provides a speedy, single point calibration

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MAY 2016

Hanna Instruments, Inc. is the world’s largest privately held manufacturer of electro-analytical instrumentation. Since 1978 Hanna has produced practical, cost effective devices for laboratory, environmental, food, and industry applications. We offer a wide array of instrumentation from research grade benchtop meters and ISEs to single and multiparameter portable meters for pH, conductivity, dissolved oxygen, turbidity, and more. Hanna has over 40 offices worldwide to ensure exceptional levels of service and support anywhere in the world.

For more information Hanna Instruments Web: www.hannainst.com. Hanna Equipments (India) Pvt. Ltd. Web: www.hannaindia.in

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MANAGEMENT

Customer delight : Moving to the right By Rashmi Ranjan Mohapatra

ustomer delight is surprising a customer by exceeding his or her expectations and thus creating a positive emotional reaction. This emotional reaction leads to word of mouth. In simple terms the net result of expectations of the customer and value creation by the seller should be positive to bring in that ‘wow’ effect! Several articles have been written about Delighting the Customer. There are several ways to get in to the “Holy Grail”. Lets look at one more path; leading towards the Delighted customer.

a set price. During this period the left hemisphere will calculate the following: Total Perceived Value of the Customer Vs Total delivered value of the marketer by the ‘customer’

There are 3 outcomes of this process. 1. If the Total Perceived Value of the Customer is less than the Total delivered value of the marketer by the ‘customer’ then we have dissatisfaction. 2. It can be equal – the customer is satisfied. 3. When the perceived value of the customer is more than the delivered value it brings in ‘delight’.

The Left Brain vs Right Brain: As demonstrated in the schematic diagram the left brain is analytical and reasoning. This is where the cognitive process takes place. The customer uses the left brain to assimilate the functions/ tangible results and the deliverables of the marketer in numerical or tangible terms. The right hemisphere is mainly in charge of spatial abilities, face recognition and processing music. The brain’s right side also helps us to comprehend visual imagery and make sense of what we see. It plays a role in language, particularly in interpreting context and a person’s tone.Emotion and art are important aspect of the right brain. The contact points with the customer will be resulting as a function and getting analysed in the left hemisphere of the human brain. These contact points can be direct or indirect contact. Direct contact: Where the marketer provides direct contact of the product/ service to the customer. These contact points can make a discerning impact in the customer’s evaluation and can bring in positive impact or surpass his expectation.

An Ayurvedic hospital can have direct contact with their customers in many points: 1. Doctors 2. Nurses

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The process:

3. Masseurs 4. Therapeutic bed 5. Attendant and so on. Imagine each of these contact points can excel on their own to bring in a personal touch and create a lasting impression in the customers mind. Organizations definitely have a challenge to provide service/ product within the financial framework.

Indirect contact: These contacts are intangible in nature. Going through a web site of a marketer can be intangible experience. But, the customer starts developing a set belief towards the brand or starts accumulating several attributes in the left hemisphere. Word of mouth or social media can bring in some association of the product/service with the customer and can generate an interest. These interests or aspirations get converted in to specific attributes or tangible demands from the customer. Whether direct or indirect contact, the marketer tries to provide ‘value’ against

The left brain analyses each attributes of the offering of the marketer and compares with its expected values. Each element is evaluated and compared with reasoning. The sum total of each of the attributes / offering when starts becoming positive, the decision starts moving to the right hemisphere of the brain.

Moving in the right direction: Its like getting the right note from the guitar. Only when we play all the strings properly do we get the right note. Similarly, as a marketer one needs to satisfy and excel in the left brain to bring in the emotion content of the right brain. This positive emotion creates that “wow” moment for the marketer and customer.

Get in to the right brain. That is the “Holy Grail”!!

Rashmi Ranjan Mohapatra Managing Director, Kemppi India

MAY 2016 ENGINEERING REVIEW

COVER STORY

Legris India :

Global Leadership in motion & control technology Q. Can you please brief us about international alliances & Legris India global infrastructure? Legris India is a joint venture with Parker Hannifin group. With annual sales exceeding $13 billion, Parker Hannifin headquartered in Cleveland, Ohio is the world’s leading manufacturer of motion & control technologies & systems through precision engineering for a wide variety of mobile, industrial and aerospace markets. The company employs over 58,000 people in 48 countries. Parker has increased its annual dividends paid to shareholders for 53 consecutive years and is just one of the five companies in the NYSE with such a track record. Legris world’s leading brand in pneumatic solutions is headquartered at Rennes France.

and simplicity of installation, Unique full bore flow fittings styles (no restriction to passage) as gripping and sealing are achieved using the outside of the tube provide customer the optimum use of compressed air.Various thread configurations and compactness makes Legris fitting the first choice of end users and original equipment machine manufactures. Parker Legris India , ISO 14001 certified and being a part of Fortune 500 Group Company has pneumatic connecting systems as its core business area. Optimising the transport and control of many fluids (compressed air, liquids, gas) through innovative

Q. What are the latest initiatives Legris India has undertaken in compressed air systems space? Which are your focus areas? Since 1969 when Legris invented world’s first push-in-fitting - the LF 3000® series, We have been continuously developing various range of fittings and technical tubes to suit the applications. Today Parker Legris connectic has worlds widest range of fittings not only for compressed air but also other inert gases as well as aggressive fluids. The unique internal design of Parker Legris fittings provides time saving

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MAY 2016

Mr. Balraj Raju, Regional Manager (WEST India) Legris India www.engrreview.com

COVER STORY the design, manufacturing and marketing of high quality connectors allow us to provide our customers with solutions adapted to a variety of applications. Parker Legris, ISO 14001 certified, has made the conservation of resources and protection of the environment a major priority. Through our Eco-Design approach, we have incorporated improved environmental management as a permanent feature in the vision and mission of the company, aiming to benefit nature, technology and mankind.

Q. Brief us about the quality policy for the business? product design has been the motto of our teams for more than 100 years. Our focus is on constant development of fitting range having compatibility to all types of air , fluid and gases and making installation for users more user friendly.

Q. What are the market opportunities for Legris India products in India? How do you plan to position these products? Parker Legris’ expertise is divided into three business activities: Legris Connectic: Fittings, Quick couplers, function fittings, valves, tubing and accessories for industrial applications. Legris Transair: Industrial gases, compressed air and fluid distribution systems for industrial buildings. Legris Autoline: push-in connection solutions for automobile fuel lines. Our product range fits in all segment of industries. The product placing fits in all segment of industries. Our knowledge and expertise are deployed in a variety of sectors: production automation, packaging, transport, food process, the pharma & medical industry Parker Legris is also involved in innovative sectors such as renewable energy, information and communication technologies. Parker Legris encourage local support and long-term partnerships with our customers. Through a dealer network of more then 60 dealers and resellers across India and also with our many sales outlets,

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professionals, we are on hand to provide you with technical advice and to offer you a wide choice of products local to your sites.

Our actions are coupled with environmental process

Q. In order to sustain at frontier position, what are the marketing strategies that are applied & will be applied for Indian market?

Parker Legris has integrated environmental protection management into the operation of its industrial sites. This approach has enabled 85% of waste to be recovered and has reduced energy consumption by 15%.

Parker Legris has always been the first choice of customer when it comes to reliability of the product and customer service satisfactions. Innovation is Parker Legris’ number one priority in order to provide solutions that meet your technological, energy reduction and environmental challenges. Our target is to provide our customers with the best solution and the highest quality. Certified ISO/TS 16949, Parker Legris includes customer quality at the heart of its processes and that’s what is a simple marketing strategy for us.

Reducing the impact on industrial sites :

Offering ecologically responsible products : Under its continuous improvement process, Parker Legris has integrated ecological design as an input parameter to innovation and uses Life Cycle Assessment (LCA) to optimise the environmental impact of its products. Providing information on the PEP (Product Environmental Profile) This communication tool is

Q. Can you please elucidate the contribution of technology innovations in the success of Legris India products? Legris has a history of 150 years and our experience and expertise in

MAY 2016 ENGINEERING REVIEW

COVER STORY common to all industries and professions and delivers a reliable and clear message for promoting ecological advances and incorporating this data within the LCA equipment. Parker Legris goes beyond its statutory obligations and endeavours to find a good match between choice of materials, limitation of hazardous substances, selection of recycling channels and industrial performance to encourage the recycling of products at end of life.

Q. Please highlight more about Legris India’s top line product range? Is there any new launch or in pipeline stage? A very large number of technical solutions exist for connecting two pipes together. Leader in industrial connection systems, Parker Legris offers a very wide range of technologies and materials to cover all requirements. Our Push-In Fittings technology provides & allows flexible and modular systems to be produced quickly. Our Compression Fittings Can withstand very high pressures and temperatures. Allows all types of tube to be connected, both polymer and metal. Our Spigot Compression Fittings Intended for the connection of very flexible or non-calibrated tubes & Our Couplers are Suitable for frequent connection and disconnection. Beside widest range of fitting technology, Parker Legris offers most reliable solution in technical tubes & hoses for connecting media fluids. Legris Transair Air treatment

ENGINEERING REVIEW

MAY 2016

products such as Filters, Filter Regulators and Lubricators from 1/8” to 1 ½” range provide simplest and economical solution to conserve treat and regulate compressed air going into the systems and machines. Parker Legris LIQUIfit , CLEANfit, Auto couplers, Cartridges Technical Tubing and Hose such as Semi-Rigid Polyamide tubes, Rigid Poly Amide, Fireproof High Resistance Poly Amide , Anti-Spark PA and Poly Urethane with or without PVC sheath PU single and multi-tube , Antistatic PU , Advanced Poly Ethylene , FEP, PFA , Antistatic PFA , Self-Fastening NBR & Braided PU are all developed from constant research ongoing programs. Worlds first and most energy efficient economical Alluminium alloy piping system “Transair” from Parker Legris has many new variety of fittings coming up in near future. Making piping network more easy to handle with highest standards of safety.

Q. What are the key technological trends that are driving compressed air piping & systems industry? Conventional fittings such as push on fittings or clip on barb fittings are making way for compact and energy efficient Push

in fitting range because of lot of awareness been created by us since 1969 at various platforms. Gifting Indian market with the latest range of fittings and tubes as per the application requirements, Parker Legris has also in one way contributed in saving energy reserves of the country. Parker Legris Transair 100% Leak proofing piping solution with reduced pressure drops and consistent quality are the prerequisites from a piping system which off course is driving this market.

Q. According to you what is the future of the fittings & compressed air piping systems industry? India is one of the fastest growing economy. Handling the demand of local Indian as well as overseas market, automation for maximum productivity with highest standards of quality is only solution. Compressed air and vacuum technology have a great role to play in future of automations. With MAKE IN INDIA as a prime initiative of current governance, Industry is bound to grow many fold, and expansion of current projects is foreseen. No automated industry can run without compressed air and so fitting company with energy efficient connecting systems & piping solutions have a tremendous potential in coming years.

Q. According you what are the factors affecting to your business? “All that Glitters is not Gold”…….. Parker Legris have invented the world’s 1st Push in connecting solution and we have lot of technical advantages in fitting range when compared to other brands. Current market has lot have blue brands offering similar range of fittings but at cost of tremendous leakages and precious energy losses. Product with reliability and safety should be the first choice to the user. We are doing consistently well since many years and our standard of quality with new innovations in product offerings is growing our business in many folds.

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FACE TO FACE

Mastercam : Technology leadership of CAM excellence

Meghan Summers West, Chief Operating Officer, Mastercam

Q. Mastercam has gained substantial market share in machine tool industry , please brief its journey from the inception & share some its milestones? Mastercam was launched more than 30 years ago. It was driven by two brothers’ specific set of skills in mathematics, programming, and shop-floor machining experience. Since then, we’ve maintained a tight focus on what made us successful from the beginning. We talk directly with machine shops around the world to see what’s needed and what’s coming. This means we not only provide practical programming tools to get jobs done quickly, but groundbreaking new techniques to inspire CNC programmers.

Mastercam users. As the world’s most widely-used CAM system, we need to be able to work smoothly with virtually any machine tool. To this end, we’ve forged many mutually beneficial relationships with machine tool manufacturers that let us prepare for “the next big thing” as well as helping them demonstrate what their machines can do. Similarly, we have excellent relationships with CAD developers because our users require us to work with virtually any type of CAD file. And we do have excellent relationships with CAD developers. SOLIDWORKS® is a great example. We have a tightly integrated Gold Partner version of the software that runs within SOLIDWORKS®, and we have a good relationship with the company to help keep us on top of what’s going on in the industry.

Q. What are the market prospects for the Mastercam products in India and How do you plan to position these products? For us, India represents an unsurpassed collection of talent, experience, skill, and opportunity. The economic growth outlook for the next few years is great by all reports. Large and rapidly growing sectors such as Aerospace, Automotive, Telecom, Medical,

Q. Please brief us about company’s global reach & what are the global alliances that has been made in order to out-front the competition? Our reach extends across the globe, with many of our representatives having decades of experience with both their local market and with Mastercam directly. We choose our partners carefully to ensure that they can build long-term support relationships with

ENGINEERING REVIEW

MAY 2016

Brothers Brian and Mark Summers stand next to Meghan Summers West.

and even infrastructure expansion require the backbone of manufacturing that we can help support. Our strategy in India is similar at its root as our strategy across the globe. Understand the needs of the industries engaged in manufacturing and, more importantly, the practical needs of the people responsible for programming parts for those industries.

Q. Can you brief us about the marketing strategies that were applied in order to stand out in the competition of the industry? I can sum up our strategy in three simple words: Practicality, Support, and Advancement. By practicality, I mean that we strive to make sure every tool in the software solves a problem or improves a process that we’ve seen in day-to-day machine shops. We want to ensure that the toolset in Mastercam gives a programmer a way to complete any project they take. In the end, our goal is not our software itself, but the results it achieves for our users. Support is the second pillar of our strategy. We feel we have the best and most experienced global support network today. We have local representatives with decades of experience, ready to share their knowledge with their customers and with the entire Mastercam community. This is vital, because in many ways, machining is the most unforgiving part of the entire manufacturing process. CAD designs can be edited, but once metal is removed, it can’t be put back. Finally, advancement is crucial to make sure that our users are as competitive and productive as possible. Our proprietary Dynamic Motion technology is a great example of this. It’s a cutting motion engine that drives many of our toolpaths. It can save up to 70% of machining time; at the

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BE DYNAMIC!

THE FUTURE OF EFFICIENCY & SPEED IS HERE – MASTERCAM’S DYNAMIC MOTION TECHNOLOGY Since 2008, Mastercam has been building Dynamic Motion into our software. That means it has been shop-tested and proven in real-world environments. Dynamic Motion toolpaths carve out massive amounts of material quickly, reducing cycle times by up to 75% – while doubling and even tripling the tool life – immediately putting more money in your pocket. Sounds unbelievable, right? But as the market leader, we’ve had our Dynamic Motion toolpaths tested in most every conceivable work environment around the world. It works.

For more information, visit www.Mastercam.com 800-228-2877

FACE TO FACE same time it dramatically extends tool life.

Q. Brief us about the R&D and Quality policy for your business? Our development is built on a repeating cycle of constant creation and testing so that as many issues as possible can be worked out as quickly as possible. At the same time, we have a large R&D machine shop in our facility that constantly tests the software in a wide variety of real-world machining situations. Finally, we run a wide and extremely valuable public Beta program so existing users can try out new features and report back with comments and suggestions.

Q. What are the key technological trends that are driving your industry? The key trends in CAM software are simple but powerful: constantly increase the speed and efficiency of the software, automate where possible, deliver programming methods that make the best possible use of machine tools, tooling and material, and make the software capable of handling the increasing variety of jobs a shop encounters. I mentioned our Dynamic Motion technology earlier. It’s a good example of a software advancement designed to address many of these points. It can dramatically reduce machining time, it’s governed by “smart” algorithms that automate much of the complex work, and it generates cutter motion that is easier on the machine, extends the life of the tool, and is smoother in the material.

Q. Could you brief us on Indian & Global perspective of machine tool manufacturing industry? What

The Mastercam corporate headquarters in Tolland, CT, USA.

are the distinguishing factors? The machine tool market has seen dramatic ups and downs since 2009. During that year, the machine tool market as a whole took a sharp drop with some manufacturers losing as much as 80% of their orders. But as the global economy began to rebound, the pent up demand for those machine tools rose quickly and has stayed very healthy since. In the United States, the machine tool market is exceptionally strong, and there are many other countries that show strong machine tool consumption including China, Germany, South Korea, and Mexico.

Q. Please comment on the current machine tool scenario in India ? India remains one of the top machine tool consumers, as well as a very large producer. However, the demand is surpassing the supply, potentially creating a gap and a demand for more machine tools than are currently available. The industry is rapidly moving toward ever more advanced CNC equipment as segments such as medical, automotive, and consumer products demand it.

Q. In your opinion how can the Indian machine tool industry become globally competitive? From working with our Indian representatives, we feel the Indian machine tool industry is on an excellent path now. Although there may be a gap between the supply and demand of machine tools, it appears more companies are looking to fill

Mastercam is extensively tested at the company’s in-house machine shop.

ENGINEERING REVIEW

MAY 2016

that gap. And the equipment they appear to be filling the gap with (increasingly sophisticated CNC machines)should yield not only a stronger machine tool market, but even more competitive machine shops. Another powerful tool for increasing global competitiveness is heavy emphasis on manufacturing education. Whether it’s a machinist sharpening their Mastercam skills through training, or a classroom of students getting prepared for and excited about the industry, manufacturing education is vital. This is especially true in any market where growth is expected – that growth will require new, intelligent, skilled people to sustain it. We’ve been dedicated to manufacturing education since we started, and it will always be an important part of our company.

Q. How do your perceive the future of the Indian machine tool industry ? We’re excited by it. There are so many positives and so many manufacturing and machine tool opportunities that India represents for itself and for the world, and we’re eager to see how we can help.

Q. What is your vision for Mastercam ? Our vision is to remain focused on the fundamentals that help make Mastercam shops successful every day – deliver software that makes day-to-day machining easy, that constantly offers creative new techniques, and that inspires machinists.

Different types of machine tools are circulated into and out of Mastercam’s Research & Development (R&D) shop.

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48 | May 2016

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INDUSTRY SPEAK » MACHINE TOOLS

Integration between CAD/CAM & highly reliable design/model for manufacture methodology will drive the industry in the future an optimal guideline or options that the manufacturing planning department can consider. Price is always a key driver, and therefore offering the above at an economical price, backed by quality support will also be critical in driving this trend.

Q. What is the impact of Union budget on the industry?

Vineet Seth Managing Director – South Asia & Middle East, Delcam Ltd., UK

Q. What trend will drive CAD/ CAM Industry in near future? Optimal integration between CAD and CAM as well as a highly reliable Design/Model for Manufacture methodology is what will drive the CAD/CAM industry in the future. It is evident that what is being designed will one day be manufactured; however – inspite of new age technology like 3D printing, there are various aspects regarding volumes, material, resource availability that a manufacturer (usually small & medium businesses) need to consider. Often, there is a disconnect between both these processes which results in inefficient manufacturing. CAD/CAM tools have the ability to tie these loose ends together by providing a system that connects the dots and provides

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MAY 2016

The budget seems to be a positive step in the right direction, with tax benefits to startups in manufacturing for the immediate short term period of about 2-3 years. Revision in Customs & Excise Duty rates would also be beneficial in sectors such as Defence Production, IT Hardware & Capital Goods. The MRO Sector in Aerospace is likely to gain through complete exemption on customs duty on spares imported for undertaking repairs. With the push in Aerospace Sector that the industry has been eyeing for a while now, this should increase potential for business. Duty benefits in renewable energy is also a very positive step. Finally, duty exemptions have been reduced on several military equipment. This shall provide a fillip to Make-in-India initiatives as well as provide a level playing field for Indian Manufacturers.

All in all I am pleased with the budget. The devil however lies in successful execution; I for one have immense faith in our system as it stands today, to propel India on the path of economic progress, strength & growth.

Q. What are the remedies do you suggest to improve the positioning of the industry you are into? We are suppliers to the manufacturing industry and the success of this industry is critical to our success. The manufacturing industry faces many challenges – most of which can be addressed by diligently applying best practices and proven formulae – in the short term. In the longer term, innovation and competitive differentiation are key to the collective success of the entire supply chain in the business. The manufacturing industry should also regulate & discourage the use of pirated software, encourage the adoption of new age technology, encourage continued education, invest in R&D – both as individual companies (micro-scale) as well as on the consortia levels (macro-scales) and most importantly pay due respect to customer requirement and resulting quality thereof.

The budget’s focus on Infrastructure Development is another very important and positive feature.

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INDUSTRY SPEAK » MACHINE TOOLS

MACHINE TOOLS » INDUSTRY SPEAK

Technology transformation will drive the machine tools industry in future Q. What trend will drive MACHINE TOOLS industry in near future ? L.J. Naidu Multi-tasking machines capable of handling complex processes, Additive manufacturing, Cost efficient Automation solutions, Highly Intelligent cnc control systems for digitalization of manufacturing processes, Ultra precision machine tools will be few major trends in near future. Mr Andreas Zieger Efficiency, flexibility and the interaction of machines. The globalisation is pushing the price fight, the scale effect is one solution to reduce the cost, but with high demand on quality. On the other side we see that optimised processes and integration of best technologies will bring additional benefits. Flexibility, is another challenge, the product cycle time becomes shorter and thus the invest needs to be flexible too. Machines need to be able to get adapted fast and easy to the new task. Finally the interaction of machines, on one side the mechanical connection to optimise a complete process and on the other side the data connection, here chaotic machine usage, shorter shut down time, tool life optimisation and finally quality information leads to higher usage of the capacity. The OEM try to outsource not only parts but also design and process development and by that the machine tool builders take over a more important role in the partnership. EMAG has here a good technology portfolio, a new modular machine concept to integrate that technologies and for all machines a build in automation to integrate machines to line and that we bring in the partnership.

Q. What is the impact of Union budget on the industry ? L.J. Naidu FY 16-17 budget has projected significant investment towards Infrastructure projects like Road/Railways/Port, this will drive

ENGINEERING www.engrreview.com REVIEW MAY 2016

Mr Andreas Zieger, Director, EMAG INDIA Pvt. Ltd

L.J. Naidu, Managing Director, GROB Machine Tools India Pvt. Ltd.

investment into related Industry. At the same time, introduction of infrastructure cess & luxury tax on certain categories of passenger car vehicles is likely to have noxious effect on Automobile Industry. Mr Andreas Zieger By focusing on education, infrastructure and defence it can be seen as initiator to set further development.

Q. What are the remedies do you suggest to improve the positioning of the industry you are into ? L.J. Naidu Rationalization of various taxes & cess for certain period, tax benefits for vehicles using alternate fuel technologies like Electric, Bio diesel etc… will help vehicle manufacturers plan their strategies on long term and will benefit overall depending industries to larger extent. Mr Andreas Zieger To build up a multi technology industry with high quality standards to be recognized a partner in global industry world.

MAY 2016 www.engrreview.com ENGINEERING REVIEW

INDUSTRY SPEAK » MACHINE TOOLS

Customization of process for higher productivity is the key for getting a bigger market share

Q. Any upheavals you had to surmount? Mr.Ashok Sheth, Chairman Solitaire Machine Tools Ltd.

Q. How was the year that went by for your company? The last financial year was slow to start with, but it picked up the speed of order receipt and execution. Domestic market is still a bit jittery for domestic consumption. Those who have good potential for Export of components / sub-assemblies are taking risk and procuring equipment and upgrading with automation. At SMT, we found the year quite good with healthy growth of about 40 %. The Export was made to various countries in North America, South America, Europe and China. The lesson learned was that customization of process for higher productivity was the key to getting bigger share of market. Customers are looking more for Solution than just a machine. The tolerances in sub-micron level are becoming reality. A tooled up automated machine with higher cost is more preferred than a general purpose machine with low cost. The quality conscious customers are also finding out that low cost second hand machine no longer guarantees them business, as they are unable to meet quality parameters which are becoming stringent day by day.

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MAY 2016

The major change was the need to reduce the price of machines being sold in domestic market. The major vendors of Castings, CNC systems, Ball Screws and all other peripherals were not willing to reduce their prices, whereas customers are under tremendous pressure to bring down the price of their products. The Rupee also kept on getting depreciated affecting the import cost and cost of manufacturing. It was hard to keep two ends to meet and still continue profitable operations. The major issue with most customers is lack of skilled manpower availability at reasonable cost. Lack of manpower and higher turnover of employees is affecting the business all around. The skill imparted by Schools, Technical institutes, Engineering colleges are all too much of theory oriented and students graduate just by reading their books. Greater interaction with industry on shop floor level is a necessity of the day.

Q. What are the innovations you wish to display this year? We would like to pursue grinding of Cam Shafts and Crank Shafts on Centerless grinders for higher productivity. The concept is being developed and may take a year or two to come up with desired solution. The savings in manufacturing time would be really big for manufacturers

of these products. We are also pursuing wider applications for New Micro Centerless Grinders. We would like to upgrade our machining capabilities for better accuracy and savings in machining time. New design tooling is being adapted for higher output. Several machines are being upgraded with CNC controls to ensure consistency in manufacturing. We would like to target full CNC machine shop by 2022.

Q. Did you ever feel there’s a better way? What would be your strategy and approach to make the most of this year and beyond? Yes, there is always a better way to do whatever you are doing. You do not need rocket scientist brain to do better. All you need is common sense and open to new ideas coming from any source from where suggestions can be received. There is no limit to how much you can learn from your colleagues, employees, customers, vendors, competitors and even a layman, who has no clue on what you are doing. The simple strategy would be to listen more than speak. We have seen that new products, new processes have been evolved just by a stray idea on why this cannot be done by us. Close your eyes and you see it running like a movie with all the variables available to make the process productive and costeffective.

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THE ALTERNATIVE TO TURNING

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INDUSTRY SPEAK » BEARINGS

“The most exciting thing at NRB is our focus on empowering the younger generation” Our company has been restructured over the last three years to give significant responsibility to young men and women under the age of 30, across functions. The average age of our workforce is one of the youngest in the industry and they hold significant positions and power to make the changes that are required to make us a market-leader.

Harshbeena Zaveri, Managing Director & President, NRB Bearings Ltd.

Q. How was the year that went by for your company? It was a challenging year for the automotive industry. However, we used the opportunity for focused product development and held our own on the financial front. Our strategy is to ensure that our progress does not stem purely from market growth; we develop new products for the future generation of mobile vehicles across applications. In the course of the year we concentrated on penetrating more deeply into emerging segments including defence, aerospace, marine, mining and off-highway along with a deeper engagement with our traditional segments such as twowheelers, cars, trucks and farm equipment. We are very upbeat about the current year as we will get the benefit of all the operational improvements implemented through the year as growth numbers soar.

ENGINEERING REVIEW

MAY 2016

Q. Any upheavals you had to surmount? The culture we strive to build is one where difficulties are looked upon as opportunities.Our approach is simplifying our strategy and attracting young men and women who enjoy engaging with the customers and are passionate about our products. Scaling up and yet being true to the essence of our goal,to be a customized friction solution provider is our differentiator. This year, we expanded our range and engineered cost effective, light weight friction solutions for a host of applications that resulted in increased fuel efficiency, noise reduction for engines and transmissions, and enhanced life.Size matters less to us than the impact and quality of the solutions we provide.

Q. What are the innovations you wish to display this year? What would be your strategy and approach to make the most of this year and beyond?

a disruptive approach which optimises material input and performance. Our true value lies not just in reducing the cost of an existing process but in creating new and innovative bearing solutions to add value to our customers which include ZF, Bosch, Daimler and Getrag apart from the Indian auto majors.NRB’sResearch &Development centres focus on cutting edge product and process technologies. Our emphasis is to be pioneers not just in existing bearings but to create friction solutions using diverse materials, technologies and manufacturing processes. What is most exciting at NRB is our focus on empowering the younger generation. Our company has been restructured over the last three years to give significant responsibility to young men and women under the age of 30, across functions. The average age of our workforce is one of the youngest in the industry and they hold significant positions and power to make the changes that are required to make us a market-leader.

We are leaders in light-weighting and the focus of our product and technology development has been the adoption of

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ENGINEERING REVIEW |

55 | May 2016

See us at EMO 2013. Hall 6 Stand C37.

• ExactDress™ Dressing Control

• AEMS Acoustic Emission Monitoring

• ExactControl™ Grind Cycle Management • SBS In-Process Balancing

Grinding Process Innovation

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SUCCESS STORY

Houghton at a 1.5 ton landmark & still counting! Houghton International (HI) celebrates a landmark one & a half century of product innovation, customer satisfaction & global growth. “Since 1865, the mission and values established by founder Edwin F. Houghton have made it possible to reach this note worthy milestone. From our early roots in Valley Forge, Pennsylvania, to becoming the largest metalworking fluids company in the world, we have come a long way.” - Sanjay Hinduja. Chairman

elebrations of success ring across the 6 continents that Houghton operates in. The company has reached a 150-year landmark and is bringing to gether its key stake holders for the occasion. Amid the festoons, the Open Houses and other events that mark the date, the heart of every Houghtonite swells with pride.

The pioneering spirit lives long A pioneer of metalworking fluids, Houghton International was born in 1865 in Valley Forge, Pennsylvania USA. This brain child of Edwin F. Houghton, a manufacturer of rust preventives, began to spread its wings and launch new metalworking products for key applications with turnkey fluid management services. HI’s prestigious customers comprise reputed global companies from key industries including Aerospace, Automotive, Bearings, Construction, Food& Beverage, Forging & Stamping, Heat Treatment, Machine & Job Shop, Machinery, Mining, Non-Ferrous, Offshore Energy, Spring & Wire, Steel and Wind Energy. From a regional US-based supplier, to a global market leader, HI has come a long way.

Leaders do things differently This leader in the metalworking fluid space believes in doing things differently, yet consistently. Houghton has never wavered from its pioneering vision to be the most successful and respected specialty chemical company in the world. Its dedication to resolving customer problems by actively partnering with them to provide innovative and sustainable technical process-fluid solutions, and improve their production efficiency through increased productivity, reduced cost, minimized risk and

ENGINEERING REVIEW

MAY 2016

minimized environmental impact, still runs asstrong as it was when the company was founded.

vision. These remain at the center of its practices, processes, policies and products.

The future is Innovation

“It is so rare for a company to reach this milestone. We want our employees to feel proud of this great achievement and we want to thank our customers for their continued support. We are and will remain committed to innovation, improvements and compliance in the metalworking industry.” Michael J. Shannon Chief Executive Officer

Houghton is reputed to be a company that stands for product innovation. Our experienced global research team works closely with our customers to better understand their needs. Solutions to customer problems are developed at the laboratory before being tested at our customers’ facilities. In addition, our scientists are part of customer improvement teams and are actively involved in the design of our customers’ next generation products. The future has in store new solutions and platforms including “green chemistry” to improve performance and effectiveness from metal working fluids to our customer’s operational requirement. Come join us in this innovation journey and partner with us to achieve your fluid management goals!

“The fast-growing economies are increasing their share of output in the industrialized world. India has made a commitment to that trend with its recent “Made in India” campaign. Houghton is making investments to support our global and domestic customers in India and partner with them to achieve their goals by providing our leading technology and solutions” Jeewat Bijlani, President, Americas & Global Strategic Business

“Befriending the ASIAN TIGER was a challenge, but not an impossible one. Houghton’s rich 15O-year old business history, expertise and wealth of knowledge helped us in our Mission India and we are happy that India is today one of our key markets in the APAC region.” Melvin Gay Managing Director, South Asia Pacific

“A crucial part of a company’s sustainability over the century and more, has been the strength and flexibility of its operations. As we innovated, launched new product lines and entered new markets, we kept our operations focused on our customers. With customer service offices and manufacturing now in six continents, our focus remains.” Marcello Boldrini President, Asia and Global Metals & Mining

“India is an integral part of our business and has earned a place of pride in our global business. We have successfully adapted global vision to Indian business culture and customers, and have been fulfilling our promise to the Indian market with competent and energetic team members.” Santosh Charkraborty Managing Director, India

The 7 core values that hold Houghton strong Despite phenomenal growth, Houghton International is committed to its core valuessuch as Environmental Health and Safety (EHS) focus, results-drive, customer-focus, innovative spirit, integrity, openness to change, and a singular global

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SUCCESS STORY

The winsome trio: Milind, Sameer and Mohini Kelkar

Garage to the Globe – The Saga of Grind Master

rind Master is a pioneer and leader in special purpose machines for Metal Finishing, Deburring, NanoFinish and solutions including Robotic automation and Abrasives. The company provides total solutions for surface finishing requirements. With over 4000 machines across 6 continents, serving a wide range of industries, it brings a world of experience of over 30 years in machine technology & process knowledge. Grind Master competes with the best in the world. It constantly strives to exceed customer expectations with Innovative & Trustworthy solutions created with Passion and Expertise.Grind Master Accounts for 20-25% of All Indian Machine Tools Exports (data from IMTMA). 75% of Grind Master Exports are to China, where Grind Master competes with German and Japanese Machine Builders on Technology.Grind Master is the only established Indian Supplier to Global Automotive Companies such as SGM, SGMW, Great Wall and DPCA for Machinery with Turnover around INR 125 Crores.

VJTI in 1984.They began developing indigenous metal finishing machines from a rented garage in Aurangabad City. Until this time, all metal finishing operations were performed manually. These manual processes had limitations on time, accuracy and consistency of finish and resulted in an unhealthy work environment. Identifying this gap in efficiency of productivity, Mr&Mrs Kelkar focused their attention on developing and manufacturing automatic and semiautomatic metal finishing machines. Their passion for machine building, reinforced by their ‘Can and Will’ motto, resulted in the birth of Grind Master, a company based on innovation and efficiency in engineering, with a grounding in strong values. Over the past three decades, the company has grown exponentially, offering one of the widest ranges of Special Purpose Machines for

Garage to the Globe Grind Master is a family owned business started by Entrepreneur couple Mrs. Mohini Kelkar and Mr. Milind Kelkar from

ENGINEERING REVIEW

MAY 2016

The Grind Master plant in Aurangabad

the processes of deburring, grinding, polishing and micro-finishing to suit every industry need. From making 2-3 machines a year, Grind Master now manufactures 450 machines in three state-of-the-art factories and additional manufacturing support units. Mr. Sameer Kelkar, IIT Bombay & UC Berkeley Graduate, has taken the organisation to next level with successful introduction of Robotic Technology. Grind Master offers a wide variety of Robotic solutions into its niche field of Surface Finishing.

Widest range in the world Today Grind Master offers the widest range of metal finishing machines in the world. The comprehensive solutions it offers for diverse industries like Automobile, Defence, Aerospace, Cookware, Foundry, Textile and Steel, comprise: • Robotic Automation for Fettling of Castings • Centreless Belt Grinding & Polishing of Tubes & Bars • Superfinishing of Cylinders, Engine & Transmission components • Gear Chamfering Deburring Machines • SPMs for Polishing, Grinding & Deburring applications • Cookware Polishing Machines • Sheet Metal Polishing & Deburring Machines • Coated Abrasives. The company rightly claims to be a ‘one stop shop’ for total solutions for metal finishing in the world. - P.K. Balasubbramaniian

For more information Grind Master Machines Pvt. Ltd. B-10/B-11/B-14, Railway Station MIDC, Aurangabad- 431005 Maharashtra (India). Tel. +91 (240) 2374104, +91 (240) 2374114 Email :sales@grindmaster.co.in Website :www.grindmaster.co.in

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MAKE YOUR MACHINE WORK SMARTER

What if your machine tool could talk? If it could inform you in real time when a cutter is nearing the end of its productive life? Or if a worn spindle bearing was about to cause catastrophic failure? What if it could intelligently adjust feed rate to compensate for material variations? And even assist in seamlessly documenting product quality? Imagination is now reality−thanks to innovative Artis and Brankamp machine and process monitoring technology from Marposs. Many of the world’s most progressive manufacturers rely on easily operable Artis and Brankamp systems to help improve productivity, enhance quality, safeguard operations and reduce cost on a broad range of machine tools.

www.marposs.com

MARPOSS INDIA Pvt. Ltd. 147, Sector 7, IMT MANESAR 122 050 - Tel. +91 124 4735700 |sales@in.marposs.com

PROFILE

Bright Roller Burnishing Tools for complete burnishing solutions

oimbatore-based Bright Roller Burnishing Tools Private Limited, incorporated in the year 1994, is an ISO 9001: 2008 certified company. With its sustained efforts, quality products and after-sales service, it is enjoying a reputation in the field of burnishing close to three decades.

Clientele : The company has a very wide customer base in India covering MNCs, Corporate, Medium and Small Industries and Public sector undertakings. With a vast experience and an ever-expanding list of satisfied customers in India, the company has set its sight on the overseas market. It is exporting its quality products to countries like, USA, Iran, Australia, Thailand, Indonesia, UK, Singapore, etc.

Applications: Bright Burnishing Tools are being used in sectors like automobile components manufacturing, motors and pump industry, textile machinery manufacturing, hydraulic and pneumatic parts, home and office appliances, machine tool manufacturing, earthmoving equipment manufacturing, railway parts, defense, aircraft parts and many more.

on pre-burnishing condition) and close tolerance is easier with less cycle time and at negligible cost, thereby eliminating finishing and quality problem, which are encountered in the day-to-day production process.

• Highly suitable for mating taper assembly, like hydraulic end fittings • Can be burnished directly after CNC turning. • Tools available with different shank options.

Product range

Special Roller Burnishing Tools

Bright’s product range includes burnishing tools for Internal Diameter, External Diameter, Internal and External Tapers, Flat circular faces, Grooves, etc.

Apart from its standard product ranges, the company also manufactures special purpose burnishing tools as per customer’s requirements. These include: • Single Roller Tool • Multi Surface Single Roller Tool • OD H Type tool • Face Burnishing Tool • Flat circular face burnishing tools • Groove Burnishing Tools

Internal Diameter Burnishing Tools • Tools for through and stepped bores • Min. Internal Dia 5mm and above • Designs available for Short bore length, Long bore length, Big internal dia. • Tools with machine feed / self feed design available • Tools available with different shank options

Outer Diameter Burnishing Tools • Tools for through and stepped bores • Min. External Dia. 2mm and above • Tools available with different shank options • Highly suitable for diameter less than 30mm & with short burnishing length

The Process and its Advantage Burnishing is a cold rolling process on ferrous and non-ferrous machined components. Achieving superior surface finish (0.1 Ra to 0.3 Ra based

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Taper Angle Burnishing Tools (Internal & External Angle / Taper) • Tools for Internal tapers and external tapers • Min. Minor Dia 5mm and above.

Burnishing Machine Apart from Burnishing tools, Bright also manufactures Burnishing machines like Hydraulic OD Burnishing Machine, Pneumatic ID Burnishing Machine, and Portable OD Burnishing Machine.

