Engineering Review March 2015 by Divya Media Publications Pvt. Ltd.

Haas Automation India Pvt. Ltd. - The Haas VF-2SS Super Speed Vertical Machining Center

March 2015 ` 200

A MONTHLY MAGAZINE ON ENGINEERING & ALLIED INDUSTRY

RELIABILITY. PRICE. REPUTATION.

Haas VF-2SS Super Speed Vertical Machining Center

= TOTAL CUSTOMER VALUE. Haas Factory Outlet

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Volume 14 No. 11

AUTOMATION » BUSINESS NEWS

OMRON showcases new concepts and products for Smart Meters at the India Smart Grid Week-2015 (ISGW)

MRON’s Electronic and Mechanical Components business arm displayed its prowess in the field of development of electronic components for smart meters at the ongoing India Smart Grid Week - 2015

(ISGW). ISGW- a conference cum exhibition organized with the support of Ministry of Communication & Information Technology, Ministry of Renewable Energy, Ministry of Power, Ministry of Urban Development and Ministry of Science & Technology – is a congregation of India’s leading electricity utilities, policy makers, regulators, and smart grid and smart city experts and researchers to discuss trends, share best practices and showcase next generation technologies and products. Commenting on the participation Mr. Vinod Raphael, Country Business Head, OMRON Electronic & Mechanical Components Division, India said, “Power is an indispensible element of the infrastructure of a country, playing a key role in driving its economy. Reports manifest that though India operates as the fourth largest power system in the world, our per capita consumption of electricity is one-fourth of the world average and one-third of our population have no access to electricity. Some of the key factors contributing

towards this issue are technical and non-technical losses including power pilferage. Omron is working towards creating products and solutions in optimal energy management to address these issues which will be truly beneficial to the Indian society in the long run.” Apart from smart meter solutions, the OMRON booth also showcased its industrial automation applications utilized by the panel builders in the field of electricity generation. Being amongst the global leaders and pioneers in bringing innovation to a variety of manufacturing fields through automation technologies, Omron’s participation underlined its long term commitment of contributing towards a smarter and progressive India. For more information Web : www.omron.com

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Shilpa Vinayak Kadam Yes A3/604, Chavandai Tower, Old Thane - Mumbai Road, Parsik Nagar, Thane -400605

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Rajeev Iyer Yes Flat No. 703,Versova, Vinayak Soc, Sardar Vallabhbhai Rd., Four Bunglow, Andheri (w), Mumbai - 400058

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2 | MARCH 2015 | ENGINEERING REVIEW

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AUTOMATION » BUSINESS NEWS

HARTING India organized “MANTHAN 2015” for German Delegation Journalists visited German companies in India

ndia is the partner country of Hannover Messe 2015. Now a group of renowned German journalists from leading media visited India. They wanted to understand how German companies are performing and why they have invested heavily in India market. To gain in-depth knowledge about Germany companies operation in India, the guest were invited to plants of ABB, Siemens, Rittal and Festo Controls, Phoenix Contact. Details of how German products are becoming an important aspect of being a “solution provider” in India is explained and presented to the group. HARTING India organized “MANTHAN 2015”, a cultural night on 24th February 2015 at Taj Vivant, Bengaluru. The theme of the event is “Manthan”, which means “Reflection Through Study”. In order to give comprehensive information about HARTING Technology Group, Mr. Edgar-Peter Duening, Managing Director, HARTING Electric, delivered the key note address and gave presentation about history of HARTING Group and its financial performance. Mr. Detlef Sieverdingbeck, General Manager

4 | MARCH 2015 | ENGINEERING REVIEW

Communications & Public Relations, presented how HARTING is positioning itself as an important enabler of solutions for the Integrated Industry/ Internet of Things and Services.. Our esteemed customers, Mr. R. Shekhar, Dy GM – BHEL, and Mr. Janardhana Kunder, Sr, Manager-Moog Controls, shared their happy experience with HARTING. The presentation was followed by various thrilling performance like Bollywood Fusion Dance, Puppet Show and Belly

Dance. The guest relish most of the finest Indian dishes and brought profound memory home.

For more information Web: www.HARTING.in www.engrreview.com

AUTOMATION » BUSINESS NEWS

FARO® continues expansion into law Enforcement

Market with Acquisition of ARAS 360 Technologies Inc.

ARO Technologies, Inc. (NASDAQ: FARO), the world’s most trusted source for 3D measurement, imaging, and realization technology, announces the acquisition of ARAS 360 Technologies Inc., a global leader in the development of accident and crime reconstruction, simulation and animation software. Founded in 2010 and headquartered in Kamloops, British Columbia, ARAS 360 produces a full suite of accident and crime reconstruction software tools that offer advanced graphics, advanced analytical tools, and the ability to work with large point cloud data sets from 3D laser scanners. The company’s newest product, FARO Reality, is a 64-bit crash and crime software solution that was launched in November 2014. FARO Reality provides customers with an intuitive and user-friendly interface enabling them to quickly generate precision diagrams with stunning details and graphic realism. “The acquisition of ARAS 360 will help FARO create a complementary suite of integrated 3D documentation product offerings for our law enforcement customers,” stated Jay Freeland, FARO’s President and CEO. “By adding the ARAS 360 products to our portfolio, along with the product offerings of the FARO CAD Zone which we acquired last year, customers can now document and analyze any crime or accident scene with the most intuitive and powerful drawing, simulation and animation tools in the market.” The all-cash transaction includes an initial payment as well as future earn out payments. For more information about FARO’s 3D scanning solutions visit: www.faro.com/india 6 | MARCH 2015 | ENGINEERING REVIEW

•

This press release contains forward-looking statements within the meaning of the Private Securities Litigation Reform Act of 1995 that are subject to risks and uncertainties, such as statements about demand for and customer acceptance of FARO’s products, and FARO’s product development and product launches. Statements that are not historical facts or that describe the Company’s plans, objectives, projections, expectations, assumptions, strategies, or goals are forward-looking statements. In addition, words such as “is,” “will,” “continue,” “ensure” and similar expressions or discussions of FARO’s plans or other intentions identify forward-looking statements. Forward-looking statements are not guarantees of future performance and are subject to various known and unknown risks, uncertainties, and other factors that may cause actual results, performances, or achievements to differ materially from future results, performances, or achievements expressed or implied by such forward-looking statements. Consequently, undue reliance should not be placed on these forward-looking statements. Factors that could cause actual results to differ materially from what is expressed or forecasted in such forward-looking statements include, but are not limited to: • The Company’s inability to

•

successfully identify and acquire target companies or achieve expected benefits from acquisitions that are consummated; Development by others of new or improved products, processes or technologies that make the Company’s products less competitive or obsolete; The Company’s inability to maintain its technological advantage by developing new products and enhancing its existing products; Declines or other adverse changes, or lack of improvement, in industries that the Company serves or the domestic and international economies in the regions of the world where the Company operates and other general economic, business, and financial conditions; and Other risks detailed in Part I, Item 1A. Risk Factors in the Company’s Annual Report on Form 10-K for the year ended December 31, 2013 and Part II, Item 1A. Risk Factors in the Company’s Quarterly Report on Form 10-Q for the quarter ended June 28, 2014.

Forward-looking statements in this release represent the Company’s judgment as of the date of this release. The Company undertakes no obligation to update publicly any forward-looking statements, whether as a result of new information, future events, or otherwise, unless otherwise required by law.

For more information www.faro.com/india www.engrreview.com

ENGINEERING » BUSINESS NEWS

Banner Engineering Heavy-Duty Q3X Laser Contrast sensor solves challenging Part-Detection applications

anner Engineering introduces the Q3X laser contrast sensor. With the ability to detect up to 2,000 events per second, the Q3X provides high-speed, reliable detection of parts, tools, pallets or registration marks with small contrast differences. The Q3X has a small laser spot and is an excellent sensor for reliable part presence, tool-in-place or broken tool detection in stamping and machining centers. Featuring speeds as fast as 250 μs and a sensing range up to 300 mm, the Q3X is ideal for high-speed packaging and detection applications of small targets, such as registration marks on packaging, or verifying placement of black gaskets and O-rings on machined

metal parts. “The Q3X was designed for precise detection in harsh environments,” said Dennis Smith, Technical Marketing Manager at Banner Engineering. “The bright laser spot and digital read-out allow machine builders to quickly set up the sensor for their application. The metal housing and robust construction means it will survive in their application.” Featuring a unique angled, threedigit display of signal intensity, the Q3X provides high visibility of operating conditions from multiple angles. For an intuitive user setup, the Q3X has two tactile buttons conveniently located below the display.

Sanghvi forging gets Rs. 1.55 Cr. cash profit, Sales up by 92% Shows the cash profit of Rs. 1.55 Cr in the third quarter after expansion. Sales shoot up 92 % to Rs.25.50 Cr vs Last year Rs. 13.28 Cr Total Order Book as on Jan 31st 2015 is Rs. 36 Cr Total Approvals reached to 25 for Heavy forging section

adodara based Sanghvi Forging & Engineering Ltd (SFEL), one of the top engineering in India announced its Q3 FY1415 results with Net Sales of Rs 25.50 Crore for the period ended 31 December, 2014, up from Rs 13.28 Crore in the corresponding period of previous year, resulting in an increase of 92 %. Company showed in current quarter ended 31st December 2014 cash profit of Rs. 1.55 Cr vs Net Loss of Rs.

8 | MARCH 2015 | ENGINEERING REVIEW

1.39 Cr in the same period last year. EBITDA Margins also improved to 18.23 % vs Last year 12.04 % on nine months basis. Export continues to drive the growth. It clocked Rs. 5 Crore for the quarter ended 31st December 2014 from Rs. 2.22 Crore in the previous year. Company already got 25 approvals for the new plant, which includes Multinationals and Indian Conglomerates. Company has also received few

Designed with robust nickel-plated zinc die cast housing, the Q3X provides superior performance, even in environments with exposure to cutting fluids and oils. Sensors are also rated to IP67, IP68 and IP69K for enhanced protection to water submergence and high-pressure washdown. For more information https://www.youtube.com/ watch?v=rVDQdkEJSBE or visit www.bannerengineering.com .

approvals from leading Indian defence & strategic sector organisation.Total Order book size as on January 31st; 2015 is Rs. 36 Cr including domestic as well as exports orders. “The results are in line with our expectations. The effort put in by our entire team is showing results now. Exports continue to drive our growth” commented Mr. Jayanti Sanghvi, Managing Director of Sanghvi Forging & Engineering Ltd. “Our Company started giving the fruits which we all were waiting for the long time by showing second time cash profit after the expansion & we are very positive that by the end of this financial year, we show an improved bottomline also.” For more information: editor@divyamediaonline.com

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

linear encoders

contouring controls

digital readouts

length gauges

rotary encoders

Absolute linear encoders LC

Contents

Monthly Magazine On Engineering & Allied Industry

Publisher - Shilpa Kadam CEO - Shekhar Dongre

COVER STORY

Editor - Rajeev lyer CMO- Shirish Dongre

GROWTH with TECHNOLOGY EXCELLENCE Mr. Vijay Karia Chairman & Managing Director, Ravin Group

122 -124

Advisory Board (Editorial) Director, Flir Systems India Pvt. Ltd. Mr. T. P. Singh : Mr. Vijay Pimparkar : Ex-General Manager, Godrej & Boyce Mfg. Co. Ltd.

Mr. Gautam Kulkarni : CEO, Hafi Electra Pvt. Ltd. Mr. Ashok Sheth : Chairman, Solitaire Machine Tools Ltd. Prof. R. Sreedaran : Faculty, Atharva College of Engineering Mr. Ravin Mehta : Managing Director, Neel Controls/Neel Industrial Systems Pvt. Ltd.

Mr. C. S. Limaye :

Director, Supertech Instrumentation Services India Pvt. Ltd.

Mr. S. A. Mohan:

Chief Executive Officer, Maini Materials Movement Pvt. Ltd.

Mr. Rajeush Ballamwar : Director, Prolific Systems & Technologies Pvt. Ltd.

Mr. P.K. Balasubramanian: President , VBS Corporate Services Marketing Team : Ladoji Pendurkar, Bhavin Shah, Bharat Shah, A.Purohit, Vinod Surve, Kavita Chaudhari Designer & Layout Arun P. Shinde, Pradeep M. Pillalamarri, Nandan Moghe, Dinesh S. Gawade Circulation Executive Satish Kadam, Amol Ranshur

FACE TO FACE Head Office : Divya Media Publications Pvt. Ltd.,

134

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.

138

PC|SHEMATIC : Time saving electrical CAD software

“Selection of the right turbine oil helps equipment perform under the most demanding condition”

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

Mr. Glen Sharkowicz, Industrial Lubricants Marketing Manager – Asia Pacific, ExxonMobil Fuels & Lubricants

TRENDSETTER

PORTFOLIO

Lubi Eyes Global Expansion

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 - S.Kadam - 09833373371 Gujarat - Dinesh Shah - 09327344559 Rajkot (Saurashtra) - Swapnil Bhatia: 09227909005

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WRI – At the vanguard of welding research in India

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ENGINEERING REVIEW Overseas Offices

SUCCESS STORY

BUDGET REFLECTIONS

144

Spraymet Surface Technologies helps in conservation of resources Mr. P.T. Bindagi, Technical Director, Spraymet Surface Technologies Pvt Ltd

TECH TRENDS Drive Systems and Energy Saving By Ashok Kumar

....126

Union Budget 2015 - Industry Reacts

FOR ADVERTISING ENQUIRY CONTACT : E-mail: shekhar@divyamediaonline.com

....66

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SPAIN: Sofiane JEDIDI Mepax España Tel : +34 963 255 886, spain@mepax.com UK: Liz Jones Tel: +44 (0)1227 276016 , l.jones@mepax.com

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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 vie-ws and expressions of its authors. ENGINEERING REVIEW does not necessarily agree to it. ENGINEERING REVIEW can not be held res-ponsible 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 act-ing on an advertisement in any matter whatsoever.

12 | ENGINEERING REVIEW | MARCH 2015

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Contents A

UTOMATION SECTION

M ACHINE TOOLS SECTION

BUSINESS NEWS

Junker Group receives technology award from Shanghai GM

Mastercam reaches their 200,000th installation What does this mean for you?

OMRON showcases new concepts and products for Smart Meters at the India Smart Grid Week-2015 (ISGW)

HARTING India organized “MANTHAN 2015” for German Delegation

FARO® continues expansion into law Enforcement Market with Acquisition of ARAS 360 Technologies Inc.

AMW Motors appoints Mehrotra Automobiles as its dealer for Eastern Uttar Pradesh

Altem Technologies Tightens grip on the 3D market in India

Porcupine cutter, splitter insert combo roughs out operations

Two new families of SECO highfeed cutters deliver increased speeds and feeds

TECH TRENDS 106 ROLLON: Reducing linear bearing wear 110 Sliding & Rolling : igus hybrid linear bearings in new sizes

112 Next-generation capping heads

TECH TRENDS

116 Smart standard drives provide servo dynamics & precision

118 First Metro Line in Suzhou rolls on, thanks in part to ProSoft Technology’s modules by Victor Garcia

Four ways 3D printing is shaping product design & manufacturing

“It’s a revolutionary product!” claims Unimac following a return on investment of just four months using the new Primo™ twin probe system.

100 Mastercam’s Design tools provide flexibility & ease of use

IR COMPRESSORS SECTION

104 Clamping force gauge Testit, clamping force measurement over machine control

BUSINESS NEWS 46

TECH TRENDS 78

146 HSIL, the faucet people, rely on Haas for high quality and productivity

Chicago Pneumatic launches its largest ever range of portable generators for construction industry

Rust proof energy efficient Airpipe compressed air distribution system

ACKAGING SECTION BUSINESS NEWS

NGINEERING SECTION BUSINESS NEWS 08

Banner Engineering Heavy-Duty Q3X Laser Contrast sensor solves challenging Part-Detection applications

Sanghvi forging gets Rs. 1.55 Cr. cash profit, Sales up by 92%

NMIMS Mumbai wins National finals of Henkel innovation challenge 2015

OWER SECTION BUSINESS NEWS

G EAR-MOTORS SECTION

GEISSEL INDIA : German quality produced in India

LAPP GROUP: Patchy performance, but outlook is positive

FLIR thermal imaging cameras help prevent power failures at utilities

TECH TRENDS 80

Werner Electric Unveils wireless crane controllers for the Indian market

“Hazards happening due to unproper earthing”

BUSINESS NEWS 22

Elecon Engineering announces launch of ETS series twin screw extruder gear box for the Plastic Industry

OGISTICS SECTION BUSINESS NEWS 24

Safexpress establishes massive Logistics Park at Jammu

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Anuga FoodTec BOSCH presents New horizontal cartoning machine CFC 2012 High output also for large-scale formats

RODUCT SHOWCASE.......165

ROJECT UPDATE.......

173

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ENGINEERING » BUSINESS NEWS

NMIMS Mumbai wins National finals of Henkel innovation challenge 2015 Team Dark Side to represent India at Henkel Innovation Challenge 8 Global Finals in Vienna, Austria

MIMS, Mumbai is the India winner of Henkel’s international student competition – Henkel Innovation Challenge 8. The young team with its innovative idea “Nanobend” will represent India at the Henkel Innovation Challenge 8 global finals in Vienna, Austria from April 8th to April 10th, 2015. The winning team presented their project “Nanobend”, which is a coating on the walls that eliminates air pollutants and provides a clean air at home. It is moisture absorbent and nutrient rich, facilitating growth of algae similar to vines. The algae would absorb carbon dioxide and produce oxygen. The winning team, Dark Side, has outwitted the other semi finalists, who were from prominent colleges across India - NMIMS, Netaji Subhas Institute of Technology, IIFT, NITIE, Welingkar Institute of Management, Indian Institute of Management Indore, Indian Institute of Technology

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– Kozhikode, Symbiosis Institute of Business Management to name a few. The 10 teams were selected from a wide variety of disciplines across India where they had to develop a visionary product or a new technology for one of the three Henkel business sectors: Beauty Care, Laundry & Home Care or Adhesive Technologies. Throughout the competition, the teams are provided with extensive support from Henkel managers, who act as mentors, advising the participants on further developing their innovative concepts. This allows the young visionaries to gain priceless, wide-ranging business experience. The Jury members for this elite competition were Mr. Jeremy Hunter, President, Henkel Group – India, Mr. Dilip Chabria, Marketing Lead, team Indus and Mr. Raman, Director, SIBM. At the event, Mr. Jeremy Hunter, President, Henkel Group India said, “We are overwhelmed by the response received from the students across

India for our Henkel Innovation Challenge 8. Innovative ideas presented by the students have been setting a new standard and we had to take a tough call as the ideas presented were brilliant and well researched. At Henkel, through such events we constantly try to seek different avenues where students can participate and shore up to the upcoming challenges in their future.” Excited about winning the National Finals, winning team of NMIMS said “We are thankful to Henkel for providing us with such a big platform to sharpen our skills and encourage us to develop our idea and compete with the best in India. Now our focus is to make India proud at the global level”.

