Engineering Review August 2016 by Divya Media Publications Pvt. Ltd.

E B R AT I N G

MULTIPLE INDUSTRIES MULTIPLE NEEDS ONE CHOICE Ravin Group is India's fastest growing conglomerate in the power sector with over 65 years of experience ranging from manufacturing a wide range of energy cables such as Low & High Tension Cables, Fire Survival Cables, Speciality Cables and Aerial Bunched Cables. The company not only excels in making the most power efficient cables in the country and across the world, but has consistently added a range of products and equipments useful for distribution of power. India's first integrated provider of power distribution cables, the company has become a powerhouse supplier of world class products and equipments to the power generation and distribution fraternity.

Energy Cables

HT/ LT

FIRE SURVIVAL

Retail Products SPECIALITY

Ravin Group offers Energy Solutions comprising of Power Cables upto 220 kV, EHV Projects & Services, Solar Energy Solutions- Single Axis Trackers, Dual Axis Trackers and Unipolar Tilted Tracking Systems; Power Equipments- Online Moisture Management System for Transformers, Retail Energy Products- Power Banks, Solar Chargers and LED Lights.

Solar Energy Solutions

POWER BANKS

EHV Projects & Services

Power Equipments AERIAL BUNCHED

SOLAR CHARGER

Ravin Cables Ltd. | Ravin Infraproject Pvt. Ltd. W: ravingroup.com | E: sales@ravingroup.com

Omira Engineered Products â&#x20AC;&#x201C; A PHILLIPS CORP Group Company

Volume 16 No. 04 | August 2016 | ` 200 | www.engrreview.com RNI No. MAHENG/2004/15135

2 EDITORIAL INDEX A ABB ADOR WELDING LTD. ALTEM TECHNOLOGIES Executive Publisher : Shilpa Kadam CEO : Shekhar Dongre Editor : Rajeev lyer CMO: Shirish Dongre Marketing Team : Ladoji Pendurkar, Amol Powle, Bhavin Shah, Bharat Shah, A.Purohit, Vinod Surve, Kavita Chaudhari Designer & Layout Arun P. Shinde, Nandan Moghe, Dinesh S. Gawade Online Division Ganesh M., Pradeep M. Pillalamarri

AMI POLYMER ARC ADVISORY GROUP

KISTLER INSTRUMENTS 36 114, 116, 232 38 229 46

B BECKHOFF BEKUM

BENTLEY SYSTEMS

6, 182

BEUMER GROUP

6, 168

BOSCHERT GMBH

232

C CEM INSTRUMENTS INDIA CONGATEC

86 8

Circulation Executive Satish Kadam, Amol Ranshur

DANFOSS

DMG MORI

186

E Head Office : Divya Media Publications Pvt. Ltd., 3rd Floor, Harmony Tower, N.S. Road, Thane-400 602. Maharashtra. Tel: +91 22-25380574/75, Telefax: +91-22-25418254 E-mail: shekhar@divyamediaonline.com Website: www.engrreview.com Branch Offices (Zonal): NORTH (Delhi & NCR regions) : Sandesh Jain : 09810837877 / 09871602777 SOUTH (Chennai & Coimbatore) : Y. V. Raghu : 09566141224 Bangalore - Vaman : 09686721340 Kochi - Sanjeev Nair : 09846249568 EAST (Kolkata & Other regions) : S. Roy - 09433097806 WEST (Maharashtra & Gujarat) : Pune - Sandeep Jaibahar - 09822751645 Baroda - Dinesh Shah - 09998687659 Rajkot (Saurashtra) - Swapnil Bhatia: 09227909005 https://www.facebook.com/engrreview https://twitter.com/engrreview http://in.linkedin.com/pub/engineering-review/87/b31/97a

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EFFICA AUTOMATION ELITE MATERIAL HANDLING EMERSON EPLAN EPP COMPOSITES

KOLLMORGEN

194

KUSAM ELECTRICAL

231

L LANTEK LAPP INDIA LIEBHERR GROUP

130

70 120 156, 192 68 231

34 38, 108, 154 26

M MARUTHI HANDLING EQUIPMENTS

MASTERCAM

MAXON MOTORS

88, 142

MECO INSTRUMENTS

234

MITSUBISHI ELECTRIC

42, 160, 162

MITSUBISHI ELEVATOR

MÖHLENHOFF

174

MRK ENGINEERS

234

N NATIONAL INSTRUMENTS NESS SOFTWARE ENGINEERING SERVICES NRB BEARINGS NTT COMMUNICATIONS

18 52 104 62

O OMRON AUTOMATION

ESSAR ENERGY

ESSAR PROJECTS

PC|SCHEMATIC

138

ESSAR STEEL INDIA

PERGO

EXXONMOBIL LUBRICANTS

28, 98

F FINOLEX INDUSTRIES

FLIR SYSTEMS INDIA

146

PHOENIX CONTACT

152, 230

PORTESCAP

POWIN ENERGY

R RED LION CONTROLS

106

GEISSEL INDIA

144

RISHABH INSTRUMENTS

148

GOODEARTH

178

ROLLON INDIA

132

H HAIMER

HANGSTERFER’S LABORATORIES

231

HARTING INDIA

150

HASS AUTOMATION

190

HEIDENHAIN INDIA

123

HEWLETT PACKARD ENTERPRISE

HITACHI HI-REL

HMS INDUSTRIAL NETWORKS

HONEYWELL

I IGUS INDIA INDIA TOOLS INDIA UNIVERSAL ROBOTS INNOVISTA SENSORS INORBIT TOURS INTERTEK

18, 134 233 110

SCHNEIDER ELECTRIC

SECO TOOLS SEE LUBE TECHNOLOGIES SHELL LUBRICANTS SIC MARKING

24, 164 82 36 166

SICK INDIA

SOLVAY

STELLA INDUSTRIES

SUZLON GROUP SYNETICS AUTOMATION

32, 44 94

230

TATA POWER

56, 60

TESTO INDIA

136

TOOLPOST INDIA

233

K KIRLOSKAR BROTHERS

S SCHMALZ

WARPP ENGINEERS

229

4 NEWS

AUTOMATION

CII Automation Conference calls for a change in the way we manufacture “Quality is not difficult to attain, but quality consistency is hard to achieve. So if you need consistent quality, volume and productivity, you have to switch to Automation,” said Mr. Ramakant Joshi in his keynote address at the CII Conference on ‘Automation for Profitability’ held at Hotel Residency Towers, Coimbatore on 22nd July. “Automation also reduces fatigue and helps the workforce to be more productive. In order to make automation achieve the desired goals, it is imperative that the buyer is equally knowledgeable and is fully involved, rather than leaving things entirely to the seller and his capabilities. At the buyer’s end, people at all levels should also be trained to assimilate the new technologies and the processes involved,” remarked Mr. Joshi. Mr. P. Ravichandran, President, Danfoss Industries was the Chief Guest on the occasion. In his address, he dealt with the after-effects of digitalization. He said that the mega trends in the domain are disrupting the world. Larger companies are fast disappearing and smaller ones are growing bigger in no time. The use of IOT technology and software are eating into every business including the kirana stores. In industries like food processing, automation is helping in close control of parameters, enabling traceability of the processes & products and also bringing down the costs. Automation is

AUGUST 2016 | www.engrreview.com

also bringing productivity, safety and sustainability through conservation of energy, water and other scare resources.” He said the industry should have the capacity and ability to deploy automation. Small and medium size companies must focus on knowledge and skill development so as to be able to embrace the sweeping changes. Earlier, Ms. Nethra J.S. Kumar, Chairperson, CII Coimbatore Zone & CMD, Lakshmi Electrical Control Systems Ltd. delivered the welcome address and Mr. Arjun Prakash, Event Chair-

man & Co-Convener- Manufacturing Panel, CII Coimbatore Zone & Director-Effica Automation Ltd. delivered the theme address. The Conference discussed as many as 16 well researched papers under four Technical Sessions viz. Automation for Higher Productivity & Flexibility; Quality in Automation; Materials Handling; and Advanced Technology in Automation. The eminent speakers represented well-known automation companies like Beckhoff, Rockwell, Festo, Hirotec, Ace Manufacturing, Lucid Imaging, Karma Innovations, Pricol, Bastion Solutions, ABB, Gudel, Arkkays National Engineering, Robert Bosch, Siemens and Fanuc India. Dr. B. Vinod, Member-Steering Committee and Head, Robotics & Automation, PSG College of Technology summed up the proceedings. Nearly 160 delegates from the manufacturing sector from across the country attended, took part in the day-long deliberations and derived benefit. The Conference was organized by CII with a view to addressing the twin challenges of adopting new technologies for manufacturing firms: big investment and scarcity of skilled manpower to handle automation. – P.K. Balasubbramaniian

6 NEWS

AUTOMATION

Baumer invests in new development and logistics center Sensor specialist Baumer is investing in its future with a new building in Stockach on Lake Constance (near to Constance) in Southern Germany. At the Stockach – Bodman-Ludwigshafen site, in addition to a central logistics center for Europe, a new high-tech center for Research & Development and Production is being built. The investment volume is approximately EUR 30 million. In doing so, the international family-owned company is intensifying its sustainable and long-term development of the Baumer Group. The aim of the new logistics center for Europe is that it can react more quickly and flexibly to the rapidly growing demands of the market. In the new high-tech center, importance is placed on sustainability and the latest infrastructure with a high level of networking between humans and machines (Industry 4.0). The project is being realized in several construction phases. In the course of the year, three buildings should be built on the 48,000 square meter site: a three-storey production building, a logistics building, and an administration building. In the initial expansion phase, the new site offers space for between 300 and 400 workplaces. The opening of the new high-tech center is planned for Fall 2017. Baumer Group The Baumer Group is an international leading manufacturer and developer of sensors, encoders, measuring instruments and components for automated image-processing. Baumer combines innovative technology and customer-oriented service into intelligent

solutions for factory and process automation and offers a uniquely wide range of related products and technologies. With around 2,300 employees and 37 subsidiaries and in 19 countries, the family-owned company is always close to the customer. Industrial clients in many sectors gain vital advantages and measurable added value from the worldwide consistency of Baumer’s high quality standards and its considerable innovative potential. For further information, visit www.baumer.com on the internet. For more information Web: www.baumer.com

AUTOMATION

Bentley announces Autodesk license upgrade program Bentley Systems, Incorporated, a leading global provider of comprehensive software solutions for advancing infrastructure, today announced its Autodesk License Upgrade Program. For consideration byowners of Autodesk perpetual licenses facing Autodesk’s imminent deadline for the write-off of the future value of their investment, Bentley Systems is offering recovery of the value otherwise subject to forfeit. Bentley Systems will credit the net value of Autodesk licenses towards upgraded “evergreen” perpetual licenses of Bentley’s applications. Bhupinder Singh, Bentley’s Chief Product Officer, said, “Bentley Systems considers purchases of perpetual licenses to be long-term investments by our users, so we continually

AUGUST 2016 | www.engrreview.com

innovate to increase their value. We are glad to now extend this ‘future-proofing’ to Autodesk license owners who otherwise will lose value in their applications.” Roy Kim, Principal of PacRim Engineering, said, “Bentley’s new Autodesk License Upgrade Program was a fitting solution for our organization -- a small business which is experiencing growth. With Bentley’s CONNECT Edition applications, our users came up to speed quickly and are already realizing impressive productivity gains.” John Cruikshank, President & CEO, JMC2 Civil Engineering + Surveying, said, “Autodesk continually sets deadlines forcing us to give up our perpetual license for an annual subscrip-

tion. Their actions have made sticking with the great Bentley products that much easier. With design software being the lifeblood of our civil engineering and surveying operations, it has always been our objective to keep our applications up to date and to maximize our investment. Bentley’s new Autodesk License Upgrade Program is the perfect solution for us. And with Bentley’s CONNECT Edition applications, our staff can get up to speed fast, giving us unheard-of growth in productivity.”

For more information Web: www.bentley.com

RIGHT NOW, YOUR BUSINESS CAN GO IN A MILLION DIFFERENT DIRECTIONS. AND ONE OF THEM IS RIGHT.

GROWTH IS LIVE. SAP’s suite of affordable solutions for small and midsize companies gives you constant control over your business. Live and in the moment. On premise or in the cloud. So you can make the right decision – right now. sap.com/India/live

8 NEWS

AUTOMATION

congatec fully supports SMARC 2.0 specification congatec – a leading technology company for embedded computer modules, single board computers (SBCs) and embedded design and manufacturing (EDM) services – has announced its full support of the new SMARC 2.0 specification, which was released by the Standardization Group for Embedded Technologies e.V. (SGET) just a few days ago. This major technology adaption extends congatec’s leading and extensive Computer-on-Module portfolio to include a brand new solution which is perfectly positioned between Qseven and COM Express. congatec’s support of the standard is no surprise for insiders, as congatec played a major role within the SGET in developing the SMARC 2.0 specification. The new specification heralds a milestone in embedded Computer-on-Module technology and is especially designed for particularly multimedia oriented

and IoT-connected small systems. Christian Eder, Marketing Director at congatec, Member of the SGET Board and editor of the SMARC 2.0 specification comments on the importance of the new specification: “Revision 2.0 has elevated SMARC onto an excellent quality level and we can unconditionally recommend it to our customers. SMARC 2.0 has got all the

right qualifications to become an extremely successful new module standard, and win significant market share.” “With congatec in the role of draft editor we were able to significantly drive the advanced enhancements of this new specification,” Jason Carlson, CEO of congatec AG explains “We see SMARC 2.0 as complementary to our existing product offerings of Qseven and COM express, and by supporting all three platforms we will have a broader product offering to meet the expanding needs of our customers.” SMARC 2.0 offers numerous leading-edge serial IOs as well as IoT, network and video interfaces and is thus destined for a wide range of multimedia and graphics-oriented IoT applications.

For more information Website: www.congatec.com

AUTOMATION

Hewlett Packard Enterprise extends All-Flash Datacenter Capabilities Hewlett Packard Enterprise (HPE) recently announced new data storage solutions to help customers unlock the value of the all-flash datacenter. Updates to the HPE 3PAR StoreServflash portfolio include the world’s most capacitydense all-flash system, persistent storage for containers, unified storage enhancements, and flashintegrated data protection. HPE’s consistent strategy has been to simplify storage with systems optimized for all-flash, and software-defined storage deployed as a data fabric across form factors. “The era of the storage-only

AUGUST 2016 | www.engrreview.com

vendor is over and has been replaced by the era of the best-integrated IT stack,” said Joybrata Mukherjee, Country Head, Storage, Hewlett Packard Enterprise India. “Underpinned by flash and software-defined storage, HPE has the unique infrastructure and software innovation required to power hybrid IT across any form factor and consumption model.” Enabling a 16x boost in all-flash density to shrink datacenter costs. All-flash storage has enabled business transformation for a large number of customers and HPE’s focus on speed, affordability and

enterprise-class data services have led to rapid growth for the 3PAR family of all-flash arrays. To extend this trajectory, HPE announced support for new 7.68TB and 15.36TB 3D NAND solid state drives (SSDs) across the 3PAR StoreServ family. With these drives, HPE 3PAR StoreServ is the most dense and scalable all-flash array in the industry, now supporting up to 24 petabytes of usable SSD capacity in a single system and 12x better density than EMC all-flash systems. Over the last 24 months, HPE 3PAR has delivered 16x flash density improvements and 40 percent

lower dollar per usable gigabyte. New and existing customers can choose from different SSD drive types and sizes to optimize deployment flexibility. Support for these large capacity SSDs is enabled by two key technologies: 3PAR Adaptive Sparing, a patented 3PAR technology which assures that any SSDs, regardless of size, can be used without compromise and with 5x the media endurance. 3PAR Express Layout is another enabler that provides concurrent access from the 3PAR storage controllers to the SSDs for higher throughput.

12 CONTENTS

Vol 16 Issue 04 | AUGUST 2016

COVER STORY

INDUSTRY FOCUS

104 NRB collaborates with the worldâ&#x20AC;&#x2122;s most respected mobility companies.......

106 Reflecting on the Past to Advance the Industrial Internet of Things

86 CEM Instruments : The blend of innovation & perfection Mr. Vikram Bhansali, CEO, CEM Instruments India Pvt.Ltd.

108 Connecting it right!

110 Why does India need more collaborative robots?

www.engrreview.com

EDITORIAL BOARD

Mr. T. P. Singh Director - S&M Flir Systems India Pvt. Ltd.

Mr. Ashok Sheth Chairman Solitaire Machine Tools Ltd.

Mr. S. A. Mohan Chief Executive Officer Maini Materials Movement Pvt. Ltd.

Mr. Rajesh Ballamwar Director Prolific Systems & Technologies Pvt. Ltd.

Prof. R. Sreedaran Faculty - Atharva College of Engineering

Mr. P.K. Balasubbramaniian President VBS Corporate Support

Mr. Ravin Mehta Managing Director Neel Controls/Neel Industrial Systems Pvt. Ltd.

Mr. C. S. Limaye Director Supertech Instrumentation Services India Pvt. Ltd.

FOR ADVERTISING ENQUIRY CONTACT: Email: shekhar@divyamediaonline.com All rights reserved. No part of this magazine may be reproduced in any form without the permission of the Editor. ENGINEERING REVIEW is owned, printed & published by Shilpa Kadam, published from 3rd Floor, Harmony Tower, Netaji Subhash Road, Court Naka, Thane (W) Thane-400 602 Tel: +91 22-25380574/75 Telefax: +91-22-25418254, Editor : Rajeev lyer. Important: Whilst care is taken prior to acceptance of advertising copy, it is not possible to verify its contents. ENGINEERING REVIEW can not be held responsible for such contents, nor if any losses or damages incurred as a result of transactions with companies, association or individuals advertising in the publications. Articles, interviews published in ENGINEERING REVIEW are the personal views and expressions of its authors. ENGINEERING REVIEW does not necessarily agree to it. ENGINEERING REVIEW can not be held responsible for such articles / interviews. We therefore recommend that readers make necessary enquiries before sending any money or entering into any agreements with advertisers or otherwise acting on an advertisement in any matter whatsoever.

AUGUST 2016 | www.engrreview.com

12 CONTENTS

Vol 16 Issue 04 | AUGUST 2016

COVER STORY

INDUSTRY FOCUS

104 NRB collaborates with the worldâ&#x20AC;&#x2122;s most respected mobility companies.......

106 Reflecting on the Past to Advance the Industrial Internet of Things

86 CEM Instruments : The blend of innovation & perfection Mr. Vikram Bhansali, CEO, CEM Instruments India Pvt.Ltd.

108 Connecting it right!

110 Why does India need more collaborative robots?

www.engrreview.com

EDITORIAL BOARD

Mr. T. P. Singh Director - S&M Flir Systems India Pvt. Ltd.

Mr. Ashok Sheth Chairman Solitaire Machine Tools Ltd.

Mr. S. A. Mohan Chief Executive Officer Maini Materials Movement Pvt. Ltd.

Mr. Rajesh Ballamwar Director Prolific Systems & Technologies Pvt. Ltd.

Prof. R. Sreedaran Faculty - Atharva College of Engineering

Mr. P.K. Balasubbramaniian President VBS Corporate Support

Mr. Ravin Mehta Managing Director Neel Controls/Neel Industrial Systems Pvt. Ltd.

Mr. C. S. Limaye Director Supertech Instrumentation Services India Pvt. Ltd.

AUGUST 2016 | www.engrreview.com

16 NEWS

AUTOMATION

HMS Industrial Networks AB acquires Intesis Software HMS Industrial Networks AB has acquired all shares of the Spain-based company Intesis Software, S.L. – a leading provider of gateway solutions for HVAC (Heating, Ventilation and Air Conditioning) system integration within building automation. Intesis was founded in 2000 and is headquartered in Igualada, Spain, close to Barcelona. Intesis offers advanced communication gateway solutions and interfaces within the building automation field. The major part of Intesis’ sales comes from the successful “IntesisBox” building automation communication solution. Intesis works closely with many major manufacturers of air conditioning and building automation systems globally. At present, the company has 30 employees. “We see great potential in lifting the Intesis business and technology platform to the next level by becoming part of HMS, one of the global market leaders

in industrial communication. I am very pleased to have found the right, industrial new home in HMS for our team,” says Pedro Lumbreras, founder of Intesis. “We are excited to be joining HMS, whose knowledge in industrial communication along with a worldwide presence will add new dimensions and even more strategic drive to our successful journey in the area of building automation,” says José Cerón, CEO of Intesis. “Intesis’ protocol and application know-

how, packaged in market-proven solutions are important additions for HMS. It is an excellent fit to our growth strategy,” says Staffan Dahlström, CEO of HMS Networks AB. “Intesis’ strong position within communication solutions for building automation system integration will complement HMS’ existing gateway offering perfectly. Intesis will give HMS a strong footprint and position in the market niche of building automation systems. Intesis is a well-established and highly regarded industrial company that, like our recent acquisition of eWON, further strengthens HMS’ unique value proposition to our customers – manufacturers of devices and machines, system integrators and installers worldwide.”

For more information www.intesis.com www.anybus.com

AUTOMATION

Honeywell User Conference highlights bottom-line benefits of IIoT The tremendous potential of the Industrial Internet of Things (IIoT) to solve the toughest problems facing manufacturers was the main topic of the 41st annual Honeywell Users Group (HUG) Americas conference. “Those who embrace digital transformation will ultimately win in the global marketplace,” said Bruce Calder, vice president and chief technology officer of Honeywell Process Solutions told the event’s 1,200 attendees. Daily general sessions at the three-day meeting of Honeywell leaders, customers and users focused on how technologies comprising

AUGUST 2016 | www.engrreview.com

IIoT can help companies improve operations. The theme resonated with attendees due in part to challenges brought on by current economic conditions, but it also articulated Honeywell’s long-term vision for delivering solutions to customers regardless of industry challenges. “The IIoT is bringing together existing technologies across all industries in order to solve issues previously considered unsolvable,” said Andrew Hird, vice president and general manager of HPS’ Digital Transformation business. “In most cases, the data needed to solve big issues like unplanned

downtime and the manufacture of off-spec products is there – it’s just not being managed and utilized in the right way.” Examples included improving business profitability with alarm management, using remote server data to improve storage management in tanks farms, and remotely collaborating through the cloud to shave weeks off incident resolution times, among many others. “We’re making the business

case for efficiency, reliability and safety gains. It’s an evolution, not a revolution,” HPS president Vimal Kapur told attendees. Key to the IIoT by Honeywell solution is the development of an IIoT ecosystem, which brings together Honeywell’s advanced data analytics, cloud technology and deep domain experience in automation with process technology providers and original equipment manufacturers. Some of these partners, including Honeywell UOP, Flowserve, SeeQ and Meshify, were demonstrating integrated solutions at HUG.

For more information Web: www.honeywell.com

18 NEWS

AUTOMATION

Heavy-duty oil rig robot wins the 2016 gold vector award Every two years, igus GmbH presents the vector award for novel applications with energy chain systems covering fast travels, adverse environmental conditions and dizzying rotations This year, the gold vector award went to the Norwegian company Robotic Drilling Systems, who use several energy chain systems from the motion plastics specialist igus in extremely limited spaces within their robots. The “Drill-floor Robot DFR-1500” from the Robotic Drilling Systems is the central robot in a fully automated oil drilling system. In an area where normal work involves the manual carriage of individual drilling elements to and fro and fixing with bolts with enormous effort, the company is working on the oil platform of the future, where the drilling is completely prepared and executed by robots. The DFR-1500 uses individual drilling elements and brings them into the correct position for the drilling operation. RBR systems from igus are used in the articulated joints of the robots, and are responsible for the supply of energy, data and media. RBR stands for “reverse bend radius”, because the chains are used lying on their side and the

The winners of the 2016 vector award were honoured at the Hannover Messe. The gold vector award was won by the company Robotic Drilling Systems from Norway. From right to left.: Rune Bjørnbekk, Jimmy Bostrøm (both Robotic Drilling Systems, speaker at the award ceremony and patron of the competition Ken Fouhy, vdi nachrichten, Harald Nehring, igus GmbH. (Source: igus GmbH)

chain links can move in both directions, allowing rotational movements. This sophisticated energy supply system solution convinced the jury of the 2016 vector award, consisting of representatives of specialised media, business and research, who honoured the application by Robotic Drilling Systems with the gold vector

Gold for oil drilling robot Inside the articulated joints energy chains with reverse bending radii supply energy, data and media in a minimum of space. (Source: igus GmbH)

award. The award, also with Euro 5,000 prize money, was received by Jimmy Bostrom, Chief Operating Officer at Robotic Drilling Systems, in front of around 500 guests at the award ceremony in the fair stand of igus GmbH at the Hannover Messe.

For more information Web: www.igus.in

AUTOMATION

NI hosts annual Certified LabVIEW Architect (CLA) Summit 2016 NI successfully hosted its first Certified LabVIEW Architect (CLA) Summit 2016 in Bangalore. The summit was an endeavor by National Instruments to bring together the most skilled LabVIEW developers from across India who are working on a variety of test, measurement and control applications. Reflecting on the event, Jeff Kodosky, Co-founder and NI Business and Technology Fellow at National Instruments also known as the Father of LabVIEW commented, “I am excited to have been a part of the first CLA Summit in India this year and witness the vibrant community of LabVIEW users and their innovative and advanced applications that our LabVIEW Certified Users here are developing to solve real-world engineering challenges.” The Certified LabVIEW Architect is the final step in the three-part LabVIEW certification process. The exam for this step presents a set of

AUGUST 2016 | www.engrreview.com

high-level requirements and tests the user’s skill in building a program hierarchy with LabVIEW and a project plan for delivering an application that fulfills those requirements. SenthilkumarMurugesan, CEO, Unilogic and the chairperson of the CLA community said, “This has been a great opportunity in bringing together the certified LabVIEW users from various industries in India and have them share their experiences and insights about their applications. The sessions included best practices shared by the CLAs, NI experts providing tips and tricks to help the engineers become more productive and efficient.”Adding to that, Jayaram Pillai, Managing Director, NI India said, “With the growing Indian economy, companies today face many new trends and technological challenges. The need for skilled LabVIEW developers in the community is ever more.”

| FB11-08E |

The compact solution for superior signal technology: Beckhoff EtherCAT Box.

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4-channel, differential inputs, 16 bit

M12

Resistance sensor

4-channel, PT100, PT1000, Ni100, etc., 16 bit

Thermocouple

4-channel, type J, K, L, M, etc., 16 bit

4-channel, single-ended, 16 bit

IPC

Analog output ±10 V, 0 / 4…20 mA

M12 4-channel, 16 bit 4-channel, 2 inputs, 2 outputs, 16 bit

I/O Motion Automation

Special functions Position measurement Communication Motion

D-Sub M12 Incremental encoder Serial interfaces IO-Link master Stepper motor module DC motor output stage

Beckhoff Automation Pvt. Ltd. Pune – 411 006, India Phone: + 91 20 40 00 48 00 info@beckhoff.co.in

22 NEWS

AUTOMATION

16mm Athlonix DC Miniature Motor features energy efficient coreless design Portescap introduces the next frame size in the DCP range of Athlonix high power density brush DC mini motors. Athlonix DCP motors offer an optimized price-to-performance solution ideal for a broad spectrum of applications. Available in a 16 mm diameter, the new 16DCP motor features an energy efficient coreless design with an optimized self-supporting coil and magnetic circuit, which ensures optimum price-to-performance is delivered. Athlonix 16DCP motors are available in 2 variations, precious metal commutation and graphite commutation, both featuring an Alnico magnet inside. The unique constant force spring design for carbon brush ensures consistent performance. An REE (Restriction of Electro Erosion) coil is an available option, which ensures extended life of the motor and provides an environment of intrinsic safety especially at high speed conditions.

With maximum continuous torque up to 2.63 mNm and higher stall torque than similar motors, Athlonix 16DCP motors are ideally suited for use in applications such as medical & industrial pumps, gas analyzers, security & access, power tools, mesotherapy guns and tattoo machines. “Athlonix motors are powered by a proprietary self-supporting coil resulting into maxi-

mized magnetic flux and ampere-turns for a given diameter” says Sunil Kumar, Brush DC Product Line Manager at Portescap. “In contrast, typical self-supporting coils have inherent ampere-turns limitations that affect the magnetic flux density in the magnetic circuit, which further limits power output and endurance of the motor,” he says. Component standardization and design modularity ensures quick customization capability for samples across various applications. “Due to lower motor regulation factor compared to comparable motors available in the market, our new 16DCP has higher load carrying capacity at minimum reduction in speed leading to more uniform power” says Sunil Kumar.

For more information www.portescap.com

AUTOMATION

Schmalz introduces new SBPL basic ejector for short cycle times The vacuum specialist Schmalz is extending its range of vacuum generators with very high suction rates with the launch of the new basic ejector SBPL (Schmalz Basic Pump Large). It is particularly well suited for safe handling of various workpieces and enables short cycle times. Schmalz has greatly increased the efficiency of the ejector over its predecessor. The new eco nozzle technology is based on a multi-stage venturi concept and ensures an optimum combination of suction capacity and energy efficiency: Thanks to the eco nozzle, the suction rate in the range from -200 to -600 mbar is, in some cases, twice as high as before. Evacuation and cycle times have been reduced considerably. When constructing the new basic ejector, the Schmalz experts also attributed great importance to the product design. The main body and nozzle system are made of extremely robust plastic. This makes the ejector highly resilient and 50 percent lighter than its predecessor, which was made from aluminum. The modular design also presents practical advantages to the user: The SBPL can be cleaned very quickly and is also very easy to maintain.

AUGUST 2016 | www.engrreview.com

The new Schmalz product is available in two varieties: The HF high-flow version (for the range up to -500 mbar) is ideal for handling porous workpieces such as cardboard, packaging and insulating material. The HV high-vacuum model (for the range from -500 mbar) is the perfect solution for transporting airtight workpieces such as glass or wood. The following optional accessories are available for the SBPL basic ejector: vacuum switch, vacuum gauge, quick exhaust valves, solenoid valves, filter and exhaust duct.

The new SBPL 25 basic ejector is available in the sizes 50, 100 and 150 with higher suction rates.

For more information Web: www.schmalz.com

24 NEWS

AUTOMATION

Intelligent sensors pave the way for the industry of the future

The exhibit on human-robot collaboration at the SICK stand in Hanover proved to be a major draw.

At the Hannover Messe (HM) trade fair, SICK AG presented innovative sensor solutions for forward-looking applications under the slogan “Industry 4.0 ready”. As a technology supplier in the field of industrial sensors, SICK’s presentation explained how intelligent sensor data can be used: from highly aggregated, complex web services in the cloud and shop-floor systems for logistics transparency to autonomous

robot control. Alongside the company’s own intelligent systems and sensors, SICK also presented various examples of its collaborations with research and industry partners. These joint exhibits featured integrated solutions typical of Industry 4.0, which were a big hit with visitors. In particular, the exhibit on human-robot collaboration proved to be a major draw, featuring a robot arm which took a glass cup from a visitor. The robot used the RFID tag affixed to the cup to read the individual print job and performed the task by itself. As the station was protected with microScan3 laser scanners, the robot was able to work without partition screens in this application. As soon as anyone came within a certain distance of the robot during operation, its movement slowed down. If someone came even closer, the robot stopped completely. Meanwhile, the trade fair also featured a first in the field of track and trace technology

SICK presented innovative sensor solutions for forward-looking applications at the Hannover Messe trade fair.

in the form of the RFU65x RFID read/write device, which creates transparent paths within the factory. The device is the first to be able to measure the movement direction of an RFID tag bearer when read. This means that, in the future, it will be possible to record not only the position, but also the transport path of workpieces with minimal effort. In this way, the current location of a part will always be evident in real time.

MACHINETOOLS

Seco Tools celebrates 20 years in India Seco Tools India Private Limited, a wholly owned Subsidiary of Seco Tools AB, Sweden located at Koregaon Bhima on Pune-Ahmednagar National Highway, has completed 20 years of operation in India on May 27, 2016. The company inaugurated its new office and factory building on May 27, 2016 at Koregaon Bhima. Internationally acclaimed industrialist Mr. Baba Kalyani , Mr. Lars Bergstrom, President and CEO of Seco Tools, Mr. Andreas Fritz, Managing Director and Sr. Vice President Asia Pacific alongwith Seco employees and other

AUGUST 2016 | www.engrreview.com

distinguished guests were present during the event. “We have been able to live up to the high standards that we and our customers place on us through our shared values: Passion for our customers, family spirit and personal commitment”, says Lars Bergström President and CEO. “These three common values help us make the

right priorities and act in a manner that has become Seco’s hallmark for decades” he continues. The shared values are of great importance for the governance of the global operations. Decisions are based on values and goals, which means that Seco, despite its size, can continue to be fast and flexible. “The information age has had a profound effect on the industry. From the need to compete globally to an ever-increasing pace of technological evolution, today’s manufacturers, we as well as our customers, face constant challenges to reduce cost and increase productivity,” says Andreas Fritz, Managing Director, Seco Tools India.

For more information www.secotools.com/in

26 NEWS

CONSTRUCTION EQUIPMENTS

Liebherr Group’s turnover reaches a total of 9,237 mn € Business developed quite differently in the various sales regions: in Western Europe, the most important of these for Liebherr, an increase in turnover was recorded. Among the contributing factors were positive developments in Germany, Great Britain and the Netherlands. Sales revenue dropped, however, in France, the Group’s third-largest market. Turnover increased in volume in America and in the Far East / Australia region, and Liebherr also enjoyed a satisfactory year in the Near and Middle East. A downturn was recorded in Eastern Europe and on certain African markets. Liebherr achieved growth in the construction machinery and mining

area and also in the area comprising maritime cranes, aerospace and transportation systems, machine tools and automation systems, domestic appliances, components and hotels. Turnover from construction machinery and mining equipment, including the earthmoving, mining, mobile cranes, tower cranes and concrete technology divisions, rose by 330 million € or 6.2 % to 5,624 million €. Sales revenue in divisions not included in the construction machinery and mining area rose by 84 million € or 2.4 % to 3,613 million €. In 2015 the Liebherr Group recorded a surplus of 294 million €, 22 million € below the 2014 figure. The operating result was slightly above the previous year’s level. The

PUMPS-VALVES

Kirloskar Brothers Limited receives ISO 50001: 2011 certification Kirloskar Brothers Limited, the leading global fluid management company, has received ISO 50001: 2011 - Energy Management System certification for its Dewas facility in Madhya Pradesh, manufacturing industrial and agricultural pumps. Established in 1962, spread across 72 acres of land with a capacity of 4,50,000 pumps per annum, KBL’s Dewas facility manufactures various types of pumps such as Surface Pumps, Monobloc Pumps, Jet Pumps, Open-Well Pumps, DB Pumps and Vacuum Pumps that find application in industrial and agriculture sectors. The products manufactured at the plant have tripled the revenues on the decade-on-decade basis.The Devas facility’s ISO 50001: 2011 – Energy Management System is certified by one of the most credible certification agency – Bureau Veritas, which is a global leader in Testing, Inspection and Certification (TIC), delivering high quality services to help clients meet the growing challenges of quality, safety, environmental protection and social responsibility. The Bureau Veritas Certification covers the evaluation and certification of products, systems and services, for all QHSE-SR* national and international norms, general and industry-based and even private referentials. Web: www.kirloskarpumps.com

AUGUST 2016 | www.engrreview.com

financial result was lower, primarily because of negative exchange-rate influences. In 2015 the workforce increased slightly: at the end of the year, Liebherr employed 41,545 people, 706 or 1.7 % more than at the end of 2014. The Liebherr Group has always put emphasis on investing in its production facilities and in the international sales and service network. Last year, investments totalled 751 million € and thus maintained the existing high level. Offset against this figure was depreciation valued at 448 million €.