Customer appreciation “Customer appreciation is our source of strength and inspiration, and the same will help us to make our products better every time and in all ways. Many of our customers have sent letters appreciating the quality of our products and after-sales service. We always focus on continuous improvement and customer delight,” says the company – P.K. Balasubbramaniian

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New Milestones in Microfinishing Precision engineered finish for automotive powertrain parts Preamble Greenhouse emissions and Energy efficiency are the critical aspects pushing the limits of Powertrain Engineering in Automotive industry. ‘Lightweighting’ and ‘friction reduction’ are two key strategies in this aspect. Deploying both strategies makes designers of Engines resort to stringent surface finish parameters on Critical powertrain components such as Crankshafts, Camshafts, Transmission shafts etc. Microfinishing is a mission critical process required to achieve these specifications. Over the last few years microfinishing technology has crossed several milestones and made possible key advances in Engine Performance.

The Author – Sameer Kelkar, Silver Medallist & Graduate of IIT Bombay, and MS in Mechanical Engineering from University of California, Berkeley, is CEO of Grind Master Machines Pvt. Ltd. Sameer also leads the R&D team at Grind Master which has several Registered Designs and Technology Patents (Pending) in the field of Microfinishing and Superfinishing. This article is compiled with the experience of the past 6 years.

New Milestones in Microfinishing The Process of Microfinishing with film backed abrasives was developed to achieve consistently uniform finishes faster and more efficiently. Microfinishing generates Lubricating Characteristics at Surface Contact through a Highly Engineered Surface Finish so that the surface provides maximum bearing area to take up heavy loads and at the same time retain enough oil in the surface for adequate lubrication. Milestones in this technology in the past few years include the process capability of achieving highly precision Engineered Finishes, as well as advancements to process more and more variety of components using Film backed abrasives. Major improvements in machine technology include flexible manufacturing systems capable of multi variants and compacter more energy efficient machines with ultra user friendly interfaces.

What is Microfinishing? Micro-Finishing is a method or process to remove the surface material of a

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dimensionally finished part to provide a precise fit to the mating part. An examination of the texture left on a metal surface as a result of machining operation will reveal tool marks, fragmented metal, chatter, etc. It is the micro-finishing operation that must be used to generate the final surface texture required for service life, performance and reliability of a product. A non-microfinished surface can be compared to a snow covered lake. A person’s weight will produce foot prints in the snow whereas, the ice will even provide support for the concentrated pressure of a person on ice skates. When a metal or steel part is machined, the surface becomes fragmented and also annealed if a heat generating grinding process is used. This type of surface will not support high bearing loads. Microfinishing is the process that removes the fragmented and annealed surface, leaving base metal for greater bearing loads.

Meeting Advanced Specifications of State-of-the-Art Crankshafts Crankshaft is the heart of an engine. This mission critical component transmits power from the combustion chamber to the powertrain. Specifications on a Crankshaft have undergone major advances globally in the past few years. While Friction Reduction has demanded finer and finer finishes, Lightweighting (and the resulting downscaling of engines to 2 and 3 cylinder engines instead of 4 cylinder engines) has led to more bearing loads on the crankshafts features. At the same time, user experience demands higher speeds, longer Engine Life and Lowest NVH (Noise, Vibration and Heat) have all led to tighter and tighter expectations from the

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crankshaft.

Reducing Friction requires the following features on the crankshaft : 1. Surface Finish Ra values to be lesser than typically Ra 0.1 microns on Main and Pin Journals, Finish Ra values to be lesser than typically Ra 0.15 microns on Thrust Walls, Tighter Oil Seal Finish requirements required to use thinner oils. 2. Bearing Area Htp requirements on all journals 3. Tighter geometrical tolerances including roundness, straightness, cylindricity. New specifications on profiles, crowning, lobing. 4. Consistent Stock Removal – Maintaining Size tolerances.

along with improvements in other specifications.

Bearing ratio is illustrated in the figure below : Microfinishing with Level II process with optimization for various process parameters led to achieving remarkable results with consistency as indicated below :

Bearing Ratio Most modern Automotive Crankshafts are microfinished using multiple Level processes, such as Level II or Level III Microfinish. Some of the case studies below will illustrate the results achieved on such crankshafts.

5-20% Htp : 0.15 microns Depth 5-80% Htp : 0.25 microns Depth 5-90% Htp : 0.35 microns Depth Surface Finish : Ra 0.1 microns

Case Study : Achieving Parameters on Automotive Crankshafts for Passenger Car Qualifying higher energy efficiency and emission norms had generated stringent requirement on journal surface so that engine NVH performance could improve. Tribology experts and engine designers came to a conclusion that to achieve the stringent requirements the bearing ratio parameters needed major enhancements,

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Figure 1 Superfinishing technology with contact roller for line contact

The above parameters were achieved with a consistency indicated by statistical process control parameters Cp (achieved Cp > 2.0 and Cpk > 1.67) Besides Finish, the corrections in geometry such as roundness correction by 50% below 3 microns, cylindricity controlled within 3 microns also indicate the process capability of Microfinishing. In one specific realization for Passenger Car Crankshafts, a special Size Control Feature with Online Gauging was deployed on a machine to achieve Diameter Tolerance ±3 µm with PP 2.19 and PPK 2.16.

Case Study : Microfinishing Replaces Stone Finishing Technology for Camshafts Stone Finishing is a traditional technology for finishing of shaft like components, including camshafts. Microfinishing with Film backed abrasives gives several advantages over stone such as consistency of results, lesser maintenance and adjustments, lower energy consumption etc. Due to the above reasons, Microfinishing has replaced conventional Stone lapping in majority of shaft type components. In one particular instance, a global leader in engine

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Transform the performance of your current CMM

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TECH TRENDS technology used combination of stone and film to achieve very stringent surface finish specifications, in plants including American facility. The earlier 3 level finish process was replaced with a 2 level process using film alone. The Surface finish achieved as below Ra < 0.067 microns with Cpm > 1.67 Rtm < 0.412 Wt < 0.45 Wc < 0.12 The resulting consistency and lowenergy operation as well as lower cycle time truly delighted the customer.

Notes : Microfinishing Automotive Transmission Components Automotive Transmission Components such as Geared Shafts (Input shaft, Output Shaft, Main Shaft) and Synchrocones, Differential Housings etc. were traditionally having only surface finish specifications such as Ra values. While not as critical as Engine Components, specifications on Transmission parts have also been upgrading over the years, necessitating the use of microfinishing technology instead of superfinishing. Apart from Ra values, many components are now specified with Rk, Tp, Rmr and Lead angle specifications. Geometry specifications such as roundness, cylindricity and size are also being

Figure 2 Microfinishing with Shoes for Surface Contact

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tightened on such components. Microfinishing is distinguished from Superfinishing in the type of contact between the abrasive film and component as illustrated by the figures below. Microfinishing gives better consistency in surface finish, bearing ratios much quicker than superfinishing. Geometry correction is not possible with Superfinishing, whereas it is guaranteed in Microfinishing. Several successful projects including Microfinishing for Balancer Shafts, Differential Gear Housing, Main Shaft, etc. illustrate the benefits.

Conclusion – Milestones in Microfinishing Microfinishing is a Key Process Technology in Automotive Powertrain for achieving engine performance in terms of energy efficiency and emissions. Capability to achieve superior finishes enables reduced friction in the powertrain and low NVH. In future specifications on finish for components such as Crankshafts, Camshafts and various powertrain parts are likely to get more and more stringent. Advances in Microfinishing Technology enable achieving these parameters with consistency.

Grind Master NANOFINISH Microfinishing Machines

Grind Master NANOFINISH range of machines includes Microfinishing and Superfinishing Machines. A wide variety of Microfinishing machines covers the full range of crankshafts and camshafts, from 200mm to 3500mm. The Machines are based on a modular design concept, and can be optimized for specific applications with configurable stations including no. of arms, Arm positioning mechanisms and Automation Systems, Peripheral Systems. Optional additions include Deburring Units. The Machines are controlled with an Engineered Software – NANOFINISH Control System – built for finishing machines. The state-of-the-art range of machines NF Series are packed with several features that make them a market winner. Optimized Cycle times, Quick Setup Change, Quick Tooling Change Ease of Maintenance are some of these. Together with the Process Know-how gathered over microfinishing more than 20 million Engine Components, Grind Master provides complete Microfinishing Solution. With Over 150 machines worldwide, 5 Registered Designs and 4 Technology Patents (Pending) for Microfinishing series, Grind Master is a leader in Microfinishing Technology.

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Solitaire No. 2 - 10" (250 mm) Precision Centerless Grinder

INDIAN ENTERPRISE

AMERICAN RIGIDITY

ITALIAN INNOVATION

Combined to give you Customized Centerless Grinders Solitaire Machine Tools Ltd. 292, Dharamsinh Desai Marg, Chhani Road, Vadodara - 390002, Gujarat, India Tel.: +91-265-2761776, +91-265-2773585 Email: sales@smtgrinders.com www.smtgrinders.com

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Mastercam® X9 for SOLIDWORKS® Brings Speed, Efficiency,& Automation

astercam X9 for SOLIDWORKS is a CAM application that is fully integrated into Dassault Systèmes’ SOLIDWORKS. The latest release features Dynamic Motion technology improvements, 3D Milling Enhancements, Multiaxis Improvements, and much more. And, Mastercam for SOLIDWORKS Lathe, Mill, or Multiaxis is included with your purchase of the comparable standalone Mastercam X9 product. Says Suchit Jain, Vice President, Strategy and Business Development, SOLIDWORKS, “Mastercam for SOLIDWORKS combines one of the world’s leading modeling software with the world’s most widely used CAM software so you can program parts directly in SOLIDWORKS, using Mastercam’s toolpaths and machining strategies.”

Dynamic Motion Technology Dynamic Motion toolpaths follow a proprietary and sophisticated set of rules that take into consideration a broad data set. To create the most efficient cutting motion possible, Dynamic toolpaths calculate not only the area where material will be removed; they also take into account the changing condition of the material throughout various stages of machining. With Mastercam for SOLIDWORKS X9, 2D HST Dynamic Mill, Peel Mill, and 3D Dynamic OptiRough support a Conventional feed rate when you are set to a Zigzag cutting method.

3D Milling Enhancements 3D HST roughing has been consolidated from six toolpaths down to two toolpaths – Dynamic OptiRough and Area Roughing. The efficiency of Rest roughing linking heights for 3D HST toolpaths has been greatly improved. 3D HST Waterline toolpaths now include an option to machine your part from bottom to top. And, Hybrid flat area processing is now available. You can choose to include the flat areas of your part in the toolpath, ignore the flat areas, or only machine the flats.

Multiaxis Improvements Now available for Port Expert, Minimize tilting creates the most efficient toolpath possible through a port. Multiaxis toolpaths are displayed as normal tool motion instead of vectors in the graphics window. All Advanced Multiaxis toolpaths, such as Port Expert and Blade Expert, are now processed through the Multi-Threading Manager,

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leaving users free to work while processing. And, the new Multiaxis Link toolpath allows users to link multiple toolpaths together to create a safe linking move between them.

Also available in Mastercam X9 for SOLIDWORKS: • Option to project the selected items to the Toolplane has been added to the Chain Manager for 2D Toolpaths and for 3D Toolpath Containments. When SOLIDWORKS Solid Bodies, Faces, Features, or Surfaces are selected, a silhouette of the selected items will automatically be generated. • Multiple Mastercam Simulator improvements such as the new Adaptive Quality tool, motion controller support, and more. • Lathe C-Axis operations, as well as Lathe Misc Op operations, are now available. • Ability to insert, delete, or otherwise rearrange holder segments using the right-mouse context menu. • Barrel tool support, as well as Thread Mill support, has been added.

About Mastercam Developed by CNC Software, Inc., Mastercam is Windows®-based CAD/CAM software for 2- through 5-axis routing, milling and turning, 2- and 4-axis wire EDM, 2D and 3D design, surface and solid modeling, and Swiss machining. Privately owned and founded in 1983, CNC Software provides CAD/CAM solutions to more than 211,000 installations in 75 countries in industries including moldmaking, prototyping, automotive, medical, aerospace, consumer products, and much more.

For more information, Web: www.mastercam.com

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PICO generators from eldec: Mobile induction heating with maximum efficiency & precision

Mr Andreas Zieger, Director, EMAG INDIA Pvt. Ltd

ontactless, fast, accurate, and precision-controlled: These are the essential advantages of induction heating. The technology can be used whenever workpieces or components are heated to a pre-determined temperature for further processing. The areas of application for induction heating are diverse, ranging from the automotive and machinery industries to power generation and electrical equipment. The experts at the eldec, an EMAG subsidiary based in Dornstetten, Germany, have a precise understanding of this wide array of applications. For over 30 years, eldec has been developing sturdy, high-quality energy sources for inductive heating. With the new PICO series, these specialists now offer their customers an extremely compact and cost-effective device with a very broad range of performance capabilities. It is extremely easy to handle a crucial factor for portable use. “Reduce to the max” was the slogan of an automobile manufacturer some years ago. The same could be said for the PICO series. This compact device is perfect for portable use andwas designed using the German

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company’s proven technology. The configuration of the machines central elements have been simplified to just the essentials resulting in not only lower construction costs and but also a lower price to the customer. “Our goal was to develop a standardized and cost-effective energy source that covered virtually all known areas of application. PICO is very simple and extremely easy to operate, yet the generator is still able to meet any demand. Ultimately, all you need to do is unpack it, plug it in, and start heating,” said Stefan Tzschupke, Head of Business Development Generators at eldec.

PICO series is also used for standard tasks such as induction brazing. Companies that install system integrators will likely find the PICO series to be a highly affordable way of integrating precision heating functions.

Turnover expected to grow Very diverse areas of application The selection that the eldec experts offer their customers with PICO is very broad. The generator comes inthree sizes: PICO-S, PICO-M, and PICO-L. These can be configured as mid-frequency or highfrequency generators from 5 to 150 kW, depending on the model. They are equipped with a specially designed eldec control unit, proven inverter technology, and an intuitive operating interface. Where and how are these devices primarily used? “Due to the extensive basic configuration, they have a very broad range of application. Even customers who need a portable generator for use on a construction site turn to the compact PICO range,” Tzschupke noted. The device is used for example during inspection at power plants, to heat the tensioned bolts on turbine casings. Another typical application is the heating of components and parts for subsequent joining processes— for example rotor caps, crankcases, or automotive powerplant components. The

The smaller PICO-S model has been on the market since the beginning of 2015. The larger M and L models followed at the start of this year. They are produced primarily from pre-assembled components, so customers can expect delivery of their device within a few weeks of ordering. With an expected turnover of up to 100 devices per year, the series occupies an important position in the company’s overall planning. Why is the market outlook for PICO so good? “PICO is a cost-effective, standardized series covering a wide range of applications. It essentially has no limitations,” explained Tzschupke. “The customers also benefit from short delivery times when making their investment decision. In light of that, we see major sales opportunities in the growing Asian markets, for example, where full functionality, high product quality, and low cost play a vital role.” For more information editor@divyamediaonline.com

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Hitting a hole in one across town? Imagine standing on the golf course teeing off, and playing well. The ball flies and flies—and lands in the hole. A classic hole in one! Now imagine that the hole were about 17 kilometers away on the other side of town. And you tee off countless times and score a hole in one each time. Hard to imagine? For any golfer in this world, yes. But not for the LC sealed absolute linear encoders from HEIDENHAIN! Positioning over a one meter path of traverse to an accuracy of ± 3 µm—at 17 km that’s half the diameter of the hole. Reliability, flexibility, resilience and its high integration density of electronic components make the LC the unbeatable champion on any course. HEIDENHAIN OPTICS & ELECTRONICS INDIA PRIVATE LIMITED Citilights Corporate Centre, #1, Vivekananda Road, Off Spurtank Road, Chetpet, Chennai 600031, India Phone: +91 44 3023 4000, Web: www.heidenhain.in Email: sales@heidenhain.in; service@heidenhain.in angle encoders

linear encoders

contouring controls

digital readouts

length gauges

rotary encoders

Absolute linear encoders LC

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La Joliverie Haas Technical Education Centre : The realtime experience

here can’t be many Haas Technical Education Centres (HTECs) in the world that are as well-built, well-equipped and well-staffed as the one at La Joliverie Technical College, in Nantes, France. All HTECs are created to the exacting standards laid down in the Haas programme, but even so, most are relatively modest additions to a school or college, perhaps with two or three Haas machines and perhaps a computer room, for a few CADCAM seats. At La Joliverie, there are ten Haas machines, supplied by regional Haas Factory Outlet (HFO) Realmeca, including an EC400 horizontal machining centre

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and an ST-30Y turning centre, with Y-axis and powered tools. There are also two Fanuc robots, several coordinate measuring machines, a couple of tool pre-setters and two multi-station, air-conditioned IT rooms dedicated separately to CADCAM and CAE. There’s also a good selection of student projects on display – go-karts, wind yachts and other wheeled transport, including the school’s world beating, hyper-mileage car.

Thierry Journaud is assistant director of professional and technical training at the school: “We run two teaching programmes here - a machining technician vocational baccalaureat, and a BTS, i.e. post baccalaureat, qualification in the industrialization of mechanical products. So it’s very important for our students to work with CNC. We’ve had Haas machines for around ten years now. We chose Haas because the machines are operator friendly, and in widespread use in industry in the Nantes region. This means that, after studying here, students go on to be employed in businesses in the region, with companies including large corporations like Airbus, or subcontractors working for Airbus, as well as small local businesses” In a building 50-meters from the HTEC is an entire department dedicated to the school’s long-term passion and preoccupation: the sleek, award-winning MicroJoule hyper-mileage ‘car’ that has been in continuous development by staff

and students for thirty years. Since the very beginning, across many generations, the project has been led and inspired by La Joliverie’s hyper-mileage guru:

Philippe Maindru: “I teach BTS qualifications in internal combustion engines. I am an automotive engineer, and since 1985 I have been an energy competitor. It’s all about building a car, which goes at 30km/h, and is designed to use as little energy as possible. Our first competition was in 1985 when we took part in the Shell Eco-marathon. In 1992 we were global winners. Since then we have successfully defended our title, and we even broke the world records for petrol, natural gas, ethanol, electricity and hydrogen powered vehicles. To put a number on it, Microjoule is able to travel 3761 km on one litre of petrol. How do we build our cars? Well, we need

(many) parts, which come from our CNC workshop – the HTEC. The design stage for the parts is done with computers, following which our team transfers the digital plans and makes the parts on the Haas machine tools. Students doing national vocational qualifications do the simpler parts, whilst vocational baccalauréat students produce more complicated ones. For the most sophisticated parts, we use the apprenticeship groups. We are delighted by the quality of the parts (made on the Haas CNC machines), which always turn out exactly how we imagined them.”

Thierry Journaud: “We will continue to build on the ten years of experience we have had (so far) with the Haas machine, because they meet our requirements perfectly. The single most important reason why we use Haas machines here is that the Haas computer numerically controlled system is widespread, operator friendly and easy to use, which is exactly what we need to teach with, and corresponds to industry practices. Also, the Haas CNC is compatible with the professional software packages we use, so by the time students leave La Joliverie with their Haas training, they can fit into the industry workplace and, critically, they can use the Haas machines they will find there.”

For more information Web: www.HaasCNC.COM

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Flying success with Dunlop Aerospace Braking Systems - A Renishaw way

Executive jet with Dunlop wheels and brakes

Dunlop Aerospace Braking Systems, a part of Meggitt plc, is a global organisation that designs, develops and manufactures wheels and brakes for commercial and military aircraft applications. Aircraft production in the UK has experienced steady growth and to meet this demand the hub and flange cell at Dunlop Aerospace purchased 3 key CNC machines between 1998 and 2000, at that time actively specifying Renishaw probe systems. This has increased process consistency and has also had a marked effect on the manufacturing time. Dramatic reductions

Spindle-mounted touch probe setting the machine coordinate system relative to existing machined features, ensuring machining starts in the right place every time

Andrew Cartledge, team leader of the hub and flange cell, speaks positively about the decision to employ Renishaw probing systems, “We’ve seen improvement both in machining cycle times and the overall set times every time we’ve introduced a component to the cell. This is critical to our New Product Introduction process (NPI) which we use every time a new wheel is introduced, essentially allowing us to ‘design for manufacture’.”

Runners, repeaters and one-offs Orders for wheels fall into three different

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categories according to the number of batches made each year. The ‘runner’ orders are classed as those wheels produced in more than 10 batches a year; ‘repeaters’ are less than 10 batches a year. Dunlop Aerospace also supply one-off orders and recently succeeded in a very impressive project to remanufacture components for the 1950s Canberra. This involved taking original drawings and reprogramming the machining through the modern CNC process. Mr Cartledge continues, “NPI involves a process we call Manufacturing Process Approval (MPA) whereby any machining

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» MACHINE TOOLS

Turret-mounted probe on Mazak Integrex setting the coordinate system by finding the position of a pre-drilled hole process must be closely analysed to see if it affects the stresses and component strengths of a wheel assembly. All the main ‘runners’ and any ‘repeaters’ that are introduced to the new cell need MPA before production can start.” Investment in technology and automation Between 1998 and 2000 Dunlop Aerospace chose to spend nearly £2 million on three state of the art multi-axis CNC machines; a multi-axis Mazak Integrex - a turning centre with full C-axis and driven tooling to give milling capability; a Mazak HV800 5-axis horizontal machine centre; and the most recent investment, a Mori-Seiki MT4000,

Wheels for a long distance executive jet

at the time the first of its type in the UK.

The importance of one hit machining

Probe systems make all the difference

During the cutting process stresses are relieved in the material, so one hit machining results in the cutting process achieving greater consistency. L77 aluminium is the most commonly used material and, with the high cost of each process, it is essential that Dunlop Aerospace keep scrap levels low. In-process monitoring and tool offset updating ensures process control and minimises scrap. The nature of the aviation industry demands ever-increasing accuracy and quality, ensuring both wheels and brakes can be reliable in all conditions and scenarios. Mr Cartledge sums up the changes to the process neatly - “We have now used probing systems on this cell for over 6 years and have cut costs and times, with a step change in process control and consistency.”

The underlying technique made possible by the integration of the probe systems is the ability to identify the component position and material condition, updating and monitoring the deviation in the wheel forgings. This reduces cutting time, as it eliminates fresh-air cuts - this is because the probe ensures that the critical surfaces of forgings are accurately located and metal cutting starts immediately.

Turboprop passenger plane with wheels and brakes supplied by Dunlop Aerospace

For more information www.renishaw.com/MTP

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FACE TO FACE

Mr. Rajesh Parsramka, Director-SBS Precision Systems (India) Pvt Ltd B.E. Electronics & Communications Engineering B.I.T. Mesra Post Graduate Diploma In Business Management I.I.M. Calcutta

Q. SBS Precision being in the industry for longtime & has gained bounteous market share in Indian machine tool industry, please brief SBS Precision’s journey from the beginning & share some its achievements? From a few handful customers a decade ago to hundreds of satisfied customers all over India today the journey has been full of challenges and success stories. We are now an important player in Dynamic Balancing & Process control business in India.

Q. What are the market prospects for the SBS Precision products in India and How do you plan to position these products? Unlike our competition SBS is highly focused and specializes in providing solutions for complex applications for dynamic balancing and process control with the widest range of products available to meet customer’s technical specifications as well as budget constraints

Q. Please elucidate in brief about the SBS Precision infrastructure & What are the measure that are www.engrreview.com

SBS Precision : The dynamic balancing & process control expert

being taken from the product manufacturing to distribution?

Q. What is your vision for SBS Precision?

SBS Precision sees India as one market instead of breaking it up into regions like East, West, North…….our quick and effective customer support is biggest strength. We provide single window solutions to all customers for any issue instead of creating separate departments for sales, service, administration etc.

To continue to be the best choice for customers for dynamic balancing and process control equipment and always try to improve our services through innovation and hard work

Q. What are the key technological trends that are driving machine tool industry? Manufacturing tolerances are becoming tighter with every passing day, product life cycles are becoming smaller, Manufacturing process have become highly flexible to adapt to any sudden changes in the business environment. All this provides high incentive to manufacturers to go for dynamic balancing and process control equipment.

Q. Please address the issues that are affecting the machine tool industry? Scarcity of working capital has been a serious concern with machine Tool OEM’s coupled with very high uncertainty about deliveries creating a long chain of blocked & un productive working capital. Lack of trained professionals in machine Tools industry is another big issue.The next generation of professionals are not yet ready to take over from the present generation who have rich knowledge and experience.

Q. How do your perceive the future of the Indian machine tool industry? Future is very bright and there are immense opportunities for growth

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The world’s largest independent producer of alternators 1 – 5,000kVA

www.meccalte.com

Mecc Alte India PVT LTD, Plot No. 1, Talegaon Dhamdhere, S.O., Tal. Shirur, Dist. Pune – 412208, Maharashtra, India T: +91 2137 619600

F: +91 2137 619699

E: info@meccalte.in

INDUSTRY SPEAK » POWER

We need to revamp our transmission & distribution systems for improving efficiency & strengthening the grid

Sameer Gupta, Chairman & MD, The Jakson Group.

Q. Is everything hunky-dory with the Power sector? While installed capacity has increased, power generation in real terms has come down. The peak demand shortage has come down to close to 2.5% which is lowest in perhaps a decade. The demand itself has been lower due to slow down in industrial demand and sluggish economic growth. The per capita consumption of power in India is at around 1000 units which is quite low and this is bound to go up in the coming years. We need to add to our installed capacities to meet the forecasted demand. Its not only power generation, there is urgent need to revamp our transmission & distribution systems with the objective of improving efficiency and strengthening the grid.

Q. Is the nation making concerted efforts, tapping all avenues,

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MAY 2016

to bridge the gap between demand and supply to fuel the all-round economic growth? The nation is evidently making an effort to tap all avenues. As per 12th five year plan, there is a road-map to add 118 GW of installed capacity. Currently around 72% of power produced is from non renewable fuel and only 28% is from renewable power. There is right emphasis on renewal power, particularly solar power and the Govt has clear plans of flipping this ratio which can make contribution of renewable power to be as high as 40% within the next 7 years.

Q. What is your contribution to the power sector? Jakson has been adding close to 750 MW of back-up diesel power year after year. We have been able to contribute towards Solar power mission of the Country significantly. We have Solar IPPs of 60 MW which we will raise to 200 MW shortly. As a Solar EPC company we have been working closely with NTPC, SECI, etc and by the end of 2016, we would have

executed projects of around 500 MW of Solar power in the Country. We manufacture Solar Panels at our state-of-the-art plant at Greater Noida which currently has a capacity of 75 MW a year and we intent to quadruplicate the capacity over next couple of years. Over next 5 years would have successfully executed Solar EPC projects of 2000 MWs.

Q. What are the prospects of the electrical industry whose fortunes are hinged to investments in the power sector? Electrical Industry has positive prospects over next decade. Installed capacity would cross 350 GW by 2022. This will increase demand of electrical machinery and generation equipment. We estimate electrical industry to grow at 20% CAGR over the next decade. There will be growth in demand due to industrialisation and economic development. Huge investments are expected due to increase in installed capacity and the policy environment is conducive. These will be drivers to growth.

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PROFILE

Nucleus Marketing : Success through Innovation

ucleus Marketing was established in 2003 with sole aim to provide vital links to products and customers. Established on lines of product promotion, concept selling the company was formed by individuals from different spheres of activity specialized in their respective field. Today we tend to provide our service and share our expertise to manufacturer, to offload their marketing and establish products in this vibrant and competitive market.

Mission: At Nucleus it is our endeavour to have perfect and cordial relationship with all the concerned elements to build a perfect and profitable business. The process of identification of the segment of the market, segment, dealers and distributors play a large role in establishing a welldefined and long term business. We stand by our philosophy, guidance and ground level to have one to one relationship with all concerned so as to make things happen. Marketing Solutions We have decades of experience supporting and helping to guide clients’ decisionmaking during this crucial phase of a product’s lifespan. • Help you create a strong business plan that clearly lays out your strategy for business • Advise on the commercial risks faced by your company • A comprehensive profile of selected markets • Specific target audiences and titles that offer the strongest potential for success • Market size and revenue potential based on both existing customers and targeted prospects • Market needs within the framework of the offering. The primary objective at product launch is to build product awareness and trial usage among early adopters and rapid followers. Emphasis is placed on building effective

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MAY 2016

distribution channels, and generating momentum with regard to positive hearsay about and experience with a new product. Thus, communications effectiveness and early-stage product trial are key concerns to clients in this phase, and we are often called upon for guidance in design and execution of research to address: Awareness and impressions of the product among early adopters and other influencers, require attention for moving forward.

products. Focused Mr. A N Arun, on Founding Partner & Manager Automation, from Home to Industries, Hotels to Resorts, from remote corner to Board rooms, controlling machines to Dispensing Liquids we offer products, technology and solutions partnering with ASA & LCN from Germany.

Product Marketing,

LCN Issendorf Germany - The LCN system

In Indian context of Low Voltage Switchboard module, Aluminium bus bars are being used extensively. Most of the bus bar supports manufactured from Europe are suitable for 3runs copper to accommodate current of 7500A. In this context a new bus bar support with the technology of FRP has been developed to accommodate bar supports which is exclusive in design and can accommodate Aluminium bars of 10mm and 5mm thickness in supporting the strength of panels which are tested up to 65Ka breaking capacity. The product design is universal in mounting and has provision to run 1, 2, 3 and 4 run aluminium for current amperage of 7500A. Process also has been set to work on Low Voltage Standoff Insulators which are universal in design and mounting and can reduce the component structure for accommodating various metric designs. More important of our application has been in the sector of Explosion corrosive, and underground atmosphere where creativity and application are critical. We are now focusing on these area of engineering to bring in more compatible design and Industrial Automation Control Switches-ASA Schalttechnik GmbH Germany. Limit Switches

Medical Switching Devices

Switchgear

Magnetic Switches

Foot Switches

Level Switches

Safety Switches

Special Switching Devices

LCN is a modular Bus system for any type of building. LCN distinguishes itself through its high powered transmission, outstanding reliability and extensive range of functions. Despite its High End, Properties, LCN offers cheap concept and amazingly simple installation. With the Local area network, practically all the functions of building can be automated, the extendible building block principle of the LCN system makes it possible to link manual commands with automatic functions, this not allows the property to be controlled and regulated across the trades but the user can additionally be offered a package for their own individual comfort. A further significant reason for deploying LCN are its considerable energy saving properties through the efficient operating of building.

Our Success Story • Erico-France: Eriflex range of Products for Flexi bar and Low Voltage components in Indian context. • Rao Engineers: Established Flexible components for Indian market specialised for Wind Energy panel board applications. • Termate-UK: for bus bar supports across India. • Pneucon Precision products for Press welded shunts and other copper components across India. For more information Email: - marketing@nucleusconsultants.com

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COMPANY PROFILE

Braco Electricals: Secure Connections Braco Electricals (India) Pvt. Ltd. Was established in 1977 by visionary electrical engineer Mr. Ramesh Sobhani. It was his vision that has today shaped into a company that is renowned for its quality, consistency and trust. All these elementsare found in every Braco product and the company shares its vision for the future in a brief rendezvous.

able glands and terminal play a key role in any secured electrical grid, are extensively used in control panels, switchgear, transformers, circuit breakers and other applicationsin the field of power supply and distribution. A product of superior raw materials and stringent quality cheeks, Braco cable glands and terminals provised hassle-free solutions for a safe network in any premises.

New Projects : “Our upcoming projects are an opportunity for us to shape the future for our company and for the industry. All our upcoming projects are based on company’s nucleus philosophy” informs Mr. Sobhani. Automation is the most crucial factor in this vision. To be in sync with the future has always been a priority at Braco. “Hence we are looking forward on manufacturing all our terminal products on completely automatic machines. Also, We aim to add impressive figures to our balance sheets by adding new products for connecting purpose, into our profile,” he adds. This expanding vision will be supported by the growing number of Braco branch offices in the metro cities of India. Starting from the metros of India, the company will strive to reach every patron in the industry and serve them with the best. The immediate upcoming project that the promoters are most excited about is

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MAY 2016

Mr. Ramesh Sobhani, Technical Director (left) & Mr. Sunil Giasotta, CEO (right) Braco Electricals (India) Pvt. Ltd. launching of all types of Aluminum Glands for domestic as well as international market. While it is the clear focus that has made all its achievements possible for Braco, today the company is focused on three areas, viz., steady growth, standardization and trust. It has been registering consistent growth from last few decades. “This legacy will continue and will be our focus area in every future planning. To complement this growth story, we aim to meet international standards of electrical industry, across the globe. This standardization of products is a step towards earning the trust of the clients and the industry alike,” says Mr. Sobhani.

Expansion Plan : Owing to its success and illustrious journey, Braco is in its full vigour to deliver exceptional results. The expansion plans encompass various factors like automatic manufacturing of products and nationwide presence. Braco will be seen in almost every metro city of India in the near future. The futuristic growth of the company is also on the radar. Manufacturing of products and equipments will be done with help of latest

technology. “We have completed three decades of trust and quality and the vision of Braco is to provide products, services and solutions that will transform the way electric power utilities manage and distribute electricity,” says Mr. Sunil Giasotta, CEO, Braco Electricals. “We have been manufacturing cable glands and terminal products for the electrical industry. We will be expanding the existing segment by adding new products to it, the products that will serve the industry and will be produced by the use of latest technology and also launched our new Metal Division providing solutions in non-ferrous metals,” Mr. Sobhani adds.

Future Challenges : The IT boom has created new challenges for many industries. The electrical industry is no exception to it. The demand for electrical supply and its products has grown beyond imagination. Hence, meeting these demands is the biggest challenge for every player in the industry. While meeting the demands of the client, quality becomes the most fragile factor. Quality maintenance is never compromised by Braco, and therefore, delivering quality products at competitive prices becomes a major challenge to overcome. Yet, the company has successfully manages to create a balance between these extreme factors. Speaking about the company’s plan over the next five years, Mr. Sobhani elaborates that it is to increase sales fourfold with the expansion of the factory infrastructure & totally automate production on the modern machinery. “We plan to raise our export revenue up to 50% of our current turnover through advertising and marketing of our product profile, to all the electrical markets around the world,” he concludes. For more information Website : www.braco.in

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PROFILE

Committed towards a better tomorrow

(L-to-R) Mr. Gautam Seth, JMD Mr. Lalit Seth, CMD, & Mr. Rishi Seth, JMD, HPL Electric & Power Ltd.

s per DRHP, HPL Electric & Power Ltd is an established electric equipment manufacturing company in India, manufacturing a diverse portfolio of electric equipment, including, metering solutions, switchgears, lighting equipment and wires and cables, catering to consumer and institutional customers in the electrical equipment industry. We have the largest market share in the market for electricity energy meters in India in fiscal 2015, with one of the widest portfolios of meters in India and the fifth largest market share for LED lamps during the corresponding period (Source: Frost & Sullivan Report). Our manufacturing capabilities are supported by a large sales and distribution network with a pan-India presence. We currently manufacture and sell our products under the umbrella brand ‘HPL’, which has been registered in India since 1975. DRHP states, we supply our products through a network of authorized dealers or distributors to institutional, non-institutional and corporate customers. We supply switchgears, lighting equipment and wires and cables, primarily through our pan-India authorized dealer network, which comprised of over 2,000 authorized dealers or distributors as on December 31, 2015, from our warehouses located in 21 states and union territories in India that are managed by our carrying and forwarding agents. Our authorized dealers or distributors further sell our products to over 12,000 retailers in

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MAY 2016

India. In addition, we supply our products to Power Utilities, which primarily includes supply of metersunder direct contractual arrangements to electricity boards and power distribution companies, as well as through project contractors. Further, we supply our portfolio of products to developers of residential and commercial building projects, original equipment manufacturers (“OEMs”) and to industrial customers through a mix of direct sales and supply through our authorized dealer network. Our sales and marketing activities are managed through over 90 branch offices and representative offices in India as on December 31, 2015. Further DRHP states, we believe that our research and development capabilities have enabled us to keep abreast of technological developments in the electric equipment industry. We have a strong focus on consistently upgrading the technology that is used in our products and the processes used in manufacturing thereof, through our continuing research and development efforts. We have established two in-house research and development centres, one each at Kundli (Haryana) (the “Kundli R&D Centre”) and Gurgaon (Haryana) (the “Gurgaon R&D Centre”, and together with Kundli R&D Centre, the “R&D Centres”). Our research and development efforts include design and development of all types of energy metering solutions, including interactive communication between metering devices and metering

infrastructure that includes automatic meter reading (“AMR”) and advanced metering infrastructure (“AMI”), prepayment metering solutions, solar net metering solutions, smart meters with two way communication and a complete range DLMS compliant meters, amongst others, and technologies and solutions that allow for active monitoring of energy consumption for electric equipment. For instance, we have developed a street lighting system that helps in saving manpower through automatic settings for sunset and sunrise timings and remote energy metering and dimming of such lights during off-peak hours to save energy. For details in relation to our research and development efforts, see “- Research and Development” below. We also operate two tool rooms at Gurgaon (Haryana) and Kundli (Haryana), within our R&D Centres (“Tool Rooms”), where we have in-house component designing & tool designing facilities. As on December 31, 2015. DRHP states that we have employed over 105 engineers at our R&D Centres, with a dedicated team of engineers to manage our Tool Rooms. Our Tool Rooms are used for making rapid prototypes, followed by tools that are used to ensure efficient moulding. The data for our Tool Rooms is generated using computer-aided design (“CAD”) software and computer numerical control (“CNC”) machines that assist in maintaining accuracy of the tools produced therein. We believe that our Tool Rooms allow us to easily adapt to changes in technology or modified specifications given by Power Utilities and/or institutional customers. As per our DRHP, we currently own and operate six manufacturing facilities

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PROFILE located across the states of Haryana and Himachal Pradesh, having in-house testing capabilities. All our manufacturing facilities have been accredited with management system certificates for compliance with ISO 9001 requirements. Further, certain of our products are 51 also certified to be compliant with various national and international quality standards, including the ISI mark issued by the BIS, the CE mark and KEMA certification for conformity with requisite European quality standards.

Our Strengths We believe that our competitive strengths include the following: • Established brand in the electric equipment industry • Large product portfolio • Robust manufacturing facilities with a focus on technology upgradation • Pan-India sales and distribution network • Established relationship with institutional customers and strong prequalification credentials • Experienced management team and skilled workforce

Our Strategies The key components of our competitive and growth strategy are as follow: • Expand our product range with focus on value added products • Expand our business and capture growth opportunities • Increase our geographical reach and expansion of addressable market • Strengthen customer base with focus on increasing customer spend on our products • Continue to enhance our brand through innovative and focused marketing initiatives • To focus on newer technologies & innovative product developments

Overview of the power sector in India The Indian Power sector has witnessed a considerable change and evolution in the last two decades owing to several policy and regulatory measures. Further, continuous growth in population and increasing urbanization and 42 industrialization have constantly added to the electricity demand

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• • • • • •

in India, with 300 million of existing population yet to receive electricity connections and the remaining one billion populations having intermittent access to electricity. Programmes such as rural electrification and ‘Power for All’ have been accelerating power generation capacities and further, helping in building effective systems for demand-side management to ensure overall efficiency improvements across generation, transmission and distribution. In September 2015, the total installed capacity for power generation in India was 278,734 MW, of which the states contributed 96,455 MW or 34.6%, and the central government and the private sector contributed 74,171 MW 26.6% and 108,108 MW or 38.8%, respectively. Demand for power in India India’s energy demand is expected to grow by 132% by 2035 and is likely to surpass China in the energy demand growth and double the aggregate demand of non-OECD countries. The primary growth drivers for rapid expansion in India’s energy demand include growth in population, rising per capita energy consumption levels and investments in industrial and infrastructure development. Supply of power in India The country’s installed capacity has been growing and almost doubled during the past decade and tripled between 1991 and 2012, boosted by the substantial contribution from the private sector. During fiscal 2015, 22,566 MW of generation capacity was added to the existing installed capacity and is expected to scale up to 266 GW by the end of fiscal 2017 and further increase to 366 GW and 516 GW by fiscal 2022 and fiscal 2027, respectively. Towards this objective, the Government of India has taken various initiatives, brief details of which are set forth below.