For more information Web: www.henkel.com/press www.engrreview.com

OBO BETTERMANN India Pvt. Ltd., Plot No O-37, Door No.8, Bharathidasan Street,Thiru Nagar, Jafferkhanpet, Chennai - 600 083, India. Tel : +91 44 4358 94 11/ 12/ 13 | Fax : +91 44 4358 9410 | Email: sales@oboindia.com | www.oboindia.com

GEARS - MOTORS » BUSINESS NEWS

Elecon Engineering announces launch of ETS series twin screw extruder gear box for the Plastic Industry The addition of this gear strengthens the product portfolio of Elecon in its quest for ‘Gearing the Future’

lecon Engineering Company Limited, one of the largest Asian manufacturers of industrial gear systems announced the launch of its new gear for the plastic industry. The ETS Series Twin Screw Extruder Gear Box which offers dual shaft counter-rotating extruder drive. The addition of this gear strengthens the product portfolio of Elecon in its quest to remain ‘Gearing the Future’. “We’re proud to introduce a unique and efficient product for the plastic industry. The additional to the special gears that we’re known to manufacture this is one of the stepping stone to our portfolio of products. Elecon is confident about the efficiency that it will bring to the progress of the sector,” said Mr. Vilas B Kalyankar, Chief Executive Officer, Elecon Engineering. ETS Series Twin Screw Extruder Gear Box is developed by featuring high torque and high speed output rate. The gearboxes are embedded with excellence high dissipation and oil lubrication system to provide stable output under heavy loading force. The axial thrust is supported by axial roller-type swivel thrust bearing coupled with thrust bearing assembled in tandem way. Engineered to deliver superior results, Elecon’s range of

22 | MARCH 2015 | ENGINEERING REVIEW

special gears for the plastic industry is a step ahead in when it comes to operational efficiency. Recognised for its robustness and meeting or exceeding deliverability commitments, Elecon’s range of special gears support a wide range of applications of single and twin screw extruder drives. About Elecon Engineering Company Ltd.: Established in 1962, Elecon Engineering Company Ltd. has grown to become one of the largest Asian manufacturers of industrial gear systems. Elecon has expertise in providing customized gear boxes for Steel Mills, High Speed Turbines, Sugar Mills, Marine Vessels, Coast Guard Ships, Plastic Extrusions, Antena Drives and Satellites in the Indian Space Programme.

For more information Web: www.elecon.com

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LOGISTICS » BUSINESS NEWS

Safexpress establishes massive Logistics Park at Jammu Facility to boost economic growth in the region

afexpress, India’s largest supply chain & logistics firm, launched its huge logistics facilty at Jammu . Spanning over an area of 80,000 sq feet, this ultra-modern Logistics Park is strategically located on Jammu-Pathankot National Highway 1A. Speaking at the launch ceremony, Mr. Rubal Jain, Director-Corporate Strategy, Safexpress said, “Jammu is a key city in northern India. The city has a number of small industries. Jammu region has a large count of food-grain mills and its economy is predominantly dependent on agriculture and allied activities. The state has rich resources of Agro, Water, Forests, Herbal and Minerals, in addition to its unparalleled natural beauty. Agricultural exports from Jammu & Kashmir include apples, barley, cherries, corn, millet, oranges, rice, peaches, pears, saffron, sorghum, vegetables, and wheat, while manufactured exports include handicrafts, rugs, and shawls. Hence, there is a massive potential for investment in this belt. From the supply chain & logistics perspective, Jammu holds strategic importance due to its location, skilled manpower and favorable government policies. Safexpress, being a pioneer in providing value-added supply chain & logistics services, has developed a worldclass Logistics Park at Jammu to contribute to the economic growth of this region.” Mr. Jain further highlighted, “Supply chain & logistics has a very vital role to play in the growth of numerous industrial centers spread across the Jammu region. Keeping this in mind, Safexpress has developed an ultra-modern facility at Jammu, which will serve as a trans-shipment hub as well as a warehousing facility. Safexpress, with its Logistics Park at Jammu, will bridge the infrastructure gaps and serve the supply chain & logistics requirements of the entire region.” Mr. Jain added, “We have made a significant investment to set up this ultra-modern logistics infrastructure. This will help the industries in Jammu belt in having access to our world-class supply chain & logistics services, which would contribute heavily in the economic growth of this region.” Highlighting the USP of the Logistics Park at Jammu, Mr. Jain said, “Our Logistics Park at Jammu has a column-less span of over 100 feet and enables loading/unloading of over 26 vehicles simultaneously. The dedicated bays and docks at our Logistics Park in Jammu provide an uninterrupted and

24 | MARCH 2015 | ENGINEERING REVIEW

unidirectional flow of inbound and outbound goods. The Logistics Park has a floor load capacity of 6 metric tonnes per square meter and has a truck docking area width of over 40 feet. To provide safe & smooth movement of goods within the Logistics Park we have installed high-tech equipment. Moreover, to make our Logistics Park eco-friendly, we have taken special go-green initiatives by investing in rainwater harvesting and developing special green zones.” Mr. Jain concluded by saying, “This Logistics Park will be operational 24x7, 365 days in a year to provide time-definite deliveries. Due to our non-stop operations, we will be providing the fastest transit time for deliveries all across India to over 610 destinations from Jammu.” About Safexpress: Safexpress has firmly entrenched itself as ‘Knowledge Leader’ and ‘Market Leader’ of Indian supply chain & logistics industry. Safexpress offers a complete spectrum of supply chain & logistics services which include Express Distribution, 3PL, Consulting, SafeAir, Campus2Home, Easy2Move, Stock2Shelf, SafeReturns and Sainik Express. Safexpress provides services to a vast array of business verticals ranging from Apparel & Lifestyle, Healthcare, Hi-Tech, Publishing to Automotive, Engineering & Electrical Hardware, FMCG & Consumer Electronics, and Institutional. Pioneered and driven by ‘Logistics Guru’ and CMD, Safexpress, Mr. Pawan Jain, Safexpress has been significantly involved in Indian economic growth saga for close to two decades. With an intention of contributing in country’s economic growth, Safexpress has kept its operations India-centric. Safexpress provides supply chain & logistics services to over 5000 corporate clients. With its fleet of over 4000 GPS-enabled vehicles and country’s largest distribution network spanning over 610 destinations, Safexpress covers every square-inch of India.

For more information, Web: www.safexpress.com www.engrreview.com

MACHINE TOOLS » BUSINESS NEWS

Junker Group receives technology award from Shanghai GM

enowned auto makers the world over rely on innovative grinding technology from Junker. The grinding machine manufacturer is now the proud winner of the Shanghai General Motors Co., Ltd. (SGM) “Leader of Technology Award”. SGM confers awards on its best suppliers in a range of categories once every two years. The Junker Group is one of two machine manufacturers from Europe to be among this year’s winners. The award recognizes continuous investment in the development of new, economical grinding machines for grinding a wide range of different car components - from crankshafts to nozzle pins. The Technology Award was presented to Junker CEO

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Rochus Mayer at the end of January 2015 in Boao, China, against the backdrop of a show to launch new car models complete with firework display. “We invest heavily in the development of new machines and technologies. This makes us particularly proud to have been distinguished with the award of Technology Leader by one of the world’s biggest car manufacturers”, says a delighted Rochus Mayer. The Junker Group The Junker Group based in Nordrach in Germany is the world’s market leader in manufacturing of CBN high-speed grinding machines. Just under 1,300 employees worldwide work

to secure the company’s technology leading edge. All renowned automotive manufacturers and their suppliers, tool manufacturers, and other sectors of industry place their trust in Junker’s innovative grinding concepts. Whether for small or mass production – Junker grinding machines operate at the highest standard of precision, economy and reliability. Alongside the Erwin Junker Maschinenfabrik GmbH, the group also includes the air filtration specialists from LTA Lufttechnik GmbH. LTA manufactures air filtration and fire protection systems for commerce and industry. For more information Web: www.junker.in

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MACHINE TOOLS » BUSINESS NEWS

Mastercam reaches their 200,000th installation What does this mean for you? a job, knowing the most widely-used software out there can help you find a job. Shops are always posting job openings, and many are looking for that Mastercam experience. Ever-Expanding User Community The Mastercam Community is constantly expanding with each new installation, and this means you have access to the largest community of CAM users on the planet. There is always someone out there who can help you in a time of need. With social media, user groups, and forums, you are never alone and can always get your questions answered.

NC Software, Inc. is proud to announce that Mastercam has reached its 200,000th installation. Specialised Orthotic Services is a UK-based company dedicated to providing customized seating for anyone needing specialized seating for correct posture and support. “Our new Mastercam-programmed robotic cell will further our ability to provide the best possible innovative special seating systems and other rehabilitation products,” says Operations Manager, Stuart Pegg, “coupled with quality service no matter how complex our clients’ disabilities.” Specialised Orthotic Services now belongs to the largest CAD/CAM community, and is obtaining the benefits of all the Mastercam knowledge and 28 | MARCH 2015 | ENGINEERING REVIEW

support out there. If you are a Mastercam customer, what does this mean for you? How can you benefit from the 200,000 Mastercam installations out there? Looking for Experienced Mastercam Users Shops around the world are always in need of experienced machinists and programmers to keep their business running smoothly and efficiently. If you are a shop owner, and looking to hire, it’s good to know that there are so many qualified Mastercam programmers in the workforce. Mastercam has the most installations of any CAM vendor, and you can use this to your advantage to find a machinist who is already experience and trained in Mastercam. Or, if you are looking for

About Mastercam Developed by CNC Software, Inc., Mastercam is Windows®-based CAD/ CAM software for 2- through 5-axis routing, milling and turning, 2- and 4-axis wire EDM, 2D and 3D design, surface and solid modeling, artistic relief cutting, and Swiss machining. CNC Software is a privately owned corporation founded in 1983. The U.S.-based company provides Mastercam CAD/CAM solutions to more than 200,000 installations in 75 countries in industries including mold-making, prototyping, automotive, medical, aerospace, and consumer products. Mastercam runs under Windows 7 and Windows 8, and is compatible with all other CAD/CAM systems.

For more information Web: www.mastercam.com www.engrreview.com

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MACHINE TOOLS » BUSINESS NEWS

is released

he Mastercam X9 Public Beta release is open to all current Mastercam customers who are on Maintenance. CNC Software, Inc. had great success with the X8 Beta release last year. We received feedback from hundreds of customers and hope to hear from them again this year with the X9 Beta release. Shops get a chance to test Mastercam before it is released and provide valuable feedback that helps shape the final product. Here are a few things you’ll see in Mastercam X9 Beta • Expanded Dynamic Motion toolpaths bring new options to our groundbreaking technique. And our widely-applied radial chip thinning lets you achieve efficient feeds and speeds while maintaining a target chip thickness. • Solid Modeling improvements including Solid Disassembly for exploding and laying out a solids assembly, Solid Positioning for easy snap-positioning of items such as fixture components, and more. • Powerful Multiaxis enhancements including Multiaxis Link, which delivers a new way to combine a safety zone with multiple operations, ensuring that repositioning between operations is as safe as possible. • Even broader tool support and improved workflow for importing, designing, and editing tools and holders. • Mastercam Simulator fixture support makes it easy to define, display and collision-check fixtures while simulating your job. • Overall streamlined workflow with improved plane management, level and geometry control, viewsheets, chaining and more. The new Analyze Toolpath feature further improves workflow by displaying useful information when you hover over a toolpath section. • And many more productivity improvements across the entire product.

For more information Web: www.mastercam.com

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MACHINE TOOLS » BUSINESS NEWS

AMW Motors appoints Mehrotra Automobiles as its dealer for Eastern Uttar Pradesh

MW Motors Ltd., one of India’s leading manufacturers of Medium and Heavy commercial vehicles, announced the appointment of Mehrotra Automobiles as its sales and service dealer for Eastern Uttar Pradesh - Allahabad, Pratapgarh, Sultanpur, Chitrakoot, Kausambia, Jaunpur, Varanasi, Sonbhadra , Gazipur , Mirzapur , Chandauli and Bhadohi. The dealership was inaugurated by Shri. Kunwar Reoti Raman Singh, M.P.,14th and 15th Lok Sabha, in the presence of Mr. R.N. Rao, Director, Marketing, AMW Motors Ltd. The dealership facility has been set up keeping in mind the growing market for AMW vehicles in these regions and the need to provide customers a full range of services including vehicle sales, financing assistance, maintenance, repair and spare parts support. Mehrotra Automobiles is led by Mr. Prashant Mehrotra, a first generation entrepreneur with several years of experience in consumer and finance industries. With a base in Allahabad, Mehrotra Automobiles will have facilities to reach out to customers across eastern Uttar Pradesh with a dedicated team of qualified and experienced professionals.

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Eastern Uttar Pradesh has a high potential for multi-axle haulage trucks and with the Government’s thrust on strengthening the infrastructure in the state, AMW also foresees a good demand for its tippers for the construction and road building segments. The high activity in agriculture, sand and other aggregates is also expected to contribute to better offtake of tippers and transport vehicles in the medium and heavy truck categories. Mr. Rao said, “The industry has seen the most difficult times in the last two years. We at AMW took this as an opportunity to enhance our product range. We introduced our haulage range and added few more tipper variants keeping in mind the customer voice and offering products which offered better operating costs, low maintenance and higher uptime. With the stable Government at the centre and the focus on infra development, we see the truck market improving. Thus it is important to increase the reach for our customers and add to our 3 S network. We look forward to a fruitful partnership with Mehrotra Automobiles for the benefit of transport operators and contractors in the region.

The entire AMW team of sales and after market teams will be available to ensure better productivity and profitability for our customers.” Mr. Mehrotra said,” As AMW’s partners, we are delighted to increase their foot print in Uttar Pradesh and will strive to offer customers an experience that will delight them and bring in loyalty. We look forward to growing with AMW with confidence and aggressive plans for the future.” AMW has 123 dealerships and over 1500 touch points across India. This network includes sales and service centres, authorized service outlets, mobile vans, workshops and a 24X7 helpline called ‘AMW SEVA’ which ensures a rapid response to customer needs. AMW Profile AMW Motors Ltd (AMW) is one of India’s leading manufacturers of medium and heavy commercial vehicles and has achieved a unique position in India’s transportation sector through innovative engineering and customer orientation. The company also received 7 consecutive awards for its vehicles from various industry forums. Wide Product Range AMW offers trucks ranging from 16 to 49 tonnes and has pioneered several segments in the Indian CV market. Manufacturing Facilities AMW’s fully integrated manufacturing facility in Bhuj, Gujarat, has a planned capacity of 50,000 commercial vehicles per annum. The facilities include a fully integrated assembly line, contemporary cab and paint shops and world class testing facilities. AMW’s 200-seat research centre focuses on research and development of new products and technologies that impact performance characteristics, safety, environment and comfort. For more information Web: www.amwmotors.com www.engrreview.com

MACHINE TOOLS » BUSINESS NEWS

Altem Technologies Tightens grip on the 3D market in India Wins Dassault Systèmes Growth Award – 2014 for Overall year revenue along with Marketing & Technical excellence award at Dassault Systèmes’ Annual Sales Kick-off 2015

engaluru-based Altem Technologies, Leaders in PLM Software market space and one of the pioneers in bringing 3D printing and scanning technologies to India, added another feather to its cap by winning the Dassault Systèmes’ Growth Award for Overall year revenue as well as the Marketing & Technical Excellence Award at the Dassault Systèmes’ ‘Annual Sales Kick-off 2015’ event. Dassault Systèmes, the 3D EXPERIENCE Company, world leader in 3D design software, 3D Digital Mock Up and Product Lifecycle Management (PLM) solutions, announced its annual VAR Excellence Awards to acknowledge the contribution and work of their VAR partners. These awards are given across 14 categories, including VAR of the Year, Best Brand Initiative, Social Impact and the Industry Excellence Awards were announced during the Annual Sales Kick-Off held in the city of Visakhapatnam recently. The 3-day annual Sales Kick-Off had senior global executives from Dassault Systèmes in attendance along with Industry representatives addressed the 200plus -strong audience on key issues like Cloud, Online Services delivery and Industry Solution Experiences which was a key focus area. Commenting on the win, Mr. Sharath Chandra, Co-Founding Director

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- Altem Technologies said “4 years ago Altem had started without any significant financial back up. Being a start-up in a significantly newer industry then, it was very difficult to acquire credits, attract talented manpower etc for software distribution businesses. Despite these barriers, there has been no looking back for Altem till date. Being rewarded with such prestigious awards is proof that we are on the right track and also an inspiration to up the game to exceed the expectations set for us by these awards.” Starting from scratch in the year 2011, Altem technologies, today has marched a long way to success. Altem had previously been awarded the “INDIA SME 100” award for 2014, and had been nominated for the “Leaders of Tomorrow” by Economic Times (ET Now) / IndiaMart and coincidently had won Marketing Excellence for Stratasys for year 2014 for their 3D Printing Business as well. For more information, editor@divyamediaonline.com

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ENGINEERING REVIEW |

37 | March 2015

MACHINE TOOLS » BUSINESS NEWS

Porcupine cutter, splitter insert combo roughs out operations

aeguTec has expanded the MillRush line by adding extended flute cutters, also known as “porcupine” or “long-edge” cutters, and splitter inserts to improve performance on roughing operations. Extended flute end mills and shell mill cutters are being added to the 3PKT 06, 10, 15 and 19 millimeter insert line. All MillRush inserts, including the 3PKT 15 and 19 splitter inserts launched at this time, are able to be clamped to extended flute end mills and shell mill cutters. Also, the two new 3PKT 15 and 19 mm inserts come in two different kinds called the SM2 (with three corners and two grooves) and SM3 (with three corners, three grooves and a different color periphery). The idea behind the SM2 and SM3 is so that there are no miss matches after machining and both offer a lower cutting load and less vibration. Furthermore, for effective use of splitter inserts, the even number teeth cutters are also available as standard items. To widen the machining depth of tools offered, the 3PKT 15 and 19 mm size splitter inserts are also added to the MillRush line. The splitter inserts have already proven effective with the launch of the existing APKT and ANHX types, which have an excellent performance record under unstable machining conditions such as long overhang or weak fixtures since grooves on the cutting edge reduce the cutting load, vibration and noise. By doing so, this allows for a higher table feed due to the reduced cutting load during machining which in turn, offers better productivity. Because of its increased metal removal rates,

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the MillRush porcupine cutter is an irreplaceable tool that is useful for machining rough edges, deep shoulders and cavities. Moreover, the new MillRush line of extended flute cutters and splitter inserts are an ideal choice for various operations in the machine shop and is a good source to use when looking to increase productivity and cut on cost. The cutters extremely strong and rigid cutter body handles heavy-duty machining of wide edges, deep shoulders and cavities with ease. The splitter inserts are covered with TaeguTec’s renowned GoldRush coating which offers improved toughness, better wear resistance

and reduced friction to chip-flow while also giving a high-quality workpiece surface finish, reduced build-up edge and insert chipping resistance across several different workpiece materials. In one case study, TaeguTec’s new porcupine cutter with splitter inserts not only increased tool life by 39 percent while machining a workpiece made from construction steel, but also raised productivity by 33 percent. In another case study conducted on cast iron, TaeguTec’s extended flute cutter with splitter inserts outlasted a leading competitor’s similar tool by 50 percent.

For more information Web: www.taegutec.com www.engrreview.com

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MACHINE TOOLS Âť BUSINESS NEWS

Two new families of SECO highfeed cutters deliver increased speeds and feeds

eco has expanded its Highfeed milling cutter lineup with the introduction of the new Highfeed 2 small-diameter and Highfeed 4 with double-sided inserts. Both families incorporate new insert designs combined with more teeth per diameter for higher productivity. Both Highfeed 2 and Highfeed 4 cutters excel in high-velocity, high-speed cutting of hard and tough materials, especially when performed on smaller machines equipped with high-speed/low-torque spindles. Highfeed 2 LP05 inserts feature two cutting edges in cutter diameters down to 12 mm. The inserts effectively machine sticky materials such as stainless steels, titanium and superalloys. Designed with four cutting edge, the Highfeed 4 LO06 insert provides up to four cutting edges for cost-effective, efficient and high-performance machining of common workpiece materials when using cutter body diameters from 20 mm to 63 mm.