For more information www.liebherr.com

Power

Essar Energy sells entire 50 percent stake in KPRL Essar Energy Overseas Limited (Essar Energy) today announced that it will sell its 50 percent stake in Kenya Petroleum Refineries Ltd (KPRL) to the Government of Kenya (GoK). The two entities, along with Essar Energy Holdings Limited, have entered into an agreement on the transfer of shares. This transaction marks Essar Energy’s complete exit from KPRL—which operates a 4 million tonne oil refinery in Mombasa, Kenya—and is consistent with Essar’s overarching goal of monetising non¬core assets to focus on value creation in its core businesses. Essar Energy became a shareholder in KPRL in July 2009 through the acquisition of shares from Shell Petroleum Company Limited, BP plc and Chevron Global Energy, Inc. KPRL will now be 100% held by GoK.

For more information Web: www.essarenergy.com

28 NEWS

MACHINE TOOLS

EuroBLECH 2016 presents online competition After the great success of the first online competition in 2014, EuroBLECH 2016 is presenting this year “The New Generation of Sheet Metal Working”. The online competition will reward six organisations or individuals in the sheet metal working industry for best practice, innovation, excellence and outstanding performance in six categories. Following this year’s main theme at EuroBLECH, “The New Generation of Sheet Metal Working”, the competition categories are focussing on recent developments and trends in the sheet metal working industry. The first category, “Factory of the Future”, will reward organisations or individuals for the clever implementation of smart manufacturing methods. The second category,“Women and Innovations”, is focussing on cutting-edge projects and accomplishments initiated by women in sheet metal working.The best university projects

in science and engineering involving sheet metal technology can compete in the category “Academic Excellence”.The category “Original Design” is open to companies producing unusual products made from sheet metal. Finally, “The Young Generation” is seeking for outstanding performance of junior employees

and young inventors, and “Clean Technology” will rewardeco-friendly solutions and sustainable manufacturing methods. The six winners will be formally presented with an award during a ceremony held at EuroBLECH 2016, 24th International Sheet Metal Working Technology Exhibition, which will take place from 25 – 29 October 2016 at the Hanover Exhibition Grounds in Germany. Detailed information about the competition and the entry requirements are available on the show website www.euroblech.com/english/ competition. All organisations and individuals in the sheet metal working industry are invited to enter if their company or project is setting an extraordinary example in one of the categories. Closing date for entries is 31 August 2016.

For more information www.euroblech.com

MACHINE TOOLS

ExxonMobil collaborates with Micromatic Machine Tools ExxonMobil Lubricants Private Limited is the official lubricant partner of Micromatic Machine Tools Private Limited, the marketing and service company of the 1,200 crore Ace Micromatic Group that is India’s largest machine tool conglomerate. Through this partnership, Mobil Industrial Lubricants will support Micromatic with its advanced range of industrial lubricant products and services, backed by its leadership and expertise in the lubricants market. Micromatic Machine Tools is the preferred supplier for many Indian OEMs and component manufacturers. Through this collaboration, ExxonMobil aims to offer Micromatic customers its high quality products addressing application needs supported by the Solcare program for coolant management. Mobil distributors’ ability to collaborate with the Micromatic service team will ensure customer satisfaction through technical services and on time product deliveries. Glen Sharkowicz, Industrial Lubricants Marketing Manager, Asia Pacific, ExxonMobil Fuels & Lubricants, said, “ExxonMobil works closely with equipment builders (EBs) to analyze machinery and equipment trends, as well as identify effective solutions that improve equipment efficiency and performance. Our collaboration with EBs has led to the development of advanced high performance lubricant solutions that our customers can rely on. Our partnership with Micromatic, one of the leading machine tool developers, will help us push the boundaries of lubrication formulation

AUGUST 2016 | www.engrreview.com

and performance” TK Ramesh, CEO, Micromatic Machine Tools Pvt. Ltd, said, “Micromatic welcomes this partnership with ExxonMobil in light of the growing global demand for Indian-made equipment and we look to leverage our collective knowledge and expertise to bring improved performance and productivity to our customers. We also look forward to Mobil’s expertise in selection of appropriate fluids which is in line with our commitment to promote Green environment.”

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

32 NEWS

MACHINE TOOLS

MAPAL relies on Safe-Lock system from HAIMER

From left to right: Dr. Jochen Kress, member of the senior management of MAPAL, Dr. Dieter Kress, managing partner of MAPAL, Claudia Haimer, managing partner of HAIMER and Andreas Haimer, managing director of HAIMER.

Within a wide range of markets, such as the aerospace industry, cutting tools from MAPAL have successfully established themselves for high-performance machining operations liketrochoidal milling. In order to offer users even greater protection against tools being pulled out of the chuck during machining operations, and to prevent damaging single workpieces or the machine itself, MAPAL is going to rely on the Safe-Lock™ pull-out protection system from HAIMER. The two companies recently signed a

corresponding licensing agreement. HAIMER and MAPAL have reached a partnership and licensing agreement. The toolholding specialist from Igenhausen near Augsburg and the precision cutting tool manufacturer from Aalen are combining their strengths to form a new partnership. In the future, they will work strategically closer together on the progression and further development of technologies and their applications in the manufacturing market. The two companies have signed an agreement that has contractually solidified their partnership. “We are proud and happy to have a strong partner at our side in MAPAL that is one of the world’s leading tool manufacturers,” emphasizes Claudia Haimer, managing partner of HAIMER. “The Safe-Lock™ system has proven itself both in the market and during our in-house trials. Consequently we have decided to use this leading system,” Dr. Jochen Kress, Member of the MAPAL Senior Management, says. “It is very frequently used for modern machining strategies. With Safe-Lock™ the productivity and tool life can be significantly increased,” Andreas Haimer, Managing

The Safe-Lock™ system from HAIMER is an integrated pull-out protection system for shank tools that combines frictional clamping and form closure. It increases processreliability, enables high material removal rates and provides results that are far better than those achieved with conventional tool clamping methods.?

Director and President of the HAIMER Group explains .

For more information Web: www.haimer.de

POWER

CLP India and Suzlon enter into JV CLP India, one of the largest foreign investors in the Indian power sector, and Suzlon Group, one of the leading renewable energy solutions providers in the world, announced their joint venturefor a 100 MW solar project at Veltoor in Telangana. As per theagreement signed between CLP India and Suzlon Group on June 14, 2016, CLP India acquired49% stake in SE Solar, a special purpose vehicle (SPV) set-up by Suzlon. CLP India has the option to acquire the balance 51% in future. The project is expected to be commissioned by May 2017 and will be funded 80% by debt and 20% by equity. India is a primary growth market for CLP and the Veltoor solar project will make an important contribution to CLP’s expansion plan. Besides, it will aid CLP to meet its target of having 20% of power generated by renewable energyby 2020. Recently, CLP India also signed anMoU with the State Government of Haryana to set up a 132 MW solar projectat its Jhajjar power station.

AUGUST 2016 | www.engrreview.com

Rajiv Mishra, Managing Director, CLP India, said, “The Veltoor solar project meets both the criteria. We believe that the state of Telangana has a favourable solar policy, which creates a conducive environment for us. We remain keen and will continue to explore such projects to expand our renewable energy footprint in Telangana and across India.” Tulsi Tanti, Chairman and Managing Director, Suzlon Group, said, “Investments in both wind and solar have garnered traction owing to the improving cost competiveness enabled through technology advancements and the need to transition from fossil fuel dominated energy architecture. The target of 175 GW renewable energy by 2022 outlined by the government of India, offers an opportunity of over 100 GW solar in the next 6 years.”

For more information Web: www.suzlon.com

34 NEWS

MACHINE TOOLS

Lantek makes new appointment to promote factory in UK To promote the Lantek Factory concept to sheet metal and structural steel companies in the UK, Lantek has appointed Adam Ball as Sales Manager for the company’s ERP products. More companies are realising that they can gain some very significant efficiency benefits from integrating all their manufacturing systems allowing them to measure performance, in real time, of the key aspects of their business. Adam Ball says, “I have been involved in supporting and supplying software for the sheet metal industry for a considerable time and there is a clear move towards automation to optimise productivity. Integration of software systems is part of the automation process, enabling users to have an accurate picture of all areas of their business including costs, manufacturing status and customer relationships.” The Lantek Factory concept is achieved through the integration of Lantek Workshop and Lantek Integra products with the Lantek Expert and Lantek Flex3d CAD/CAM products which handle CAD data, unfold

parts, create nests and generate CNC code for the cutting process. Starting with a customer enquiry, CRM software makes available the complete history of a customer’s orders. Quotation software then makes it very quick and easy to generate an accurate cost to include material, and all the manufacturing operations such as cutting, bending, painting and assembly. At the same time the production schedule can be interrogated to make sure that material is available and that there is sufficient production capacity to deliver parts on time. Once the order is placed, delivery dates, manufacturing stages and material requirements are all specified and scheduled. These are then synchronized with the other work going through the factory, enabling engineers to create dynamic nests of parts for each material type where appropriate, manage remnant material and prepare parts for cutting while keeping to the delivery dates. For more information : www.lanteksms.com

MACHINE TOOLS

CNC Software unveils Mastercam 2017 CNC Software has announced the release of Mastercam 2017. Mastercam 2017 brings a new suite of programming tools focused on delivering speed, automation, and efficiency for all machining jobs. Mastercam 2017 introduces a more efficient workflow, improved usability, Dynamic Motion improvements, and so much more. Mastercam 2017 features a new ribbon

AUGUST 2016 | www.engrreview.com

interface and makes it easier to find the functions you need to complete your tasks. “Many of our more powerful tools were underused because customers did not know where to find them,” says CNC Software President, Meghan West. “We spent a lot of time with users determining the best way to simplify this, and the response has been overwhelmingly positive.” The ribbon tabs group similar functions and displays them in order from simple to more complex. Each tab relates to a type of activity, from creating wireframe geometry to generating toolpaths. Editing functions are on the same tab as creation functions so you have all the tools you need, when you need them. Mastercam’s Dynamic Motion technology can slash machine time by as much as 75% or more. And, Dynamic Motion will help you get the most out of any machine in your shop—new

or old. Mastercam’s Dynamic Motion technology maximizes material removal rates, extends tool life, reduces cycle time, saves wear and tear on machines, and cuts hard materials more easily. New to 2017, micro lifts now use a line-of-sight approach to move the tool where it needs to go through unobstructed areas. This results in reposition moves that are more efficient, less complex, and travel a shorter distance resulting in shorter cycle times.

For more information Web: www.mastercam.com

World’s First Bluetooth pH Electrode Compatible with edge blu and most Android and iOS devices The HALO family of pH electrodes are the ﬁrst to incorporate Bluetooth® Smart (Bluetooth 4.0) to turn your Android or Apple device into a professional pH meter when running the Hanna Lab App. · Up to Five Point Calibration · Good Laboratory Practice (GLP) · Probe Condition · Graphing · Data Logging · Sharing of Data

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36 NEWS

MACHINE TOOLS

Shell Lubricants announces ‘The Future of Hydraulic Oils’ Shell Lubricants, the global market share leader in finished lubricants, announced the launch of Shell Tellus S2 MX and Shell Tellus S2 VX- ‘The Future of Hydraulic Oils’ in India, at a press conference. India marks the first leg of the global product launch which shall be followed by unveiling of the new products across Singapore, Thailand, China, S Korea, Malaysia, Indonesia, Germany, Australia and France markets to name a few. The Shell Tellus range of hydraulic oils have been developed to enable equipment operators to select the fluid that will help to deliver optimum value to their operations through: wear protection, long fluid life, and system efficiency. The company has invested in R&D to upgrade the previous formulations and is now ready to roll-out the next generation hydraulic oils that offer significantly improved

performance in these three areas. Shell Tellus S2 MX and Shell Tellus S2 VX are the upgraded formulations of the Shell Tellus S2 M and S2 V hydraulic fluids respectively. For customers, this amounts to more reliable and efficient equipment operation, which can help reduce unplanned downtime, lower maintenance

costs, and contribute to savings in total cost of ownership (TCO) Speaking about Shell Lubricants’ latest offerings, Mr. Hans Gerdes, Shell Tellus Brand Manager, said, “Changes to equipment technology and operating conditions in recent years have placed increasing demands on the hydraulic oil. For example, demand for increased power output means equipment is often operating under higher loads and temperatures, which places increased stress on the hydraulic oil. In light of this, we have developed two upgraded formulations of Shell Tellus S2 hydraulic oils that deliver dramatically improved performance over the previous generation.”

For more information Website: www.shell.com

POWER

ABB inverter dramatically boosts performance of solar power installations ABB’s PVS980 central inverter – an essential component in every solar installation that converts direct current (DC) produced in solar panels into alternating current (AC) for use by electrical grids – increases the amount of incoming solar power connected to a single inverter by as much as 40 percent: a dramatic improvement that completely changes the economics of a solar installation. Thanks to its increased power, the PVS980 central inverter also allows operators to use 30 percent fewer inverters than previously. The high power 1500 VDC central inverter PVS980 is capable of processing more incoming direct current power from photovoltaic

AUGUST 2016 | www.engrreview.com

ABB solar inverters – supporting the shift in the global energy mix More than

22 GW DC

For residential, commercial and utility-scale solar power plants

(PV) panels through one inverter, reducing the total number of inverters needed onsite, which helps reduce overall costs across the lifetime of a solar plant. Central

of solar inverters installed globally AC

Enough to power over 7,500,000 homes

Emission reduction by more than 20 million tons per year compared to conventional power plants

inverters are used for applications such as large field installations as well as large arrays installed on buildings and industrial facilities. Originally introduced at Intersolar

as a concept last year, the PVS980 is now shipping commercially and has already seen strong interest among customers, with a number of pilot projects in place. Another attribute of the new inverter is that it is designed to seamlessly integrate into digital smart grids and operate efficiently in reducing the carbon footprint of electricity consumption. ABB engineers have improved the compactness of the device, enabling a power density increase of more than 40 percent making it possible to build large power rated inverters in the same physical size.

For more information Web: www.abb.com

38 NEWS

POWER

Altem wins ‘India’s Small Giants’ Award Altem Technologies, one of the leading companies involved in 3D Printing technology and stimulation software, recently won the prestigious “India Small Giants” award. Kalraj Mishra, Honorable Union Cabinet minister of MSME, Government of India, felicitated Altem’s team in Mumbai on Friday. India Small Giants was constituted by the India SME Forum, established in 2011, to help the growth of small and medium business enterprises in the country. The award recognizes honors and acknowledges India’s most successful entrepreneurs who have created a legacy. Altem is among the 40 Small Giants chosen by a panel of Jurists. The year 2016 saw over 1600 nominees for this award.

The final selection of Small Giants is made keeping in mind the current status and potential to become a giant in the coming days. It will be a great moment for the winners, which is constantly striving to evolve and combine new technologies to create the best solutions for their clients. This award will embolden them to achieve new heights. Altem, established in Bangalore in 2011 by Mr. Prasad Rodagi along with his friends, has been instrumental in creating awareness about 3D printing technology in India. Their vision and drive established them as one of the leading players in the industry in the South East Asian region in less than 2 years of their inception. Sharath Chandra, a co-founder, of Altem Technologies who received the award from

Hon. Minister Kalraj Mishra, said “We are very proud to win this prestigious India Small Giants Award. It is a testament to our team’s hard work and vision. Altem, since its inception, has been dedicated to creating

awareness about 3D printing technologies in India, and help more people realize the benefits of this technology in India. This award emboldens us to continue to our work and take it new heights.”

POWER

Lapp India launches OLFLEX HEAT 650 Lapp India, a 100% subsidiary of the Lapp Group Germany and a leading supplier of integrated solutions and branded products in the field of cable and connection technology in India, has introduced OLFLEX®HEAT 650. OLFLEX®HEAT 650 can withstand ambient temperatures up to +650°C. With a constant temperature resistance of up to +650°C, OLFLEX®HEAT 650 is designed to be used in heavy industries. It is also used in heating modules, electric heating devices, heat lockers, furnaces, electric ranges, ceramic processing and chemical

AUGUST 2016 | www.engrreview.com

industries. Nickel strands and braided glass fibre insulated single core (SC) cables makes OLFLEX®HEAT 650 extremely strong and durable at high temperatures, coupled with a good resistance level. Whether it’s in power plants, blast furnaces or engines – cables must be able to withstand extreme heat and mechanical stress. Right cabling solutions are critical for safety. To meet the industry requirements, the Lapp Group offers

specialised cabling solutions such as OLFLEX®HEAT 650. The product is flame retardant according to IEC 60332-1-2. Its halogen free property eliminates the threat of forming caustic and contributes to less corrosion damage to equipment near the fire 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 2015 about 140,000 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.

For more information Web: www.lappindia.com

maxon product range

The solution is always a matter of the right combination.

If versatility and intelligent drive solutions are called for, the maxon product range provides the answer: A wide range of brushed and brushless DC motors up to 500 watts complemented by gearheads, sensors, brakes, positioning controllers and accessories offer a consistent modular system to realize whatever you have in mind.

maxon motor is the worldâ&#x20AC;&#x2122;s leading supplier of high-precision drives and systems of up to 500 watts power output. maxon motor stands for customer specific solutions, high quality, innovation, competitive prices and a worldwide distribution network. See what we can do for you: www.maxonmotor.in, info.in@maxonmotor.com.

Visit us Automation 2016 - BEC Mumbai, Stall J 7, Hall No.1, Aug 22-25 2016

42 NEWS

POWER

Mitsubishi Electric India launches second edition of national-level automation competition for students Mitsubishi Electric India, a leading player in Factory Automation, is launching its second edition of national-level automation competition for students in India. The Mitsubishi Electric Cup has been opened its registration. Students can register themselves at http://www.mitsubishielectric.in/fa/mecup/ The maiden edition of the competition which concluded itself in February, 2016 received an overwhelming response from engineering colleges from various cities including New Delhi, Maharashtra, Haryana, Pune, Chandigarh, Gujarat, Uttar Pradesh, Bangalore, Chennai and many more. The second edition of the competition invites participation from technical institutions across the country. Students are required to inte-

grate Mitsubishi Electric’s factory automation products (including PLC, servo, inverter and human-machine interface, etc.), build up and achieve an analogous system of intelligent manufacturing and energy saving management application, based on e&eco-f@ctory concept while taking e-f@ctory system as the trunk. The theme of second edition of the Mitsubishi Electric Cup is “Intelligent Manufacturing for greener tomorrow”, under which students will be asked to independently design and produce a complete set of devices / models by using Mitsubishi Electric factory automation products, the control system shall be built up based on e&eco-F@ctory concepts. The top 35 teams need to prepare working model of various industrial manufacturing pro-

cesses, energy saving solutions, smart solutions for building automation etc. Teams will be provided with technical support, training and FA equipment to make the model, on a returnable basis by Mitsubishi Electric India. Additionally, each team will be given a financial support of Rs 7000 upon achievement of required skillset.

For more information http://in.mitsubishielectric.com/en/index. page

POWER

Powin Energy receives patent for Battery Pack Operating System Powin Energy, a leading designer and developer of safe and scalable energy storage solutions for utilities, C&I, and EV fast-charging stations, is pleased to announce that their unique Battery Pack Operating System(bp-OS) has been awarded United States Patent and Trademark office patent number US20140015469 A1, which is defined as a battery management system for distributed energy storage systems and associated applications. The patented bp-OS utilizes a unique algorithm to actively and passively balance batteries down to the cell level, enabling

AUGUST 2016 | www.engrreview.com

the minimization of voltage differentials across all battery cells over the system’s lifetime. The bp-OS also delivers unprecedented visibility into battery health through realtime battery monitoring, stateof-charge management, and detailed diagnostics to ensure safety, optimize performance, and extend the operational lifetime of batteries used in stationary storage systems and EV fastcharging systems. “We’re focused on creating the safest and most technologically advanced energy storage unit and battery management software in the world,” said Virgil Beaston,

Chief Technology Officer of Powin Energy. “Using Powin Energy’s bp-OS that is made specifically for the needs of the energy storage industry, battery system owners and operators will unlock new levels of insight into the use of their batteries, have access to higher optimization schemes, and see noticeable increases in the total lifecycle value of their storage systems.” Powin Energy’s bp-OS also features two industry firsts – the Battery Odometer and the Warranty Tracker™. The Battery Odometer measures capacity degradation and calculates

remaining battery lifetime by keeping track of voltage, temperature, state-of-charge, charge and discharge times, and other critical data for every cycle of the battery. The Warranty Tracker™ maximizes operational uptime and prevents potential economic losses by alerting operators to possible issues, isolating problem zones, automatically filing warranty claims, and avoiding full-system shutdowns.

For more information http://PowinEnergy.com

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44 NEWS

POWER

Suzlon powers Ahmedabad Municipal Corporation’s maiden wind project Suzlon Group, one of the leading renewable energy solutions providers in the world, announced the completion and commissioning of the 4.20 MW maiden wind project for Ahmedabad Municipal Corporation (AMC). The wind energy project, located at Nakhatrana, Kutch comprises of 2 units of Suzlon’s newest product variant, S97 120 meter hybrid tower wind turbine. It will help in offsetting 9,000 tonnes CO2 emissions annually. S97 120 meter is the world’s tallest all-steel hybrid tower which ensures 12% - 15% higher energy yield and further enables viability of sub-optimal wind sites. It achieved best in industry class Plant Load Factor (PLF) of 35%

for a period of 12 months from the launch in November 2014 and was also incidentally, inaugurated by Hon’ble Chief Minister of Gujarat, Smt. Anandiben Patel. Mukesh Kumar, IAS, Municipal Commissioner, Ahmedabad Municipal Corporation (AMC), said, “The investment in wind energy is part of AMC’s long term focus on sustainable development and harnessing green energy is one step towards that. Renewable energy is one area where even at a Municipal level we can show global leadership and where we all can play our small part in helping to mitigate climate change challenges. We are glad that this project is dedicated to the Nation by Hon’ble Chief

Minister, Smt Anandiben Patel and is aligned to the Renewable Energy Mission initiated by our Hon’ble Prime Minister, Shri Narendrabhai Modi.” Tulsi Tanti, Chairman and Managing Director, Suzlon Group, said, “Ahmedabad is a truly green city and we are thankful to Ahmedabad Municipal Corporation for the faith reposed in Suzlon’s capabilities and technology. Suzlon is committed to provide sustainable, affordable and reliable energy to all.”

For more information Web: www.suzlon.com

POWER

Schneider Electric launches “mySchneider” app With a goal of increasing productivity for our customers and partners viz., Panel Builders, OEMs, Electricians, Distributors and more, Schneider Electric™, the global specialist in energy management and automation, has launched its “Free Customer Care” tool for smart devices, mySchneider app. Available as a free download for iOS® and Android™ devices, mySchneider app offers productivity-improving tools in three areas: Tailored Services, 24/7 Self-service, and Connect to Schneider Electric. Tailored services allow users to customize the information and options they use to better fit their specific job needs. Registering as a user in mySchneider app allows access to additional features, such as real-time notifications, order tracking, and product pricing and availability. Help is always available with 24/7 self-service options, including the ability to search products by

AUGUST 2016 | www.engrreview.com

name or reference number, receive product information by scanning QR codes, or retrieve technical documents. An auto-complete feature speeds up searches by proactively offering a list of suggestions. Users can learn from more than 1000 courses on a range of topics, find answers through FAQs, and access Green Premium eco-label information. Users of mySchneider app can request assistance on products and technical information either through a live, one-tap connection to local experts, or by using a convenient “call me back” option. In instances where time is less of a concern, cases or queries can be submitted through an easy in-app form.

For more information schneider-electric.com/myschneider-app

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46 NEWS

POWER

Tata Power’s Club Enerji sensitizes 20 lakh citizens across Mumbai Tata Power’s nationwide resource and energy conservation movement Club Enerji, has been constantly spreading awareness about resource conservation across the country, with a strategic focus on national building. Continuing with its momentum, in 2015-16, Tata Power Club Enerji sensitized around 20 lakh citizens in Mumbai through primary contact programme and secondary sensitization and saved around 20 lakh units of energy in the city. Tata Power’s Club Enerji movement in Mumbai currently has 30187 Energy Champions and 28,620 Energy Ambassadors across schools. Tata Power’s ‘Energy Conservation Programme’ introduced in more than 205 schools in the city, aims at creating maximum impactby educating and creating awareness amongst citizens on the effective management and conservation of energy in our everyday life. The Club Enerji initiative has been contributing extensively towards a brighter and greener tomorrow by undertaking several

successful initiatives.In 2015-16 the programme also launched an online module (http://www. clubenerji.com/) of the Club Enerji programme wherein the users would simply need to register for a detailed access to it. As part of its initiatives, Club Enerji recently organised activities for the school students like nature trails and visits to Tata Power Mahseer hatchery in Lonavala to increase awareness on its conservation projects and also provide practical knowledge about the environment. Speaking on this achievement, Anil Sardana,

CEO & Managing Director, Tata Power stated, “We, at Tata Power are delighted and proud to achieve this significant milestone with our focused approach of spreading the message of energy conservation across the country. Today, it gives me immense pleasure to say that our efforts have managed to save a considerable amount of energy in Mumbai which could light up thousands of homes in the city.”

For more information Web: www.tatapower.com

ENGINEERING

Navigating Innovatively in a Competitive World ARC Advisory Group’s fourteenth India forum for process and discrete industries, titled Industry in Transition: Navigating the New Age of Innovation attracted close to 270 delegates. The theme was apt because the industry is transitioning through constant changes in terms of new and innovative technologies; and only those companies that can navigate through all the available information and technology and effectively implement them will emerge successful. In today’s marketplace innovation is the buzzword, and this innovation is not confined to just product changes - it encompasses innovation at all levels of the value chain from the shopfloor to the end user. It is about becoming collaboratively networked enterprises, managing dispersed centers of technology, engineering, production, and resources. Industrial growth hinges on effective networking and collaborating – and ARC forums provide the right platform and visibility to all attendees. New technologies, such as cloud computing, mobility, social technologies, Industrial Internet of Things, Big Data/analytics, and digitalization

AUGUST 2016 | www.engrreview.com

have now taken center-stage; and most of the presentations at the Forum emphasized these topics. Andy Chatha, President & CEO, ARC Advisory Group’s video presentation highlighted how digital transformation is gaining momentum across all industries and how innovative companies are disrupting the status quo. He said that today’s proprietary systems are ripe for next-gen digital transformation as process plant assets are usually more than 35 years old and are prone to failures and incidents. The other keynote addresses which set the tenor for the forum were given by B.R. Mehta, Senior Vice President, Reliance Industries; Achyuta Ghosh, Head of Research, NASSCOM; Bob Gill, General Manager, SE Asia, ARC Advisory Group; and B. Ashok, Deputy Project Director, Aeronautical Development Agency. Speakers were from the sponsors, industry association sponsors, and invited end user speakers. For more information editor@divyamediaonline.com

48 NEWS

POWER

BEKUM appoints Dr. Wilfried Lehmann as Technical Director BEKUM Maschinenfabriken now has a new Technical Director. Dr. Wilfried Lehmann will take over this role with immediate effect. Dr Wilfried Lehmann is known to BEKUM customers already, as he previously held this position from 1998 to 2002. With this foundation, he will be able to draw on his practical experience in blow-moulding technology. Dr. Lehmann looks back on many years of international management experience in the plastic and machine tool industry, including at Ferromatik Milacron and Kampf Schneid- und Wickeltechnik. In his role as Technical Director he aims to focus specifically on standardisation and modularisation for all blow-moulding system series at BEKUM. Here, potential synergies from the packaging sector and automotive industry will be more closely linked. For Dr. Lehmann, the sustainable development of process and rheological expertise is on the agenda, with the aim of ensuring lasting customer satisfaction. Dr. Lehmann: “Our customers should be so satisfied with our machines that

they keep recommending BEKUM to others with complete conviction. From our perspective, high availability, process reliability and high production quantities of our machines and equipment form the best basis for the BEKUM brand to convince the market.” The outstanding role of BEKUM, known as a technology leader in the blow-moulding industry with high quality standards worldwide for over 55 years, will receive a dynamic impetus from the new Technical Director Dr. Lehmann. BEKUM will gain from Dr. Wilfried Lehmann’s in-depth expertise in the industry and his many years of experience to develop its range of machines, to safeguard the technological value of the BEKUM brand and help shape the company’s future success. Following the successful implementation of the BEKUM Group reorganisation with offices in Berlin (Germany) and Traismauer (Austria), Dr. Lehmann will now secure the company’s market success in development and design, and continue to advance and provide impetus in the areas of packaging and automotive.

POWER

Danfoss acquires full ownership of privately-held Sondex Holding Danfoss and Sondex have announced an agreement for Danfoss to acquire full ownership of privately-held Sondex Holding A/S, a global leader in heat transfer technologies. Sondex develops, produces and markets heat exchangers, and the company represents an ideal match to the Danfoss Heating business segment. Thus the acquisition confirms Danfoss’ strategic focus on building leading positions and accelerating profitable growth. “Sondex is a well-performing company with a second-to-none heat exchanger expertize, which perfectly fits our ambition to further strengthen our position within heat transfer solutions. By joining forces we are able

AUGUST 2016 | www.engrreview.com

to offer a broader, even more competitive and innovative product and service portfolio within heat transfer to the benefit of our customers”, said

Niels B. Christiansen, President & CEO, Danfoss. Combining the two businesses, Sondex and the Danfoss Heat Exchanger business, is an important lever to

develop the already strong market position in district energy and HVAC, and to increase relevance within industries as marine, food & beverage, off-shore, and industrial refrigeration. “Sondex and Danfoss both come from positions of strength and we already enjoy a strong and long-standing relationship in key areas. Now, we combine our businesses to make an even bigger impact in the markets we serve. I am very pleased about the opportunity to combine our strengths as I am confident that together we will have a very compelling and unmatched value proposition in the market”, says Aage Søndergaard Nielsen, CEO, Sondex.

50 NEWS

ENGINEERING

Essar Projects bags Rs. 300 crore contract from IFFCO Essar Projects, a leading EPC (Engineering Procurement & Construction) company announced that it has won a Rs 300¬crore contract from IFFCO (Indian Farmers Fertilizer Co¬operative). This is its fourth major contract from the Indian fertiliser industry giant. The latest project entails the construction of a new Phospho Gypsum Stack at IFFCO’s Paradip unit in Odisha, which is India’s largest phosphatic fertiliser complex. The project has two phases: Phase I, which is valued at about Rs 190 crore, involves completion of approximately 60% of the total construction and must

be completed in 20 months. The second phase involves construction of the remaining 40% and will have to be completed in 10 months. Until date, the company has, completed three major projects for IFFCO Paradip, handing them over well ahead of the scheduled date of completion. AV Amarnath, COO, Essar Projects, said: “The fact that this is our fourth major back¬to-back project with IFFCO, is a reflection of the customer’s confidence in our capabilities. We are pleased to say that we have already delivered some key works of the current contract that had to be completed before the

onset of the monsoon.” Essar Projects’ previous contracts for IFFCO includes construction and commissioning of 2 x 2500 MT DAP / NAP silo, revamping of an existing sulphur silo, and EPC & commissioning of the 8th evaporator system of the Phosphoric Acid Plant (PAP) at the IFFCO Paradip complex.

For more information Web: www.essar.com

ENGINEERING

Finolex Industries bags BT-CSR Excellence awards 2016 Finolex Industries Ltd, India’s largest PVC Pipes manufacturer and their CSR partner Mukul Madhav Foundation,was honored with BT-CSR Excellence Awards 2016 in New Delhi. Finolex Industries Ltd and their CSR partner Mukul Madhav Foundation (MMF) received the award for their work in Satara district in improvingthe standard of living for children suffering with Cerebral Palsy. Nitin Kulkarni, President of Sales & Marketing, Finolex Industries Ltd was present to receive the award from Hon’ble Union Cabinet Minister for Heavy Industries and Department of Public Enterprises, Anant Geete. This was the first ever recognition been conferred to Corporate India on such a huge platform for their contribution in uplifting the weaker sections of the society as well as working towards environment sustainabil-

AUGUST 2016 | www.engrreview.com

Mr. Nitin Kulkarni, Vice President, Sales & Marketing, Finolex Industries receiving the award from prominent guests

ity. Bureaucracy Today, a leader in governance readership which hosted the first edition of the BTCSR Excellence awards this year, recognized exemplary work in 35 categories, some of them being Best CSR Projects -Swaach Bharat, CSR Projects for Improving Air Quality, CSR Project for Work in Pollution Avoidance etc. The nominations were judged by illustrious six member jury team comprising

of members from Ministry of Home Affairs, Ministry of Information and Broadcasting, ONGC, FICCI, CII and ASSOCHAM, who reviewed each entry based on their merit and impact. Finolex Industries Ltd and their CSR partner MukulMadhav Foundation (MMF) received the award for their work in Satara district in improving the standard of living for children suffering with Cerebral

Palsy. Finolex Industries and MMF’s journey to help children with Cerebral Palsy in Satara began in Nov 2015, when they were approached by the Zila Parishad of Satara district after a survey conducted by them identified 314 children diagnosed with Cerebral Palsy in that region.

For more information Web: www.finolexwater.com

52 NEWS

ENGINEERING

Bauma China International Trade Fair to be held in China Bauma China, the International Trade Fair for Construction Machinery, Building Material Machines, Construction Vehicles and Equipment will be taking place from 22 to 25 November 2016 in the Shanghai New International Expo Centre (SNIEC). Bauma China takes place in Shanghai every two years and is Asia’s leading platform for experts in the sector. 3,098 exhibitors from 41 countries and more than 191,000 trade visitors from 149 countries: bauma China set new records again in 2014. International buyers in particular were strongly represented at bauma China. Their numbers rose by 12 percent. The show once again occupied all 300,000 square meters of exhibition space at the Shanghai New

International Expo Centre. Bauma China promotes interaction with and among exhibitors and visitors by responding better to their needs, facilitating trade and communication more intelligently and digitally, and providing participants with efficient services. All the international key players will present their machines and products at bauma China. 93 percent of all visitors here are decision-

makers who are looking specifically for new solutions: CEOs, managers, investors and buyers from around the world—and of course from Asia’s major growth markets in particular. InORBIT Tours Pvt. Ltd. will provide special travel packages for Indian visitors. Further details can be obtained from Om Prakash – Director, InORBIT Tours who has been organising visits since over 36 years

For more information E-mail: omprakash@inorbittours.com Web: www.bauma-china.com

ENGINEERING

Ness announces leadership moves To build upon the strategic services, the company provides to its customer base, Ness Software Engineering Services has relocated Satyajit Bandyopadhyay, president &chief delivery officer, from India to the United States to be closer to Ness’s customers based in the United States and Europe. Ness, a provider of digital transformation and custom software product engineering services, also announced the appointment of Narayanan Nair to chief people officer. Satyajit Bandyopadhyay will be based inTeaneck, NJ. This move enables Bandyopadhyay to engage more closely with customers, leveraging his 30 years of delivery experience to identify further opportunities to

AUGUST 2016 | www.engrreview.com

advance the delivery excellence for which the company is known. He will also extend Ness’s technology practices in DevOps, integrated user experience design and software development, data analytics and Business Process Management, which are increasingly required by

customers to accelerate outcomes and expand the business value of their digital transformation programs. Narayanan Nair, who will work out of Ness’s offices near Pittsburgh, will lead the company’s global recruitment and human resources functions,

including initiatives around talent management and acquisition and strategic programs to help Ness achieve its growth plans. Nair has previously held leadership roles at GlaxoSmithKline,GE – GXS, Computer Associates, and most recently comes from Mphasis, where he led HR and Recruitment for large-scale, global operations. “These two moves are important for Ness. Bringing Satyajit to the U.S. positions us to build upon Ness’s role as a strategic partner to our customers as they define and execute their digital business programs,” said Paul Lombardo, CEO at Ness.”