• • • •

Increased focus on renewable energy Smart grid initiatives Rural electrification Financial revival of state distribution companies Promoting public private partnerships in the distribution system However, the power sector in India continues to face several challenges, including: Aggregate technical and commercial losses (“AT&C Losses”) Power theft and pilferage; High dependency on coal as part of India’s fuel mix for power generation; & Political interference and lack of proper corporate governance in Power Utilities

Overview of the Indian power transmission and distribution sector The increased focus on power generation has resulted in relatively lesser investment in the transmission and distribution sector. While India has adequate power generation capacity, there is significant power deficit primarily due to inadequate transmission and distribution infrastructure and high AT&C Losses and power thefts. Several measures are being undertaken to curb these losses, such as investing in new and advanced technologies like 1200, 765 and 400 kV transmission lines, planning new smart grids and establishment of a national grid by Power Grid Corporation of India Limited as of 2014. These steps have further helped efficient and effective use of power by transferring electricity from power surplus areas to power deficit ones. Continuous reforms have been undertaken to reduce AT&C Losses to 15% levels through investments in automation and smart metering. Further, peak power and energy deficit has been decreased significantly over the last few years primarily due to low power demand coupled with

MAY 2016 ENGINEERING REVIEW

PROFILE improved power generation in India. Additionally, the financial restructuring plans of the Government of India announced in September, 2013 are expected to improve the financial condition of the state power distribution companies that have been affected by poor financial health and corporate mismanagement for years.

Overview of the electrical equipment industry The Indian electrical equipment industry is immensely diversified, comprising manufacturing capabilities for high technology equipment on one hand, to low technology electrical components. The electrical equipment industry contributes 9.9% in value to the entire Indian manufacturing sector, translating to 1.4% of India’s GDP. The Indian electrical equipment industry is estimated at grow at a CAGR of 8–12% during 2016– 2020, varying across electrical equipment. Low tension (“LT”) electrical equipment such as switchgears, energy meters and wires and cables are expected to witness a faster growth in comparison to generation equipment. Further, the generation equipment segment is targeted to reach a size of ` 125,000 crore and the transmission and distribution equipment (“T&D Equipment”) segment is targeted to reach a size of ` 375,000 crore by 2022. The Indian electrical equipment industry comprises power generation equipment and T&D Equipment. The power generation equipment includes boilers, turbines and generators, whereas T&D Equipment includes transformers, switchgears, transmission towers, wires and cables, energy meters and other equipment such as capacitors, instrument transformers and surge arrestors. T&D Equipment is further classified into high tension (“HT”)

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MAY 2016

and LT electrical equipment. LV electrical equipment include LV switchgears such as air circuit breakers, moulded case circuit breakers (“MCCB”), changeover switches; LV control gear such as contactors, relays and capacitors; energy meters for household electricity metering purposes, panel meters for industrial metering purposes and utility meters; LT wires and cables used as part of industrial and commercial wiring; building wires and flexible wires used as part of residential wiring; lighting products such as compact fluorescent lamps (“CFL”), LED lamps, incandescent lamps; and residential and commercial protection devices such as miniature circuit breakers (“MCB”) and residual current device.

Key demand drivers for the electrical equipment industry • Establishment of smart cities and real estate growth • Affordable housing • Open markets favouring a competitive landscape • Capacity addition and investments in the power sector • Modernization drives and new technology adoption • Indian Electrical Equipment Industry Mission Plan 2012-2022

Government Initiatives: The Government of India has announced various schemes and plans, including for the establishment of ‘smart cities’ in India in a phased manner and by facilitating growth of the electric equipment industry, including pursuant to the Mission Plan 2012-2022. Based on the ‘smart cities’ initiative, the Government of India aims at revamping the urban infrastructure of India. The Mission Plan 2012-2022 sets the guidelines for

making India the choice for production of electrical equipment. This would drive for domestic production of electrical equipment within the country. The major areas focused on under the Mission Plan 2012-2022 include achieving industry competitiveness, technology up gradation, skill development and promotion of exports. Further, Government of India initiatives such as the ‘Make in India’ campaign, which has plans to create a brand image of India as one of the leading manufacturers of electrical equipment globally, will help the sector to become a key participant in the global industry. Under the ‘Make in India’ policy, 100% FDI through the automatic route has been permitted in construction, operation, and maintenance in specified rail infrastructure projects, which is expected to necessitate demand for LED lamps for domestic consumption. We believe that these initiatives of the Government of India will drive the demand for domestic and industrial electric equipment, including for electric equipment that we manufacture. Further, increasing urbanization in India coupled with rising income levels have resulted in progressively increasing demand for housing, particularly quality housing, across Indian cities. We believe that this growing demand for quality housing will drive demand for quality electric equipment and accessories, including those we manufacture. Any failure in the effective implementation of such plans would significantly and adversely affect our business, financial condition and results of operations. Further, other policies and regulatory changes by the state and central Government and related agencies can also impact our business results of operations. For example, the minimum wages of workers in the state of Haryana has recently been increased significantly. Since a majority of our facilities are located in the state of Haryana, we may incur significant expenses towards payment of wages of workers in our facilities. In 2015, the Government of India mandated BIS certification for LED lamps to be sold in India. While this initiative is expected to give impetus to Indian manufacturers of LED lamps and acts as an entry barrier for cheaper imports, the implementation and effectiveness of this regulatory requirement is presently uncertain.

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Rish Insu 5Dx

A field Insulation Testing instrument

Measurement range up to 10 TΩ Test voltage selectable from 100 to 5kVDC PI, DAR, RAMP mode Internal memory & PC Communication Mains & Rechargeable battery operation CAT IV 600V protection

Rishabh Instruments Pvt. Ltd. Trishala Unit, C-6, NICE Area, MIDC, Satpur, Nashik - 422007, India. Tel.: 0253-2202028/371 | Mail:marketing@rishabh.co.in | Web:rishabh.co.in

TECH TRENDS

Geissel India – German excellence at home Geissel India is an established name in India as a supplier of cable glands and electrical wiring accessories since 1994. The 100% German owned & family run Company since 1920 manufactures goods as per exacting German standards and has created a niche for itself in the Indian electrical market with its International Class Products.

with IP 68 and only three sizes to suit cable dia from 12 – 34 mm. Discerning customers have praised the product for its design, easy application and convenience of only three sizes. Designed and engineered in Germany, but manufactured in India, customers of International repute are finding many advantages in using these glands over others.

The “Geissel” brand of cable glands is well known and accepted worldwide. Products include cable glands in brass, polyamide and stainless steel S.S 303(1.4305) & S.S. 316 TI (1.4571) – according to RoHS standards, in IP 54, IP 68, IP 69K and EMC - upto cable dia of 116 mm with all kinds of threads, i.e. Pg, metric and inch. Other products are plugs, reducers, enlargements, lock nuts, etc. In other words - a wide range of electrical wiring accessories. Some of our “Star” products from the Geissel stable have created an impact in the Indian and International electrical market:

Conduits & Conduit glands: The conduits are available in galvanized steel as well as PVC coating on galvanized steel in grey and black colours. Complementing them are the conduit glands which fit the conduits perfectly. The design and application is simple and customers get a one-stop solution to their needs for conduits and the ease in fitting them.

Double Compression cable glands: The first of its kind in the Indian market

EMC glands. Available in brass with nickel plating in metric as well as Pg threads, these glands are very user-friendly. Customers of international repute have appreciated this simple but effective design.

Multisealing inserts: To fit both brass and polyamide glands, with an assurance of IP 68 protection. IP 69K brass glands: the most recent entry. Geissel’s way to increase the threshold of water ingress at high pressure. PBE: Pressure balance element – to let out excessive moisture from enclosures/ boxes.Detailed technical and pictorial descriptions of all Geissel products are available in their recently upgraded catalogue which can be downloaded from the website www.geissel.com Geissel India’s USP is the availability of mostly all products ex-stock from their factory in Pune. For more information: Email: info@geisselindia.com

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MAY 2016

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TECH TRENDS

Time saving electrical CAD software

AUTOMATION - electrical CAD software PC|SCHEMATIC has been a leading Electrical CAD software developer on the global market for 35 years, specialising in intelligent design and documentation of electrical control systems and PLC diagrams, pneumatics and hydraulic systems. The electrical CAD software PC|SCHEMATIC Automation is designed from the basic concept of setting you free to focus on the electrical aspects, while the program handles the practical side. Beyond the basic drawing functions, Automation offers you a comprehensive series of functions specially designed for electrical projects with IEC/EN standards.

Documentation When you click on a component in the component vendor database, you automatically get a menu containing the electrical symbols for the component. By placing these symbols in the diagrams you also transfer information to the electrical diagram which enables the program to fill out order lists or files automatically.

Integration PC|SCHEMATIC Automation can interface with PLC I/O tools, wire numbering tools, label systems, send files for component ordering systems, edit PLC data via Excel, import and export the standard CAD formats DWG and DXF, and update all types of lists automatically. Furthermore the program supports practically any database format, so that it can work with the database format used in your company.

Our solution saves 80% time

Mr. Ove Larsen, International Sales Director, PC|SCHEMATIC A/s, Denmark

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MAY 2016

To make it possible for existing and new users to get started quickly, PC|SCHEMATIC - and its distributors - offers a consulting service, consisting of an analysis of the already existing electrical documentation. Based on this analysis, the optimal set of subdrawings, models and project templates can be effectively created. This also has the consequence that new users can get started creating complete electrical documentation projects really quickly. In larger companies, this way of

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PC|SCHEMATIC Market Consultant in India: A. Venkatakrishnan / venkat@pcschematic.in / +91 988 654 0077 Dubai: Jojin Mohamed Shaf Mobile:+971 50 843 1129 E-mail: sales.dubai@pcschematic.com Cadilz Systems and Solutions FZC Post Box: 329045 BC-4 Business Park RAK Free Trade Zone,UAE

TECH TRENDS Support: How can I get it?

working might result in that just one single person needs to be pointed out as the main responsible for creating the company subdrawings, while the others in future almost only will need to create documentation by dragging templates and subdrawings into projects. Experiences from the industry suggest that the documentation time can be reduced by up to 80 percent.

Why should I buy PC|SCHEMATIC Automation? People buying PC|SCHEMATIC Automation usually tell us they did it because: • It is easy to work with, and is very flexible in the everyday work routines. • The Module and Model Based drag’n draw functions, makes it possible to create electrical schematic pages extremely fast. • We have an excellent support team, and you can get support via NetViewer. Our support team can then see your screen, and guide you directly on your own PC. • Intelligent reuse of existing material with intelligent renaming - saves lots of time. • The intelligent connection between database and symbols is unique. • Electrical standards are integrated intelligently. • Functions for automatic project generation, automatic graphical plan generation and automatic documentation of symbols in projects/libraries.

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MAY 2016

When you buy PC|SCHEMATIC Automation, you get “Tier 2support” from the PC|SCHEMATIC in India as well from our Head Office Denmark. This can take place using e-mail, telephone or NetViewer (where we can guide you directly on your own PC). • Free access to the complete set of electrical design manuals for PC|SCHEMATIC Automation. • Free access to our electrical design videos - where you can see PC|SCHEMATIC Automation in action. • Free access to articles about electrical design CAD programs. • Free access to the PC|SCHEMATIC user forums.

Can I convert my schematic diagrams from other systems to Automation? Yes! You can convert schematic diagrams from practically speaking any CAD system to the PC|SCHEMATIC Automation format - as long as the CAD system can produce DWG or DXF files. PC|SCHEMATIC also offers a consultant service for converting drawings from other systems to the PC|SCHEMATIC Automation format.

Can I export to other formats? From PC|SCHEMATIC Automation, you can export to the DWG and DXF formats. PC|SCHEMATIC is an active member of the OpenDWG alliance. From PC|SCHEMATIC Automation, you can also export projects as intelligent PDF files with active link between references etc.

Electrical standards: How well are they integrated in PC|SCHEMATIC? At PC|SCHEMATIC we have detailed insight in electrical documentation standards, and we are active members of standardisation committees. We also publish the book “Electrical documentation according to standards”. This insight in the IEC/EN electrical standards is an integrated part of PC|SCHEMATIC Automation. However, the program is designed so flexible, that you can also use it for other standards than the IEC/EN standards. - Even for your own set of standards!

When you have bought PC|SCHEMATIC Automation, you can either attend PC|SCHEMATIC training in your own country, or attend a web seminar about the topics you need to get familiar with. Please contact venkat@pcschematic.in for further details.

Contact us at any time At PC|SCHEMATIC we are very interested in hearing about your experiences using the PC|SCHEMATIC Automation program. It is because of the feedback from our many users, that we are able to make a better product year by year! So Feel free to contact us at any time.

Conclusion Your success is our success. We want YOU to experience success and achieve your goals – regarding your customers, your workers, and your possible superiors. This is important to us. Because when you achieve success, we succeed as well.

Contact Details India A.Venkatakrishnan Market Consultant – INDIA venkat@pcschematic.in

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INDUSTRY SPEAK » TEST & MEASUREMENT

Power Industry demands efficiency & accuracy

Q. What are the remedies do you suggest to improve the positioning of the industry you are into? Mr. T.P. Singh, Country Manager, India-Instruments, FLIR Systems India Pvt. Ltd.

Q. What trend will drive POWER industry in near future? Power Industry is moving towards modernization keeping good pace with other developments in Modern India. More and more sophisticated equipments are being added for maintaining vital backbone ,which is Power Sector. Today’s Power Industry demands efficiency and accuracy. New technology like faster communication (between the equipment and computer/ devices and outside) is the trend alongwith greater accuracy with hitech features. FLIR is committed to provide the same and we have added many new products in our basket to meet and exceed demands of Modern, Young India.

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To support new innovative developments in the Industry, It will be great if India move from L1 (Lowest in price) system of procurement procedure to a system where better technology/product is also given some weightage. May be we can add term T1 ( highest technology wise) into our tender system and add some points for the same. This may help our utilities to buy best equipments at competitive rates.

FLIR Systems - The World’s Sixth Sense

Q. What is the impact of Union budget on the industry?

FLIR Systems, designs, develops, manufactures, markets, and distributes technologies that enhance perception and awareness. FLIR provides innovative sensing solutions into daily life through thermal imaging and other test equipments. FLIR is a global company with approx. 3000 employees and its 2015 revenue was USD 1.6 Billion (approx. 11 200 Crores in INR). FLIR has direct presence in India alongwith service support.

As per my understanding, Additional depreciation @ 20% on plant and machinery is allowed in the budget.

For more information, Website: www.flir.in

MAY 2016

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TECH TRENDS

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“The infrared resolution is simply tremendous.” The engineering firm Adler in Herten in the German Ruhr area is using the top-of-the-range FLIR T1020 handheld thermal imaging cameras for maintenance applications.

he engineering firm Adler has been providing highly qualified industrial thermal imaging services since 1996. The focus here is on thermographic inspections of electrical switching and distribution systems in all voltage ranges. However, Martin Adler’s engineering services also include thermography of mechanical equipment and components as well as

measurements in industrial settings for process analysis, diagnosis, process optimization, product development and research, and the inspection of machines, equipment and insulation. In addition, he advises clients in the planning of installed, user-specific infrared measurements and offers problem analysis and troubleshooting for already installed IR-measuring systems.

20 years of thermography experience

Thermography of high-voltage components always requires a relatively large safety distance. The UltraMax feature can be particularly helpful in this regard by providing good resolution and accuracy even from a distance.

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Of course Martin Adler’s many years of practical experience are the most important factor here. There is hardly an industrial thermographer in Germany, who has this much experience. Even during his studies at the University of Applied Sciences in Gelsenkirchen at the beginning of the nineties, Martin Adler programmed his own evaluation software for infrared measurements at the laboratory for energy technology. “There were no standardized solutions at the time and therefore individual initiative

Contactor with pronounced abnormality of the right phase on the lower terminal connection. The possible cause could be increased resistance at the terminal connection, an internal connection or the contactor. The labels are also easily recognizable here thanks to the MSX feature. was required,” Adler recalls. From the passion he developed as a student, he then established his own company in 1996, which celebrated its 20th anniversary in April 2016 (www. ingenieurbuero-adler. de). Even back then, the focus was on electrothermography. “It became clear to me: there was a great interest in thermographic inspection in the industrial

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» TEST & MEASUREMENT day, this reputation obliges him to use the best available thermal imaging camera model.

The FLIR T1020

The middle phase of this motor protection switch looks abnormal. This could indicate increased resistance at the terminal connection.

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With the T1020, Martin Adler is using the absolute top of the range of industrial thermography from FLIR. “The detector’s IR resolution is huge,” explains Adler enthusiastically “which of course increases efficiency: On a significantly sharper and more detailed thermal image, you can discover problems much more easily and with much more certainty. You can even discover small anomalies, which may not have been recognizable with the other camera or a lower resolution.” And camera operation has also become increasingly easy over the years according to Martin Adler: “This reduces the error rate, not only during camera usage, but also in the evaluation phase.” Adler used to always have a notepad and pen ready to write down the errors found. “It’s a familiar problem: the notes can not always be clearly assigned later on. Today, descriptions are stored in the camera in advance. Therefore my T1020 “knows” exactly where it is, e.g. in property No. 1, building No. 10, switch room on the first floor. If, for example, I discover a problem in the 39th object, then its position is automatically linked with the thermal image, thus avoiding confusion.” Martin Adler also praises the camera’s sophisticated concept: “With over 50 years of experience, FLIR is not only the technology and global market leader when it comes to thermal imaging, but to my knowledge it is the only thermal imaging camera manufacturer that does everything

sector, but there was a fairly meager selection of qualified services. In 1996, there was still no recognized qualification for thermographers in Germany and only two years later the first certifications were introduced here according to the American standard.” Measurements conducted by inexperienced service providers were often not reproducible and some of his competitors offered little more than colorful pictures with their infrared cameras. Martin Adler recalls a particularly horrific scenario involving an energy provider. An inexperienced thermographer had inspected insulators on high voltage lines on an extremely sunny day and thus found a high number of overheated units.

“However, most of the insulators were perfectly in order, and the man simply did not have the necessary experience. Outdoor recordings often simply do not provide useful results in strong sunlight. Such faulty inspections at that time brought the whole industry into disrepute” Based on his studies, Martin Adler took a very different and much more systematic approach, which he has remained faithful to. Regularly repeated inspection of critical components under reproducible conditions plays the decisive role here. “Back then, I first had to gain the confidence of my customers,” Adler recalls. “Often a whole year passed between the first phone call, the first appointment, a demonstration of the technical measurement possibilities, internal coordination between the customer’s technicians and the purchasing department, and the actual order.” And the initial investment of 120,000 Deutsche marks for a thermal imaging camera from FLIR’s predecessor company Agema didn’t make the start any easier for Martin Adler. It took several years to fully amortize this investment and Martin Adler used the time to develop his excellent reputation. To this

Martin Adler taking thermal images of a low-voltage main distribution

Alternator with abnormality on the primary front plug connector. A bent pin on the angle plug connector is found to be the cause.

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MAY 2016

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High pressure compressor heads in a chemical plant (within the area at risk of explosion). itself, including designing the camera, the detector, the electronics and even the software. You can really see this in the final product.”

Electrothermography Electrothermography is the most important area of use for Martin Adler. Detecting malfunctions before they bring a chemical plant to a halt, for example, not only makes sense for fire protection and security reasons, but also with regard to economic aspects. “In chemical plants, a half-hour standstill can incur 6-digit costs, and this is not only due to interrupted production. The plant must be commissioned again as stipulated and certain components inside the system may need to be removed in order not to cause negative effects. Fast procurement of spare parts for older components can also require great effort and thus be expensive.” To make sure that none of this happens, Martin Adler conducts regular inspections according to a clearly defined schedule.

Agitator drives below a mixing tank in an area at risk of explosion in a chemical operation.

Regular thermal images of a melting furnace allow for determining the condition of the lining.

Thermal imaging in areas at risk of explosion

economic the operation can be. However, a furnace with a defective lining could also have disastrous consequences. The molten metal would destroy the shell and, in addition to high costs, this could even cause injury in the worst case. Using a thermal imaging camera, it is possible to determine the condition of the lining from outside the furnace even during operation. Regular thermography inspections ensure safety and prevent economic losses.

Inspections in areas at risk of explosion are also part of Martin Adler’s everyday work, even though he finds far fewer errors in this setting. “Areas at risk of explosion are from the outset so critical that a high value is placed on safety. Of course this applies to the electrical and mechanical installations, so here we find errors significantly less often.” Nevertheless, the inspections here are anything but superfluous, because any abnormalities in such areas could pose very significant risks.

Lining of furnaces Industrial furnaces consist of a furnace shell which is protected by a fireresistant inner lining against the extreme temperatures of the molten metal. Of course this lining is exposed to normal aging processes: It is exposed to wear in operation and is eventually damaged to the extent that it requires replacing. The time between two linings is called the “travel time”, and the longer the journey, the more

THE FLIR T1020 HD THERMAL IMAGING CAMERA FOR ABSOLUTE EXCELLENCE With its uncooled 1,024 x 768 pixel detector, the premium thermal imaging camera FLIR T1020 sets the new standard for industrial and construction thermography. It combines outstanding performance with superior image quality and a high level of user friendliness. Its thermal sensitivity exceeds the industry standard for uncooled sensors twice over. By combining the FLIR UltraMax image enhancement technology and the patented FLIR MSX feature, the T1020 provides the best image quality of all compact systems available on the market.

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Qualification and certification Today, Martin Adler is one of the most sought after thermography specialists with certifications according to the European DIN EN ISO 9712 Level III, the ASNT, the CFPA and the VDS in adition to his many years of experience. This can be seen in his continually growing order volumes. Adler doesn’t worry about competition from inexpensive thermal imaging cameras: “Cheap devices hardly play a role in the area of professional industrial thermography. Plant operators may ometimes purchase them for the occasional inspection, but they can’t meet the insurance requirements with regard to systematics and accuracy with these devices.” Therefore Martin Adler continues to have good prospects for his company. After all, he has 20 years of experience in industrial thermography and, in his opinion, the best thermal imaging camera hardware on the market. www.ingenieurbuero-adler.de Tel. +49 2366-585181 Email: ib-adler@t-online.de For more information www.flir.com/instruments

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Let’s breathe better……

e can’t survive without air… every child knows. But, is the air we breathe causing us harm..slowly taking us into the grip of diseases. There have been numerous studies on this subject. The worsening air quality in Indian cities is already affecting the lives of the very young and the elderly, and reducing labour productivity. The effect range from breathlessness to asthma to damaged lungs preventing us form leading normal healthy lives.Is there something we can do about this! Are we the one causing this pollution – knowingly or unknowingly giving pain to the people around us, to the people who serve us. The journey begins with knowing what we breathe.

Do we know that – • Air around us might have dust, fine particulates, photo- chemical smog, odors, gases such as SO2, H2S, 02, NO, NO2, etc. • Industries we work in or run might be emitting toxic gases & toxic dusts such as Silica, Beryllium, Arsenic, etc.

DT-9881 / 9880 Particle Counter This 4 in 1 Particle Counter comes with 2.8’’ color TFT LCD display & a MicroSD memory card for capturing images (JPEG) or video (3GP) for viewing on your PC. Proving fast, easy and accurate readings for particle counter, GAS (HCHO, CO) detectors (Model DT-9881 only), air temperature & relative humidity, most surface temperature measurements. It is the first combination of these measurements in world. Would be the best instrument for environment protection and energy conservation. The dew-point temperature measurement will be very visible for wet and dry proof. It is a good handy industrial measurement and data analyzer. The real scene and time can be displayed on color TFT LCD. Any memory readings can be recorded in Micro SD card. Offline analysis of the measured air quality under the support of software, can be done. • • • • • • • • • • •

2.8” TFT Color LCD display 320*240 pixels Images (JPEG) & Video (3GP) Micro-SD (max. 8GB) memory card Air temperature and humidity Dew-Point & Wet Bulb temperature Simultaneously measure and display 6 channel of particle sizes HCHO detectors (DT-9881 only) CO detectors (DT-9881 only) MAX, MIN, DIF, AVG record, Date/time setup controls Auto Power Off

Accessories While air purifiers & air filters are now easily available, how do we know if we need to install these. And if we install, which are the most affected areas where these can be installed. IF ONLY WE COULD MEASURE THE POLLUTION IN THE AIR, ALL THIS COULD BE POSSIBLE. We could possibly realize what is going wrong and do something about it. AIR PARTICLE COUNTER is an amazing instrument that can exactly do this for us. A particle counter, accurately measures the diameter and number of particles in the air with greater accuracy than can be obtained by any other method. The particles may be either droplets of fluid or particles of solids. Since the particle size of most pollutants is clearly known, the APC can help accurately measure the type and the level of pollutants in the air. APC are very cost effective & extremely easy to use.

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NiMH Battery, Gift Box, Carrying Case and Instruction Manual.

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Some of the areas where an APC is begging to be used and are common environments most prone to Airborne Particulates are • Diesel vehicle transportation & service depots • Power generation (fossil fuel burning) units • Traffic-related emissions • Charcoal-based heating/cooking • Cement manufacturing, mining, & stone crushing locations • Metallurgy processes (melting, pouring, torch-cutting) • Agro. industrial (flour milling & agricultural field burning) ….and many more. The Air in the industrial environments might also contain Carbon monoxide (CO) gas, which is a deadly, colorless, odorless, poisonous gas. The incomplete burning of various fuels, including coal, wood, charcoal, oil, kerosene, propane, and natural gas produce it. Carbon monoxide is harmful when breathed because it displaces oxygen in the blood and deprives the heart, brain, and other vital organs of oxygen. Large amounts of CO can overcome us in minutes without warning causing us to lose consciousness and suffocate. Besides tightness across the chest, initial symptoms of CO poisoning may include headache, fatigue, dizziness, drowsiness, or nausea. Sudden chest pain may occur in people with angina. During prolonged or high exposures, symptoms may worsen and include vomiting, confusion, and collapse in addition to loss of consciousness and muscle weakness. Symptoms vary widely from person to person. CO poisoning may occur sooner in those most susceptible: young children, elderly people, people with lung or heart disease, people at high altitudes, or those who already have elevated CO blood levels, such as smokers. Also, CO poisoning poses a special risk to fetuses. CO poisoning can be reversed if caught in time. But even if we recover, acute poisoning may result in permanent damage to the parts of our body that require a lot of oxygen such as the heart and brain. Significant reproductive risk is also linked

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Key features • Air Particle Counting from OJum to 10.0um • Capability to check the presence of deadly CO and HCHO Gases • Easy recording of data of air particle

All at a price about

50% of the available options in the current market!

ABOUT US

We are OEMs to the top global brands of testing & measuring equipment. Our facility comprises of : • In-house Team of over 50 R&D Engineers focused on developing break-through technologies • All products manufactured under strict TUV GS approved standards • Production facility spread over 30,000 sq. m.- Shipping to over 50 countries • Right from housing design to final product all made under one roof • Workforce of over 1300 people • An ISO-9001 company • Products being made as per CE, IEC complied standards We have our offices across the world including USA, RUSSIA, GERMANY and many other countries.

WHY US • • • • • •

State-of-art technology 48 Hour Replacement Guarantee* Adedicated service back-up Instruments that can communicate the readings to your smartphone Facility to store the readings & data in cloud - access from anywhere Most economical hi-tech product

to CO. One may be exposed to harmful levels of CO in boiler rooms, breweries, warehouses, petroleum refineries, pulp and paper production, and steel production; around docks, blast furnaces, or coke ovens; or in one of the following occupations: • Welder • Garage mechanic • Firefighter

• • • • • • • • • •

Carbon-black maker Organic chemical synthesizer Metal oxide reducer Longshore worker Diesel engine operator Forklift operator Marine terminal worker Toll booth or tunnel attendant Customs inspector Police officer

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Non contact Video Infra Red Thermometer DT-9862S This infra Red VIDEO Thermometer is capable of non-contact (infrared) temperature measurements with visual camera (for both still and video photography) at the touch of a button. The built-in laser pointer increases target accuracy while the backlight LCD and handy push-buttons combine for convenient, ergonomic operation. This IR VIDEO Thermometer can be used to measure the surface temperature of the objects that is improper to be measured by traditional (contact) thermometer (such as moving object, the surface with electricity current or the objects which are uneasy to be touched.) The High Distance to sighting ratio helps to measure temperature of small targets from larger distance. The Dual Laser helps to understand the diameter of the area whose temperature is being measured. For precise temperature measurement we need to make sure that both the lasers • Taxi driver. An APC helps measure the CO levels too in the air and can prove to be a life-saver.

Where do I get good quality APC from? Although APC’s have been available in In India too, these are either low in quality of priced too high. Recently, CEM is a world leader in the advanced Testing & measuring instruments, has announced its entry into the Indian market. It has launched a range of high quality APC though CEM India, which is a joint venture with an Indian company and shall be headed by Mr. Vikram Bhansali, who has more than 20 years of experience in the field. Explaining us his reasons for bringing CEM products to India, Vikram says “CEM’s 3 in-house R&D centres have worked for months to work out the magic for us. We want to be the leaders in India replicating the success stories we had created in European & North American markets.“ CEM is ISO-9001 certified and the products are approved by globally benchmarked UL, GS, CE and RoHS.

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fall within the target. Adjustable emissivity helps to measure temperature of wide variety of substances. With JPEG and AVI

record function it becomes easier to establish and record time related events with proof. Has Fast Response of 150ms, which helps in detecting fast moving events in temperature profiling. It has a built-in Micro SD Card slot that can be used for extending the memory while recording temperature or taking pictures. Data Logging with real time and date stamp can be done for collecting data. It has a 2.2” TFT LCD display, 640*480 pixels (30 million pixels) . It comes with re-chargeable battery and battery charger. It has auto data hold and Max/Min/Avg/Diff. Record facility. The distance to sighting ratio is 50:1. The emissivity is adjustable from 0.10 to 1.00. The temperature range is -50 to 2200 Degree C. It also measures Atmospheric Temperature, Dew Point & Wet Bulb Temperature and Humidity. A K-type thermocouple can be used to measure temperature from -50 to 1370 Degree C in the contact type mode.

CEM Air Particle Counter with unique built-in camera for capturing videos and photos that are stored onto internal memory or a microSD card. The DT-9880/ DT-9881 can measure up to 6 channels of particle sizes plus Air Temperature and Relative Humidity. Use the included software to generate reports with videos, photos, and data points. The instrument simultaneously measures and displays 6 channels of particle sizes (down to 0.3 µm), Air Temperature, Humidity, Dew Point and Wet Bulb. The Model DT-9881 also measures CO and HCHO Concentrations in air. It has a 2.8” TFT Color LCD display with Built-in 320x240pixel camera takes videos (3GP)(DT-9881 only) and photo images (JPEG) and records them in internal 74MB memory. It stores 5000 records (date, time, counts, humidity, temperature, sample volumes, and location label) and 20 minutes of video. It has selectable sample time, count data, and programmable delay. Max, Min, DIF, AVG record, Date/time setup controls, Auto Power Off and Mini-USB port connection is also provided. All the meters that

CEM sells carry a warranty against any manufacturing defects. This hassle-free warranty allows the customer to get the instrument replaced within an unparalleled record period of 48 hours. The conditions of warranty are however, mentioned on the website www.cem-instruments.in Other products from CEM : Thermal Imagers, Infrared Thermometers, Digital Multimeters, Clamp-on Meters, Video Borescopes, Radiation meters, Air Quality Products, Data Loggers, Insulation Testers, Electrical Testers, Light Meters, Sound Level Meters, Thermo-Anemometers, Gas Detectors, Manometers and various measuring instruments. All these products are available directly from CEM’s office at Kolkata. Along with normal sales channels, CEM will also be pursuing online sales via all leading e-commerce portals like Tolexo, Paytm, Urjakart and Indsutrybuying. All CEM product details and catalogues are available on its website www.ceminstruments.in. CEM can be reached at info@cem-instruments.in For more information Web: www.cem-instruments.in

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Cables that provide Power! As Managing Director of Lapp India Pvt. Ltd, Marc Jarrault is responsible for spearheading the robust growth and profitability of the business and building the undisputed leadership of Lapp India in the control cables market with over 20 sales offices across India and 2 state of the art manufacturing facilities. Marc has an in-depth knowledge of the manufacturing industry acquired from senior leadership roles held in MNCs. Prior to joining Lapp India, he was CEO of Lafarge Cement Indonesia where he almost doubled the sales in 5 years while launching an aggressive development roadmap with the construction of 3 cement plants until 2020. He had previously set up from scratch the 33 MUSD Lafarge cement business in Vietnam in only 3 years and in a very competitive market and participated to large acquisitions of Lafarge, cement world leader, in Asia including Tata and Raymond cement plants in Chattisgarh, India. He held also senior leadership roles for Vinci, a world leading Construction Company, in Mexico and South Africa. Marc has overall 15 years of in-depth experience of business practices and an extensive network across leading players of the manufacturing industry in Asia, and he capitalises on a large experience in leading multicultural teams internationally. Marc was born in France where he pursued his engineering from a top Engineering school in France and completed his MBA from INSEAD. He is also a French Foreign Trade Advisor and member of Eurocham. Mr. Marc Jarrault – MD – Lapp India Pvt. Ltd.

he 2015 Gardner Business Media Survey estimates Indian Machine Tool Industry at 14th in production and 10th in the consumption of machine tools in the world. With emphasis on ‘Make in India’ and growth in manufacturing, for which the machine tools sector serves as the mother industry, India is all set to become a key player in the global machine tools industry and is likely to see widespread high-end machine tool manufacturing in the next few years. The Indian machine tool industry has around 1000 units in the production of machine tools, accessories/attachments, subsystems and parts. Of these, around 25 in the large scale sector account for

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70 percent of the turnover and the rest are in the SME sector of the industry. Approximately, 75 per cent of the Indian machine tool producers are ISO certified. While the large organized players cater to India’s heavy and medium industries, the small-scale sector meets the demand of ancillary and other units. Machine tool industry is inherently complex. The main objective of this industry is to build machines which will work towards reducing operational downtime for its customers. Hence, a wide range of cabling solutions is required for the machine tool industry. According to the Indian Machine Tool Manufacturer’s Association (IMTMA), the industry is increasingly moving towards sophisticated CNC machines driven by

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key user segments like automobiles and consumer durables. This calls for increased focus on identifying and sourcing the right quality of cabling solutions which enhances the productivity, precision and reliability of the machine tool. • The cables should be oil resistant and must also be able to sustain vibrations. As all machines require constant oiling and regular maintenance,oil has a tendency to get absorbed into the cable resulting in swelling and softening. This eventually degrades the tensile property of the cable. Cables should also be able to function with any kind of vibration to ensure no loose connections are caused in the circuitry. The connecting glands must be unaffected by the oil as well. • The cable glands must be ingress protected. The cabling should be dust resistant and must be protected against temporary/ continuous immersion in liquids. Machine Tool Industry generally requires a significant volume of industrial electrical installations which require a high level of ingress protection. • It is mandatory that the cables be highly flexible and durable.Most industrial machines consist of at least one moving part. In this context, the cable is required to be sufficiently flexible to cope with the to-and-fro or up-and-down motion.Cables should be flat and highly flexible and durable, making them ideal for high movement applications. They should be highly flexible and capable of withstanding harsh environmental and operational conditions. • Flame retardant and able to withstand high temperature.Requirements for low smoke emissions, low generation of corrosive and toxic gases and low fire propagation characteristics have produced a rapidly growing market for Halogen-Free Flame Retardant (HFFR) & Fire Survival (FS) cables. These cables come with annealed bare copper or annealed tinned copper conductors. Having a double layer glass mica tape for insulation, these cables come with special linked polyethylene. The inner sheath comes with halogen free

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compound with galvanised steel wire which prevents spreading of fire. These cables are specially designed for optimum cabling solutions under fire mishap by maintaining the circuit integrity for temperatures up to 6500 C, 7500 C and/ or 9500 C as per application requirements. The inner and outer sheaths are specially designed with halogen free compound which reduces emission of fumes and acid gases in the event of fire. Cable requirements of this industry vary from machine to machine depending on the type of equipment their clients need. Each type of machine will demand numerous types of cables. Some can be ordered right off the catalogue while others have to be custom-made for the client. To address this, issue a range of power, control and data cables specific to machine tool industry is required. Given the demanding applications of the machine tool industry, specialized cables that sustain high mechanical and chemical stress are required.

About Lapp India Lapp India is a 100% subsidiary of the LAPP GROUP Germany, is a leading supplier of integrated solutions and branded products in the field of cable and connection technology. Having started its operations in 1996 with a manufacturing unit in Jigani, Bangalore Lapp India provided in 2014 about 120,000 km per year of control, instrumentation, power and data cables along with connectors, accessories and End to End Systems to over 3000 customers pan India spread across different industry segments such as automation, textile, automotive, machine tools, oil and gas, renewable energy, process industries, as well as in the infrastructure and building sectors. • 23 Sales offices close to customers all over India • 300 employees committed to best serve customers • Strong Network of 146 dealers • 2 top of the notch manufacturing units Bangalore and Bhopal • State of the Art Laboratory • Fully fledged Technology and innovation

center In 2012, Lapp India completed phase 1 of its second manufacturing plant in Pilukedi, Bhopal which produces more than 216,000 kms of single core cables per annum, catering mainly to the Building Cable Segment . The production area at Jigani was also doubled in 2014 and a new multi core line was commissioned in Bhopal with a total investment of over 5 Million Euros.

Lapp Brands – ÖLFLEX®, UNITRONIC®, ETHERLINE®, HITRONIC®, EPIC®, SKINTOP®, SILVYN®, FLEXIMARK® – are some of the bestknown in the cable technology field and have earned an outstanding reputation as premium products. All over the world, they stand for the values which Lapp and their customers consider paramount: quality, precision and reliability.

About the Lapp Group: Headquartered in Stuttgart, Germany, the Lapp Group is a leading supplier of integrated solutions and branded products in the field of cable and connection technology. The Group’s portfolio includes standard and highly flexible cables, industrial connectors and screw technology, customized system solutions, automation technology and robotics solutions for the intelligent factory of the future, as well as technical accessories. The Lapp Group’s core market is in the industrial machinery and plant engineering sector. Other key markets are in the food industry as well as the energy and the mobility sector. The Lapp Group has remained in continuous family ownership since it was founded in 1959. In the 2013/14 business year, it generated consolidated revenue of 820 million euros. Lapp currently employs approximately 3,200 people across the world, has 18 production sites and over 40 sales companies. It also works in cooperation with around 100 foreign representatives.