HQ IMG Highfeed 4 Assortment

Both the Highfeed 2 and Highfeed 4 cutters significantly reduce vibration for smooth, stable cutting and increased productivity. Their innovative designs also efficiently evacuate chips for worry-free operation. Headquartered in Fagersta, Sweden and present in more than 50 countries, Seco Tools is a leading global provider of metal cutting solutions for milling, turning, holemaking and toolholding. For more than 80 years, the company has provided the technologies, processes and support that manufacturers depend on for maximum productivity and profitability. For more information on how Secoâ&#x20AC;&#x2122;s innovative products and expert services bring success to manufacturers across all industry segments,

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For more information Web: www.secotools.com

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ENGINEERING REVIEW |

43 | March 2015

BUSINESS NEWS

ICAI organizes Workshop on Energy Efficient Motors & Pumps

nternational Copper Association India in connotation with Karnataka Renewable Energy Development Limited (KREDL) organized an interactive workshop on Energy Efficient Motors & Pumps in Bangalore on 22nd Jan.15. The intent of the program was to create awareness about IS:12615 Standard for Energy Efficient Motors and address barriers in the adoption of Energy Efficient Motors & Pumps. The workshop was addressed by a panel of dignitaries comprising Mr. Sanjeev Ranjan, Managing Director, ICA India, Mr. GV Balaram, Managing Director, KREDL along with representatives from Siemens, Bharat Bijlee, and Grundfos. This event saw huge participation and was well received by industrial end users from SME’s, Karnataka government departments and other industry experts. Though motors are the lifeline of the manufacturing industry in India, penetration of high efficiency motors and premium efficiency motors is low. In an effort to address the existing barriers, Sanjeev Ranjan, Managing Director, ICA India said, “Through this workshop, we aim to increase awareness and address hindrances in the adoption of energy efficient motors and enlightened the motors standards scenario in India. The global harmonization of efficiency classes, testing methods and access to global markets triggered the Indian motor industry to match its standards with the latest International Electrotechnical

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Commission (IEC) standards”. He further added “Large scale awareness programs should be developed and put in place to inform industrial and commercial electricity users of the significant savings potentials possible through the use of efficient motor-driven systems. These programs should target those responsible for procurement of electric motors and motor driven systems, including operations and maintenance managers, production and plant managers, and company executives and decision makers responsible for overall company policy on energy, carbon and cost reduction.” The workshop introduced IS12615: 2011 standards for energy efficient motors which have undergone revision to be in line with the global efficiency norms. The experts further highlighted and addressed the challenges faced by industrial units in adopting the energy efficient motors in day-to-day applications. The main features of the revised standard IS12615:2011 are: • The range covers ratings from 0.37kW to 375 kW for 2, 4 and 6 poles, for voltages up to 1000V. • Intermediate ratings are considered based on the Indian markets. • The efficiency classes are in line with IEC 60034-30 termed as IE2 and IE3, • The testing method specified is as per IS:15999 Part 2, Sec. 1 [which is the harmonized version of the IEC

60034-2-1 (2007)]. • The other performance parameters like starting torque and starting current are considered and specified for two levels (IE2 and IE3) • The standard also stresses upon the importance as defining MEPS of IE2 (to prevent influx of inefficient motors by means of cheap imports) and also to enable local manufacturers to export their products to the EU and other countries where they have set IE2 as the MEPS. The standard also recommends the phase out plan for IE2 motors going forward. Commenting on this initiative GV Balaram, Managing Director, KREDL said “We really appreciate the effort taken ICA India and are happy to be associated with them. This initiative will further help Karnataka Government’s various departments using Motors & Pumps and industrial end-users to adopt the revised standard for energy efficient motors in their technical specifications. Through this combined effort, we aim to promote this technology and ensure that it benefits the industrial units with higher efficiency, reduced cost of operation and save energy”. He further added, “Energy sustainability is key societal issue & energy efficiency is first part of the solution. There is a need for more such workshops to educate industries to develop and create a pull for energy efficient motors”. www.engrreview.com

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AIR COMPRESSORS Âť BUSINESS NEWS

Chicago Pneumatic

launches its largest ever range of portable generators for construction industry

nternational construction equipment manufacturer Chicago Pneumatic has launched its largest ever range of portable generators, designed to provide a safe and stable power supply for every type of worksite. The CPPG range comes in two distinct lines. The new Pro Line includes Professional, Advanced and Advanced+ models offering powerful performance for all-day, intensive heavy-duty applications and provides different levels of functionality, depending on the needs of the user. The Standard Line contains a simple, straightforward petrol generator designed for occasional use. Among the generators within the new Pro Line is the CPPG Professional model, designed for continuous usage and available either with a petrol or

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diesel engine. Users are protected by an optional Earth Leakage Relay (ELR) in both types of engine, while Automatic Voltage Regulation (AVR) is an option for the petrol-engine unit that ensures consistent electrical output. The CPPG Advanced generator, with petrol and diesel engine options, is built for intensive, all day operation. The generator benefits from more advanced features and additional protection to extend its life expectancy and safety, making it particularly well suited to the rigours of the rental market. Alongside AVR, the CPPG Advanced model protects its users with an isometer protection and thermal protection circuit breaker, as well as incorporating an intuitive

Continue on page no.48 www.engrreview.com

AIR COMPRESSORS » BUSINESS NEWS

Continued from page no.46 instrumentation panel, electric key start and a number of alarm and shutdown options. Building to even higher standards, the CPPG Advanced+ generator is enclosed and soundproofed for the most demanding, dusty or heavily populated locations, as well as complying with European noise regulations. The petrol-only CPPG Standard Line, launched in 2014, is ideally suited for private and professional users who occasionally need a portable generator. Straightforward and simple, CPPG Standard generators are designed to provide stable electrical output and safe, user-friendly operation over a long service life and come equipped with large, reinforced fuel tanks, ergonomic handles and AVR. Commenting on the launch, Product Marketing Manager (Power) for Chicago Pneumatic, Daniel Escuer, said: “By launching our widest ever

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range of portable generators, we believe we can offer the construction industry the best possible choice, depending on their budget and their requirements. The models within both lines have different features but what they all have in common is reliable performance, robust build quality and simple operation to ensure users can complete their jobs quickly and effectively when on site. In this way they perfectly underline our position as a trusted partner for the construction industry globally.” Both the Standard Line and Pro Line generators have been developed through extensive field testing and reflect Chicago Pneumatic’s reputation for equipment that is easy to operate and maintain. Features include user-friendly control panels and the option of an hour counter to help monitor maintenance schedules. Additionally, thanks to their simple handle design, the generators can be

easily lifted or transported on wheels. All CPPG models also feature a strong main frame with extra reinforcement around sensitive components and a protected electrical panel. Sockets are also covered and recessed for enhanced protection. About Chicago Pneumatic Since 1901, the Chicago Pneumatic name has represented high-performance tools and equipment designed for an extensive range of applications. Chicago Pneumatic offers a wide range of pneumatic, hydraulic and petrol-driven equipment, portable compressors and generators, light towers, rig-mounted attachments, and compaction equipment for the construction and demolition industry. With a global network of distributors, Chicago Pneumatic provides customers with worldwide sales and service support. Web: www.cp.com

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Advantech India 809, 8th Floor, South Block Sacred World, Wanwadi Pune - 411040 Toll Free: 1-800-425-5070 Email: sales.in@advantech.com

PACKAGING » BUSINESS NEWS

Anuga FoodTec BOSCH presents New horizontal cartoning machine CFC 2012 High output also for large-scale formats Processes up to 200 folded cartons at 12 inches per minute High flexibility through servo-controlled format changes Optimized conveying technology for gentle product handling

t Anuga FoodTec, Bosch Packaging Technology, a leading supplier of process and packaging technology, launches the new horizontal cartoning machine CFC 2012. It was developed especially for largescale secondary packaging formats of the food industry with a width up to 12 inches. “The development of the CFC 2012 is based on our long-term experience with bagin-box machines and in-feed solutions, and backed by our profound line competence. Thanks to an optimized control and conveying technology, the cartoning machine ensures quick format changes, as well as safe and reliable product handling,” explains Daniel Sanwald, product manager at Bosch Packaging Technology. Flexible infeed and fast format changes Due to a wide range of in-feed systems, the machine can be flexibly used for many different products, such as bags with or without side gusseting, as well as stand-up bags with gable top. Even with the largest folded carton and

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product formats, for instance for cereals, the machine achieves an output of up to 200 folded cartons per minute. Modern servo technology guarantees supported, fast and reproducible format changes. Optimized conveying technology for safe product handling Due to the insertion aid, the CFC 2012 achieves the highest efficiency and product safety. The products are reliably and gently inserted into the folded cartons, thus ensuring that they remain intact at all times. Since transportation is lubricant-free, no grease can compromise the product infeed. The products are transported via a robust strap conveyor belt, which can be expanded segmentally. Moreover, the CFC 2012 operates quietly and requires little maintenance. A three-star rotor with patented dual drive enables the safe removal from the large stock of folded cartons, and ensures highest process safety throughout the entire format range. Thanks to the especially compact design, the machine can be easily accessed, cleaned and maintained from the operator side. “Together with the intuitive operation with an integrated HMI (Human Machine Interface), the horizontal cartoning machine stands for maximum operator friendliness at minimum maintenance effort,” says Daniel Sanwald.

Primary packaging solutions for dry food products For the packaging of dry free-flowing products such as coffee or tea, Bosch offers customized and modular vertical form, fill and seal machines allowing for high flexibility and a broad variety of pack styles and top closures. For customers looking for packaging solutions for flour or sugar, the new mandrel-wheel machine concept and its design provide a high degree of flexibility by shortening size changeover times. The portfolio is complemented by product protection systems such as valves and fully integrable equipment including hygienic auger fillers as well as checkweighers. Depending on customer requirements, the primary packaging machines can be combined with the respective cartoning machine to form a line. This way, the bagged products receive the matching secondary packaging. For more information Web: www.boschpackaging.com

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LOGISTICS » TECH UPDATE

Laboratory automation demystified Be it pharmaceutical, biochemical or a chemical manufacturing unit, laboratory automation fits the bill – but only if you know where you want it and why.

hat was once the stronghold of manual precision and observation is fast giving way to automation solutions. Becoming the order of the day, laboratory automation involves the use of instruments and processing equipment with minimum intervention and involvement of a human arm or mind. Laboratory procedures in the engineering sector are becoming more complex and process-oriented. To contain costs and ensure zero error, automation expertise is needed. Laboratory automation also leads to improved turnaround time and increased productivity since more tests can be conducted in a given time period. From software solutions to instrument handling, engineering companies are coming up with better and advanced solutions for catering to the market. Automating workflow – from the initial sample preparation stages to data mining – has led to a significant shift in how laboratories function in today’s world. Delving into the history of laboratory automation, experts consider the Coulter Counter as the first step, which in 1957 was used to count a variety of peripheral blood cells, including red blood cells and leukocytes. After fully automated clinical laboratories became popular, robotic sample transporters – Cartesian robot, gantry

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robot, cylindrical robot, etc. – arrived at the scene. These are now the most widely known laboratory automation technologies. However, automation projects for laboratories need a considerable amount of due diligence and number of factors can cause the project to fail. Often, there is a lack of flexibility since the processes or the people operating these can’t be changed. Experts point to a few thumb rules that will stand you in good stead when it comes to laboratory automation. Evaluate your needs not just from your current state but what you would want it to be at the optimum level. Logistics and handling issues should also be considered, as well as the space that you have. There is also a strong case for mapping workflow and identifying bottlenecks. Workflow mapping is crucial – how the material and/or specimens flow; how the processes and data flow, along with an understanding of workload map. Turnaround time measures and workflow should be studied for the process so that bottlenecks can be identified and fixed. Remember: not all solutions need major automation; small yet robust, low-cost reengineering projects often go a long way and yield better and more cost-effective results than automation. For more information, visit: www.safexpress.com

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POWER Âť BUSINESS NEWS

GEISSEL INDIA : German quality produced in India

eissel India is an established name in India as a supplier of cable glands and electrical wiring accessories since many years. The 100% German owned Company manufactures goods as per exacting German standards and has created a niche for itself in the Indian electrical market. Products include cable glands in brass & polyamide in IP 68 and EMC, conduits, conduit glands, plugs, reducers, enlargements, etc. The German parent is a family run Company and exists since 1920. It is managed now successfully by the fourth generation. After creating a name for itself in the Indian electrical market, both in the single & double compression glands segments, Geissel has also achieved success in the EMC glands. Available in brass with nickel plating in metric as well as Pg threads, these glands are of a user-friendly design and customers of international repute have appreciated this benefit. Geissel Indiaâ&#x20AC;&#x2122;s USP is the availability of all products ex stock from their factory in Pune. German engineering and design have been successfully implemented with strict adherence to quality, resulting in International Class Products. For enquiries contact Geissel India Pvt. Ltd., E-mail: info@geissel-india.com Web: www.geissel.com

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ENGINEERING REVIEW |

55 | March 2015

POWER » BUSINESS NEWS

Targeted investments in growth markets & industries

LAPP GROUP: Patchy performance, but outlook is positive

uring the 2013/14 business year (1 October to 30 September), Stuttgart-based Lapp Group further consolidated its market position and gained new market shares. Still, the company did not succeed in achieving its targets. Andreas Lapp, Chairman of the Board of Stuttgart-based Lapp Holding AG, said: “We’re better than the benchmark, but we should have made more gains. We’ve invested a lot over the last few years, but this hasn’t had as much of an impact on our performance as we had expected and hoped.” Revenue fell by 1.2 per cent last year, from 830 to 820 million euros, while income before taxes rose from 35.5 to 37.1 million euros. The number of employees increased to around 3,200 staff. Falling copper price impacts performance The significant decrease in the price of copper, which fell by an average of 10 per cent from 583 euros/100 kg to 525 euros/100 kg over the year, had the biggest impact on revenue development. Because the actual cost of a cable is based on the market price of copper on any given day, revenue automatically falls with copper price. In addition, there was the negative currency development outside the Eurozone. Combined, these factors caused net revenue to fall by almost five per cent over the previous year. This means that, when adjusted for the price of copper and the exchange rate, revenue was up by 3.7 per cent from the previous year. The fall in net revenue was further influenced by the turbulent economy in key markets such as the German plant and machinery sector, as well as the Ukraine crisis. By contrast, the cable system solutions business, which includes e-mobility and 56 | MARCH 2015 | ENGINEERING REVIEW

tailored, customer-specific solutions, made a positive contribution. Revenue grew disproportionately in these areas. Andreas Lapp noted, “We’re sensing that business conditions have become more difficult worldwide, and there’s nothing we can do about economic and political developments. In a tough environment, we’ve managed to gain additional market shares, but one thing is clear: we set ourselves targets that, even without these external factors, we wouldn’t have achieved. We just didn’t do our homework properly. But we know where our weaknesses lie, and now we’re going to tackle them specifically.” Positive outlook for the current business year The Lapp Group has got off a good start in the 2014/2015 business year. Without taking into account the risks and opportunities related to the development of exchange rates and the price of copper, the company expects to see a slight growth in revenue this year. The Asian and American markets are expected to make a significant contribution to revenue growth. The Group is not anticipating any significant growth in Europe due to issues related to the economy and exchange rates. Developments in the regions vary Due to the weakened rate of expansion of the world economy, revenue developed in different ways across the Lapp Group’s regions. Europe (including South America, Africa and the United Arab Emirates): With a share of 70 per cent of total revenues, Europe is the Lapp Group’s most important market. Revenue here amounted to 574 million euros, which corresponds to a slight decrease of 1.6

per cent. If it weren’t for the fall in the price of copper and fluctuations in the exchange rate, there would have been revenue growth of significantly more than three per cent. In Germany, the most crucial individual market in Europe, revenue came to 265 million euros. The investments made in the previous years are now taking effect, helping to improve the Group’s competitiveness. Chief Financial Officer Andreas Hermann explained: “In particular, our logistics and service centre in Ludwigsburg, which began operating in 2013, now gives us the opportunity to respond to customer demands in a more tailored way, and consolidate our position in the market.” Revenue in the UK, Benelux, Austria and Poland has developed particularly well. America (USA, Canada, Mexico): Revenue development in this region was overwhelmingly positive (share of total revenues 10.4 per cent). Despite the developments of exchange rates, the Group managed to increase revenue by eight per cent to 85.4 million euros. Asia (including Australia and New Zealand): The rate of growth in Asia cooled off slightly last year – a trend that also affected the Lapp Group’s revenue in the region. With a share of 19.6 per cent of total revenues, Asia is the Lapp Group’s second most important region. Revenue fell by 4.1 per cent to 161 million euros. Above all, this drop was driven by a significant revenue decrease in Korea – a result of the difficult market for photovoltaics. However, Lapp Korea is now showing growth of around 20 per cent in the current business year. There was positive development in China, after Lapp opened its own production plant

Continue on page no.60 www.engrreview.com

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POWER » BUSINESS NEWS

Continued from page no.56 in Shanghai in 2013. There was also slight growth in India. Earnings and financial position remain solid The earnings and overall financial position of the Lapp Group are extremely solid. Despite the negative development in the market for copper, the Lapp Group made targeted investments for the future. The number of employees rose by 4.7 per cent to 3,200. HR costs, write-downs and other operating expenses climbed from 272 to 286 million euros. At the same time, the Group improved its earnings before taxes by 1.6 million euros, or 4.5 per cent, to 37.1 million euros. Even equity ratio climbed from 54.3 to 56.3 per cent. Andreas Lapp stated, “The Lapp Group is in great shape. In light of the various internal and external factors that prevented us from achieving higher revenue and results, our performance isn’t that bad – now we must work towards stable, long-term growth.” Investing in further growth Compared with the previous year, the Lapp Group increased its investments from 26.2 to 27 million euros in the 2013/14 business year. In Brazil, the Group opened its first production plant in South America. The new Cabos Lapp Brasil plant has a production space of 6,200 square metres, which will soon be expanded to 10,000. The new plant opened with 40 staff, but this number will rise to 180 in the medium term. To date, 5.3 million euros have been invested. Capacity at both plants in India was also increased. At the Bangalore plant, production space was more than doubled. The new space will allow the manufacture of 60,000 kilometres of multi-core conductor cables and 78,000 kilometres of single conductors. The investment came 60 | MARCH 2015 | ENGINEERING REVIEW

to around 1.8 million euros. At the second plant, in Bhopal, a new production line for multi-core conductor cables was installed. In Poland, a new sales and logistics centre began operations. The Lapp Group has had its own company in Poland for 14 years now, and the new building will accommodate the increasing demand in the Polish market. A total of 4.1 million euros have been invested. Despite the crisis in Ukraine, the foundations for a new sales and logistics centre were laid in Samara, Russia last year. The new centre will be completed by autumn 2015. Overall, 5 million euros are being invested in the site. Outstanding examples of application In particular, Lapp’s cable system solutions business developed very positively last year. For example, the new BMW i3, BMW’s first completely electric car, makes use of the Lapp HELIX – the new Lapp charging system. The new BMWi3 can be charged in a number of ways, in addition to using public charging stations: either via a “Mode 2” charging system that uses regular household sockets, or via a rapid charging system, for extra-fast charging at public stations, for example. Additionally, drivers with a permanent parking space can now request the BMWi Wallbox – a charging station that can be mounted on the wall of their home or garage. Lapp Systems supported BMW with implementing both solutions, in addition to developing both the rapid-charging cable and the cable and connector components for the BMWi Wallbox Pure. The Heilbronn-based firm Illig Maschinenbau GmbH & Co. KG, a world leader in thermoforming, is now using the new ETHERLINE® Cat.6A cable from Lapp for its 68 standard production machines and customer-specific configurations. This highly flexible cable facilitates data transfer rates of up to 10 Gb/s, and is also able to withstand the stresses of production. The

customer hopes this will provide sufficient potential capacity for the continuously rising transfer rates. Lapp was the first provider in the market to be able to supply cables with this transfer rate to the required industrial quality, i.e. for use in both energy chains and with torsions, and in accordance with the crucial PROFINET standard. Previously, cables with these properties were only available for transfer rates of up to 1 Gb/s. An additional focus last year was expanding Lapp Group’s portfolio in robotics the Champions’ League of cable technology. The robotics specialist Lapp Muller, based in Grimaud on the Côte d’Azur, provided the Italian automation technology manufacturer Comau with robotic cables for its “Open RoboGate” framing system, which is being deployed at the Fiat plant in Melfi, for example. The system can put together an entire car body in less than a minute. Because of the short cycle times, rapid acceleration and hard braking, the cable is subject to significant mechanical stress. But thanks to the high quality of the Lapp robotic cable, Comau can still offer an eight-year warranty on the entire system, including cabling. Finally, for the refurbished El Dorado airport in Colombia’s capital of Bogotá, Lapp supplied 222 kilometres of flexible, halogen-free ÖLFLEX® CLASSIC 130 H cable for energy transfer, as well as UNITRONIC® BUS EIB H data cables. These halogen-free cables will be used for lighting in the three passenger terminals. Thanks to their high flame resistance and low fire propagation, they meet even the most stringent fire protection requirements.