For more information Web: www.ness-ses.com

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56 NEWS

AUTOMATION

OMRON introduces color mark sensor on IoT platform Omron Automation has introduced a new range of color mark sensors to enable the food and beverage makers with the right technology for stable detection of color marks on food packages. The sensors - Photoelectric Sensor E3S-DC Series (E3S-DC) and Color Fiber Amplifier Unit E3NX-CA Series (E3NX-CA) can detect color marks which are printed on glossy or colorful materials and may have only subtle differences in colors – which are currently very difficult to detect. This leads to a

considerable reduction in the time necessary to start production and maintenance contributing to an overall enhancement in productivity in the entire packaging process. “Inspired with our quest to proactively identify the challenges and needs of the target industry, we worked closely with the customers to come up with these sensors equipped with OMRON’s proprietary sensing technology and algorithm to stably detect ‘differences in colors’ under varied demanding conditions. The sensors also

help in optimizing initially set parameters to adjust to minor changes in the color of the packaging materials. This solves the current issue of repetitive teaching of the sensors even for small color variations in the packaging material leading to improvement in the uptime of the packaging units by about 10 – 15%” said Sameer Gandhi, MD, Omron Automation, India. “These sensors are IoT enabled to help our customers take full advantage of the benefits of a digital factory”, he added.

ENGINEERING

InORBIT’s massive delegation at DRUPA 2016, Germany Over 300 experts & professionals representing Printing, Packaging & Printing Ink Industry marked their presence at DRUPA 2016 group, organised by Om Prakash, Director InORBIT Tours. More than 1,850 exhibitors and over 314,500 visitors from 130 countries attended the Show. Drupa’s range was impressive, featuring both traditional and pioneering technologies for pre-press and pre-media, printing (machinery, appliances and accessories), book binding and print finishing as well as paper converting services including packaging production, materials and consumables. At a special Reception organised by Messe Dusseldorf to welcome the InORBIT delegation, Werner Reinhard, Managing Director – Messe Dusseldorf spoke about the highlights of DRUPA 16. He informed about the dramatic changes in the world of Printing, such as 3D & Digital Printing and asked the visitors to visit Hall No: 7 to see the innovations. He also provided the facts & figures about the exhibitors at Drupa 2016. Reinhard paid high tribute to the living legend Om Prakash, for his dedication of 44 years in promoting DRUPA in India. This is certainly an unparallel record by any individual worldwide. Xavier Rebello, Executive Director – Messe Dusseldorf India also spoke and welcomed the Indian delegation. Dhananjay Sathaye founder President of All India Printing Inks Mfrs. Association spoke about the contribution of AIPIMA to the Indian Printing industry. Similarly Mr. Arvind Jain & Mr. Rajendra Jain (IMPA) addressed the delegation. Om Prakash thanked the leading Printing Associations in India for their confidence and support which has been the strength behind his dedication of 44 years and in organising such large delegations. The InORBIT delegation members enjoyed the friendly interaction among all the members, which has helped them to gain national & international business partners, personal friends & to study the latest developments in printing industry.

Prominently seen Mr. W. Reinhard – Mg. Dir. & Mr. Xavier Rebello (Messe Dusseldorf), Mr. D.M. Sathaye, Mr. B. Kampani, Mr. B.B. Sen (AIPIMA), Mr. Rajendra Jain – Founder President (IMPA) addressed the delegation, Mr. Om Prakash & Mr. Tarun Malhotra – Directors, InORBIT Tours Pvt. Ltd.

AUGUST 2016 | www.engrreview.com

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60 NEWS

ENGINEERING

Wire China to witness increased attention Asia’s No.1 wire, cable, tube and pipe industry exhibitions, the 6th All China -International Wire & Cable Industry Trade Fair (Wire China 2016) and the 7th All China – International Tube & Pipe Industry Trade Fair (Tube China 2016) will join hands again for the 7th time in Shanghai New International Expo Centre from 26 to 29 September, 2016. Following the success of the past six editions, Wire Tube China 2016, coming up with the show’s 10th anniversary, is drawing more attention from the industrial practitioners than ever before. The organizers, Messe Düsseldorf (Shanghai) Co., Ltd. and Shanghai Electric Cable Research Institute, will further upgrade the shows’ quality by showcasing more highlights and providing more value-added services. Wire Tube China 2014 witnessed a total of 1399 exhibitors showcasing the latest

technologies and applications in an exhibition space of over 86,500 square meters. The parallel exhibitions attracted 33,469 trade visitors from 85 countries travelled to Shanghai to gather information, making new business contacts and placing concrete orders. Such scale of visitors and exhibitors from abroad promoted and boosted the internationalization and quality of the exhibitions. Conferences and seminars

including China International Tube & Pipe Conference, China Wire & Cable Industry Conference etc. shared the latest ideas, expertise and insights in the industry, and enriched the contents of the exhibitions. Wire China has a new member Fastener Special Zone, which serves as the extension of the downstream industry chain of wire and cable industry, will help trade buyers to make one-stop purchasing of raw materials of fasteners, its production equipment and the finished product. A special travel package for Indian visitors is organized by INORBIT TOURS PVT LTD.

For more information E-mail: omprakash@inorbittours.com Web: www.cantonfair.org.cn

ENGINEERING

Canton Fair to be held in China With the recent devaluation of Chinese Currency “Yuan”, Indian importers can benefit for import of various Consumer & Industrial products displayed at CANTON Fair 2016. At CANTON Fair more than 150000 products are on display – Indian businessmen visit CANTON in large numbers and transact business for many commodities and products. Most prominent imports are of Gifts, Home Appliances Decorative Materials, Lighting Equipments, Hardware, Textile Garments and Medical Devices. 185,596 overseas buyers from 210 countries and regions around the world attended the 119th Canton Fair, an increase of 0.43% over the 117th session of last year. InORBIT Tours organise exclusive travel arrangements for Indian visitors since many years. Associations & Chamber of Commerce are invited to arrange their groups for their members and encourage them to increase their business opportunities. Details of Canton Fair & travel package available with Om Prakash – Director, InORBIT Tours

For more information E-mail: omprakash@inorbittours.com Web: www.cantonfair.org.cn

AUGUST 2016 | www.engrreview.com

China Coat conference set to witness increased visits CHINACOAT -THE WORLD’S COATING SHOW CHINACOAT was organized since 1996 and now alternates its venue annually between Guangzhou and Shanghai, P. R. China. The last 2015 Shanghai show broke several significant records. A total of 29,580 trade visitors from 81 countries/regions and 1,088 exhibitors from 32 countries/regions gathered on a gross exhibit area of over 70,000 sq.m. All these figures prove once again CHINACOAT’s position as the world’s Coatings show! In 2016, CHINACOAT will return to Guangzhou and will continue to deliver success from there! In terms of exhibit size, number of exhibitors and visitors, CHINACOAT 2016 is now one of the largest coatings shows held in the world today whose scope includes coatings, printing inks & adhesive products. SFCHINA offers unique access to the industry’s most influential decision-makers within 3 days. High-level technical exchange programmes will attract more industry professionals to join the show. The finishing market is facing rapid upgrading and transformation in recent years, which greatly contribute to the sustainable growth of the industry. With the continuous development of the automotive, construction, electronics, household appliances, aviation, aerospace and shipbuilding industries, and growing public demand for better living conditions, the need for decorative and functional products increases significantly. For the benefit of the members of Paint, Printing Inks, Adhesives & Coatings Industries in India, a special travel package is arranged to CHINA COAT 2016, Guangzhou.

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62 NEWS

ENGINEERING

Intertek launches SATELLITE Data Acceptance Program Intertek, a leading Total Quality Assurance provider to industries worldwide announced the launch of its SATELLITE Data Acceptance Program, a unique testing and certification model for the Indian market. Intertek’s SATELLITE™ program has 4 progressive levels, each of which allows Intertek qualified manufacturer laboratories to use their test results for the certification process and deliver costs savings and flexibility in the product development phase. Blue Star, one of India’s leading air conditioning and commercial refrigeration companies recently received a SATELLITE™ Level One certificatefor their Dadra and Thane facilities in alignment with the ‘Make in India’ initiative. Speaking of the program, Sandeep Vig, Director, Electrical and Wireless, Intertek India, said, “I am pleased to certify Blue Star under the Intertek SATELLITE™ program which enables them to gain significant control

of their launch pipeline, thus bringing speed and cost efficiency to their processes. I congratulate the entire team for making this happen and wish them well as we continue to partner with them to access global markets.” On receiving the certification, JitendraBhambure, Executive Vice President, R&D and Technology, Blue Star said, “It is a great honor to receive this certificate from Intertek for our facilities in Dadra and Thane. The two key philosophies of Blue Star are delivering high performance and safety for our customers and this recent certification will provide testing and assurance for our export products that follow stringent guidelines. We thank Intertek for holding our hand at every step in making this happen and we look forward to their continued support.” For more information Web: www.intertek.com

ENGINEERING

McLaren-Honda and NTT Communications announce three year partnership McLaren-Honda has announced the start of a three-year technology partnership. Under the agreement NTT Communications becomes a Technology Partner to McLaren-Honda. Over the course of the partnership, NTT Communications will provide network, cloud, data connectivity and other innovations to meet McLaren’s need for an IT communications platform that delivers optimum performance to support its Formula 1 race team. The McLaren team celebrates its 50th anniversary on the Formula 1 grid this year and this partnership will underpin its new IT strategy which has a focus on cloud, mobility and people centric services. Ron Dennis, Chairman and CEO, McLaren Technology Group that includes the McLaren-Honda team said: “I am delighted to welcome NTT Communications to the roster of McLaren-Honda’s high-technology and premium brands. NTT has a long association with technology that goes all the way back to the introduction of the telegraph in Japan. Given McLaren’s long association with innovation; it is only fitting that we should join forces with such an established and well-respected leader

AUGUST 2016 | www.engrreview.com

in enterprise communications technology who well understands our own drive for relentless technical development. “NTT Communications has a resilient and high-capacity network that will allow the team to access its systems without delays.” Tetsuya Shoji, President and CEO, NTT Communications said: “The NTT Communications technology repertoire is wide and deep, and McLaren’s ex-

cellence in Formula 1 is world renowned. With innovation a part of the DNA of both companies, this partnership will help McLaren-Honda transform how it manages the data generated during Formula 1 races and transcend hitherto established boundaries in motorsports racing.”

For more information Web: www.ntt.com

64 NEWS

ENGINEERING

Mitsubishi Elevator India launches new plant at Vemgalnear Bengaluru Mitsubishi Elevator India has announced the launch of new plant in Vemgal, near Bengaluru city. Spread over an area of 89,000 sqm, the facility with floor space of 25,400 sqm and manufacturing capacity of 5,000 units annually has the capability to expand production in the future. The first elevator is scheduled to be delivered in December 2016. By producing locally, Mitsubishi Elevator India expects to strength the product competitiveness in terms of price and cut down on delivery time by focusing on its NEXIEZ-LITE elevator model for low to mid-rise buildings in

the Indian market. Special emphasis will be placed on the efficient integration of sales, manufacturing, installation and maintenance. One of the breakthrough product of Mitsubishi elevator is the fastest elevator [speed of 20.5 m/sec] in the world (Shanghai Tower in China)] that use artificial-intelligence technologies, continue to receive high evaluations industry-wide. Speaking on the occasion, Iwao Oda, Managing Director, Mitsubishi Elevator India said “We recognise the growth potential of the Indian economy and through the launch will directly cater to the emerging elevator market which

is now the world’s second largest after China. Mitsubishi Elevator India emphasises on the safety and quality of all the products, it will be a collaborative effort of Japanese technology with trained Japanese technicians training their Indian counterparts and working towards well-being of Indian society. As part of Make in India initiative, the new manufacturing facility at Vemgalwill roll out new series of products and will be our 14th manufacturing facility in the world that have so far supplied elevators, escalators and moving walks in 93 countries world-wide.”

For more information www.mitsubishielevator.in

ENGINEERING

Pergo introduces Sensation Pergo, the world’s best laminate flooring reinvents the laminate floor all over again with the introduction of Pergo Sensation. Pergo Sensation takes laminate flooring to a whole new level – even when it comes to water resistance. The new range in Pergo Laminate called “SENSATION” which is water repellent flooring is not only designed to look great, they are also innovative when it comes to performance. With the brand new AquaSafe technology your new laminate floor is now protected against water like never before. The surface protection of the new Sensation floors extends all the way into the bevels to create a fully closed surface. This laminate floor comes with silk matt finish and true-tonature cracks and knots, thanks to Genuine rustic – a surface

AUGUST 2016 | www.engrreview.com

“Pergo has been a pioneer in Laminate flooring and with the introduction of Pergo Sensation; we are re-inventing it all over again. Because our new collection of laminate floors is nothing short of what the name suggests. The new Pergo Sensation floors are not only designed to look great, they are also innovative when it comes to performance. With the brand new AquaSafe technology your new laminate floor is now protected against water like never before! The new Pergo floors are nothing short of a sensation has it is safe to say that in terms of design as well as performance.” said Naresh Maheshwari, CEO, Pergo India Pvt. Ltd. texture that accentuates details such as cracks, knots and scraped effects. Pergo Sensation has water repellent coating on the plank edges ensures that water cannot

penetrate the floor. Being waterresistant, a Sensation floor is also hygienic. Dirt just like water, simply stays on the surface and can be wiped away easily.

For more information Web: www.pergo.co.in

66 NEWS

ENGINEERING

Solvay expands Diphenols product range and capacity Solvay, worldwide leader in Diphenols and derivatives, has recently announced a capacity extension project for hydroquinone (HQ), catechol (PC) and para-methoxyphenol (MEHQ or PMP) at its Zhenjiang site, China. From this innovative and environmentally friendly new capacity, Solvay will continue to serve the market growth in India and Asia. This expansion is scheduled to be operational in 2018. “From this hydroquinone and catechol competitive platform, Solvay intends to grow in butyl hydroxyl anisole (BHA) and tertio butyl

hydroquinone (TBHQ) Diphenol derivatives used as food and feed antioxidants” revealed Jacques Guglielmi, Asia VP & General Manager at Solvay Aroma Performance. For this purpose, Solvay has already invested and successfully started up a new high quality BHA production in France since November 2015 and will start a new technology TBHQ production in India in July 2016. Based on its strong and sustainable worldwide Diphenols & derivatives expertise, Solvay also recently started a new Vanillin plant in China, fully FSSC 22000 food certified along the

ENGINEERING

Taiwan Hardware show will witness 400 exhibiting companies For three days from 12 to 14 October 2016, over 28,000 international buyers and hardware industry specialists will convene at the Greater Taichung International Expo Centre to see the newest high-technology hardware products and solutions at the 16th Taiwan Hardware Show (THS). As Asia’s leading premium hardware show, visitor registration to THS has been growing steadily and is set to welcome buyers from India, Iran, Malaysia, Singapore, United States and many other countries with strong hardware purchasing power. With some 400 exhibiting companies showcasing their best hardware selection, the exhibition will stand as the region’s most comprehensive sourcing and procurement platform that offers the latest hardware offerings for wide industry demands and applications. Gerd Keim, President of Kaigo Co., Ltd highlighted that, “With more products, more innovations and more market insights available, visitors can procure or identify products for distribution wisely with informed decisions

AUGUST 2016 | www.engrreview.com

on product specifications, manufacturing processes and application quality. These critical sourcing concerns are only made available by trusted companies exhibiting at THS 2016.” Highly regarded as the sole event that continually brings fresh innovations for the consumer-driven hardware markets, THS is set to feature trendy new technologies, advanced systems with smart devices as well as hardware range with digital and automated applications. Mirroring Taiwan’s stature as a globally recognized top hardware-producing country, the 17,571 sqm showfloor across 2 halls will be filled with products that meet international quality standards. Trade buyers and professional buyers will find hardware solutions with quality design and high performance capabilities for energy and cost efficiency.

For more information www.hardwareshow.com.tw

integrated production from Catechol to Vanillin. “Solvay is determined to reinforce its position in India by bringing the highest level of food safety for the benefit of Indian consumers,” affirmed Mukesh Malhotra, Solvay’s India Country Manager. India is a strategic market where Solvay will continue to consider every next growth opportunity.

For more information Web: www.solvay.com

SNIPPETS

US$ 40

Over the last decade, the automotive components industry has scaled three times to US$ 40 billion in 2015 and expected to grow in 2016

US$ 1

India’s manufacturing sector has the potential to touch US$ 1 trillion by 2025.

US$ 125.4

The capital goods and engineering turnover in India is expected to reach US$ 125.4 billion by 2017

US$ 45

India’s pharmaceutical sector will touch US$ 45 billion by 2020.

11%

The share of solar capacity in the renewable energy sector is likely to increase to 11 % in 2016

68 NEWS

ENGINEERING

Essar Steel India Q1 performance improves significantly Essar Steel India has made significant performance improvements in the quarter ended 30 June 2016 on the back of robust production growth. The gross revenues of Rs 4,482 crore in the quarter saw a 12% jump when compared to the revenue of Rs 4,006 crore clocked in the corresponding quarter in FY2015-16. The flat steel production in the first quarter was 1.22 million tonnes. This translates to a growth of 48% when seen in comparison with the 0.824 million tonnes produced in the same period last year. Even pellet production grew by 58% to 2.02 million tonnes, as against 1.28 million tonnes in the same quarter last year. By the end of FY 2016-17, Essar Steel India expects to record a marked increase in its capacity utilisation, and produce 80% of its rated capacity. Essar Steel‘s efforts to de-commod-

itise its steel production and focus on developing value-added grades are bearing fruit. The Company focuses on producing steel that is tailored to customer requirements. This ensures that there is low finished goods inventory, thus saving on working capital. In the last one year, Essar Steel has developed 17 new grades, which have given it a first-mover advantage in many industrial segments. The new grades enable Essar Steel customers to substitute imported products with indigenous Made in India steel, and make substantial savings. Commenting on the performance, Dilip Oommen, MD & CEO, said, “Over the last few months, we have taken several steps to strengthen our operations. We have also been able to maintain higher operating margins. In addition, the markets have been stable and

customer response has been encouraging. This gives us the confidence to aim for full production going forward.” Essar Steel’s downstream facility in Pune clocked its highest ever quarterly production. Essar Hypermart has recorded a 40% growth in sales volume. With the natural gas price plummeting to US $6/mmbtu (from a high of US $20/mmbtu), Essar Steel has been able to contain cost, improve margins and ramp up production. The company is looking at restarting all its gas-based DRI units in the current fiscal.

For more information Web: www.essarsteel.com

AUTOMATION

Eplan data portal tops one million mark

High-quality data has become essential for engineering, and a new Eplan Data Portal record proves it: in June 2016, users downloaded around 1,000,000 device and component data, with the trend continuing upward. It even caught Eplan managers by surprise, as this was something they never expected when they initiated Eplan Data Portal eight years ago. Users’

AUGUST 2016 | www.engrreview.com

interest is running extremely high – after all, they’re saving precious time by integrating current data directly into Eplan Project using drag and drop. Right now there are more than 620,000 device data available in the portal, plus more than 1.2 million variants via

configuration. The trend moving towards products and solutions compatible with Industry 4.0 is further amplifying the interest in these valuable parts data – data that can be used throughout the entire product development

process. Stefan Domdey, Global Coordinator Eplan Data Portal, explains: “We’re delighted that our portal is being so outstanding received around the world and that the number of downloads is continually increasing.” Intense discussions are going on with component manufacturers worldwide in order to incorporate into the portal these industrial stakeholders who are not yet participating in it. So far, the number of manufacturers represented is 147 – and is continually growing. In 2016 alone, Eplan was able to welcome 33 new manufacturers. Users appreciate the large variety of device data and use Eplan Data Portal for their daily design engineering.

70 COMPANY PROFILE

Effica’s ROBOTIC solutions

A customized robot engaged in machine tending

oimbatore-based Effica Automation, incorporated in 2005, is today in the focal business of materials handling automation encompassing machine tending, palletizing and conveying, making the most of robots. Under the stewardship of Mr. Arjun Prakash, President, who is the grandson of late Dr. G.R. Damodaran – a statesman, educationist, humanitarian and founder of the legendary PSG Tech, Effica is eminently poised to take industrial automation in India to subliminal heights. A mechanical engineer from PSG, Mr. Arjun pursued an internship and intensive training and experience in the field of mechatronics. The education and insights he received in mechanical engineering, electronics, robotics, computers and software applications helped him build a strong foundation for Effica Automation which is today in the forefront of integrating robotic systems to enhance operational efficiency, productivity & profitability in Indian industry which is poised to join the big league using robots for automation and manufacturing excellence. Effica started off in 2005 designing and manufacturing special purpose machines (SPMs) for a plethora of applications. It even developed robotized special plasma cutting systems for marking and precision cutting power transmission poles of 60 ft long. Way back in 2009 it executed a project worth Rs. 2 crores in Houston. This was a complex job involving different disciplines – mechanical, electrical, electronics, robotics, machine vision and so on. It involved handling, rotating, holding and cutting of poles where cost of error was very high and forbidden.

Present focus Over the years, the company has changed its focus. Since 2011, to be precise, its focus is on materials handling automation which includes machine tending, palletizing and conveying. The company offers robot based CNC and ma-

AUGUST 2016 | www.engrreview.com

tion systems are used by machine tool, forging, plastic injection molding, sheet metal fabrication and FMCG segments. “We have made our systems modular and user-friendly so that in the event of a failure, the user can also fix it. This way we have removed the fear of breakdown and consequent downtime from the mind of the end-user,” reveals Mr. Arun Prakash. Effica’s state-of-the-art production facility in Coimbatore

chine tending systems. These include multiple CNC, forging presses, sheet metal pressing machines and other process machine loading and unloading using robots. It offers conveyors – roller, belt, overhead, slat and special food grade; we provide servo-based 2, 3, 4-axis pick & place systems with flexible gripping solutions for CNC & machine loading and unloading, secondary packing and palletizing systems; and machine vision based picking and intelligent gripping solutions for packing and inspection. It also offers gantry machine tending to replace articulated machine tending projects for payloads from 40 grams to 100 kg. This is an economical solution, and with this the existing plant layout need not be disturbed. It also does bag conveying & palletizing automation. This is a robot-based high speed palletizing system with a speed of 20 T per hour. Effica’s automa-

Modern facilities Effica has a sprawling manufacturing facility housed in a land of 10,000 sq. mtrs. It has an in-house Machine shop, Assembly shop, Design & Dev. Dept., Quality Control section and so on. The Controls Dept. has multiple robots and PLCs. The company has a dedicated workforce of 35 people. Marketing is done directly. However, it has channel partners in strategic locations like Coimbatore, Chennai and Bangalore to extend its reach to the customer. Automobile industry & automobile ancillaries are its major customers. Its growing client list includes some big names like Ford, Nissan, L&T, LGB, LMW, Saint-Gobain, Amara Raja, Pricol, Roots, etc. Effica is highly customer-centric in its operations. “When we offer tailor-made solutions, we go beyond the call of duty to satisfy the customer and entail him the benefits of flexibility, efficiency, safety, savings and quicker ROI,” states Mr. Arun Prakash.

72 COMPANY PROFILE

Maruthi & its customized

MATERIALS HANDLING solutions A

n automobile engineer starting a materials handling business? Yes, that’s precisely what Mr. S.S. Pillai did way back in 2000. But he had had 15 years’ experience in a materials handling company as a Production In-charge before relinquishing the office and deciding to do something on his own. That’s the beginning of Maruthi Handling Equipments based in Coimbatore, the company that has carved a niche for itself in offering in-plant materials handling solutions. Mr. Pillai remembers that the first product he came up with was a Pallet Truck. Then he made a Manual Stacker and Semi Electric Stacker, all in quick succession. Today Maruthi offers a whole range of materials handling equipment which includes Pallet Trucks, High Lift Pallet Trucks, Manual Stackers, Semi-Electric Stackers, S.S. Pallet Trucks, Pallet Trucks -Paper Roll Model, Floor Cranes, etc. “We have 350 plus medium size customers. Most of them come to us again and again with their new requirements. They are quite happy with our quality products and our prompt service,” says Mr. Pillai. Maruthi products go predominantly to textile & dyeing units, chemical plants, pharma, paper and engineering industries – all for in-plant materials handling. The company has developed a Stainless Steel Pallet Truck for chemical and pharma plants where hygiene and contamination control in handling are of paramount importance. The company has also come out with Pallet Trucks with weighing scales which can weigh payloads up to 3 tonnes. Maruthi has its manufacturing facility in Neelikonampalayam, Coimbatore which is ISO certified. Quality is a watchword at Maruthi. At least 25% of its products are custom-built to meet specific needs of the customer. “We

AUGUST 2016 | www.engrreview.com

closely interact with the customer, understand his application and then develop a product to suit his needs. Since reliability is the fulcrum of materials handling products, we pay utmost attention to the selection of the right material of construction. When it comes to fabrication, we use MIG welding for obtaining sound, flawless welds. We make doubly sure of the strength of the components like the chassis which is the backbone of the equipment which has to handle load,” explains Mr. Pillai. The company also has an efficient set-up to attend to service calls, if any. “When there is a problem, we attend to it promptly and see that the customer’s pain point is addressed with least delay so that productivity is not hampered, “ reveals Mr. Pillai. No wonder Maruthi is taking a premium for its quality materials handling products which are precision engineered to perform in tough work environments. – P.K. Balasubbramaniian

74 PROFILE

“Improve quality, you automatically improve productivity”

S Mr.Yogesh Kale - Director Stella Industries

tella Industries is a leading manufacturer of injection moulded plastic components for companies in the cosmetic, FMCG & pharmaceutical sectors. We pride ourselves on our adherence to quality and our objective is to benchmark ourselves against the global players. We manufacture plastic moulded products to the highest quality as efficiently as possible, ensuring our customers receive the very best service Our motto is continuous improvement. We do this by constantly adhering to the best practices and processes, and by benchmarking ourselves against the best in the world. We do this by following our systems of management whilst engaging in continual improvement in everything that we do. Our firm was established in 2015 and we operate out of a facility in Silvassa, India.

Our speciality Our expertise and speciality lies in creating injection moulded parts for industries such as • Cosmetic • FMCG • Pharmaceutical and many more…

Where are our products used • • • •

Caps & Closures Electrical Writing Instruments Automotive & many more

Our focus Our focus is to make global quality standard products at competitive price. At Stella Industries , we encourage and welcome our clients to come up with their custom designs of products. Stella plans and prepares to constantly improve their range of products to meet the ever changing needs of our clients.

Our goal Our goal is to provide the best quality Injection Moulded plastic components. We also aspire to become an integral part of each of our customers’ business model and it is our firm belief that they will consider us for all their projects and business.

For more information Unit No. 1/2/3, Krishna Industrial Estate Survey No. 906/2, Bldg No. A, 66 KVA Road, Silvassa – 396230 Email: yogeshkale@stellaindustries.in sales@stellaindustries.in AUGUST 2016 | www.engrreview.com

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

HIGH QUALITY FOR YOUR MACHINERY

MGM brake motor main features

VARVEL production lines

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

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

agency.com

A new generation of electric motors and gearboxes for power transmission quality from the alliance of two dynamic italian companies. For those who want quality.

MGM-VARVEL Power Transmission Pvt Ltd Ware House No. G3 and G4 • Ground Floor • Indus Valley's Logistic Park • Unit 3 • Mel Ayanambakkam • Vellala Street Chennai - 600 095 • Tamil Nadu, INDIA • Phone: +91 44 64627008 • info@mgmvarvelindia.com • www.mgmvarvelindia.com REGIONAL OFFICE: KOHLI TOWERS • 4th Floor, Dapodi • Near Bharat Petrol Pump • Pune - 411012

76 MANAGEMENT

OPTIMIZING

PERFORMANCE E

very professional’s dream working day is certainly the one in which he puts up his feet at the end of the day with a self satisfied smile. A feeling of achievement underlies this happiness and this helps him to ride the crest even on the next day. So how does one get to this blissful haven? Well by optimizing one’s performance and in delivering one’s best in one’s working sphere. There is no magic spell that one needs to know. It all comes from careful strategizing. It comes from tapping one’s inner resources and from honing one’s best asset: Oneself! Here are some very easy life skills to reach that zenith of joy. Planning your goal is the first step. What do you want to achieve? Knowing what you want to do will help get you started. Becoming involved in a special interest, would help one to gain from newer experiences. Join a club that includes people that have similar skills. Discussing your aspirations with all and sundry is a wonderful way of getting a riot of ideas. These would widen one’s horizons and also help one to do one’s best. Practise. This is the absolute key to success. If you want to excel at anything, you can’t expect to get there if you don’t try. Practice as much as you can, and at any opportunity. Practice makes one perfect. Develop different skills – Widening your skill set is a very emphatic way of reaching an optimal level of performance and staying up there. The skills could be anything from academic, physical or artistic. It could be anything from speaking German to chess, from learning a dance form to mastering a musical instrument. Don’t try to be the best at everything; just be the best at everything you do.

AUGUST 2016 | www.engrreview.com

Remember, at the end of the day, just have fun. Enjoy each moment you have doing your interest. Most professionals who have optimized there working performances are generally viewed as efficient workers. They are described as troubleshooters and those who would not take no for an answer. A secretary who is able to juggle his or her boss’s busy schedule; a factory worker who learns to produce more units in less time; a sales manager who increases sales by 10 percent: These are just a few examples of efficient professionals. Put simply, being efficient means producing results with little wasted effort. The better the results obtained, the more efficient the professional. The sum of these individual performances is what enables a company to achieve high all-around performance. It is always possible to strengthen the numerous factors that have an impact on personal efficiency. Being efficient in the workplace hinges more on an individual’s ability and work ethic than it does on the company he or she works for or its management. The six main factors in determining personal efficiency are: responsibility, capability, self-motivation, self-management, creativity and simplification. Any professional can affect the performance of these variables. In particular, responsibility, capability; self-motivation and simplification are largely shaped by an individual’s own attitudes and actions. To be a successful professional first requires embracing personal responsibility. If you refuse to take charge of your own performance, nobody will do it for you, and you will almost certainly underachieve. Next, capability determines to what extent individuals possess the knowledge

and skills necessary to fulfill their tasks and achieve their objectives. Being efficient then requires not only knowing how to do your job, but also actually wanting to do it and being self-motivated. Simplification involves doing tasks the simplest way possible. In fact, simplification has a multiplying effect on efficiency, as it enables the worker to achieve better results with fewer resources. The final variable self-management makes doing the other things possible. However, individual’s ability to self-manage ultimately depends on managers apart from themselves. Even though individuals can try to steer working conditions in certain directions, their ability to manage themselves depends greatly on the organizational framework they must work within. For that reason, companies must try to provide individuals with appropriate organizational conditions for performing efficiently. One can improve one’s performance by developing concrete perspectives and mindset associated with these efficiency variables. Take responsibility, for example. This requires that you aspire towards realistic goals and show tenacity so as to not fall to pieces at the first sign of an obstacle or deterrent. It is a great idea to compete with self than with outside forces as it prevents de-motivation. Making tasks simpler, learning to prioritize and being able to focus on what is important are key aspects of the art of simplification. Optimizing one’s performance is like reaching for the horizon, and hence an adage to ponder over: “Be able, be willing and then you will be the BEST.” Dr. Jyoti Vora

78 IN FOCUS

KISTLER : The global technology leadership Q. How would you introduce your company in two minutes? The Kistler Group develops sensors and systems to measure pressure, force, acceleration and torque. Our products can be used to measure processes on the frontiers of physics. Kistler’s solutions facilitate the analysis of physical processes; they control industrial operations and deliver valuable information that is used to optimize product quality. The knowledge gained often prompts customers to develop their own innovations, thereby strengthening their competitive edge. “Technological leadership, proximity to the customer and a highly committed workforce has helped Kistler group to grow very successfully and dynamically in recent years. To Kistler, market leadership means both motivation and an obligation to maintain quality leadership and continue optimizing our range of products and services”

Q. Kistler operates in which product and industry verticals? Kistler’s product offering is used for Engine development and monitoring, Vehicle technology, Plastics pro-cessing, Metal machining, Roads & Highways, Technical Research as well as Assembly and testing technology. We supply sensors, electronics, software and flanking services from one single source. So, we work very closely with Automotive, Machine Building, Defence, IITs & Highway Industry verticals.

Q. Tell us about your Production Monitoring product range? Our maXYmos XY Monitors are used for 100 % Quality in Production, Assembly and Product Testing. We have maXYmos BL - XY-Monitor for Quality Control & Type 5867B XY-Monitor for industrial applications. The main Properties of these units are: 16 measuring programs, Up to 8000 XY-values per curve, Color touchscreen, up to 4 evaluation objects per curve & Functionality expandable via licensing.

Q. Tell us about your Joining Systems business unit? Kistler offers a wide range of products that

AUGUST 2016 | www.engrreview.com

guarantee complete monitoring and control of press-fit and joining processes – including sensors, measuring chains, monitors, evaluation units and NC joining systems. Typically, these products are used in the automobile industry and the automotive supply sector, e.g. for assembling engines or transmissions. Kistler’s portfolio includes the maXYmos family – making us the only provider to offer a complete family of products with a uniform operating philosophy for tasks ranking from XY process monitoring all the way through to extended control of NC joining modules. Kistler systems are outstandingly user-friendly and their integrated sequential control ensures maximum flexibility to handle joining processes, no matter how complex. The main advantages of our Servo Spindles are - Energy-efficient systems: up to 80% savings on energy, Low installation outlay, space-saving design, Monitoring and traceability of joining processes & Low-maintenance operation. NC joining systems deliver comprehensive control and monitoring of all joining and press-fit processes.

Q. How much does Kistler invest in R&D and what is the scale of Global setup? Kistler Instrumente AG was established in 1959 at Winterthur in Switzerland. Since then, Kistler has become the global leader in dynamic measurement technology. Proximity to our customers – in terms of geography as well as time is a key factor in our company’s success. That’s why Kistler is now present on every continent with 31 Sales and Production Centers, three Tech Centers and over 30 distributors. Customer-focused services such as calibration, repairs or regional product adaptations are provided by Kistler Tech Centers in Germany, the US and China – underpinning our guarantee that every customer will receive the best possible support. Kistler currently employs about 1,450 staff at 56 different locations across the globe. In fiscal 2015, the Kistler Group posted sales revenue of CHF 329 million. Over the last three years, average sales growth amounted to more than 10%. Some 10% of our yearly sales revenue is devoted to research and development.

Mr. Anil Anand, Country Head – Kistler Instruments India Pvt. Ltd.

Q. What about the Kistler setup in India and your contribution? The wholly owned Indian Subsidiary of Kistler group was established in 2010. Now we have a specialized team of Sales, Support & Calibration Engineers with Head office in Faridabad and branch offices at Chennai and Pune. The Team is working very closely with the Automotive, Machine building, Defense, Top Technical Institutes & Highways Industries. In a short span Kistler India has created a customer base of approx. 200 customers. While building our Team we have taken special care to Reinforce our organization with best human skills and establish business practices which can be benchmarked with the best professional and technology norms globally. Also our Goal is to establish reliability and a track record of delivering hi tech innovative solutions economically.

Q. Could you elaborate on your work ethos? Put your best and don’t worry about the accomplishment. Providing genuine solutions to assist our varied customers in accomplishing their goals while keeping up our commitment towards people & environment, Set your goals higher then you can achieve!

Q. What are your comments on the prevailing business environment and how conductive is it to growth of your business? The Government is committed to business growth and the GDP numbers are very encouraging. We expect the manufacturing sector to perform much better in the coming years. An awareness is now prevailing about boosting the R&D Infrastructure. These endeavors shall always make a positive contribution to have a Sustained Economic growth required for the business growth.

Q. What’s your vision for your company? Emerge as technologically advanced preferred partner on the Automotive, Industrial & Sensor Technology front while providing ingenious solutions.