For more information Web: www.lappindia.lappgroup.com

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PROFILE

STEEL MART : The expertise with technology excellence

Mr. Juzer Faizy - Director, STEEL MART

Steel Mart was launched with an intention to cater to the needs of all kinds of Small / Medium & Large scale industries and have been very successful in terms of meeting the requirements of the clients to their utmost satisfaction

teel Mart was founded in the year 1986 Steel Mart is now run by dedicated & experienced staff / workers and the owner ( Juzer K Faizy) though only 52 years old now has a total of 36 years of business experience

Steel Mart has 3 different divisions:1. STEELS n METALS DIVISION 2. LAMINATION STAMPINGS DIVISION 3. MATERIAL HANDLING DIVISION 4. Steel Mart is an ISO 9001:2008 certified company Steel Mart was started with a small office space of 200 sqr feet – today Steel Mart has an office space of 800 sqr feet + 2000 sqr feet of godown + 2000 sqr feet of open ware house + 2000 sqr feet of factory. Steel Mart was launched with an intention to cater to the needs of all kinds of Small / Medium & Large scale industries and has been very successful in terms of meeting the requirements of the clients to their utmost satisfaction Steel Mart started with the trading of all kinds of TOOL / ALLOY / DIE / STAINLESS

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STEELS and gradually became one of the largest stockists / suppliers of the same. Steel Mart now possesses a huge stock of all the Grades & Sizes and are well equipped with Bandsaw Machines , Profile Cutting Machines , Electronic Weigh Scales , Inhouse Testing Facilities etc to ensure 100% guaranteed & cut to size materials. Steel Mart has also ventured in the business of manufacturing all kinds of CRGO & CRNGO Transformer Lamination Stampings used by major Transformer Industries and also by UPS and Voltage Stabilizer manufacturers. Steel Mart has set up 2 manufacturing units in Panvel + 1 unit in Taloja – 1 each for CRGO & CRNGO grade E&I Laminations & 1 unit specially for the Mitered / V Notch Strips. Steel Mart has developed hitech tools & dies for producing excellent quality Transformer Stampings , E&I Laminations & Strips Steel Mart is also in the business of Importing & Supplying all kinds of MATERIAL HANDLING EQUIPMENTS & ACCESSORIES viz: WIRE ROPES , WIRE ROPE SLINGS , CHAINS , CHAIN SLINGS , HOOKS , DEE & BOW SHACKLES , TURN

BUCKLES , EYE BOLTS , CHAIN PULLEY BLOCKS , MINI ELECTRIC HOIST , PLATE LIFTING CLAMPS, POLYSTER-WEBBING SLINGS etc etc. Steel Mart is now also in the exports of all the 3 product categories as per the 3 divisions and are looking to explore the International Market and to meet the requirements of the International Clients with as much dedication , sincerity & honesty which is the backbone of the success of the company.

For more information STEEL MART Mr. Juzer Faizy - 9820038502 2/14, Pais Street, Byculla (West), Mumbai- 400011, Tel: 022-23080096 / 23097594 / 23090362 E-mail:- steelmartmumbai@yahoo.com / steelmartmumbai@hotmail.com , Web sites: www.steelmart.in / www.steelmart.co.in / www.steelmart.net / www.industrialalloysteel.com

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LAMINATION STAMPINGS IN CRGO & CRNGO GRADES SUITABLE FOR TRANSFORMERS / RECTIFIERS / STEP VOLTAGE REGULATORS / VOLTAGE STABILIZERS / UPS / INVERTERS

Importers Dealers Stockiest Wholesalers & Retailers For Industrial Electricals SS CABLE TIES

CABLE TIES

RELEASEABLE CABLE TIES

marke

r tie CABLE TIE TOOL INDUSTIAL PLUG & SOCKET

CRIMPING TOOLS ID CABLE TIE

PVC CHANNELS & SPIRAL

XTRA / YYT / YAC TOOLS

4 WAY TPN & DMC INSULATOR

TERMINALS

LUGS

CRC SPRAYS

terminal, tools lugs, tools & glands nylon & ss cable tie

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13 Tawawala Bldg,151 Lohar Chawl, Mumbai - 400002. | Tel: 022 22002288 | Email: marktradelinks@hotmail.com | www.xtraindia.com

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E SINC 2

196

Distributors & Stockiest for Industrial Electricals

CABLE TIES

CRIMPING TOOLS

TERMINALS

CABLE GLANDS

CONNECTORS

INDUSTIAL PLUG & SOCKET

TOGGLE SWITCH & CONNECTORS

EHI LUGS

PVC CHANNEL

CRC SPRAYS PROXIMITY SWITCHES

SPRAYS

LUGS

terminal, tools lugs, tools & glands nylon & ss cable tie

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spray for industrial maintenance

crimping tools cable ties

P.V.C. channel

plug socket

strip connectors, toggle & micro switches

proximity switche & photocell / sensor

154, Kantilal Sharma Marg, (Lohar Chawl), Mumbai- 400002 India. | T: +9122 2208 9295, +9122 22062688 F: +9122 2206 0951 | email: mec1962@hotmail.com, mercantile1962@gmail.com| www.mercantileelectric.com

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Interface

Highest degree of variability. For each application purpose.

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FACE TO FACE

Mr. Kalidas Bhangare, Managing Director Testo India Pvt Ltd

Testo : Trendsetter of smart & user-friendly technology Q. What trend will drive POWER industry in near future ? Today, professionals in the power industry are very particular about their standards and work surroundings. Every day, maintenance personnel struggle to minimize downtimes, prevent damage to mechanical and electrical components and ensure availability of production facilities or systems. On the other hand, temperature differences, instrument failure, heat loss etc, tend to impose operational challenges. To curb down these daily operational and maintenance hindrances, facility owners and managers are now heading towards the acquaintance of Thermal Imaging technique as a solution. Potential

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weak spots such as circuit breakers and power switches, or malfunctions in the transformer cooling, can lead to an interruption of the energy supply. Early and reliable identification of these sources of error is now possible using testo 885 and testo 890, high-resolution thermal imagers with super telephoto lens which allows the detection of smallest of anomalies even from a distance. In addition, the standard wideangle lens also provides a fast overview and a professional reporting using the testo IRSoft analysis software.

Q. What is the impact of Union budget on the industry ? The Union budget this time seems

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FACE TO FACE to certainly give a boost to the ‘Make in India’ initiative of the Government with the focus on agriculture, rural economy and development of the infrastructure sector. In addition, the Government has also rationalized indirect taxes to give more thrust to domestic manufacturing. The budget this time, confirms the Government policy to revive the investments in the infrastructure (including energy & resources) sector by addressing the root problems impacting these sectors. On the tax front as well, the government has laid stringent roadmap for phasing out of exemptions/deductions with specific sunset dates. Hence, this plan of higher spends on infrastructure segments such as roads and highways, irrigation and smart city development is surely expected to boost the cement & power industry.

Q. What are the remedies do you suggest to improve the positioning of the industry you are into? Testo is rigorously working towards driving the industry trend to the new smart and user-friendly technology. Gone are the days that demanded manual

Testo 330i: Flue gas analyser with Bluetooth

intervention, calculations and analysis. To provide the required thrust to the test and measurement industry and push it into the category of rapidly growing sectors, it is very necessary to come up with solutions which can support the ongoing trend of smart processes, to assure an equal growth of the industry as a whole along with the tremendous growth of domestic and global demand due to enormous industrialization. To support this industry trend, Testo now have so many measuring instruments that are now integrated with apps

on smartphones or tablets. The App integration via Bluetooth opens up new possibilities for efficient analysis and documentation. The users can read off the measurement data on a Smartphone or tablet, allowing them to work more quickly and conveniently. The recent launches from Testo like Smart Probeseight innovative, pocket-sized pro measuring instruments suitable for all important parameters like temperature, humidity, pressure and flow velocity measurements and testo 330i- the flue gas analyzer with the provision for wireless operation, display and documentation which can be intuitively operated by smartphone via a free App, are just the opening of the new gateway to digitization.

Testo Smart Probes operated from Smartphone App

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INDUSTRY SPEAK » AUTOMATION

“We expect users in Indian market to shift towards premium mindset”

Mr. Sridhar Nalluri, General Manager, InnoVista Sensors

Q1. What trend will drive AUTOMATION industry in near future? The industry is turning to remote communication and user-friendly (Smart) technology. And, the customers expect to reduce the man power and to get the upto-date data from remote locations. Also, in today’s trend, people are not ready to wait for longer durations for programming, integration and installations. Industry is keen to adapt technologies which can be easily and quickly integrated.

Q2. What is the impact of Union budget on the industry? This Union Budget 2016-17 has a positive impact on Automation sectors on a overall front. The decision of making smart cities will definitely get good business as far as Automation sector is concerned. The Smart city means digitalized and automated cities

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with an uninterrupted power supply and potable water. This pave the way for Water treatment plants. A smart Grid system will be installed, henceforth It’s a very good opportunities for relays, timers, counters, Micro switches, PLC’s. As far as Swach-Bharath campaign, the government is in-line with green toilet concepts, therefore the Rajdhani trains will be implemented with Railways with green toilets, where PLC’s can be used. This step towards smart city not only help automation sector also it elevates and encourages the growth of other allied sectors.

Q3. What are the remedies do you suggest to improve the positioning of the industry you are into ? The people in the industry should be aware of the new technologies; they should be more innovative, more aggressive and sportive towardsavailable new trends. We expect users in the Indian market towards more ‘premium mindset’ (value for money) instead of too much of cost consciousness. Users need to focus on long term returns over the short-term gains. In this regard, we also need to accompany the users of the industry to create the awareness.

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INDUSTRY SPEAK » AUTOMATION

The field of robotics is in a massive growth phase similar to what IT was in late 90’s

Arjun Prakash, Director, Effica Automation Ltd.

Q. Effica is a name to reckon with in automation. What precisely is your niche? We started off in 2005 designing and manufacturing special purpose machines (SPMs) for a plethora of applications. We even developed robotized special plasma cutting systems for marking and precision cutting power transmission poles of 60 ft long. Way back in 2009 we executed a project worth Rs. 2 crores in Houston. This was a complex job involving different disciplines – mechanical, electrical, electronics, robotics, and industrial PCs. It involved handling, rotating, marking and cutting of poles where cost of error was very high. Over the years, we have changed our focus. Since 2011, to be precise, our focus is on material handling automation using robots which includes machine tending, palletizing & conveying.

Q. What are the automation solutions you offer for the manufacturing sector? We offer robot based component loading and unloading systems. The solutions are available for multiple CNCs, forging presses, sheet metal presses, plastic injection moulding and similar processes.

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Along with this we offer all the accessories required to complete the solution like conveyors – roller, belt, and slat, the end effectors for gripping various types of components, the safety systems, infeed and outfeed component stacking magazines. We also offer gantry machine tending to replace articulated machine tending projects for payloads from 2 kg to 100 kg. This is an economical solution, and with this the existing plant layout need not be disturbed. We also do bag conveying & palletizing automation. This is a robotbased high speed palletizing system with a speed of 20 tonnes per hour. For the FMCG segments we offer pick and place solutions for the packing requirements. These are very high speed solutions for light weight products with a special emphasis on hygiene. We have made our systems modular and userfriendly so that in the event of a failure, the end-user can fix it themselves. This way we have removed the fear of breakdown and consequent downtime from the mind of the end-user.

Q. What are the challenges ahead for a company like you in today’s context? The field of Robotics is in a massive growth phase similar to what IT was in the late 90s. When this happens, we have to be ready to scale up our production to ride the growth wave. Side by side, we must educate the customer on the benefits of automation. They must be induced to adapt the manufacturing processes to make room for robots to take charge. We have to remove the fear from the minds of the customer that there won’t be any issues of breakdown and idle time since they

themselves can address the snags if any and keep the machines humming.

Q. What’s the shape of things to come in factory automation and how do you envisage making a dent in this exciting field? Some 20 years ago a robotic solution cost Rs.30 lacs. Today it is in the vicinity of minimum Rs.15 lacs. The inflation adjusted prices are dropping down massively and will drop down further in the days to come. This will help manufacturers to go in for more and more robotic automation. There has not been any change in technology in Robotics for the past four decades. However, we are seeing significant changes in technology in the last 2-3 years. The next wave of robotic technology like collaborative robots which work side by side with humans and super easy programming and operation methods which are similar to your mobile devices and apps are already rolling out. The worldwide robotic sales for the year 2013 is said to be 179,000. This is nowhere near the potential demand for robots in the world. In the year 2014 China is the largest consumer of robots. Indian SMEs should think progressively and take pathbreaking decisions to reap the benefits of productivity and flexibility offered by robots. We in India are on a growth trajectory. And robots will play a pivotal role in enhancing our quality, productivity and operational efficiency in the days to come.

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INDUSTRY SPEAK » AUTOMATION

Automation is the future of India to this Industry, however the FDI and other Industry related programs will support Automation Industry

Mr. Subhrajyoti Mukhopadhyay

P.L. Muthusekkar, Managing Director, NORD DRIVESYSTEMS PVT. LTD.

Mr. Subhrajyoti Mukhopadhyay Director, WeldIndia Consultancy Pvt. Ltd.

MAKE IN INDIA is going to be the driving force of in house Manufacturing. Today Indian industries have geared up to meet the stringent quality requirement & the productivities in order to be competitive in the Global market. This is perhaps one more chance that we have been given to prove our mettle in the Global market.

Q. What are the remedies do you suggest to improve the positioning of the industry you are into ?

Q. What trend will drive AUTOMATION industry in near future ? P.L. Muthusekkar Our Make In India program and Defence, Railways new localization policies and improving manufacturing contribution from 2% of the GDP to 12 % of the GDP vision will enhance the Automation programs. Also the GST will create centralized automated ware houses and sorting and delivery management will also enhance the Automation. In simple Automation is the future of India.

P.L. Muthusekkar Automation clusters to be developed with central R&D and testing facilities to boost this industry and it is also in the interest of National goal to reduce imports, Electronics and automation products forms the third largest category of imports other than oil & Gold. Also Start up benefits as planned in capital goods industry or other sectors to be extended to Automation Sector. Mechatronics & Skill development part is the need of the hour. Germany like PG courses curriculum in Mechatronics and also involving the Expert services / Retired technology engineers to be also roped in for Skill development in this industry.

Mr. Subhrajyoti Mukhopadhyay Automatic Laser Vision system, Cordless Remote Control, Voice interfaced Robotic Controller Units with effort able user friendly software driven Closed loop feed-back systems are the key areas of developments in Automation Industries in near future.

Q. What is the impact of Union budget on the industry ? P.L. Muthusekkar Budget has not made significant changes

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Mr. Subhrajyoti Mukhopadhyay Import duty including various Taxes on Plant & Machineries for manufacturing Industries should be brought further down to minimum in order to Make in India, a great success. By adopting the up-to-the-minute Global Manufacturing Technologies, Indian Industries can manufacture goods not only with International quality but also in adequate quantity to compete in the Global MNCs.

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PROFILE

Indus: Committing the green revolution Indus has a complete end to end solutions under one roof of providing Document Life Cycle Solutions with it’s four verticals: • Document Management Software Solutions (EDMS, ECM, WCM, ERDMS, ICM) • Document Control Consultancy • Documents & Records Management Training • Providing Manpower Resources in India and Abroad.

Objectives

Mr. Prakash Patel, Founder & Director

ndus provides a complete end to end Document and Records Management Life Cycle Solutions committing to green revolution. Indus brings faster returns on investments with high level of comforts to manage every type of documents in any format and can be retrieved within fraction of seconds with highly user friendly tool exactly emulate hardcopy process. It has four verticals to provide every aspect of Document Management as per the compliance and governance to mitigate all problems and gaps organizations who are facing challenge to manage documents due to lack of space, inexperienced Document Controllers, legacy DMS system or still hanging on excel spread sheets with lots of redundancies and not meeting to the Integrated Management System.

• To Bring a Revolutionary Change in the Small & Medium Scale Industries • Provide Full Proof Sophisticated Solutions to Mitigate Risks to Giants • Enhances Efficiency by Integrating Information Content to the Business Processes • Spread Awareness and Improve Skill Level of every Participants • Processes with Consistency and Confidentiality to Reduce Time & Cost • Give User’s a Friendly Environment using EDMS for getting Best Results

Who Are We? Indus Infosolutions LLP is exclusive Document and Records Management Company started by team of dedicated Document Management Professionals with more than 30+ years of experience, specialized in development and implementation of Web Based Document Management Systems.

Founder & Director Prakash Patel who is in the field of Document Management system for more

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than 35 years and has a great exposure in implementation of the Documents & Records Management Software System in various organizations in India and abroad. He is Professional Member of ARMA (Association of Records Managers and Administrators). He worked in many companies like Aconex,Bechtel, KBR-Halliburton, Louise Berger, Petrofac, Chemtex, Hindustan Dorr-Oliver,Topaz Marine & Engineering, Lindenberg where he acquired all the knowledge of maintaining millions of documents in hard and softcopy. Co-Founder & Director Rajendra Salunke is a Technology visionary with strong focus on Document Control area in automating business processes through Electronic Document Management and Archival with more than 30 years of experience working with various sectors in India and Abroad in companies like Tata Consultancy Services, Reliance, Chemtex, Mott MacDonald. He is Masters in Records Management.

Director- IT & Finance Abhishek Mehta is specialized in the IT and Database with success in designing, development and implementation of the Hardware, Software, and Networking. He has a concentrated experience for over 14 years in India and abroad with skills in vivid scenarios for the implementation of the Desktop based or Web Technology Applications and Database.

WHAT WE DO? Indus provides end to end Document Life Cycle Solutions under one roof of providing with it’s four verticals: • Document Management Software Solutions (ECM/EDMS/ERDMS/ICM/ WCM) • Document Control Consultancy • Documents & Records Management Training ( Only if Client enquires) • Providing Manpower Resources in India and Abroad. ( Only if Client enquires) Fore more details : Conact : +91 9022779087 /+91 9850604231 Email : info@indusinfosolutions.com Web: www.indusinfosolutions.com

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FACE TO FACE

ROSS Controls: The Pneumatic Safety Expert and machines but to the bottom line.

Q. What are the market opportunities for your company’s products in India? The greatest market opportunities are in our focus industries; glass, metals, press and pneumatic safety. Our focus is to drive our poppet and safety technology into these key industries, such as mechanical power presses, hollow glass and steel processing, that value long-term reliability and productivity. The growth in infrastructure investments offers opportunities for our steel and aluminum focus products, while the increase in consumer consumption creates demand for our hollow glass products.

Mr. Jay Dalal, Managing Director Ross Controls India Vice President Global Engineering ROSS Controls

Q. Please brief us about company’s Indian & global reach? ROSS Controls has its headquaters in the United States with manufacturing & sales offices located in Germany, United Kingdom, France, Brazil, China, Japan & India. Our Indian facility is located in Chennai with sales engineers in Chennai, Coimbatore, New Delhi, Pune and Kolkata.

Q. Please also highlight the latest initiatives in your industry domain? Safety awareness is the key initiative. Business leaders are realizing they cannot afford to have their employees operating in an unsafe work environment. When I talk about safety, it is two things. It is not only protecting employees that are interacting with equipment, it is also protecting the equipment itself from possible damage and things not functioning the way they are designed to work. Some countries are behind others, but even countries new to safety are beginning to understand the importance of safety not only to their people

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Q. What is future prospect for your industry? India is a growing market for both pneumatic automation and pneumatic safety. With the focus on “Make in India”, industry is beginning to invest in higher level automation and worker safety which bodes well for long term growth opportunities.

Q. Is there any plans for expansion & new investment in terms of product development or new technology adoption to cater the demand of the industry? Yes, our Indian engineering team is developing products for both the local and global markets. We look at certain industries that we think value our expertise and product portfolio. What we want is our field engineers or sales engineers to know as much about the equipment that our product is going on as the customer knows. We want them to look to us on how to handle the pneumatic circuitry on their equipment. Companies have put a great deal of effort into streamlining processes, and people do not have time or experience to think about the pneumatic circuitry of their equipment.

In a perfect environment, they look to us to help design their equipment. In certain industries, we certainly have that ability to help them, but we are not trying to be that expert in every industry. We are focused on where we know we can be successful - where productivity is important to a customer and critical to them making money. When that is the case, we have a lot of success.

Q. What is the top line product range & Is there any plans to launch new products? We have many top line product ranges, depending on the industry. One product I would like to highlight is the DM2 valve used on mechanical power press clutch/ brake applications. The DM2 is a patented 3/2 normally closed valve distinguished by CrossflowTM passages. This arrangement provides outstanding flow characteristics and an integrated monitoring capability with total memory. The valve provides dynamic monitoring and dynamic memory which is unique in the industry. We are continuously developing new products, for example the Crossflow Size 6 (CF6). The CF6 is also used on mechanical power press clutch/ brake applications but was designed in India for the unique requirements of this market. The valve uses CrossflowTM passages for enhanced flow and offers external monitoring options.

Q. What is your vision for your company? ROSS Controls will continue to pursue being the full safety solution provider to our customer base along with being the global technology leader in our focus industries. What is great about ROSS is that we are very focused on what we do well - we are the pneumatic leader at providing safety solutions and enhanced productivity for our customers.

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Driven By Innovation Automatic Doors and Loading Bay Solutions

DOCK LEVELERS / SHELTERS

Platforms For Loading / Unloading Solutions

Avians Innovations Technology Pvt. Ltd.

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TECH PROFILE

SICK continues to grow Sensor manufacturer celebrates its 70th anniversary with encouraging business figures

ow in its 70th year of doing business, the SICK Group is continuing its success story. The company, which was founded as a one-man operation by Dr. Erwin Sick in 1946, has grown steadily over the last seven decades to become one of the world’s technology and market leaders for sensors for industrial applications. In the fiscal year 2015, the SICK Group had 7,417 employees and recorded sales of EUR 1,267.6 million. Earnings before interest and tax (EBIT) were EUR 129.1 million. The pioneering spirit of the company founder can still be felt in the SICK Group today. It has been a critical factor in the company’s ability to continue to set standards in sensor technology by delivering innovative solutions during the past fiscal year. Reflecting this trend, sales increased by 15.3 percent to EUR 1,267.6 million and orders received rose by 13.2 percent to EUR 1,270.5 million. After a rather cautious start, both sales and orders received picked up speed during the course of the year. “As in the previous year, SICK saw growth in all regions of the world in 2015. Of particular note, however, is the increase in sales in the Americas and in the Asia-Pacific regions, where a gain of more than 20 percent was recorded in each case,” explained CFO Markus Vatter when the balance sheet ratios were published. In both regions, demand from customers in logistics and process automation in particular was high. Currency effects also had a positive impact on sales growth: “In total, just under six percent of all growth was attributable to the devaluation of the euro, in particular against the US dollar and the Chinese renminbi,” Vatter went on.

Sales growth results in outstanding earnings performance The strong growth in sales is reflected in earnings before interest and tax (EBIT). EBIT was EUR 129.1 million, up 25.1 percent; its growth was stronger than that recorded for sales. Although currency effects had a noticeable impact here too, there was

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also a clear improvement in the use of materials in production. The EBIT margin as a percentage of sales was thus in double digits, recorded at 10.2 percent (prior year: 9.4 percent). After deducting the tax burden, the consolidated net income for the year stands at EUR 90.8 million – due in part to the favorable development of the interest rates. This constitutes a rise of 30.1 percent on 2014. The net return on sales increased to 7.2 percent (prior year: 6.3 percent).

Markus Vatter, CFO

Increase in number of employees across the world There is an inextricable link between the development of innovative sensor solutions and investment in employee skills. So, in the fiscal year, SICK increased its global workforce to 7,417 (up 6.6 percent on 2014). Almost 60 percent of employees work in Germany, where the number of employees has gone up by 5.8 percent. Growth in employee numbers in other countries was slightly higher, at 7.8 percent. There was also a huge increase in the cost of basic and advanced training. At EUR 9.3 million, this figure was up 16.3 percent on the previous year. Furthermore, in this anniversary year, employees will get to share in the success story of the company, which has been played out over seven decades, in a very special way. A special bonus will be paid in 2016 based on duration of employment with the company.

Further expansion of research and development activities Proof of SICK’s strong ability to innovate is provided by its intensive R&D activities,

Dr. Robert Bauer, Chairman of the Executive Board which is reflected in a further increase in R&D expenses: in the past fiscal year, EUR 129.0 million was spent on R&D. This is an increase of 11.0 percent compared to the previous year. The share of R&D expenses as a percentage of sales thus equates to 10.2 percent of sales (prior year: 10.6 percent). In the fiscal year 2015, an average of 864 employees (5.8 percent more than in the previous year) worked on new technologies and new products. Development capacities were expanded in foreign R&D locations in particular.

A moderate forecast for this fiscal year The trend in the first quarter of 2016 is similar to that seen in the previous fiscal year: sales and orders received are better than in the previous year, but still modest. However, Dr. Robert Bauer, Chairman of the Executive Board, is cautiously optimistic about sales and earnings for this year: “Despite the challenging economic conditions, we are confident of achieving sales growth and increasing earnings in 2016, even if growth rates are not as impressive as they were in 2015. Since changing our brand claim to “Sensor Intelligence.” in 2004, we have been unswerving in our commitment to making our products, systems, and services ready for the networked world of Industry 4.0. As a result, we are ideally positioned to face the challenges of the future.”

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TECH TRENDS

Automatic storage system

Smart Factory Industry 4.0 concept

he Industry 4.0 technologies are the aspects on which the individual suppliers intervene. The development of these technologies and procedures will finally allow the shift towards the Industry 4.0 design principles. In this transformation - both technical and procedural -machines (Autonomous Robots), IT products and systems (Big Data & System Integration)will be connected along the value chain, beyond the single company: these connected systems will interact with one another using standard protocols and will analyze the data to predict failures and auto-configure themselves to adapt to new situations. The collection and analysis of data will thus make allprocesses faster, more flexible,and more efficient to produce higher quality goods at lower costs. This, in turn, will enable the improvement of the economy and encourage industrial growth, by changing the profile of the workforce and impacting the competitiveness of businesses. The fields in which nextgeneration solutions have already been tested include logistics and warehouse management. In the new factory, digital and

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Industry 4.0, or the “Smart Factory”, is the fourth industrial revolution, the collective term embracing technologies and concepts of value chain organization. flexible, the internal communication flow between workstations will be continuous and in real-time, integrating production and the warehouse.

The use of automatic storage systems results in manyadvantages, including: 1. Optimization of space 2. Implementation of the “goods to man” principle 3. Reduction in operating costs 4. Reduction of resources used in repetitive and low value added activities 5. Traceability of stored goods 6. Reduction of errors 7. Improvement of the storage conditions of goods 8. Better inventory management 9. Improvement of ergonomics and safety in the work areas.

There are two elements that distinguish an automatic warehouse: • Shelving

• Automation for picking and storage operations As for the design of the shelving structures to be installed in seismic zones, Ferretto Group adheres to the EN 16681 standard recently introduced and currently in force. On the subject of resistance to seismic action there is an on-going Research &

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TECH TRENDS Development initiative for the construction of building systems which seek to reduce the risk of stored goods falling, since these can often have an economic value (or a significant impact in reconditioning operations) greater than the value of the shelving itself.

As regards automated picking and placing on the shelving, the main machines used are: STACKER CRANES • Telescopic fork stacker crane for single depth shelving:a machine with a good ability to implement cycles, but a system with a limited capacity in terms of storage. • Telescopic fork stacker crane for double depth shelving:a system which compared to the previous system doubles capacity in terms of storage but loses something with regard to its ability to implement cycles. It begins to be important to have channels (in this case 2 elements) which store material with the same code and production lot. • Stacker crane with shuttle for multidepth storage: a system that favors storage capacity over execution speed for picking and placing cycles. It is fundamental to have channels with homogeneous material by code and lot. • Steering stacker cranes (with forks and shuttle operating on any type of shelving): these are machines that can serve multiple parallel and non-parallel rows, fork and shuttle systems can be mounted.

LEVEL SHUTTLES • Ground level shuttles and shuttles for warehouses with multi-depth shelving; this solution is the manner to speed up the picking and placing of goods. • Multi-shuttle: the latest evolution of the concept of increasing the speed of cycles in a multi-depth storage system takes advantage of the fact that the picking and placing shuttle is no longer tied to the shuttle at ground level with a power cord. The former are in fact battery

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powered and in this way a single shuttle at the floor level can handle 2 or more picking and placing shuttles, significantly reducing travel times along multi-depth spaces. Ferretto Group has been designing and building automatic storage systems for over 25 years. Ferretto Group offers the solution for specific requirements: storage heads, automatic storage systems with stacker cranes for pallets and bins and miniload for box drawer systems, multi-depth and dynamic,special and self-supporting systems. The company provides global solutions and “turnkey” projects, and is therefore a single and reliable partner able to fully manage on its account the complex andintegrated phases typical of storage installation systems. The sectors involvedinclude all firms with automatic storage, picking and handling requirements.The design, manufacture and installationof input/ output conveyors, stacker cranes, static structures and management systems are the upshot of the extensive knowhow generated inside the company,a guarantee of cutting-edge and highperformance logistic solutions

About Armes Maini Storage systems Pvt. Ltd. Two of the leading brands in material handling and storage solutions, Ferretto Group from Italy and Maini Group from India, joined hands to form Armes Maini

Storage systems . Operating from India, the company provides end-to-end solutions pertaining to Racks, Mezzanines and Automatic Storage Solutions. “Ferretto Group SpA is an Italian company producing racking, mezzanines and automatic storage systems. The company, founded in Vicenza in 1956, is a sector leader that can provide a complete range of solutions for all storage and filing needs. Besides operating massively in the Italian market, where it boasts many important references, the company has started a large internalization process through direct sales and a widespread network of dealers in the main countries of Europe, Middle East, Africa and the Americas. Competence, experience, competitiveness and excellent service make Ferretto Group SpA one of the worldwide leading companies in the sector of goods handling and storage systems.” Maini Group is one of India’s leading design and manufacturing company, synonymous with innovation & cutting edge technology. The group offers comprehensive solutions in high-precision engineering components, material handling, warehousing & logistics , aerospace and electric vehicles.While the manufacturing base is in India, the warehousing and marketing networks extend over 25 countries. [Contributed by Maini Materils Movement Pvt. Ltd] Web: www.mainimaterials.com

MAY 2016 ENGINEERING REVIEW

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TECH TRENDS

» AUTOMATION

Detectable plastics from igus for maximum safety in foods Magnetic, lubricant-free motion plastics aid in preventing foreign substances from entering foodstuffs

n the food and packaging industry, the highest safety standards apply. To protect consumers, food must be free of contaminants of any kind. As part of its ball and spherical bearing series, igus offers plastic products that are lubricantfree and at the same time, detectable. This guarantees that no lubricants and no plastics enter the production chain during operation or in the event of a system failure. In the plants of the food and packaging industry, metal detectors are now an industry standard. They detect any metallic conductive particles derived from the production environment. Subsequently, the products can be sorted out as soon as possible. But how can plastic particles be traced? That was the question that developers at Cologne-based motion plastics specialist igus asked themselves.

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The solution was finally the development of a special high-performance plastic, which can easily be traced with standard metal detection methods. The material is used today in selected products in the igubal series, which includes rod end bearings and clevis joints, flange bearings, spherical bearings and pillow block bearings. Both the housing and the spherical balls are made of the detectable plastic. This characteristic is sought after in other areas of bearing technology. For example, xiros M180 is a lightweight polymer ball bearing, whose material is also detectable.

production process of the food and packaging industry is the avoidance of contact of product and lubricants in the machine,” points out Lars Braun, Industry Manager for Food and Packaging Technology at igus. A major contribution towards this is made by the lubricationfree and maintenance-free plain bearing materials from igus. Because, they precisely meet these requirements: materials like iglidur A181 or iglidur A350 need not be actively lubricated. Moreover they are compliant with the EC Directive 10/2011 and also with FDA specifications for repeated contact with food

Freedom from lubrication ensures additional safety In addition, these high-performance polymers do not require external lubrication. “A central point in the

For more information Web: www.igus.in

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Anticorrosive coatings protect train components

Corrosion-resistant coatings ensure that rails used in pullout battery compartments and other railway maintenance areas last for their expected lifetimes.

s economies around the globe continue to confront higher energy prices and population density in large urban centers, the worldwide rail industry is poised for steady expansion and ongoing technological innovation.

Keeping trains in service

Chamber where salt spray testing was conducted in accordance with ISO 9227.

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For trains to function at their best, all mechanical moving parts must meet demanding performance and maintenance specifications. Rail products face harsh environmental conditions day after day, including humidity, brake dust, dirt, and corrosive agents that can damage train components. Even seemingly innocuous substances, such as human hair, can build up over time and threaten the smooth functioning of train components. Among the most vulnerable components in this setting are the telescopic linear guides used to enable door movements, passenger ramps for wheelchairs and strollers, and service access to power generators, battery compartments, and HVAC systems. These sliding components face an especially high threat of corrosion because guides must remain closed while trains are moving or out of service, thereby trapping dirt and humidity inside their working

Rails on trains Where are linear rails found on trains? Several styles of these rugged sliding components, including both compact and telescopic rails, are used throughout railcars: • Sliding chairs, doors, and tables in passenger areas • Passenger access doors and ramps for wheelchairs, strollers, and luggage • Pullout compartments for battery and HVAC system Maintenance mechanisms. To make matters worse, maintenance intervals tend to be sporadic and lengthy. In order for telescopic guides and other linear rails to function reliably for guaranteed service lifetimes, metal parts must be treated with durable anticorrosive coatings. In fact, the most demanding rail applications require components to survive industry-standard, salt spray testing for up to 500 hours in compliance with ISO 9227 NSS (neutral salt spray). One such surface treatment — called RollonAloy and applied to Rollon telescopic guides — recently exceeded that standard by 44 percent when it withstood 720 hours of salt spray testing

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2016_04 Engineering Review.pdf 1 22/02/2016 16:45:03

Linear solutions global provider.

CMY

Linear Line Telescopic Line Actuator Line

ROLLON India Pvt. Ltd. - INDIA 1st ﬂoor Regus Gem Business Centre 26/1 Hosur road, Bommanahalli Bangalore 560068, INDIA www.rollonindia.in - info@rollonindia.in

Rollon is a global provider of linear motion solutions for several industrial sectors, such as: industrial machines, railway, automation, packaging and logistics, aerospace.

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without any signs of corrosion.

Surface treatments combat corrosion RollonAloy is a RoHS-compliant trivalent chromium treatment originally used in the automobile industry as a substitute for treatments containing hexavalent chromium, which was found to have negative environmental and health effects. After a galvanizing treatment is completed in accordance to ISO 2081 standards, RollonAloy is applied using a comprehensive passivation process. Applying the passivation layer essentially creates a barrier effect that significantly increases corrosion protection for metal parts. This protective layer handles the wear, friction, and corrosive elements faced by moving parts, keeping the base metal intact and prolonging its working life. RollonAloy is suitable for all styles of Rollon linear guides and is recommended for rail applications where moving metal parts are regularly exposed to harsh environmental conditions, such as high humidity, dirt particles, hair, brake dust and many other corrosive agents. Rollon also offers surface treatments well suited to less demanding railway applications, such as parts that move infrequently or those shielded from punishing environmental factors. Besides RollonAloy, electrolytic galvanization and chemical nickelization are anticorrosive coating methods recommended for use in the railway industry. Electrolytic galvanization, also known as zinc plating, involves applying a thin layer of zinc to the base metal using an electrodeposition process. The primary benefits of this surface treatment include corrosion resistance and the ability to easily apply paint to treated surfaces. The chemical nickelization process

Telescopic Rails from Rollon are used in several railway applications, such as pullout passenger step platforms that must confront harsh environmental conditions. The right coating helps protect rails from damaging corrosion.

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Salt spray testing results

To Lube Or Not To Lube?

In compliance with ISO 9227, several linear rails are placed in a test chamber and subjected to a 5% solution of sodium chloride (NaCl) with a pH of 6.5. The neutral NaCl solution is administered with a continuous spray nebulizer nozzle at 35° C for the testing duration. Evaluations of test samples take place at set time intervals: Test administrators take measurements to determine the quality of surface protection and corrosion resistance among the various test samples. Results of recent salt spray testing determined that the Rollon linear guides coated with RollonAloy survived 720 hours without showing any signs of corrosion. Rollon linear guides treated with two nickelization process–one high quality process and one standard–survived roughly 360 hours. A sample treated with an electrolytic galvanization process had less than half the salt spray resistance of RollonAloy. Comparison guide samples fared even worse. After only 120 hours of salt spray testing, the corrosion-resistant coatings on rails from a Rollon competitor were completely depleted. Test rails included one coated with standard zinc plating and another treated with a nitrocarburizing finish.

Coatings are not the only way to extend the life of linear guides in railway applications. Lubrication can play a role too, though that role is somewhat controversial. Some rail operators choose to avoid the application of external lubricants to linear guide components. They rightly believe that lubricants have to potential to attract particulate matter that could gum up the guide over time. Other operators discount the threat of contamination and apply lubricant to extend the life of linear guides. Both of these approaches have merits, depending on the application. Operators should be aware, however, that the judicious use of an external lubricant can extend linear guide life substantially by a factor of 10 or more in Rollon’s testing. If a lubrication regime is adopted. Operators should favor high-temperature greases. Linear rail manufacturers can provide more specific guidance regarding the best lubricant type. For example, Rollon’s engineering department, can offer recommendations based on the particular railway application.

the time span of the nickelization process. Surface preparation vital to performance Surface preparation is another factor closely associated with the quality and performance of coated metal parts. If base metal surfaces enhances corrosion resistance by adding a are not properly prepared before coatings thin protective layer of chemically treated are applied, even the best coating will nickel to moving metal parts, such as linear not perform as expected. Correct metal rails. Beyond corrosion defense, other benpreparation involves rigorous adherence efits of this process include improved hardto a multi-step process that improves the ness and wear, as well as an extremely tight base metal’s strength and surface finish tolerance range for coating thickness, which even before the final anticorrosive coating improves the linear precision of moving is applied. While some manufacturers may parts. Surface treatment take shortcuts with respect to surface thickness is conpreparation, Rollon follows an extensive trolled by step-by-step method during its rail-finishing processes. Rollon India Pvt. Ltd. 1st floor, Regus Gem Business Centre 26/1 Hosur road, Bommanahalli Bangalore 560068, INDIA Compact Rails from Tel: +91 80 67027066 Rollon are available with a variety Fax: +91 80 67027004 of anticorrosive surface treatments, E-mail: info@rollonindia.in with the right choice determined Web: www.rollonindia.in by the application.

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Experience ‘Integrated Industry’ now: With ready-to-use products for IoT and Industrie 4.0 from Beckhoff

s the world’s leading industrial exhibition, Hannover Messe 2016 provides the premier platform for Industrie 4.0 and highlights the progress towards ‘Integrated Industry’, making it truly tangible. The Beckhoff presence in Hanover is in line with this year’s lead theme ‘Discover Solutions’ and can be found in several areas of the exhibition grounds, focusing on IoT and Industrie 4.0. At the Beckhoff main booth in Hall 9, visitors can explore the expanded Industrie 4.0 forum. Spanning 1,000 square meters, Beckhoff will demonstrate basic technologies and ready-to-use products for the smart factory. TwinCAT Analytics records industrial data synchronously with the process cycle and serves as the basis for comprehensive analytics. TwinCAT IoT supports common protocols used in cloud communication and enables easy-toconfigure connections between the Internet of Things and the Internet of Services. In addition, visitors can see the latest Beckhoff innovations such as EtherCAT P and TwinCAT HMI, and the new terminal integrating highend measurement technology.