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

ENGINEERING REVIEW |

61 | March 2015

POWER » TECH UPDATE

FLIR thermal imaging cameras help prevent power failures at utilities ‘Detecting maintenance issues before failures occur is crucial to E.ON Bayern’ In Western Europe electricity is usually taken for granted. Due to thorough maintenance programs power surges are a thing of the past in most European countries. To ensure continuous power supply regular inspections of the network’s components are really a must. FLIR thermal imaging cameras can play an important role in determining the state of operation of these components, so utility companies can more accurately maintain and repair their network.

ne of the first European utility companies that realized the potential of thermal imaging technology for the maintenance of their electricity network was E.ON Bayern. “In our maintenance program thermal imaging plays a pivotal role in ensuring that components are replaced in time, before any failures occur”, explains Ronald Hintzsche, head of the measurement department of E.ON Bayern. E.ON is a power and gas utility company of German origin. It is the main power supplier in central Europe and combined with its subsidiaries it is also one of the world’s largest investor-owned power suppliers. One of E.ON’s subsidiaries is E.ON Bayern, headquartered near Regensburg, Bavaria. With a network area stretching over 41,000 km² E.ON Bayern is one of the largest regional energy service providers in Germany. 62 | MARCH 2015 | ENGINEERING REVIEW

Generally speaking all electronic equipment and components heat up before they break down. “Detecting this rise in temperature in an early stage allows us to plan our maintenance accordingly and to prevent costly failures”, continues Hintzsche. “The thermal imaging cameras from FLIR Systems play a crucial part in our preventive maintenance program.” All components are checked periodically The predictive maintenance program contains an exact planning of when each part of the systems needs to be inspected, depending on the importance of that part for the operation of the entire system and on how prone its components are to failure. “Each component of the network is checked at least once in every 12 years”, explains Hintzsche. “But crucial parts will be inspected in cycles of 4 to 5 years and some installations near busy traffic intersections or in difficult industrial environments where the components can be affected by pollution, such as salt, dust, smoke or soot, are inspected once a year.” In addition, the thermography team keeps a 24/7 stand-by service which jumps in when impending failure is suspected. “An inspector or technician might hear a strange sound

With temperatures approaching 80° C this transformer requires further inspection.

This connector has become resistive due to loosening and corrosion. This can be easily remedied by opening, cleaning and reassembling the connector.

in the transformer of a substation, for instance”, explains Otto Heigl, one of the thermographic inspectors that use the thermal imaging cameras. “In such

Continue on page no.64 www.engrreview.com

POWER » TECH UPDATE

inspections of transformer stations or substations and for long distance observations of power lines or high voltage transformation substations we change the lens to the 7° telephoto lens. This flexibility is very important for us.” Otto Heigl, thermographic inspector at E.ON Bayern, demonstrates the use of the FLIR thermal imaging camera.

Continued from page no.62 a case we have to find out whether there is a problem and if there is a problem we have to find out very quickly what is causing it. Our FLIR thermal imaging cameras help us to do that.” Excellent thermal image quality The cameras used by E.ON Bayern’s inspectors are one FLIR P65 thermal imaging camera and three FLIR P60 thermal imaging cameras, purchased in 2004. Both of these models incorporate an uncooled microbolometer detector that produces thermal images at a resolution of 320 x 240 pixels and a thermal T820176 {EN_uk}_A sensitivity of below 80 mK. “One of the reasons why we chose these models, apart from the excellent image quality and accurate temperature readings, was the visual imaging camera”, Heigl explains. “It helps us to exactly locate which component is showing up as being hot on the thermal image.” Interchangeable lenses Another advantage is the fact that these thermal imaging cameras from FLIR have interchangable optics. “We use a 45° wide angle lens for close up

The overheating high voltage fuse should be replaced and the contacts should be cleaned.

64 | MARCH 2015 | ENGINEERING REVIEW

Word compatible software speeds up reporting To enable better maintenance predictions the thermal data gathered in the field is combined into a report, using FLIR Reporter software. “Because the software is fully compatible with Microsoft Office we can easily and swiftly compile reports with the most commonly used text editor: Word”. “Everybody can immediately start using the software, since most people know Word already.” The models currently being used at E.ON Bayern – the FLIR P60 and P65 – that were bought in 2004 are not currently marketed by FLIR Systems. In the current product range these models have been replaced with the FLIR P660 thermal imaging camera. It mostly has the same important features, such as a visual imaging camera and exchangeable lenses, but its uncooled microbolometer detector produces better thermal images with a resolution of 640 x 480 pixels and a thermal sensitivity of below 30 mK. The older FLIR models used by E.ON Bayern still function perfectly, however. “And if there is a problem with one of our cameras the service we get from FLIR is very good”, adds Hintzsche. “The camera is repaired and sent back very swiftly.” Good training is crucial The operation of thermal imaging cameras from FLIR Systems is relatively easy, but that doesn’t mean that it’s just a matter of pointing the camera and pressing a button, explains Hintzsche. “It’s very important that the operator knows at least the basics of thermographic theory. Without it is very easy to draw the wrong conclusions. Luckily, FLIR offers thermography courses in

The T-connector that shows up as a hot spot is overheating due to increased resistance. This can probably be solved by cleaning the connector.

This wait switch requires further inspection and might have to be replaced.

co-operaqtion with the Infrared Training Center (ITC). We therefore make sure that all of the inspectors at E.ON Bayern have at least followed a threeday thermography training course at the ITC.” FLIR: a reliable long term partner “FLIR simply delivers the best combination of thermal imaging camera quality, interesting extra camera features, very good repair service, excellent customer support and top of the line training options,” continues Hintzsche. “And as the global market leader FLIR has also proven to be a reliable long term partner, so why change our thermal imaging camera supplier? When buying a new thermal imaging camera becomes an option again our choice is clear: it will be a FLIR.” For more information 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: manpreet.kaur@flir.com.hk Web: www.flir.com www.engrreview.com

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BUDGET REFLECTIONS

Union Budget 2015 - Industry Reacts The Union Budget 2015 has just been announced. Is it a growth-oriented Budget? Will it give the much needed impetus to Manufacturing, Infrastructure and allied sectors to give a new fillip to our economy? What’s its impact on the Industry and its prospects? Here below are the reflections from the captains of the industry. .......Editor

Mr. A.K. Tyagi, Chairman & Managing Director, Mecon Limited

t the outset this budget has given emphasis on restoration of macro-economic stability, sustainable poverty alleviation, creation of jobs and achievement of double digit economic growth. In last nine months our national economy has experienced remarkable GDP growth of 7.4% and it is expected to achieve 8-8.5% in the year 2015-16. To increase public investment in infrastructure, it is proposed to increase outlays on both the roads and the gross budgetary support to the railways, by Rs. 14,031 crore and Rs. 10,050 crore respectively and CAPEX of the public sector units is expected to be Rs. 3,17,889 crore and this will revamp the business of the Industry in totality. In this budget, steps are taken to curb black money, promote domestic manufacturing, improve business through minimum government and maximum governance, improve the public health through “Swachh Bharat” initiative and provide benefits to middle class tax payers. Reduction in corporate tax from 30% to 25% over the next 4 years will have a tremendous impact towards high level investment, higher growth and more jobs. The

increased Service Tax rate from 12% to 14% and Excise duty rate from 12% to 12.5% is required towards convergence of GST - proposed to be introduced from April 2016. Government has also proposed to collect 2% Swachh Bharat Cess to achieve the noble mission of Swachh Bharat. The increase in customs duty of steel products upto 15% is likely to help deter cheap imports and provide impetus to objective of “Make in India” - a welcome move for the steel industry. The increase in Basic customs duty on coal to 5 per cent and import duty on Met coke to 5 per cent will have an impact on costs across the coal/coke intensive steel industry. However, the proposed increased expenditure on Infrastructure is expected to lead to the development of major projects, including road and railway networks which will improve the domestic demand scenario for the steel sector. On the private sector investment front, the prospects of rationalising the corporate tax regime are promising, but have to be delivered on. Fast-track legal resolution of disputes, as promised in the budget speech, would also be a huge benefit. There are several detailed proposals related to taxes and transfer pricing, that require specialists for assessment, but they seemed to be ‘pro-business’ on the whole. Initiatives on tax incentives for greenfield investments and for growing the venture capital industry in India will hopefully also come forward in the policy agenda in the next year. In fine, this is a unique Budget because an excellent cohesive force exists between growth, fiscal discipline and inclusiveness covering all the sectors of the society. It is positively a growth oriented budget.

I Mr. G.K. Pillai, Managing Director & CEO, Walchandnagar Industries Ltd.

66 | MARCH 2015 | ENGINEERING REVIEW

n my opinion it is definitely a growth oriented and a balanced budget that Finance Minister Arun Jaitley has presented. It is definitely in line with the overall positive sentiment that has been built up since the new government took over in May-14. While committing to adhere to the medium term fiscal deficit target of 3%, the budget lays a roadmap for significantly higher Continue on page no.68 www.engrreview.com

BUDGET REFLECTIONS Continued from page no.66 investments in infrastructure, strengthening of indigenized manufacturing, roll out of the long awaited uniform tax rate in the form of GST, rationalization of subsidies, strengthening of rural credit to support both agriculture and public goods creation, giving a fillip to better defence preparedness, encouraging foreign investments in the country, deepening financial markets & curbing the malaise of black money within the economy. All in all it touches upon all important elements of the economy & in my opinion would herald the start of a sustained high growth rate for the Indian economy in the years to come. The budget does address the issues of giving a fillip to domestic manufacturing as well as encouraging investments in infrastructure. Increase in infrastructure investment by INR 70,000 crore, launch of tax free infrastructure bonds for projects in rail, road and irrigation, plans to build 2 crore houses in rural India and 4 crore houses in urban India, formation of the “National Investment and Infrastructure Fund (NIIF)”, further strengthening of PPP (Public Private Partnership Model) in infrastructure creation, announcement of 5 UMPP (Ultra Mega Power Projects) of 4000 MW each to be awarded post all clearances, target of GST roll out by 1st April 2016, increase in defence expenditure by approximately 10% over last year’s budget outlay, etc in my view are fundamental budget announcements which would give the necessary fillip to infrastructure creation and would help in increasing the share of

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

T 1. 2. 3. 4. 5.

he maiden union budget of Modi Government presented by finance minister Arun Jetali is historic and long term growth driven. The high lights of the budget are Make in India theme Impetus to Manufacturing in india Fiscal consolidation Tax rationalization Ease of business.

No FM in the past in my opinion tried to work on such holistic approach and present it to parliament. Let us look 68 | MARCH 2015 | ENGINEERING REVIEW

manufacturing in the overall GDP. Walchandnagar Industries Ltd. Has a diversified business portfolio of EPC business in the Sugar Plant, Co-generation and Cement Plant equipments and niche manufacturing in the domains of Defence, Aerospace, Missiles, Gearboxes and Nuclear Plant Equipment. The budget positively impacts us in a number of ways – a) Almost all announcements positively influencing infrastructure creation would lead to higher demand for cement. Though the present levels of capacity utilization in the cement industryare modest, we expect a fillip to demand for cement plant equipment. b) Approx 10% higher allocation to defence and the concomitant emphasis on capital purchases with an increasing indigenization % would definitely benefit our defence portfolio which we see as a strategic growth area. c) Renewable Energy has been mentioned as a key focus area and an integral part of the energy sufficiency strategy of the government. We are already present in this sector through the biomass based boilers design and supply. We expect heightened activity in this area and at the same time it also opens up new vistas like Solar Energy which we could explore going ahead. d) Strengthening the PPP model in railways has been mentioned as part of the Railway Budget. Given our strength in mechanical fabrication, we also see this as a growth area going ahead.

at some of the highlights in brief • GOI has increased outlays on both the roads and the gross budgetary support to the railways, by `14,031 crore, and `10,050 crore respectively. The CAPEX of the public sector units is expected to be `3,17,889 crore, an increase of approximately `80,844 crore over RE 201415. In fact, all told, investment in infrastructure will go up by `70,000 crore in the year 2015-16, over the year 2014-15 from the Centre’s Funds and resources of CPSEs. • 5 new Ultra Mega Power Projects, each of 4000 MW, in the Plug-and-Play mode. All clearances and linkages will be in place before the project is awarded by a transparent auction system. This should unlock investments to the extent of ` 1 lakh crore. The Government would also consider similar plug-and-play projects in other infrastructure projects such as roads, ports, rail lines, airports etc. • Ports in public sector will be encouraged, to corporatize, and become companies under the Companies Act to attract investment and leverage the huge land Continue on page no.70 www.engrreview.com

BUDGET REFLECTIONS Continued from page no.68 •

• •

•

resources. National Investment and Infrastructure Fund (NIIF), to be established with an annual flow of `20,000 crores to it. This will enable the Trust to raise debt, and in turn, invest as equity, in infrastructure finance companies such as the IRFC and NHB. The infrastructure finance companies can then leverage this extra equity, many fold. Tax free infrastructure bonds for the projects in the rail, road and irrigation sectors. PPP mode of infrastructure development to be revisited and revitalised. The major issue involved is rebalancing of risk. In infrastructure projects, the sovereign will bear a major part of the risk without, absorbing it entirely. Target of renewable energy capacity revised to 175000 MW till 2022, comprising 100000 MW Solar, 60000 MW Wind, 10000 MW Biomass and 5000 MW Small Hydro. As against likely expenditure of this year of ` 2,22,370 crore the budget allocation for defense for 2015-16 is ` 2,46,727 crore. Make in India policy is being carefully pursued to achieve greater self-sufficiency in the area of defense equipment including air-craft. Revival of growth and investment and promotion of domestic manufacturing for job creation. GOI proposed to undertake a series of steps in the direction to attract capital, both domestic and foreign. Additional investment allowance (@ 15%) and additional depreciation (@35%) to new manufacturing units set up during the period 01-04-2015 to 31-03-2020 in notified backward areas of Andhra Pradesh and Telangana. Balance of 50% of additional depreciation @ 20% for new plant and machinery installed and used for less than six months by a manufacturing unit or a unit engaged in generation and distribution of power is to be allowed immediately in the next year.

Mr. D.P. Nadkarni, Senior Director, Jakson Power Solutions

or Generating Set Industry and Power Solutions Business, there is practically no incentive. In fact, Central Excise has gone up marginally from 12.36% to 12.50% making the generating sets dearer to that

70 | MARCH 2015 | ENGINEERING REVIEW

• Micro Units Development Refinance Agency (MUDRA) Bank, with a corpus of `20,000 crores, and credit guarantee corpus of `3,000 crores to be created. MUDRA Bank will refinance Micro-Finance Institutions through a Pradhan Mantri Mudra Yojana. • A significant part of the working capital requirement of a MSME arises due to long receivables realization cycles. GOI is in the process of establishing an electronic Trade Receivables Discounting System (TReDS) financing of trade receivables of MSMEs, from corporate and other buyers, through multiple financiers. This should improve the liquidity in the MSME sector significantly. • Bankruptcy law reform, that brings about legal certainty and speed, has been identified as a key priority for improving the ease of doing business. SICA (Sick Industrial Companies Act) and BIFR (Bureau for Industrial and Financial Reconstruction) have failed in achieving these objectives. GOI will bring a comprehensive Bankruptcy Code in fiscal 2015-16, that will meet global standards and provide necessary judicial capacity. • Efforts on various fronts to implement GST from next year. • Proposal to reduce corporate tax from 30% to 25% over the next four years, starting from next financial year. All above initiatives will enable revival manufacturing, which in turn will create new jobs and give filip to the economy. This will also boost confidence of private sector and motivate them to invest in infrastructure and allied industries. Most of the above initiatives are directed towards investment in infrastructure, Railways, defense and power sector. This is good news for welding industry. About 65 to 70% of its business is contributed by these sectors. Over all its excellent budget with long term focus on growth and manufacturing in India.

extent. It is the market sentiment that would determine the growth of this vital Industry. Lowering of crude prices probably could have given helped in demand growth but the roll back on petroleum prices had nullifying effect. Leveraging demand for generating sets from this budget seems a far cry. Generally, Corporate Tax and Income Tax restructuring will not have any tangible impact on this important Industry. It could be perhaps the political compulsions that are holding back the Mody Government from fulfilling election promises and make them visible to common man across the Country. How the fine print in the Union Budget translates in to ground realities remains to be seen. www.engrreview.com

03_2014_ Engineering Review.pdf 1 10/03/2014 09:34:40

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ENGINEERING REVIEW |

71 | March 2015

BUDGET REFLECTIONS

Mehul Lanvers-Shah, Managing Director, Hannover Milano Fairs India

he union budget 2015-16 has been designed for growth and indicates special impetus on - manufacturing, renewable energy, education, infrastructure, agriculture & health, sectors that will impact India’s growth target greatly. Large Infrastructure investments to the tune of 70,000 Crores and 5 ultra mega Power Projects, increased Defence allocations among others are aimed at making India a hot investment destination. The ‘Amrit Mohatsava’ in 2022, the year of country’s 75th independence, as the timeline to accomplish many big initiatives such as Housing for all, medical facilities to all the villages, providing basic facilities - electricity, water and road to every village is ambitious but necessary for India’s growth. We would have liked to see more for the common man, through changes in taxation, but reduction in Corporate Taxes will be seen as a welcome move. While the budget lays emphasis on PM Modi’s “Make in India” & “Skilling India” campaign & aim to make India a self sufficient manufacturing hub & an entrepreneurial economy by 2022, a further delay in the implementation of GST to April 1st 2016 is discouraging for the manufacturing sector. Subsidized taxes on imports of 22 important raw materials to reduce manufacturing cost domestically, conveys government’s dedication to promote & encourage ‘Make in India’ initiative. A special allocation of investment to lay an impetus on renewable energy is certainly a much needed initiative from the government- India’s opportunity for renewable energy is immense and will attract interest from Global Investors. I think this is a very positive budget and offers something to everyone. After a long time we have seen a budget that has a vision and has been proposed in a defined time frame which is excellent. I am now excited to see successful implementation of the budget in the coming year.” Mr. Vineet Mittal, Vice Chairman Welspun Renewables

e would like to congratulate the Honorable Finance Minister Shri Arun Jaitleyji for offering measures conducive to the growth of the infrastructure sector. Overall it’s a positive budget for the industry. As direct investment in the infrastructure sector will surely lead to increase in the GDP growth of the

72 | MARCH 2015 | ENGINEERING REVIEW

country. With the announcement of the renewable capacity target Honorable Minister has re-emphasized the government’s commitment to renewable energy. The infrastructure sector has been facing funding challenges and some of the measures introduced will surely help this situation. By doubling the cess on coal to Rs. 200 per tonne , the government is creating an additional corpus of funds for clean energy projects. INR 75,000 crore has been apportioned for infrastructure sector. We are happy that it’s a sizable amount. The Honorable Minister has provided much needed clarity on capital gain tax on the Sponsors, at the time of offering the assets to InvIT, and waiving it off. This was one of the issues which was preventing the implementation of the InvIT . Waiving it away will help this vehicle to take-off and will attract billions of dollars of foreign investments in India. The National Investment and Infrastructure Fund (NIIF) with an annual flow of Rs 20,000 crore has been announced and this will help raise investments as equity in infrastructure finance companies which can further fund the Renewable Projects at competitive pricing. This could be used to develop a sizeable IDF to fund the huge capital outlays required to achieve the target of 175 GW by 2022. The IDF can make a substantial contribution to the Infrastructure development and can attract investors if provided tax breaks for the Investors.