80 IN FOCUS

MAXON MOTORS

:Precision with perfection Mr. Daniel Von Wyl Business Unit Director Maxon Medical Extended Managment Board

Q. Maxon motors is one of leading name in the field of small, high-precision electrical motors and drive systems, please brief us more about company’s achievements? Maxon motor was founded 1961 in Switzerland when it started to develop, produce and sell high-precision coreless DC motors. Since then, the company grew steadily over the years and has today a worldwide coverage. It offers brushed and brushless DC motors together with gearhead, position sensors and controls for all kind of demanding applications such as medical, aerospace, robotics, industrial automation and instrumentation. The motors are produced in different production sites in Europe and Asia. Global turnover are 420 million US$, and the global workforce are 2’200 employees

Q. Please brief us more about Maxon Motor’s global reach AUGUST 2016 | www.engrreview.com

& latest initiatives in the field of small, high-precision electrical motors and drive systems ? Today, maxon motor products are sold in more than 40 countries. In all important countries, maxon motor has its own subsidiaries. In recent times, enormous efforts were made in the field of aerospace and heavy duty applications, such as downhole drilling in the oil and gas industry. These motors have to withstand high vibration, shock and temperatures up o 300°C. – Maxon motor is a specialist for applications with demanding specifications and requirements. In other words: maxon motor does not leverage economy of scale as low-cost motor manufacturer, but is technology leader and produce high end customer-specific solutions. They are based on a wide range of standard offerings which can be tailored to customer specific requirements. The latest innovation are the state of the art CTO products. The Configure-To-Order products can be modified by the customer himself directly on the internet. Once the choices made, the product can directly be order on the Online Shop, and the products are delivered within 11 working days. This service allows the customers to shorten their development time dramatically with customer specific unique identification number.

Q. What are the applications of the small, high-precision electrical motors and drive systems in various industries? How do you plan to position these products? The strategic markets of maxon motor prod-

IN FOCUS 81

ucts are medical, industrial automation and robotics, instrumentation, aerospace, whereby the medical applications account for almost half of the global business. In the medical technology field there are applications such as insulin pumps, surgical power tools and surgical robots or radiation equipment. All of them are highly demanding requirements. The top priority is quality and maxon motor does everything to achieve top notch quality and high reliability of the product. Furthermore, maxon motor constantly launches new products and is therefore the innovation leader in the field of small electrical drives. A high one-digit percentage of the annual revenue is spent for research & development to say the least.

Q. What is the current scenario of the small, high-precision electrical motors and drive systems ? There is an ongoing trend to increase the power density of the motors. In other words: by using the best magnets and with continuous improvements in winding technology, maxon motor is trying to reach the physical limits again and again. High efficiency and increased miniaturization is an ongoing goal. Furthermore, progress is made in order to meet the demanding requirements regarding tough, heavy-duty environments. Withstanding high shock, vibrations and accelerations in space applications, or thousands of autoclavable cycles in a medical product are challenges that maxon motor is willing to fulfil.

Q. What is your quality policy for the business? Continously high level quality is our biggest goal. Maxon motor product are high-end products which go into critical applications. We fulfil various ISO standards such as ISO 9001 for industrial products, ISO 9100 for aerospace products and ISO 13485 for medical applications. Beside this, the environmental standard ISO 14001 is also fulfilled.

ISO 9001: First quality management certificate as 7th company in Switzerland in 1988.

ISO 9001:2008: Recertification in 2015.

ISO 14001 (environmental standard): Recertification in 2015.

ISO 13485 (medical standard): maxon medical: certification in 2008. Recertification in 2015.

EN 9100 (aerospace industry): Since October 2012.

Q. According to you what are the measures taken by Indian manufacturers in order to compete with global players? India is one of fastest growing economy at the moment. This provide ample opportunity in all markets and maxon also look forward to it. Opening FDI in segment like defence, aerospace and pharma will help India in meeting global standards. maxon can leverage its technological leadership and breadth of product in these markets. Indians are at par with globe and have an excellent education. Indians speak English and therefore can communicate with the whole world. Furthermore, India is a huge country and therefore offers a huge domestic market. The economy is doing well and the need for small high-electrical motors will certainly increase in future. These are important fundamentals in order to be successful as an economy. It is important to be focused and to work hard until you have a product that is mature to be launched. Many Indian companies have excellent ideas, develop prototype products but give up too early. The projects are often abandoned too early. Due importance should be given to research & development. If Indian companies can cope up this issue and control and maintain a good quality, they will have a great future.

Q. Could you brief us about your top line product range? What are value added services you provide to your customers? Our top line product line has been the brushed type DC motors in combination with planetary gearheads and encoder systems. Since ever

maxon motors produces so-called coreless motors which differ from conventional DC motors. Coreless motors contain a rotor made out of a self-consisting winding in the shape of a cylinder. This type of motor offers technical advantages against conventional motors: they have an increased power density, high degree of efficiency, linear characteristics, they are highly dynamic and have an extended life time. The biggest offer for our customers is customization. We try to find the best solution for our customer by taking a standard product out of our many platforms. In discussion with the customer, we then modify and adjust the motor to perfectly meet the customer requirements. â&#x20AC;&#x201C; In order to do so, we try to be as close as possible to our customers with a dense sales network. Our sales people all have a deep technical understanding in order to consult and advice our customers in the best way possible. â&#x20AC;&#x201C; Customer focus and customer proximity was finally also the reason why maxon decided in 2009 to start with its own subsidiary in India. Since then, Indian business is growing nicely year by year.

Q. What are your future plans to maintain substantial market positioning in the small, high-precision electrical motors and drive systems ? Maintain the high level of innovation and quality. Identify and develop new demanding niche market where small and mid-sized volumes are required. Understanding customer need and providing solutions as close as possible through innovation, research & development, quality and support. With the above we maintain and further enhance our market leadership. Geographical expansion into emerging markets such as India.

Q. What factors bestow the success of your company? Continuity in the management, long-term thinking, customer orientation, high level of innovation (substantial amount of the turnover is invested in R&D every year), no profit thinking, investment into long-term employees, international coverage and global sales & marketing network

www.engrreview.com | AUGUST 2016

82 IN FOCUS

Revolution in

CUTTING OIL TECHNOLOGY automobile sector, pulling the requirement of coolants & lubricants. The expected CAGR is at around 3.5%. Opening up of FDI in defence sector is also going to push the demand upside.

Q. Which sectors will impact demand & sales the most? How do you plan to capitalise on these opportunities?

Mr. Munish Garg Managing Director, See Lube Technologies (P) Limited

Q. What are the latest advancements in technology and product upgrades that you have introduced? Expected growth of Industrial lubricants stands at 3.5% CAGR and this growth is technology based. To compete in this market, adoption of new technology is inevitable. With the increase in demand, there is a big problem of disposal of used lubricant is becoming a big challenge. To counter this problem, we are working towards biodegradable Lubricants. We have developed cutting oils with vegetable oils which are biodegradable using nanotechnology. These oils will have lesser problem of disposal.

Q. How do you see the coolants & lubricants market performing in the next few years? High demand in engineering sectors, mainly

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Automobile sector will impact the most. We are working towards to penetrate in more OEMâ&#x20AC;&#x2122;s and their ancillaries. Opening up of aviation and defense sector will also increase the demand of Lubricants. We are also introducing the minimum quantity Lubrication where lubricant will be used less than 100 ml per machine in one shift in mainly cutting & milling operation. These lubricants are based on misting technology, thus giving relief in quantity buying and disposal too. We are also introducing complete range of products thus we become full line supplier for any industry. Apart from our main stream products, we are also moving in to value added product and services like regeneration of used lubricants at customer premises only. We are also introducing equipments for the same, which will be available off the shelf from July 2016. Last year we have launched Total Lubrication management system, where we take responsibility of Lubrication needs of our client through single window system. We manage, test & optimize the lubricants at clientâ&#x20AC;&#x2122;s premises. There is couple of customers who got benefitted with our efforts in terms of reduction in consumption. This year we are increasing our sphere to Coolant Management

services too. We will be taking responsibility of coolant management for procurement, usage & disposal, thus giving a much relief to our customers. This activity will not only help customers in systematic way to optimize the usage of coolant ( cutting oil), but also reduce the cost of operation.

Q. Do you see a requirement to scale up operations in the coming years? Yes, this is requirement of time. Operations in terms of optimization in production house as well as scaling up marketing, is to be done. Now a days, conventional methods of growth are old story, one has to be very creative to sustain growth. New avenues to be dig out, new concepts to be launched and utmost is adoption of energy conservation systems to be introduced in manufacturing set up.

Q. What are the challenges that stand in the way of success? Today world has become very small. Biggest challenge is over use of technology. One has to be open for change in technological concepts. Today along with demand, competition has also become manifold. Unless one is not working on the concept of cost reduction, he will be out of the race. Cost reduction is not only at your location even at your customer location has become your responsibility. One has to be on foot continuously to work in this direction. More and more companies are coming to India with their products, but in my opinion, unless you become complete solution provider for your customer, success will be a distant dream.

86 COVER STORY

CEM INSTRUMENTS : The blend of

INNOVATION & PERFECTION Q. CEM INSTRUMENTS has gained credible market share in measurement technology industry. How did the company manage this significant growth? We could manage this growth basically because of our inherent strengths. We design products as per customer requirements. Our dedicated R&D Centers are engaged in new product development for specific applications as required by the customer. We are able to provide complete end-to-end solutions to test and measurement requirements. Over 50 Engineers are working on new products to provide customers tomorrowâ&#x20AC;&#x2122;s product today. We have a dedicated workforce of 1000 plus in our manufacturing facility. All these are our strengths which help us serve large OEMs to their entire satisfaction.

Q. What are your initiatives in testing & measurement technology space? Which are your focus areas? We provide: Thermal Imagers both with low and extremely high resolutions, Fixed Thermal Imagers for continuous monitoring, Smartphone connectivity for test and measuring instruments, Cloud service to store measured data for on-the-go engineers who do not want to get back to office to get test results (This makes communication and inference of data for trouble-shooting very simple and easy), Data Loggers for recording all possible data of various sources like wind speed, vibration, temperature, humidity, air pressure, light, sound, voltage and current. We also offer Radiation Detectors for assessing presence of radioactive materials and to prevent radioactive contamination.

Q. Could you brief us on CEMâ&#x20AC;&#x2122;s global network & activities? We have our Head Office in China with global operations. Our sales offices are in USA, Germany and Russia. The marketing office in INDIA has been newly established. We look forward to work with distributors and dealers to provide complete sales support to the customer. We are working with all e-portals for B2C business.

Q. What are the market opportunities for CEM in India? How do you plan to position these products? We offer High Quality Products at Reasonable pricing, These Products complying with European and American Standards are offered at a throw away pricing. All products are calibrated to national and international standards. We give 48 hours replacement warranty. With the growth in Indian economy and with

AUGUST 2016 | www.engrreview.com

the increase of industries and infrastructure, we see more possibilities to position our products at a place that is acceptable to customers in India. Q. What is your marketing strategy for Indian market? We would be conducting direct sales to high end customers, appoint Dealers and Distributors for Retail and Industrial sales, shall have e-commerce website to promote our products, Participate in various exhibitions, and also deploy Sales Engineers for promotion and highlighting how our products are one up compared to competitive products. Q. Could you please elucidate the contribution of R&D in the success of CEM products? The R&D Centers have helped us design thermal imagers to break the US$ 200.00 mark for the international market. It has helped us

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develop products that can seamlessly transfer measured data on the internet. It has provided us with products to take images of the measurement place for evidence hunting. Connecting the instruments to smartphones, does not need the senior engineers to move around in the factory while the critical measurements are being made.

Mr. Vikram Bhansali, CEO CEM Instruments India Pvt.Ltd.

Q. What is your quality policy? The products being sold in India adhere to international standards. These products are the same as the ones being exported to USA or European markets. All products are calibrated to international standards. Our products carry international safety standards. Calibration certificate is provided with all the products with the facility to re-generate these certificates after their expiry. The 48 hour replacement speaks volumes of the faith we have in the products we make. Q. Could you tell us more about your topline product range? Our top line product range comprises: • Thermal Imagers from 31 x 32 resolution up to 384 x 288 pixel resolution. We are developing thermal imagers, which can communicate with smart phones. We are also developing thermal imagers with built-in Multimeters. • Clamp meters integrated with 50,000 count Multimeters. • Flexible clamp to measure currents up to 3000A • Video Borescopes to take videos and images of hard to reach areas where we cannot see with our naked eye. • Video Borescopes for online, non-destructive, preventive maintenance. • Radiation detector to show presence of radioactive material. Measures doses of alpha, beta, gamma and x-rays. • Multimeters with built-in Digital Storage Oscilloscope that can communicate by blue tooth to the PC or with smartphones. • Multimeters with smartphone interface. • Data Loggers to record various data that can either be downloaded to the computer or can be connected to smartphone via Bluetooth adaptor to download the measured data.

Q. What do you think are the strengths of Indian measurement technology industry? How has it positioned itself against global markets? The Indian TMI industry is entering the era of Predictive and Preventive maintenance. The Thermal Imagers and Video Borescopes are such instruments that could save a lot of money without stopping the production so that there are no operational losses. With the phenomenal growth of smartphone usage, the Indian TMI industry is growing towards integration of Instruments with these devices to provide seamless data transmission and storage on cloud based systems. Q. Please highlight the Global perspective of TMI and its differentiating factor. While the Predictive and Preventive maintenance has come in vogue in the Indian industries, while the global giants work a lot on it. The global industries have properly developed PPM programs that are engineered efforts, which optimize the relationship between equipment ownership and operating profits by balancing cost of maintenance with cost of equipment failure, and associated production losses. Equipment ownership cost is a function of three factors • Purchase price • Equipment life and • Maintenance cost …where Material and labor cost required to repair the item + Cost of preventive maintenance to avoid repairs +Cost of lost production while the unit is out of service for repairs Maintenance Cost = PPM includes actions which extend the life of equipment and avoid unnecessary failures by substituting selective programmed effort for “fix it when it fails” maintenance. Predictive maintenance is the complement of preventive maintenance. Through the utilization of various non-destructive testing and measuring techniques, predictive maintenance determines equipment status before a breakdown occurs. With predictive devices currently available, it is incumbent upon maintenance organizations to include the process of predictive maintenance in their maintenance programs. PPM program consists of: www.engrreview.com | AUGUST 2016

88 COVER STORY

Office Overview of CEM Instruments

1. Proper organization 2. Proper operation of equipment 3. Proper lubricants, in the right quantities, in the right location, at the proper time 4. Predicting wear and deterioration by regularly checking, measuring and adjusting A. Regular inspection to identify small repairs before they become major repairs B. Predictive techniques to replace components just before they fail i.e (i) Vibration monitoring and analysis (ii) Infrared inspection ( iii) Sound detection (iv) Lubrication and oil sampling., etc. The Indian Industry is slowly

but surely moving away from the “Fix it when it fails” mentality and is catching up with the global industries for the Predictive and Preventive Maintenance.

• Capturing pictures of measured data with the relevant background. This helps to capture evidence for maintenance of various industrial machines when it malfunctions.

Q. What are the key technology trends that are driving measurement technology industry? Some of the trends that drive MTI are: • Integration of various instruments, measuring various relevant data in one unit. • Seamless transfer of measured data from the instrument on to the PC, smartphone, cloud service to move the data via Internet.

Q. According to you what is the forecast for the measurement technology industry? Following are the developments we can forecast: • Instruments that can measure MORE with the same equipment. • Moving away from single usage instrument to multi-tasking instruments. • Data Measurement and Storage, for measured data at various locations, at one single place. This helps in analyzing the measured data in one single go, thus allowing time for trouble-shooting and maintenance. • Sensors and Data Loggers to measure data in hard to reach areas that could increase productivity and reduce maintenance cost. Q. What are the factors affecting your business? Having a dedicated R&D center with over 50 experts, helps us in not just understanding and addressing the needs of the current market but also to developing capabilities to stay on the cutting edge of the TMI industry and coming up with future ready products using our ingenuity, vast experience and wherewithal. One of the main factors that helped us in reaching where we are is our continued effort in understanding our customer’s current needs and developing products to address their needs before they arise.

CEM Product Range

AUGUST 2016 | www.engrreview.com

Linear solutions global provider.

ROLLON India Pvt. Ltd. - INDIA 1st ďŹ&#x201A;oor 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. Mumbai (INDIA) August 22-25, 2016 Hall G13 - Stand 40-41-42

90 TECH UPDATE

Process optimization through integrated condition monitoring Advanced measurement data processing with TwinCAT 3 TAR Automation specializes in high-quality automation technology, supporting manufacturing companies through the integration of innovative control solutions. In addition to the design and implementation of new systems, as well as modernization of existing production machines, TAR develops system solutions in the areas of motion control and condition monitoring. The company, which is based in Dinslaken, Germany, recently developed an efficient condition monitoring system (CMS) for production equipment, based on integrated automation solutions from Beckhoff. “In the early days of our enterprise, we used conventional PLC and SCADA products almost exclusively. Today, we increasingly employ PC-based automation solutions from Beckhoff,” Alfred Rachner, Managing Director of TAR Automation, explains. “The multi-functional TwinCAT 3 automation platform provides an efficient development environment for our engineers to create software components. It is modularly structured, but nevertheless integrated. The finely scaled series of Embedded PCs provides the ideal hardware platform for the performance requirements of any task at hand.”

Highly precise & customizable: Seamlessly integrated condition monitoring system “The PC-based control solution enables us to integrate numerous new functions in automation technology, which in the past could only be realized using dedicated ‘black-box devices’. Condition monitoring for production equipment is a good example,” says Alfred Rachner. A conventional CMS is usually installed as a separate subsystem within the overall system. It consists of special hardware for data sampling and evaluation, has a fixed number of channels and a defined functionality. This makes such stand-alone solutions very inflexible: the user AUGUST 2016 | www.engrreview.com

is unable to respond to changing needs, and condition monitoring functions become difficult to integrate, as well as very expensive. Enhanced flexibility and reduced costs drove the TAR engineering team to develop the TAR 9964 condition monitoring system, which is based on a CX5140 Embedded PC with TwinCAT 3 software, the TwinCAT Condition Monitoring library and EtherCAT Terminals as the control platform. EL3632 Condition Monitoring terminals are used to connect IEPE acceleration sensors. The integrated configuration provides numerous benefits: • The system is freely programmable, enabling the addition of new functions at any time. • Vibration and analog channels, in addition to temperature measurement or digital I/Os, can be retrofitted at any time using the range of modular EtherCAT Terminal I/O. • EtherCAT, as a broadband real-time network with high- precision clocks for synchronization, as well as oversampling technology, facilitates sampling rates of up to 100 kHz for analog signals and 50 kHz for acceleration values. • The EL3632 condition monitoring terminal provides connection of IEPE sensors (acceleration, microphones, etc.) and features

oversampling technology, parameterizable hardware-based antialiasing filters, digital filters and offset compensation. • Basic analysis algorithms can be integrated as a PLC library, permitting the modification or expansion of functionality at any time. • – Integration into the customer’s system is straightforward – a function of the availability of all common interfaces, including PROFIBUS, PROFINET, EtherNet/IP, CANopen, and Ethernet, among others.

More than condition monitoring: Process optimization of a granulator The TAR 9964 condition monitoring system provides, as a real-world example, monitoring and process optimization of a shredding machine for recyclable material such as components used in PCBs, cooling units, washing machines, various plastics or tires. The granulator has a 400 kW drive for the cutter shaft and a 12 kW hydraulic unit for the pushing unit and stator adjustment. The cutter shaft features acceleration sensors, whose data are logged via the EL3632. First,

TECH UPDATE 91

The TAR 9964 condition monitoring system is based on a CX5140 Embedded PC with TwinCAT 3 software, the TwinCAT Condition Monitoring library and EtherCAT Terminals as the control platform.

The condition monitoring system is supplied ready for operation, installed in a compact terminal box.

software function blocks from the TwinCAT Condition Monitoring library acquire and bundle data in a very fast task. In one or several subsequent tasks, various analysis function blocks are used for additional operations, such as Fourier analysis, limit value monitoring, averaging and classification. The condition monitoring library also ensures correct time correlation of the acquisition and analysis tasks. The integrated condition monitoring system results in tangible benefits for the operator of the shredding system: • Bearing monitoring: In the past, bearings were monitored via temperature measurement, so that impending bearing damage

was usually detected too late. • Vibration, limit value and trend analysis: Detect potential bearing damage before costly damage actually occurs. • Over-lubrication detection: Minimize lubrication waste Optimized system operation: If the working area is not closed properly, the material “dances” on the cutter shaft and does not shred correctly. The resulting increased vibrations can now be measured, and the feed corrected by applying pressure. • Automatic V-belt tension detection: Automatic detection and adjustment of loose V-belts Detection of blunt cutters: In the past, the plant was inspected “by ear”, requiring personnel to actually listen for changes in equipment and the cutters were sharpened manually when needed. The condition monitoring system supplies reliable measurement readings for detecting blunt cutters and sharpening is carried out automatically. • Integration into the machine control system: The material feed was historically controlled manually. Previous attempts to control the

infeed with optical measuring systems were unsuccessful, because the materials to be shredded differ greatly in size and form. Now, the vibration analysis function of the condition monitoring system enables reliable detection when the granulator is empty, supplying new material automatically. Continuous utilization of the machine increases productivity by up to 50 percent.

New potential for system integrators “For TAR, integrating condition monitoring into the automation and control system also opens up new opportunities and sales potential,” points out Alfred Rachner. “TwinCAT is ideal for us as an integration platform: From simple control tasks to motion control, CNC applications, condition monitoring and safety technology – we can solve any task with a single system. This eliminates costs for training programmers on different platforms, and we only have to install and maintain a single engineering system in our departments. The same savings apply to maintenance procedures at our customers’ sites.” “In addition, TwinCAT supports all common fieldbus interfaces such as PROFIBUS, PROFINET, EtherNet/IP, and CANopen, so that we can easily integrate our solutions into the control environments our customers use – for example, when it comes to modernizing an existing system. The most effec tive way forward is a fully integrated PLC/NC/CMS solution based on TwinCAT, although this is obviously only possible for new systems.” Industry 4.0: Communication standards for vertical and horizontal networking The wide range of Embedded PCs are scalable in terms of performance and I/O configuration while offering diverse networking options. This offers many degrees of freedom when implementing control architectures and, as a result, optimum solutions for the tasks at hand. “Whether we are dealing with a small, standalone solution, networking of decentralized, intelligent controllers or a high-performance central solution – anything is possible,” concludes TAR’s Managing Director. “In combination with support for OPC UA as the universal standard for vertical networking, it is also possible to integrate ERP systems, both within a site and across sites.” Beckhoff India Contact : Ajey Phatak Email id: info@beckhoff.co.in

www.engrreview.com | AUGUST 2016

92 IN FOCUS

HITACHI :

3 DECADES

of technology leadership in India Dr. Kazuhiro Imaie, Managing Director Hitachi Hi-Rel., Ahmedabad, India

Dr. Kazuhiro Imaie having 26 years experience in power electronics field is the flag bearer of Hitachi Hi-Rel Power Electronics, India since from April 2016 which is recognized as a pioneer in Power Electronics, and is on its way to the next level of success. Q. Please describe in brief about yourself and association with Hitachi? I have taken over the responsibility of Managing Director of Hitachi Hi-Rel Power Electronics, India in April 2016. Having strong Power Electronics background (Ph.D. in Power Electronics), I have been associated with Hitachi Japan for more than 26 years and worked in different roles, be in Technology or Business. I am happy to be at the helm of Hitachi Hi-Rel Power Electronics (HHPE), which is now a 100% Hitachi Group Company and is recognized as a Pioneer in Power Electronics, and is on its way to the next level of success.

Q. Please share how Hitachi made Hitachi Hi-Rel in India a Wholly-Owned Subsidiary of Hitachi? The demand for power electronics products

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is expected to increase in keeping with the development of various industries in India and Southeast Asia as well as the recent rapid growth of renewable energy market worldwide. In this market background, Hitachi has decided to take direct control of Hitachi Hi-Rel operations by acquiring 100% stake in Oct 2015, after having major stake in way back in 2011. This was done mainly to reinforce power electronics business through increasing product competitiveness and expanding application fields by enhancing Hitachi Hi-Relâ&#x20AC;&#x2122;s R&D, design, and manufacturing structures with making full use of the Hitachi Groupâ&#x20AC;&#x2122;s sales/service network. By further expanding power electronics business, Hitachi will contribute to the development of industry in India and throughout the world.

Q. Please describe in brief about your company, its vision and product range? Having more than 3 decades of experience as Hi-Rel Electronics Pvt. Ltd, we have garnered a significant level of trust in our market segment and now with direct control of Hitachi management, we continue to offer world class power electronics products, value added services & customized solutions at Hitachi Quality. Our vision is to be recognized as the most trusted power electronics company by supplying superior products and services. We target to lead all our current market segment be it grid tied solar inverters, UPS for industrial (non-IT) and enterprise (IT & commercial) applications, medium & low voltage variable frequency drives and other product domain.

Q. Please describe your Establishments

IN FOCUS 93

in India? I am particularly pleased with the fact that we are contributing to the “Make in India” initiative of the Govt. of India since 2011, much before its launch. I am proud to note that HHPE has been a strong contender in the market for the last 33 years with state-of-the-art manufacturing facilities, both at Sanand & Gandhinagar, to manufacture power electronics products conforming to global standards to cater to the Indian and global market. Our ultra-modern Sanand Manufacturing Works Spread over 26,000 Sq mtr. is modelled on Hitachi’s Omika Works in Japan and is one of the most modern power electronics manufacturing facilities in India. This Company is a key hub, for both “Manufacturing” as well as “Research & Development”, within the Power Electronics division of Hitachi Group and we will leverage it to drive Innovation and Growth. This geographical advantage, value added solutions and technological leadership help us in serving the customers in India and across the globe – USA, Africa, Middle East, South East Asia and Australia. For Solar, presently, we are operating on our maximum manufacturing capacity (150 MW / month). We have expansion plan in place and our production capacity for both Center Inverters and Variable Drives would be double in next year.

Q. Kindly brief about your offerings in Solar Industry? We are offering highly optimized energy solutions based on Hitachi technology. For Solar, we offer grid tied solar Inverters (HIVERTER NP 201i) which is available from 250 kW to 1.25 MW capacities. With 3 level IGBT technology and wider MPPT range, HHPE inverters are delivering considerably high reliability and maximum power generation. Hitachi 1.25 MW Solar Inverter is among the most popular grid tied Solar Inverters currently in India for its various technical advantages

and major saving in EBOP. We offer highly reliable after sale support from dedicated & decentralized after-sales-service centres located at strategic locations across the country.

Q. Kindly enlighten our readers on the performance of your Inverters in India in various geographic locations, customer feedback? Performance of our Inverters is definitely good….giving excellent generation. We have installations base of more than a 1 GW in India and installed around 962 Inverters units at different sites (65 locations) at all terrains. Yes, we did experience some challenges initially in terms of Inverters breakdown due to differences in Installation practice followed in India. We have overcome to this challenge and introduced some minor changes in new systems.

Q. Present some noteworthy projects, case studies of solar plants built using your solar Inverters? I proud to inform you that we have been chosen as Inverter partner for world largest Solar power plant in India (648 MW) by leading business group and we have supplied 360 MW worth of Inverters in record time of 3 months. In last financial year, we have worked on one more mile stone project in country and supplied Inverters for 150 MW NTPC Ananthpur project through EPCs & successfully commissioned within time frame. This was the first solar plant of NTPC under UMPP scheme.

Q. What are your plans for India, your view on the Indian Government aggressive target of 100 GW Solar Power by 2022 Looking ahead, we are expecting a historically strong year in Indian solar market be a State Policies, UMPP or SECI projects. I am confident that, with our leading technology, strong brand

name & superior products, we will further solidify our market leading position. HHPE experienced truly unique achievement – a much deserved entry into 1000 MW Club. We are poised to achieve even bigger targets (1.5 GW) leveraging the experience gained in past. We are confident to meet industry demands looking forward to consolidate & fortify our brand for promising future in coming years.

Q. What is your vision and future plans for Hitachi Hi-Rel Power Electronics? As the Managing Director of Hitachi HiRel Power Electronics, my vision is to take Hitachi Hi-Rel to a new height, to position our organization as one of the most admired company in the world, number 1 power electronics company in India, and as one of the top performing of Hitachi group companies with power electronics business at the centre contributing significant growth in revenue and profit. With expertise, experience and an efficient product line, we will always try to be a leader in power electronics sector. One of our values – Customer Delight, encourages us to realize our customer’s expectations and to serve them better - All Time, Every Time.

Q. Any message to Indian Industry? I firmly believe that our success lies in the success of our valued customers, strategic partners, business associates and employees. This we can achieve by working together in a cohesive and vibrant environment. I have a vision to not only lead from the front, but also lead by setting examples – be it by offering state-of-the-art products, well-timed services and through happy and content employees We appreciate the constant and valuable support extended by our business partners in the past and hope to receive the same in our future endeavors too. I promise to deliver the best to Industry from Hitachi Hi-Rel. Wishing all readers a successful year 2016-17.

www.engrreview.com | AUGUST 2016

94 INDUSTRY FOCUS

SYNETICS aims to be in the top league in automation

Coimbatore-based Synetics Automation Solutions Pvt. Ltd. is in the forefront of automation, providing innovative and costeffective solutions to the manufacturing sector. Six years down the line, the company has proven its engineering prowess and innovativeness in the areas of its core competence namely CNC auto-loading, assembly automation and robotic solutions, and added an impressive list of customers to its portfolio. Reduced dependence on labour, reduced overheads, increased throughput, increase in quality and consistency and ultimately increased customer satisfaction are some of the benefits of automation the user-industry should take advantage of, says the top brass of Synetics in an interview with Mr. P.K. Balasubramanian. Excerpts: Q. Could you explain the beginnings of Synetics?

“We have to convince the customer on the tangible and intangible benefits of automation.”Karthik Soundararajan, Director, Synetics Automation Solutions Pvt. Ltd.

AUGUST 2016 | www.engrreview.com

Vijayaram Balasundaram : Synetics is the brainchild of two engineers – me and Karthik Soundararajan. We both have done our Masters in Automation & Robotics from the Rochester Institute of Technology, in the US. After my MS, I joined General Motors and worked there for 10 years and got rich experience in automated car and truck body welding lines. Karthik joined Alliance Automation Systems as a Controls Engineer handling electrical design of machines, PLC and robot programming. After working for five years, he moved to Assembly & Test Worldwide (ATW) and stayed there for 1 ½ years. In 2007 he came to India to start and head their Indian Operations. Synetics was started by us jointly in the year 2010 with a view to serve manufacturing companies who wanted to reduce their dependence on labor

“Government should encourage automation and provide loan subsidies for capital investment.”Vijayaram Balasundaram, Director, Synetics Automation Solutions Pvt. Ltd.

and at the same time improve their quality and productivity. We started the factory with just two employees and today we have a dedicated workforce of 43 people.

Q. Who was your first customer and what’s your present range of manufacture? Vijayaram: Our first customer was Adulon Polymers based in Coimbatore. For them we developed a painting line using robots. After the initial order, we did two more projects for them – naturally because they were quite happy with our first project. Our current range includes robotic solutions, assembly automation solutions and CNC auto-loaders.

Q. So, what is your niche in automation today? Karthik Soundararajan: We are primarily

INDUSTRY FOCUS 95

A turnkey project done involving robotic automation

which is a boon to machine shops. Inserts are costly and hence their issue and proper usage should be monitored and controlled. We have come up with two versions. The smaller version is designed for single insert vending to be used for turning centers, while the larger one is meant for machine shops with vertical & horizontal machining centers which need supply of more inserts. Our prototypes are ready and are getting perfected. We shall be launching these machines in a couple of months. The ASRS we have developed for food vending is also a novelty in retail outlets and public places. We have already supplied about 20 such systems. They are now being launched in Singapore.

Q. How do you convince the prospect of the fast realization of ROI.

full-fledged system integrators and machine builders providing end-to-end solutions. We have a very strong mechanical design team with experience in 3D modeling and analysis, backed up by a controls team with vast PLC & robot programming knowledge. We do the entire assembly, integration and testing in house to achieve ultimate customer satisfaction.

Karthik: Our CNC Auto Loader needs special mention. With auto-loaders attached to 4 CNC’s, one operator can run four (4) machines. So across three 8 hour shifts, the auto-loaders can replace 9 operators. They are less expensive(40% less) when compared to robotic solutions and can be easily retrofitted to existing machines. Another revolutionary product is our Carbide Insert Vending Machine – Pro-Crib,

Q. What are your capabilities and major strengths in turnkey automation? Vijayaram: We are highly creative and we apply our automation experience to come up with innovative solutions that address the customers’ problems. We use high quality and reliable automation components for our systems integration. We focus on building operator-friendly systems also taking care of ergonomics. We have a thorough understanding of OSHA safety standards and lay greater emphasis on the safety of our systems. Our systems are also designed with serviceability in mind and are very maintenance-friendly. When it comes to aesthetics, our products are world-class.

Q. Which are the major projects you have executed recently?

Q. What are the do’s and don’ts in Automation?

Vijayaram: We have executed five robotic projects – one for machine tending, a large overhead gantry system for welding and two for painting. We have a steady stream of orders for our CNC Auto-loaders.

Q. Which are the innovative products you have developed for automation?

Vijayaram: When it comes to automation and calculating the return on investment, the customer should consider reduction in manpower, and also the improvement in productivity. With automation one can expect at least 15-30% improvement in productivity. The savings can be worked out as follows: Suppose you have 7 CNC machines. If you attach auto-loaders to 6 machines and achieve a 15% improvement in productivity per machine, you can achieve a cumulative 100% increase. So instead of running 7 machines, for instance, you can achieve your production with 6 machines. This obviates a capital investment of Rs.20 lakhs and also saves on floor space and power required for the 7th machine. On the other side, with manpower, one can achieve only 85% efficiency. When you implement Automation, you can get closer to 95% efficiency and realize several tangible and intangible benefits. And most important, you have peace of mind. One of our customers has realized a huge increase in production. In 12 hours, with manual loading they used to get 1100 components. Now with an Auto Loader, they get 1440, a gain of 30%. At this rate, the 4th CNC machine can be used to produce other components!

A carbide insert vending machine from the crucible of Synetics

Karthik: People generally have a bad impression about Automation. This is because the requirements are not defined and customer may not be aware of the Do’s & Dont’s. In order to reap the full benefits of Automation, the end-user should work very closely with the supplier and have a complete understanding

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96 INDUSTRY FOCUS

of what they will get. Both should get involved and make things happen.

For implementing Automation, the following factors should be considered: 1. Identify areas that provide maximum value addition. 2. Select areas which are easier to implement and bring ROI faster. 3. Select projects where the process is stabilized and less complex 4. The input component quality should be consistent, automation cannot handle parameter variations 5. Areas where cost of labour is more (or) hazardous environments. 6. Take time to define the scope thoroughly.

Q. These days all are talking of low cost automation. What are your views? Vijayaram: Yes. People say they have achieved low cost automation. But in effect, it may not be true. While working out the cost, one should also include the cost of time invested by their employees and the cost of failures. People should go for cost-effective automation, based on ROI calculations.

Q. How do you keep yourselves abreast of the latest trends? Karthik : We interact with various vendors who keep us informed of the product developments.

Q. Which are the major industry segments you serve and who are your major customers? Karthik: Automotive industry, pump industry and materials handling are some of the key industry segments we serve. We want to get into assembly automation in a big way. That’s our core strength.

Q. Which is the most challenging development you have handled? Karthik: It is the food vending machine we have developed. First we developed with pneumatic automation. Later it was switched to all electric. It is materials handling in a different form. The development was quite exciting and satisfying.