Industrie 4.0 from Beckhoff: Four times at Hannover Messe Under the motto ‘Discover Solutions’, Beckhoff will focus this year’s exhibits on concrete solutions for ‘Integrated Industry’

Based on comprehensive and cycle-synchronous data recording, the new TwinCAT Analytics solution enables seamless online and offline analysis of machines and production data.

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in no less than four locations: At the Industrie 4.0 forum on the main booth in Hall 9, Booth F06, Beckhoff will present live demonstrations of products supporting analytics, big data, and IoT communication. As part of the booth for the ‘it’s OWL’ technology network (Hall 16, Booth A04), Beckhoff will demonstrate the current state of ‘Scientific Automation’ and ‘eXtreme Fast Automation’, both of which are BMBF-funded leading-edge cluster research projects. A showcase of SAP, Beckhoff and other technology partners in Hall 7, Booth C04, will feature a live application that demonstrates the close interaction between production processes & business administration workf lows. Its foundation will be the XTS (eXtended Transport System) from Beckhoff. The SAP software communicates directly with the XTS on the basis of standardised services. As a Microsoft Gold Partner, Beckhoff will present its new IoT products such as its easy & secure link between the automation & field levels and the Azure™ cloud at Microsoft’s booth in Hall 7, Booth C40.

Experience ‘Integrated Industry’ now: The Industrie 4.0 forum All applications with Beckhoff PC control technology are essentially ready for Industrie 4.0 today. The new specific IoT and Industrie 4.0 products from Beckhoff make using these features even easier. The complete process control mappings which can be generated from the control technology make it easy for the user to assess the various machines and systems. Extensive Industrie 4.0 features are available at the click of a button. All of this is made possible by a variety of new products. TwinCAT Analytics provides the foundation for predictive maintenance and machine optimisation.

In the smart factory Beckhoff meets the demands with TwinCAT Analytics regarding online and offline state analysis, predictive maintenance, pattern recognition, machine optimisation, and long-term data archiving. requirements regarding online and offline state analysis, predictive maintenance, pattern recognition, machine optimisation, and long-term data archiving. This requires data capture to be as continuous as possible and in sync with the processing cycle. That is exactly why Beckhoff developed TwinCAT Analytics software. All process data can be provided as needed, either locally or as a cloud-based solution on a server, whether on your own corporate network or in a public cloud.

For fast and standardised cloud communication: TwinCAT IoT With its new TwinCAT IoT solution, Beckhoff supports standardised protocols for cloud communications and for sending push messages to smart devices. Quick and easy to configure, TwinCAT IoT provides a variety of functions for exchanging process data via widely-used communication protocols such as AMPQ, MQTT, and OPC UA, and for accessing special data and communication services that belong either to public clouds or local systems.

Complete acquisition and analysis of process data: TwinCAT Analytics The smart factory introduces numerous

Website: www.beckhoff.com

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TECH UPDATE

The real

game changer MSME in Maharashtra would now get latest of Autodesk CAD-CAM-CAE software just for 1999/-*

utodesk, a leading CAD/ CAM software provider announced that it will provide advanced design technology to local MSMEs from the manufacturing sector as per a Memorandum of Understanding (MoU) with Maharashtra government in the launch commenced at Hotel Trident in Mumbai on 5th May, 2016.

Chief Minister Devendra Fadnavis said, “This will enable our MSMEs to uniquely design and manufacture their products as per international standards. This partnership of Government of Maharashtra and Autodesk will create a potential for Maharashtra MSMEs to become globally competitive and locally productive.” Mr. Apurva Chandra, Principal Secretary (Industries) of the Government of Maharashtra was the chief guest for the event & being welcomed by Autodesk Team along

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with Pradeep Nair, Managing Director, Autodesk, India and SAARC. As per the agreement Autodesk will be offering 2 years subscription of Fusion 360 software just for the price of Rs.1999 only which is discounted by around 90% of its offer price, further it will be offered free of cost to the MSMEs of Maharashtra with the annual turnover less than 1 crore who are registered with the Department of Industries, Government of Maharashtra. Autodesk also launched the customer showcase portal www.bharatfusion360.com which will help promote the work of MSMEs who derive greater business success by using Fusion 360. Further, the company will help the MSMEs to showcase their work at national and international platforms. Autodesk would also be training around 8,000 franchisees in the state on the optimum usage of Fusion 360 design platform. Commenting on the occasion, Apurva Chandra, Principal Secretary (Industries) of the Government of Maharashtra said, “We are glad to see global technology leaders like Autodesk coming to the forefront in helping the growth of MSMEs in Maharashtra. Our government will leave no stone unturned in ensuring that we provide the most congenial growth environment to the businesses in the manufacturing sector. With

the cutting-edge design technology from Autodesk, we are confident to witness many innovative products being churned out by the MSMEs of Maharashtra.” “Today, with Cloud technology, it’s possible to democratise design. As the pioneer in delivering the entire product development process on a cloudbased platform, Autodesk is uniquely positioned to enable Indian MSMEs to leapfrog to world class manufacturing capability,” said Pradeep Nair, Managing Director, Autodesk, India and SAARC. The event included the real-time experience of various users of

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TECH UPDATE

Autodesk Fusion 360 from Nashik, Pune and Thane. They shared their most exciting experience of using this software by achieving cost and production efficiencies. Fusion 360 is a complete CAD, CAM and completely integrated product development platform available on the cloud. It helps move easily between industrial design and mechanical engineering with direct, freeform and parametric modeling. It saves the extra cost for data management, simulation and visualisation. It enables you to work online, offline, Mac, PC or mobile.

lntegrated CAD CAM You can forget expensive, disjointed tools to design, engineer and generate CAM output. Take your product development from design to engineering to fabrication, including integrated CAM for a cost for less than the maintenance on other CAM systems. The CAM capabilities of Fusion 360 enable you to quickly generate toolpaths that cut cycle times, reduce machine and tool wear, and produce the highest-quality finished parts. When manufacturing, Roughing operations often consume the most time, and always remove the most material. Fusion 360 contains the same proven HSM family of cutterpaths, including Adapative Clearing the leading strategy for faster machining, constant loads and reduced tool wear. 2D strategies include drilling, contouring, pocketing, facing, and adaptive clearing. 3-axis CAM offers parallel toolpaths, horizontal clearing, penciling, scallop/constant stopover strategies, and spiral/ morphed spiral for more organic designs. Avoid file translation frustration Fusion 360’s accurate design file import and translation functions mean communication issues with partners, suppliers and customers are a thing of the past. Fusion 360 gives you the ability to work with customers using various popular CAD syslems, resulting in improved collaboration and desisn processes, allowing you to save more time and win more business. With fully integrated CAD/CAM functionality, you can also make necessary CAD edits quickly and professionally withot costly rework. lmport file formats such as SLDPRT, SAT, STEP, IGES STL and OBJ and many more. Export back data in

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the formats such as IGES, STP, SMT, DXF, DWG and lnventor. Work anywhere from any device, share with anyone Just Login with your user name on any device and get access to your data anywhere. Invite unlimited team members to your projects. Keep track of versions, and view the work others have done within the project through a live activity feed. You also can keep track of progress and team activities via the A360 Team application in your web browser. Securely share your designs with specific individuals using the public sharing link from your data panel. The link will allow the recipient(s) to view and download the design within their web browser with our free 3D viewer-even if they don’t have an Autodesk Account.

MAY 2016 ENGINEERING REVIEW

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Why you should use Aditron Systems? IMPLEMENT : Know you need to implement Aditron quick die change system in your shop, Process of starting Aditron QDC system, low cost automation at your press shop

DITRONQDC few lean manufacturing methods increase press uptime, lower per-part costs, and provide an immediate return on investment (ROI) as readily as quick die change (QDC) does. Although the merits of QDC likely are well understood within the stamping field, tailoring a program to a company’s current equipment and operational requirements can be challenging Implementing a ADITRONQDC program is an easy and straightforward process, if it is done by grouping dies and presses in an orderly way. For each group of presses, ADITRONQDC implementation consists of die handling roller top trolleysdie storing roller top system with optimum use of man power and equipments 1. To develop a plant standard, consider all the data from several presses, rather than a single press, when possible.– or select few presses or divide the die weight wise or size wise or application wise 2. Determine Die Lifting Requirements with Aditron heavy duty long life die lifters Determine if die lifting is needed to mobilize the die easily during changeover. Inspect all the dies in the press to ensure their bottoms are flat. Examine the bolster plates, which require full or temporary supports during lifting, for large cutouts or other features that may interfere with aditron die lifters 3. Select aditron Lifting Device Style Die density die weight will decide lifting device style.- roler size Low-density dies enerally can be lifted with aditron roller rails, , which allow the die to be moved in liner direction). High-density dies usually require several rails or a pair of heavy-duty roller rails, which move in only one direction, the direction it is inserted, or inline 4. Lift Capacity Select a aditron die lifter enough power to

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lift the maximum die weight in that size of t slot/ u slot and move the die in the desired direction. List out die sizes and weights. Calculate the die load in kgs per 300 mm pair of aditron die liftors. Bolster bed length in the direction of slots in feet/ mm. Die width in the direction of the slots in feet (assuming the slots are in the same direction as die insertion) Die weight — safety of factor ten percent Calculate each die’s density as defined here and determine which has the greatest density. WARNING: It is very important that you do not select rails’ lift capacity by the overall length. Rails that are as long as the entire bolster allow for the die insertion, but only the length of the rails that is under the die at any given time is actually lifting the die.–select Aditron die lifter suitable for your largest die on this press Once you have calculated for the heaviest die, confirm that the lifters chosen have the capacity to lift all the dies. Typically, choosing the heaviest die density will ensure correct capacity. However, slot location can be a problem if both large and small dies are run in the same press, because some of the dies might be too small to have all the rails under them. For example, four die lifters are in the bolster to lift a large die, but when small dies are added, only the two middle lifters actually are in a position to do the lifting. You need to verify that the two middle ones can lift all the smaller dies.–with aditron roller top die lifters perform this calculation for all dies to verify that each die can be lifted: Die weight : Once you have determined which aditron die l styles and capacities are needed, you can determine the needed overall rail length ) and slot configuration (3⁄4-inch slots, 1-in. slots or two inch , T slot, or rectangular). 5. Choose Die Removal Method Getting the operating die out and the new die in begins by choosing a die removal method, based on space needs and press operations. die weight

For all die sizes, there are three basic options: • Aditron hydraulic oller top trolies • Permanently mounted roller top die table–stationary design • Aditron roller top mechanical trolleys with automatic interlocking facilities Mobile hydraulic or mechanical trolley that takes the die to the press; provides some type of alignment to it; and has a means of moving the die into the press directly. It provides some interesting options, but the control and accuracy limitations of bulk moving equipment typically available may seem contrary to smooth and accurate die placement. Permanently Mounted Aditron roller top Die Table. This is basically a heavy-duty table with rollers attached to the press. It allows die staging and eliminates the need to remove dies from the area, consistent with lean manufacturing principles. However, die tables can interfere with press access and press operations and are a fixed investment. Bolster Extension. These are equipped with rollers that are level with the press’s die lifters and are attached to the press during die movement. Once the die is moved onto the bolster extensions, it is easily accessible from the bottom for removal. Bolster extensions can be removed IMPORTANT: You need to see your pay back is directly or indirectly the reduction in die change time- reduced efforts not waiting for other equipment to come for die exchange lifting shifting to avoid all delays resulting in increased production:–although the time required to remove clamps and re clamping remains same Web: www.aditronqdc.com

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Design tools for all: The 35-Year evolution of CAD Jon Hirschtick is the founder of Onshape, the first professional 3D CAD system to run on a web browser, phone or tablet. He previously founded SolidWorks, was the director of engineering at Computervision, and began his career as an intern at the MIT CADLab. His hobbies include magic, golf, blackjack, 3D printing, tennis and yoga.

ver the last four decades, I’ve watched CAD grow to become a vital part of the way virtually all products are designed and manufactured. In 1981, when I was a student at MIT’s CAD research lab, there were probably only thousands of CAD users in the world. Now there are millions. It’s understandable why CAD began as a tool for the elite few. Back then, one seat of CAD cost hundreds of thousands of dollars – you ordered the computer, the software, the monitor, the table and even the chair all from the CAD company. It was sold as a “turnkey system.” The notion that you’d buy software and run it on an independent computer was considered wacky. At the same time, engineers were paid a fraction of what they are paid today. You had one super expensive computer surrounded by a lot of “cheap” engineers. Now, it’s the exact opposite: Each highly-paid engineer can easily be surrounded by many relatively cheap computers – laptops, desktops, tablets,

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and their phones. Then two very significant things happened in the 1990s. First, CAD technology evolved from simple “wireframe” and 2D drafting to 3D solid modeling. Equally important, the computing platform migrated from mainframes and proprietary terminals (the CAD companies made the hardware) to UNIX workstations and Windows PCs. Moving to desktop personal computers was truly transformational: It was the democratization of CAD, making the tool accessible to millions of engineers whose companies previously could not afford the technology. With 3D professional CAD, every company could make design improvements faster and dramatically speed up their production cycle. Having been personally involved in some of these changes, it’s been gratifying to see 3D solid modeling go from a curiosity in a lab to eclipsing 2D and becoming the way products are routinely designed. But the story isn’t over. The computing platform is evolving yet again. Cloud, web and mobile technologies are making CAD available on any computer, tablet and phone.

Running CAD in a web browser means engineers can work on any Mac or Windows PC or even on inexpensive Chromebooks, lowering the financial barrier for entrepreneurs and startups to turn their ideas into successful products. With cloud-based CAD, design tools are also finally adapting to the way people really work today. Many products are no longer designed and manufactured under one roof. Design teams are often distributed in offices around the world. For the first time, multiple engineers can simultaneously work on the same CAD model. With mobile CAD fully running on phones and tablets, design teams no longer are chained to their offices; work can happen whenever and wherever inspiration strikes. Engineers aren’t so “cheap” anymore. Increasing their productivity is vital for a company to survive and thrive. As CAD technology continues to rapidly evolve with the times, I’m thrilled to still have a front row seat.

For more information editor@divyamediaonline.com

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TECH TRENDS

» AUTOMATION

NORD drives provide boost for in-house paint shop At the NORD DRIVESYSTEMS headquarters, the power, functionality, & intelligence of NORD products are used to the company’s own advantage across the factory floor, with geared motors & drive electronics handling various applications. Notably, this includes a recently established surface coating facility, where NORD systems drive overhead conveyors, fans, & hoists. The new surface coating facility at the NORD DRIVESYSTEMS headquarters in Bargteheide, Germany, has twice the size of the previous paint shop. New paint booths, an automated high-bay warehouse for paint cure, and packing stations together occupy 1,400 m². An intelligent control system has, on average, halved the lead times for paint jobs. Any drive can be painted and shipped within two hours after assembly.

Paint line with a fast lane NORD configures each drive system to order, drawing almost exclusively on components manufactured in-house. Application-specific coatings are part of this process. Fast processing of urgent orders has now become much easier. Previously, geared motors were routinely returned to the end of the queue once the first coat had been applied. The new conveyor system enables completely flexible routing: after curing, highpriority products can jump the queue and immediately get their next paint coat. Intelligent sorting algorithms also ensure that paint jobs with equal priority are optimally grouped by coating systems and shades. This has reduced wastage and setup times. In addition, state-of-the-art filter systems in the paint booths limit pollution to a minimum. The packing stations also draw on the smart sorting capabilities of the conveying systems: each packing station can be designated to handle a particular mode of shipment.

The right drive for each and every task More than 100 drives take over various tasks in the new facility – NORD drive technology powers conveyors, hoists,

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Three out of four available paint booths are now regularly used, up from two before the recent extension. exhaust ventilation and cooling fan systems. Drawing on its own modular drive program, NORD has configured optimal solutions for each of the various requirements. Both highly efficient helical bevel gear units and worm gearboxes with very high gear ratios are used. Depending on the performance and function requirements, the motors are controlled by different frequency inverter models.

Ventilation systems Four fans with a 22,000 m³/h circulation capacity ensure proper air exchange in the paint booths. The fan drives are equipped with 22 kW distributed drives from the SK 200E frequency inverter series. The control solution enables standby mode and ensures adequate compensation of filter pollution by regulating the motor speed based on the measured air flow

rate. Like all NORD inverters, these drives provide smart energy saving functionality. They automatically detect partial load and reduce the energy consumption of the motor accordingly. Since the inverters are installed on the roof along with the ventilation units, they are designed for IP66 ingress protection.

Overhead conveyor The NORD motors and gear units passing through this facility often weigh several hundred kilograms. Robust hardware is therefore required. The overhead conveyor is operated at a maximum speed of 10 m/ min. It is equipped with over 100 smoothrunning worm geared motors. Some parts of the facility are classified hazardous areas (Ex zone 2). The 14 drives installed within them are controlled by SK 500E series cabinet-installed inverters. All other drives

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TECH TRENDS

» AUTOMATION

Paint jobs can be handled more efficiently and faster.

feature a motor-mounted SK 180E type inverter. Designed to achieve a great price/ performance ratio while offering a full complement of efficiency functions, the SK 180E supports motor outputs from 0.25 to 2.2 kW to address all simple handling tasks in horizontal applications. A technology box installed with the inverter adds a Profibus interface as well as various sensor and pneumatic interfaces for transmission of position data and controlling switches. The integrated drive configuration capability as well as the consistent use of plug connectors was instrumental in minimizing the drive installation effort in the extensive facility. The AC vector drives have a separate 24 V control voltage supply and can therefore be accessed via Profibus even when the 400 V power supply is switched off.

Hoist technology The facility includes a high-bay storage as a drying room. An automated storage and retrieval unit enables flexible access to all drive components. Each drive unit can be retrieved via its individual designation and automatically transported to a paint booth with the overhead conveyor. The automated storage and retrieval unit is equipped with powerful helical bevel geared motors for hoisting and driving. The telescopic jib that picks up the payload is extended by means of a light-weight, compact aluminum helical inline geared motor. NORD has implemented position control loops for the hoisting and driving axes. That is, type SK 545E frequency inverters simultaneously process absolute position data and the signal of an incremental motor encoder. They then autonomously adjust the position according to the set value specified by the automated storage and retrieval unit’s PLC and report back the reached position to the PLC. The drive electronics control speed and gentle acceleration and braking (S ramps). In this application, Profinet interfaces were integrated for communication with the PLC.

Company background Technology box for easy connection of sensors and Profibus communication with the control system.

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NORD DRIVESYSTEMS develops, produces and sells drive technologies with around 3.200 employees, and is one of the

The new paint-coating facility at NORD enables extremely flexible management of paint jobs by means of automated conveyor and warehouse technology. international leaders in the industry. In addition to standard drives, NORD supplies application-specific concepts and solutions, even for special applications, for example with energy-saving drives or explosionprotected systems. Gross sales amounted to approx. EUR 540 mn in the 2015 business year. The company founded in 1965 now has over 36 subsidiaries worldwide. The closely meshed sales and service network ensures optimum availability for short delivery times and customer-oriented services. NORD produces a wide variety of drive units for torques from 10 to 200,000 Nm, electric motors with powers from 0.12 kW to 1,000 kW as well as the necessary power electronics in the form of frequency inverters and servo controllers. Inverter solutions are available for classical installations in the switch cabinet and for decentralised and fully integrated drive units. For more information Web: www.nord.com

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TECH TRENDS

» AUTOMATION

Simply aim, trigger, done! Fast, versatile barcode reader from Balluff for harsh industrial use The wireless version features Bluetooth to give the user the greatest possible freedom of movement within a range of up to 100 meters around the base station. This flexible portable reader is ideal for a variety of applications including traceability, automated replenishment and logistics.

ith the new Industrial Handheld Reader BVS HS-P Balluff expands their offering of optical identification: the portable reader with intuitive operation reliably reads high-resolution barcodes as well as codes over a wide range at a read distance of up to 110 centimeters. Direct Part Marking (DPM) codes can also be read. The ruggedly constructed device offers IP 65 protection and withstands drops from up to two meters without any damage. The wireless version features Bluetooth to give the user the greatest possible freedom of movement within a range of up to 100 meters around the base station. This flexible portable reader is ideal for a variety of applications including traceability, automated replenishment and logistics. The ergonomically designed Industrial

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Handheld Reader BVS HS-P from Balluff decodes all common 1D, 2D and stacked barcodes on objects moving at up to 0.8 meters per second. Even tilts of up to 40° and rotation angles of up to 180° do not affect the read reliability. The optical aiming system with a highly visible laser marking border makes handling and target acquisition simple. Acoustic and optical LED signals including a projected LED spot on the code ensure reliable read confirmation in loud or bright surroundings. The wireless version with its highcapacity rechargeable battery increases the flexibility and enables a variety of portable situations. The Industrial Handheld Reader BVS HS-P from Balluff is simple to integrate via USB, Bluetooth or RS 232 interface. The ergonomic design and low weight ensure comfortable and fatiguefree.

For more information Web: www.balluff.co.in/

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Innovation Generates Opportunity

Nordson EFD solutions offer the latest advancements in precision dispensing technology. Find out how our innovative systems can generate new manufacturing opportunities. Learn how you can achieve: Faster Dispensing • New valves that jet at up to 1500Hz Greater Accuracy • Innovative systems that deliver precise, repeatable deposits as small as 150 µm in diameter Lower Cost of Ownership • Robust, modular, tool-free designs that easily adapt to different applications EFD’s innovative solutions can help you improve process control and productivity for greater overall cost savings and profitability. To learn more contact us at +91 80 4021 3600 or india@nordsonefd.com .

See it in action

nordsonefd.com/improved-dispensing

Nordson India Pvt Ltd, 143A, Bommasandra Industrial Area, Bangalore – 560099, India. india@nordsonefd.com +91 80 4021 3600

Engineering Review 0316.indd 1

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ENGINEERING REVIEW |

163 | May 2016

TECH TRENDS

» AUTOMATION

Smaller and smarter : Fischer Connectors expands its robust Fiber Optic Series with a new single fiber optic connectivity solution Fischer Connectors, the worldwide leader in push-pull circular connectors and cable assembly solutions, today launched its new single fiber optic connector (FO1) within its Fischer FiberOptic Series. This miniature, lightweight, rugged connectivity solution is easy to use and ensures premium performance even in harsh environments.

he FO1 connector is available either in pre-configured reels or integrated into custom assemblies for applications in instrumentation, sensing, defense and broadcasting – to name only a few of the various fields for which this new product is ideally suited.

Combined miniaturization and robustness The new connector fulfills the growing market need for higher data transmission rates over long distances, while reducing space and guaranteeing performance by means of rugged miniature solutions. The FO1 connector integrates fully into the existing Fischer FiberOptic Series, wellknown for its robust and faultless optical performances in any conditions, combined with easy use, cleaning and maintenance even in the field. UPC & APC polishing reduces insertion and return losses, making

devices more secure, while IP68 sealing provides highly valuable device protection. The push-pull locking system allows quick and easy connections and disconnections, making these connectors ideally suited for outdoor environments. The removable sleeve holder (monobloc mate adapter) ensures that end faces can be cleaned easily, keeping electronics in top condition.

More flexibility for more efficiency “We’ve extended our Fischer FiberOptic Series bearing our customers’ needs for flexibility and efficiency in mind”, says Christopher Martin, FiberOptic Product Manager at Fischer Connectors. “The product line’s main benefits – high optical stability in harsh environments, robustness, and ease of use, cleaning and maintenance – remain the same. But we’ve designed this smaller product to be even lighter and more flexible so that it’s easy to integrate into existing solutions, saving time and money for our customers.” As a reminder, the Fischer FiberOptic Series already includes two versions: a rugged fiber optic connector with two or four fibers, and a rugged hybrid connector with two fiber channels and two electrical contacts.

In a nutshell: main technical specifications • IP68 mated & IP67 unmated ingress protection (Norm IEC 60529) • UPC & SM APC polishing • Easy cleaning even in the field • High optical performances for high precision and data transmission rates • Harsh/extreme environment fiber optic

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AUTOMATION »

solution (Norm IEC 61753-1 Cat. E) • Push-pull user-friendly mating plugs & receptacles • Available with gas-tight panel receptacles and with SM & MM optical fibers • Size: 13 mm

The FO1 connector has been tested to withstand temperatures of -40oC. Selecting fiber optic solutions made easy The FO1 connector can be pre-configured with Fischer FiberOptic Series reels of any required length, a convenient and flexible turnkey solution. To enable customers to choose the right connectivity solution for their specific needs, Fischer Connectors also provides a user-friendly request form that guarantees the mistakeproof configuration of cable assemblies.

Showcased at OFC tradeshow The FO1 connector will be showcased for the first time at the Optical Fiber Communication Conference and Exhibition (OFC, 22-24 March, Anaheim, California, USA) on Timbercon, Inc.’s booth no. 2012, among other

are commonly used in fields requiring faultless quality, such as medical equipment, industrial instrumentation, measuring and testing devices, broadcast, telecommunication and military forces worldwide. Primary design and manufacturing facilities are located in Saint-Prex, Switzerland, with subsidiaries

TECH TRENDS

and distributors located worldwide.

For more information www.fischerconnectors.com

IIoT Data. Processes. Devices. Locations. Red Lion has been connecting devices and moving data for years, enabling customers to easily advance to the Industrial Internet of Things (IIoT). Our IIoT-ready industrial automation and networking products: • Connect: Extend equipment lifespan with protocol conversion • Monitor: Improve process visibility with visual management • Control: Push control to the edge with remote monitoring • Network: Expand network reliability with industrial Ethernet Learn more today at www.redlion.net/moreIIoT

Fischer FiberOptic Series solutions. About Fischer Connectors: Fischer Connectors has been designing, manufacturing and distributing high performance connectors and cable assembly solutions for 60 years. Known for their reliability, precision and resistance to demanding and harsh environments, Fischer Connectors’ products

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» AUTOMATION

Optimize! Softing’s New Tagline and Logo Highlight the Company’s Value Proposition for the Future Softing, an international manufacturer of hardware and software for implementing and improving the performance of data exchange processes in applications for the automotive industry, industrial production and IT networks, reveals elements of its new corporate design.

ith the publication of its annual report for 2015, Softing is gradually introducing its updated corporate brand, which is being expressed primarily through a new logo and tagline. “Softing’s growing internationalization and the recent expansion of its range of expertise and services have made it necessary to reposition the company,” said Dr. Wolfgang Trier, CEO of the Softing Group, explaining the motivation behind the change. In cooperation with the renowned brand strategist Günter Käfer, the new brand identity was developed reflecting the company and its enlarged portfolio of services. The resulting brand positioning, which applies to all divisions, will also be expressed through new communication elements. “Since Softing was founded over 35 years ago, its appearance has remained largely unchanged. The new lettering has made the logo more technical and modern without damaging its recognition value. Furthermore, the bright blue symbolizes our technological core expertise and two key values of our brand personality: service and loyalty,” said Wolfgang Wende, Senior Vice President Corporate Marketing. The logo can be supplemented with the tagline “optimize!” depending on the use case. This communicates the condensed value proposition of the Softing corporate brand. The tagline is an appeal: Upcoming trends such as the Internet of Things, connected cars

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and Industry 4.0 have prompted efforts to more comprehensively improve the efficiency of equipment and processes, meaning that companies will be under even more pressure to optimize in the future. In order to cope with this, reliable information and the efficient exchange of data are essential – and Softing is a competent partner here.

About Softing Softing is a management holding company run in accordance with the principles and values of a German Mittelstand enterprise. Due to the increasingly international focus of its operating divisions, Softing is respected as a strategic partner by global corporations too. The Automotive, Industrial and IT Networks business segments market cutting-edge software and hardware products as well as services. In close partnership with customers, Softing uses standard products, among others, to create highquality, customized solutions that bridge technological gaps. Softing’s engineering intelligence implements and improves the exchange of data and information, enabling customers to optimize their value chains.

For more information Web: www.softing.com

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12 INTERNATIONAL MACHINE TOOLS EXHIBITION

AIEMA

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FACE TO FACE

GEM glistens in process cooling & drying Gem Equipments Pvt. Ltd. based in Coimbatore and founded by the technocrat colleagues, Mr. K.P. Manoharan. Mr. G. Ravichandran and Mr. C. Raviselvan way back in 1984, has carved its niche in process cooling and drying. In a little over three decades, Gem has established itself as the largest manufacturer of compressed air dryers in the country, making over 6,000 dryers in a year, a large chunk of which goes to OEMs. These dryers are used in core sectors like petroleum, chemicals, fertilizers, gas processing and co-generation electrical utilities. GEM has an on-going tie-up with Orion of Japan for manufacturing Desiccant Dryers in India. Gem is also a renowned name in cooling towers and chillers. The first Indian cooling tower company to replace aluminium alloy sprinkler with nylon 66, the first Indian company to develop combo cooling systems to conserve industrial water, and the first South India company to develop modular cell FRP cooling towers for higher flow applications and as alternative to RCC towers, Gem has been treading a path of innovations all through these years. Mr. P.K. Balasubbramaniian speaks to Mr. K.P. Manoharan, Managing Director, Gem Equipments to get more insights into his company’s technological innovations, future thrusts and growth strategies in a highly challenging business environment. Excerpts: Q. You are known for your capabilities in designing customized systems. What’s the latest in your compressed air dryers?

“Comprehensive range of products & solutions, presence in air and water, patronage from OEMs, contemporary technologies and back-up from our Japanese partners are our major strengths,” says Mr. K.P. Manoharan, Managing Director, Gem Equipments Pvt. Ltd.

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Our Nexgen Refrigerated Air Dryer is an embodiment of engineering excellence, innovation and reliability. The heat exchangers are designed to provide highly efficient heat transfer. It features honeycomb construction of aluminium fins giving true cross-flow for greater effective temperature differences, nonclogging larger cross-sectional area for air flow, integral air-air and air-refrigerant exchanges, with stainless steel demister moisture separator, robust non-corrosive grade aluminium, and larger heat transfer area for higher efficiency. The rugged electronic panel displays inlet,ambient and dew point temperatures in single display on demand. The tripper module gives alarm for compressed high discharge pressure, compressed low suction pressure, expansion valve malfunction, auto drain valve function and fan motor cycling. The VFD compressor with speed control proposed to manufacture in future is one of the major developments towards optimization of refrigeration systems based on average load under R&D now. For periods of high cooling demand, the

compressor speed can be increased, and vice versa for low cooling demand. In short, it is PLC based, operating on conventional gas, using optimized power, and demonstrates better dew point capacity and reliability.

Q. What are your innovations in cooling towers? Our bottle type FRP cooling towers with a capacity range 100 to 4500 lpm are really innovative. They require no sprinklers to be maintained, and operate for lower pressure return water. They are ideal for multiple inlets and outlets. These FRP towers also come in square type with stationary nonclog nozzle for easy maintenance, and PVC fills for larger contact surface area. Inevaporative cooling, we offer both coil type and modular type. In the coil type, the cooling water moves in a closed loop; hence no contamination. In the modular type, aerodynamically designed FRP fan blades are used for better efficiency and walkway is provided for access and service Our Dry Cooling Towers are in a class apart. The DCT type has a capacity range of 120 to 3,000 kVA generator ideal for 1-10 MW power plants. The DGAS type comes in horizontal configuration, suitable for gas generators and adaptable for heat

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FACE TO FACE

GEM is a dominant name in cooling towers. As of now it has 10,000 installations in the country.

recovery. The capacity range is 500 to 3000 kVA Power generator. Our Aqua Saver( GAS) is designed to suit 100 to 5000 kW induction furnaces and 30 to 1000 HP air compressors. All these models reduce water consumption and conserve water. Moreover, in the absence of scaling, they hardly require any maintenance. We have recently bagged an order from Jordon (through ISGEC) for a dry cooling system valued at Rs.1.8 crore. Similarly we have also received an order valued at Rs.2.3 crores for a dry cooling system from Suzuki for their Gujarat Plant. We would also soon execute an order for large size evaporative cooling towers from a customer in Philippines.

Q. Your Bottle type FRP Cooling Tower is said to be a revolutionary product. What are its special features? Our Nexgen Bottle type FRP Cooling Tower features superior extended shaft flange mounted frame, waterproof with aluminium body, S.S. shaft and EPDM sealing. The body is UV protected with a glossy finish. The FRP louver profile reduces water spillage. It has a high efficiency aerodynamic fan with axial flow and low noise. It is made of corrosionfree aluminium which is computerized balanced and wind tunnel tested in Germany. The spiral fills made of rigid PVC are clogg-free resulting in long life. This revolutionary product manufactured using the RTM(Revrse Transfer Mould) technology goes with a 5-year warranty for FRP body

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GEM has its modern, well equipped manufacturing facility in Coimbatore. Seen here is its Testing & QC Section.

and structure.

Q. Anything new in your chillers? Well, we offer Industrial Chillers up to 100TR capacity. These factory assembled packaged unites go with a 2-year warranty which is industry’s first. The Mini series Industrial chiller uses a coaxial type heat exchanger. The design maximizes exchanger efficiency by using copper tubes in a coiled tube-in-tube arrangement. It promotes turbulence break-up boundary and maximizes the heat transfer rate with minimum pressure drop. A counter flow pattern is used to achieve maximum temperature difference. A series of Nexgen Chillers from 5 to 15 tr capacity under development has a high power efficiency and low footprint.

Q. So what’s your expanded portfolio today? We are primarily into Refrigerated Air Dryers, Cooling Towers and Industrial Cooling Systems – all utility products essential for every industry. You can add to these the compressed air accessories we make like the After Coolers, Moisture Separators, Compressed Air Dryers, Air Filters and other contamination removing equipment, you get a complete picture of our product spectrum.

Q. Could you throw some light on your manufacturing facilities? We have a sprawling, well equipped manufacturing facility in a 5-acre verdant land. We have a workforce comprising 200

dedicated employees. A good number of them are professionally qualified managers and engineers involved in Engineering, Planning, Procurement, Production, Quality Assurance and other allied functions. They are assisted by a select few consultants and specialists in specific domains. We are following the state-of-the-art manufacturing process and the Japanese methodology for chiseling out products of impeccable quality and enduring value. We have a technology tie-up with Orion, Japan for manufacturing Desiccant dryers as per their design in India and for marketing them under Gem brand in India and abroad. We have vast experience in designing, manufacturing and supplying Air Cooled Heat Exchangers for various process applications.

Q. What’s your R & D set-up? With an unwavering commitment toquality and excellence, we have set up and nurtured our in-house R & D with the best of talents and in-depth knowledge of international codes which facilitate designing products to ISO standards. We have ISO-2001-2008 accreditation from DNV. We are also a member of CTI. We work in close co-ordination with research institutes and the user industries which help in developing new products and improving existing ones to meet the exacting requirements of our customers spread across the world.

Q. What’s your customer base? Just as our basket is full of varied products,

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FACE TO FACE

A view of GEM’s cooling tower warehouse our customers also represent diverse industry segments like automobiles, cement, food processing, pharma, glass, plastics, power, textile PET bottle, chemical & fertilizer, etc. Some of the prominent names are: L &T, Gujarat Cement, Ultra Tech Cement,Zuari Cement, Hindustan Newsprint, TNPL, West Coast Paper Mills, ITC Bhadrachalam, Neyveli Lignite, Ennore Thermal Power Station, Karnataka Power Corporation, Areva, Vizag Steel, Jindal Steel, Bhilai Steel, Tata Steel, Bhokaro Steel, Powerica, Hindustan Lever, Saint Gobain, ELGI Equipments, Atlas Copco, Chicago Pneumatics, PSG Group and so on.

Q. What is your service set-up? We have a strong team of 22 service engineers who are responsible for erection, commission and upkeep of our systems. They work in tandem with our channel partners spread across all major cities in India. This ensures that all service calls are attended with the shortest time.

Q. What are your growth strategies?

We are opening a Warehouse-cumAssembly Unit at Bhiwandi, near Mumbai shortly. The unit will stock all our standard products and accessories. The end product can be assembled here and supplied to the customer. We shall have a dedicated Q. Why do they come to you team attached to the unit. We shall be again and again? working in tandem with Almost 80% of the our channel partner to orders we receive are make this business model repeat orders. Product a success. This would quality, excellent service ensure availability of our back-up, and ability to products and services provide cost-effective & to the local customers optimum solutions are our at a short notice. Once attributes that make these this is a success, we shall discerning customers replicate the model and come back to us again set up such warehousesand again. We do value cum-assembly units engineering, save costs in key industrial hubs and keep a constant check like Delhi, Ahmedabad, on input costs so that the Hyderabad, Calcutta etc. GEM’s bottle type FRP Cooling benefit can be passed on Our OEM business Tower with attractive features and to the customer. for cooling systems is end-user benefits

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Nexgen Refrigerated Air Dryer – an engineering marvel expected to grow steadily. The off-take of compressor manufacturers like ELGI, Atlas Copco, etc. will increase substantially. This would help our business to grow at least at 15%. The business with Powericais expected to double next year. We can also expect increased business from St. Gobain, Nissan and Maruti Suzuki. Our order booking for radiator cooling for gensetsin marine containers is also growing at a fast pace. Last year we sold approx. 10 units, this year 110 units and next year it should touch 200 sets. At our plant we have introduced the bin system for all fast moving items. At any given time we shall maintain sufficient numbers in stock. Thesestock model would improve our delivery time and enhance the delivery rating with our esteemed OEM’s

Q. Where will you be five years hence? Our target is to touch a sales turnover of Rs.100 crores by 2020. With our innovative products, ever-growing customer base and our planned growth strategies, it would not be difficult for us to achieve this target.

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173 | May 2016

INDUSTRY SPEAK » COMPRESSORS

In the days to come, all our compressors can also be controlled through a smart phone app making it easy to the operator as well as owners

Mahesh Nandurkar, Vice President & SBU Head-ACD, Kirloskar Pneumatic Co. Ltd.

Q. What are the positive developments which would give a new fillip to the compressor industry? As we know, Positive displacement compressor segment is categorized into reciprocating and screw compressors. These compressors occupy around 68% of the market share. Due to its low cost, these compressors are widely adopted and preferred all over the world. Screw air compressors are the most commonly adopted compressor technology and is advantageous for applications requiring less input power. However, owing to the ever-increasing cost of power, the need for energy efficient compressors is increasing. Further, in the sizes of plants, be it steel, power, cement or textiles, there is multi-fold capacity enhancement seen in recent times. Both these factors put together are ready to give a boost to Centrifugal Compressor technology. The estimated growth of Centrifugal machine will be about 13 % plus CAGR. The Govt. has accelerated road

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building to almost more than 6.8 km per day. This would step up the need for Diesel portable machines. The Rajasthan Govt. has announced funding for improving the energy efficiency of textile plants. This would give impetus to large electric screw and centrifugal machines. The commodity prices are likely to remain stable. All these are conducive to industrial growth. Kirloskar Pneumatic will have a fair slice of the cake.

Q. Any flip side that would hamper growth? Despite the sluggish economic growth, we have seen growth of about 20% plus. With things moving in a bit more positive direction, things would only improve from here on.