Mr. Pramod Chaudhari, Executive Chairman, Praj Industries.

he Union Budget 2015-16 shows lot of pragmatism for a long haul. The budget gives ‘long term’ direction by way of reducing Corporate Tax from 30% to 25% which is definitely welcome. The Make in India initiative is also well supported including by way of infrastructure growth. Clean Ganga initiative has been given budgetary support and tax exemption, thereby putting investments behind the intent. Companies that have the technology to clean Ganga will now be able to avail tax exemptions. Benefits owing to rationalization of taxes through GST are expected to kick start in 2016.. Higher investment allowances would have certainly helped further.” www.engrreview.com

BUDGET REFLECTIONS

Sanjeev Ranjan, Managing Director, International Copper Association of India (ICA India)

Mr. Tushar Mehendale, Managing Director, ElectroMech Material

t is heartening to see that the GST rollout date has been committed as Apr 2016. Now after an eternal wait, we can finally begin the countdown to a simpler indirect taxation regime. This will definitely give a massive fillip to the manufacturing and logistics industry as effective economies of scale can be achieved and processes can be simplified. Focussed disinvestment in loss making PSUs coupled with a contemporary bankruptcy code will definitely aide in cleaning the mess and introducing overall efficiencies in the industry. This will have a long term impact of ensuring the “survival of the fittest” and breed excellence that is much required if India has to emerge as a preferred global manufacturing hot spot. Announcement of 100,000 km of roads and 4 UMPPs is surely a move in the right direction and will help in giving a good boost especially to the capital goods companies. Overall a good budget for the economy.” Mr José Ruiz Hernandez, Managing Director, Isolux Corsan India.

he Government has decided to keep its action plan for the infrastructure sector simple. The major requirement for the roads and highways and the infra sector is fund and the government has tried to address that by increasing capital outlays. Along with the capital infusion, the government has also declared the ambit of tax-free bonds once more which will allow the sector to call upon foreign investors and drive up foreign investment inflow in the sector. We are also glad that the government has decided to keep its focus on the Public Private Partnership play in the infrastructure sector and Mr Jaitley’s words that the government will seek to increase public capex in the PPP format will instil enough confidence in the private players to go for PPP models to expedite the development of roads and infra projects which will be essential to compliment India’s economic growth. The government’s decision to convert the excise duty of Rs4 on petrol, diesel into road cess augurs very well for roads and highways sector as it has enabled the government to allocate an additional 14,000 crores for the sector. The additional revenue shall help the government fuel its ambitious National Highways Development Project and introduce the e-toll collection system which shall help save another Rs 88,000 crore.” 74 | MARCH 2015 | ENGINEERING REVIEW

he railway budget had set up a roadmap for reforms and the tone for the Union Finance Budget has followed more or less a similar pattern. It is more of a directional budget which talks about the “what” & “where” rather than “how”. The intent of the budget has been to focus on Growth & Equality and as a budget which has something for everyone. The thing which stands out that the government has realized that there is a very strong case for improving the Global Competitiveness of India by focusing on infrastructure, ease of doing business by bringing in regulatory reforms to cut bureaucracy and improve existing taxation norms and help to generate jobs. The announcement that GoI will set up 5 more ultra mega power projects of 4000MW, entailing investments of around Rs 1 lakh crore, is a big positive for copper industry. Though we do not have anything specific for real estate but the clarity that there will be no capital gains tax on contribution to REITS will also be positive. Consolidation and improvement in operations of railways by bringing in better technology will also be a big positive for the copper industry. We are happy with government sticking to its vision of ‘Housing for All’ by 2022 which will mean the government will build 60 million homes -- 40 million in rural areas and 20 million in urban areas by allocating Rs 22,407 crore for taking measures in housing and urban development across the country in 2015-16. If this happens, then it will be a big boost for our building wire for residential application. We would have been more happy if the exemption limit on interest on home loan was increased too. Additional public expenditure is likely to increase to Rs 1.25 lakh crore, with Rs 70,000 crore of capital expenditure. This commitment of government to have participation of sovereign in Infrastructure space can be a very positive step for boosting the almost defunct PPP model. The idea of having National Infrastructure Investment Fund is very good, concept of Plug and Play kind of projects where all clearances are worked out before allotment of the project is also very good. By and large we as an association, our happy with the announcements in the budget and feel that it will all boil down to “How” part and quick creation of capital on the ground which will mark how successful this budget has been in setting a roadmap for future. www.engrreview.com

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76 | March 2015

AIR COMPRESSORS » Tech Trends

Rust proof energy efficient

Airpipe compressed air distribution system

e wish to introduce our self as subsidiary of Eco Pipe Ltd. company. We are leader in the compressed air distribution market. After several years of research, Airpipe was introduced. On the initial note the improvement for compressed air distribution system is immense. A few of the most effective benefits that you could expect after renovation are as follows:Corrosion proof aluminum alloy piping. The pipe material has been engineered so as to counter the common problem of corrosion which results in scaling and porosity resulting in pressure drop and leakages. As per the latest data from prominent external body institutes a leakage from a hole of a size of 800 micros represents a loss of INR 80,000 annually. Minimal pressures drop by the virtue of long lasting internal smooth surface of the pipe resulting in laminar flow as compared to the turbulent flow of the mild steel pipe material. This results in huge energy savings. British compressed air society confirms for every I bar of pressure drop the compressor represents a 7% increase in compressor energy cost Zero Leakages Our “Airpipe” pipe and fittings a system ensures that there are no leakages from the piping and the components and comes with a 10 years zero leak guarantee. Plus there are many more benefits such as: no water retention in the system, ability to take out drop line even when the system is charged, scientifically designed fittings which ensure full flow and minimum pressure loss at drop points, in built

78 | MARCH 2015 | ENGINEERING REVIEW

sturdiness and flexibility in the system to ensure any future expansions plus many more. A brief catalogue on the system is enclosed. We have in all more than 10000 installations world over. It would also be worth mentioning here that with our Aluminum piping one can earn carbon credit from leading institute since it is green building concept . Technical specification • Working temperature : -20°C to +70°C (-30°C to +80°C) • Maximum working pressure :13bar • Vacuum Degree: 0.13bar absolute pressure • Compatible with compressed oil • Fireproof (Meet UL-90-VC standard) • Suitable for outdoor installation • Size from 20mm to 200mm • Suitable for compressed air, inert gases and vacuum

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POWER Âť Tech Trends

Werner Electric

Unveils wireless crane controllers for the Indian market Werner Electric 66 & 67 series offers high quality wireless crane controllers at an affordable cost for higher savings

erner Electric India Pvt. Ltd. Offers An Impressive OneStop Catalogue Of Over 40,000 German Electrical Components In 40 Product Groups Each product quality designed, specified, manufactured, tested, certified and reliably proven to meet every engineers, technician and consultants demanding automation, process, control, manufacturing and industrial project requirement today. Each Werner electrical component is assembled, tested and certified in India at Werner facilities and resources with customer sales and technical support at Mysore, Delhi, Bangalore, Coimbatore - soon also Mumbai. Each component made available to exact Indian industry standards, certification and customer specification.Each component proven to deliver continuous performance and reliability regardless of application, climate, and demanding working conditions. Each component fully supported by Werner Electric qualified technical sales engineers and technical data. Each component delivered swiftly and efficiently to customer workplace by choice of land, rail, sea or air service. This means that customers across India can now benefit from the widest one-stop range of quality premium German electrical components - very competitively priced - locally sourced in India - delivered to customer requirement, specification, certification

80 | MARCH 2015 | ENGINEERING REVIEW

and application. The Werner Electric India product catalogue offers a wide range of MCBs, relays and sockets, mosaics, controllers, sensors, contactors, terminal blocks, circuit breakers, light bars, light curtains, fittings, accessories and more. Werner Electric India PVT. LTD was established in India in 2011 - a wholly autonomous company and subsidiary of Werner Electric GmbH in Germany. Werner Electric has a proud history in the design, manufacture, industrial certification and supply of electrical components dating back almost 100 years ago and today represents a world leading German industrial brand that is synonymous in just about every country across the world as the highest quality and most reliable electrical components available. It is worth noting that behind every great global brand, marques, merchandise and equipment lies the class leading manufacturing and outstanding production that enables those products to arrive to market meeting retailer and customer demand, perception and expectation. Attention to quality control at the vital design, planning, production, process and manufacturing stages ensures that the valuable reputation and premium brand value, endures well into the future prosperity of each company. The vital industrial equipment, systems and automation required to manufacture and process any market leading product in those factories and plants greatly depends on the quality, robustness, design and reliability of each individual component, in every piece of industrial equipment, at

Continue on page no.82 www.engrreview.com

POWER » Tech Trends

Continued from page no.80 every stage of the manufacturing process - every hour and every day of every working year. As India takes centre stage to becoming a hub of world industry, manufacturing, technology and innovation so comes the fundamental crucial need - and valuable opportunity - to build a world leading reputation for being a centre of quality, excellence and reliability. The Werner Electric philosophy has always been.. ‘ “Think Revolutionary But Act Evolutionary.” Previously availability of Werner components in India to consultants, designers, engineers and technicians was only via components imported directly from Germany or via a very few distributors in India. This situation made it impractical, uncompetitive and ultimately more costly to specify Werner high quality components over those cheaper more accessible components in India and components brought in from the Far East, USA, Europe and other

82 | MARCH 2015 | ENGINEERING REVIEW

sources. In 2011 an entrepreneurial move from an astute Indian businessman saw the opportunity to change this situation for industry, manufacturing and process control across India.To meet customer needs and realise the necessity for manufacturing, automation and production superiority in India there is now

Werner Electric India Pvt. Ltd. Mr Vinod Gupta is managing director of the Werner Electric India Pvt. Ltd company. Mr Gupta, Managing Director said.. “By importing Werner base components from German and assembling them in India - to Indian industrial specification and certification - so now the viability and cost efficient access to these high quality Werner components becomes a reality to customers and industries across the nation. The prospect of purchasing highest quality electrical components from a vast catalogue and range of products quickly and competitively priced with local customer technical support - is

now a reality to customers in India.” Werner India electrical components are ideally suited for engineering, automation, panel building, LV switchgear, process control, OEM, manufacture, rail, marine, aviation and aerospace, energy and utilities, high technology, hospitals, education, HVAC, elevators, IT, food processing, agriculture and many other industrial, processing, control and manufacturing purposes. The future for Werner Electric India Pvt. Ltd looks bright and the future for India as a world leading centre for superior production and manufacture of premium brands, marques, products, tools and equipment looks even brighter - so long as there are available superior components behind all equipment, plant and equipment.

For more information Website: www.wernerelectric.de www.engrreview.com

ENGINEERING REVIEW |

83 | March 2015

POWER » Tech Trends

“Hazards happening due to unproper earthing”

E Mr. Haren Shah – Senior Marketing Executive

84 | MARCH 2015 | ENGINEERING REVIEW

very electrical equipment’s, appliance, system must be Earthed or grounded to obtain a low resistance path for dissipation of current into the earth. Earthing plays an important role in Generation, Transmission & Distribution for safe and proper operation of any electrical installation. Ground fault current directly has an impact on human safety. Major accidents happen due to improper Earthing. Leakage current passes through human body and fatality occurs. Even every Overhead line / Sub station / Generator station which is exposed are liable to injury from lightning. In electricity supply systems, an earthing or grounding system is circuitry which connects parts of the electric circuit with the ground, thus defining the electric potential of the conductors relative to the Earth’s conductive surface. In particular, it affects the magnitude and distribution of short circuit currents through the system, and the effects it creates on equipment and people in the proximity of the circuit. If a fault within an electrical device connects a live supply conductor to an exposed conductive surface, anyone touching it while electrically connected to the earth will complete a circuit back to the earthed supplyconductor and receive an electric shock. Electricity most often hurts a man not causing extreme physical injuries but by merely shocking the life out of the body suddenly. This is due to life and electricity in minute form being closely inter-related so that a small current can prove fatal. When body is alive it is found to maintain a potential difference between its inside and outside. Galvany in 1780 proved that all live muscles contract when electricity applied. When contraction due to electricity is more that will power contract and relaxes which brings to death due to

electric shocks. The current affect heart muscles and when contract become too powerful, muscles bewildered and fall in state of flutter, called ventricular fibrillation, the heart stops functioning. It will be proper to know what current and potentials are safe to handle.

Importance of Proper Grounding Systems.

Earthing

• The main reason for proper earthing in electrical network is for the safety. When all metallic parts in electrical equipments are grounded then if the insulation inside the equipments fails there are no dangerous voltages present in the equipment case. • If the live wire touches the grounded case then the circuit is effectively shorted and fuse will immediately blow. When the fuse is blown then the dangerous voltages are away. • Purpose of Earthing in an electric power system is to limit, with respect to the general mass of earth, the potential of current carrying conductors, which are part of the equipment, non-current carrying metal works, associated with the equipment, apparatus and appliances connected to the system. • It is also important to take precautions against leakage of current. Insulation Resistance values should be checked periodically. It is also necessary to maintained Earthing properly of all electrical Installation. As the same time it is also very important at regular interval to check and if required unproper Earthing should be repaired. The records should be maintained if results are poor, action should be taken to be improved.

Continue on page no.86

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POWER » Tech Trends

Continued from page no.84 Measurement Of Earthing / Grounding - The Most Neglected Subject Today ! Old Measurement Methods with Four Spikes, hand generating are: Old Measurement Methods is called fall of potential method./ In this method earth grid is to be isolated from the earth electrode. Two auxiliary electrodes – one current electrode and another potential electrode are placed besides the electrode to be tested at equal distance in a straight line. A measured current is passed through the auxiliary current electrode. The potential difference developed between the auxiliary potential electrode and the electrode to be tested is measured. Resistance is calculated from the above current and voltage values. Normally in the site we use three lead digital earth testers for the measurement. In the field the condition of earthing is so poor and normally earth resistance or leakage current is not measured either because of prevailing tedious & time consuming methods or handy instruments were not available. Many a times the important aspect of proper earthing is neglected resulting in complex problems associated with poor earthing. The Distribution Transformers fail because of earthing not being proper and lightening arrestors do not carry out their work. In case of HT consumers the meter behaves erratic as unbalance voltages are recorded due to poor earthing. To ensure proper monitoring of earthing it is necessary to give a handy and easy to use equipment to the field staff. Now Latest Handy Instruments are available to measure Ground / Earth Resistance and Leakage Current on Live Load By just clamping to the grounding lines without disconnecting the circuit or Driving auxiliary electrodes. MECO Introduce Clamp-On Earth / Ground Resistance Tester Model 4680BL & 4680BLC, which can measure ground resistance from 0.099 Ohms ~ 1000 Ohms & Leakage Current from 80mA ~ 30A AC by just clamping to the grounding lines without disconnecting the circuit or driving Auxiliary Electrodes. Suitable for Flat Strip (Jaw Size 65 mm), Data hold, Data Storing Memory, Auto power off & Continuity Loop Test are Key features of 4680BL / 4680BLC. It Is based on an unique principal in which a pre-defined current is injected in the ground circuit under test and then the induced magnetic current there by generated in the circuit is measured at a high frequency by use of special clamp -on current transformer in the instrument. This is an extremely handy instrument especially at place where it is next to impossible to measure Earth /Ground Resistance by conventional methods. Substantial time saving and easy operating justify the investment in these instruments Regulations for earthing system vary considerably among countries and among different parts of electric systems. The objectives of Maintaining Proper Earthing is very good but the road ahead is very long, rough and tardy but with the cooperation and strong will, nothing is impossible. E-mail : haren.shah@mecoinst.com / harenvshah@yahoo.com

86 | MARCH 2015 | ENGINEERING REVIEW

MECO Clamp-

On Earth / ground resistance & leakage current tester Model: 4680BL & 4680BLC

very Electrical Equipment’s, appliance, system must be Earthed or grounded to obtain a low resistance path for dissipation of current into the earth. Earthing plays an important role for safe and proper operation of any Electrical installation. Ground fault current directly has an impact on human safety. Major accidents happen due to improper Earthing. Leakage current passes through human body and fatality occurs. MECO Introduce Model 4680BL & 4680BLC at very Low Price having Jaw opening of 65mm x 32mm, which is suitable to take measurement from Earthling Strip or Conductor of Φ65mm x 32mm approx. This testers are capable of measuring Ground Resistance from 0.010 Ohms to 1000 Ohms (4680BL) and Leakage Currents in TRMS mode from 0.80mA to 30A AC (4680BLC). Data hold, Data Storing Memory, Configurable Alarm, Auto power off & Continuity Loop Test are Key features of 4680BL / 4680BLC. Standard Resistance Calibration Plate provided to verify the calibration check of tester. Substantial time saving and easy operating justify the investment in these instruments. This is non-contact type innovative solution for measuring Ground Resistance and Leakage Current of any Electrical Installation. This method of measurement completely eliminates the use of ground and auxiliary rods avoiding shutdown. This is an extremely handy instrument especially at place where it is next to impossible to measure Earth / Ground Resistance by conventional methods.

For more inforamtion Web: www.mecoinst.com www.engrreview.com

ENGINEERING REVIEW |

87 | March 2015

MACHINE TOOLS » Tech Trends

Four ways 3D printing is shaping product design & manufacturing How the Mojo® & Uprint® lines of desktop 3D Printers enable users to turn designs into reality without leaving their desks

enable users to turn designs into reality without leaving their desks.

Through case studies and expert perspectives, readers will learn about applications in the following areas: • Making ideas tangible in the conceptual design stage • Preparing functional prototypes • Crafting jigs and fixtures for manufacturing • Creating custom end-use parts

roduct engineers and tooling manufacturers have much to gain from 3D printing: By generating low-cost physical prototypes early in the design process, they can check form, fit and function; gauge customer response; and compare design iterations without commitment. It’s even possible to quickly craft end-use parts, customized for a particular job. And no longer are manufacturing professionals limited by 3D printers that are too big, unfit for the office environment, and prohibitively expensive. Today, affordable, compact, office-friendly units are moving 3D printing capabilities to the desktop and dramatically expanding the availability of high-quality prototypes and parts. This white paper will describe how the affordable Mojo and uPrint lines of desktop 3D printers from Stratasys®

88 | MARCH 2015 | ENGINEERING REVIEW

In the span of just a few decades, 3D printing has gone from being the stuff of science fiction to a valuable driver of real-life product design and manufacturing. Today, the technology is helping companies in a wide range of industries to realize their design ideas at every stage, from concept to end-use parts and to save time and money while doing so. What’s more, the diversity of 3D printers available in the marketplace now makes it possible for even very small start-ups to implement this paradigm-shifting technology. Product engineers and tooling manufacturers, in particular, have much to gain from the efficiencies that in-house 3D printing can create. Generating inexpensive, yet highly accurate prototypes early in the design process allows manufacturers and engineers to check form, fit, and function without committing significant resources. They can rapidly gauge Continue on page no.90 www.engrreview.com

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MACHINE TOOLS » Tech Trends

Each part produced on a 3D printer can be uniquely identified with its own rev control number.