Q. What’s your vision for Synetics and how do you look at the future of automa-

Assembly automation in progress

AUGUST 2016 | www.engrreview.com

Synetics’ CNC autoloader

We read technology journals, attend seminars and conferences, meet people, visit exhibitions and also access Internet for knowledge and information.

tion vis-à-vis Synetics? Vijayaram: We want to be one of the top 10 players in the automation industry in India by 2025. Our national agenda is to make India a manufacturing hub for the world. But this is possible only if we implement automation and take our manufacturing to the next level. Look at Ford. They have put up a plant in Gujarat with 85% automation in their bodyshop, the highest in Asia-Pacific. Automation has to be taken seriously and implemented by our tier-2 and tier-3 companies. The fact remains that China is way ahead in automation in manufacturing. That is why they are able to mass produce components at cheaper prices. In the days to come there will be more compulsions to go in for automation. The semi-skilled labour cost which stands at a level of Rs.350/- per day is likely to touch at least Rs.800/- per day by 2025. Today most of the components for automation are imported – PLC’s, servo motors and robots for instance. With the “Make in India” campaign gaining momentum, some of these products will also be manufactured in India and their prices will come down. A combination of increased labour costs and reduced automation component prices will be a big enabler and ROI will be much quicker. In the 80’s the machine tools industry was comfortable with conventional lathes. There was inertia on the part of manufacturers to go in for CNC machines. But in 90’s transition did take place. Today everyone wants only CNC’s because they realize the benefits. Similarly automation is also going through a transition phase in India and the country has to embrace it on a much larger scale so as to keep pace with the industrial growth envisaged.

98 IN FOCUS

The INDUSTRIAL LUBRICANT market in India has grown significantly

Mr. Imtiaz Ahmed, Asia Pacific Mobil SHC Brand Manager, ExxonMobil Lubricants Private Limited

Q. What are the major technology trends in the metalworking lubricants and coolants industry? Tougher metals, more advanced, severe metal working processes and the ongoing drive by machine shops to increase productivity and reduce costs has seen the importance of cutting fluids rise up in the agenda of metal working operators in recent years. The metalworking industry continues to go green as more shops adopt vegetable-based coolants

AUGUST 2016 | www.engrreview.com

and implement recycling programs. To reduce overhead costs, more shops are investigating in new ways to reuse their coolant rather than dispose it, including new coolant recycling programs that can reduce coolant waste and increase sump life. However, with a multitude of factors including the operating environment, machining application and machined metal type, all having an impact on a cutting fluid, one cutting fluid cannot provide the lubrication, cooling and protection required in each and every operation. As such, leading lubricant and metal working fluid providers such as Mobil Industrial Lubricants have developed a range of fluids to meet many of the varied machining operations in machine shops today. There are two classes of cutting fluids: Water Soluble (Aqueous / Water Miscible) and Neat (Straight). While water soluble cutting fluids are used in a number of machining operations and are provided in a concentrate form and must be diluted with water at the machine shop site before use. Neat cutting oils are not mixed with water and are provided in packs for immediate use. They are used in applications which are beyond the typical performance profile of water soluble coolants, such as tapping and threading of high alloy steels

Q. Brief us on the influence of metalworking fluids on the machining process. With new materials coming in, how is the industry aligning its R&D to the changing demand trends? Whether a manufacturing company specialises in producing nuts and bolts, complex gear sets or high precision valves, keeping its equipment running efficiently is the key to profitability. Lubrication plays an integral role in reducing friction between critical rotating or moving machine tool

components, dissipates heat which can translate into equipment durability and availability. To help ensure that the machine tool runs smoothly, it is important to choose a combination of high-quality lubricants – slideway oils, water soluble cutting fluids and neat cutting oils. As a company that helped pioneer synthetic lubricant technology, ExxonMobil devotes significant resources to product research and development. We use an advanced, scientifically engineered ‘balanced formulation approach’ that leverages the company’s leading technology and application expertise. This comprehensive process enables us to develop lubricants that deliver exceptional performance across all critical areas for each application - such as oxidative stability, component wear protection, corrosion control, filterability, shear stability and extreme temperature performance. New challenges continue to be addressed with our new products and services. With every new technological development there will be continuous challenges in the industry. With our relationship with equipment builders we closely monitor the trend of technology development on the equipment side so that we are geared up to deliver the right product, which will cater to this requirement in the industry. So that is how proactive we are in terms of developing and delivering the right product for the industry.

Q. How is the metalworking industry evolving in terms of tie-ups with OEMs and end-users to enhance value propositions of their products? Original Equipment Manufacturer (OEM) or Equipment Builder (EB) recommendations/ approvals are a key factor when industrial organisations select lubricants for their machinery. Working closely with EBs to

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100 IN FOCUS

elevate awareness and knowledge of metal working fluid technology including health and safety aspects of usage, at the same time delivering improved productivity of the equipment on a shop floor is very important since they help one understand equipment trends as well as current and future lubricant requirements. At ExxonMobil, our ultimate goal is to improve our customers’ competitiveness by facilitating improved productivity through our commitment to being the technology leader with the highest level of application expertise. We at ExxonMobil place an enormous emphasis on ongoing investment in R&D, working side-by-side with the world’s leading EBs / OEMs to develop the most effective products as well as maintenance solutions. By working so closely with EBs / OEMs and our customers, we can ensure that our Mobil-branded lubricants deliver exceptional all-around performance. As a result, we are much more than a lubricant provider— we’re a valued, strategic business partner to many EBs / OEMs. With many of the world’s leading EBs / OEMs, we actually participate in early product development, assisting with new machine designs while making recommendations on lubricants and lubrication systems. Our range of high-performance synthetic lubricants are recommended for use in a wide range of applications by more than 500 major equipment builders, and is ideal for use in a wide range of industries. This close collaboration has enabled ExxonMobil to develop a range of high performance industrial lubricants which help to optimise the performance of industrial applications. ExxonMobil’s flagship Mobil SHC™ synthetic lubricants are approved for use in more than 10,000 applications and have preferential endorsements from more than 2,500 equipment builders. The Mobil SHC™ 600 Series oils alone are recommended for use in 1,800 applications by more than 500 OEMs

Q. Which are the market drivers for coolants & lubricants? In India, the lubricant industry is on a growth path. The industry has been growing considerably above industrial output in

AUGUST 2016 | www.engrreview.com

the last few years. The industrial lubricant market in India has grown significantly owing to strong growth through green field projects, capacity expansion and upgrading to new technology in key sectors like Energy, Manufacturing, Process, and Metals in the last decade and an increasing number of customers are demanding superior performing, high technology products to deliver sustainability benefits. We envision a robust growth in this sector despite efficiencies in lubrication as well as equipment technology in the next few years

Q. What are the various innovations happening in coolants & lubricants in terms of lower operating costs, extended tool life, better surface quality and productivity improvements in metalworking industry? Technology is evolving and new energy efficient technologies are contributing to reducing energy demand. Mobil Industrial Lubricants have developed a range of fluids to meet many of the varied machining operations in machine shops today.

Slideway oils Poorly formulated slideway oils may not separate readily from aqueous coolants. This can result in the formation of ‘tramp oil’ which can compromise the effectiveness of the coolant by shortening its effective life and adversely altering cutting performance. Tramp oil can also lead to bacterial growth resulting in foul odour, short service life and potential health and safety concerns. To identify high performance slideway oil, maintenance professionals seek out products with outstanding frictional properties and Exceptional coolant separability. One product that meets these requirements is the Mobil Vactra Oil Numbered Series of slideway oils, which have a proven track record in service.

Water Soluble Cutting Fluids To optimise productivity it is very important to choose technology-leading aqueous coolants. The highest performing coolants can provide reduced maintenance requirements by resisting biological attack which helps to extend batch life. Ease of

maintenance needs to be balanced with good machining performance as well as protecting the machine tools and work pieces from corrosion and sticky deposits. In addition, the fluids should meet the latest Health and Safety regulations and be easy to monitor and maintain in service. Collectively, these properties will help deliver long service life, excellent cutting performance and reduced maintenance downtime. The Mobilcut range of water soluble cutting fluids have demonstrated superior performance in demanding applications in the industry across various geographies in India.

Neat Cutting Oils The new Mobilcut series from ExxonMobil, comprising milky emulsions, high performance micro-emulsions and a fully synthetic grinding fluid, are cutting fluids designed to offer long service life, good operator acceptability and easy waste management. The high performance, long-life semi-synthetic cutting fluids in particular have been designed to meet the wide variety of applications and operations found in medium to small sized machine shops where flexibility, inventory management and machine downtime are of paramount importance. From Mobil Industrial Lubricants’ perspective, we are geared up to meet and exceed industry requirement through a suite of step up technology lubricants designed to potentially deliver Energy Efficiency benefits. As a pioneer in energy efficient lubricant technology, Mobil Industrial Lubricants is committed to help customers improve their fuel economy and energy efficiency – these are key metrics important to customers. In addition, Mobil Industrial Lubricants offer a range of system oils that help enhance machine tool productivity and continuous operation of utilities that keep machine shops operating with minimal downtime. Mobil SHC range of supreme performance gear and bearing circulating oils, Mobil Grease brand of high performance industrial greases and a host of other lubricant products supported by Technical Services deployed through our expert network of engineers deliver enhanced productivity with safety and environmental protection.

104 INDUSTRY FOCUS >BEARINGS

NRB collaborates with the world’s most respected mobility companies to provide futuristic products & solutions, says Harshbeena Zaveri, Managing Director & President, NRB Bearings Ltd.

Harshbeena Zaveri Q. What are the growth drivers for the Bearings industry? How is the industry faring? The automotive market is highly dynamic with a constant change in the design of vehicles and consequently their components. Our competency in creating customized product solutions has given us great foresight in adapting to the changing environment and ultimately delivering what the customer wants. The key to success in this industry is product and process innovation, research on cutting edge technology development and light weighting.Our emphasis is to be pioneers not just in

existing bearings but to create friction solutions using diverse materials, technologies and manufacturing processes.

Q. What’s your niche in Bearings? NRB’s domestic market strategy is to be the pre-eminent supplier of Needle and cylindrical bearings to emerging leaders, while retaining existing business at entrenched players. We have been the largest Indian Needle Bearing supplier with our group having close to 70 percent market share and are market leaders in automotive cylindrical bearingswith a growth rate of 46% in this segment. We have copyrighted our in-house developed analysis software, which was instrumental in enabling the design, and development of the path breaking thin walled cylindrical bearing. Apart from this, we have filed for patents in India and in USA for improved sealing devices for needle bearings and thrust bearings as well as a design that will lead to higher stress bearing capacity in bearings.

Q. What’s your product spectrum today? NRB’s product range covers over 5500 different types of customized friction solutions

AUGUST 2016 | www.engrreview.com

Our product range covers over 5500 different types parts of primarily customized friction solutions. We are one of the three largest

INDUSTRY FOCUS >BEARINGS 105

suppliers in the world of customized bearings and crank pins to the two and three wheeler industry. For cars and SUVs, we are a significant emerging player in transmission bearings for high end luxury cars and the small car market, globally; our newest products have found a space in the world’s most highly engineered dual clutch, automated manual and variable speed transmissions. Our largest volume and range of bearings are deep drawn or formed type bearings that are lighter than conventional (solid race) bearings and are often specifically designed for the application.

Q. We know you are an innovator. What are the product innovations you have showcased recently? 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.We employ the frugal innovation approach wherein we devise smart solutions using sustainable design that preserves resources. We constantly invest in state-of-the art equipment from across the globe to achieve high precision standards that comply with the highest quality and environmental certification levels. Many of the products we manufacture are within a one-micron tolerance. Our focus, going forward will be on developing scalable standard operating processes, ensuring at the same time, that we don’t lose our speed and innovation-driven ethos.Size matters less to us than the impact and quality of the solutions we provide.

Q. What are the industry segments you are serving at present? Currently we supply a wide range of customized friction solutions for all mobility applications. In CV we now supply 100 percent of the needle and cylindrical bearing requirement to Eicher Volvo, the emerging leader. In tractors, apart from supplying entrenched players such as Mahindra and TAFE, NRB is 100 percent supplier of needle and cylindrical bearings to high growth companies, who are swiftly gaining market share, including Sonalika and John Deere. In passenger cars, we are the most critical suppliers of custom designed bearings at India’s largest players, especially in transmission bearings. Our foray into Defense has begun successfully with our products being accepted at DRDO and NAL at breakthrough speed.

NRB employs state-of-the-art equipment from across the globe to achieve high precision products conforming to highest quality standards

Q. Which are the emerging applications you wish to tap? NRB’s strategy is to carve a niche in applications that are extremely difficult and therefore have historically been the domain of the world’s most respected technology-driven engineering product suppliers. We have expanded our friction solutions and added new high precision product lines, including the supply of balancer shafts. This is one of the high precision engine components and puts NRB in a position to expand engine applications in a major way going forward.Our ongoing focus is on specific application based lighter than conventional bearings and higher stress capacity bearings.

Q. Could you throw some light on your production facilities and manufacturing excellence? We believe in constantly upgrading our technology. We employ state-of-the-art equipment from across the globe to achieve high precision and deliver products that comply with the highest quality standards. Our focus is on scaling up the R&D from product design to in-house machine design. This constant improvement in existing processes has not only increased efficiency manifold, but also celebrates originality through patents for the machine designs. As a result of this, a climate of R&D has been

carefully cultivated that percolates into all aspects of business. We have substituted modern techniques for age-old practices that have led to quantifiable improvements in increasing yield and tool life.

Q. What are your growth plans and future thrusts? NRB’s culture revolves around the ability to collaborate with the world’s most respected mobility companies and respond with innovative products that improve the performance and carbon footprint of their future generation of vehicles. We have two Government accredited Research & Development centers that focus on quality engineering and disruptive technologies that will drive our future growth. In the future, NRB is looking to penetrate more deeply into emerging segments such as defense, aerospace, marine, construction and off-highway. Geographically,apart from the Eurozone, where we have significant penetration at our key customers, we are now targeting new growth at Japanese, Russian and Korean customers.Our motive is not just collaborating with our customers on technology to develop friction solutions for cutting edge engines and transmissions, but also endearing ourselves to them with our unique responsiveness.

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106 INDUSTRY FOCUS

Reflecting on the Past to Advance the Industrial

INTERNET OF THINGS Whenever we can take a moment to reflect, it is possible to find patterns that can help clarify future projections. One such pattern can be seen in the preservation of infrastructure value associated with the four previous industrial revolutions.

istorically, the idea of extending the lifespan of equipment in industrial applications is not a new or marvel concept. As in the past, leveraging existing equipment not only saves money, but can also strengthen a companyâ&#x20AC;&#x2122;s foundation. Industry, as it is currently understood, began with the first industrial revolution (~1780 -1840), which involved the migration from piecemeal production by hand to machine-assisted production. This change was pushed by readily available energy from water and steam to power factory machines and tools. These initial advancements were followed by the second industrial revolution (~1870 -1914), whichintroduced newer technologyand electric power sources to factories. By providing round-the-clock light, electricityenabled more continuous manufacturing,allowing workers to produce goodsduring the day and night. Much of the equipment from the first industrial revolution, however, was still functional and in operation. Rather than replace working machinery, it was simply retrofitted with electric engines in place of steam-driven versions. This required only nominal investments to extend

AUGUST 2016 | www.engrreview.com

equipment lifespanwhile still benefiting from the increased capabilities of consistently available grid power.

Tracing the digital revolution The third industrial revolution (~1947-2010), more popularly referred to as the Digital Revolution, traces its roots to the invention of the transistor. The transistor enabled the development of computersthat spread to factory floors in the form of automation equipment tosupport manufacturinggoals of waste reduction and production enhancement. While the automation of factory equipmentincreased production efficiency, it also required the purchase and implementation of vast amounts of new tools and machinery. These additions enabled factories to once againtake production to the next level by further increasing output and reducing loss. Production began occurring in manufacturing cells with local control and monitoring. Maximizing efficiency of a single step within production required workers to supervise certain aspects of machine operation, such as watching over machine resourcesand monitoring equipment status.

By Colin Geis, Product Marketing Manager, Red Lion Controls

INDUSTRY FOCUS 107

data despite differences in source programming. When equipment from disparate manufacturers is connected, organizations can more easily access operational data to improve process visibility and therefore, drive productivity and operational efficiencies through real-time communication and data processing. In this fourth revolution, forward-thinking manufacturers can once again take advantage of existing equipment investments by retrofitting

current machinery with industrial automation and networking devices that support new capabilities to drive IIoT advancements. As a result, the benefits that began with continuous power and production— and then switched to increased efficiency—will next drive truly smarter production enabled by data interchange and analysis. As we’ve seen with past trends,advances that extend the lifespan of existing equipment stand to realize greater returns & success.

Control The era of the IIoT The current or fourth industrial revolution – the Industrial Internet of Things (IIoT) – is once again focused on refining processes to reduce waste and downtime by connecting all aspects of the supply chain to enabledata communication between deployed equipment and processes. Where the Digital Revolution enabled the automation of production, the fourth revolution focuses on coalescing and connecting the vast amounts of data currently spread throughout organizations. Extracting data from existing equipment provides operational intelligence and visibility to increase production efficiency andreduce the time-to-market for produced goods. The integration of production information can present complicated scenarios for existing facilities designed to optimize individualized processes. Some obstacles can be easily overcome through the use of media converters that provide the ability to change between cable media types (e.g., Ethernet to fiber optic or RS-232 serial to Ethernet) to physically connect equipment. A more difficult situation arises when it is not just a physical connection barring communication, but a logical one. For instance, factory equipment designed to perform a particular task uses protocols defined around unique parameters and are therefore not shared by other machines or machine components. Communication between disparate protocols (e.g., Siemens S7 TCP/IP to Allen-Bradley DF1 serial) requires the use of IIoT-ready protocol convertors like Red Lion’s Data Station Plus, which is designed to allow the interchange of

Processes. Devices. Locations.

IIoT Advantage: Remote Monitoring for Edge Control Red Lion’s rugged RAM® cellular RTUs push control to the network edge with an easy-to-configure event engine that simplifies remote asset monitoring regardless of location. • Trigger I/O or send SMS text message alerts based on real-time operational data • Address harsh environmental conditions with rugged, secure all-in-one platform • Support varied connectivity options from I/O to serial, Ethernet and Wi-Fi Learn more today at www.redlion.net/RemoteMonitoring

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108 INDUSTRY FOCUS

Connecting it

RIGHT! I

Mr. Marc Jarrault, Managing Director, Lapp India

The cable is the backbone of Industry 4.0, since nothing happens at all without an efficient cable solution that connects countless components in an automated factory AUGUST 2016 | www.engrreview.com

ndustry 4.0 or the fourth industrial revolution is the current trend in automation and data exchange in manufacturing technologies. Over the last few years, Indian manufacturing has come a long way by having automated factories with robots and computers. As factories are turning smarter and moving beyond the traditional methods, many repetitive and high precision works in large factories are being taken over by industrial robots. Today’s industrial robots have high computing capabilities, to scale up production and precision vastly improved vision systems, and increasing operational degrees of freedom. Therefore, they can essentially be considered tools of long production runs. Apart from that it also allows the manufacturer to deliver in a world where radically shortening production cycles and a high degree of product variation and personalization are fast becoming nuts and bolts of the industry. For instance, to improve product quality and efficiency in production, automobile makers are investing a large amount of time and money to improve the manufacturing process, by adopting robotics. According to the International Federation of Robotics, robot installations globally will increase by 12 per cent a year on average, between 2015 and 2017, thereby promising to deliver better quality products and increase productivity gains. The future of manufacturing shall witness a series of products being manufactured rapidly and efficiently by means of intelligent and inter-communicating machines.

Robotics is preferred by manufacturers today to: • • • • •

Maintain consistent quality Maintain precision and accuracy Rapid payback Maintain short cycle time Keep the manufacturing cost as low as possible

In smart factories, the manufacturing process has to be dynamic, flexible and organized in different ways as compared to the traditional

INDUSTRY FOCUS 109

set up. Every individual step included in the production process has to be fully connected and integrated in these futuristic factories. Some of the processes to be impacted are factory and production planning, logistics, product development, enterprise resource planning and manufacturing execution systems.

An efficient cable solution is required The cable becomes the backbone of Industry 4.0, since nothing happens at all without an efficient cable solution that connects countless components in an automated factory. Complex automated industrial systems such as manufacturing assembly lines require an organized hierarchy of cables to function productively. Thereby, in automated applications, cable flexibility, compatibility and durability is important to consider since, the cable must follow the robot’s movements. Sometimes even a small electrical loss can lead to poor quality, precision and accuracy. So, when it comes to smart factory automations, cable manufacturers’ today work towards manufacturing cables which ensures smooth and reliable operations.

However, there exists many different types of cables and not all of them are suitable for robotic applications. Hence, power and control cables for robotic applications are manufactured keeping in mind: • High resistance to torsion, reverse bending and continuous flexibility • Slim in construction and light in weight • EMC and Loss less transmission • Plug and play / complete connectivity solution • Application specific and long lasting • Composite cable solution

Manufacturing intelligent Cables Torsion resistant, reverse bending and continuous flexibility

Machines perform way better with customized torsion-resistant cables instead of standard control cables. These modified cables are specially designed to withstand the torsion and repetitive motion of their particular application. The cables are manufactured in a way that it can provide the smallest bending radius possible within the machine. Specifically designed cables for power chain, cable-track configurations and torsion applications can help overcome the challenges that are presented when designing automation machines. This can also reduce the amount of cable failure during operations. Cables need to be highly flexible, have a very small bending radius and be able to withstand high torsion loads. To ensure durability of components, there is a strong need for high quality cables. Today, for example, stud welding machines are used by robots for automotive manufacturing. The machine is automatically positioned by the robot and sets the studs for wiring harness assembly in the body shells. This requires the highest levels of efficiency and precision in terms of the executed movements and system productivity. Cabling would need to be laid over all of the robot’s axes and would therefore need to be able to follow all of its angular movements and rotations.

Slim in construction and light in weight To avoid restrictions to the robot’s movements, various cables are usually laid over the robot axes in the smallest of spaces. This is to avoid any confusion with other cables such as the welding cable, the data network and signal cable as well as the air and protective gas conduits. The cables need to be slim in design and light in weight which would ensure that cables occupy a small cross-section, among the rest.

EMC / Loss less transmission A common challenge faced by cable manufactures is electromagnetic compatibility (EMC) in relation to the copper cable, resulting electromagnetic interference. The data network and signal cables need to be protected with additional copper/aluminum screening for this. When using suitable insulating material, it is particularly tricky to achieve both electrical and mechanical requirements. Combining all these components in complex hybrid cables shall offer loss less transmission, robot-compliant flexibility and torsion strength, with a durability of more than two million bending cycles.

Composite cable solution Machines used in smart factories require data/ networking for greater bandwidth with power control cable. This is one reason for installing customized and composite cable solution mix of single/multi-mode fibres with power and control conductors of different gauges and types are assembled under one sheath in these cabling solutions. Hence it takes up less space and reduces installation cost.

Application specific and long lasting System component suppliers need to be able to supply high-quality standard products while also being able to primarily develop individual customized products. The use of standard ware in complex areas, in cases of doubt, leads to unwanted compromises, which in practice can lead to problems with using the machines and production systems. System cable division takes on the often time-consuming development of individual solutions that can involve intensive consultation, and they do this in cooperation with the customer. One of the most important sectors that the specified customer groups serve is automotive manufacturing. All components in this sector must meet strict requirements in terms of quality and durability. If, for example, a cable fails, the entire production belt will come to a standstill and trigger losses running into the millions within a very short space of time.

Plug and play / complete connectivity solution No system is complete without connecting all the individual components, and for this a reliable partner who lives up to the really very high demands, is essential. Customised solutions are often required in order to implement new ideas to meet the top line growth requirements of an industry: cables and connectors that you cannot simply buy ‘off the shelf’. These futuristic factories represent the absolute pinnacle of technological expansion and manufacturing development, which is here to stay and grow. Greater intelligence will be required to manufacture cables for automated machines in near future. Therefore, manufacturers have to be more focused on the quality and service life of the cables, while making cabling decision for automation. Thus, it is important to select appropriate power and control cable for smooth and reliable operations.

www.engrreview.com | AUGUST 2016

110 INDUSTRY FOCUS

There is a need for a different thought process and a move away from traditional means, in terms of the applications of co-bots, as they are being explored by several industries and will enable mankind to walk into a futuristic working environment

Why does India need more

COLLABORATIVE ROBOTS? AUGUST 2016 | www.engrreview.com

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112 INDUSTRY FOCUS

he future of automation is Human-Robot collaboration. The outcome of this is that people and machines work in collaboration with one another, doing what they do best. The shortcomings of one, are compensated by the qualities of the other and vice versa. The basic prerequisite for this is, a safe human- robot collaboration without a protective cage and simple programming of the robot. Almost every heavy industry is relying on automation or robotics to improve its production quality and efficiency. These robots are safe and easy to operate and require human intervention with their creativity. The automation of processes reduces the repetition of mundane tasks but does not take away the credibility of the human. These robots are called collaborative robots or co-bots and they are very different from Industrial or traditional robots. What are collaborative robotics? The combination of light, easily programmable, flexible, economical, safe and collaborative is extremely strong - and corresponds exactly to the needs of companies in industries like manufacturing, packaging and automobile assembly. It is crucial that the product not only benefits entrepreneurs, but also the employees. Companies benefit from the use of co-bots with flexibility, productivity, cost-effectiveness and sustainability. Employees, on the other hand, are relieved of their monotonous and burdensome tasks and have a flexible tool at their hands that can support them in almost innumerable tasks. â&#x20AC;&#x2DC;Autonomationâ&#x20AC;&#x2122; is a concept introduced by Sakichi Toyoda, founder of Toyota Industries and Corp. where the machines work harmoniously, using their power and precision along with their creative and skilled operators. This technological innovation reduces the physical and mental load on the workers, thus creating more engaging opportunities for them. This is a win-win situation where work itself becomes more appealing for workers, reduces the ideal time taken, increases productivity of the product and consistently leads to lowering the cost of production without compromising on the quality. Industrial robots are usually preferred in large manufacturing plants for activities like assembly line, dispensing, welding and even processing. For years manufacturers have been weary of implementing such robots simply because of safety concerns and also because

AUGUST 2016 | www.engrreview.com

they are space consuming, heavy and expensive, especially considering the fact that they require a safety cage or enclosure to avoid any contact while co-working with humans. Human and robot system interaction in industrial settings is now possible thanks to ISO/TS 15066, a new ISO technical specification for collaborative robot system safety. The certification legitimizes these robot systems or Cobots and ensures that they are properly safeguarded. UR robots were also the first on the market that enabled small and medium companies to automate. UR robots give companies of any size the flexibility for production processes of every type that are so indispensable today. Among other things, they can be operated by any employee - and not just by experts or specially trained personnel. The combination of attractive prices, simple programming, flexibility, and the shortest payback time in the industry - with an average of 195 days - makes us so successful. India has one of the lowest penetration levels by robots in the automation of manufacturing facilities, but there have been heavy investments for larger robots, especially in the automotive sector. However, the features of lower costs, more flexibility and higher number of applications would help increase the sales of co-bots and their diversification into various industries other than automotive and packaging. UR robots were not developed to replace people, but to combine the abilities of people and machines. Therefore, the robot takes on the role of a tool which can be applied universally and supports people to accomplish high precision, repetitive or burdensome tasks. The way we see it, the current changes and shift in manufacturing must lead to a result wherein people and machines both do what they can do best. The weakness of one is compensated by the strength of the other - and vice

By Pradeep David, General Manager, India Universal Robots

versa. Consequently, people will still be needed on the factory floor in the future. There is a need for a different thought process and a move away from traditional means, in terms of the applications of co-bots, as they are being explored by several industries and will enable mankind to walk into a futuristic working environment. First, we do not intend to waste creativity and talent by performing time-consuming, monotonous or potentially unsafe activities that are ought to be done manually. Secondly, working procedures which require high accuracy and power, such as manufacturing, and other automotive industries which include activities like pick and place, injection molding, palletizing, CNC, packaging, assembly, polishing, painting, machine trending, gluing and also dispensing, process application, board handling, screw application and welding, will be directed with an accuracy and unwavering quality which could never be accomplished by a human.

114 REFLECTIONS >WELDING

Industry’s response to

AUTOMATION

is lukewarm: Satish Bhat

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

Q. What’s your area of Specialization in Automation? ADOR Welding Limited offers standard and customized Automation solutions for different types of Industries, like Ship building, Power Process, Automotive, Heavy Fabrication, Infrastructure and road building, structural work, pipe and pipe mills, wind turbine manufacturing, conveyor roller manufacturing etc.

The wide ranges of ADOR Products include: 1) Standard welding automation products: • Column & boom • Welding positioners

AUGUST 2016 | www.engrreview.com

• Welding rotator • Trolley for linear GMAW welding (MIG AUTOMATION) • Trolley for circular shell welding (MIG) • Fume extractor

2) Application wise customised products: • • • • • •

Square axle welding SPM Robotic welding H beam welding SPM Idler roller welding Cylinder welding SPM Weld Seamer

3) Multi-level automated welding lines: • H beam fabrication system comprising of CNC cutting machine for 3.5 – 15 mtr profile cutting (1+8 oxy fuel); H beam assembly machine; Flange & web Assembly and Tack welding with MIG process; H beam full joints welding with SAW process; Beam conveying, turning & tilting arrangement through Beam rotation & transfer; Beam straightening machine for straightening of the flange with respect to the web • Twin head welding gantry comprising of welding gantry for idler roller welding; Vision system to observe the process and provide

REFLECTIONS >WELDING 115

correction feedback; 5 Ton capacity Rotator for job rotation

Q. What are the latest trends in automation in your domain? The latest trends in Welding Automation are developments in HNG SAW, HNG MIG, Tandem MIG / SAW, Friction Stir, Electron Beam, Saddle Welding Automation, Robotics, Laser spot welding, Hot wire TIG, Orbital systems, Automation with hybrid welding systems like Plasma – MIG, Laser – MIG and major advances in the cutting processes (Precision Plasma, Laser Cutting, Water-jet cutting etc.). ADOR Welding is actively involved in absorbing the advanced technologies and processes through state-of-the-art in-house R & D set up, technical collaborations, mergers and acquisitions etc.

Q. What are the benefits of automation to the end-user? • Consistency in weld result - Error Proofing: A welding supervisor can limit the amount of changes an operator can make during a program, preventing him from accessing the override screen through the use of a key switch or password. • Multiple parameters for multiple weld-run: In addition to the ability to adjust parameters between weld passes, operators of microprocessor-based welding machines can also program changes to weld parameters during each pass, which offers distinct advantages for certain applications. • Store parameter for sharing on other machines with same applications: A microprocessor-based power source can store programmed welding procedures on data cards. This allows the operator to easily transfer programs developed on one machine to other machines being used either in the same facility doing the same type of work. • Quality control: Microprocessor-based machines can immediately alert the operator if weld parameters fall outside pre-selected limits. Parameters can be directly to a quality-control computer program for storage or statistical analysis. This eliminates time-consuming radiography in many applications.

• Date storage and records: It is now very easy to display a set of welding parameters and operator or supervisor can observe the welding procedure. Moreover, the data can be printed in the form of reports, which can be presented to the customer as quality assurance procedure. • Quicker Weld-Fault diagnostics – lower repair time: The system can be stopped if the measured values cross a certain preset variation limit. It is possible to stop the machine in out-of-tolerance conditions. This enables the operator to perform timely functions and take necessary steps to prevent the deposit of faulty welds.

Q. How does the user industry react? Is there inertia in switching to automation for reasons other than the investment involved? The response from Indian Industries – especially the medium and small scale ones towards Automation is still lukewarm, due to the availability of skilled welders at low wages. But the rising labour costs are driving these industries towards nominal, low-scale partial automation. It is this area where ADOR has a major advantage over many others, having an elaborate team of designers, welding process specialists, application engineers, and their own advanced welding power sources to complete the whole package of jigs, fixtures, handling arrangements, weld torch manipulators and welding power sources, backed up with the abundant range of high quality and productivity welding consumables to suit any process, productivity norms and most stringent quality demands. ADOR is capable of offering low cost automation, specifically customized for the end-user requirements, which not only calls for minimal investment in terms of capital purchase, but extremely high ROI in terms of enhanced productivity, quality and minimizing rejections.

Q. Are we in step with the world by using contemporary technologies? In fact, to achieve the perfect qualities and higher levels of productivities, most manufacturing processes involving metal joining and

cutting are moving towards Automation, partial or complete process lines. Complete Robotic Work cells (unmanned) with intelligent handling, vision control and anti-collision systems have been developed both for automobile as well as other heavier fabrication industries like shipbuilding, heavy structural fabrication etc. In addition to enhanced performance characteristics, the ability for direct digital control has also markedly expanded the automation possibilities of difficult welding processes. This direct control allows these supplies to become an integral part of the complete system and all of their capabilities to be accessed and controlled from a single controller. With the ability to enable/disable the supplies, change modes between DC and AC, vary current, voltage, and AC phasing, all based on part or torch position, automated continuous root-to-cap multipass welds are achievable. Waveform Control Technology® is adapted for Root Pass MIG and submerged arc welding. The power supplies provide constant current or constant voltage operation and allow variable frequency and amplitude for AC output. The software-driven AC, DC-positive or DC negative output allows the user to control the deposition and penetration. The result is a more consistent, smoother arc at a wider range of parameters, increased weld speeds, consistently higher-quality welds, and improved efficiencies in a single- or multi-arc environment. The sophistication of the software based inverter design allows a significant ability to be integrated into an adaptively controlled dynamic system required for the challenging narrow groove environment. Newer, more advanced power sources and seamless integration into the overall narrow groove system architecture have dramatically enhanced the operating envelope and flexibility of the welding process. It is important to note that the efficiency of these inverter-based power supplies yields significant savings in operating costs over traditional transformer/rectifier designs. In a typical industrial operating environment fabricating pressure vessels, each machine can potentially save up to 7,00,000 per year in operating costs due to its unique design and use of energy- efficient, high-speed inverters.