Q. How would you bring down the total ownership cost to the customer? We at Kirloskar are working on this; we are trying to find every way possible to achieve lower ownership cost. As a solutions provider, we understand that the customer needs a product worth every penny he invests. We have started various initiatives in our company so that we can get the first-time-right product with better quality. Energy efficient machines are the new trend in the market; these machines ensure that you pay less on your electricity. While

being energy efficient, our machines also entail low maintenance cost; and almost all the key components are manufactured by us in-house, thus giving a great handle on cost.

Q What innovations do you propose to showcase as a part of your growth strategy in a competitive environment, but a burgeoning economy? We are working to widen our product basket. The market is slowly shifting towards centrifugal technology and we have to be ready for it, when it happens. So far this project seemed to be a great success and we hope this turns out as expected. In an era of automation and remote access of everything, machines with remote monitoring features are to be marketed; this will be beneficial for both sides; for Customer to keep an eye on his machine and Service provider to tackle the problem from any corner of the world. IOTs are going to govern our personal as well as professional life. Compressors being a vital utility product, we are building compressors with state-of-art ‘IOTs’ which will help in remote operations & maintenance of the same. In the days to come all our compressors can also be controlled through a smart phone app making it easy to the operator as well as owners.

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Deisel driven Compressors Capacity: 155-1200 cfm; Presuure: 7-22 barg

Quality Compressed Air Provider. Exceeding your expectations. Our Products:

Reciprocating Compressors Electric Screw Compressors Diesel Driven Compressors Centrifugal Compressors Electric Screw Compressors Capacity: 30-1047 cfm; Presuure: 7-13 barg

KIRLOSKAR PNEUMATIC CO. LTD.

A Kirloskar Group Company

Enriching Lives

REGD. OFFICE & WORKS : PUNE : Hadapsar Industrial Estate, PUNE 411 013. Ph : 020 - 26870133 / 26727000 Fax : 020 - 26870297 / 26870634. Email : acdmktg@kpcl.net Regional Offices: New Delhi www.kirloskarkpcl.com

INDUSTRY SPEAK » COMPRESSORS

The budget has also given a huge boost to the Make in India program by correcting the inverted duty structure in 22 thrust sectors Q. What trend will drive AIR COMPRESSOR industry in near future ?

Santosh Kumar, Managing Director Instamod Airpipe Pvt. Ltd.

The global air compressor market is expected to reach USD 37.18 billion by 2022, according to a new report by Grand View Research, Inc. Increasing industrialization and growing awareness on energy saving has led to advancements in compressor technology. Growing replacement demand is anticipated to be a substantial driver for the rotary equipment industry, as aged equipment undergoes part replacements, retrofits, overhaul or complete substitution with improved technology. With the current overall GDP of 7.3% ,particularly with industrial sector contribution of 30.02%,manufacturing @17.18,%construction @8.04%,we see there would be good potential for growth in compressor industry .

Q. What is the impact of Union budget on the industry ? This budget has laid down the roadmap for taking India to double digit growth. We not only see a clear direction in which the economy is going to be steered but also the key milestones that we need to cross

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on the way. The additional Rs. 70,000 crore spend on infrastructure sector in the coming year will provide a huge impetus to overall growth and should help in crowding in private sector investment in due course. The budget has also given a huge boost to the Make in India program by correcting the inverted duty structure in 22 thrust sectors.

Q. What are the remedies do you suggest to improve the positioning of the industry you are into ? AIRPIPE is 2 years old company in India ,with trend of GDP and growth in infrastructural activity & Make in India concept ,increase in FDI ,this all signifies that more industry will come to India and with more investment we have to educate the importance of using Aluminium pipe which will help to keep environment clean. When we talk to 10 customer out of that 8 customer knows about this but to take this concept in there factory they hesitate even if knowing that ROI would be less than 1.5 years after using AL pipe and pressure drop would be minimal with zero percentage leakage. So it’s all zoom down to awareness ,with clear mind set .

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PROFILE

Shavo Technologies offers high-tech tailor- made solutions

Mr. Rushil Shah, Managing Director, Shavo Technologies Pvt. Ltd.

havo Technologies Pvt. Ltd., a part of the Shavo Group founded by Mr. H.K Shah, a pioneer in the pneumatics field in 1960, is in the frontiers of niche high technologies cutting across diverse disciplines. The company headquartered in Pune and headed by Mr. Rushil Shah, Managing Director, represents some of the world leaders in their respective fields for technology solutions like static elimination, precision air movement, high quality instrumentation, high purity gas delivery, corrosive gas handling, energy absorption and so on. With a vast portfolio, the company serves over a thousand customers from diverse key sectors including semiconductor, aerospace, defense, chemical, oil & gas, automobile and so on. “Over the years, we have gone from selling components to systems and solutions and turnkey capability in an effort to keep offering better value by leveraging the technologies we provide,” says Mr. Rushil Shah.

All its principals have specific technologies that would be classified ‘cutting edge’ considering the fact that all of them are world leaders in their fields. Following are brief details of their principals and business areas: TESCOM is a recognized leader in the manufacture of high-pressure regulators up to 20,000 psig designed to work with all types of fluids, both corrosive. Tescom range covers over 70 standard models of high-pressure regulators to meet almost any requirement. HAM-LET specializes in the design, development and production of high quality instrumentation valves and fittings in a wide variety of materials for high, pressure, temperature and vacuum applications. These products are used in diverse industries like petrochemical, semiconductor, energy, food, biotechnology, pharmaceutical, defense, pulp & paper and mining. CLASSIC FILTERS brings you filter elements to filter housings to complete filter systems for almost any function. It

Applied gas delivery systems

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PROFILE

High quality instrumentation valves delivers some of the most robust high quality, coalescing filters and particulate filters in the world. In order to manufacture high tech devices such as semiconductor devices, flat panel displays and even photo voltaic or solar cells, precise fluid control is a must. HORIBA is the established world leader in offering a full line-up of gas, liquid, and vapor delivery products. Applied Energy System Inc. is one of the world leaders in the field of ultra high purity gas delivery systems like gas cabinets and panel for solar, semiconductor, nano technology and other high purity industries. Gas specializes in design and manufacture of air moving products

High pressure regulators

including vacuum pumps, compressors, air motors, gear motors, vacuum generators and regenerative blowers. “As a matter of fact, our journey of working with high technology industries started with Gast which today remains one of the world leaders in air motors and fractional horse pumps,” reveals Mr. Shah. Meech’s forte is industrial electrostatics. With a standing of over 40 years, Meech has developed a wide range of products like ionizing bars,

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hand-held ionizing air curtains, etc. for effective static neutralization and dust removal. With the experience gained from more than 200 successful web cleaning installations, Meech can offer both noncontact and contact web cleaning systems. ITT Enidine is again a world leader in energy absorption and vibration isolation products, providing solutions to a wide range of industrial markets. ITT Corporation is a high-technology engineering and manufacturing company operating on all seven continents in three vital markets viz. water & fluid management, global defense & security, and motion & flow control. Shavo feels fortunate to work with some of India’s top companies and institutions like Reliance, Tata’s,, Biocon, GE, Department of Space, Ministry of Defense and many more. It has in excess of 1000 live accounts. The company has a full service capability at its Pune office and is in the process of building a world-class service center in its Bangalore factory. “Our service support is the key pillar of the value we provide,” says Mr. Shah. – P.K. Balasubbramaniian

For more information Web: www.shavogroup.com

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TECH TRENDS

» AIR COMPRESSORS

Airpipe: Zest for Innovation & Excellence

Mr. Kishore Kumar Kalita, RSM (North & West ), Instamod Airpipe Pvt.Ltd.

calculation .With the help of this software ( ROI – Return of investment ) we could calculate the payback time with reference to old GI/MS pipes or fresh GI/MS pipes. It has been widely appreciated by our customers for bringing such observation to their kind attention.

Technical specification • Working temperature: -20°C to +70°C

(-30°C to +80°C*-30°C to +80°C • Maximum working pressure: 13bar • Vacuum Degree: 0.13bar absolute pressure • Compatible with compressed oil • Fireproof (Meet UL-90-VC standard) • Suitable for outdoor installation • Size from 20mm to 200mm For more information, Website: www.airpipe.in

ear 2015 - It has been an event full year for Instamod Airpipe Pvt. Ltd. We successfully offer & install our efficient and energy saving compressed air piping system throughout all major spectrum of industries – be it Textiles , Automobiles ,Foods etc. Now Airpipe is no more away from our end clients . Our services & all deliverables are getting more and more closer to our ends customers ,thanks to our over 30 – strong distributors catering almost all major industrial areas. Clubbed with high degree of motivation & spontaneous urge to exceed the customer s’ expectation our sales team have started designing modular aluminium compressed air piping system right from compressor to point of use which in turn we have created an awareness among our customers how to go for an optimum compressed air piping system. And this has become possible with the launch of our new software called ‘’Airpipe selection chart’’. A big congratulation & thanks to our R&D team for their great contribution ! Not only that this software would enable us to make proper size of pipes ; but go on guiding us to keep the air velocity within optimum range. Higher air velocity beyond the specific range causes frictional losses , whereas lower air velocity tends to carry forward moisture particles. Another remarkable development in this year is yet another new software – ROI

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AIR COMPRESSOR »

TECH TRENDS

Decay and the single regulator We’re never surprised at how many engineers and technicians don’t know what droop and decaying inlet are, since so little is published about these effects. Nevertheless, understanding them and using the flow curves to properly evaluate a regulator’s performance for an application is the secret to a trouble-free installation.

is the amount of change seen on the set point of a pressure reducing regulator as the inlet pressure varies. The decaying inlet characteristic has an inverse relationship between the inlet and outlet pressure of a single stage regulator; as the inlet pressure goes down, the outlet pressure goes up (see chart below).

How It Works To see how decaying inlet works, let’s consider a few Tescom regulators for the same application.

Parameters: Our application is a compressed gas that is packaged at 3500 PSIG. Our process requires a 200 PSIG set point.

Considerations

Mr. Rushil Shah, Managing Director, Shavo Technologies Pvt. Ltd.

ome people work with pressure regulators all of their lives and never know what is really going on inside. Tescom spends a great deal of time teaching our distributors and customers about the key operating characteristics of pressure regulators. We’re never surprised at how many engineers and technicians don’t know what droop and decaying inlet are, since so little is published about these effects. Nevertheless, understanding them and using the flow curves to properly evaluate a regulator’s performance for an application is the secret to a trouble-free installation. For the benefit of everyone in the Tescom family, we will review Decaying Inlet in this column, and Droop in a future column.

Definition The decaying inlet characteristic

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We must consider decaying inlet when our pressure source is a compressed source, such as a cylinder, tube trailer, or hydril. When our source gas comes from a compressor, or liquid source such as a dewar, the inlet pressure is fairly stable, and the effect of the decaying inlet characteristic on set point is negligible.

Scenario A: We’ll look at the BB - 1, which is rated for 3500 PSIG max inlet pressure, and has a PSIG/ 100 PSIG decaying inlet characteristic. Assuming that we start with full inlet pressure of 3500 PSIG, and that the source pressure will decay to 500 PSIG before it is either changed out or recharged, the net change on the inlet of the regulator is 3000 PSIG. If the regulator is initially set for an outlet pressure of 200 PSIG with 3500 PSIG on the inlet, then the outlet pressure will rise by 210 PSIG to 410 PSIG. 3000 PSIG change in inlet pressure ÷ 100 PSIG = Factor of 30; Factor of 30 x 7 PSIG decaying inlet characteristic = 210 PSIG increase. Scenario B: The 44 - 2200 and 44 – 5200 have much lower decaying inlet characteristics (1.5 PSIG/100 PSIG). Using the same operating conditions in the previous example, we find that these regulators will see a pressure rise of 45 PSIG on the outlet, from 200 PSIG to 245 PSIG. Clearly, we get better outlet pressure stability with these regulators. Scenario C: To further reduce the decaying inlet

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» AIR COMPRESSOR

effect, we should consider taking the pressure reduction in two steps, or stages. We typically use a two-stage regulator like the 44 – 3400 to do this. The 44 -3400 is composed of two 44 – 2200 regulators built into the same body and internally connected in series with one another. The decaying inlet characteristic of the 44 – 2200 is 1.5PSIG/100 PSIG. The first stage is preset at a nominal pressure of, say 500 PSIG. The second stage is adjusted to our original 200 PSIG set point. When the source pressure decays from 3500 to 500PSIG, the first stage sees a net decrease of 3000 PSIG on its inlet. The outlet pressure of the first stage will increase by 30PSIG, to 530PSIG. The second stage now sees a net increase of 30 PSIG on its inlet. The outlet of the second stage will go down by. 45PSIG (.3x1.5 decaying inlet characteristic =.45PSIG). To anyone reading a typical pressure gauge on the downstream side of the two-stage regulator, the decaying inlet characteristic is transparent.

Controlling decaying inlet characteristic Two-stage pressure regulators are frequently employed as cylinder regulators for packaged specialty gases. The flows are typically lo, and the twostage reduction allows the operator to provide stable delivery pressures to the process. There are times when a single - stage regulator is used on the cylinder,

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which feeds a header in a lab or process facility. Points of use regulators are installed along the header, permitting individual users to adjust their pressures accordingly. The use of a single stage source regulator, along with point-ofuse regulators, provides the two-stage reduction necessary for controlling decaying inlet characteristic. For higher flow applications, Tescom offers regulators with balanced main valves, like the 44 - 1300. The 44-1300 is so highly balanced that its decaying inlet characteristic is a very low. 1PSIG/100PSIG with a 0 – 300 PSIG control pressure. For a 3000 PSIG reduction on its inlet, the 44 – 1300 would yield a 3PSIG increase on its outlet, nearly transparent to anyone working with this regulator. The 44-1300 is often used as a tube-trailer regulator because of its high flow, and extremely low decaying inlet characteristic. These qualities allow users to employ only one regulator to provide the required working pressure for their process.

Mistaken Identity Many times, unknowing regulator users observe the decaying inlet characteristic and mistake it for a leaky regulator. In the non-flowing condition, the user observes that the set point has climbed above the original set point, and believes the regulator is creeping. One quick method to confirm that the regulator is not creeping is to observe the gauge reading for a short period of time. If the pressure has stabilized at a few pounds above the original set point, then this is probably decaying inlet. If the pressure is slowly climbing, and not stabilizing, then the regulator seat is contaminated, and the regulator must be removed for servicing. By confirming that the source pressure is a compressed

source such as a cylinder, you can quickly correlate the drop in inlet pressure to the increase in set point.

Sizing a regulator There are several reasons to consider the decaying inlet characteristic when evaluating regulator first and foremost, can the system handle the increase in outlet pressure? What if the outlet pressure decays to a point where a relief valve triggers, or rupture disk ruptures, for example? Second, can the process itself tolerate the pressure swing involved? In our BB-1 example mentioned earlier, could the process tolerate a 210PSIG increase on the set point? Are gauges another instrumentation downstream of the regulator sized to handle this increase in pressure? Our responsibility as applications specialists is to consider all possibilities when selecting a regulator for our customer’s application. When we take a few minutes to teach our customer about the nuances of pressure regulators, the customer is grateful, and looks to us as regulator experts, ensuring that we’ll be the first company contacted for future applications. Furthermore, by taking into account the decaying inlet characteristic when you size a regulator, you can avoid any surprises and unhappy customers that would otherwise result when the regulator is placed into service. If you need help with the decaying inlet characteristic of a particular regulator, please call us and we’ll provide you with this information.

For more information Web: www.shavogroup.com

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129, Vora Indl. Est. No.4, NAVGHAR , VASAI (E) - 401210, Dist.; Thane, Maharashtra Phone: (0250) 2390654 / 2390060 Mobile: 08080866288 Email: thermojacket@yahoo.com

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MGM-Pubblicità(210x297)_Layout 1 08/04/13 10.33 Pagina 1

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

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Empowering power transmission for Industries

With our extensive knowledge and experience in the power transmission arena, we continuously innovate and launch new products, aimed at meeting the varied application needs of our customers. Our product spectrum ranges from worm and helical gear motors to planetary drives, from electric motors to frequency inverters, manufactured at our Chennai production facility in India, applying state-of-the-art technology, ensuring superior quality standards and matching the best cost/performance ratio. At Bonfiglioli, we are geared to deliver a wide range of solutions - from simple to complex. Bonfiglioli Group, is an ideal partner to enhance the performance and competitiveness of your machines. Experience the world with Bonfiglioli. Bonfiglioli Transmissions (Pvt) Ltd Survey No. 528, Perambakkam High Road, Mannur Village, Sriperumbudur Taluk • Chennai 602 105, Tamil Nadu www.bonfiglioli.com - salesindia.ins@bonfiglioli.com

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INDUSTRY SPEAK » POWER TRANSMISSION

Import substitution of gears & gearboxes to cater to niche markets is our prime focus today or less for more area of contact and higher efficiency. The Customers today are more knowledgeable and looking for technically advanced products.

Q. How does your organization keep in step with them?

Debashis Chattopadhyay, Head-Sales & Marketing, Shanthi Gears Ltd.

Q. What are the new trends in Mechanical Power Transmission? There are various devices being used for transmitting Power from Motor to Machine, like Belt Drives, Chain Drives, Gear Box, etc. depending on the type of application, shaft locations and amount of Power required to transmit at what rpm. Major challenges involved while transmitting power is that how efficiently you are doing so i.e the efficiency of the drive. That’s why the entire world is now working towards energy efficient, compact drives. For Gear Industry, the trend is to go in for more and more planetary drives so that high torque can be transmitted with minimum space. Conventional gearboxes like standard worm Gearboxes which become less efficient as you want to have more reduction ratio, are being designed with special double envelop profile which can be as efficient as 98%. Gear accuracy in terms of Lead, Profile and Pitch are also an important factor and we can observe that even for general applications Customers are now insisting on ground gears with improved DIN class of accuracy. Straight bevel gears are now being re-designed with Spiral Bevel profile with DIN Class 3

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We, at Shanthi Gears, are always oriented towards delivering “Quality” to our Customers. We have a strong team of 12 Engineers at our R&D center who are constantly working for product innovation and providing support to our Engineering Department. Our Design Engineering department is also equally strong, managed by more than 45 Design Engineers, who are designing gear boxes as per application requirements and life expectancy. Almost 70% of our production is custom-built and special application based product, designed to suit Customer requirements. We are the only Indian Company, who have designed and supplied with our own capability a VRM Gearbox for Roller press application and it is working even better than overseas OEM supplier for more than 2 years. We are constantly investing on latest machinery which can deliver best quality gears with lowest production cycle time. Equipped with the latest machinery with skilled and experienced workforce coupled with our in-house Design and R&D facility, we are able to take up newer challenges and emerging as the most potential Indian manufacturer to replace import substitute products and develop new products for critical applications.

Q. What are your comments on ‘Indian engineering’ and how are you geared to make a significant contribution from your domain in its pursuit of excellence?

and can compete with any Global players in terms of Designing, Delivery of quality products and also provide on time service. Further, Indian market is having its own demand and is growing very fast. Considering the above facts, almost all Global players are looking for a foothold in the Indian market through any existing manufacturer or by way of taking support from its manufacturing base to nearby country. We, at Shanthi Gears are planning to focus more on niche segment of products to develop Critical Gears and Gearboxes, which are so far getting imported from various European countries. We are also planning to invest more on modern machinery apart from strengthening our R&D and Engineering team. We do also have an aggressive plan to reach our Customers through modern IT systems, where Customers can not only place orders on-line, they can get basic information on Drive efficiency, Power calculations as well as on-line PD drawings for checking their design layouts. We have already started working partially for Textile Gears with the above concept and started getting encouraging response from the market. We have also planned to expand our Service network across India and conduct more training sessions to our Customers by way of sharing knowledge on various Gear related issues and Case Studies in terms of Real Life Situations. We want to establish ourselves as the only manufacturer in India to provide Complete Drive Solutions in the field of Mechanical Power Transmission Engineering.

Indian Gear Industry is now more matured

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FACE TO FACE

Sumitomo Drive : The legacy of technology perfection Sumitomo Drive Technology Cyclo Manufacturing Factory in Obhu Japan.

Mr. Chandrashekhar Paradkar, Country Manager Sumitomo Drive Technologies, Pune, India

Q. Please brief its journey from the inception & share some its milestones? The Sumitomo Group began more than 400 years ago when Masatomo Sumitomo opened a book and medicine store in the city of Kyoto, Japan. Over the next 100 years, the Sumitomo family developed a leading presence in copper refining, which led to the family opening the Besshi copper mine. From these beginnings, the Sumitomo Group continued to grow and diversify to become one of the largest corporate groups in the world. Even after 400 years, the Sumitomo family “business spirit” is alive in each of the Sumitomo Group companies. The core of the Sumitomo Group, listed below, consists of 20 companies who share the Sumitomo Emblem as well as many common values and ideals.

Q. Please brief us about company’s global reach & what are the global alliances that has been made in order to out-front the competition? Sumitomo Heavy Industries, Ltd. In 1888, a company was formed to provide equipment

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repair services to the Besshi copper mine. Almost 50 years later, in 1934, the company incorporated as Sumitomo Machinery Co., Ltd. to manufacture machinery for the steel and transportation industries in support of that period of rapid economic growth. In 1969, Sumitomo Machinery Co., Ltd. merged with Uraga Heavy Industries Co., Ltd. to create Sumitomo Heavy Industries, Ltd. The company continues to innovate and expand to meet the demands of new market frontiers. Today, Sumitomo Heavy Industries manufacture injection molding machines, laser systems, semiconductor machinery and liquid crystal production Machinery. Sumitomo Drive Technologies of Sumitomo Heavy Industries began early in the 20th century. In 1911, Sumitomo Machinery Co., Ltd. began manufacturing direct-current electric motors (3.7kW) for the Besshi copper mine. In the late 1930s, the company formed a technical cooperation agreement with CYCLO Getriebebau Lorenz Braren KG of Germany. In 1939, Sumitomo Drive Technologies was born when Sumitomo Heavy Industries, Ltd. began to manufacture CYCLO® Drives. In 2003, Sumitomo Drive Technologies

was implemented as a global group brand to bind all power transmission businesses of the world. For more than 60 years, Sumitomo Drive Technologies continues to lead the world in knowledge and innovation in power transmission and control devices. Sumitomo Drive Technologies strives to be the “dependable partner” for our customers.

Q. What are the market prospects for your company products in India and How do you plan to position these products? CYCLO® Drives are also used for precision control. They combine the high strength and impact resistance of CYCLO® gears with very low backlash design. Because they are the component type, they are easy to install in customer machines. High precision alignment is made possible when combined with servo motors. This line is ideal for applications that require higher rigidity and precision stopping. They are Used in machine tools, industrial robots and factory automation equipment. The FC-A, F1C-A, F2C-A, F2C-C, F4C-D and F2C-T Series are available to

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FACE TO FACE suit different types of Applications. The STD and LB Series CYCLO® Drive can be directly connected to general-purpose servo Motors. There are standard backlash models and low 6min backlash models. The IB Series P1 Type low backlash reduction gears use a Sumitomo-unique planetary gear Mechanism. When combined with servo motors, they can be used in all types of precision alignment applications, such as robots for injection molding machines, machine tools and packaging machines.

Q. Can you brief us about the marketing strategies that were applied in order to stand out in the competition among industry? Why do customers prefer to use Sumitomo Drive Technologies products? The answer is that we offer the broadest range of products that are the most reliable and the highest quality available. The CYCLO® Drive products provide customers with almost limitless flexibility and reliability in their applications. The revolutionary Hyponic products give customers highefficiency performance in a compact design with hypoid gear technology. The Paramax product family provides industrial customers a strong, reliable gearbox that is designed for years of trouble-free service. Our development engineers design these products with years of proven expertise in the power transmission industry. The industry recognizes that Sumitomo Drive Technologies products are the most reliable on the market. By using careful planning and verification testing over the entire development process, the engineers insure that these products are the most reliable and the highest quality available.

Q. Please elucidate in brief about the your company’s infrastructure & What are the measure that are being taken from the product manufacturing to distribution? More than 35 years ago, Sumitomo Drive Technologies began to develop a global

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Cyclo Engineering Office in Japan. presence in response to the challenges of the company mission to facilitate premier support of our partners’ needs that lead to the development of operations located around the world. In 1966, Sumitomo Drive Technologies established Sumitomo Machinery Corporation of America, the very first overseas manufacturing plant, in the United States to support the Western Hemisphere. In 1974, we signed a capital sharing agreement with CYCLO Getriebebau Lorenz Braren KG of Germany to bring further innovation to the Cyclo technology through technical collaboration of both companies. Eventually, the partnership formed Sumitomo (SHI) Cyclo Drive Germany,GmbH. The global Sumitomo Drive Technologies web extends to 50 countries with 9 main hubs, 5 manufacturing plants, 35 assembly plants, and 250 sales offices. Through this extensive web, we provide the world with high performance, reliable, and premium quality products and services. Our global web links the resources for marketing, procurement, production and distribution to support customers at a world-class level for speed and accuracy.

Q. Brief us about the R&D and Quality policy for your business? In striving to satisfy customers without compromising on the goals of innovation and reliability, Sumitomo Drive Technologies aggressively invests in Research and Development. As technology changes and improves, the power transmission and controls systems must also change and improve. To challenge the technical horizons of mechanical and electrical components, Sumitomo Drive Technologies relies on research to uncover new levels of performance, reliability, and quality. From these “seeds” of research

come the technologies of the future and the creation of new products to better serve customer needs. The strength of our Research and Development efforts is in the ability to generate original concepts that transform into unique, customer focused products. Sumitomo Drive Technologies Research and Development believes that “what was not possible before is now possible.” Meet and exceed customers’ expectation, that is our passion.

Q. How far the factors like government norms, excise duty, taxation, exim policies are affecting your business? Government is now providing proper financial support and other Economic Benefits to Small Scale Industries. The factors like excise duty, Exim policies are directly financially affecting Motion Control Equipment Industry as well established Industries because of increase in certain un-established Industries.

Q. What is your vision for your company? We are always moving forward in pursuit of new ideas that inspire our partners to create new values that will change the world. Each of our skilled, knowledgeable, creative employees contributes to the creation of unique technologies and innovative solutions that meet and exceed our partners’ expectations. Our global network facilitates premier support of our partners’ needs. We stand poised to meet the challenges of today and tomorrow, so that our partners may walk with confidence as industry leaders.

Always on the move Sumitomo Drive Technologies: A dependable partner, creating Unprecedented change and opening up unseen worlds. That is who we are.

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Improve Your Gear ‘Apps’

Learn how Gleason’s latest gear production, inspection and service technologies are taking India’s gear applications to the next level.

www.gleason.com/GWI

INDUSTRY FOCUS » POWER TRANSMISSION

500CB Cutter build inspection machine

Mobil SHC Gear series oils meet new GE Gear Oil D50E35 specification

E G

leason Corporation introduces its latest innovation, the 500CB Cutter Build Inspection Machine. The 500CB delivers more accurate and highly automated build, truing and inspection of all types of stick-blade bevel gear cutters. The 500CB features automated closed-loop blade positioning creating a highly accurate and repeatable build quality. An accurately built cutter head is a critical factor in achieving precise gear quality and maximum tool life. In addition, the 500CB also automatically controls the tightening of the blade clamp screws, consistently applying the correct torque. These features require greatly reduced operator involvement to build highly accurate and repeatable cutter heads, while freeing personnel to perform other functions. This advanced machine has an intuitive operator interface including “wizard” functions to guide an operator through the build process. The software has many smart features, making recommendations to the operator while continually displaying key data as the head is being built. The 500CB is supported by the Gleason Global Service network with strategically located spare parts centers and over 250 service professionals in all major markets worldwide. Gleason Corporation’s mission is to be The Total Gear Solutions Provider™ to its global customer base. Gleason is a leader in the development, manufacture and sale of gear production machinery and related equipment and automation solutions. The Company’s products are used by customers in automotive, truck, aircraft, agriculture, mining, energy, construction, power tool and marine industries and by a diverse set of customers serving various industrial equipment markets. Gleason has manufacturing operations in the United States, Brazil, Germany, Switzerland, India, China and Japan, and has sales and service offices throughout North and South America, Europe and in the Asia-Pacific region. For more information Web: www.gleason.com

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xxonMobil has announced that its Mobil SHC™ Gear Series of synthetic industrial gear oils have been approved for use in General Electric (GE) off-highway vehicle motorized wheel gearbox applications requiring GE’s new gear oil specification, D50E35. Effective Jan. 1, 2016 the new GE D50E35 specification replaces the D50E27 specification for GE drives used in equipment such as construction vehicles and mining haul trucks. The new spec establishes micro pitting protection requirements in addition to scuffing wear resistance and other improvements. “Since their introduction, Mobil SHC Gear Series oils have been helping companies in the mining and construction sectors get more out of their equipment,” said Larry Mokan, senior equipment builder engineer at ExxonMobil Fuels & Lubricants. “Mobil SHC Gear Series synthetic oils meet the stringent new gear oil requirements for GE motorized gear drives with a formulation that delivers outstanding protection in extreme temperature and load conditions while combating micro pitting fatigue wear, rust and corrosion.” The Mobil SHC Gear Series represents the company’s continued commitment to developing advanced, high-performance lubricant technologies that can help customers decrease costs and improve the productivity of their operations. These oils contain an advanced, proprietary additive system designed to protect gears from conventional wear modes, such as scuffing, while offering a high-level of resistance against micro pitting fatigue. In addition, the oils offer the potential for improved lubrication of gearbox rolling element bearings as compared to conventional gear oils. “We began GE D50E35 qualification testing early and met the new requirements shortly after they were published in late 2014. We are confident that owners of GE OHV motorized gearbox drives who choose Mobil SHC Gear oils will also experience the same excellent field performance enjoyed by our customers over the past four years under the current GE specification,” said Mokan. The complete range of viscosities for the Mobil SHC Gear Series, ISO VG 150, 220, 320, 460 and 680, are approved for use under GE Material D50E35, categories A-E.

For more information www.mobilindustrial.com

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Witness a true international event with state-of-the-art infrastructure

Venue: The Exhibition Center, Helipad Ground, Gandhinagar, Gujarat, INDIA.

Resistance Welding Solutions For Every Industry

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mechelonic engineers pvt. ltd. C-230, Solaris-1, Sakivihar Road, Powai, Mumbai - 400 072 (022) 2857 1582 sales@mechelonic.in http://www.mechelonic.in Kolkata : 60, Circular Court 8, Acharya J. C. Bose Road, Kolkata - 700 017 (033) 2247 5307 kolkata@mechelonic.in Bangalore : A-102, Blue Cross Chambers, 11, Infantry Road Cross, Bangalore - 560 001 (080) 2559 1761 / 2590 bangalore@mechelonic.in New Delhi : 209, Ansal Chambers – II, 6, Bhikaji Cama Place, New Delhi - 110 066 (011) 2610 3052 newdelhi@mechelonic.in ENGINEERING REVIEW |

197 | May 2016

INNOVATOR

MEPL - The Leader in Resistance Welding

hen we talk of Mechelonic Engineers (MEPL for short), the first thing that conjures up in mind is the image of a Rail Welding Line it developed for the manufacture of continuous welded railway tracks for the Indian Railways. After long and rigorous R & D, Mechelonic Engineers developed the expertise to design and manufacture Rail Flash Butt Welders along with allied equipment like weld flash strippers, weld data recorders, rail straightening presses and rail grinding machines. It’s decades since the Railways have been using these robust equipment to make quality welds on which hinges the lives of millions who travel by rail. Flash Butt Welders is just one example of the early success of MEPL, the company founded by Mr. K.P. Antony who even today feels proud that he built not only machines but also relations with the giants in the industry. According to Mr. Gabin Kattukaran, the Director, the indomitable urge to provide dependable and cost effective solutions to the customer has culminated into the development of a number of special machines for the industry. The container line developed for the metal can making industry in India is a classic example. This machine designed for side seam welding can make 360 containers per minute. Productivity is paramount here. These cans are used for packaging

MEPL’s state-of-the-art manufacturing facility

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“We introduce machines yielding high productivity at low power consumption.” - Gabin Kattukaran, Director, Mechelonic Engineers Pvt. Ltd processed mango pulps. No downtime is acceptable. During season, the machines have to work for 24 hours a day, non-stop!

Engineering marvels The special purpose flash butt welding machine it has developed for BHEL for welding tubes end-to-end for heat exchangers is truly an engineering marvel. MEPL was pitted against several others for developing this machine. The company worked for over three years to develop this SPM. The challenges involved were manifold. The testing criteria of the tube joint are critical. The tube is to be bent without cracking. The material build-up should be minimal. After the coils get assembled, a metal ball of 80-85% ID of

the tube is passed from one end to the other to check free passage. MEPL met all these requirements and bagged the order against stiff competition. Subsequently it supplied three more machines to this power equipment giant. The machine is hydraulically operated, fully tropicalised and specially designed for heavy duty application where repeatability in performance is important. It is provided with a powered manual adjustment facility for proper alignment of the fixed and moving tubes before welding. For accurate and consistent weld results, fully solid state electronic controls are provided. All electrical controls are housed in a separate cubicle with required protection. The machine operation does not require any skilled labour. The welding parameters are easily settable through a user-friendly interface to the control system. Quality is assured with a PC based welding monitor. MEPL has also come up with a Steel Grating Welding Machine with a rating of 1800 KVA for manufacturing steel gratings by electrical resistance welding. The application of high current and high forging pressure under precise control of a special welding controller and a PLC based sequence controller results in high quality electro-forged weld joints. The machine is used for manufacture of world-class gratings using round, square or twisted cross bars. The company also offers special machines for mesh welding. Its seam welding machine with 2-axis CNC controlled sheet handling is designed for continuous and roll spot seam welding of plate type and econocoil type heat exchangers. MEPL has exported such seam welding machines to handle sheets of 9 m length to China as well. Indeed, MEPL is a leader in resistance welding. Though there are ‘n’ number of manufacturers in this category, no one has a comprehensive range that MEPL has. Its customers also represent wide ranging industry segments like automobiles, railways, aerospace, defence, power, steel mills, white goods, metal can making, electronics, switchgear and so on. “We specialize in handling difficult jobs which others cannot

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INNOVATOR touch. We cater to specialized markets where customized design plays a pivotal role. That’s our niche”, elucidates Mr. Gabin. “And we do not depend on any one industry for our bread & butter. For instance, the automobile industry has not been doing well for quite some time now. So we had to change our gear and concentrate on other industries where our contribution was valued and realization was faster. We sell our equipment for a premium. And our customers do not mind paying a little extra for our quality, expertise and involvement in providing solutions based on our vast experience. They know once we take up a job, we shall accomplish it – no matter what amount of efforts go into it and how much time it takes. For instance, the equipment for tube welding for heat exchangers supplied to BHEL took over three years for us to develop.” Mr. Gabin is quite clear that MEPL is not in the commodity market. “We are in the niche market where our domain knowledge and vast experience are constantly put to test. Most of our products are import substitutes. We believe in indigenous technology and are proud of the made in India tag.” Mr. Gabin relates that in some cases the welding per se is hardly 10%. The rest is job handling, testing, assembly and allied operations. The customers prefer one company that is capable of handling everything. That is where MEPL scores over.

Core strengths “Our people are our core strength”, confides Mr. Gabin. There is a strong sense of belonging amongst them. Each employee has put in an average of 10-15 years of service in the company. This stability, commitment, accumulated experience and process knowledge of our people is what is giving us the confidence to take up complex jobs.” The company has spearheaded several innovations in the field of resistance welding. It was one of the first to introduce microprocessor-based controls in its machines some two decades ago. It used solid state electronics in the controls and powerpacks. It introduced servo-based systems in the machines depending on the dimensional accuracies and tolerances demanded. In keeping with the trend, it

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A special purpose boiler tube welding machine developed by Mechelonic Engineers also automates its machines using CNC & other controls, linear guides, etc. “Today all components are available off-the-shelf. Hence, integration is easy provided you know the welding process, have the domain knowledge and know the components,” he adds.

Pursuit of excellence “Our aim is to provide more and more customized solutions to the customer. We introduce technologies relevant to the region in an energy starved country machines yielding high productivity at low power consumption. There are some states where ample clean power is available. In some others there is acute shortage. So we have to make the necessary changes in our machine design to suit the power availability. It is universally known that with DG power the weld quality takes a beating. But we have now come up with machines which can make perfect welds even with DG sets,” reflects Mr. Gabin. “Resistance welding is a niche area. We cannot dictate changes. We have to follow change. We should be flexible. No matter what happens, we have to continue to be there,” declares the leader. MEPL has two manufacturing units now. One is in Mumbai and other in Vapi. These plants chisel out 120 machines a year on an average. The company has a highly motivated and dedicated workforce of 125 people. It has regional offices in Delhi, Kolkata, Bangalore, and Pune and resident engineers

in Jamshedpur, Ahmedabad and Chennai to attend to service calls and stay closer to the customer. “Mechelonic machines hardly require any trouble-shooting – so much so that a seam welder supplied to a customer in Mumbai some 36 years ago is still going stronger. If at all there is any wear & tear, it would be in the cooling system, pipes or cylinders.” Nevertheless, the company maintains a team of engineers and technicians specifically to service and maintain large welding plants. It currently provides such services to several Railway Flash Butt Welding Plants of the Indian Railways. Good spare parts inventory and management help in maximizing uptime of its machines at customers’ places. The pursuit of excellence has been a constant endeavour at MEPL. Its success is attributed to constant updating of technology, a firm commitment to continuous research and development, and a strong team that believes in itself and the company it belongs to. MEPL has every reason to boast of the widest range of products, systems & solutions in the Indian resistance welding market. Or as they would like to say: “Bigger, Better, Faster and More” welding solutions than anyone else in this part of the world. -P.K. Balasubbramaniian

Website: www.mepl.co.in

MAY 2016 ENGINEERING REVIEW

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INDUSTRY SPEAK » WELDING

Innovation is a part of our culture Q. How was the year that went by for your company?

Mr. Satish Bhat, Managing Director, Ador Welding Ltd.

The year FY2016 was good overall. In spite of GDP not growing as expected and manufacturing sectors growth was subdued, we have grown in volumes in both Consumables and Equipment. This is as a result of our reach to customer, value addition approach through technical support, strong after-sales service in higher customer satisfaction Index and many more activities. In case of consumables we have grown in spite of low business from key accounts of FY2015. This means we have reached out to more number of end users and have successfully converted and retained them to Ador Welding. The year was good for Automation business as well as for Project Engineering Business due to launch of new products and successful commissioning of projects during the year.

Q. Any upheavals you had to surmount? The market was tough, Capex had dried out and thus market became fiercely competitive leading to price wars. No new projects launched, Margins were seriously under pressure. Thus the challenge was to acquire more customers by serving their specific needs with our technical expertise and support.

Q. What are the innovations you wish to display this year? Innovation has been a part of our culture with increased focus since last 3 years. We have established an Innovation Council which is responsible for creating the culture of Innovation. Over 100 employees in the organization at various levels have undergone training in this

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regard. TM and OD activities are focused on Innovation. Innovation in Products and Services is indispensible in today’s competitive market. We have also done a lot of Innovation in our processes at support functions and manufacturing apart from our Products and Services. For example, in one of our manufacturing processes we have increased the efficiency of our Wet Drawing machine by changing the design of the pulley that was provided by the OEM manufacturer of the machine. A constant zeal of finding avenues to add value to the organization is the spirit of our employees, and this is what leads to such innovations at multiple levels.