Continued from page no.88 customer response to an item, adjust the design and produce multiple iterations to compare alternatives. They can even quickly craft end-use parts that are customized for a particular job and they can do all of this in hours or days, not the weeks or months that are required for traditional outsourcing to machine shops. What’s more, manufacturing professionals are no longer limited to massive 3D printers that are both expensive and unsuitable for an office environment. Today’s affordable, compact units, exemplified by the Mojo and uPrint lines of desktop 3D printers, are expanding 3D printing capabilities and increasing the availability of high-quality prototypes and parts.

Making a real impact in the real world To illustrate how owning a 3D printer can improve business workflows, we’ll explore how two very different companies Worxsimple and Redshield 90 | MARCH 2015 | ENGINEERING REVIEW

Technology are utilizing their 3D printers to enhance manufacturing processes. Based in Sandy, Utah, Worxsimple, LLC, is an original equipment manufacturer of custom medical parts and equipment. The company’s engineers create prototypes and test fixtures on their 3D printers. To meet their various needs, Worxsimple uses three Stratasys 3D printers: the Mojo, uPrint, and Objet®30 Pro™. Both the Mojo and uPrint employ FDM technology, which crafts extremely durable parts by extruding thermoplastic. In contrast, the Objet30 Pro features PolyJet™ technology, which operates in a similar fashion to an inkjet printer (instead of jetting ink, it jets layers of photopolymer resin that is cured with UV light) and is useful for parts that require fine feature detail. It’s easy to see how the company’s needs evolved, says David Baker, owner of Worxsimple. “We had the Mojo first ... I think about four months,

and it was always full and we could never really get in [all the print jobs that were in queue],” he explains. That spurred the purchase of the uPrint. Soon after that, they realized the need for a printer with enhanced surface texturing and accuracy, which was satisfied with the Objet30 Pro. “Having all three [printers] has been pretty beneficial in the machine design business because we can build pretty much anything we want,” he says. The second company, Redshield Technology, is an agricultural machinery manufacturer based in North Liberty, Iowa. Using a uPrint SE Plus®, its designers create 3D printed parts for sensor brackets, computer module housing and exterior trim pieces for machines that test soil composition. Because Redshield Technology is a start-up with a limited budget, owner Stacey Schildroth was very concerned about the cost of producing parts. Owning a 3D printer seemed to be the logical answer. “With the 3D printer, we have more control of profitability,” she explains. “We can print as many parts as needed. We avoid the downtime that outsourcing would have involved. And we are able to maintain better quality control, since it is now in-house. Having our own 3D printer improves the bottom line dramatically, as it pays for itself so much faster than going to an outside party.”

Turning Conceptual Designs Into Tangible Models Producing realistic physical models by traditional methods is time consuming, but the models are a necessity if clients are to fully comprehend a project’s design intent. With in-house 3D printing, professional models can be created very quickly to demonstrate designs, illustrate assemblies and identify potential problems before resources are invested in tooling and Continue on page no.92 www.engrreview.com

MACHINE TOOLS » Tech Trends

Worxsimple uses 3D-printed parts, such as the yellow point guard shown here, in prototyping and end-use applications.

Continued from page no.90 production. For Worxsimple, buying a 3D printer was a leap of faith, says David Baker. He explains that although he was very excited from the start about incorporating a 3D printer into his workflow, he was somewhat overwhelmed by the range of possibilities. However, he quickly realized the breadth of what he was able to do with the technology and how it would fit in with his company’s business process. “I remember one night I woke up at 2:00 [a.m.] and I started doing all these SolidWorks drawings,” he recalls. “I drew the parts out. I came in the next day. I printed them [on the] Mojo, and it was one of those days like, ‘Wow! That worked! I can’t believe it.’ And it just kept building on itself.” Now, all three of Worxsimple’s 3D printers are in near-constant use, turning their designers’ concepts into reality. For Redshield Technology, which is still in the startup phase, the focus is on keeping costs minimal and that includes maintaining a small inventory. Since it takes only a few hours to create a new part with the uPrint 3D Printer, workers can create parts on a just-in-time basis. This speed also helps them turn around orders 92 | MARCH 2015 | ENGINEERING REVIEW

rapidly; workers can fully assemble a soil-testing machine in less than a day. Schildroth explains that Redshield also seeks to control costs by making each CAD model as accurate and complete as possible before it’s sent to the 3D printer, so reprints won’t be needed. “However,” she continues, “from that point on, the printer is always involved from the first prototype to production parts that go on the final assemblies shipped to the customers.”

Preparing functional prototypes Physical models are also important tools for testing a product’s accuracy and viability. Unfortunately, when outsourcing the creation of such a model, manufacturers can’t be certain that the fit, strength and texture will be right. In addition, long turnaround times may lead to delayed projects and the loss of business and profitability. An in-house 3D printer enables companies to evaluate performance and fine-tune products without committing to production tooling. “It’s very cost-effective for us to do our initial bids [this way],” explains David Baker. “We can push ‘Print’ [on any of our 3D printers] and go home, see our families and come back the next morning and put our parts together. They look great. They’re very

pleasing to the eye, and they perform as well as any machined part in a lowstress situation.” He noted that one particularly useful benefit of prototyping with a 3D printer is that it eliminates errors due to version-control issues. “We have a lot of scrap parts and if you’re going through a lot of changeovers, or you’re still redesigning your machine with very minute differences between the parts, you can accidentally put the wrong part in the final device,” he explains. “With the rev control [number printed] on the part, that really saves us a lot of headaches later on down the road.” Schildroth also believes that the uPrint has helped improve Redshield Technology’s prototyping significantly, and observes that the 3D printer really pays off when time is critical. “We were in a situation last spring where we needed to deliver a prototype to a customer that was evaluating our machine for a possible purchase,” Schildroth says. “Unfortunately, we found an error in the design only days before delivery. We were able to redesign the part, get it printed on the uPrint SE Plus, and assemble it to our machine without missing our delivery date. We would never have been able to do that if the 3D printer weren’t in-house.” As other Stratasys customers like Continue on page no.94 www.engrreview.com

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MACHINE TOOLS » Tech Trends

Continued from page no.92 Digi, Oreck and Thogus / rp+m have shown, financial justification of a new 3D printer based solely on jigs and fixtures can be quite easy and the outcome quite profitable. The important elements of these justifications are to equate the ease and simplicity of AM with more fixtures put into service. Then carry the savings out to the production floor to calculate labor reduction and profit gains from getting product on the shelves sooner.

Crafting Jigs & Fixtures Custom-made tooling and fixtures can be produced as needed on a 3D printer, improving a company’s ability to respond to customer demand. Strong, durable jigs and fixtures can be created in one night instead of weeks. “We bought [the Mojo] primarily to do prototyping for our fixturing that goes into our final machines,” says David Baker. “We would do some development work and test them on the machines, and then later on we would convert to a stainless steel part or aluminum part before we finally shipped it. As we started working with Mojo, we found out how accurate and how reliable the parts were that came off of it. We started using it for

94 | MARCH 2015 | ENGINEERING REVIEW

more brackets and even more special widgets that we would ship with the final product to our customers.” Printing out components overnight and using them the next day provides substantial time savings, he notes: “You’re cutting days and weeks out of the lead time for building machines.”

Creating End-Use Parts A 3D printer can speed up the tooling process but it can also enable manufacturers to skip it completely. Both Mojo and uPrint utilize production-grade thermoplastics for their models, so users can simply print enduse parts directly from CAD files. “Since we sell a high-value, low-volume product, we utilize parts off the uPrint SE Plus for both prototyping and production,” says Schildroth. “It saved us from having to invest in high-volume tooling, and we can change the design immediately if needed.” “Our customers are really surprised that we can create our machines in-house using a 3D printer,” Schildroth continues. “They’re impressed with the level of detail involved, the quality of the parts, and the durability. If we don’t tell them that the parts are made on a 3D printer, they would

have no idea.” When building a part or a machine, if it looks like it’ll work, that’s half the battle, according to David Baker. “If everybody feels very good about it and is very positive about a machine that you’re building, then they will go that extra mile to make sure that it’ll work,” he says. “I think 3D printing really lends itself to making something [that’s] very aesthetically pleasing. The curves of the devices, the curves of the parts, it really improves the look of a machine.” The most important aspect of uPrint, believes Schildroth, is that it dependably produces quality parts. “We looked at less expensive ‘prosumer’ models,” she says, “but it seemed that you were forever tweaking and adjusting them to get good parts out. This is our business and we can’t afford the time to print multiple parts before we get a good one. With the uPrint SE Plus we can send the design to the printer and rely on good parts being built.”

For more information about Stratasys systems, materials and applications, visit www.stratasys.com

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MACHINE TOOLS » Tech Trends

“It’s a revolutionary product!”

claims Unimac following a return on investment of just four months using the new Primo™ twin probe system. on-machine part setting, part inspection and tool setting, helping to eliminate manual setting errors, improve accuracy and part conformance, whilst reducing non-productive time and scrap. All of which increase productivity, improve quality and boost profits. The Primo system is straightforward to install and use, and represents a low initial financial outlay. It also has an exclusive, enhanced warranty to offer users peace of mind.

Mr. Ashok Mungale from Universal Manufacturing Company (Unimac) has been using Renishaw probing technologies for the past ten years and is a highly satisfied client of the UK-based company

he Pune-based Universal Manufacturing Company (Unimac) has consistently reduced inspection time by 90% over four months after installing a Primo™ twin probe system, designed for on-machine part setting, part inspection and tool setting. Unimac manufactures components for railway engines, power generation plants, cement manufacturing plants, and other heavy engineering applications. For Unimac, maintaining accuracy of 15-20 microns on large parts is vital. A major challenge for Unimac has been the inspection of large parts during the manufacturing process.

96 | MARCH 2015 | ENGINEERING REVIEW

According to its Director, Mr Ashok Mungale, “The issue was resolved five months back when Renishaw’s Primo system was installed on the machine, based on application requirements. The on-machine probe is not only easy to use, but performance driven, which has resulted in increased machine utilisation time. Renishaw has truly been instrumental in our growth by providing an outstanding probing system that helped shorten our cycle time.” Innovative probing The Primo twin probe system consists of a Radio Part Setter and a Radio 3D Tool Setter. It enables automated

Up and running in a day It is so easy to use the Primo system that at Unimac its installation and evaluation were completed on the same day. The Primo GoProbe training kit and pocket guide make it very quick to learn and implement the system. A key benefit is that there is no need for extensive G-code knowledge. Simple, single line commands are used instead of multiple lines of code, removing the necessity for any special training. Unimac, the company Mr Mungale started Unimac in 1987, after purchasing a second-hand machine from Germany for manufacturing components needed in sugar and cement plants. He later switched to manufacturing general engineering components. Currently, the company manufactures large precision parts used for railway engines, power Continue on page no.98 www.engrreview.com

MACHINE TOOLS » Tech Trends

A Primo system was installed at Unimac five months ago, following a process audit

Amazing 90% reduction in inspection cycle time on turbocharger housing

Continued from page no.96 generation plants, cement manufacturing plants and other heavy engineering applications. The company has its own tool room, horizontal boring machines, floor boring machines, HMCs and VMCs. One of the VMCs has a bed size of 4.5 m x 2.75 m. Making a difference Unimac manufactures precision components, such as turbo chargers that are used in railway engines and oneoff single components, for its customers. Before the Primo system was installed, the cycle time for machining a turbo charger housing was 46 hours. During this process, at the semi-finished stage, the part would be taken to an inspection facility to be checked for flatness, squareness, parallelism and positional accuracy. The part would then be brought back to the machine, and have to be realigned and set before further machining could take 98 | MARCH 2015 | ENGINEERING REVIEW

Primo – twin probe system

place. This process would take three hours and have to be carried out twice, meaning that the machine lay idle for six hours during each manufacturing cycle. In this manual process, part setting itself takes 30 minutes. The Primo twin probe system enables inspection to take place on-machine, removing the need to breakdown and move the part, and reset it once it has been inspected. Now at Unimac, the new process takes just 30 minutes, has reduced inspection time by 90%, reduced cycle time by 12% and led to a very fast return on investment (ROI) in just four months. Optimising throughput Mr Mungale said, “After installing the Primo system, the manpower cost, material handling costs, material equipment and power consumption charges are saved so no additional investment is required. This gives flexibility to the manufacturing unit in accepting orders for any size and for segments such as the machine tool industry. The manual analysis of results is also avoided, as the data is available on the same controller. It’s an amazing experience to use Renishaw machine tool probes, which are being used by us for the first time.” “Another advantage of the Primo system is that it combines part set up, part inspection and tool setting capabilities in one system so there is no need to source separate items. The Primo system is definitely worth

recommending for every engineering industry.” Building trust Unimac first heard about Renishaw when ten years ago it purchased its CMM, which came fitted with a Renishaw probe. Following this, Unimac formed a relationship with Renishaw, and received regular updates about new product developments. Renishaw engineers analysed all of the machining applications at Unimac thoroughly, and offered best practice advice and guidance on which Renishaw products would be most suitable for Unimac’s needs. The Primo system is the company’s first machine tool probe. Mr Mungale concluded, “Since we were convinced with the sales, service and application aspects of Renishaw, we installed its telescoping ballbar to help maintain machine accuracy. After this, it was easy to ascertain whether the fault was during machining and the errors could then be eliminated. Results from the ballbar are always perfect so a mutual trust has developed between Renishaw and us”.

For more information www.renishaw.com www.engrreview.com

MACHINE TOOLS » Tech Trends

Mastercam’s

Design tools provide flexibility & ease of use

astercam is known for powerful NC programming, but it also delivers a suite of shop-tested design tools including 3D surfacing and solids. The streamlined CAD engine makes design work easier than ever before. Mastercam Design streamlines modeling and editing geometry. It also supports advanced geometry creation, including NURBS curves and surfaces, 2D and 3D associative dimensioning, surface extension, blending, trimming, splitting, variable filleting, solid modeling, hybrid modeling, and so much more! A few new enhancements to Mastercam X8 Design are: New Solids Workflow The solids interface and workflow has been completely redone for

Mastercam X8 and makes constructing and editing solids a lot easier and more intuitive then it’s ever been. Every existing Solids function has been updated to reflect this new workflow. All solids functions have been given a new modern interface that allows you to work in the interface and on the screen as needed. And, by putting the solid selection filters in a new dialog that pops up at the start of an operation, it’s easier to set them up as you are working.

Solid Edge Awareness Solid Edge Awareness is now throughout wireframe modeling. The goal for Mastercam X8 is to allow solid edges to be used as reference entities and eliminate the need to create temporary geometry. If you are in a function that supports Solid Edge Awareness, the Edge filter will be available and can be used to recognize or ignore solid edges.

Smart Chains in Solids This enhancement automatically reconnects wireframe chains that have been edited so you don’t have to re-chain them. For example, when you extrude a rectangle, then go back and fillet a corner, you just have to regenerate the operation instead of having to re-chain the wireframe.

Some Surface Modeling improvements include: • Change Normal function supports the new color display of the non-normal side of the surface in shading. • Orient Normals positions the normals of neighboring surfaces to one another. Once you set the initial position, you can flip the results and display arrows that show the direction. • Fillet Surface to Surface and Surface to Plane functions display a Maximum Recommended Radius. Once you select the surfaces, Mastercam analyzes them and displays a maximum recommended radius that can be successfully created.

Surface Modeling Improvements

For more information Web: www.mastercam.com www.mastercamdesigntools.com 100 | MARCH 2015 | ENGINEERING REVIEW

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MACHINE TOOLS » Tech Trends

Clamping force gauge Testit,

clamping force measurement over machine control Hainbuch and Siemens enter into partnership maintenance status are, or from the centrifugal force losses while turning with jaw chucks, is extremely sceptical of such makeshift calculations and hence builds in a high safety value. Machining of easily deformable components is also extremely critical. Usually only a very small margin of holding force is available. If an item is clamped too strongly, a sensitive component will be excessively deformed. Applying to little clamping force results in an inefficient set-up for rational machining.

The clamping force measuring device increases productivity through precise clamping force measurements.

he Siemens Sinumerik CNC controllers have been getting the maximum productivity out of each machine for over 50 years. Now they have another partner on their side: the Hainbuch Testit software. It is available on a data carrier for installation on Siemens CNC controllers [Sinumerik 840 D sl plus PCU50]. This means that a separate laptop is not needed anymore and manufacturing with »theoretical clamping forces« is also a thing of the past. Thanks to Testit, the operator always knows which clamping forces exist and where, and the actual maintenance status of the clamping device. And given the safety standard DIN EN 1550, it is a »must have«. This means: The Testit clamping force gauge together with the Siemens CNC controller executes a target-actual comparison of the maintenance 104 | MARCH 2015 | ENGINEERING REVIEW

status of a clamping device. If the limit values are underranged, a warning message is output. Perfect, don’t you think? Trust is good, control is better Based on his apprenticeship a machine operator or programmer has been taught to work in such a manner that a workpiece does not get destructed, e.g. when programming the manufacturing steps he builds in a lot of safety measures to minimize this risk. However, in reality, effective measurement data regarding the holding forces of a clamping device, and also in regards to the clamping forces of the clamping cylinder itselfcan only be obtained as vague reference values. A machine operator who knows how dependent the holding forces of a clamping device derive from its current

Safe results - even with mandrels However, the globalization of markets requires an optimum of the machining process. Those who face stiff competition can no longer afford to manufacture just by »feeling«. Measurement data is demanded! It not only functions perfectly for outer diameters and during rotation, it also precisely measures the holding force of mandrels for inner diameters. Key advantages: • Clamping force measurement for O.D. and I.D. clamping • Can be used rotating [under RPM] and for stationary applications • Direct input onto the Siemens CNC controller

For more information www.hainbuch.com www.engrreview.com

AUTOMATION » Tech Trends

ROLLON: Reducing linear bearing wear Contamination and poor lubrication practices can shorten the life of linear bearings. Here is a look at how to avoid both problems.

Unlike recirculating ball linear guides, Rollon’s Compact Rail system utilizes large rolling elements that can pass over any debris that fall into the rail.

o get the longest working life out of a linear bearing, keep it clean and well lubricated. This common-sense advice may sound easy enough to follow. Yet in the real world of round-the-clock, high-cycle manufacturing operations, bearings do get dirty and dry. And when either of these conditions happens, linear bearings will wear prematurely. In the worstcase scenarios, contamination and inadequate lubrication can create metal-on-metal contact between the bearing’s rolling elements and raceway. This can cause excessive wear in the form of denting, pitting or galling results. This warning about contaminants and the importance of lubrication will not come as news to anyone who has designed or worked around industrial machines. When using linear guides on medical, food, packaging, semiconductor or other sensitive equipment, machine builders often take extraordinary measures to keep the contaminants out and the oil

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in. They may add expensive bellows to cover the guides, or they may opt for a pricey automatic greasing system. Yet in their zeal to keep linear motion systems running smoothly, machine builders can overlook less expensive design solutions to contamination and lubrication issues.