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116 TECH TRENDS

WELDING

AUTOMATED WELDING

An Imperative for Competitive Advantage

he shortage of skilled workers is no surprise to anyone in the manufacturing sector. You may be just reading about in the headlines or see discussions about it on the nightly news, but we live it. Statistics from the Manufacturing Institute state that thousands of manufacturing jobs are going unfilled in India and the rest of the world simply because employers are unable to find candidates with the right skill sets for the open positions. The association also reveals that 75% of manufacturers attribute this skills gap as hampering business expansion efforts. Two of the biggest areas with jobs going unfilled are machining and welding. At ADOR Welding Limited, there is a fully equipped Welding Demonstration Centre at the Equipment Plant in Pune, where there are frequent visits from manufacturers. They come to our facility to see what automated welding is all about. They visited to assess whether or not automation could solve not only their production and throughput issues but also their hiring challenges. In many cases, these individuals walk away with a game plan to improve their productivity and quality, and fill empty positions. And, automated welding is at the heart of that plan. In fact, to achieve the perfect qualities and higher levels of productivities, most manufacturing processes involving metal joining and cutting are moving towards

AUGUST 2016 | www.engrreview.com

Automation, partial or complete process lines. Complete Robotic Work cells (unmanned) with intelligent handling, vision control and anti-collision systems have been developed both for automobile as well as other heavier fabrication industries like shipbuilding, heavy structural fabrication etc. Narrow Gap MIG, TIG and SAW systems are invariably fully automated with multi-axis motion controls, seam tracking, intelligent arc control, and capable of rolling out a variety of parts with the touch of a fingertip to change the job program number. Wind Tower fabrica-

tion, ship building, pressure vessel fabrication, pipe lines â&#x20AC;&#x201C; all are industries moving heavily towards these processes. Fully automated laser stitch and spot welders will come largely in application in the thin sheet fabrication in automobiles and aircrafts. Friction Stir Welding Automation is another exciting automated process which can weld a wide variety of thicknesses using the same outfit â&#x20AC;&#x201C; 1.2 to 25 mm in one-sided welding and up to 50 mm in two- sided welding. This process does not require any filler material, as most environment friendly as it does not give out any

TECH TRENDS 117

ADOR Welding Limited offers standard and customized Automation solutions for different types of Industries:

welding fumes or toxic chemicals to the air. Hot Wire TIG Processes is now replacing MIG in many automated applications for vertical cladding (internal and external) anti-corrosion weld overlay cladding of manifolds for petrochemical and gas industries

Standard welding automation products: • • • •

Column & boom Welding positioners Welding rotator Trolley for linear GMAW welding (MIG AUTOMATION) • Trolley for circular shell welding (MIG) • Fume extractor

MULTI-LEVEL AUTOMATED WELDING LINES H BEAM FABRICATION SYSTEM Comprising :

TWIN HEAD WELDING GANTRY Improving quality through automation – Robotic Cells

Quality also is a determining factor in the decision to automate the welding process. An example is a manufacturer who has welded the same part for 20 years. The company has been spending close to large sums per month as people’s salaries, just to grind spatter off the part and change out filters in a paint system. A customized robotic welding system incorporated in the same factory was able to provide stable, reduced-heat, short-arc pulse. Within hours of getting the parts into the robotic cell, the company was welding parts with zero spatter. Companies don’t usually talk about scrap and quality issues freely, but they are real. In manual welding, if you run into an issue and can’t solve it, you have to shut down the entire process and do touch-up. And for the manufacturers who don’t accept touch-up on parts, if a problem is detected halfway through production, those parts will become costly scrap. With robotic welding, there is a much simpler solution in a program known as production monitoring. There are systems that deliver real-time welding system monitoring. Beyond production monitoring capabilities and crucial alerts, robotic welders also have another benefit when it comes to quality– easy access to all angles of a semi-complex or complex part. Because the part can be rotated,

ITEM

APPLICATION

CNC CUTTING MACHINE FOR 3.5 – 15 MTR

PROFILE CUTTING (1+8 OXY FUEL)

H BEAM ASSEMBLY MACHINE

FLANGE & WEB ASSLY & TACK WELDING WITH MIG

H BEAM FULL WELDING

FULL JOINTS WELDING WITH SAW

BEAM CONVEYING, TURNING & TILTING A RRANGEMENT

BEAM ROTATION & TRANSFER

BEAM STRIGHTENING MACHINE

STRAIGHTENING OF FLANGE WRT WEB

Application wise customised products • • • • • •

Square axle welding SPM Robotic welding H beam welding SPM Idler roller welding Cylinder welding SPM Weld Seamer

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118 TECH TRENDS

ITEM

APPLICATION

WELDING GANTRY

IDLER ROLLER WELDING

VISION SYSTEM

TO OBSERVE THE PROCESS AND PROVIDE CORRECTION FEEDBACK

ROTATOR: 5 TON

JOB ROTATION

the operator can program the robot to access sections of it that can’t be reached manually without stopping to reposition it. This 360-degree view and access facilitates quality welds and increased production.

Automation helps fill the skills gap As the economy changes and the workforce changes, the primary reason why people automate also changes. In today’s environment, manufacturers are turning to automation on the production floor to fill jobs and provide the productivity and quality required to keep North America competitive. Last year, when manufacturers were enjoying increased sales, they turned to automation to get more product made. Today, they are doing it because they are having trouble manufacturing parts, period. Why? Because they just can’t find trained welders. When you can’t find qualified welders, robots make sense. You can make different parts without needing to find people simply by changing out cell components. Additionally, when you automate, the person who oversaw the welding in that cell remains there and works closely with the technologist or engineer who oversees the programming and work environment of that robot. You do bring in people, but you train them to a higher skill level. Many traditional welders are more than capable to be trained as technologists or even as engineers. In some ways, automation gives manufacturers a new way to invest in people. In a typical fiveyear cycle, you incrementally boost production and move people up in the organization, while improving sales.

Not “if,” but “when” For manufacturers who have not yet incorporated robotic welding cells into their production line, the question truly isn’t if they should pursue automation, but when. Automation of any sort provides the competitive advantage North America needs to remain relevant in the manufacturing segment. Manufacturing is the engine that will spur economic growth, automation is a key cog in manufacturing, and welding remains a critical cost driver to support manufacturing. Robotic welding is a critical component to improving productivity, efficiency, cost, and quality. Investing in our workforce through education, training, and automation will help maintain the dominant position the United States has held for the last century. [Courtesy: Ador Welding Ltd.]

AUGUST 2016 | www.engrreview.com

120 TECH TRENDS

ENGINEERING

Loading Dock Design

he loading Dock is a key component of any facility, whether it is a warehouse, grocer, retail outlet, plant, or other material handler. Through a variety of equipment loading docks can speed up traffic and capture costs that add up if left unattended. With careful planning many of the risks and expenditures associated with a design lacking proper safety features can be alleviated. Improving dock function, employee safety, and effective transfer of goods from your facility to its intended destination should be a primary concern of all conscious business owners and purchasers. Common problems on the loading dock are often rooted in initial design elements which do not take into consideration future dock uses or the evolution of manufacturing and production. Often times docks will have poorly planned approaches, small doorways, excessive slopes, gravel approaches, improper bumper projections, and docks that are too low to accommodate any standard over the road trailers. By planning for the future steps can be taken to safeguard against large remodelling costs later. The initiation of future planning can take many forms, whether that is installing knock out panel walls for future door expansions, or building your dock to standard height and using wheel risers for smaller trucks. These simple inexpensive concepts can save you and your customer’s time and money further down the road. Due to the diversity and variations that may exist at the loading dock, any specification, drawings or other material pertaining to the loading dock should be developed and approved by an experienced professional architect and reviewed by an experienced loading dock professional. Follow best practices for compliance to traffic engineering conventions in design to meet state and local codes. It is important to include in the specifications of any project that the selected manufacture must provide; specifications, approval drawings, installation manual(s), owner’s manual(s) and employee equipment training, to the owner.

AUGUST 2016 | www.engrreview.com

SAFETY MATTERS Despite the loading docks potential to save money it has exponential safety risks which can cost your company in excess of one million dollars from direct and indirect costs. Financial hardships affect your tenants, customers, employees and bottom line, for this reason aggressive dock safety practices are considered good business sense. Note: It is the employer’s responsibility to ensure proper training and operating practices of their employee’s.

APRON SPACE The approach leading up to a bay door, known as the Apron Space, is an area necessary for trucks maneuvering into position at the loading dock opening. When planning this extension of your dock recognizing the needs of current and future potential freight is fundamental to the long term viability of the facility. Factors to consider are the direction of traffic flow, total vehicle lengths received, and materials used for the landing and leading up to the dock. A simple guideline for determining apron space is to take the sum of the longest possible combination of truck and trailer and multiply the total length by two, then adding an additional safety factor of 5’0” to 10’0” on the

outcome. (i.e. a truck with an overall length of 70’ requires a minimum apron space of 150’). Keep in mind that a dock receiving box trucks and trailer jockey trucks today may not be using these in later years. Always consider long term construction in order to avoid costs in later years. If the apron space is to be surfaced with asphalt, a concrete landing strip must be poured. This is necessary due to asphalts tendency to become malleable under heat, resulting in depressions changing your truck differential to the dock. This is a serious problem which can make a leveler or board ineffective as well as making it difficult to properly secure wheel risers due to uneven ground. A gravel-covered loading dock apron should be avoided because it creates uneven and unsafe dock conditions. Note: unless the loading dock is designed to handle peak traffic loads, space must be provided for a truck waiting area. This should be situated so as not to impede the movement of trucks positioning for docking and leaving the facility.

TRUCK BAYS Truck bays are a complicated portal requiring many pieces of equipment in order to operate safely and efficiently. Factors which ensure the safe function of those pieces of equipment is relative to dock door displacements from each other as well as adequate staging space within the facility. For docks with multiple loading bays door displacement is crucial to effective loading and as a deterrent to bottlenecking from cramped staging areas. Typically the minimum displacement for doors is 12’ on center of the opening. This provides an overall truck width of 10’

TECH TRENDS 121

including the mirrors. With greater displacements loading is made more economical, safer, and easier. When determining the number of loading bays needed to support your product flow, consider the number of trucks received per day, delivery schedules, how many pallets can be loaded or unloaded per hour at one opening, and the number of trailers typically staged at your dock. Bottle necks inside and outside your facility should always be avoided. Bottlenecking within your dock is the result of too little space for staging; this causes blind spots and reduces the mobility of your loaders, increasing safety risks and lowering productivity. Outside your dock on the apron, bottlenecking occurs when trucks are staged for loading without adequate room for safe departure of other trucks leaving the facility. Another form of restriction from bottlenecking occurs when there is not enough room on the sides of the trailer to safely turn out away from other trucks on the

Dock Bumper

apron. By utilizing a 14â&#x20AC;&#x2122; door differential trucks can safely and effectively exit and couple with the loading dock. This also provides additional space between doors for staging.

DOCK APPROACH Level dock approach The most effective approach grade for a loading dock is approximately a 1%-2% incline. This puts the top of the trailer further away from the wall, while also channeling water runoff away from the facility and your product. (Note: when raising the nose of the truck to couple with a tractor the grade is changed, the dock bumper projection must be able to accommodate this change in incline)

DOCK TYPES Cantilever Loading Dock Design In a cantilever loading dock design, the foundation wall (dock face) projects past outside building wall. This can prevent damage to the building wall, should a dock bumper fail.

Enclosed Loading Dock Design This design often used by package handlers utilizing fleets of box trucks, allows for control against pilferage while improving efficiency and comfort; it also doubles as space for overhead cranes loading/unloading flat bed trucks. It is the most expensive loading dock design requiring greater initial investment and maintenance. A main concern for this type of dock is the need for ventilation, adequate air-exchange, due to the exhaust fumes of motors operating within.

Flush Loading Dock Design The most common type of loading dock used today is the flush loading dock. This dock shares the same foundation as the wall. When the building wall projects past the foundation

due to the use of metal or other finishing material, dock bumper projection must be considered more closely; i.e. bumpers should always

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122 TECH TRENDS

be a minimum of 4.5” from the wall, if the wall projects 1” past the foundation where bumpers are mounted, then the bumper will need to have at least one more 1” of projection.

TRUCK TYPES

Type of Truck

Truck Bed Height Total Range

Double Axel Semi

45” - 55”

City Delivery

45” - 48”

Trucks come in a wide variety of heights, overall lengths and bed heights. The above general information about truck can aid in designing the loading dock, it is best to remember that each of the above truck heights can vary as much as 6” to 8” (12” if air-ride trailer suspension) in height from empty to fully loaded, this is know as “float”. When designing the dock it is a good practice to ask the client for a list of trucks serviced at the loading dock; i.e. height, width, overall length, bed height and frequency that they arrive at the loading dock. If a wide variety of trucks are to be serviced it may be practical to have several dock heights or one (1) dock position dedicated with a dock scissor lift or a truck leveler to accomplish this. If it is a standard captured fleet (all trucks are the same width, length, height and bed height), then one (1) dock height can possibly serve them all.

Container

55” - 62”

DOCK HEIGHT

Flatbeds

47” - 62”

Optimal dock height plays a critical role in providing smooth product transfer...The following selection criteria must be considered for a

Furniture Van

23” - 36”

High Cube Van

35” - 43”

Low Boys

19” - 25”

Panel Truck

19” - 25”

Reefer

50” - 60”

Stake Truck

42” - 48”

Step Van

19” - 30”

Straight Semi

48” - 52”

AUGUST 2016 | www.engrreview.com

proper loading dock height. • Service range of the variety of trucks to be service and mid-point. • The maximum grade capability of your client’s material handling equipment, consistent with dock leveler and board length. • Dock leveler and board length that can accommodate the height difference from dock to truck, and truck/trailer “float” during loading/unloading. The average loading dock height is between 48” and 52”. Many facilities may have more specific qualifications for their loading docks which can put them above or below this level. When considering your client’s application determine the highest and lowest truck received, in addition find the average truck bed height (note whether the trailers are refrigerated or not). If the differences in dock height are too great to service all traffic consider options such as wheel risers. This allows a dock to receive standard trailers at a 48” dock height and box trucks which would come in below the operating range of many Dock levelers. Knowing the maximum grade capability of your material handling equipment can help determine the dock height and dock leveler length. The maximum grade capability of a pallet jack is 3%, electric pallet jack 7%, electric lift truck 10% and gasoline fork tucks is 15%. When planning the dock height always try to strive for the least incline/decline approach to load/ unload the vehicles that arrive at the dock, this will provide a longer life for the material handling equipment and the dock leveler.

For more information www.elitematerialhandling.com

The author is CEO at Elite Material Handling Co., based in Bangalore. Elite is one of the foremost companies in the field of materials handling with a reputation spanning over six decades. The company has a wide range of time-tested products proven in all fields. By Manpreet Sachdev

TECH TRENDS 123

ENGINEERING

High-Performance Robots Thanks to

ENCODERS with EnDat 2.2

Robots are only as productive as their controls and components allow, and transforming this simple wisdom into specific products requires a wide range of expertise. Itâ&#x20AC;&#x2122;s for this reason that the Italian manufacturer Comau places its trust in encoder solutions with EnDat-2.2 interfaces from HEIDENHAIN for its new robot control and 3-D laser system. As a result, users now have the handiest control currently available on the market and a high-precision, dynamic laser system for mid- to large-size robots.

The new C5G control

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Interface

Highest degree of variability. For each application purpose.

MENNEKES Electric India Ptv. Ltd. No. 2 D, Dhanakottiraja Street Ekkattuthangal 600 097 Chennai – INDIA Tel. 044 222 535-61 / -62 / -63 Fax 044 222 535-65 | info@MENNEKES.in

“AMAXX DUO provides switched and interlocked safety as multiple distributor.”

126 TECH TRENDS

Integrated design of the Smart Laser system for 3-D laser welding

omau Robotics & Service, a subsidiary of the Comau Group, develops and produces robot cells for welding, handling and palletizing in addition to several other products. These robots are used in a wide diversity of industrial applications, and technologically superior solutions are needed to set themselves apart from the wide spectrum of other robot manufacturers. As a consequence, HEIDENHAIN encoders equipped with the bidirectional EnDat 2.2 interface are used on the new C5G robot controls and 3D SmartLaser laser welding systems.

Completely updated The new C5G control has been completely reworked from its previous design, and upgrading to a new generation of inverters meant that the encoders had to be re-specified as well. A further reason was that previously used encoders not always fulfilled expectations in terms of reliability. The new C5G robot control brings together the expertise of three companies: Software developed by Comau for controlling the robot axes and technological processes, position encoders with EnDat 2.2 digital interfaces from HEIDENHAIN, and the B&R hardware platform. The result is a product with extremely high innovation. With its compact design, the C5G is currently the handiest robot control for mid- to large-sized robots, and compared to the previous model has improved performance, higher processing power, superior reliability and reduced energy consumption.

Absolute rotary encoders with EnDat 2.2 The ECI 1118 range of absolute rotary encoders from HEIDENHAIN with inductive operating principle for generating absolute serial signals has proved to be the ideal solution for this appli-

The ECI 1118 rotary encoder

AUGUST 2016 | www.engrreview.com

cation. 262,144 positions per revolution (18 bit) can be measured with the ECI 1118 absolute singleturn rotary encoder, and this high resolution guarantees controllability of the drive system at all speeds. Oscillations in control loops are also reduced to a minimum. Thanks to its modular design with no ball bearings, coupling or transmission, the encoder has a very short construction length of only 12.3 mm with an outer housing diameter of just 36.83 mm. Singleturn scanning without additional mechanical components also improves resistance to shock and vibration loads. As a result, the low-noise rotary encoder is predestined for use in highly dynamic, compact servo motors for automation technology and industrial robots. The ECI 1118 rotary encoder is equipped with the EnDat 2.2 digital interface. This purely serial interface permits fast and secure data transmission at clock-pulse rates of up to 8 MHz for high drive dynamics, even in environments with potentially high electromagnetic interference potential. The scanning signals are digitalized directly in the scanning head and

calculate a position value with high resolution that is transmitted synchronously to the clock signal set by the subsequent electronics. In addition to the position value, the signal also provides supplementary information (temperature specifications and performance reserves for example) and enables monitoring and online diagnosis of the encoder. With a greater voltage range of 3.6 V to 14 V, there are also no problems caused by voltage drops in longer cables. A further benefit of the digital EnDat 2.2 interface is that evaluation numbers can be called during drive operation without sacrifices to the performance of the control. The diagnostic system generates error messages and warnings and therefore makes an important contribution to ensuring the availability of the overall system.

3-D laser system completes the product spectrum To round off its portfolio, Comau Robotics & Service has also completely upgraded its 3D SmartLaser laser welding system, equipping

128 TECH TRENDS

The LIC 4017 exposed absolute linear encoder is used for feedback operation with the four linear motors controlling deflection of the laser beam in the new 3D SmartLaser laser welding system

The new ECA 8412 is based on the functional principle of optical linear encoders without integral bearing

these with HEIDENHAIN encoders. The patented system consists of a laser source with focusing module that is set completely without robot motion, achieving a laser welding system uniting the agility of a robot with the outstanding performance of extremely precise laser technology, while being controlled merely by the C5G. The 3-D laser system also features very good dynamic characteristics over its complete range of operation. Positioning the system is via a linear motor that can be accelerated up to 8 g, and repositioning the Z axis is therefore 10 times quicker than with standard robots, which in turn achieves extremely low cycle times (only 11 s for welding a vehicle door for example). The laser beam is deflected (in X and Y) by positioning lenses and reflectors, and these are operated via direct drives with speeds in excess of 1000 m/min. With linear motors there is principally no additional rotary encoder for measuring the speed, and position and velocity are therefore determined through the position encoder. Linear encoders that generate a high-quality position signal with only small interpolation error are therefore essential for the meaningful operation of linear drives. Encoders that use photoelectric scanning such as the LIC 407 linear encoder are particularly suited for this

AUGUST 2016 | www.engrreview.com

task since very fine graduations can be used as measuring standards by this method. These encoders provide benefits in the positioning, speed stability, and thermal behavior of linear drives, and absolute position value calculation and the associated availability of the position value immediately after encoder switch-on are further positive features. As a consequence, Comau Robotics & Service took the decision for HEIDENHAIN’s LIC 4017 exposed absolute linear encoders, with these being installed on the four linear motors regulating deflection of the laser beam. A resolution of 1 nm and accuracy of up to ±5 μm together with a maximum traversing velocity of 480 m/min provide the laser beam focusing system with the required dynamics and precision. The two ROC 425 absolute singleturn rotary encoders with 25 bit resolution and the ECA 8412 angle encoder have the task of guiding the laser beam onto the workpiece in the remaining two axes. The ECA 8412 exposed angle encoder with segmented geometry and absolute position measurement was used as a prototype in this project to achieve overall consistency with EnDat 2.2.

The outlook For HEIDENHAIN, the project reflects the successful application of a diversity of encoders together with EnDat 2.2. The next step is cur-

rently being implemented—the manufacturer from Traunreut in Southern Germany will soon be presenting encoders with functional safety and mechanical error elimination for coupling, products that will also provide the Comau robots with a further development boost.

High-precision encoders for sophisticated positioning tasks DR. JOHANNES HEIDENHAIN GmbH develops and manufactures linear and angle encoders, rotary encoders, digital readouts and numerical controls for demanding positioning tasks. In addition to automation technology applications, products are used primarily in high-precision machine tools as well as in plants for the production and processing of electronic components. Since 1948, when the company began anew in Traunreut, HEIDENHAIN has shipped over 5 million linear encoders worldwide, over twelve million rotary and angular encoders, almost 470,000 position displays and nearly 240,000 TNC controls.

By Abhilash Tripathi, Associate Director-Sales & Service, Heidenhain India

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EtherCAT P with a wide range of IP 67 I/O options

Minimised cabling and assembly costs at the field level

he extensive IP 67-rated I/O range available for EtherCAT P minimises wiring requirements and facilitates the highly flexible, decentralised data acquisition of all I/O signals in a machine or system. It is based on the one-cable solution EtherCAT P, which integrates proven EtherCAT technology with a power supply for connected devices. With EtherCAT P, Beckhoff combines ultra-fast EtherCAT communication and power supply (2 x 24 V DC/3A) in a standard 4-wire Ethernet cable. It enables direct power supply for both EtherCAT P slaves and the connected sensors and actuators in such a way that separate power lines can be eliminated, considerably simplifying system cabling. This makes EtherCAT P the ideal sensor, actuator and measurement bus, providing advantages both for connecting small remote I/O stations in terminal boxes and for decentralised I/O components located throughout the actual process.

Flexible choice of topology

components in protection class IP 67 is currently available for the 24 V I/O level. For connecting sensors and actuators, users can integrate any of the wide range of well-established EP Box modules from Beckhoff in the new EPP versions for EtherCAT P. These include a variety of 4, 8 and 16-channel digital input box modules; 4, 8, 16 and 24-channel digital output modules; numerous 4, 8 and 16-channel IP 67 I/Os with combined digital inputs/outputs; as well as RS232 and RS422/RS485 serial interfaces. There are also new EPP Box modules for analog input and output quantities, such as ±10V/0...20 mA, differential/absolute pressures, and data from resistance sensors, thermocouples and incremental encoders.

A full range of EtherCAT P system and I/O

Free and flexible choice of topology, as enabled by EtherCAT, is equally possible with EtherCAT P. The following IP 67 infrastructure components are available to set up the required network architecture in the field: • EPP1111 EtherCAT P Box with ID switch • EPP1322 EtherCAT P junction with power feed-in and junctions with or without power refresh (EPP1332/EPP1342) • EPP9001 EtherCAT P/EtherCAT connector

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with power transmission • EPP9022 EtherCAT P Box for diagnosing Us (system and sensor supply) and Up (peripheral voltage for actuators)

Significant benefits for machine engineering applications EtherCAT P – which is now fully supported by the EtherCAT Technology Group (ETG) – reduces material costs for machinery, time and cost of installation as well as the frequency of errors in the installation process. In the machine itself it also minimises the installation space required for drag chains, cable trays and control cabinets. The entire automation process benefits from the reduced size of sensors or actuators, made possible by the new EtherCAT P cables. Overall, equipment manufacturers now have considerably more freedom when designing their machinery and more leverage to reduce machine footprint.

For more information Web: www.beckhoff.com

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Rollon: pick-and-place system delivers improved

PRODUCTIVITY & SAFETY D

eciding between a gantry and a robot for your application isn’t always as clear-cut as it may seem. To automate a simple, yet time-consuming and potentially dangerous task in its factory, a company that makes particleboards weighed the benefits of using a gantry system against a robot system.

ROBOT OR GANTRY? Chicago Electric was approached to design an automation system for stacking the metal screens used to make particleboards. These screens are stacked at the end of the process and sent back to the beginning for reuse. For some time, two workers stood on opposite sides of these screens to carry and manually stack them one by one. This tedious process put its workers in harm’s way and the company decided it was time to bring automation into the mix. “After considering important factors like cost and efficiency, we chose a gantry system instead of a robot,” said Bob Kaska of Chicago Electric. Using a gantry requires less maintenance than a robot since it only uses two motors instead of six. This application’s long reaches at high capacities are easier to achieve with a linear actuator than a robot system. In addition, its range of motion and weight of the product would have made robotics a much more costly solution – at least twice as expensive as the gantry solution. Built around a pair of mating Rollon actuators, Chicago Electric designed an X-Z gantry system to stack the metal screens, allowing workers to use their time and expertise in other areas. “The system’s primary motivator was safety,” said Kaska. “The task involved repetitive motion and the coordination of two

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TECH TRENDS 133

the required amount of weight. The SC-130, part of Rollon’s PLUS series, mounts directly onto the R-SMART unit without an adapter plate. This actuator also features high capacity and increased rigidity. Another important characteristic of the SC-130 is its stationary carriage and moving extrusion. By contrast, most other Rollon products have stationary extrusions and moving carriages. This feature makes the actuator a good choice for vertical applications like the new gantry system for particleboard screens.

people. It required the operators to be in close proximity to moving equipment to place the screen header on a moving sheet.”

RELIABLE LINEAR ACTUATORS FOR THE JOB. Finding an actuator to meet all the requirements of your application can be a challenge. Some things to consider when selecting the right actuator are accuracy, repeatability, capacity and travel length. For this gantry system, Chicago Electric chose Rollon’s R-SMART 160 and SC-130 linear actuators. With a carriage made from machined anodized aluminum, the R-SMART 160 uses a dual linear guide – rather than a single linear guide – to provide high moment load capabilities and properly handle

PICK-AND-PLACE SYSTEM FOR REDUCED CYCLE TIME. The X-Z gantry system that Chicago Electric designed is a pick-and-place system that reduces cycle time from 30 to 15 seconds, while also improving safety. This fully automated pickand-place system travels 3.7 m horizontally and 1.2 m vertically to stack the metal screens. The system’s X-axis has speeds of 1.3 m/s and a force of 270 kg. Its Z-axis has a stroke of 122 cm and force of 224 kg. Also on the Z-axis, the gantry is fitted with a heavy duty magnetic tool that flips on once the tool comes down. Chicago Electric’s pick-andplace system also features a 1.27 cm header bar that’s engaged by a chain conveyor and used to connect the steel screens.

AUTOMATION 2016 –

EXTENDED LIFE OF THE SYSTEM. Rollon engineers determined the Z-axis moment on the R-SMART would be the limiting factor in this X-Z gantry system. With a maximum speed of 1.5 m/s, acceleration of 33 g and 1/3 factor of safety, this actuator has an Mz of 1192 Nm, which falls well within the limit of 5707 Nm. Rollon performed a life calculation to find

out how long the system could last and discovered that it could last up to 21 years. This number comes from the assumption that the system would complete an average of four cycles each minute for 16 hours per day over a 360-day period. In reality, however, the system is only used a few times each week. For more information Web: www.rollonindia.in

www.engrreview.com | AUGUST 2016

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IGLIDUR HSD350: New high-performance plastic for continuous use in steam Free of lubrication, maintenance and corrosion, the new igus material introduces itself as a low priced alternative to metallic options

utoclaving is one of the most important methods for killing bacteria during the production of foodstuffs, medicines and in the cleaning of medical products. In the standard method, heating to 121°C at 2 bar takes place in the pressure vessel for 15 to 20 minutes, or to 134°C for 2 to 3 minutes at 3 bar steam pressure with particularly resistant bacteria. A challenge for the individual parts of the machine, as well as for the bearing. For metallic bearings a special autoclavable lubrication is often necessary. However, the sterilisation affect is reduced significantly for product that use grease. Therefore polymer bearings are offered as a lubrication-free and maintenance-free alternative, whose materials are resistant to heat, pressure and moisture.

The iglidur HSD350 material is the new allrounder for use in hot steam sterilisation: Low priced, corrosion-proof and maintenance-free. (Source: igus GmbH)

As standard and as a customised special part An all-rounder in the igus product range is iglidur HSD350, which is suitable for the hygienic continuous use even for regular sterilisation. The new material can withstand temperatures up to 180°C continuously and temporarily up to 210°C. Because of the corrosion-free property, iglidur HSD350 is ideal for use in wet areas and displays a low moisture absorption and thermal expansion there. The new material also proves to be extremely resistant to media and doesn’t get ruined even in hot steam sterilisation. This provides the customer with the opportunity of designing bearings and joints so that perfect cleaning results can be achieved in more complex, non-separable units. iglidur HSD350 is now available from a quantity of one piece and available for immediate delivery from 24 hours.

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ABOUT IGUS : The igus GmbH is a world`s leading manufacturer in the field of energy chain systems and polymer plain bearings. The family-run company is based in Cologne, represented in 29 countries and contracts 2,200 employees worldwide. In 2012 igus generated a turnover of 399 million Euro. igus operates the largest test laboratories and factories in its industry to offer customers innovative and tailor-made products and solutions within the shortest time.

For more information, Website: www.igus.in

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Testo AG ‘s all round solution for the

HVAC/R SECTOR After intensive research and development work, Testo AG has now reached its target to provide an all round solution to the HVAC/R sector by introducing first of its own set of electrical measuring instruments, backed by latest German technology

ith this launch, the company tries to provide uniquely different solutions with advanced features to their customers. These intelligent electrical measuring instruments from Testo makes it possible for the users to carry out their daily measurement tasks more easily, safely and efficiently than ever before. In contrast to many products in the market, the measuring instruments from Testo show many differentiating benefits and an excellent price-performance ratio. Added to this is the advantage, that with 12 products, Testo India completes its basket of necessary tools for measuring needs of HVAC/R.

Making HVAC/R measurements easier The market for electrical measuring instruments today already offers a multitude of solutions for many different measurement parameters. This is the reason why Testo did not want to simply launch yet another measuring instrument on to the market, but to provide a real added value for the target group. In particular, Testo wants to provide innovative technology to enable efficient working of HVAC/R sector than with existing measurement solutions. The new instruments are extremely user-friendly: they are easy and intuitive to use, save many work steps, offer the highest level of safety, and are suitable for various applications.

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Five product families Testo is launching a total of five product families for all important measurements on electrical appliances and systems. These include a digital multimeter in three versions, which automatically recognizes the measurement parameters by socket use, and which can be more safely operated using function buttons than with the usual rotary dial. Three clamp meter models with a unique clamp mechanism for measuring tight-fitting cables. This allows current cables to be grabbed precisely. It is available with two current-voltage testers which fulfil the newest voltage tester standard, and allows selection of measurement parameters automatically and without the danger of confusion. Completing the range are three voltage testers – all equipped with an all-round LED display which can be read from any position – and a non-contact voltage tester with a filter for high-frequency interference.

testo 760 – the first automatic multimeter The testo 760 digital multimeter family comprises of three models for all important electrical measuring tasks. Function keys replace the traditional dial on all three instruments, which

means easier operation and greater reliability. Incorrect settings are now impossible, because the measurement parameters are detected automatically via the assignment of the measuring sockets and also shown by the illumination of the appropriate function keys. The testo 760-1 model is the standard version for almost all daily measuring tasks. The testo 760-2 is differentiated by a larger current measurement range, the true root mean square measurement - TRMS - and a low-pass filter – for VFD output voltage measurements accurately. The testo 760-3 is the model with the highest specification and, in addition to the features of the other two models; it has a voltage range of up to 1,000 V, along with higher measuring ranges for frequency and capacitance. In addition, µA current measuring range is also available.

testo 770 – grab cables with out touching The three instruments in the testo 770 clamp meter family are ideally suited for non-contact current measurement in switching cabinets with a unique feature of inrush current measurement as well. One of the two pincer arms can be fully retracted into the instrument. This unique grab mechanism means that cables in tight switching cabinets can be easily grabbed. The automatic measurement parameter detection also ensures reliable work: in the current and voltage area, all three instruments detect direct and alternating current and select other parameters such as resistance, continuity, diode and capacitance automatically. The testo 770-1 model is the standard version for

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testo 750 – the voltage tester with all-round LED display The three models in the testo 750 voltage tester family are the first instruments with an all-round LED display. The display can be seen from any position and guarantees an ideal voltage indication thanks to its unique fibre optics. All three models meet the latest voltage tester standard EN 61243-3:2010 and have a safety specification according to CAT4. They have the most important functions for voltage testing, continuity testing and rotating magnetic field measurement. The testo 750-2 is also suitable for single pole voltage testing and has a flashlight along with an RC trigger function. Vibrating load buttons ensure that trigger tests cannot be carried out accidentally. In addition, the testo

daily measuring tasks, including starting current measurement.The testo 770-2 also has a µA range as well as an integrated temperature adapter for all type K thermocouples. In addition, the testo 770-3 offers a power measurement function, along with Bluetooth.

testo 755 – the first voltage tester measuring current Both instruments in the testo 755 current/voltage tester family are the first of their kind: voltage testers which meet the latest standard and which can also measure current. This means they are suitable for virtually all daily electrical measuring tasks. Each time they are used they automatically select the right settings and therefore prevent dangerous

750-3 is fitted with an LC display to show the current reading.

testo 745 – the non-contact voltage tester The testo 745 non-contact voltage tester with a voltage range of up to 1,000 V is particularly well-suited to fast initial checking of any suspected fault sources. When the presence of voltage is determined, the testo 745 gives a warning via a clear visual and acoustic signal. In order to increase reliability, the voltage tester has a filter for high-frequency interference signals and is also waterproof and dustproof according to IP 67. With the introduction of the electrical measuring instruments, Testo now offers portable and stationary measurement solutions for almost all areas of application from one provider for HVAC/R.

incorrect settings. Both instruments have all the important functions for determining voltage/de-energization, for measuring current and resistance, as well as for continuity tests. In addition, the integrated flashlight enables dark spots to be illuminated. The measuring tips can be changed easily, so that the whole instrument does not need to be replaced in the event of damage. The testo 755-2 model is differentiated by the larger current range of up to 1,000 V and special functions, such as the single pole phase testing and rotating magnetic field measurement. In addition, it is also certified according to voltage tester standard DIN EN 61243-3:2010.

www.engrreview.com | AUGUST 2016

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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

A.Venkatakrishnan, Market Consultant – INDIA venkat@pcschematic.in

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.

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.

Integration

Why should I buy PC|SCHEMATIC Automation?

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.

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.

Our solution saves 80% time 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 working might result in that just

AUGUST 2016 | www.engrreview.com

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

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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 Auto-

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mation. 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!

Support: How can I get it? 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. 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 Mr. Ove Larsen, International Sales Director, PC|SCHEMATIC A/s, Denmark

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On the road with the

MECHANICAL HERD

Image ©foolpool

The German artist group called foolpool made mechanical animals from used bicycles and are traveling around with a herd of them. maxon supported the art project with drives. The approaching slow-moving creatures make an eerie impression. With their long thin limbs, they look like a cross between a giraffe and a gazelle. Their heads turn from side to side. It seems as if they are scouting their surroundings. These animals are mechanical creatures, created by foolpool, a German artist group. The herd has grown to eight animals; the human members of the group are the shepherds. The group travels from town to town to visit various festivals all over Europe. Wherever they go, the people stare in disbelief and fascination.

The “animals” are up to 2.5 m tall. The mechanical beings essentially consist only of recycled bicycle parts, bolted and welded together to create something new. Maximilian Auerbach of foolpool explains that every animal in the herd is different. Some are female and some male. They are between 1.5 and 2.5 m

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tall and up to 2.5 m long. The animals move autonomously. They go forward and backward, at different speeds. “To the audience, it looks as if the creatures are reacting to the calls and guidance of the shepherds.“

The drives are almost unnoticeable Without robust and compact drives, the mechanical creatures would not be able to move at all. To solve this problem, maxon motor provided several motor-gearhead combinations. DC motors and planetary gearheads of various types and sizes have been integrated into the animals, including RE 40 and A-max motors. Both are equipped with the special ironless winding that makes them very energy-efficient. The micromotors provide the necessary force to get the herd animals moving - and yet are hardly visible. “A typical question from the audience is: So where’s the motor? This shows how well the drives have been integrated into the animals,” says Maximilian Auerbach. He also praises the cooperation with maxon motor: “Although we lack expertise in motor technology, maxon motor always provided the

consulting that we needed to make the right decisions.”

Criticism of blind trust in technology The herd of mechanical creatures is complete,

The mechanical creatures on the road. Image ©foolpool

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maxon RE 40 motor

maxon A-max 22 motor

maxon GP 42 C gearhead

With its ironless winding and strong neodymium magnets, this micromotor has an efficiency of more than 90 percent. The drive is robust and easy to control.

This is the cost-effective version of a reliable brushed DC motor. Automatic manufacturing processes make these drives an interesting alternative choice.