This year the Innovation focus will be on: • Ease of doing business. • Significant value addition to customers by enhancing their operational efficiency. • New Technology and Solutions for our customers.

Q. Did you ever feel there’s a better way? What would be your strategy and approach to make the most of this year and beyond? There is always a better way. The strategy going forward would be to sustain the initiatives taken in the last 3 years and capitalize on our Customer Relations, Technical and Manufacturing capabilities. Build synergies with our current capabilities and resources to offer new products to our customers.We would look at creating value through forward as well as backward integration. The focus would be on pursuing growth irrespective of the Economic or Market scenario.

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INTERFACE

» WELDING

“We need to churn out thousands of welding professionals to meet the growing demands of a burgeoning economy,” says R. Srinivasan, President, IIW The Indian Institute of Welding, recognized as the premier national body related to welding in the country, is celebrating its Golden Jubilee this year. With a membership base of 4,500 individuals and 250 plus corporate members, IIW is taking giant strides, making its imposing presence in the welding world and propagating the art and science of welding. The Institute just held a 3-day International Colloquium on ‘Welding Research’ in Hyderabad during 7-9 April, for collaboration in India for fulfilling the research needs of the country, which was attended by nearly 135 delegates from 19 countries. The event identified the gaps in Welding Research in critical applications like Aerospace and Defence, Power & Energy, and Infrastructure, and prepared an action plan to bridge the gaps in the nearest future. The Institute has a series of activities and programs lined up for this momentous year. Mr. R. Srinivasan, President, IIW gives a rundown of all those in a one- to-one with Mr. P.K. Balasubbramaniian, Engineering Review. Excerpts: Q. What’s your agenda for the Golden Jubilee celebrations?

Mr. R. Srinivasan, President, The Indian Institute of Welding

Q. What’s your feeling when you are a part of the Golden Jubilee celebrations of IIW as the President? It is a great feeling to hold the mantle of this great professional body on the eve of this significant milestone. I am the 24th President of the IIW. With over 4500 individual members and 250 corporate members, the Institute serves the cause of welding through its 13 branches and two technology centers. We have a checkered history and an impressive list of achievements. I have a 3-year term till Sept 2017 and have a lot many things to accomplish.

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We kicked off the Golden Jubilee celebrations by holding the 6th Welding Research and Collaboration Colloquium in Hyderabad during 7-9 April ’16. It was organized by our Hyderabad Branch under the auspices of the International Institute of Welding Study Group RES (Research Strategy and Co-operation). The mission was to promote welding related research especially in collaboration with international researchers. This was the first time the Colloquium was being held in Asia. Some 135 delegates from 19 countries including Australia, Japan, Germany, Brazil, Brussels, Canada, United Kingdom and Korea participated. Some 35 research papers and 30 flash talks, and 20 posters by young research students were presented. The highlight of the event was that almost 50% of the participants were young engineers in their 30’s. It helped in formulation of vision for welding research; bring the academia and industry together on one platform to exchange information, knowledge, problems and solutions related to various industry segments like Power & Energy, Aerospace, Defense, Heavy

Engineering & Shipbuilding, Oil & Gas, Nuclear, Automotive & Surface Transportation. On 22nd April, which is the date of incorporation of IIW, we have a day- long program in Kolkata wherein we shall be felicitating the past presidents, vice presidents and honorary secretaries of IIW. Subsequently we shall be presenting the Golden Jubilee Welding Ratna Awards to 15 outstanding contributors/achievers. In the 2nd half, we shall have a Symposium on ‘Welding for Nation Building’ wherein there will be presentations on topics like Status of Welding Fabrication in India, Welding Consumables – Present & Future Needs, Welding Power Sources, Status of R & D in Welding, Modular Welding Education & Skilling, and Building up a National Welding Capability in the Country by eminent speakers including the president of the International Institute of Welding. On the same occasion, we shall also be bestowing the IIW Excellence Award expressing our gratitude to the Minister of Defence, Shri. Manohar Parrrika, who is one of our members. We feel honored to give this award to one of our members who has become the country’s Defence Minister.

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WELDING »

INTERFACE

Q. Could you pinpoint some of the most significant achievements of IIW in the past five decades? Introduction of AMIIW Exam for those engaged in welding is one of the most significant achievements of IIW. This Exam, approved by the Govt., is equivalent to the Bachelor of Engineering Degree. This apart, in 2008 we introduced the International Welding Engineering Qualification. Till date, over 900 engineers have acquired this qualification. Under the Skill Development Initiative of the country, we are proud to say that IIW has been appointed as a knowledge partner in three important sectors such as automobile, capital goods and steel. We are the sole assessing in the fabrication sector for the MES scheme of the Govt. of India. Under these schemes, we got the mandate to assess 30,000 welders in MES bodies from the year 2010.

Q. What is the strength and spread of IIW today? IIW stands for fostering the development of welding science, technology and engineering in India. As I said earlier, we have 4500 individual members and 250 plus corporate members spread across the country. As of now we have 13 Branches in strategic locations. We shall soon add three more branches: one in Surat, one in Chandigarh and the third in Coimbatore. We have established and registered our Welding Exhibition brand name ‘WELD INDIA’ in the country and today it is considered as a premier show in welding in the country.

Q. What are the core activities of IIW today? IIW conducts International Welding Qualifications conforming to ISO-3834; certifies Indian manufacturers, after technical audit, under the auspices of the International Accreditation Board of the IIW International, to gear up to do business with European Union; and conducts periodical up-gradation programs (such as metallurgy for non-metallurgists; ASME inspection codes). Every year we hold National Welding Seminars in metro cities, and National Welding Meets in smaller ones. We present more than 20 awards every year to the best technical papers in various categories

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WELD INDIA 2015 Exhibition organized by IIW in Mumbai- A sectional view. during the National Welding Seminar and Welding Meet. We shall end up the Golden Jubilee celebrations this year by holding a National Welding Seminar in Kolkata during 15-17 Dec. Besides these, we have a technical understanding with the American Welding Society for deputing their experts to India once in two years for delivering talks on specialized welding topics. We are also in discussion with TWI of UK and with the Brazilian Welding Society for exchange of technical information.

Q. What would you consider to be the greatest contribution of IIW? Today if you see in the industry, personnel connected with welding in different positions like managers, supervisors or welders lack proper welding qualifications. This is s a sorry state of affair. IIW is the only professional body which can formulate suitable training modules to suit various industry segments. With the co-operation of the Govt., we would like the country to adopt our National Welding Training Capability & Certification Scheme (NWTCS) under which IIW would test and qualify these welding personnel and impart training wherever needed to make them fully qualified. We do have structured modules for training the trainers. This way we can provide enduring solutions to several problems and mishaps related to welding.

Q. As a national professional body, could you solve any problems after liaising with the Govt.? Nothing much so far. We are now planning to open a National Investigation Cell related to welding engineering. We could help

study the facilities, analyze and give proper recommendations to the sector.

Q. Any other issues on hand that you have to address? a. There is a dearth of qualified welding personnel in the country. The existing gap between demand and supply will widen further if the Govt. gives a kick-start to the pending projects worth Rs.1,40,000 crores presently on hold. There are several reasons for this acute shortage of qualified welding personnel in the country. One of them is Welding not being taught in Engineering Colleges. IIW is preparing a white paper to be submitted to the Govt., urging it to introduce a 4-year Degree Course in colleges so that we can churn out a good number of welding engineers who can straightaway be absorbed in the industry. Today the MSMEs and SSEs cannot afford to appoint full-fledged Welding Engineers. We are having dialogues with Vice-Chancellors of select Universities for the same. IIW can get fully involved in preparing the syllabus, providing faculty for full time or part-time lectures. We have a pool of experts. b. We hear about collapse of bridges here and there. The root cause of such disasters is poor quality welding. We can pre-empt such mishaps if we use qualified welding people and certified welding procedures and of course quality materials. The Govt. should make it mandatory to get these approved by an agency authorized by the Quality Council of India (QCI) under certain norms. c. Today the road building activity in the

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INTERFACE

» WELDING

The Institute held a 3-day International Colloquium on ‘Welding Research’ in Hyderabad during 7-9 April, for collaboration in India for fulfilling the research needs of the country, which was attended by nearly 135 delegates from 19 countries. country is to the extent of 7 km per day. The Govt. is planning to step this up to 20 km a day. This would further increase the demand for welding professionals to three fold, once again widening the said gap. d. IIW can help prepare training modules to suit different levels of personnel required for different industries. QCI can audit our training and evaluate. We would be making representations to the Govt. to remedy the said situations.

Q. What is the status of the welding industry today? The economy is on an upswing. If the signals are clear, the GDP presently at 7 percent may go beyond 10% in the nearest future. This would mean hectic activities in the manufacturing sector. The growth of the welding industry is directly linked to the steel production / consumption in the country. Normally it is 3-5% of the total steel production. Today our steel production is in the vicinity of 84 million MT. This is expected to touch 160 million MT by 202122. The per capita consumption of steel in India is 75 kg today as against a world average of 235 kg. This is expected to touch 150 kg by 2022 according to official figures.

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This will give an up-thrust to welding in the country. The efficiency of thermal power stations is currently at 37%. This is expected to be pegged to 50% efficiency by 2017. Crude oil refining has to go up. All-round growth is also expected in the oil & gas sector, infrastructure, agricultural and heavy engineering sectors. All this is good news for the welding industry.

Q. Are we in step with the world when it comes to technology? In terms of technology we are more or less at par with the international level. On a scale of 10, we must score 6.5 marks. The setback we have is lack of facilities for R & D in high-tech areas like aerospace and defence. We strongly feel that there should be an R & D Center for Welding with publicprivate participation so that the entire industry can benefit. Today research is done in isolation by institutions and individual companies. Within IIW we have a Research Wing which connects with IIT’s who are doing some amount of R & D work.

Q. What’s the professional support you get from the International Institute of Welding? The International Institute of Welding is

doing commendable work through its 15 Technical Commissions and the benefits do percolate down to member Institutes like ours. It also facilities prominent member institutes like the American Welding Society (AWS) to share technical knowledge and information. AWS periodically deputes experts to SAARC countries like India to keep us abreast of the latest trends and to bridge the technological gaps.

Q. What is the contribution of Welding Industry to the national economy? Welding is all-pervading. Every engineered product leans on welding for its quality, cost-effectiveness and reliability. And there is hardly any industrial segment which is not using welding for its production process or maintenance Our welding manufacturers , some of them pioneers, provide high quality products and enduring solutions for consistency, repeatability and automation in welding to enhance productivity. Though we cannot quantify the direct contribution by the welding fraternity, we are making a catalytic contribution to the economy, ensuring that the ‘Make in India’ flag flies high always.

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TECH TRENDS

» WELDING

Validation of the ARC Welding equipment with ARC Validator L650 Kemppi’s Arc Validator is the first ever automated and universal solution for welding equipment validation. It offers fast, consistent and thorough welding equipment validation, meeting the requirements of ISO 3834 and EN 50504 standards

alidation of the welding equipment is to ensure that the equipment function correctly and produce the desired welding parameters (Current, Voltage & Wire Feed Speed) as per its operation characteristics with adequate accuracy. In General, the Validation Should be carried out once in a year. It may be necessary to validate at more frequent intervals, depending upon the recommendation of the manufacturer, the requirements of the user, or where there is reason to believe that the performance of the equipment may have deteriorated. Validation should always be carried out after any repair or operation liable to affect the validation.

Picture Shows the Arc Validator L650 unit, the remote control(RC)device used for operating the Arc Validator, saving and transferring validation data from and to a computer and the PC Software installed on the computer used to generate report & Validation certificate creation..

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Today, welding companies face strict requirements from customers, regulators and inspecting bodies. If their welding equipment is not validated, they fail to meet national and international standards and customer requirements for welding equipment accuracy.

ARC VALIDATOR L650: Kemppi’s Arc Validator is the first ever automated and universal solution for welding equipment validation. It offers fast, consistent and thorough welding equipment validation, meeting the requirements of ISO 3834 and EN 50504 standards. Among the benefits it offers are up to 80% faster validations, effortless reporting and standards compliant documentation and certificate creation. It is compatible with all brands and models of welding machines and welding processes (TIG, MIG & MMA). Arc Validator is used for current, voltage and wire feed speed validation of welding power sources and wire feeders. In manual mode, Arc Validator is compatible with the vast majority of welding equipment with absolute unit meters – despite the brand or the type. In case of Kemppi’s Fast MIG M, X, Pulse, KMS & Kemp arc Pulse Series welding Power sources and its suitable Wire feeders Automatic Validation option is available. In that mode, Arc Validator automatically controls and operates the validated equipment through the remote control connection during the validation process. The user / customer can choose either standard validation (normal accuracy) or precisionvalidation (higher evel of accuracy) according to the European Standard EN 50504. Manual validation is often very time

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WELDING » Picture shows the typical validation Certificate is generated from the PC Software.

TECH TRENDS

Validation accuracy for Wire feed Equipment as per EN 50504

Grade

Accuracy

Standard

±10%

Precision

±2.5%

consuming. The welding equipment is set up and the person coordinating the validation process has to manually adjust the parameters and write down whether they are within the certain tolerance limits. This process is slow and prone for simple human errors. With Kemppi Arc Validator we don’t need to calculate or write down anything. Just connect the validator to your welding equipment and let the system do everything. As all the tests and parameter adjustments are done automatically and we are less likely to have errors in the process, thus the Arc Validator delivers consistent and accurate results.

Why Validation is more Critical in Pulse welding:

Validation accuracies for Standard grade Power sources as per EN50504:

In case of Digital Meters Display

Accuracy

Current

±2.5%

of maximum rated welding current

Voltage

±2.5%

of no-load voltage, or according to the manufacturer’s specification

Validation accuracies for Precision grade power sources as per EN50504

In case of Digital Meters Display

Accuracy

Current

±1%

of maximum rated welding current

Voltage

±1%

of no-load voltage, or according to the manufacturer’s specification

Generally, Slope and pulse controls are considered to be precision grade and the validation accuracies should conform to ±5 % of setting, unless specified by the manufacturer. The validation of pulse controls are very important contribution to the quality of pulsed welding. It is a more difficult task than the validation of slope controls. It requires equipment with a faster response than is necessary for the validation of slope controls. An instrument response of at least ten times that of the maximum pulse frequency of the power source is recommended to validate the Pulse controls. To Validate the Pulse Controls, normally the high knowledge of the power source control circuits and special instrumentation is required and is most likely to be carried out by equipment manufacturers.

For more information Web : www.kemppi.com [Contributed by Kemppi India]

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Turboprop passenger plane with wheels and brakes supplied by Dunlop Aerospace

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TECH TRENDS

» WELDING

Welding consumables for fabrication of boilers & pressure vessels Failure of pressure vessels and boilers in service can not only cause monetary and production losses, but could also constitute a serious health hazard. Designers and fabricators must therefore scrupulously follow safety codes, standards and regulations which govern their construction.

pplication of welding has permitted design flexibility, significant weight reduction and operation at higher levels of strength and pressure to pressure vessels and boiler manufacturing. This has resulted in improved quality and safety, longer service life and economy of construction and operation. Industrial demand of pressures upto 3,500 psi, temperatures from 649°C down to -260°C, cyclic pressure and temperature, exposure to corrosive agents, hydrogen-containing environments and neutron irradiation have thrown up challenges to the designer and the fabricator. They should therefore keep themselves abreast of the evolution in materials, design and welding techniques. Failure of pressure vessels and boilers in service can not only cause monetary and production losses, but could also constitute a serious health hazard. Designers and fabricators must therefore scrupulously follow safety codes, standards and regulations which govern their construction, like the ASME Boiler and Pressure Vessel Code, Rules and Regulations of Lloyd’s Register of Shipping, Rules for Building and Classing Steel Vessels of the American Bureau of Shipping, and the Indian Boiler Code.

alloys, Ni and its alloys, Cu and its alloys and titanium).

Their choice is determined by the following properties: a. Short time yield strength, tensile strength and ductility at room and maximum operating temperature. b. Notch toughness and impact resistance, especially when low-temperature service is involved c. Creep strength, rupture strength and ductility for service temperatures in plastic flow range d. Weldability and need for preheat and post heat treatments e. Thermal conductivity, expansion and shock resistance f. Resistance to fatigue loading g. Resistance to corrosion, corrosion fatigue and stress corrosion

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A pressure vessel is usually cylindrical in shape, and is made from a number of shell courses and either ellipsoidal or tworadius torispherical heads called dished ends. Special shapes include cylinders, spheres, ellipsoids, tori and cones in several combinations. In designing pressure vessels, one must consider the maximum allowable working pressure, maximum working temperature and the possible use of pressure relief equipment.The maximum working pressure and temperature governing the design has to be stamped on the vessel. There are also several other design criteria to be considered, such as fluctuating and repeated pressure loading and temperature, effects of platforms, supports

AWS classification

Typical weld metal major elements

Recommended for the base metal

Preheat temp. (12.7 to 57mm thick plate)

E8018-B2

0.07C-1.25Cr-0.5Mo

P4 materials e.g. ASTM SA 182/182M Gr.F2/F11/F12, SA 213/213M

150oC

E9018-B3

0.07C-2.25Cr-1Mo

ASTM A 335 Gr.P22, A 387 Gr.22 materials, 12CrMo910, 10CrSiMoV7

150oC

E8018-B6

0.07C-5Cr-0.6Mo

P5B materials e.g. SA 336/336M Gr.F5, SA 387/387MGr.5

150oC

E9018-B8

0.06C-9Cr-1Mo

9% Cr type P5B materials in forging, pipes, tubes and casting form

200oC

E9018-B91

0.06C-9Cr-1Mo0.4Nb-0.04 N-0.5Ni0.2V-0.03Al

P91, T91 and F91 materials, 1.4903 and similar steel Grades

200oC

Materials of Construction The alloys used in pressure vessels and boilers are: plain carbon steels, low-alloy steels, quenched and tempered steels, chromium steels, austenitic stainless steels, clad steels (carbon and low-alloy steels clad with straight chrome steel or austenitic stainless steel or nickel and its alloys) and non-ferrous metals (AI and its

h. Structural stability in service i. Age-hardening and embrittlement in service

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WELDING » and attached equipment, and wind and earthquake loading. Code rules provide data on efficiencies for the welded joints. Butt joints welded from both sides must be used in the design as far as possible, as they offer maximum assurance uniform or complete fusion.

TECH TRENDS

Ador Welding Consumables for the fabrication of boilers & pressure vessels: AWS Classification

Brand/Product Name

Third Party Approvals

E6013

Metalbond

BHEL, ABS, LRA, BV, DNV, BIS, IRS, IBR

E7018

Supabase

BHEL, NTPC, IBR, ABS, LRS, BV, DNV, BIS, IRS

E7018

Supabase X Plus

NPCIL, IBR, ABS, LRS, BV, DNV, IRS

Carbon steels: -

E7016

Tenalloy 16

IBR, ABS, LRS, BV, DNV, BIS, IRS

Represents broad range steels with 1.7% max. C, 1.65% max. Mn & 0.6% max. Si. Depending upon the carbon percentage further sub divided into, low, mild, medium & high carbon steels. Weldability gets decreased as the percentage of carbon. Hence the preheating of the job is recommended to avoid the weld cracks.

E7018-1

Tenalloy Z Plus

IBR, ABS, LRS, BV, DNV, IRS

E7018-A1

Molyten

BHEL, ABS, NPCIL, IBR

E8018-B2

Cromoten

BHEL, ABS, NPCIL, IBR

E9018-B3

Cromoten C

BHEL, ABS, NPCIL, IBR

E8018-B6

Cromoten D

DNV, IBR

E8018-B8

Cromoten 9

DNV

E9018-B9

Cromoten 9M

IBR

E9016-B9

Cromoten 9M (Spl)

IBR

E9015-B9

Cromoten 9M 15

EIL

E308-16

Superinox-1A

BHEL,NTPC, RDSO

E308L-16

Superinox-1C

BHEL, NPCIL,

E316-16

Superinox-2A

RDSO, TOYO

E309-16

Betanox D

IBR

E309L-16

Betanox DL

BV, IRS, NPCIL

E347-16

Superinox-1B

BHEL, NTPC

ENiCrFe-2

Nicalloy Fe2

Low alloy steels: In order to reduce the hydrogen induced cracking and to improve the strength of the joint by refining the microstructure by adding small amount of Cr, Cu, Mo, Ni, P, V or Zr. Generally this requires stress reliving. Stress reliving does not alter the strength level of the weld significantly but improves its ductility & notch toughness. Steels with yield strength range of 350 - 1240 N/mm2, which are supplied in quenched & tempered (Q & T) condition. Some of them have excellent toughness at subzero temperatures. Post weld treatment including stress-relief is avoided in the case of these steels as far as possible, because it may reduce the toughness of the base metal as well as the weld metal.

Sr. No SMAW

Chromium-Molybdenum steels: This group basically used in the power sector where the application temperatures are high. They are distinguished from the other low alloy steels by their remarkable oxidation resistance, resistance to sulphide corrosion or high temperature creep resistance. The Mo content is varying between 0.5-1.0% according to the Cr content of the steel. The 2.25Cr-1%Mo steel has the best high temperature strength. They are usually supplied in the annealed or normalised & tempered condition.

Boiler drum – Power generation – ASME 516 Gr 70 C-Mn steel

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TECH TRENDS Sr. No

» WELDING AWS Classification

Brand/Product Name

Third Party Approvals

TIG / MIG – Solid wires 1

ER70S-2

Tigfil 70S-2 / Automig 70S-2

DNV, LRS, ABS, NPCIL, IBR

ER70S-6

Tigfil 70S-6 /

ABS, DNV, IRS, LRA,

ER80S-D2

Tigfil 80S-D2 / Automig 80S-D2

IBR

ER80S-B2

Tigfil 80S-B2 / Automig 80S-B2

IBR

ER90S-B3

Tigfil 90S-B3 / Automig 90S-B3

NPCIL, IBR

ER90S-B9

Tigfil 90S-B9 / Automig 90S-B9

ER308L

Tiginox 308L / Miginox 308L

NPCIL

ER309L

Tiginox 309L / Miginox 309L

ABS, IRS, NPCIL, IBR

ER316L

Tiginox 316L / Miginox 316L

ABS, IRS, LRA

E71T-1C

Automig FC71T-1

BHEL, LRS, IBR, RDSO, ABS, BV, DNV, IRS

E71T-1CJ

Automig FC 71T-1CJ

E71T-5C

Automig FC 71T-5

E81T1-B2C

Automig FC 81T1-B2

E91T1-B3C

Automig FC 91T1-B3

E110T5-K4CH4

Automig FC 110T5-K4

E308LT1-1/4

Miginox FC 308LT1-1/4

E316LT1-1/4

Miginox FC 316LT1-1/4

E309LT1-1/4

Miginox FC 309LT1-1/4

E347T1-1/4

Miginox FC 347T1-1/4

F7A4 / F6P4-EM12K

Automelt B71+EM 12K

Automig 70S-6

MIG - FCW

SAW 1

Separator – Refinery - ASME 516 Gr 70 material - Insulated

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ABS, IBR

The Cr- Mo steels are air-hardening steels & undergo microstructural transformations that depend on the rate of cooling from above the upper critical temperatures. The mechanical properties are dependent on these transformations. With faster cooling rate, strength & hardness increase and ductility is reduced. However, because of the lower carbon content (0.15% max.), carbides are presents in limited amounts and this results in higher ductility at any given strength level than that obtained from high carbon steels. These steels are readily weldable with the conventional arc welding and electro slag welding processes. The air-hardening property of the base metal and high alloy content of the weld-metal demand that correct welding procedures including preheat, postweld heat treatment, low-hydrogen consumables, and filler metal chemistry are used to prevent HAZ and weld-metal cracking. The preheat temperature must be increased as the thickness and carbon and alloy contents increase to ensure crack-free joints. The welding process can also determine the preheat condition. With a low-hydrogen process such as TIG, or a high heat input process such as electro slag, much lower preheat would be justified or even none at all. The chemical composition of the filler metal must be the same as of the base metal, except for carbon content which is lower for the weld-metal. When different Cr-Mo steels are to be welded at the same time, filler metal selection can be restricted by using the same filler metal for a variety of steels. For example, 1.25 Cr-0.5% Mo filler metal can be used for three base metals: 0.5% Cr-0.5%Mo, 1% Cr-0.5% Mo and 1.25% Cr-O.5% Mo. Similarly 2.25% Cr-l % Mo filler metal can be used for 2% Cr-O.5% Mo and 3% Cr-l% Mo steels. Electrodes are supplied in Vacuum packed ready to use packing as per the requirement. Wires are supplied in spools of 12.5 / 15 / 25 kgs and also in bulk drum packs of 100 / 250 / 500 kg.

[Contributed by Ador Welding Ltd.]

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TECH TRENDS

Ceramic Coatings in Machine Tool Industry By P T Bindagi, Technical Director, Spraymet Surface Technologies Pvt. Ltd. , Bangalore

achine Tool Industry has undergone major developments in providing longer lasting life to spindles , arbors and bearings. Ceramic coatings by Plasma spray process have been in use since 1960 in many industries. Since last decade this process and ceramic coatings are used to provide hard surfaces to seal areas of spindles, contact faces of arbors and electrical and heat insulation to bearings. Apart from OEM level coatings, many user industries are using ceramic coating for refurbishing of spindles and other machine tool parts.

WHAT IS PLASMA SPRAY? The plasma spray gun comprises a copper

anode and tungsten cathode, both of which are water cooled. Pressurised plasma gas (argonor nitrogen with hydrogen 15% as secondary gas) flows through the anode and passes the anode. The plasma arc is initiated by a high voltage discharge between anode and cathode which causes localized ionisation. The resultant heating from the arc causes the gas to reach extreme temperatures, dissociate and ionise to form a PLASMA. Plasma arc ( flame) extends down the nozzlewith temp upto 15000 deg C and velocity upto 600 mts/sec. Fine Powder is fed into the plasma flame through an external powder port mounted near the anode nozzle exit. The powder softens and hits the target( grit blasted job) in semi molten state with high velocities creating well bonded and dense coating.

Typical spray materials used with Plasma Spray Metals and its alloys : Steels, Ni alloys, Co alloys, Moly, bronze, copper, Babbitt, etc.

Coating selection Plasma sprayed Ceramic-coating on spindles and other machine tool parts (best-suitable for parts and areas that require wear and corrosion resistance) Tipycal Base material of spindles/Arbor high carbon chromium bearing steel (SUJ2) chrome molybdenum steel (SCM415, 435) carbon steel for machinery (S45C) martensite stainless steel (equivalent to SUS440C ) austenite stainless steel (SUS303, 304)steel alloy for tools (SKS3, SK4) aluminum chrome molybdenum steel (SACM645)

Choice of ceramic Coatings Chromium Oxide( Black) : 72 Rc Very hard and low on impact Alluminum Oxide( white) : 62 Rc Good wear and thermal and electrical insulation Al oxide + TiO2 ( Grey/Black) 58Rc Widely used as it is easy to grind and less brittle and takes high finish ( 0.2 Ra)

Ceramic coating on New spindle or refurbish + coating procedure : Under cut the diameter to be coated

Normally 0.4 mm on dia

Grit blast the surface

Get Clean rough texture

Plasma spray ceramic coating

To required thickness + Grinding stock

Finish by diamond grinding and super finishing

To required size and finish Upto 0. 1Ra finish can be achieved

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Spindle bearing/seal area/parts coated with ceramics - Picture courtesy: Unionchemnitz

Arbor & sleeve ceramic coated – Al Oxide = Tio2

Split Babbitt or bronze bearing Thermal sprayed/ machined

Ceramics: Chromium Oxide, Aluminum Oxide, Al Oxide + TiO2 , ZrO2 , etc. Carbides: Tungsten carbide, Chromium carbide, TiC Hardness range of coatings: From SOFT 60 Rb( Bronze) to HARD 70 Rc ( tungsten carbide.)

BENEFITS OF PLASMA SPRAYED CERAMIC OVER HARD CHROME Environmental: Less hazardous as there is no Hexavalent chrome involved Dust disposal easier than bath liquid. Performance: 3-4 times wear resistance than Hardchrome Micro porosity holds lubricationSelective area coating is possible Higher thickness upto 300 microns per side is possible Limitations : Ceramics are brittle & to be handled carefully Process not as widely available as hardchrome

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INDUSTRY SPEAK » PUMPS & VALVES

Yagnesh Buch, Dy. General Manager, KSB Pumps Ltd.

“Indian made Pumps and Solutions are steadily getting more and more acceptance and are becoming customers’ preference the world over” Q. With so much of developments planned and envisaged in various sectors including infrastructure, agriculture and water management, the pump industry has a pivotal role to play in maintaining the throb of the people, industry and economy. Your comments? This is an important area of focus for our country; and while the machinery is doing all that needs from the planning perspective; the signals or momentum in the market still suggests that there is a ”slip between the cup and the lip”. As we know, India’s fragile and finite water resources are depleting while the multi-sectorial demands for water from sustained economic growth (over 8%) is driving the increased demand for water through coupled dynamics between increased energy and consumption. Exponentially increasing demand for water due to population growth and agricultural use, coupled with a high degree of variability in the availability of water resources throughout the country, will drive per capita accessibility of water to under 1,000 cubic metres by 2020 if left unchecked. Climate change and extreme climate variability are further likely to accentuate these numbers. The future evolution of the inter-sector shares is complex and uncertain; however, higher usage in the domestic and industrial

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domains is likely as the pace of economic development grows. To offer a background to the seriousness of the situation; the agricultural sector uses around 79% of the available freshwater supply and wastes one-half and four-fifths of the irrigation water. The domestic sector consumes around 6% while the industrial sector consumes around 5%. Increasing urbanization is significantly increasing demand away from the countryside, to the city. There are approximately 50 cities with a population of more than 1 million. Furthermore, the total number of cities and towns in India has increased from 2,250 in 1991 to 5,161 in 2001, and has increased to 7,936 in 2011 (as per the 2011 census indicators). Projected municipal and domestic water demand will also double by 2030, to 108 billion m3 (7% of total demand), while projected demand from industry will quadruple to 196 billion m3 (13%), pushing overall demand growth close to 3% per annum. The foregone certainly is a challenging situation for the country’s central and state administrations who are required to take giant and brisk steps in implementing projects and stemming a likely water catastrophe. Even in the Water and Waste water sector, Global water companies such as Veolia Water, Suez de Lyonnaise

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PUMPS & VALVES » INDUSTRY SPEAK (Degremont) and VA Tech Wabag, Nalco, GE Betz-Dearborn etc, have established a presence in India with many projects initiated or underway worth several billion Euros; the challenge of mobilization of funds / clearances etc. still remain a bottleneck for a ‘smooth takeoff’ of many of these projects. Having said this; the Indian Pump Industry in general and KSB Pumps Limited, in particular, is fully geared to keep pace with these requirements with the right products; technology; solutions and systems to satisfy the needs of these sectors, with great aplomb, in India

Q. How self-reliant are we when it comes to constructing pumps and pumping systems for handling oppressive media and arduous applications? The breadth of the Indian Pump Manufacturers product portfolio addresses the needs of myriad customers. KSB in India has been; and continues to be a trendsetter, developing and providing pumps for virtually all conceivable applications throughTechnological leadership and solid German heritage. These include pumps for customers from basic domestic water, to supply and consumption of water in commercial buildings and offices including that for HVAC purposes and firefighting. Moving towards Industry, Indian Pumps are a heart of the process! They reliably transport fluids ranging from Industrial water to acids to viscous and solid laden liquids and abrasive solvents with ease. In the Refinery and Petrochemical sectors, cryogenic and explosive media is handled with great finesse. In the Power sector, be it a Conventional or a supercritical or a Nuclear Power plant, we save energy while helping the nation to generate more. And to keep our fields green, our pumps romance the life-giving element, water, with great panache. KSB in India is indeed a “One Stop Shopping Centre” when it comes to delivering value to the customers with reliable pumping solutions to what-so-ever

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or how-so-ever the application may be!

Q. In technology and capability, where do we stand in the global arena? Indian made Pumps and Solutions are steadily getting more and more acceptance and are becoming customers preference the world over. Not only does India have an cost advantage, but also the capability and credentials of the Indian workforce stands as a benchmark amongst those of the developed countries. That is why when it comes to technology, we are in step with the world. Take for example – KSB Pumps Limited; Heir to a lofty tradition of technological leadership, since 1871 in Germany, we have access to contemporary technology and solutions for all pumping needs. Some are so advanced, that India is not yet ready to imbibe them – remote monitoring systems for instance! We expect more and more evolutions to take place – more efficient and integrated and automated solutions to be used by the Indian Industry, for which KSB is completely ready!

Q. What’s your niche and contribution to the dynamic pump industry? Having started our journey in 1960 in India, when the country was predominantly driven by an agrarian economy, KSB in India brought in the submersible bore-well pump. This was a time when an electric motor running under water was not even heard of! After successfully pioneering and concept selling the submersible pumps; as industrialization accelerated; KSB has been continuously introducing many “firsts” to the Indian pump industry and has never looked backsince by pioneering and introducing world-class products and solutions to the myriad and demanding needs of the Indian customers! Whether it was the end suction pumps in back pull out design; nonclog pumps; process pumps; submersible sewage pumps; high pressure multistage pumps; vertical canister pumps or even the primary heat transport pumps for the

nuclear reactors … KSB in India has been an undisputed trendsetter! And since then, we have never rested on the laurels. We have been continuously up-grading existing products, introducing new products, newer materials, efficient designs and offering optimal solutions at great value to our customers. At KSB – quality is a way of life and brooks no compromise what-so-ever and where “special is our standard”! To do so, we have five ultramodern manufacturing plants including our own state-of –the-art cast iron and alloy steel foundry in India and we reach out to our customers through an effective sales and service network comprising 4 zonal offices, 18 branch offices, over 800 authorized dealers, 5 own service stations and over 150 authorized service centers across the length and breadth of the country! While KSBs strength of supplying quality and reliable products is recognized and acknowledged strongly by customers from all market segments; the dependence of KSBs undisputed worldwide leadership for pumps for the energy sector is recognized in India too. What with all the Supercritical and Nuclear power stations in India having complete dependence on KSB for all their critical pumping needs! And as the demands to generating more and more power to drive our nation forward; it is imperative that India has made an aggressive roadmap for power generation. Recognizing this need and to fulfill the reliance the Energy sector has reposed in KSB not only in India, but the world over, KSB in India is in the process of setting up a special plant near Pune to cater to the growing demands of the Power sector. This unit is expected to be operational by the 1st quarter of 2017.

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TECH TRENDS

FCRI’s large water flow lab – The largest in the world By P.K Suresh

he Water Flow Laboratory, established in 1989, has been providing technical consultancy, research, training, testing and calibration in flow measurement for our clients across the globe. Activities of water flow laboratory are centered on calibration and testing of flow products including flow meters, valves, water meters, pumps, water conveyance pipe and fire fighting equipment with water as medium of calibration/testing. The static gravimetric method as per ISO 4185 is adopted here for the measurement of flow rate. The Water Flow Laboratory has two divisions viz. the 600 mm Water Flow Laboratory and the 100 mm Water Flow Laboratory. The flow meters are calibrated to the highest accuracy by weighing the quantity of water that passes through the meter during a known time interval. The laboratory is designed to handle a maximum flow rate of 4500 m3/h and a maximum pressure of 3 bar. Pipes upto 900 mm NB diameter can be accommodated in the system. The test rig has different test lines sizes up to 900 mm NB and the laboratory is capable of extending the line size upto 1200 mm. A large underground sump of 370 m3 capacity is used to store the required water. The test rig is supplied with water at constant head from an overhead tank of 50 m3 capacity and 18 m head. During operation the constant head tank (CHT) is continuously overflowed using different low pressure pumps, which can be selected according to the requirement of the test meter. Weighing tanks of capacities 30 kg, 300 kg, 2000 kg and 20000 kg are made available for the flow measurement. Diverter systems are used to divert the flow to the weighing tank for an accurately measured time period (flying start and stop method). The mass measurement is by high precision electronic balance/load cell. Time is measured

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using universal counter which is triggered by a photo switch connected to the diverter system. A set of high precision differential pressure transmitters are available for the measurement of differential pressure. Resistance temperature detectors are used to measure the water temperature. The density of water at flowing condition is measured using an online density meter. Together with measurement of density at the moment of each diversion enables mass readings, after correction for buoyancy, to be converted into volume. The volume is divided by the respective diversion time to obtain accurate measurement of flow rate. The laboratory has been accredited by National Accreditation Board for Testing and Calibration Laboratories (NABL) and certified by GCAS for ISO 9001.

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Did you know that FCRI is also into

Special Assignments & Projects?

Some of the Special Purpose Test Facilities at FCRI LOCA/MSLB TESTING FOR NUCLEAR COMPONENTS

CRYOGENIC TEST

HIGH PRESSURE AND HIGH TEMPERATURE FACILITY

HYDRAULIC IMPULSE TESTING

ENDURANCE TEST FACILITY

ENVIRONMENTAL TEST FACILITY

FCRI Water Flow Lab, India’s leading facility for calibration/ testing of flow products with highest accuracy class ww Yes. Apart from hydraulic performance tests and calibration, FCRI also evaluates and certifies flow products in our Special Purpose Test Facilities. The world-class facilities where products are tested for performance in arduous operating conditions. Our Special Assignments & Projects Group also undertakes sponsored projects for study & assessment of flow related problems. Backed by a dozen well equipped and NABL accredited test labs at FCRI including the Water Flow Lab, India’s leading facility for calibration & testing of flow products like flow meters, valves, pumps and fire fighting equipment with water as the flow medium. And the Large Water Flow Lab, one of the largest flow measurement facilities in the world, designed for a maximum pipe diameter of 2000 mm with a flow rate of 15,000 m3/hr.

FCRI is indeed a Resource to Industry.

So, whatever be the challenging assignments akin to flow, FCRI has the expertise, engineering acumen and resources to accomplish them eminently and cost-effectively within the shortest possible time.

FCRI’s Large Water Flow Lab, one of the largest flow measurement facilities in the world

Fluid Control Research Institute

(Under Ministry of Heavy Industries & Public Enterprises, Govt. of India) www.fcriindia.com

Kanjikode (W), Palakkad, Kerala - 678 623 | Ph : 0491 -2566120 / 6596 / 9010 Fax : 0491-2566326 | Email : customercare@fcriindia.com

NABL, BIS W&M, UL, CPCB, CCE, IFE, ITEC/SCAAP NMi, NPCIL

Flow Metering | Special aSSignMentS & projectS | training & Skill DevelopMent

vijayshreyaarts@gmail.com

Recognized by

TECH TRENDS Brief Specifications of the Water Flow Laboratory Max. Flow Rate (m3/h)

4500

Measurement Uncertainty

Max. Size

900 mm

In Mass Flow rate ±0.04%(Upto 250 T/h) ±0.10%(300 to 1800 T/h)

In Volume Flow rate ±0.05 % (Up to 200 m3/h) ±0.10 % (200 to 2500 m3/h) ±0.15 % (2500 to 4500 m3/h)

International Inter-comparisons Water Flow Laboratory has conducted inter laboratory comparisons with International laboratories like Delft Hydraulics - Netherlands, National Engineering Laboratory - United Kingdom and proved that the FCRI results are well comparable with International flow measurement systems. Recently water flow laboratory has conducted an Inter comparison with Czech Metrology Institute(CMI) as part of Bilateral Inter Laboratory comparison (BILC) and CMI has certified FCRI.