Combating contamination Contamination comes in many forms, some more aggressive than others. Metal chips from machining operations, for example, qualify as one of the biggest offenders from a wear perspective. Silicon dust produced during semiconductor manufacturing can also be tough on linear bearing surfaces. Modern manufacturing processes can throw off a long list of other abrasive, wearinducing contaminants. Less aggressive contaminants can pose problems too. Even soft contaminants such as those found in food processing can gum up linear bearings. This kind of debris is not necessarily a wear issue, but it can keep the

linear motion systems from functioning smoothly. Consequently this can have a negative impact on positioning accuracy and product quality. If a linear bearing gets gummed up to the point it stops working, then there are also potential maintenance and downtime costs. Keep in mind, too, that contamination is a twoway street. In addition to worrying about contamination from the product interfering with the linear motion system, machine builders also worry about stray lubrication or particulate from the linear bearing contaminating the product. This type of machine-to-product contamination is a cause for concern in contamination-sensitive industries such as medical, semiconductor and electronics. To combat contamination, machine builders will often supplement the linear bearing’s built-in seals with bellows or other types of covers. Though these can substantially add cost to a machine and add to the maintenance burden, they do have their place. Some clean-room environments, for example, may require some physical barrier between the product and the machine elements. And inside machining centers, it is crucial to physically protect any motion systems from metal chips. But there are many less severe contamination scenarios. And in these cases, machine builders should consider bearing styles that are less affected by contamination and less prone to generate any of their own. Bearings with large, sealed rolling elements fall into this category. With conventional linear guides, the tiny recirculating balls in a raceway have very little clearance. So even a relatively small pieces of debris can interfere with the balls. Bearings based on larger diameter rollers, by contrast, can roll right over even relatively

Continue on page no.108 www.engrreview.com

AUTOMATION » Tech Trends

Continued from page no.106 large contaminants. Rollon’s Compact Rail system, for example, is built around rollers that are from 14 to 50 millimeters in diameter. These linear bearings can roll over all kinds of contaminants that can stop smaller rolling elements dead in their tracks—including metal chips, plastic particulate, paper dust and more. Large rollers are also more damage tolerant than smaller rolling elements. Even if a contaminant does happen to mar the roller or the rail surfaces, the large rolling element can usually keep on running.

Well-oiled machines Lubrication problems are often described in terms of not enough grease or oil. And sometimes that is the case as lubrication leaches out or is squeezed out of linear bearings, leaving them susceptible to metal-on-metal wear. There is a flip side to the lubrication issue too. Maintenance workers, with grease guns in hand, often over-lubricate linear bearings, potentially blowing out seals and introducing oil into environment. And keep in mind that lubrication also qualifies as a contaminant. So overlubed bearings can also worsen contamination problem or force machine builders to opt for bellows or physical covers. Getting just the right amount of lube into a linear bearing at the right interval can be tricky because it depends on application-specific factors such as the type of bearing and the duty cycle. The application’s sensitivity to oil contamination comes into play too with sensitive industries demanding lighter lubrication

Rollon’s Compact Rail ball bearings are permanently lubricated and sealed within the rollers, which isolates these small rolling elements from contaminants. schedules. There are ways to make sure linear bearings stay properly lubricated throughout with little intervention on the part of maintenance workers. On the expensive end of the system are expensive automatic greasing systems. These systems are a legacy of the linear way systems used in the machine tool industry. The auto-greaser was crucial for maintaining the film of oil that separate a linear way’s bearing surfaces. Some of these expensive auto-lubrication systems have made their way into applications that employ more modern linear guides, and they can be a valid way to get the lube levels right while reducing the maintenance burden. But aside from their cost, auto-greasing systems can introduce unacceptable levels of contaminant into the factory environment which, again, will create problems is an issue in clean-room and other sensitive manufacturing operations. A lower-cost, cleaner alternative to automated lubrication exists in the form of self-lubricating wipers that integrate into the linear bearing’s carriage. Rollon, for example, has an optional

The Compact Rail slider incorporates an integrated wiper (see inset) that automatically satisfies the systems minimal lubrication requirements.

108 | MARCH 2015 | ENGINEERING REVIEW

self-lubricating wipers on its Compact Rail system. These provide lubrication for 2 million cycles before they need to be refreshed, and they cost a fraction of what PLC-controlled auto-greasing systems cost. The very idea automatic lubrication is the only way to achieve optimal lubrication is somewhat outdated. Some linear guides, such as those based on recirculating balls, do require regular lubrication in all applications. But bearings based on sealed rolling elements may not need much, or any, external lubrication at all in many applications. With Compact Rail, the roller acts as a true sealed bearing. Its ball bearings, raceway, and their lubricant are contained inside the outside housing of the roller. The need to add lubricant between the roller and the profiled rail thus becomes less importantor even unnecessary in light duty applications. This capability makes a big difference in contamination-sensitive applications industries that would normally resort to expensive bellows or covers to keep stray oil off their shop floors, out of their air and off their products.

For more information, Rollon India Pvt. Ltd. Web: www.rollonindia.in www.engrreview.com

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AUTOMATION » Tech Trends

Sliding & Rolling : igus hybrid linear bearings in new sizes

Move doors or control panels with just one complete rail and the new double roller hybrid bearings. (Source: igus GmbH)

drylin double roller hybrid bearings now available for rail diameters of 10 and 16 millimetres

gus, The Cologne-based specialist for lubricant-free bearing technology; has expanded its range of double roller hybrid bearings with two new sizes. The range of hybrid bearings will now be completed with sizes of 10 and 16 millimetres. Lighter and quieter linear running on two rollers -- also for applications with reduced installation space. The quiet and smooth-running hybrid linear bearings from igus are used not only in camera technology, sliding doors or machine tool doors, but increasingly in cabins for construction machinery, or even for the individual hobbyist’s needs. To facilitate the design engineer in their selection, there is the option of two additional sizes of hybrid carriage. Behind the innovative concept of this bearing from igus is the combined advantages of plain and roller bearings. For extremely smooth and almost silent operation, the concept provides two angularly opposed rollers made of maintenance-free high performance plastics. The rollers take

the weight in the main load and ensure low driving forces for manual operation. When misuse or moment forces occur, they will be absorbed smoothly over the sliding element,. thus eliminating the risk of the carriage leaving the rail at the same time the movement of heavy loads becomes possible with minimal effort all absolutely free of lubricant.

Suitability for the design of smaller installation sizes “The hybrid bearings available with 20 mm diameter have already proven themselves in practice,” says Stefan Niermann, head of the drylin linear and drive technology division at igus. “If only one guide rail is necessary, the user saves considerable space. In this aspect we have now gone one step ahead and offered the double roller hybrid bearings in new, smaller installation sizes of 10 and 16 millimetres.” These allow the design engineer now an even more flexible installation of the bearings, such as for control panels or

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

110 | MARCH 2015 | ENGINEERING REVIEW

The double roller hybrid bearings in 10 and 16 millimetres complete the hybrid bearings range from igus. (Source: igus GmbH) stage setting installations on double rails and in combination with a complete carriage. Since the hybrid bearings encompass more than 180 degrees, they can also be used on simple shafts.

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

For more information Web: www.igus.in www.engrreview.com

AUTOMATION » Tech Trends

Next-generation capping heads The new ROBA®-capping head for filling plants – almost wear and maintenance-free

he rustproof ROBA -capping head with their continuous, impact-free torque, apply screw caps made of plastic with a maximum of precision and repetitive accuracy. mayr® power transmission has now developed a new, extremely wear-resistant and almost maintenance-free generation of capping heads for minimum downtimes and maximum plant availability. We all know this problem stubborn screw caps on plastic bottles are sometimes very hard to open or cannot be opened at all without using tools. To prevent this, the capping heads which apply these caps in the filling plants and which screw them shut to a defined torque must work precisely and with high repetitive accuracy. The rustproof ROBA®-capping head (hysteresis capping head) has long proven its worth in the beverages industry, as well as in the pharmaceutical and cosmetics industries. mayr® power transmission ®

has now developed a new generation of these products, and perfected the already maintenance-friendly design of the capping heads. The new, extremely wear-resistant plastic/stainless steel linear guide, which is lubricated for the entire lifetime of the product, reduces necessary servicing and maintenance costs to an absolute minimum. A simple visual inspection once a year is sufficient. And even better: No manufacturer service personnel are required for the inspection, in contrast to other commercially available capping heads. On-site employees can carry out the inspection themselves, and the top part of the capping head can be easily and quickly dismantled without requiring tools. This ensures substantially reduced standstill times and therefore high plant availability and productivity.

Contactless hysteresis technology With the ROBA®-capping head, the

Fig.: mayr® power transmission

112 | MARCH 2015 | ENGINEERING REVIEW

Fig.: mayr® power transmission The new, extremely wear-resistant ROBA®-capping head with plastic/ stainless steel linear guide reduces service and maintenance costs to the absolute minimum.

hysteresis technology not only provides contactless and therefore wear-free torque transmissions: It is also impactfree and low-vibration, and thus guarantees a longer plant lifetime. The capping heads also feature a high torque repetitive accuracy of +/- 2%. With their continuous and impact-free closing torque, they are therefore the optimum choice for the application of plastic screw caps with preformed threads. They are better suited for the task than permanent magnet couplings with intermittent torque in slip operation, which in part “hammer down” the screw caps and make them hard to open. With the ROBA®-capping head, the limit torque can be easily and continuously adjusted, and can be read off directly via a scale. The enclosed construction also makes the capping heads resistant to dirt and aggressive media. It is possible to adapt the head pressure easily according to the customer requirements. ROBA®-capping head in a filling plant for drinking yoghurts. Due to the continuous, impact-free slip torque, these capping heads are more suitable for plastic bottles than the permanent magnet capping heads.

For more information editor@divyamediaonline.com www.engrreview.com

High Voltage Dividers Model: VD series

AUTOMATION » Tech Trends

Smart standard drives provide servo dynamics & precision

eamed with advanced inverter electronics for smart control functionality, standard asynchronous motors providing IE2 or IE3 efficiency and permanent-magnet IE4 synchronous motors can deliver servo-level dynamics and agility. Based on state-of-the-art frequency inverters for motor-mounting, wall-mounting, or cabinet installation, NORD DRIVESYSTEMS implement highly precise positioning tasks, safety applications, and sophisticated functions such as synchronization, coordinated multi-axis operation, winding control, and flying shear. These systems are significantly more economic than conventional servo technology solutions since the purchase costs are much lower and since there is

a much larger variety of available system components, including a very versatile gear program that allows for a wide range of custom-specific configurations. The frequency inverters feature a real-time microprocessor (cycle time 10 ms) and support free programming of drive-related functions according to IEC 61131 to relieve the workload of external PLCs. 200% overload reserve capacity ensures high operating safety, for instance in crane and hoist systems. Employing field-oriented control technology, these controllers achieve excellent consistency under flexible loads and from near standstill up to the motor’s rated speed, even without an encoder. Furthermore, the drives provide high starting torques and speed feedback can also be implemented.

Highly dynamic, coordinated drives with built-in intelligence manage complex handling assignments

116 | MARCH 2015 | ENGINEERING REVIEW

The top-of-the-range frequency inverter SK 540E from the control cabinet line integrates a universal encoder interface for SSI, BISS, EnDat profile 2.1, and Hiperface. NORD’s line-up of distributed inverter technology covers the performance range up to 22 kW, while cabinet devices range up to 160 kW. The German drive expert provides full-scale mechatronic drives, manufacturing geared motors and electronics units and programming logic functions in-house.

Company background NORD DRIVESYSTEMS develops, produces and sells drive technologies with around 3.000 employees, and is one of the international leaders in the industry. In addition to standard drives, NORD supplies application-specific concepts and solutions, even for special applications, for example with energy-saving drives or explosion-protected systems. Gross sales amounted to approx. EUR 450 mn in the 2012 business year. The company founded in 1965 now has over 35 subsidiaries worldwide. The closely meshed sales and service network ensures optimum availability for short delivery times and customer-oriented services. NORD produces a wide variety of drive units for torques from 10 to 200,000 Nm, electric motors with powers from 0.12 kW to 1,000 kW as well as the necessary power electronics in the form of frequency inverters and servo controllers. Inverter solutions are available for classical installations in the switch cabinet and for decentralised and fully integrated drive units.

For more information Web: www.nord.com www.engrreview.com

AUTOMATION » Tech Trends

First Metro Line in Suzhou rolls on, thanks in part to ProSoft Technology’s modules by Victor Garcia

icturesque gardens dot the city of Suzhou, in eastern China’s Jiangsu province. Some of these gardens, known as the Classical Gardens of Suzhou, date back as far as the 11th century, and were designed by some of China’s renowned sch olars. Nearby, numerous canals crisscross the city that is known as the Venice of the East. Forty-two percent of the city is covered in water through its canals and waterways. “Suzhou City is one of the most famous tourism cities in China,” said Gary Zhang Zhen Hua, ProSoft Technology China Sales & Technical manager. But while the area is likely one of the more picturesque in the world, thanks to its gardens and canals, it is also highly populated with more than 10 million people and is largely industrial. Like many cities in China, automobile congestion is a problem. The city needed

118 | MARCH 2015 | ENGINEERING REVIEW

to install its first subway system to help alleviate its traffic congestion. After more than four years of construction, the Suzhou Metro Line I opened in April 2012. It encompasses 24 stations that connect the east side of the city to the west side over about 16 miles. The line extends from the Mudu station in the eastern portion of the city to Zhongnan Jie station in the west, near Suzhou Industrial Park. Metro Line I is the start of a larger subway system in Suzhou. Later this decade, the city will construct Metro Line II, which travels north and south. “The Metro Line I is the first Metro Line in Suzhou, which goes from west to east, and connects two economic development zones and the downtown,” Gary Zhang Zhen Hua said. More than 150 ProSoft Technology Modbus to ‘C’ Programmable communication modules were installed in the Metro Line’s

Building Automation System, which plays a vital role in the underground tunnels and stations that make up the subway. The modules allow Rockwell Automation ControlLogix and FLEX I/O systems to communicate and gather data from ventilation systems, air conditioners, as well as monitor the overall environment inside the subway system. Most people think of a train speeding down an underground tunnel when they think of a subway. A Building Automation System is likely the last thing that comes to mind, but without this critical piece, a subway would not be able to operate. The ProSoft Technology solution is a good one,” said Jianshui Gan, the Building Automation System engineer working on the Suzhou Metro Line I. “We chose ProSoft Technology’s product because they are the communication adapter between field devices and the ControlLogix controller.” More than 200,000 people per day, tourists and Suzhou residents alike, now use the Metro Line to get from one end of the city to the other and avoid automobile congestion. ProSoft Technology® designs industrial communication solutions that connect automation products seamlessly. ProSoft Technology is a highly diversified, customer intimate, global organization with a focus on quality and ease-of-use. Their products include in-chassis communication modules for PLC/PAC controllers, standalone protocol gateways, and a wide range of robust, field-proven wireless solutions. These are found in applications spanning the industrial marketplace. With 500 distributors and regional offices in Asia Pacific, Europe, Middle East, Latin America and North America, ProSoft Technology provides an unparalleled support to customers worldwide.

For more information Web: : www.prosoft-technology.com www.engrreview.com

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Lubi Eyes Global Expansion

ubi Industries, established in 1965, is a leading Indian manufacturer of Water Pumps & Electric Motors. It produces more than 4,500 types of pumps and motors. Located at Ahmedabad, the heart of Gujarat, its plant is just 10 Km away from the International Airport and 400km from the Sea Port. With a massive strength of 2500 steadfast employees, Lubi Industries boasts of having a manufacturing capacity of 700,000 pumps per annum consisting of Borewell Submersibles pumps, Centrifugal Pumps, Drainage & Sewage Pumps suitable for various Applications viz. Irrigation, Water Circulation, Building Water Supply, Pressure Boosting, Fire Fighting, Gardening, HVAC, Civil Water Supply, etc. Lubi is equipped with a state-of-the-art infrastructure with a vertically integrated ultra modern manufacturing set-up. It is accredited with National certifications like ISO, ISI & BEE and International Certifications like CE & UL. Lubi Industries is recognized as a Market Leader in the Pump Industry, manufacturing the widest range of products which can be utilized in

120 | MARCH 2015 | ENGINEERING REVIEW

almost every imaginable segment be it Agricultural, Domestic, or Industrial & Building Services. Global Expansion Having established its leadership in the Pump Industry in India, with its nationwide spread through its sprawling manufacturing facility and headquarters in Ahmedabad, 20 branches and over 1200 distributors / dealer network, Lubi is now spreading its wings in the global market. It already has its presence in more than 80 countries spread over 7 continents. It also has operating branches in UAE. â&#x20AC;&#x153;We are known for our manufacturing excellence. Our main motto is to provide Customer Satisfaction in terms of meeting their exacting requirements and unmatched after-sales support. Our vision is to strengthen our position by becoming a benchmark in the Pump Industry,â&#x20AC;? states the company on the threshold of its Golden Jubilee Year.

For more information, Website: www.lubipumps.com www.engrreview.com

Bft, Italian technology for your access automation systems. Sliding gates

Boom barriers

ǩ Operators for sliding gates up to 3,500kg ǩ Wing speed up to 39m/min. ǩ Magnetic/electromechanical limit switch ǩ Release with personalised key ǩ Bluetooth compatible on demand

ǩ Barriers with 24V/230V power supply for intesive use ǩ Useful passage up to 8m and opening time up to 0,7sec ǩ Impact reaction via encoder ǩ TCP/IP and RS485 compatible on demand ǩ Stainless steel version available

Security bollards

Automatic doors

ǩ Hydraulic / electromechanical bollards ǩ Shaft diameter up to 330 and height 1200mm ǩ Available in both access control version and anti-terrorism range “XPass” (K4 and K12 tested and certified) ǩ Stainless steel version available

ǩ Automatic pedastrian doors available for sliding, swing, telescopic and revolving versions ǩ Max leaf weight up to 250kg ǩ Impact reaction via electronic torque limiter ǩ Continuous use cycle

U-link

d-track

24 V

rolling code

U-LINK is the new Bft serial communication protocol, thanks to which all the systems can communicate with each other, exchanging information on positions, speeds, and much more. But U-LINK is also a door open to the outside world.

Intelligent torque management system based on the microprocessor technology of BFT.

BFT 24V technology ensures optimum performance: precise slowdown control during opening or closing; safety and reliability.

BFT transmitters use a rolling code system that manages the commands in a completely secure way and prevents any type of external violation.