The GP42 planetary gearhead supplies the necessary torque for the mechanical creatures. It is equipped with ceramic parts, making it extremely robust and durable.

for the time being. However, the artists plan to build two more creatures resembling dogs. For a bit of variety. â&#x20AC;&#x153;We want to surprise the visitors again and again, touch them emotionally and make them think,â&#x20AC;? says Auerbach. He has been performing with foolpool at events for 30 years. Never before has the artist group counted so heavily on mechatronic elements in their performance. But the audience seems to like the artwork, maybe in part because the herd of mechanical animals addresses several hot issues, such as throw-away mentality and the

handling of resources. On the other hand the figures reflect a world that is heavily influenced by robots. And last but not least, the artworks subtly criticise a blind trust in technology.

For more information www.maxonmotor.in

www.engrreview.com | AUGUST 2016

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Geissel India – GERMAN EXCELLENCE at home G

eissel 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 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:

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

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

AUGUST 2016 | www.engrreview.com

and customers get a one-stop solution to their needs for conduits and the ease in fitting them.

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@geissel-india.com

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Compact FLIR thermal imager game Changer for condition monitoring

FLIR AX8 IS A COMPACT AND AFFORDABLE THERMAL-BASED CONDITION MONITORING SOLUTION FOR MANUFACTURING COMPANIES AND UTILITIES From process manufacturing applications to complex processes in utilities, it is important to guarantee uptime and proper functioning of all machinery. Condition-based maintenance systems help to maximize yield and quality, while decreasing unscheduled outages and maintenance and repair costs. Taiwanese technology integrator ADE Technology Inc. has now developed a compact and affordable condition monitoring solution for these companies, based on FLIR’s AX8 thermal imaging sensor. AUGUST 2016 | www.engrreview.com

The AX8 combines a thermal and a visual camera in a small, affordable package.

oday, the majority of production companies in the semiconductor industry conduct preventive maintenance of critical equipment based on statistically derived and predefined intervals. While these practices have had relative success in managing equipment availability and product yield, the cost, both in time and materials, remains high. Sometimes, interventions are performed on machines that do not need it. Other times, maintenance actions that are missed will result in machine failures, bad product quality, and unscheduled downtimes. “Maintenance is one of the key issues in modern semiconductor manufacturing,” says Wayne Sun, Sales Manager at FLIR Systems Taiwan. “In the past, condition-based maintenance and monitoring has been successfully adopted in utility companies and highend industries, where costs associated with equipment downtime are critical for the companies’ bottom lines. But increasingly so, the semiconductor and electronics manufacturing industries, like we have here in Taiwan, are starting to see the benefits of condition-based maintenance and condition monitoring as well.”

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DETECTING HEAT Condition monitoring is a way to identify features within the equipment that are indicative of the equipment health and of the potential degradation process. Heat build-up inside a machine is such an indicator, next to vibration and power consumption for example. The ability to predict machine and system failures before they happen can reduce costs and increase availability significantly. ADE Technology Inc., based in New Taipei City, Taiwan, has been serving the industrial market for years with advanced video processing technology that seamlessly integrates with other industrial devices and other data sensor types in order to build various applications in the field of the Internet of Things. “ADE knows the needs of utilities and manufacturing companies in terms of preventive maintenance very well,” says Wayne Sun. “Typical technologies that are used today for preventive monitoring are visual CCTV cameras and thermocouples. While both of these technologies have proven their use, they do have limitations in a preventive maintenance context.”Visual cameras do have their use in 24/7 monitoring of equipment and can spot certain production problems in time, but they cannot see the heat build-up that is typically associated with impending equipment failures. To investigate equipment temperatures, thermocouples are often used as well. But this technology is also limited, as thermocouples only measure one point on the object at a time and do not provide a complete heat signature of the problem.

THERMAL CAMERAS Thermal imaging cameras are used for condition monitoring and process control applications worldwide. Typical equipment that is monitored by thermal cameras includes

Cast resin transformers need to be able to handle temperature shocks safely. Insulation breakdown on cast resin transformers can lead to system failure and safety issues. The FLIR AX8 can detect temperature raises due to insulation breakdown in an early stage.

T-Guard makes use of FLIR’s AX-8 camera and ADE’s AD-TG200 network video recorder. It allows managing temperature-driven alarms triggered by the FLIR AX8 sensor, in addition to other sensor information like IP cameras, voltage measurement and environment temperature measurement.

high- and low voltage installations, turbines, compressors and other electrical and mechanical equipment. “Thermal cameras can see thermal irregularities in equipment that indicate failures and provide more information to production specialists and decision makers,” says Wayne Sun. “And what’s more, they can monitor problems continuously, without interrupting the production flow, and see problems before they develop into something worse.” As a solution integrator and distributor for FLIR thermal imaging cameras, ADE knows the power of thermal imaging very well. The company has been integrating thermal cores and components into larger systems for many years and for many vertical markets. But it wasn’t until the introduction of the FLIR AX8 thermal imaging camera that ADE decided to build a dedicated condition monitoring solution for manufacturing companies and utilities: the T-Guard.

T-GUARD TEMPERATURE MONITORING SYSTEM ADE’s T-Guard solution consists of FLIR’s AX8 camera and ADE’s ADTG200 network video recorder and has been designed to help factories and utilities manage temperaturedriven alarms triggered by the FLIR AX8 sensor, in addition to other sensor information like IP cameras, voltage measurement and environment temperature measurement. Based on collected, real-time temperature data, T-Guard monitors the health status of equipment and generates critical impact alarms for a control center to follow up upon. The temperature information allows the system to send out differentiated alarms, according to the extent of the temperature raise and the criticality and imminence of the failure. T-Guard can manage up to nine

FLIR AX8 cameras and can be used for enterprise-wide electricity management, solar PV management, Environment Control Systems (ECS), and many other applications.

COMPACT AND EASY TO INTEGRATE Installation of condition monitoring sensors into production equipment requires these sensors to be compact and easy to integrate. With the introduction of the FLIR AX8, integrators have exactly that. The AX8 combines a thermal and a visual camera in a small, affordable package, which only measures 54 x 25 x 95 mm, making it easy to install in spaceconstrained areas. According to Jeffrey Chow, ADE’s General Manager, “The AX8 is definitely a game changer for traditional conditional monitoring. AX8 can be easily integrated with current-day automation PLC and NVR systems. With the FLIR AX8, the safety industry can finally dispose of an affordable smart sensor for thermal-based condition monitoring. Our T-guard solution leverages the advantages of the AX8, by integrating it with a network video recorder and alarm mechanism.” For more information about thermal imaging cameras or about this application, please visit: www.flir.in/automation The images displayed may not be representative of the actual resolution of the camera shown. Images for illustrative purposes only.

FLIR Systems India Pvt. Ltd 1111, D Mall, Netaji Subhash Place, Pitampura, New Delhi – 110034, INDIA Tel: +91-11-4560 3555 | Fax: +91-11-4721 2006 Email: flirindia@flir.com.hk | Web: www.flir.in www.engrreview.com | AUGUST 2016

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POWER

Power Network

METER ND30

umel SA, Poland, a Rishabh Group company has come up with a new intelligent power network meter - ND30. ND30 is first of its kind network meter with its compact construction in 9 6 x 96 sq.mm. With an attractive TFT LCD screen user has flexibility of selection from the eight colours viz. Green, Red, Yellow, White, Purple, Olive, Blue and Light Blue available in the palette. It is also suitable for installation in single phase or three phase network. Due to its versatile functionality and flexibility user can adopt its intelligence to over come complex data management.

Few of the functions which make ND30 most intelligent product are as below; • Measurement of 54 Electrical parameters including individual harmonics for current and voltage up to 51st order • Display of 8 parameters of user choice • 2x PT100 input (ex. Monitoring of Oil & winding temperature of the transformer) • 2x configurable alarms allowing user to create conditional alarming • Analog output for re-transmission of any required parameter • Data logging in internal 8GB memory • Data access using in-built web server and FTP server

For more information Web: www.rishabh.co.in AUGUST 2016 | www.engrreview.com

150 TECH TRENDS

Industrie 4.0.: More than a powerful trend T

he path to the fourth Industrial Revolution is not always clear. Many companies and industrial organisations have different views on the precise meaning of Industry 4.0. As a pioneering technology group, HARTING offers solutions for these rapid developments and, to make them more comprehensible, has grouped them into six recognisable trends. Products and solutions from the HARTING Electronics subsidiary work together to support the intelligent production systems of tomorrow.

The impact of digitalisation Digitalisation now impacts on every area of modern life. Almost without exception, we are all networked with our fellow human beings and the environment via a smartphone or other mobile device. This is a development which is also forging ahead in areas outside of everyday life. More and more intercommunicating end devices and products are finding their way into industrial production. This increasing digitalisation, this merging of two major areas – software/ IT and traditional automation – is becoming more widely known as Industry 4.0, a term now entering the mainstream. But what exactly does it mean? In many companies, particularly SMEs, the meaning of the term is still opaque and it is subject to a number of different interpretations.

Modularisation Modular approaches are becoming increasingly significant. A shift towards custom-tailored manufacture is spelling the end for rigidly structured mass production. Modular components save time by allowing rapid changes and adjustments to production systems to be carried out faster.

Identification – Auto-ID solutions Condition monitoring can be uncomplicated and cost efficient with RFID sensor-transponder systems. They help to report wear early on and reduce downtime. While goods and workpieces used to travel “invisibly” through a production system, they can now use RFID to communicate with their environment and provide information

AUGUST 2016 | www.engrreview.com

about how they should be processed.

Integration – Intelligent devices and software solutions Smoothly functioning communication between objects and third-party systems such as a PLC from the web shop to the shop floor – flexible software solutions tailored to meet the requirements of any application.

Convergence of real and virtual systems Real production and virtual control systems are converging to an increasing extent. This can be seen in the HARTING HAIIC MICA energy management system for efficient production and condition monitoring.

Miniaturisation Networks in the field are becoming more highly populated, and at the same time, smaller and more powerful components are demanded. This also applies to computer systems and plug connectors.

Customisation Individual system solutions and products which coordinate perfectly. Open-source software platforms meet customer requirements just as much as custom-tailored hardware assemblies. The fourth industrial revolution is accompanied by increasingly dense networks of sensors, actuators and smart devices in the field. Machine-to-machine communication and digitalisation of previously anonymous workpieces require increasing numbers of interfaces and connections. There is a growing demand for smaller and more powerful components that can be operated faster and more easily. Industry 4.0 and the associated modular structure of production systems are resulting in higher mating cycles and data rates for plug connectors. HARTING Electronics, a HARTING Technology Group company, is offering a range of hardware solutions for plug connectors which support the Industry 4.0 trends towards miniaturisation, modularisation and digitalisation.

The trend towards miniaturisation is evident in all the lifelines of industry – power, signal and data. This miniaturisation allows housing to be configured on a smaller scale and provided throughout with M12 connectors.

The significance of HARTING’s preLink® system The stand-out example here is HARTING’s preLink® system, a flexible cabling solution for the applications of the future in which HARTING has found a way to separate the formerly indivisible combination of cable and plug connector into two independent and reusable parts. The preLink® terminal block can be used with 8-core Ethernet cable which can be safely assembled in the field with the compatible preLink® pliars in a single operation. This terminal block fits into a number of sockets and plug connectors. Enabling the flexible connection technology of the preLink® system to serve a wide range of different situations, it is available with different mating faces used routinely in industrial applications. They include RJ45 network plugs and sockets and M12, PushPull Variant 14 and as an insert in Han® 3A for IP65/67-compliant applications. The current focus for transmission over distances exceeding 100 metres is on optical fibres, which allow substantially higher data rates over several kilometres. Factors such as the type of optical fibre, the transceivers and the protocol used determine the limit. For this variant, HARTING offers a PushPull plug connector in an optical LC Duplex variant. With these trends firmly in mind, HARTING is creating easily accessible products and solutions for the fourth industrial revolution.

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New generation of

AXIOCONTROL CONTROLLERS

for demanding automation Simply more productive Processing speed plays an increasingly important role in many automation applications, and not just in motion control applications. The focus here is on the speed of the entire application, which depends significantly on the components used. This is because the right devices enable higher processing speeds for individual work steps, which in turn increases the productivity of the entire machine or system. The heart of every machine or system is the programmable logic controller (PLC) and a powerful I/O system. The important criteria for the PLC are the processing speed of the control program, the transmission rate of the bus system used, and the highest possible synchronicity and low jitter for data transfer between devices. This applies in particular if the applications require short reaction times or a rapid analysis of counting pulses, for example. Phoenix Contact had these considerations

AUGUST 2016 | www.engrreview.com

in mind when developing its new generation of Axiocontrol units. The AXC 3050 offers users a high-performance control system that meets even the highest standards. This PLC is distinguished by three main characteristics that are required in different measures for different applications: fast data transmission, rugged design, and ease of use. The AXC 3050 was specifically designed for application areas that pose ongoing long-term challenges on the flexibility and speed of the application, as well as the installed components. This is the case in the renewable energies sector with application areas such as wind parks, infrastructure projects, and machine and system engineering.

Response times in the microsecond range When seeking to increase the speed of an automation application, the time that is required for different process steps becomes very impor-

tant, in addition to the processing speed. Fast response times, i.e., the time needed to read, process, and output a signal, and the rapid analysis of input signals are required in several applications to achieve this. The AXC 3050 excels in this regard with a processing speed of one microsecond per 1000 lines of code (data type: bits) as well as integrated technology functions. In applications that require rapid counting and event task processing, the high-performance controller fully exploits the speed of the Axioline I/O system. The combination of the Axiocontrol PLC and the I/O modules from the Axioline F product family makes it possible to achieve response times in the microsecond range and counting functions in the kHz range.

Minimizing system outages The Axiocontrol AXC 3050 is designed for the mechanical stresses given by harsh environmental conditions. The robustness of the PLC is ensured by stringent test criteria and additional vibration and shock testing. Furthermore, the built-in uninterruptible power supply (UPS) helps increase the availability of machines and systems. This is because installing an external UPS in the control cabinet is not possible in several small-scale applications for reasons of cost and space. That is why the AXC 3050 already features a short-term buffer that keeps the high-performance control system ready for service during a power failure. This allows the most important data, such as the values of remanent variables, to be saved securely to an SD card, and a freely programmable user action

TECH TRENDS 153

Updates by means of USB stick or SD card As well as easy programming and data exchanging, the Axiocontrol unit provides intuitive user interaction, and it has a very compact design that permits installation and operation even in very constricted control cabinets (Figure 3). If an update is required for the firmware or the control project, this can be done by means of a USB stick or the optional SD card (Figure 4). A PC is not required. The USB stick and the SD card can be used as logging memory or to expand the PLC’s memory.

Conclusion

to be executed in the application program. The PLC is therefore reliably shut down, which in most cases also applies to the machine or system. The AXC 3050’s power failure security enables application downtimes to be kept to a minimum.

The combination of the Axiocontrol AXC 3050 and AXC 1050 controllers and the Axioline I/O system not only make the machine or system faster, they also make it more rugged and easier to use. Special electromagnetic properties (Class B interference emission), the mechanical design, and power failure security increase the overall reliability of the application. Integrated technology functions, such as fast counters and event task processing, enable the implementation of the corresponding applications without using special I/O modules. This is why it pays to look closely at the individual components used in the automation solution when designing the machine or system. In this context, the AXC 3050 can significantly increase the application’s speed, flexibility and availability - without requiring significantly higher investment costs.

Flexibility for networking Like all the other Phoenix Contact controllers, the AXC 3050 is programmed using the PC Worx development software. The five programming languages specified in IEC 61131-3 can be used. Using this standard makes it easier to become familiar with Phoenix Contact’s controller paradigms, and it also makes it possible to reuse existing program code. Automatic inputting from the connected I/O modules and easy-to-use diagnostic and debugging functions also number among the standard functions of the Axiocontrol control system. The AXC 3050 supports a wide range of IT protocols, which in combination with the built-in Ethernet ports make it easy to integrate the controller into a company network and provide quick access to production data statistics. The three separate Ethernet ports also create high flexibility for networking machines and systems. For example, an IP address range can be used for the standard configuration within the application while several machines are connected to a network over another range of IP addresses. The third port can then be used as a remote signaling connection to connect an additional user interface or to connect to the office IT system. Process data is exchanged over the Ethernet ports via standard protocols such as Profinet or Modbus TCP, meaning that local I/O stations as well third-party devices can be integrated seamlessly with the system.

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154 TECH TRENDS

CABLE & CONNECTION Technology for Automation By Marc Jarrault, Managing Director - Lapp India Pvt. Ltd.

ndustry 4.0 or the fourth industrial revolution has changed the automation and data exchange in manufacturing technologies, which is driven by rapidly-increasing digitalization of the economy and society. The nature of manufacturing has changed with the introduction of technology and production process has become more flexible, efficient and customer-specific. Product development, logistics and customers are intermeshed with the help of the latest intelligent information and communication technology. The world of factory automation, which is largely based on electrical engineering and hierarchical structures, is metamorphosing into smart factory networks, in which production plants can communicate with one another. This represents a turning point that offers enormous opportunities and at the same time confronts the sector with enormous challenges. It is only with consistent, interdisciplinary collaboration of all involved participants from industrial machinery, electrical engineering, automation and information technology that uniform, ground-breaking standards can be created and the future can be shaped. Component, system and solution providers must all change the way they think. In the course of Industry 4.0, the demands on cable and connection technology are also changing. Cable and connection technology is being re-thought. Since data rates will climb with the consistent networking of company and business

AUGUST 2016 | www.engrreview.com

processes, it is a development that demands high-performance networks. In future, network cables will no longer only be used to connect machinery and within control cabinets, they will also be laid directly to intelligent actuators or sensors in the field. The solution lies in systemspecific field-compatible Ethernet cables and robust connectors. Reliable networking of production across all levels is only possible with a comprehensive cabling and connection concept. Ethernet cables in a production environment must be substantially more robust than LAN cables in an office environment. They have to be oil resistant, must withstand high temperatures and must also function reliably and durably in the drag chain. It is an enormous challenge to combine the requirements of flexibility, robustness and the highest data rates. In addition, it must also be possible to install network connectors in the field without special tools. Added to this, are the growing demands in terms of the protection rating. Whilst an RJ45 data connector was sufficient up to now in the control cabinet, dirt and moisture-resistant connectors are becoming more and more important in the field. Lapp product portfolio is also adapting more and more to the requirements of the modern age. As a competent partner in the realisation of future-oriented networks, we have greatly extended our cabling and connection technolo-

gy range for Industrial Ethernet and fibre optic cables so that we can supply the market of the future with ground-breaking solutions. Within the framework of Industrial Ethernet applications, Lapp offers solutions such as the highly flexible ETHERLINEÂŽ FD Cat. 6A for applications where the highest data rates have to be transmitted with consistent reliability in drag chains that are under constant movement with a data rate of 10 Gbit/s. Connectors that comply with the Cat. 6A standard are required for the connection. If water-tightness and dirt resistance in accordance with IP67 are also required, we recommend the use of M12 connectors. The most important principle of all our industrial network solutions is that network technology in an industrial environment must be kept simple on the one hand, and must be rapidly connectible without special tools on the other hand. Space-saving yet robust solutions such as the 30 per cent thinner ETHERLINEÂŽ EC are suitable for use at sensor/actuator level and allow the tightest bending radii. Drag chains can also be configured with such extremely small dimensions. Thanks to the robust PUR outer sheath, the cable can also be used with high mechanical stresses or in oily environments. The robust 4-wire Cat. 5e Ethernet cables are also available as finished products with a pointed, space-saving M8 connector that is substantially smaller than the M12 connector that is otherwise commonly used with Industrial Ethernet. In general, the trend is towards smaller and smaller yet also more and more efficient connectors and cables. Today besides successfully meeting current demands of the automation industry, Lappâ&#x20AC;&#x2122;s innovative technology is ready to shape Industry 4.0 - the fourth industrial revolution.

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156 TECH TRENDS

POWER

Leroy-Somer expands

LIQUID COOLED series

Designed to withstand harsh environments and meet specific requirements, the LC motor range is a step forward to satisfy the most demanding customer expectations in terms of high reliability, energy savings and ease of integration into their facilities

Key features: • Frame sizes: 315 to 500 (< 315 and > 500 on request) • Voltage: 400 V for 315 to 450 mm / 690V for 500 mm • Number of poles: 2, 4 & 6 • Power: 150 to 1,500 kW • Frequency: 50 or 60 Hz • Insulation class: F or H • Mounting: B3, B35 and V1 (other position on request) • Double nameplate: DOL + variable speed characteristics

AUGUST 2016 | www.engrreview.com

ased on the success and reliability of the IMfinity platform, the LC motors achieve the highest electrical and mechanical performance, including some innovative characteristics. The latest generation frame housing, with cast iron or steel flanges for DE and NDE bearings, allowing excellent heat dissipation. A sophisticated cooling system which maintains the thermal efficiency, enabling the motor to be used together with a variable speed drive, for heavy duty applications that require constant torque. The design has reduced noise level, decreased in average by -10 to -20 dB (A) compared to air-cooled motors due to the lack of fan, offering ultimate comfort. Improved modularity thanks to its fabricated steel design, providing higher flexibility for retrofit installation. The liquid cooling system of LC motors, provided by water circulation over the frame housing, offers additional significant advantages, such as the power-weight ratio (increased power in the same motor frame size) and compactness (saving up to 25% of volume compared to an air-cooled motor for easier and less costly integration within a machine or a system. Moreover, LC technology makes it possible to eliminate external components, such as ventilation equipment. A design that optimizes energy efficiency Based on the new IMfinity® induction

motor range, the LC series has been designed to achieve the efficiency levels defined in IEC 60034-30-1. As standard, LC motors are IE3 Premium from 150 to 1500 kW. Perfectly suited for use in variable speed, the LC motor has been designed to integrate specific features as standard, such as a thermal reserve for maintaining the rated torque over an extended speed range. In order to meet particular requirements, options can be provided upon request, including reinforced winding insulation and insulated bearings. The motor can also be equipped with an encoder for applications that require precise positioning. Variable speed can generate immediate operating profits, such as up to 50% energy savings (depending on the application and operating conditions) or increased productivity as a result of improving the process and reducing machine downtime. The return on investment is consequently extremely quick.

A design giving priority to safety and reliability Benefitting from optional IP56 or IP65 protection to safeguard against external hazards, the LC range is fitted with a water leakage detector to control the water circuit reliability. Another option, space heaters, ensure safety during motor start-up, while winding and endshield thermal protection control and monitor the

158 TECH TRENDS

motor temperature. Developed to reduce operating costs without compromising industry needs, LC motors are equipped with a patented breathable membrane. This completely waterproof (IP 66 minimum) feature considerably reduces condensates, whose evacuation is achieved by drain plugs. The Liquid-Cooled technology ensures a clean surrounding environment, as there is no pollution associated with airflow. Moreover, there is no impact on ambient temperature, as the waste heat from the motor is carried away by the cooling circulation. For these reasons, the risk of installation ageing and malfunctioning .due to air pollution and high temperatures is considerably lowered. This reliability ensures easy maintenance of the motor within customer systems. An easy-to-select and easy-to-install solution, the new LC motors are particularly recommended for plastics & rubber, test stands, industrial refrigeration, marine and nuclear applications, and crushers for the food and animal feed

AUGUST 2016 | www.engrreview.com

industry.

About Control Techniques and LeroySomer: As part of Emerson Industrial Automation, Control Techniques and Leroy-Somer have operated globally as sister companies for many years, each with their individual areas of expertise and specialist technologies. Now our combined business allows us to provide optimized drive and motor technology, develop perfect industry-specific and customized automation solutions, with strong local technical and sales support on a global scale. For more information visit www.EmersonIndustrial.com/Automation

About Emerson Industrial Automation: Emerson Industrial Automation, a business of Emerson, is a global technology provider that enables productivity, efficiency and quality gains for customers across a spectrum of industries. Our products include alternators, electric motors and drives, electrical distribution devices and mechanical power transmission, fluid

automation and ultrasonic joining solutions. Emerson brands include Appleton, ASCO, BransonUltrasonics, Browning, Control Techniques, Kop-Flex, Leroy-Somer, McGill, Morse, Numatics, O-Z/Gedney, Rollway, SealMaster and System Plast. For more information, visit www. EmersonIndustrialAutomation.com.

About Emerson: Emerson (NYSE: EMR), based in St. Louis, Missouri (USA), is a global leader in bringing technology and engineering together to provide innovative solutions for customers in industrial, commercial, and consumer markets around the world. The company is comprised of five business segments: Process Management, Industrial Automation, Network Power, Climate Technologies, and Commercial & Residential Solutions. Sales in fiscal 2015 were $22.3 billion.

For more information, Web: www.Emerson.com

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160 TECH TRENDS

POWER

Mitsubishi Electric Cup 2016: Encouraging students to Eco-imagine!

co Imagination is a lateral way of imagining and developing technologies for a sustainable world. It is an important concept that has to be seeded into the minds of young engineering students, to encourage them to think beyond conventional methods, keeping the larger global view in mind. The Mitsubishi Electric Cup is a novel opportunity for students to channelize their innovative ideas and showcase them to the world. Supported by Mitsubishi Electric India, the Mitsubishi Electric Cup is a national level automation competition focused on exposing students to the latest solutions in high-end factory automation technology and exciting them to stretch their imagination by giving them an opportunity to apply this technology in their projects. The first Mitsubishi Electric Cup tournament was held at the Vishwakarma Institute of Technology –(VIT), Pune in February 2016. The theme for the maiden edition of the contest, in tandem with the environment statement (Eco Changes) of the Mitsubishi Electric, was ‘Eco

AUGUST 2016 | www.engrreview.com

Imagination through Smart Manufacturing’. Under the theme, students were required to integrate Mitsubishi Electric’s factory automation products including PLC, servo, inverter and human-machine interface (HMI) to build up and achieve an analogous system of intelligent manufacturing and energy saving management application, based on e&eco-f@ctory concept while taking e-f@ctory system as the trunk. The tournament received an overwhelming response from engineering colleges across cities. The organizing committee of the Mitsubishi Electric Cup shortlisted a total of 24 teams from across the country to compete in the final round.The winner team ‘Inferno’ from Dayalbagh Educational Institute, Agra walked away with prize worth of Rs. 1 lakh. The second place was taken by ‘N-Dimension’ from Vishwakarma Institutes of Technology, Pune who took home prizes worth Rs. 75,000 and “A’utomation” from CVR College of Engineering, Hyderabad secured the third spot and received prizes worth Rs. 50,000. All the participants received certificates of participation.

The competition aimed at providing on-field training to budding engineers from across the country and improving the ability of college students for engineering application, stimulating their interests in learning engineering technology and building up an innovation capacity in them. During the first edition of Mitsubishi Electric Cup, Mitsubishi Electric India also supported Vishwakarma Institute of Technology (VIT), Pune with extension of their Factory Automation lab equipped with the latest technology. With the looming energy crisis and increasing environmental pollution, energy conservation, emission reduction and environmental protection based green factory technologies have become common pursuits. In such a scenario, the Mitsubishi Electric Cup is setting a new benchmark in the efforts to bring academia and industry to work together to foster Innovation in students and ensuring a future-ready generation. For more information Web: www.mitsubishielectric.in

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162 TECH TRENDS

POWER

Mitsubishi Electric Cup 2017: Intelligent manufacturing for a greener tomorrow

itsubishi Electric India, a leading player in Factory Automation is pursuing a vision to shape the future through technology that ensures a brighter, better and greener ‘tomorrow.’ The second edition of the Mitsubishi Electric Cup- 2017 underscores this vision with its theme “Intelligent Manufacturing for Greener Tomorrow” Conceived as a national-level automation competition for students in India, the second edition, Mitsubishi Electric Cup 2017, offers a challenging platform for students to collaborate, innovate and excel in the field of Automation thus ultimately contributing to the National Mission of Skill Development in the long run. Students will be asked to independently design and produce a complete set of devices or models by using Mitsubishi Electric factory automation products (including PLC, servo, inverter and human-machine interface) with the control system based on e&eco-F@ctory concepts. As per the theme “Intelligent Manufacturing for Greener Tomorrow”, it is expected to include IoT, interfacing through web based solutions and connectivity with upper layer of Manufacturing Execution Systems (MES). This year’s competition aims at improving the ability of college students for engineering application, arouse their interests in learning engineering

AUGUST 2016 | www.engrreview.com

technology, build up an innovation capacity and cooperation spirit in them, as well as improve self management ability and communication skills. It is also intended to embody the “learning for practice” ideology, review students’ actual manufacturing and commissioning abilities, meanwhile enhance exchange and cooperation between university and enterprise. The organizing committee of Mitsubishi Electric Cup will shortlist top 35 teams, who would need to prepare working model of various industrial manufacturing processes, energy saving solutions, smart solutions for building automation etc. Teams will be provided with technical support, training and Factory Automation equipment to make the working model, on a returnable basis by Mitsubishi Electric India. Additionally, each team will be given a financial support of Rs. 7000 upon achievement of required skillset. All the participants will be given certificates of participation and the winning team will get a prize worth of Rs. 1 lakh. The runner up team will be awarded prize worth of Rs. 75,000 while the team winning the third spot will be given prize worth of Rs. 50, 000 and many more prizes in different categories. The last date for registration and submission of proposal is September 1, 2016. The top 35 teams selected will be announced on September 15, 2016 and these teams will have to submit

their intermediate reports by December 15, 2016. The final competition will be held on February 16 to 18, 2017 at the College of Engineering, Pune (COEP). Mitsubishi Electric Cup 2017 is now open for registration. Students pursuing engineering can know more about this competition and register themselves at http://www.mitsubishielectric.in/fa/mecup/. For details please visit website: http://www.mitsubishielectric.in/fa/factory-automation.php

About e-F@ctory: e-F@ctory is Mitsubishi Electric’s integrated concept to build reliable and flexible manufacturing systems that enable users to achieve many of their high speed, information driven manufacturing aspirations. Through its partner solution activity, the e-F@ctory Alliance, and its work with open network associations such as The CC-Link Partners Association (CLPA), users can build comprehensive solutions based on a wide ranging “best in class” principle. In summary, e-F@ctory and the e-F@ctory Alliance enable customers to achieve integrated manufacturing but still retain the ability to choose the most optimal suppliers and solutions. For more information Web: www.mitsubishielectric.in

164 TECH TRENDS

MACHINE TOOLS

Solid-carbide end mills increase application range The Jabro-Solid2 JS554 range of solid-carbide end mills gains further utility and versatility with smaller neck diameter options

he new range of tools provide greater clearance when machining complex components, such as those found in aerospace, medical and general machining applications. Smaller neck dimensions make it easier to access parts clamped in complicated fixturing arrangements, as well as enable users to take full advantage of 4-axis and 5-axis machining capabilities. The neck sizes are optimised to retain tool rigidity while providing full compatibility with standard toolholder connective systems. The tools maintain their ability to productively machine materials in the ISO P, M, S and other material groups.

High stability

Benefits • Smaller neck dimensions make it easier to access parts clamped in complicated fixturing arrangements • Ability to take full advantage of 4-axis and 5-axis machining capabilities • Optimised to retain tool rigidity • Full compatibility with standard toolholder connective systems

AUGUST 2016 | www.engrreview.com

JS554 end mills provide high stability and low deflection. They also bring an excellent price-performance ratio to a range of applications, and these latest additions further expand the line’s advanced capabilities. The range of JS554 end mills covers tool diameters from 3 mm to 20 mm and typical cutting lengths 2xD + 2 mm. Reach lengths are 3xDc. The range also includes corner radius and 45˚-chamfer versions, for both Cylindrical and Weldon shanks. Seco Tools is a leading manufacturer of high performance metal cutting tools. Seco’s product range includes a complete programme of tools and inserts for turning, milling, drilling, reaming and boring as well as complementary tool holding systems. With more than 25,000

standard products, Seco is a complete solutions provider for the metal cutting industry and equips machine tools from the spindle down to the cutting edge. The company is headquartered in Fagersta, Sweden and represented in more than 50 countries worldwide with 40 subsidiaries, distributors and channel partners.

For more informaton www.secotools.com/in

166 TECH TRENDS

MACHINE TOOLS

The significance of

SCRIBING TECHNOLOGY The mechanical system is much simpler which has for consequence reduced maintenance

cribing is a marking process whereby the mark (text or logo) is produced by a carbide or diamond tip that penetrates and indents the surface. This produces a deep groove that forms continuous lines across round, concave, flat, or arched surfaces, and on almost any material. Also called “drop and drag” or “scratch marking,” scribing technology is an ideal choice for applications where noise level limitations are imposed. If dot peen markers are considered too noisy when used on steel pipe, for example, a pneumatic scribing machine might be preferred. SIC Marking’s scribing technology guarantees a high quality mark and is ideal for

requirements that include Optical Character Recognition (OCR) or aesthetics concerns (logos, symbols…). SIC Marking’s product range runs from standard machines to custom engineered solutions. All systems are created with careful attention to bring functional design, quality, innovation, and performance to manufacturing lines. Every site, every job, and every customer is unique. As an example, one of our customers in the automotive industry has asked our engineers to set up a system adapted for eight of his exhaust pipe’s production lines. The traceability and identification of exhaust pipes can be a complicated task since the parts are hollow. Our customer’s main issue was compliance with the noise limits which is the reason why scribing marking systems were chosen.

Easy integration Our i113s marking systems have been easily integrated and implemented on each work station. Thanks to the reliability and flexibility of SIC Marking’s scribing systems, our customer was able to adapt the marking head’s position to fit each of his production lines.

AUGUST 2016 | www.engrreview.com

New scribing marking machine To complete its scribing range SIC Marking launches a new i63s marking machine. This new scribing marking head complements the i113s machine dedicated to deep marking on steel and other hard materials. i63s marking system has a compact yet robust design engineered for integration on production lines of all types of industrial environments. The marking quality is excellent with perfect continuous lines and very fast for materials of all kind, from plastic to hardened steel (up to 62 HRC). The mechanical system is much simpler which has for consequence reduced maintenance. Already equipped with full connectivity (digital I/O, Ethernet TCP/IP, RS232...), our i63s scribing systems also offer many features to interact with all the elements that set up their environment. Our machines can be easily integrated on all production lines using Profinet, Profibus and Ethernet/IP. For more information Web: www.sic-marking.com

168 TECH TRENDS

MATERIAL HANDLING The route of the overland conveyor for the end customer, Cemindo Gemilang, passes through the middle of the rain forest

Beumer develops & implements

COMPLEX SYSTEM solutions The Beumer Group uses its newly created Conveying & Loading Systems (CL Systems) division to develop and implement complex system solutions throughout the world for different industries, such as mining and the cement industry Picture credits: BEUMER Group GmbH & Co. KG

he team is made up of experienced staff from the branches distributed around the world who work together on the projects. What they all have in common is that they understand the user, which means that they can develop tailor-made solutions. This is demonstrated by three impressive completed projects. Dr Andreas Echelmeyer, who has headed the Conveying and Loading Systems division in the BEUMER Group at its headquarters in Beckum since August 2015, stated that

AUGUST 2016 | www.engrreview.com

“We can use our comprehensive expertise in system solutions to advise our customers and provide them with complete plant systems. Each industry poses its own unique challenges”. The most important point is to listen carefully to the customer and then ask the right questions. This can only be done locally. Employees positioned around the world are therefore in close contact with the customer. They are familiar with the specific customs of the particular country, understand the language and are wise to

the particular requirements of the market and the customer. They identify appropriate potential and any possible need for action. The operators for whom BEUMER has successfully commissioned conveying plants includes the TPI Polene Public Company Ltd. The third largest cement producer in Thailand uses this complex system solution to transport crushed limestone from the quarry to the blending bed.