Special tests Validation of Flow Nozzle assembly as per PTC 6 Standard In order to conduct the turbine acceptance tests, the accurate determination of primary flow is necessary to compute turbine heat rate or steam rate. All known errors must be reduced so that their individual effect is less than 0.05% of the primary flow to be measured. Excellent results have been obtained using lowbeta-ratio throat-tap nozzles, and, for this reason, PTC6 code recommends to use a calibrated low beta flow nozzle for turbine testing. Experience shows that the coefficient of discharge for a particular flow section cannot be satisfactorily predicted to meet Code uncertainty objectives, and, therefore, it is necessary to calibrate each flow section. At FCRI, calibration can be undertaken

In Total Volume ±0.05 % (Up to 20 m3)

In Total mass ±0.01 % (0 to 2000 kg) ±0.025 % (2000 to 20000 kg)

in a similar Reynolds number to those in the actual installation. The physical construction of the piping in the calibrating setup will be similar to that in the test setup from the standpoint of pipe configuration, immediately upstream and downstream of the flowmeasuring section. Reynolds number in the range of 4 million can be achieved at our facility. The calibration consists of at least 20 acceptable points over a wide range of Reynolds numbers. All four tap sets need to be calibrated individually. In the turbine test, the two tap sets that most closely comply with the calibration criteria mentioned in the PTC6 code will be chosen. Many Indian and overseas customers are utilizing FCRI facility for the calibration of their PTC6 flow nozzles.

Laboratory Proving of Compact Provers Water draw calibration of Compact Prover, Pycnometry and meter proving can be conducted, as per API MPMS at the laboratory. The Base Volume of the compact prover will be established by water

Compact Prover under water draw calibration

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TECH TRENDS

draw method. The prover will be then installed at site for the proving of custody transfer flow meters. The Many other tests which are customized as per customer requirements are also conducted in the water flow laboratory. This laboratory is tailor made for the calibration of Coriolis mass flow meters with highest accuracy in the country.

CENTRE FOR WATER MANAGEMENT Centre for water management (CWM) is equipped with state of the art equipment used for evaluation of flow product, mainly domestic and bulk water meters. CWM offers different kinds of services like flow product assessment, in-situ measurement/calibrations, analysis/design and consultancy service related to flow problems especially in water distribution networks, surge, etc. to various sectors. In this facility, accurate measurement of flow in terms of volume is determined by gravimetric system. A flow rate up to 300 m3/hr, through 150 mm pipeline, can be achieved in the laboratory with overall uncertainty in volume better than 0.03 %. Assistance is being offered to different water Utilities during bulk purchase of water meters. A Model approval program is launched to help the manufacturers to improve the quality of their meters. Details of models passed the endurance test will be made available in FCRI website. This is expected to help water boards to verify the models submitted by suppliers and proceed with quick purchase with acceptance tests on randomly sampled meters and applying the prescribed acceptance criteria.

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219

TECH TRENDS

600 mm Wafer Check Valve under test

Water Meter Testing Around 3000 water meters of various sizes are tested at CWM every year. The test facility is accredited by NABL and recognized by Bureau of Indian Standards. Testing of water meters of all sizes are conducted as per Indian and International standards. Tests include Hydrostatic Pressure Test, Accuracy Test, Pressure Loss Test, Temperature suitability Test and Endurance Test (continuous and discontinuous flow test). Most of the water boards in India insist endurance tests and acceptance tests at FCRI during their bulk purchase of meters. This has ensured reasonable life for meters in the field and has yielded substantial increase in the revenue of water boards.

In-situ calibration of large flow meters In-situ calibration of flow meters is necessary mainly due to the difficulty in dismantling the flow meters from the installed location. It is also difficult to make installations similar to site conditions in the laboratory. In these situations calibration is carried out at the installed condition at site. An insertion type turbine flow meter is used in in-situ calibrations. This turbine flow meter is inserted into the pipe through 3 inch tapping and traversed across the pipe. Velocity measurements are taken at different pre-defined locations in the diagonal. Similar observations are repeated in different diagonals

and the discharge is computed. Then the discharge is compared with the readings from the flow meter under calibration. In-situ calibration service is provided to various transmission lines of water boards, cooling water circuits of power plants, raw water pumping lines to refineries etc. Using the insertion-type turbine flow meter, calibrations/ discharge measurements were successfully carried out in pipelines up to a diameter of 3000 mm.

Services offered • Analysis, simulation and design of drinking water distribution systems • Performance evaluation and augmentation of networks for firefighting systems • Surge analysis of transmission systems for major cities • Root cause analysis of pipe breaks and implementation of remedial measures • Setting-up of test facility for water meters and other flow products • Assessment of flow product test facilities for various flow product manufacturers and water boards • Bulk procurement of water meters by various water boards • In-situ flow measurement & calibration done • Flow measurement in large dia. pipes up to 3000mm • Field efficiency Test of hydro-electric turbines up to 250MW • Surge pressure measurement in transmission mains • Flow measurement using non-conventional techniques like tracer dilution method, Gibson method etc. • Performance evaluation of cooling water systems • Measurement in open channels • Assessment of calibration and testing facilities for flow products • Training for professionals from water boards, consultants and manufacturers

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TECH TRENDS Apart from flow meters calibration and valve testing, the laboratory can also take up performance testing of pumps and turbines. The laboratory consists of an underground water sump of capacity 3000 m3 on which 5 Vertical Turbine pumps are erected. The Pumps are of rating 110 kw, 200 kw, 295 kw, 395 kw, & 485 kw and are used in combinations to meet the wide flow range requirements. Four Electromagnetic flow meters are operated in parallel as reference flow meters.

The major specifications of this facility are as under:

The Largest & Unique Water flow Calibration/ Testing laboratory in the World was established at FCRI in the year 2012. For meeting the demand of Manufacturer/user industries in connection with calibration/testing of large sized flow meters/ control valves with high accuracy. The laboratory is designed for a maximum pipe diameter of 2000 mm and maximum flow rate of 15000 m3/h with an uncertainty of ± 0.5 %.

1. Flow Medium : Water 2. Maximum flow rate : 15000 m3/h 3. Head : 20 m of Water Column 4. Pipe Line Size (Max.) : 2000 mm (Design ) 5. Sump Dimensions : 50m long x 8m wide x 7.5m deep 6. Type of Flow : Direct Pumping 7. Pumps Type : Vertical turbine 8. Type of Drive : Electrical Motor 9. Power : DG Sets, 1250 KVA (2 No.s) 10. Uncertainty : +/- 0.5 % [The author is Chief Research Engineer at Fluid Control Research Institute, Palakkad www.fcriindia.com]

Major sectors/plants availing the laboratory facility • • • • • • •

Water treatment & desalination plant Irrigation and hydrology departments Power plant Sewage plant Integrated urban water management Drinking water and sanitation authority Petrochemical industries and refineries

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MAY 2016 ENGINEERING REVIEW

221

INDUSTRY FOCUS » PUMPS & VALVES

KEPL shipped API BB4 pumps to Mirfa International Power & Water Company

une-headquartered Kirloskar Ebara Pumps Ltd (KEPL), a joint venture of Kirloskar Brothers Ltd (KBL) in India, has successfully completed the manufacturing and testing of High Pressure Ring Section type Boiler Feed Water Pump with 3.9 MW motor. These pumps are for 1400 MW greenfield combined-cycle power generation plant - Mirfa Independent Water & Power Company, Abu Dhabi (U.A.E). The testing of high pressure Boiler Feed Pump took place at Kirloskarvadi, Maharashtra which was witnessed by officials from various users and EPCs of the power industry.

KEPL pump model 250 X 200 KBDH is an 8 stage pump designed for high pressure Boiler Feed Water application.BB4 pump is a multistage between bearing, ring section and single casing pump designed for high pressure applications. This pump has a motor rating of 3900 kW having capacity of 740 m³/ hr and 1380 meter differential head achieved at a speed of 2974 revolutions per minute (RPM). The Mirfa Independent Water and Power Plant (IWPP) is a Power and Water Desalination Plant with a total combined net power capacity within the range of 1,400 and 1,600 MW of power generation

and a total combined net water capacity of 52.5 million imperial gallons per day (MIGD), located on the Arabian Gulf coast, at Mirfa, approximately 160 km West of the city of Abu Dhabi in the Emirate of Abu Dhabi (UAE). This project will involve the acquisition of certain existing water and power facilities; the development, design, engineering and construction of new power and water facilities; as well as the operation of the plant. “Supply of these 6 High Pressure Boiler Feed Water Pumps to Mirfa Independent Water and Power Company is a great achievement for us. We are glad to manufacture and supply the biggest boiler feed water pump from our state-of-the-art manufacturing facility at Kirloskvadi.” said Aseem Srivastava, Managing Director, KEPL.

About KEPL: KEPL is a joint venture company of Kirloskar Brothers Limited in India. KEPL, established in 1988, is an ISO 9001:2008, ISO 14001:2004 and OHSAS 18001:2007 Certified firm. It is a leading brand in API process pumps and API steam turbines. KEPL caters to Hydrocarbon processing, petrochemical, fertilizer and chemical process industries, power plants, water treatments plants etc.

Manufactured Products: 1. Centrifugal Process Pump as per API 610 2. Multistage Boiler Feed Water Pump 3. Steam Turbine as per API 611 4. Steam Turbo-Genset

For more information, Web: http://kepl.in.net/

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INDUSTRY FOCUS » PUMPS & VALVES

ValvTechnologies, Inc. Enhances ValvXpress® program to include three different options & meet customer demand

alvTechnologies, Inc., manufacturer of zero-leakage severe service isolation valve solutions, announced the enhancement of the ValvXpress® automated valve, mounting kit and actuator program, providing customers with three different options: The Total Package, Build-YourOwn and Actuator-Only. ValvXpress® is perfect for power customers who require quick delivery of zero-leakage automated valve solutions for severe service water and steam applications. ValvXpress® is typically used in highpressure high-temperature applications that demand reliability with single source, compact automation packages. “In today’s high-temperature, high-cycle environments, end users have asked for quick delivery and demand quality and dependability,” said Vice President of Sales, Gary Marler. “With nearly 30 years of valve performance experience, ValvTechnologies has configured the size, efficiency and dependability for the precise ValvXpress® automation package.”

The Total Package The ValvXpress® package includes the superior quality of the V1-1 valve, integral stop mounting kit and ValvTechnologies’ actuator, backed with the best four-year guarantee in the industry.

The Total Package includes: • Complete pre-engineered V1-1 valve, mounting kit and actuator fully assembled , tested and ready to install • ValvTechnologies’ standard accessories • Standard delivery of two weeks • Four-year warranty* on total package • ValvXpress® Total Package Benefits

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• Fastest lead-time - in time for your outage • Quick shipment Fully assembled, tested, ready to install 100% pre-engineered for speed Longer service life Reliable, maintenance-free operation Four-year zero-leakage warranty for power applications on the complete package • Improved performance • Reduced overall cost of ownership • Improved safety

Build‐Your‐Own Build-Your-Own ValvXpress® includes the superior quality of any ValvTechnologies’ valve and integral stop mounting kit and allows customers to choose custom accessories based on their specific needs.

• Improved performance • Reduced overall cost of ownership • Improved safety

Actuator‐Only Select your ValvXpress® actuator and pair it with any ValvTechnologies’ valve and integral mounting kit.

The Actuator‐Only package includes: • Complete integral stop mounting kit or integral stop conversion kit which adapts lever operated stock valves to an automated valve • Your choice of actuator (spring-return, double-acting) • You supply and mount all accessories • Standard delivery four + weeks • Four-year warranty* on the total package, excluding accessories

ValvXpress® ActuatorOnly Benefits The Build‐Your‐Own package includes: • Complete valve and integral stop mounting kit • Your choice of actuator (spring-return, double-acting or fast-acting) • Your choice of accessories. Select from our standard accessories or specify your own make and model for us to assemble. • Standard delivery four + weeks • Four-year warranty* on the total package

ValvXpress® Build‐Your‐ Own Benefits • • • • • • •

Short lead-time Customized to meet your specific needs Fully assembled, tested, ready to install Engineered-to-order Longer service life Reliable, maintenance-free operation Four-year zero-leakage warranty for power applications on the complete package

• Fully customized actuator based on your specifications • On par with any ValvTechnologies’ valve • Benefit from the reliability of the integral stop mounting kit • Longer service life • Reliable, maintenance-free operation • Improved performance • Reduced overall cost of ownership • Improved safety • *steam and water applications ValvXpress® pre-engineered, automated packages are the industry’s best solution for customers who demand the most reliable valve solutions for their severe service applications. With three options to choose from, customers now have even more flexibility and can take advantage of superior quality and dependability while enjoying lower total cost of ownership. For more information Web: www.valv.com

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INDUSTRY SPEAK » MATERIALS HANDLING

“There is a growing appetite for automation in warehouse operations” S. Mohan, CEO, Materials Movement Pvt. Ltd.

Q. How was the year that went by for your company? The year 2015-16 continued to be slow with no major growth drivers from an Industry Segment perspective. The Industry witnessed organic growth. New investments into Materials Handling Equipment and Storage Racking was largely limited to a few segments such as e-commerce and manufacturing. So, in short, it was an average year.

Q. Any upheavals you had to surmount? We did not face any noteworthy upheavals.

Q. What are the innovations you wish to display this year? We have observed a growing appetite for Automation in Warehouse Operations. This seems to be driven by very high costs of real estate, limited availability of qualified manpower, productivity requirements required to meet scaling-up needs of the business and to ensure process outcomes. The investment to return ratio’s are being looked at with all these considerations. We have extensive experience in design and

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execution of Automation projects in Europe and other parts of the World, through our JV partners. We are seriously considering introduction of automated solutions to the customers in India in current fiscal year. This will allow us to move up the value chain and grow along with our customers.

Q. Did you ever feel there’s a better way? What would be your strategy and approach to make the most of this year and beyond? The introduction of GST and its implementation is necessary for bringing about structural changes to the Logistics and Warehousing Industry Segment. This will be the real driver for growth. While this happens at Govt. level, we will continue to work with available opportunities and make the most of it by offering end–to-end solutions.

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PROFILE

Materials handling equipment from Mahindra Stiller

aridabad-based Mahindra Stiller Auto Trucks Ltd (MSATL for short) makes diesel engine operated platform trucks up to 5T capacity and tow (hauling) trucks up to 11 T. Its battery operated versions are made up to 20 T capacity. It makes battery operated stackers, pallet trucks and walkie trucks up to 3 T. The Stiller battery operated hydraulic crane(up to 3 T) is a big hit in the user industry. The same is the case with its elevating tables which are used for wide ranging applications on the shop floor including maintenance. It also offers trailers & trolleys, and tipping & dumper trucks. Last, but not the least, its battery operated vehicles are a runaway success. All these products are known by the brand name ‘Stiller’. Besides standard products, MSATL also supplies custom-built equipment for very special applications. The ingenuity of the company’s design team has been implicitly acknowledged by Vikram Sarabhai Space Centre for whom the company has specially developed diesel engine operated Tow Trucks. It has supplied Hydraulic Elevating Tables to Indian Space Research Organization with a platform which rotates 360 degree and side travel of platform in X, Y & Z axis movements. The company’s largest custom-made

Elevating Tables of 3 T having a platform size of 5 x 2.5 metres with a lift of 5 metres is in operation at giant automobile manufacturing units like LML, Escorts, Yamaha Motors and so on. Premier steel plants in India have also benefitted from the engineering prowess of MSATL. It has specially developed & supplied battery operated Platform Trucks of 5 T capacity to handle cinder at Tata Steel as well as Durgapur Steel Plant. Yet another winsome product from the stable of MSATL has gone to Printers House in Faridabad. It is the largest ever Hydraulic Elevating Platform of 10 T capacity along with battery operated pallet truck of 8 T capacity for container stuffing. MSATL also has it in its range battery operated stackers for drum handling. They feature fully hydraulic clamping, lifting and tilting up to 180 degrees. The company also makes battery operated golf carts and passenger vehicles for golf courses, hotels, farmhouses and industry. Its customers for diesel-engine driven pallet trucks are none other than the Indian Railways, Ordnance Factories, Naval Dockyards, L&T, Escorts, Eicher, BHEL, HAL, NTPC, SAIL, JCT, SAMTEL Group, and Maruti. For more information Mahindra Stiller Auto Trucks Ltd, Web: www.mahindarstiller.com

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INDUSTRY FOCUS

Under the motto „Be Part of Something Bigger“ Liebherr invited visitors to participate in various exciting activities and thus become part of this top-class event.

“Be Part of Something Bigger”: Liebherr enjoys success at Bauma 2016

rom 11 to 17 April Liebherr was represented at Bauma 2016 with over 100 products, an outdoor exhibition stand, a stand for the components division in Hall A4 and a career stand in Hall B0. During the trade fair week, the Group invited visitors to take part in several activities under the motto “Be Part of Something Bigger”, and thus become part of this top-class event. “Bauma 2016 was an absolute success for Liebherr. With this year’s appearance we were once again able to show our innovative strength, performance and

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technological diversity to a very large and international visitors from the industry. We conducted interesting discussions with numerous customers and partners from various countries and discussed new projects”, reports Stefan Heissler, Member of the Board of Directors of the Liebherr Group. Liebherr showcased over 100 exhibits from the areas of construction machines, mining equipment and components at the trade fair. “Our customers showed keen interest in our and we received several orders from

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INDUSTRY FOCUS diverse markets. Our expectations were even exceeded in some areas”, is how Heissler sums up the positive experience for Liebherr at Bauma 2016.

New products and exciting activities at the stand From 11 to 17 April customers and visitors not only had the opportunity to obtain information about products, innovations and trends in the construction machinery industry. Exciting activities also generated lots of excitement and enthusiasm: A “Social Wall” was created on three LED screens: Visitors had the option to take selfies at the stand and post them on Twitter, Facebook and Instagram using the hashtag #LiebherrBauma. The posts were then displayed on the Social Wall and are also online at www. liebherr-bauma.com. This also allowed Liebherr fans at home to send greetings to Bauma. Thus everyone became “Part of Something Bigger” – Bauma guests and fans worldwide. Visitors were also encouraged to write their feedback on “Liebherr at Bauma” on coloured post-its. The post-its were gradually added to a board and in the end formed a motif of a Liebherr machine. A highlight event on 12 April was the table tennis match between the men’s national teams from Germany and Austria. The match was played in the 130 cubic metre dump body of the T 264 mining truck. The top German players Timo Boll and Patrick Franziska

Besucher konnten Produktvorführungen auf dem gesamten Liebherr-Stand erleben – zum Beispiel den Mining-Bagger R 9200

The stand of the Liebherr Group at Bauma 2016

with their trainer Jörg Roßkopf faced Austria’s singles world champion from 2003, Werner Schlager, and the reigning Team Europe champions Chen Weixing and Stefan Fegerl. The “Match in the Mining Truck” was moderated by ZDF sports commentator Norbert König. The grand finale of this year’s Bauma was the legendary “final honking” between all the machines on the exhibition grounds. Following a construction period of six months and a week-long trade fair, on Monday Liebherr starts to dismantle the massive outdoor stand, the components stand in Hall A4 and the career stand in Hall B0.

For more information Web: www.liebherr.com

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PRODUCT SHOWCASE

PRODUCT SHOWCASE Hangsterfer’s Cutting Oils for Sliding Head Machines Hangsterfer’s Cutting Oils are recognized by Swiss Style Screw machine manufacturers around the world. Hangsterfer’s Hard Cut oils have improved tool life and surface qualities by as much as 300%! They are the first choice of leading Aerospace, Electronic and Medical component manufacturers. Aluminium, nickel, stainless steel and titanium alloys are machined with much greater ease. All of our oils are engineered to withstand the extreme condition at the tool workpiece interface. In addition to the lubricity provided at the cutting zone, our cutting oils provide excellent lubrication for the machine’s slides, guide bushings, bearings and spindles. Some can even be used in bar feeders. These products are available in a wide range of viscosities and chemical compositions. We have an oil for every application, from tapping and threading of

small, pin-like components, to broaching and fine blanking of large gears. Hangsterfer’s Hard Cut Series is formulated with the industry’s safest chlorinated extreme pressure additives. The CC Series has all the quality of the Hard Cuts but are Chlorine Free. Our Missile Lube Series is both Chlorine and Sulphur free. It was developed in the early 1960’s for the aerospace industry. Dr. Hangsterfer created a synthetic fat that met the performance and chemical standards needed for aluminium, magnesium, nickel and titanium alloys. This valuable technology, although highly concentrated in the Missile Lube series, is also contained in many of our other products. This results in unparalleled performance. No matter what the environment, Hangsterfer’s has a cutting solution for your facility.

For more information Hangsterfer’s Laboratories, Inc.USA Sanjay Tools & Adhesives Mobile : +91 9822028518 / +91 9892516810 E-mail: hangsterfers@sanjaytoolsnsk.com Web : www.hangsterfers.com

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“KUSAM-MECO” HIGH VOLTAGE DETECTOR (36.5KV / 81.5KV) MODEL - 230 HD / 290HD

“KUSAM-MECO” has introduced the advanced High Voltage Detector Model 230 HD, which detects high & extra high voltage in AC lines. An extendable insulation rod permits checking of high tension circuits at safe distance for voltage. Also it is telescopic, compact, light, weight, easy to use and handy. The intermittent lighting in red of a high intensity light emitting diode and intermittent audible sound of an electronic buzzer greater than 50 dB are easy recognizable at full daylight & noisy locations, from 3 m apart. The detecting head, being

tightly enclosed, is free from any trouble due to dust & water. The retracted overall length is 893 mm & extracted length is 1520 mm. The 485gm weighing model can be operated in - 10°C to 50°C temp. The electrical specifications are as follows. Measuring Voltage range : 3KV to 36.5KV, Operating Start Voltage (to ground) - 1.35 KV, Freq - 50/60Hz , With Stand Voltage - 100kV / 300mm, Insulation Resistance - 2000MΩ , Leakage Current - less than 100μ A. It is most suitable for use in switch yards of Electricity Beards & also H.T. Corporate Customers. Model 230HD is suitable for use upto 36.5KV. & Model 290HD is suitable for use upto 81.5KV.

For more information Kusam Electrical Industries Limited G-17, Bharat Industrial Estate, T.J. Road, Sewree (W), MUMBAI – 400 015, Maharashtra, India Tel. No. : 022-2418 1649; 2412 4540 Fax No. : 022-2414 9659 Email Id : kusam_meco@vsnl.net, sales@kusam-meco.co.in Website : www.kusamelectrical.com / www.kusam-meco.co.in

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PRODUCT SHOWCASE

Pioneer in intuitive programming • Offer the easiest-to-use and most adaptable alternative Automation Solution for specialized and demanding needs • An experienced technical team • A pioneer in the simplification of programming

em4 - MORE THAN JUST A PLC • All-in-one fully connected nano-PLC • Remote management & maintenance on a PC & mobile devices • Accurate & performant

sensor measurement

Millenium 3 - Logic Controller • Compact & expandable • Easy to program • Multiple configuration options

Specialist in electromagnetic & electronic technology • Specialist in time management with an extensive automation components offer that includes timers, monitoring relays • In addition to highperformance products, advice and support, offers tailor-made solutions for any application

TIMERS: • Simple to use • Multi voltage • Multi or mono function

MONITORING RELAYS:

ENGINEERING REVIEW

MAY 2016

Ador’s KING CUT PRO is a CNC portal cutting machine which is very precise and reliable. The machine has one head for plasma sheet metal cutting and one head for flame cutting of sheet metal with a dual side longitudinal drive with AC motors. The standard equipment comes with a basic machine package with CNC controller, one torch, central gas diffusion with manometers and a remote flame ignition.

The following equipment are supplied as required by the customer: Additional Equipment: • Plasma power source KJELBERG with machine torch • Programming software MOST 2D • Support table for sheet metal with segment extraction system • Extraction-filter system • Laser position indicator for determining the cutting point

Optional :

• Close-up protection for total availability of equipment • All anomalies are detected • Optimise continuity of service

For more information InnoVista Sensors #23 - Trident Towers - 4th Floor - 100 Feet Ashoka Pillar Road 2nd Block - Jayanagar - Bangalore - 560011 - India Tel: (1) +91 8041132204/05 Tel: (2) +91 080 40818916 E-mail: india@innovistasensors.com Web: www.innovistasensors.com

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KING CUT PRO – The large gantry type CNC Cutting Machine

• Extension of the longitudinal rail • Additional cutting head

The CNC Controller – Phantom: The Phantom brings you the performance of a cutting edge CNC that is built on more than

40 years of experience in the motion control and cutting industries. This controller is designed for multiple axis cutting machines and features the latest advances in CNC technology on a proven platform engineered to increase productivity, reduce costs and enhance profitability. The software provides flexibility, ease of operation and technologies that put Ador’s experience and expertise in your operator’s hands, resulting in extremely good cut quality and high productivity. The Phantom can operate any cutting machine and interface with virtually all plasma systems. Following are its standard features: Bright touch screen interface, Touch screen interactive display, Expandable shape library, True multi-tasking environment, Fast Dxt file conversion, Go to(Job interrupt), Quick plate alignment, and Monitor & track consumables. Advanced Plasma Process Control (Plasma Process Wizard) is available as optional extra. Ador offers cost-saving height control unit for simple plasma cutting applications. The KHC1 system provides all the essential functions that are needed for good cuts and optimum utilization of workpiece.

For more information Corporate Marketing Office Ador Welding Limited , Akurdi Chowk , Chinchwad, Pune 411 019 Phone : 020- 4070 6000 Email: cmo@adorians.com

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PRODUCT SHOWCASE

MECO “TRMS Digital Multimeters MECO introduced new 6000 Count TRMS Digital Multimeters, Models: 666TRMS, 153B+, 171B+. 666TRMS is a 6600 Counts Auto & Manual Ranging Digital Multimeter having AC & DC Voltage Range upto 1000V, and Current Range upto 20A AC & DC, Basic accuracy for DC Voltage ±1.0%rdg + 4dgt, for AC Voltage ±1.0%rdg + 5dgt, for DC Current ±1.0%rdg + 2dgt, and for AC Current ±1.5%rdg + 5dgt. It has special features like Auto Power Off, Resistance, Capacitance, Frequency, Duty Cycle, Temperature, Diode Test, Audible Continuity and Data Hold. 153B+ TRMS is a 6000 Counts Auto Ranging Digital Multimeter with LCD Backlight & Holster having Voltage Range upto 1000V DC & 750V AC and Current Range upto 20A AC & DC. Basic accuracy for DC Voltage ± 1.0%rdg + 4dgt, for AC Voltage ±1.0%rdg + 5dgt, for DC Current ± 1.0%rdg + 2dgt, and for AC Current ± 1.5%rdg

+ 5dgt. It has special features like Auto Power Off, Resistance, Capacitance, Frequency, Duty Cycle, Diode Test, Audible Continuity, Data Hold. 171B+ TRMS is a 6000 Counts Auto & Manual Ranging Digital Multimeter with LCD Backlight & Holster having Voltage Range upto 1000V DC & 750V AC and Current Range upto 20A AC & DC. Basic accuracy for DC Voltage ± 1.0%rdg + 4dgt, for AC Voltage ±1.0% rdg + 5dgt, for DC Current ± 1.0%rdg + 2dgt, and for AC Current ±1.5%rdg + 5dgt. It has a special features like Auto Power Off, Resistance, Capacitance, Frequency, Duty Cycle, Temperature, Diode Test, Audible Continuity, Data Hold, Max/Min, REL∆

For more information MECO Instruments Pvt. Ltd. Plot No. EL-1, MIDC Electronic Zone, TTC Industrial Area, Mahape, Navi Mumbai 400710. (INDIA) Tel: 0091-22-27673311-16 (Sales),27673300 (Board) Fax: 0091-22-27673310, 27673330 Web: www.mecoinst.com

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Fastener for Machine tools light & heavy engineering Industries (7/42)

We have developed some Fasteners which are useful in Machine Tools, Light & Heavy Engineering Industries. Components are Hex Socket type Allen Bolt, Hex Socket to Socket type Grub Sc, Plunger Screws, Eye Bolt, Hex Bolt Nut Washers, Machine Bolt, Hex Nut std, Lock, Dome, Nylock, Flanged Castle, Long Nuts. Washers plain, Machine Spring Star, Disk Fan, Bearing Wave, Disk Spring, Tapper Washers, Circlip, Knurled Safety lock washers. BSP, BSPT, NPT Tapper plug, Sq hd, Hex hd, Tapper plug, Hex hd Collar plug, Allen plug. BSP Copper washers. Philips Star Punch and Slotted Machine Sc, Self Tapping Sc, Rivet, Stud, Carriage Bolt, NIB

Bolt, Sq hd Bolt, T-Bolt, Set Sc, Solid Dowel pin, Tapper pin, Spring Dowel pin, etc. Components as per sample or drawing. STANDARD REFERENCE:- It can be supply as per IS, BS, JIS, DIN, ISO, ASTM & GOST Standard THREADS:- MM Size Coarse & Fine Pitch, BSW, BSF, UNC, UNF, BSP, BSPT, NPT/NPTF, 6BA to 0BA, 4 to 12No. Size NC/NF. MATERIAL’S GRADES:- M.S. 4.6gr, En - 8gr, 8.8gr, En - 19, 10.9gr, En - 24, 12.9gr, Brass, Copper, Nylon, SS 202, 303, 304, 316 & 410, HTS RST & V grade.

For more information ZENITH INDUSTRIAL PRODUCTS | ABC INDUSTRIAL FASTENERS E-122, Ansa Industrial Estate, 1st Floor, Sakivihar Road, Sakinaka, Andheri East, Mumbai - 400 072 Tel.: 022-2847 0806 / 2847 0705 / 6692 3987 E-mail : zenith@zip-india.com / abc@precibolts.com Website:- www.zip-india.com

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PRODUCT SHOWCASE

Welding carriage

These Welding carriage are used for Automatic Welding of Fillet, Butt, Joints in different Welding Position. GMAW/FCAW process is normally used along with these kind of carriage. These carriage uses permanent magnet to hold on to the Job and can be used in different

Welding position depending on the Tractor Force of the magnet used. Either guide wheel or the track are used to move the trolley along the Weld Seam. Weaving & Weaving pattern are available on some model to realize the required Weld Beads.

For more information WARPP ENGINEERS PVT. LTD. B-1005, Western edge-II, Near Metro Cash & Carry, Western Express Highway, Borvali (E), Mumbai-400066 Tel : 8080808737, 28542272/73/74, E-mail: sales@warpp.co.in, salessupport@warpp.co.in, Website- www.warpp.co.in

ElMeasure’s Intelligent ACCL

Limiter (iACCL). The compact product is built with high precision microcontroller that offers automatic changeover between main supply and generator supply. iACCL allows supply from mains as long as the load current is below the programmed current. When the mains supply fails and stand by generator supply is on, it connects the DG power to each consumer in sequence & starts monitoring its load. Whenever the load current exceeds the allotment, power is automatically switched off for 10 seconds, and automatically restored. This cycle repeats for 5 times each time with double the time (20, 40, 80 & 160) and then enters into lockout mode until it is ‘Reset’ manually. This helps to protect against over voltage from DG side. Its current limiting capabilities are ideally suited to the efficient utilization of the standby generators

frequently used in multistoried apartments, commercial complexes, etc.

Features: • Microcontroller based automatic source changeover with neutral isolation • DIN Rail/surface mountable for single phase and Surface mountable for 3 phase • SMPS based design for low power consumption • Intelligent re-connection once trip has occurred due to either over voltage or over load • Manual Reset provision when in sleep mode for restoring power supply • Energy, Current, Voltage measurement for DG & Current measurement for EB • Programmable threshold setting for both source independently • Over voltage protection for DG

For more information ELECON MEASUREMENTS A Group of ELMEASURE INDIA PRIVATE LIMITED # 764, 4th Phase, 707, Yelahanka New Town, Bangalore - 560 064 Karnataka INDIA Ph : +91 80 28461777/28461744 | Fax : +91 80 41272461 Customer Support : +91 80 32904489 E-mail: marketing@elmeasure.com Web: www.elmeasure.com

Hooked, good and proper

The power instability coupled with inefficient power distribution has created the need for backup power usually using a DG set. The manual switching of DG every time the utility supply fails

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leads to the disruption of key functions and causes damage to expensive equipment. To overcome this problem ElMeasure has introduced an Intelligent Automatic source change over with current

Elesa+Ganter wide range of standard machine elements has for many years offered locking mechanism operating along the “latch-frame” prefriction principle. But to keep a sliding door shut, you’ll need a different principle: the hook-type latch GN 115.8 acting in radial direction. Not all doors, flaps or even manhole covers have frames which may be

used as an abutment for locking mechanisms with clasp impeder. With hooktype latches, these locking challenges are no problem at all. Hook-type latches essentially consist of two elements, namely the fixed closing bolt and the hook including the rotating setup. The assembly locks in radial direction to the axis of rotation, the angle of rotation is normally 90 degrees

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PRODUCT SHOWCASE to the left or right – depending on the installation of the hook and the associated stop pin. Without this pin, the hook can be turned by as much as 360 degrees. As the hook features a catch bevel, mounting tolerances are no problem. The mechanism closes up to a side offset between axis of rotation and bolt of as much as 4 millimeters. Elesa+Ganter’s hook-type latches also boast high vertical installation tolerances: the bolt rests in a longitudinal hole, allowing it to be adjusted by as much as 10 millimeters – which in turn delivers a perfect locking effect even with higher tolerances, without needing major refitting or adjustment work.

To operate the GN 115.8 hook-type latch, Elesa+Ganter offers three options: 1. Lockable with cylinder lock and key, with and without additional operating handle. 2. Non-lockable, fitted with triangular, square, slot and VDE double bit drive with socket key. 3. The variant with star knob, wrench, knurled knob, lever or T-handle operated manually. Casing and axes of the hooktype latch are made of die-cast zinc, the operating elements are made of plastic, all other parts are made of zinc-plated steel – all complying with RoHS, of course. In all, the best possible hook-type locking mechanism can be found for virtually every specific requirement. And if not, Elesa+Ganter will always find a nonstandard solution.

For more information Elesa and Ganter India Pvt. Ltd. A-54, Sector -83, Noida - 201305 (U.P.) INDIA Tel. +91 120 472 6666 / Fax +91 120 472 6600 E-mail : info@elesaganter-india.com www.elesa-ganter.com

IR sensor safety guard for machines Safety light curtain are developed based on micro controller technology for protection of safety of HAND, FINGER, PROTECTION OF BODY AND PART OF THE BODY when the time of Working on the machine. These are available two types such as parallel beam type and cross beam

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type. Safety guards are used for preventing injuries of hand, finger, body, body part while working at Power Press for Metal, Processing Machine for Wood, Plastic, Leather, Rubber, Glass Etc, Filter Presses, Folding Or Benting Machine, Robots, Processing Line, Welding Press, Inserting Machine, Petletizers,

Handling & Stroaging SYSTEM, SPM, RUBBER MOULDING MACHINE, injection moulding machine etc .. etc. these are available in 4,6.8.10.16.24, 32 Beams with protected height of

90 to 1710 mm. The response time of cut on is 10 to 15 milli second. Easily connected with 230 volt operated systems as well as directly connected with PLC system.

For more information MRK ENGINEERS, 15/1A2, Plot: III, Lakshmi nagar, Ramamoorthy street, Moondramkattalai, CHENNAI- 600128. Mob. 09444668125. 09444659962. Email. ramakrishnan252008@yahoo.com Web: www.mrkchennai.com

Magnetic float switch Float switch is an electrical on-off switch which operate automatically when the liquid level goes up or down with respect to a specified level. the signal thus available from the float switch can be utilized for automatic control of pump or allied elements like solenoid, lamp, relays etc., These magnetic float switches are available in a very wide range according to operating and

mounting methods to suit variety of individual application. These are rugged, accurate and reliable operation. These floats are available in VERTICLE TYPE, HARIZONTAL TYPE IN PVC, STAINLESS STEEL, NYLON MATERIAL DEPENDS ON APPLICATION. We can also supply high temperature application, cable type electrical float as well as other than water like oil, sand, granule, salt, wood etc.,

For more information RS ELECTRONICS, 15/1A2, Plot: III, Lakshmi Nagar, Ramamoorthy Street,Moondramkattalai , Chennai- 600128. Mob. 09444668125. Email: rselectronics75@ymail.com.

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PRODUCT SHOWCASE

Shot Blasting Machine for Fasteners

ANGLE DEKKOR Angle Dekkor for Engineering College . Widely used to measure of the angle of job under test, precision angle dekkor uses the principle of optical reflection where a beam of light is projected on a mirror. The beam reflects with an angle as that of the mirror surface and as such the deflection can be measured

Surface Finishing Equipment Co. have launched intelligent Shot Blasting Machine Tumblast Type for cleaning and roughening of Fasteners. The Fasteners require uniform surface roughness suitable for anti corrosive coating.

The thread of screws posed problem of delecate handling. All these issues are taken care of in the Machine. The Machine has got high rate of production and meet Central Pollution Control Board Norms

For more information SURFACE FINISHING EQUIPMENT CO. E-100, M.I.A., Phase II, Basni JODHPUR – 342 005 (Raj.) INDIA TF: 0291-2740128/3296344/5120021 E-Mail : sfecjodhpur@gmail.com Website : www.sfecindia.net

Autocollimator Autocollimator for Engineering College , This system is used in glass shop for checking straightness and flatness, Checking square and V blocks, checking deflection of a structure under load Measuring tapers, checking the angles of small castings. Checking the cutting angle of tools, setting angles of jigs and machine tool

For more information Toolpost (india) MUMBAI. Tel:09819345050 www.indiatool.net

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For more information Toolpost (india) MUMBAI. Tel:09819345050 www.indiatool.net

Floating Carriage Micrometre Floating Carriage Diameter Measuring Machine for Engineering college

The Floating Carriage Micrometer is used for accurately measuring the ‘Thread Plug Gauges’. The Floating Carriage Diameter Micrometer effectively measures the various dimensions of the gauge like outside diameter, Pitch diameter, Root diameter etc.

Sine Centre Sine Centre for Engineering College : Size: 0-200mm, 0-300mm Sine centre is basically a

heads. Dark field graticule is used to get good image from un silvered glass surface or surfaces having poor reflection.

visually or by an electronic detector.

sine bar with block holding centres which can be adjusted and rigidly clamped in any position. These are used for inspection of conical objects (having male and female centres.) between centres. This is a very useful device for testing the conical work centred at each end. The principle of setting is same as of sine table. For more information Toolpost (india) MUMBAI. Tel:09819345050 www.indiatool.net

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BUSINESS AVENUES

INSIDE BUSINESS AVENUES Information on latest manufacturing projects in India SR. NO.