Difficult environment safely overcome Dr Echelmeyer was aware that “The challenge

170 TECH TRENDS

lay in the nature of the ground between the quarry and the cement plant”. It was exceptionally demanding. We had to make allowances not only for numerous obstacles but also for a steep downhill section of the conveyor”. The team designed a complex, but above all cost-effective, integrated system comprising a total of eight belt conveyors covering a distance of 6,129 metres. BEUMER also supplied a PLC plant control system, transfer stations, filter systems and foreign body collectors. The system is designed for a conveying capacity of 2,200 t/h. The key items in the limestone transport system are two downhill belt conveyors operating in the generator mode followed by a troughed belt conveyor with horizontal curves. The material passes from the crusher discharge belt the first two troughed belt conveyors. The material is then transferred to a long overland conveyor with a speed of 4.5 meters per second by an accelerator belt with a speed of 2.6 meters per second. Three more conveyors finally transport the material to the blending bed.

Cost-effective operation guaranteed One particular feature of the downhill conveyors is their power generation. With a total of 640 kW/h generated energy that is fed into the power grid they make a substantial contribution to the cost-effective operation of the overall system. BEUMER supplied four further belt systems with a total length of 989 metres to deal with the discharge from the blending bed and supply the material to the raw mill feed hopper.

BEUMER managed to route the conveyor along a very narrow stretch of land in Vietnam for the cement producer Cong Thanh

The conveyors were all built and installed in only eleven months.

Complex and curved Cong Thanh, the Vietnamese cement producer, also relies on the system solution expertise of the BEUMER Group for transporting crushed limestone from the quarry to the blending bed. The CL team discussed the various technical options intensively in a joint workshop held with the producer. Various routes were worked out and compared on the basis of the narrow terrain that was available. Dr Echelmeyer explained that “We have appropriate software for this, with which we can match satellite and aerial photographs with topographical data”. One conveyor section that drops steeply in some places with numerous obstacles in the terrain and seven road crossings was Among other things, BEUMER supplied a troughed belt conveyor with horizontal curves and a length of 3.5 kilometres for the Thai cement producer, the TPI Polene Public Company.

particularly challenging. A total system consisting of four conveyors with a combined length of 3.5 kilometres is now in use, BEUMER also supplied a PLC plant control system. The main component is an overland conveyor with three horizontal curves and a total drive rating of 600 kW. It is designed for a continuous conveying capacity of 2,200 t/h. The heaped material is transported in trucks from the quarry face to the crusher. The limestone that has been pre-crushed to less than 100 millimetres is then transferred by discharge conveyors to an accelerator belt that feeds the long belt conveyor. The troughed belt conveyor for downhill transport is one meter wide, with a distance between centres of 3,200 metres, and drops 70 metres. The conveying speed is 4.5 meters per second. The low operating costs are a special feature. Due to the downhill section the operation of the fully loaded conveyor is virtually energy-neutral. Its consumption during continuous operation is less than 200 kilowatts, which means that not even 0.1 kilowatt is required per tonne of transported material. According to Dr Echelmeyer “This, together with the low maintenance and repair costs, contributes substantially towards costeffective operation”. After the installation and commissioning his team submitted the plant to a performance test that it passed successfully on all points.

Through the middle of the rainforest The CL Systems division of the BEUMER Group has also been very successful in

AUGUST 2016 | www.engrreview.com

172 TECH TRENDS

Transfer situation before the blending bed

Achmed Ammoura, chief erector in the BEUMER Group, at the belt conveyor with horizontal curves

Indonesia. The plant construction company Sinoma International Engineering Co. Ltd. was awarded the contract by the Indonesian end customer, Cemindo Gemilang, to supply a turn-key cement plant to Java. It should reach a daily clinker production of 10,000 tonnes. Sinoma commissioned BEUMER with the design and supply of an overland conveyor between the quarry and the plant. The challenges in this project were not only the demanding topographical routing but also the evergreen rainforest. Joint discussions were held between the BEUMER team, Sinoma and the end customer. The team worked various routes out and compared them. “The very narrow corridor of land in addition to the tropical climate required a complex and sophisticated design” explained Dr Echelmeyer. Among other things his team

designed a solution with tight horizontal curves that fitted optimally into the landscape. The entire system now comprises six conveying plants with a total of length of 7.6 kilometres. BEUMER also supplied acceleration and discharge conveyors and a PLC plant control system.

Controlled loading ensured The system is designed for a maximum continuous conveying capacity of 3,000 tonnes per hour. The main component is a 7.4 kilometre long overland conveyor. Upstream of this troughed belt conveyor is an intermediate hopper with a capacity of about 120 tonnes. The material passes from this hopper via a variable-speed discharge conveyor to a downstream acceleration belt that feeds the overland conveyor. This controlled loading

system ensures cost-effective operation of the plant, especially during the startup phase. It also has a favourable effect in the dimensioning of drive components and the belt, and reduces the operating costs. According to Dr Echelmeyer “The acceleration belt with a speed of 4 meters per second protects the belt of the overland conveyor and increases its service life”. For further protection there are also upstream units for collecting any iron and non-ferrous metals. The limestone is then transported to the blending bed on short troughed belt conveyors. The troughed belt conveyor has a width of 1,200 millimeters and a distance between centres of 7,381 metres. One tail drive and two head drives are installed, each with a rating of 545 kilowatts. The plant conveys the material at a speed of 5 m/s and negotiates a height difference of minus 188 metres.

Protection of people and animals

Transfer tower in the feed area

AUGUST 2016 | www.engrreview.com

The conveying system also runs past villages and for long sections passes through rainforest that deserves to be protected. The CL Systems team has taken numerous design measures to reduce the noise impact on people and animals. Dr Echelmeyer explained that “Among other things, we have used low noise idler rollers and appropriately dimensioned protective hoods at the drive station” . This means that the limestone passes through the rainforest in virtually silent mode. The construction time lasted only one year. For more information Web: www.beumergroup.com

174 TECH TRENDS

ENGINEERING

MOTORIC VALVE DRIVE :

The versatile valve drive for all applications With its Motoric Valve Drive, Möhlenhoff, the specialist for heating, ventilation and air conditioning solutions, has included a motor-driven valve drive in its portfolio for the first time

T A functional display with optional backlighting alternately shows the drive position and status, the applied control voltage and the operating position.

he Motoric Valve Drive extends the popular “OEM Actuator 5” product range and is particularly suitable for applications that demand higher actuation forces and the greatest possible strokes. Whether it is used with balanced valves, line valves or in fan coils – the Möhlenhoff Motoric Valve Drive excels wherever a rapid control response is required independently of the temperature. Perfectly harmonized gearing with a robust, high-end stepper motor ensures absolute precision combined with an impressively low sound level. With an actuation force of up to 200 Newtons and a stroke of up to 8.5 millimeters, the Motoric Valve Drive also offers particularly high performance. Both of these parameters can be configured ex works, as can the runtime. This guarantees many different uses and potential application variants for trade and industry alike.

High energy efficiency The Motoric Valve Drive excels not just through its low-noise operation but also through its high level of energy efficiency. The entire micro-

AUGUST 2016 | www.engrreview.com

15KV HIGH VOLTAGE INSULATION TESTER

An ISO 9001:2008 Company

MODEL KM 7015

FEATURES : — Microprocessor controlled Menu driven. — Measuring 30 Insulation Test Voltage Ranges. 500V, 1kV, 1.5kV, 2kV, 2.5kV, 3kV, 3.5kV, 4kV, 4.5kV, 5kV, 5.5kV, 6kV, 6.5kV, 7kV, 7.5kV, 8kV, 8.5kV, 9kV, 9.5kV, 10kV, 10.5kV, 11kV, 11.5kV, 12kV, 12.5kV, 13kV, 13.5kV, 14kV, 14.5kV, 15kV. — Insulation Resistance 70GW / 0.5KV.

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— AC Voltage : 0 ~ 700V. — DC Voltage : 0 ~ 1000V.

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— PI, DAR & Auto Hold Function. — 2 Lines X 16 Characters large LCD Backlight display. — Auto ranging on all insulation ranges. — Internal memory for data storage. — 2 optical LEDs are built in for data transfer.

Preliminary Data

CLAMP-ON TYPE EARTH RESISTANCE TESTER MODEL KM 1720

FEATURES : — Leakage Current Measurement

— Current Measurement : 0.00 ~ 20.0A

— Alarm function for Earth Resistance & Leakage Current. — Automatic self calibration &

— Measured Current frequency : Sinusoidal 50Hz — Storable Measurement Data : 99 Units

range selection.

— Memory to store data. — Resistance Measurement

— Measurement resistance Frequency : >1KHz

range : 0.01 ~ 1000W

www. kusamelectrical.com

function.

G-17, Bharat Industrial Estate, T. J. Road, Sewree (W), Mumbai - 400015. India. Tel. : 24124540, 24181649, 27750662 Fax : (022) 2414 9659, 27751612 An ISO 9001:2008 Company

E-mail : kusam_meco@vsnl.net , sales@kusam-meco.co.in

176 TECH TRENDS

Because the housing with protection class IP54 is protected against moisture irrespective of the assembly position, the valve drive can always be installed as requirements demand.

With the Motoric Valve Drive, Möhlenhoff now has a motor-driven valve drive in its portfolio for the very first time. It excels wherever higher actuation forces and the greatest possible stroke are required.

Thanks to the unique valve adaptor system, the Motoric Valve Drive is compatible with practically every valve as well as with Möhlenhoff’s 0-10 V thermoelectric valve drives.

controller-based motor control unit ensures low power consumption. Because the housing with protection class IP54 is protected against moisture irrespective of the assembly position, the valve drive can always be installed as requirements demand. A functional display alternately shows the drive position and status, the applied control voltage and the operating position. The display is also optionally available as a backlit unit.

Flexibility The Motoric Valve Drive can be used in twopoint or three-point mode as required. The continuous variants are controlled using a 0-10 V control voltage or a PWM signal. On request,

AUGUST 2016 | www.engrreview.com

the valve drive can also be equipped with valve stroke recognition and a feedback signal. Thanks to Möhlenhoff’s unique valve adaptor system, it is compatible with practically all valve types. The connecting cables are the same as those used for Möhlenhoff’s thermoelectric valve drive technology. Assembly is performed easily using a plug-in system without the need for any tools. The maintenance-free valve drive offers a high level of functional reliability and a long service life. OEM customers can also benefit from numerous customizations – from customer-specific labeling, through accessories kits bearing their own corporate designs and on to individualized product designs.

178 TECH TRENDS

CONSTRUCTION

Designing an

ECO-FRIENDLY home

A detailed look at what it takes to build an eco-friendly home By Natasha Iype, Director, GoodEarth

f you are designing an eco-friendly home, what kind of materials, fittings and fixtures should one use. Let’s start with design for natural light and ventilation. One of the most important features when it comes to planning an eco-friendly home is its design. Design your home to ensure adequate natural light and cross ventilation. Large windows, wide verandahs, air channels for circulation, and thermally conducive materials, are all features which reduce the necessity for artificial light and ventilation. It also makes the house look spacious and helps in channelizing the flow of natural energy. An eco-friendly home should inspire you to conserve, care for, and appreciate the environment that surrounds you.

Use Sustainable Building Materials If building an eco-friendly home is your goal, then using environmentally or eco-friendly materials like reclaimed timber, any material that does not have high embodied energy used in its production, like aluminum, glass. It is better to use materials that are earth –based, like mud blocks, terracotta. . All these products reduce the impact of construction on the environment. Also using them conservatively- not in excess, but only where required. The materials must be used functionally, which creates a better aesthetic, rather than using them to create an “artificial aesthetic.

AUGUST 2016 | www.engrreview.com

term savings you can put into your pocket is a stunning example of the benefits of turning your life from black to green. The location of your house and the way you have constructed solar panels can determine how much power you can collect. By taking advantage of solar power you can bring down your energy consumption and supply excess energy, if any, to your utility company. Also, government grants, incentives and tax breaks are huge bonus to those who want to use solar power in their home.

Rainwater Harvesting Ms .Natasha Iype founder of GoodEarth

Reduce, Reuse, Recycle Reduce your need for buying new products that are not environment friendly. Reuse your old material such as wood floors, doors, windows in your next home. Recycled materials such as recycled glass, aluminum, recycled tile, reclaimed lumber, recycled plastic can be used in green home building.

Install Solar Panels Solar energy is clean and renewable source of energy. Solar panels are an emerging and hot technology for people who want to utilize the natural power all around us, the sun. Solar panels may be expensive at first, but the long-

Install a rainwater harvesting system while building your green home to collect rainwater from roofs and store it in a tank. The collected water can then be used for other purposes such as cleaning and sprinkler systems. Rain barrels are one of the most common methods of rainwater harvesting being used today.

Water Conserving Fixtures Low flow faucets, toilets, showerheads are few of the ways that you can use while building a green home to conserve water. They can cut down on your water bills and make your home much more environment friendly. Apart from that, consider buying washing machines and dishwashers that give you same kind of cleaning and can save water and energy.

180 TECH TRENDS

Importance of investing in a planet-friendly home The world as we know it has limited resources. It is our responsibility to ensure that these

AUGUST 2016 | www.engrreview.com

scarce resources are used in a prudent manner. One of the basic ways in which we can make a difference to society is by investing in a planet-friendly home. Planet-friendly homes or green homes take into account each and every aspect of design and construction and has the power to change the way we live. It enhances and can reinforce the intention of any community. It is a tool to create environments that are responsive to climate, location and human needs. Scientific understanding of structural requirements, properties of materials, efficient engineering, and construction are some of the important foundations on which green homes are ideated and built. Shelter, is a basic human requirements and thus investing in a planet-friendly home is the most important need of the hour; if we want to preserve this beautiful world for our future generations.

Converting a non-green home to an eco friendly one Being environmentally friendly simply means having a lifestyle that is better for the environment. One can convert a non green home to an eco-friendly one by taking small steps towards mother earth so as to make this planet a better place for our communities and generations to come. A good way would be to start with conserving water, driving less and walking more, consuming less energy, buying recycled products, eating locally grown vegetables, joining environmental groups to combat air pollution, creating less waste, planting more trees and many more.

For more information Web: www.goodearth.org.in

182 TECH TRENDS

AUTOMATION

Connecting IT with Operational & Engineering Technology for Asset Performance Modelling As operations technology (OT) leverages the Industrial Internet of Things (IIoT) with sensors on operating equipment and assets producing an enormous volume of big data, there is a need for improved security, information sharing and data management By Bhupinder Singh, Chief Product Officer, Bentley Systems and Anne-Marie Walters, Global Marketing Director, Bentley Systems

s operations technology (OT) leverages the Industrial Internet of Things (IIoT) with sensors on operating equipment and assets producing an enormous volume of big data, there is a need for improved security, information sharing and data management. This, in turn, is driving an unprecedented convergence with IT. However, organizations are struggling to make use of the data from their OT and IT systems, causing them to miss opportunities to improve asset performance. This is due, in part, to the fact that the digital engineering models developed during the engineering phase of capital projects, are typically not playing a role in operations. What if owner-operators could use these models in operations? Imagine how a digital engineering model—the engineering technology or ET of an asset—could help operations and maintenance people forecast problems, do better planning, and improve performance. It is now possible for companies to converge their IT, OT and ET – and seamlessly integrate process and information flows between them – to enable asset performance modeling to deliver actionable intelligence for decision

AUGUST 2016 | www.engrreview.com

support through an immersive environment for visual operations.

The Digital Engineering Model For many years, engineering departments have been using advanced modeling and simulation applications that focus on the process of design and construction of an infrastructure

Figure 1: Digital engineering models bring together critical information in a virtual 3D environment.

asset – a plant, bridge, highway, railway or utility network – in a way that improves project delivery and asset performance. Better project delivery enables companies to optimize CAPEX – through both the depth of information modelling and the breadth of information mobility for collaboration during design and construction. There’s a staggering amount of information related to assets– detailed component specifications, precise geo-location, configuration management, fabrication details, cost information, predicted lifetimes, recommended maintenance and repair information. Today’s engineering technology makes it possible to bring all of this information together within the federated digital engineering model, making it possible to track, access, and share with others collaborating on the project (see Figure 1). The technology also enables engineers to model projects in a 3D virtual setting for design integration and construction work packaging, so that when the project is actually constructed in the real world, the project teams and stakeholders are able to minimize unforeseen situations and keep the project on track.

184 TECH TRENDS

The Beginning of IT/ET/OT Convergence

Figure 2: Asset performance monitoring brings together IT and OT with big data analytics.

Figure 3: Asset performance modeling integrates 3D models with IT and OT systems used to model asset performance.

The Industrial Internet of Things (IIoT) is driving a convergence between operational technology and information technology. Digital engineering models can accelerate this convergence and add the visual representation of the real world needed to aid decision making; this can have far-reaching impacts on the safety, productivity, efficiency and operations of industries worldwide. For example, consider how South Australia Water is currently using predictive and real-time operational analytics to forecast water demand and improve customer service while reducing operational costs. To create a demand forecasting tool, they needed to pull information from both the operational and IT sides of the organization in real time. Bentley’s predictive analytics software was chosen as the operational intelligence platform due to its real-time ability to connect and capture data from a wide variety of sources, ability to perform complicated calculations and analysis, and its impressive visualization capabilities. Real-time monitored sensor data is brought in from the reservoirs, water treatment

plants, valves, flowmeters, and pumps spread across the extensive pipeline network. This operational data is combined in real time with climate, energy, cost, and population data and is displayed on dashboards. Bringing these data sources together has resulted in huge benefits, including improved performance, enhanced understanding of interrelationships, and better decision-making and more accurate predictions of short- and long-term demand. Tying together IT, OT, and ET also allows the company to take advantage of lower forward market pricing for electricity. They can use an energy portfolio management spot-market power price tool to determine the optimal timing for pump operations on five pipelines, as well as when to purchase power in highly volatile markets. The impact on OPEX can be significant – a savings of AUD 3 million per year.

For more information Web: www.bentley.com

Bhupinder Singh- Chief Product Officer, Bentley Systems Bhupinder joined Bentley in 1994 and was appointed to chief product officer in 2016. His team is responsible for the development, sales, and user success of Bentley’s industry-leading software solutions for advancing infrastructure. His prior roles at Bentley include senior vice president of Bentley Software, senior vice president of the Platform Products Group, and managing director of sales for Bentley South Asia. Prior to Bentley, Bhupinder held various software engineering positions at Montgomery Watson Hazra (now Stantec-MWH), Bell Labs, and Intergraph Corporation. Bhupinder holds a master’s degree in computer science from Rutgers University and a master’s degree in structural engineering from Vanderbilt University. He also holds a bachelor’s degree in civil engineering from the Indian Institute of Technology, New Delhi, and a certificate in management from the Wharton School of Business at the University of Pennsylvania.

Anne-Marie Walters- Global Marketing Director, Bentley Systems

Anne-Marie Walters joined Bentley in 2004 as a global marketing director. In this capacity she is responsible for the marketing and positioning of Bentley’s solutions and products that address the needs of the Process, Power, and Enterprise arena. Ms. Walters, who is a chartered chemical engineer, represents Bentley on the board of the Construction Industry Institute and is also heavily engaged in the activities of FIATECH. She sat on the board of the Engineering Contractors and Constructors Association between 2005 and 2010 and was the Chair in 2009. In addition, she is a founding member of the Process Industries STEP Consortium (PISTEP) committee and has served on the boards of CIMsteel and the United Kingdom’s chapter of the International Alliance for Interoperability (IAI). She is frequenta guest speaker at industry events sponsored by these and other organizations.

AUGUST 2016 | www.engrreview.com

186 CASE STUDY

AUTOMATION

How automation helped

SPECK BOOST its productivity Since 2010 SPECK has consistently relied on automated machine tools from DMG MORI Systems in order to boost capacity in its production

AUGUST 2016 | www.engrreview.com

PECK PUMPEN Walter Speck GmbH & Co. KG from Roth produces more than 250,000 pumps and pumping systems for industrial applications a year. The company has been supplying customers in over 40 countries for more than 100 years. SPECK produces its specialised products primarily for customers from the medical technology, chemicals and pharmaceutical industries, for cooling and temperature control equipment and for the plastics industry. The high level of specialist expertise of its more than 450 employees worldwide is supported in mechanical production by state-ofthe-art machine tools. Automated systems from DMG MORI have played a significant role here since 2010, as the latest investment proves. For this DMG MORI Systems linked a MILLTAP 700 and a CTV 160 using an automation solution. When asked about the core competences and

the differentiation features of his company, the CEO Wolfgang Krüger mentioned especially its innovative and application-orientated capability. “We unite this with a high level of flexibility in production and assembly in the manufacturing of our many different components and with short delivery times.” To appreciate the importance of this statement it is worth taking a look at the product programme. The company’s website mentions no less than 26 or rather 33 areas of application in its fluid and vacuum pump divisions. Its list of references includes standard applications in machine tool manufacture, in laser and welding technology or in agricultural and rail vehicle manufacture as well as the proverbial exotic use of special pumps for tobacco moistening. To accommodate this multitude of applications SPECK in Roth offers a total of 18,000 different

CASE STUDY 187

pump versions in over 80 series – and often in different performance classes as well. So it is no surprise that there are no standard parts in the production halls. “The average batch size in mechanical production is just 50 to 100 parts.” In view of the outlined requirements profile, the question as to the importance of its own production is easy to answer. Wolfgang Krüger points out the close interaction between machine tool, tool and cutting material and

stresses: “The autonomous development of new or alternative manufacturing strategies and continuous further development in all the sectors mentioned are what boost the productivity of our manufacturing processes.” The company would lose a big portion of relevant expertise if it purchased workpieces from outside. “Added to this is the extremely high demand placed on the quality of the pumps.” In order to maintain a high degree of efficiency, the gap dimensions

of the SPECK pumps are often in the range of a few hundredths of a millimetre. Such quality pressure is further intensified by the trend towards ever smaller pumps with an ever higher degree of efficiency. But in the last instance, it is not just economic and qualitative issues that are decisive for Wolfgang Krüger. “Demands for ecological and humane compatible production are growing in importance.” One example of this is efficient dry processing or at least a reduction in the amount of coolant lubricant needed. Another example at SPECK are automated manufacturing systems.

DMG MORI Systems‘ first automated machine tool This productive form of manufacturing has grown dramatically in importance since 2010 when DMG MORI Systems installed the first automated machine tool – a CTV 160. A highly complex system comprising a CTX alpha 500 with stations for measuring, truing and pressing followed in 2011. A shaft and a rotor are connected to an armature shaft that SPECK produces for pump motors on this system within about a minute. “The original procedure involving several machining steps and a manual pressing process took far, far longer”, recalls Dieter Meier, Head of Mechanical Production. Nowadays all that is

www.engrreview.com | AUGUST 2016

188 CASE STUDY

needed is to feed the automation solution with the orders for the different component variants and load the respective blanks. “The high level of precision achieved in machining is also of great benefit. Automated production scores points in this respect due to its high repeat accuracy.” Such automation drastically reduces throughput times and boosts quality while at the same time gaining time for the specialist workers to perform other tasks, as Dieter Meier goes on to tell us: “Our workers can operate several machines simultaneously during the autonomous machining cycles.” It was this same motivation that lay behind the investment in meanwhile two such linked systems for the manufacture of motor bearing shields. Turning

AUGUST 2016 | www.engrreview.com

is carried out by a CTV 160 in both systems, while a MILLTAP 700 handles boring in the case of the newest automation. As DMG MORI did not have the compact machining centre in its programme in 2012, the older investment uses a DMC 635 V for this purpose. “The output of the two systems is enormous”, says Dieter Meier. SPECK produces over 250,000 motor bearing shields a year on the two respective linked machine tool systems.

Achieving diversity in components However, the high quantity does not mean that the actual batch sizes do not remain relatively small, as the Head of Production goes on to explain: “We need the components in a number of different diameters and variations, so both systems had to be set up to be extremely flexible.” DMG MORI Systems

achieved such diversity in components by incorporating flexible chuck jaws. The equipment in the rotary magazine can be adjusted to the right diameter in no time at all. DMG MORI Systems designed and implemented the two linked systems on the basis of the components. “We were able to start production within three months”, says Dieter Meier looking back at the fast realisation of the first system. Installation of the second system was even less complicated: “Apart from the MILLTAP 700 this system was identical in design to the first one, because we were more than satisfied with that first investment.” Dieter Meier believes that automation is the future of manufacturing: “With their short throughput times, higher capacity and considerable boost to productivity, due not least to multiple machine operation, automated manufacturing systems pay for themselves extremely quickly.” Such machining solutions also simplifies the work of our employees enormously. For more information Web: www.dmgmori.com

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190 CASE STUDY

MACHINE TOOLS

Trusted Family-Business

TRUSTS IN HAAS Having invested in the first Haas CNC machine in 2007, G-Tech has continued to trust the capabilities of Haas machines

t seems there’s always a need for general-purpose machine shops, wherever in the world they find themselves. These are companies, often family-owned, that make a specialization out of being generalists. Usually they don’t have their own product lines; they maybe don’t even have a preferred industry sector or a particular technology that sets them apart from other job shops. What they do have, however, is their reputation. Italy has its fair share of such companies, and G-Tech CNC, based near Reggio Emilia, is one of them. “We are here for what the market needs, when it needs it,” says Davide Gherpelli, com-

AUGUST 2016 | www.engrreview.com

pany front man. “We can supply prototype parts in small quantities, or we can provide parts in high volume – large batches of series production. No particular sector; we think of ourselves as a 360 degree company.” From the 1970s until 2011, Davide’s father, Giorgio Gherpelli, ran G-Tech. In fact, the company actually began with his father, Davide’s grandfather. It was 2004 when Davide joined and almost a decade later when they welcomed Mirko, his younger brother, whom they

CASE STUDY 191

call the ‘mago’ (the magician), for his skill with the Haas CNC. Now, there are 5 employees at G-Tech. But between them, they run a very busy machine shop. “We invested in our first Haas CNC machine in 2007,” remembers Davide: “An SL-10 turning centre. We then bought a Super MiniMill, an ST-10Y turning centre with live tooling, a VF-

2SS high-speed mill, and a VF-1, which is our general-purpose machine. In fact, we have a Haas machine tool for almost all our machining needs. We have a very good selection!”

Trusted capabilities Davide claims that his early experience with

Haas helped make up his mind about the capabilities of the machines, and their suitability for a growing job shop. “It’s not just me, though,” he says. “You can look around the workshop and see how much we all love these machines. We eat, sleep and breathe Haas!” Projects vary as much in type and industry sector as they do in volume of parts required. The company’s Haas VF-2SS, equipped with an HRT210 is, says Davide, always busy. “We use this machine a lot for more complex parts – typically, prototypes. We use TopSolid CADCAM and programme off-line, whereas, with the ST-10, we usually programme at the machine. We’re currently using the ST to make bearing housings for the Airbus A350 and Ti rear wheel hubs for the Politecnico di Torino hyper-mileage car. The VF-1 is being used to machine parts for a drone used to measure contours of the land in 3D.” Around the workshop are various other projects that the company isn’t at liberty to discuss openly. One component in particular looks like the inner part of a steering wheel for a high-performance sports car. “I can’t tell you anything about that,” smiles Davide. “Secrecy is important for some of our customers.” Good reputations are hard to come by but very easy to lose. “We’ve built our reputation on delivering good parts on time,” says Davide, “but also for being trustworthy and discreet, at the same time. “The automotive sector in particular is very sensitive, especially in this part of Italy. There are some big names nearby.” As proud Italians, that’s work the Gherpelli family intends to keep and may well be the key to the company’s future growth. “As our assignments become more complex, and we attract more big-name customers, we already know we will need more Haas machines; the UMC750, for example.” For more than 50 years, five axis machining was simply too expensive for small to medium sized job shops like G-Tech CNC. Not anymore. “The UMC750 is an affordable 3+2 machine tool,” concludes Davide. “Like the Haas machines we already own, if we buy one it will allow us to expand and build our business for years to come.” And with its reputation preceding it, perhaps this family will stay in business for many more generations, as is the Italian way.

For more information Web: www.HaasCNC.com www.engrreview.com | AUGUST 2016

192 CASE STUDY

AUTOMATION

European reliability drives selection in Thai retail distribution centre When it comes to refrigeration applications, Emerson Industrial Automation has been offering solutions to this demanding market for many years

ased in Bangkok and established in 1986, Sirayooth has evolved to become one of Thailand’s leading providers in the design and implementation of refrigeration systems for seafood, fruit, vegetable and poultry cold storage. Besides working in Thailand, Sirayooth also offers its in depth technical services and expertise in neighbouring countries such as Indonesia, Vietnam and the Maldives. This particular project centred on a retail distribution centre for Thailand’s largest retail company. The requirement here was for Sirayooth to design, fit and commission a series of ammonia based compressors, in order to keep contents within the facility at optimum temperature levels. Sirayooth utilise ammonia as it’s both very efficient and friendly to the environment. In refrigeration applications, trouble free operation is a key requirement. If any system

AUGUST 2016 | www.engrreview.com

components used are of poor quality this would jeopardise the performance of the refrigeration system and ultimately risk products inside the facility being spoilt. This potential cost to the retailer has to be mitigated for, as system failure could potentially cost them a great deal in terms of spoilt produce, stock replacement and lost sales. With this in mind Sirayooth looked to limit risk by selecting motors for their compressor systems from a manufacturer who has a long-standing reputation for quality and reliability. Indeed, the retailer has a preference for European designed and built motor products.

Long and rich relationship Sirayooth has a long-standing relationship with the local Emerson Industrial Automation representative. After a period of technical consultation Emerson’s know-how in refrigeration applications proved invaluable, particularly when it came to the final motor selection based on the key specification point of reliability. It was decided that a number of Leroy-Somer IMfinity® 2 motors in the power range of 9 to 250kW were the ideal fit. Leroy-Somer, based in France and part of the Emerson group, has for the best part of a century been supplying motor solutions for a wide range of applications. Within this field it has built up an enviable reputation for quality reliable solutions. What’s more,

the industrial refrigeration market is a particular area of expertise. Featuring an advanced mechanical and electrical design (magnetic core optimisation) IMfinity® has been designed to deliver extreme reliability in all installed applications. Representing a truly global motor solution IMfininity® is able to operate with all the major worldwide voltages and frequencies covering at least 80% of power supplies.

Cost effective and technically capable motors Another key factor in this particular application was the rapid supply of motors for the build, utilising Emerson’s Express Availability service. Indeed the whole project including the delivery of motors from Leroy-Somer’s European facility, through installation/commissioning to full operation took just four months. “Both the pre and post sales support that Emerson gave us was a clear indication of their knowledge of the refrigeration market and the optimum motor solution for this particular application” stated Mathieu Balay of Sirayooth. “The fact that they were able to offer cost effective technically capable reliable motors means that we have complete confidence that trouble free operation will be assured.”

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194 CASE STUDY

MACHINE TOOLS

Interconnected engineering service increases productivity for startup Kollmorgen’s backlash-free direct drive solution allows exact synchronicity and concentricity with maximum precision up to 2 µm, and is more cost-effective

Equadrat AG is a start-up that has been providing highly specialized solutions for four years as a mechatronics service provider, particularly in the laboratory and medical areas. Interdisciplinary thinking plays a fundamental role in this company’s product development activities. Original ideas related to implementation, efficient development and customized support also characterize the collaboration they had with drive specialist Kollmorgen on their new production module for the medical sector. Kollmorgen’s backlash-free direct drive solution allows exact synchronicity and concentricity with maximum precision up to 2 µm, and is more cost-effective

municipality of Root in Lucerne, is networked thinking and the creation of new machines and systems that meet its customers’ needs through consistency in the software used, the sophisticated mechanical and electronic components, and the associated increase in the degree of automation. One thing is clear for Stefan Nyffenegger, a member of the executive management team at MEquadrat AG: “The interlock between the mechanics, electronics, and software is the key to innovative products and higher productivity. We also break new ground with our unconventional approach, as can be seen with the current project for a machine module that is designed for processing thin-walled material in the medical sector”.

Networked thinking

Precise clamping despite high levels of rotation

One of the founding concepts of the service company MEquadrat AG, situated in the

AUGUST 2016 | www.engrreview.com

The two-sided and torsion-free clamping of

196 CASE STUDY

highly sensitive glass and aluminum tubes is a particular challenge for the production module developed and constructed in Root. The product diameter ranges from between around one millimeter to 20 mm, with very thin wall thicknesses of around one-tenth of a millimeter. Cutting and joining processes are carried out on the sensitive hollow rod material. The high speed for the material clamped on both sides in the process requires absolute precision in terms of the synchronicity. Developing the overall module in such a compact manner in accordance with the customerâ&#x20AC;&#x2122;s strict specifications required a highly meticulous and extremely precise drive system for the spindles in the workpiece

AUGUST 2016 | www.engrreview.com

feeder mechanism and for the relevant process steps with the clamped product. Stefan Nyffenegger highlights: â&#x20AC;&#x153;With the KBM kit motor solution from Kollmorgen we have found the perfect solution for our needs, as the product can be guided through the drive in a fluid process thanks to the large hollow shaft.â&#x20AC;?

Collaboration on an equal footing The engineers at MEquadrat already had the idea of selecting a direct drive as they were designing the drive system. Their intention was to use an existing modular design in order to meet the precision requirements and to guarantee implementation on a time and cost-efficient basis. But it became apparent that a rotor

and a stator with the full functionality of a servo drive should be used as a result of the compact packing density and complexity of this assembly. In the end, the company decided the best solution was from Kollmorgen. The experts at the drive manufacturer were ready for any special requests. Decisions at the implementation stage for this project were made very quickly, as the experts from both companies collaborated with each other on an equal footing. The synchronicity however remained a problem. But a few ideas were developed for this and the product selection was narrowed down during some initial telephone discussions. The Key Account Manager at Kollmorgen,

198 CASE STUDY

Benefits • High flexibility of the coordinated components • Integrated hollow shaft for special application predestines integration of a clamping system which maintains its clamping force even at 3000 rpm • Direct drive without any play or redundant mechanical parts allows exact synchronization and concentricity with the utmost precision up to 2 µm and is thereby hard-wearing • Excellent, comprehensive support from Kollmorgen from design through execution to commissioning • Easy conversion to different diameters

the optimum price-performance ratio.”

Precise positioning with plug-andplay solutions

Martin Zimmermann, and his colleagues providd their full support: “When MEquadrat only requested the rotor and the stator for the feeder unit in this project, we knew that a mechatronics engineer would need to focus on the motor in greater detail. You have to have confidence when trying new things like in this project, which requires mutual and absolute trust”. Aside from the time pressure and the extreme requirements related to precision in the functional specifications, there was another additional crucial challenge related to the medical technology: “The drive solution must be free from abrasion and lubricant, and we weren’t able to carry out any experiments

AUGUST 2016 | www.engrreview.com

at the implementation and commissioning stages for the mechanics and software”, says Nyffenegger. All of the components provided in this machine module therefore had to be tested and shown to be absolutely reliable. The interaction of the direct drive with AKD Drives and the controllers from National Instruments (NI) enables extremely precise positioning. The cycle times in the current regulator are around 670 ns, and are just 62.5 µs in the speed regulator. Nyffenegger stresses: “This allows us to achieve optimum synchronicity in line with these high dynamic requirements. As such this drive combination represents

The crucial thing here that the two synchronized axes achieve extremely precise concentricity of 2 µm. Nyffenegger adds: “We’re talking about accuracy ranges that are otherwise only seen in spindle axes in large production plants.” The high speed was another of the major challenges in this project. There are systems on the market that “can indeed clamp sensitive products such as these at the required level of accuracy, but they often lose their clamping force from 500 rotations per minute. I haven’t seen any comparable product on the market that maintains its full clamping force at 3000 rpm!”, highlights Nyffenegger. The “AKM” drive with single-cable solution and SFD feedback were selected for the linear axis in the machine design. The components now just needed to be put together and everything fitted perfectly. The resolver method as a single-cable solution is one of the drive expert’s specialties aimed at making optimum use of the robustness of the resolver. Nyffenegger stresses: “The wiring required in the AKM motor is also minimal here as a result. Highly compact cable carriers can also be used which really are sensational for tight spaces.”

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