NICOMAC DOORS SYSTEMS Pvt Ltd. BFT AUTOMATION PRIVATE LIMITED Plotno No:10-A, I,D,A, MiyapurNear Miyapur, Plot 6, Shed No.Bollarm, 2, IDA Near Bollaram, Hyderabad 502 325 India Hyderabad-502325. ph. +91 4032 914113 ph.: 8897141999 fax040-31000775, +91 8458 279790 email: bftasia@gmail.com

www.nicomacdoors.com www.bftworld.com www.bftindia.com

made in Italy tuned to you

COVER STORY

Growth With Technological Excellence Mr. Vijay Karia Chairman & Managing Director, Ravin Group

Q. Ravin Infraproject being one of the leading player in power and energy sector and has established its brands in the market over the time, please brief its journey towards this milestone and share some of its achievements? Ravin as a group was established in the year 1950 in the name of our flagship company M/s Ravin Trading co. In 1978 we started with cable manufacturing at our 1st plant in Ankleshwar in Gujarat,and in 1997 in the 2nd plant in the name of Ravin Cables Ltd. at Pune, in 2009 in the third plant at Fujairah, U.A.E under the name of Power Plus Cables Co. LLC. Since inception, the group has been in power and energy sector and has been a reputed and well respected organization with its presence not only in India but all over the world. The group exports its products to more than 50 countries around the world. Exports to so many countries is today a matter of pride but it meant a lot of hard work when we started our exports in 1999. Indian products especially electrical products were considered to be of a lower grade and people were not willing to touch our products. From that stage of non acceptance, to being a supplier of repute to many advanced countries 122 | MARCH 2015 | ENGINEERING REVIEW

around the world has been a pretty fruitful journey with its own share of experiences. It was about 10 years ago we realized that mere manufacturing of cables was not something that really excited us, as we wanted to be a complete power products group, with a bouquet of products as well as services. Hence we started with specialized EPC services, went on to manufacture specialized power equipments and we later forayed into solar and into retail energy products. We envisage that Ravin Infra will be a specialized power and energy company with a top line of about 1500 crores in the next 2 – 3 years’ time. It is our vision and the hard work of the entire team that has won us many awards, the last one being to me personally for “Enterprising Entrepreneur” of the year by Economic Times in Feb 2015 Q. How about Ravin Infra’s initiatives in solar energy space? Which are your focus areas? Our foray into solar energy was a well thought out process. More than 3 years ago when solar was not such a big area of interest, we recognized that this space had not only the potential but would also be an essential and

integral part of country’s growth. Today, fortunately we have a government that clearly recognizes the importance of solar energy and is willing to push this area. A few facts which cannot be ignored are that: a. Fossil fuels are going to be more expensive. If solar and wind was not there, oil and coal would have been much more highly priced today. b. India, with its large area and low per capita power consumption would have to have generation to be decentralized c. India has enough solar irradiation to meet the energy needs of the entire world d. The cost of administration of electricity to agriculture and small villages would be much more than the cost of generation of electricity e. India’s distribution systems would require lot of capital and overhaul to reduce the huge losses we have. f. Solar micro-grids would be an answer to all the above listed problems Therefore, our foray into the solar energy space was a lot more of a specialized process where we forayed into tracker manufacturing for increased www.engrreview.com

COVER STORY

efficiencies. We are going to focus on rooftop systems, on agricultural pumps and on Megawatt scale systems with trackers so as to increase the output from the same panels to about 35% more than what a fixed system would generate. We see efficiencies playing a bigger role in the coming years than what it is playing today. Another area that we are looking at is Home Lighting Systems, Solar Chargers and Solar Plug & Play systems. Q. What are the market opportunities for Ravin Infra’s products in India? How do you plan to position these products? The market opportunity for our products in India is going to grow to a scale where one cannot imagine the kind of demand that would be there from our vast population. For the cities and commercial and residential buildings we have rooftop systems. For the rural areas as well as smaller towns and villages we have Plug & Play Home Lighting Systems, and for an individual user we have solar chargers, solar torches, solar lanterns, etc We are already in the retail markets which was a new area for us as over the past six decades we were essentially a B2B organization. Large scale rooftops will yet be B2B. Agricultural pumps and rural products would be a mixture of both and we are positioning ourselves to market these products on pan India basis through Direct Marketing, distributor/dealer/retailer network as well as through e-tail. Q. What is your marketing strategy for Indian market? As explained above we plan to market

Ravin Dual Axis Tracker System installed at BPCL Kota, Rajasthan www.engrreview.com

for products through Defect policy at all stages, Direct chain of constarting with product tact with industrial design to raw materials utilities/contractors to final product usage. It that we have in our is but natural that quality customer bank over plays the most important the years. For our role in the sustainabilretail products we ity of the business and have already built therefore quality is a non retail marketing compromisable aspect chain and we have of our products and Termination at 40mtr Height also established our imbibed in each member marketing through of our organization. e-commerce with our products being sold on flip kart, snap deal, amazon, Q. Can you brief us more about your top ebay, etc and also have our own portal line product range? www.ravinretail.com We also spend a We are not only a product company substantial amount on various forms but also a complete electrical solutions of advertisements as well as through provider and a EPC service provider. We technical seminars and direct customer specialize in difficult and complicated interactions. EPC solutions for EHV and we are one of the very few highly qualified compaQ. Can you please elucidate the nies in India. We are also the only comcontribution of R&D in the success of pany in India to have carried out termiyour products? nations of 220 KV cables on towers at From inception we have been a pretty 40 meter height. We also manufacture progressive company in terms of R & moisture removal systems for transD. We are the people who introduced formers in collaboration with Transec XLPE cables at the cost of PVC cables in U.K. Our product range also includes India, we are the people who changed mobile chargers, solar lanterns, solar the construction of high and medium torches and solar home lighting sysvoltage cables in India to filled cables. tems. Hence our entire product range In tomorrow’s India there is going is top line. to be high emphasis on affordability and optimum costs and efficiencies. Q. Please highlight the Indian and Global Cost of ownership is going to be a very perspective of solar product industry? important factor in the buying pattern The solar industry in India today is of India and R & D will play a huge role envisaged to be the largest producer of in the cost of ownership. We have a solar energy in the world by 2030. Today dedicated R & D department and a team India’s power mix is still dominated by of dedicated professionals who undercoal which makes about 60% of the stand the business and the products installed capacity and solar just stands and therefore we will be well placed in about 1% of the capacity. Over the last imbibing newer technologies of tomorfew years, fundamentals of energy suprow. Next few months are going to see ply in India have changed significantly the launch of a host of exciting products in terms of kWh, solar energy which was from our stables. about 7 times more expensive than coal in 2010 has today come to a factor of Q. Brief us about the quality policy for less than 2x. your business? Globally solar energy has been Ravin has always been known for its incredibly successful with USA & China total quality approach built on a Zero leading the pact. China intends to install ENGINEERING REVIEW | MARCH 2015 | 123

COVER STORY

as much as 70 GW by 2017, because of the large solar production capacity within the county. Even if we utilize just 0.5% of our entire land mass, we could build as much as 1000 GW from solar, which would meet the demand of the entire country. In terms of thought process and desire to implement, India today is at par with most global economies such as USA & China. However implementation of this desire will be a challenge and the bottleneck today in India are the overly complicated procedures and the subsidies for installing solar projects. And of course the government trying to regulate the industry. Government needs to move out from trying to be a regulator and a negotiator to be a mere facilitator and bring in simple implementable policies without any bottlenecks and give adequate tax incentives for the next 5 years to whosoever wants to set up a solar plant. Once we do this, see the way the industry grows. Q. What are the key technological trends that are driving solar industry? The key technological trends are: • Improvement of efficiencies • Cheaper and more cost effective solar panels • HCPV which today is not put to a very big use is going to be a technological driver tomorrow. Most of all we see the Tracker System being put to use in a much bigger way than they are being used at present. Q. According you what are the factors affecting to your business? The major factor is the lack of funds available for infrastructure growth

Ravin Dual Axis Tracker System installed at L&T, Telangana

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and unless this area Our Retail Offerings: is not addressed, no major businesses nor the country can grow. Secondly, the higher costs of administration and finance in India, where we spend more time and money on filing various tax returns and submitting data to the government than we spend on the business itself. Thirdly the inward looking and the non business friendly licenses and export policies that our country has are something which needs to be changed urgently. For example, why should an • Give deemed export status to the advance license which I take for export solar industry orders have a restricted time period for • Incentivise solar by offering tax import of materials? Why should there credit certificates be a restriction on the time frame of • Encourage growth of micro / mini imports when I have already fulfilled grids my exports? Why should there be any • Remove rooftop installations from kind of penalties or restrictions once FSI / municipal regulations of exports are completed? Why should covered area there be a form that has to be filled prior • Exempt solar industry from GST to my exports which makes me decide • Government is claiming to be giving whether I want to claim duty drawback subsidy for various sources of energy or advance license or DEPP against my i.e. Diesel, Gas, NEFTA etc. Give solar exports? industry such subsidies in terms of Some simplifications have come in tax credit. recently, but a lot has to be done. Unfor• Reduce the cost of finance for solar tunately the previous governments have projects and get easy finance. massacred the ease of doing business in • Allow tax incentive for individual like India. My plea to the government would under Section 80 C for investment in be to first make it simpler for Indians Solar to do business in India before inviting • Promote in a massive way solar water foreigners. pumping in all area. • Review duty structure on imporQ. What are the issues you need to tant element of raw materials which address that are related to solar impact final costs. industry? The simplest thing for the government What we require for the solar industry to do would be remove subsidies and are the following: allow 200% tax exemption as allowed • Get government out of the regulafor R&D projects. If the government tion of the businesses. does all this they will be easily able to • Remove subsidy as it is the major achieve the target of 100 GW by 2019 in blocking point in progress. place of 2022. www.engrreview.com

TECH TRENDS

Drive Systems and Energy Saving By Ashok Kumar

“

The issue of energy savings in electric drives and systems has been catching on to the minds of the people all over the world as energy conservation not only makes end product competitive but affects profit margins also. Energy efficient operation also results in cooler operation. The consequence of this is reduced maintenance.

hree-phase induction motor is the most commonly used drive in industries. This is so as induction motor is rugged, almost maintenance -free and gives trouble free service throughout its life. Induction motors are available from small ratings to quite high ratings. Almost constant speed operation of induction motor was the main drawback as flow control was possible only with throttling, an inefficient operation. This problem has been overcome as variable frequency operation resulting in variable speed operation of induction motors has become possible and efficient flow control by varying speed is possible. The variable speed operation of induction motors saves a lot of energy. Also location of valve operation handles is simplified resulting in simpler pipelines, etc. This saves space and time required for installation. Low speed operation of induction motors is also a problem at present but such applications are few and other drives for such applications are used. Motors are generally directly coupled to the load as belt drives, etc. result in inefficient operation and, hence, loss of energy. Still there are many applications where direct coupling is not possible and belt drives are to be used. Belt drives have their own problems such as more space requirement, maintenance, etc. These are inevitable.

“

Energy conservation in induction motors The issue of energy savings in electric drives and systems has been catching on to the minds of the people all over the world as energy conservation not only makes end product competitive 126 | MARCH 2015 | ENGINEERING REVIEW

but affects profit margins also. Energy efficient operation also results in cooler operation. The consequence of this is reduced maintenance. People hardly used to bother about energy conservation till 1970s as energy costs were not that high but after the oil crises of mid after 1970s, there was awakening about the issue of energy conservation. Since then, lots of research and development efforts in the direction of energy conservation have gone. Three phase induction motor is the most commonly used electric drive in industries. Induction motors consume 70-80% of the electrical energy billed in any industry. Hence, even a 5% increase in efficiency of induction motors can save a lot of money in any factory. As soon as the line voltage begins operating higher than the minimum possible voltage, or the mechanical load is lower than maximum possible load, the motor’s power factor will be less than optimal. The average power factor of AC motors used in the industries is about 0.7. This means that as much as 30% of a source’s generated power could be lost due to the less than optimal power factor of the AC induction motor. There is a great need to optimize the operation of all AC induction motors when there is scarcity of electric power supply in our country. Induction motors consume energy costing many times more than its cost during its life. The efficiency of any three phase induction motor is load dependent, that is, if load varies, its efficiency also varies. For every motor, there is a specific load at which the motor operates at maximum efficiency at the rated voltage. If we wish to increase the efficiency of the motor, Continue on page no.128 www.engrreview.com

ENGINEERING REVIEW |

127 | March 2015

TECH TRENDS Continued from page no.126 there is need to decrease the voltage across the motor terminals. An induction can be designed for maximum efficiency at a particular load only. Hence, induction motors are designed for maximum efficiency at about 80% of the rated load assuming that the motor will be operating around this load for most of the time. This may not be true as motor may operate at a load less than 80% of the rated load. In that case, the motor will operate at lower efficiency. This happens with most of the induction motors being operated in industries all over the world. The result is that the motors operate at lower efficiencies. When any load is applied to an induction motor, it draws a current decided by the load. The current consists of two components, that is, magnetizing component and load component of the current. The magnetizing component depends on the applied voltage and it is independent of the applied load. Load component is decided by the load. The magnetizing component and load component decide the power factor at which the motor operates. When load varies, load component varies but magnetizing component remains the same as applied voltage remains the same. Hence, power factor of the motor goes down. As a result, efficiency goes down. The next question is what should be done to increase the efficiency at reduced load. The solution lies in reducing the magnetizing current and, hence, increasing the power factor. Actually the ratio of magnetizing current and load current will have to be increased by decreasing the voltage at reduced load. We can reduce the magnetizing current by reducing the applied voltage across motor terminals. Reduced voltage across motor terminals will also affect the load component also but overall current drawn from the supply reduces. As we further reduce voltage across 128 | MARCH 2015 | ENGINEERING REVIEW

motor terminals, supply current further reduces. As we go on reducing voltage across motor terminals, supply current goes on reducing; thus improving efficiency and power factor of the motor. If we further reduce voltage across motor terminals keeping the load constant, the supply current shoots up. The torque produced by the motor may not be enough to keep the motor running and the motor may stall also. Hence, it is not desirable to reduce the voltage across the motor terminals below the value at which current drawn is minimum. It is desirable to operate the motor at this voltage and keep the efficiency maximum at this voltage. How much voltage should be reduced? It depends on the load applied to the motor. If the motor is operating at the rated load and voltage, it will not be possible at all to reduce the voltage as the motor might already have been operating at maximum efficiency. Even slight decrease in voltage across the motor terminals will result in shooting up of the current drawn from the supply and all other consequences such as reduced torque, severe heating, etc. of the motor will start appearing. Hence, the amount of voltage which can be reduced depends on the load applied to the motor. The higher the deviation of the load applied to motor from the rated load, the higher will be the reduction of voltage from the rated voltage to get maximum efficiency. Power given to an induction motor is given by P = â&#x2C6;&#x161;3VI cos j where P = power taken by the motor, V = voltage across the motor terminals, I = current drawn from the supply and cosj = motor power factor. If voltage is reduced, power factor cosj improves and current reduces. If voltage is reduced too much, current will shoot up as Vcosj will reduce. If Vcosj is more than the previous value, current reduces. On the other hand, if Vcosj is less than the previous value, current

increases. These regions are shown in the following current v/s voltage plot.

In an industry where many motors operate simultaneously, it may not be practically possible to reduce the voltage across all the motors according to their loads at all the times and increase their efficiencies. What can be done is that supply voltage at incoming point can be controlled at regular intervals so that minimum current can be drawn. Three-phase auto transformer or some other equipment of suitable capacity may be installed at the entry point itself. Installing an autotransformer or some other equipment will involve some expenditure but it can be recovered as a result of reduced energy consumption over a period of time. Techno-economic study will have to be carried out to justify installation of autotransformer or some other voltage controlling equipment. Another way of controlling voltage across the motor terminals is to install power factor controller for each of the motor. The power factor controller operates the motor at a set value of power factor. The voltage is reduced till power factor of the motor rises to the set value. The motor may not operate at maximum efficiency but it will surely operate at higher efficiency compared to the condition when rated voltage is applied to the motor terminals. The drawback of power factor controllers is that ripple is introduced in the supply voltage applied to the motor and it increases the losses. Still there will be overall energy saving with the use of power factor controllers. www.engrreview.com

PORTFOLIO

Welding Research Institute, Trichy

WRI â&#x20AC;&#x201C; At the vanguard of welding research in India

elding Research Institute, a premier research Institute for Welding and allied areas stands as an exemplary example for Industry-driven research organization. Established in 1975 as a premier National Institute of Importance by the Government of India, it has flourished under the flagship of Bharat Heavy Electricals Limited, Tiruchirappalli. The mandate for the Institute has been to excel in welding related technology for different sectors and cater to application-oriented problem solving. Since its inception, WRI, as it is widely known, has carried on in realizing that vision. WRI was incubated initially through grants from UNDP and GTZ, which brought experts from all parts of the world for training budding engineers from India. Thus, it was uniquely positioned to absorb the best practices throughout the world and assimilation of those practices in India. This

130 | MARCH 2015 | ENGINEERING REVIEW

enabled a generational continuity for best of welding practices through successive leaderships. Over a period of these four decades, the knowledge assimilation on welding has enabled WRI to offer a range of solutions to different sectors, different problems, different scope typically through the entire spectrum of welding activity. WRI has a two -pronged approach towards achieving technical excellence. The first is to collaborate and compete with the peer group in welding applications. It has been offering welding solutions through consultancy towards different sectors of economy like Power, Defence, Aerospace, Shipbuilding, Automotive, Structural Fabrication, Petro-chemical etc. on a continual basis. It had signed MoUs with renowned International Institutes like Japan Welding Research Institute (JWRI), Welding Research Institute, Bratislava, E O Paton Welding Institute, Ukraine, and

Edison Welding Institute, USA to name a few. The associations continue and today WRI is also jointly working with institutions like DVS-Germany and Leibniz University of Hannover, Germany. Mission Projects WRI works on two major thrust areas, identified as Mission Projects. One of the Mission projects is to develop Advanced Ultra Supercritical Boilers (AUSC), a superior efficiency and high Continue on page no.132

A Training Booth at WRI

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PORTFOLIO

Continued from page no.130

capacity thermal power plant. WRI is proud to be associated in this venture which as formed by Government of India as a consortium between BHEL, IGCAR (Kalpakkam) and NTPC. Another Mission project is to its commitment to be a world class Institute. This thrust is to reinforce the leadership position of WRI in welding field by upgrading its facilities, updating its knowledge base and demonstrating its capabilities in solving industry specific problems. WRI leadership role naturally demands a mode of operation which includes training of human resources. WRI has scaled different programs from the lowest rung of welders till the highest rung of qualified engineers. Skilled manpower is projected to be in shortage for industries in India despite the abundant availability of employable manpower. WRI addresses this issue with certified training modules for welders for all sectors. WRI’s certificate of training is widely recognized and approved in Welders’ training. To its credit it has trained over 5,400 Welders since inception and they have been employed in all international positions. It has also trained over 18,600 Engineers & Supervisors updating their knowledge on welding and inspection with inputs from different specializations. They have

The Thermo-mechanical Simulation System

132 | MARCH 2015 | ENGINEERING REVIEW

The Robotic Welding Facility at WRI

been conducted both at WRI and also at customers’ locations. In keeping up with its social commitments, WRI in partnership with the Government of Tamilnadu, has also been regularly training people from underprivileged sections to mould them for their livelihood. WRI has filed more than 140 IPRs with 1060 published technical papers, supplemented with 70 national and international awards. It is equipped with a full-fledged library with emphasis on welding literature and is also publishing its own quarterly publication of WRI Journal. It is a recognized research Centre by DSIR, DST, DIT, IIT, NIT, IISc and is also authorized by Indian Boiler Regulations for training and certification of welders. Many of the WRI employees are on board in standards organizations including BIS, ASME, etc. With state-of the-art welding and testing facilities and with experienced work force, WRI is on a sure foot to its commitment of serving the welding fraternity as a world class facility. www.engrreview.com

FACE TO FACE

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.

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

Documentation When you click on a component in the component vendor database, you automatically get a menu containing the electrical symbols for the component. By placing these symbols in the diagrams you also transfer information to the electrical diagram which enables the program to fill out order lists or files automatically. Integration PC|SCHEMATIC Automation can interface with PLC I/O tools, wire numbering tools, label systems, send files for component ordering systems, edit PLC data via Excel, import and export the standard CAD formats DWG and DXF, and update all types of lists automatically. Furthermore the program supports practically any database format, so that it can work with the database format used in your company. Our solution saves 80% time To make it possible for existing and new users to get started quickly, PC|SCHEMATIC - and its distributors

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- 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 one single person needs to be pointed out as the main responsible for creating the company subdrawings, while the others in future almost only will need to create documentation by dragging templates and subdrawings into projects. Experiences from the industry suggest that the documentation time can be reduced by up to 80 percent. Why should I buy PC|SCHEMATIC Automation? People buying PC|SCHEMATIC Automation usually tell us they did it because: • It is easy to work with, and is very flexible in the everyday work routines. • The Module and Model Based drag’n draw functions, makes it possible to create electrical schematic pages extremely fast. • We have an excellent support team, and you can get support via NetViewer. Our support team can then see your screen, and guide you directly on your own PC. • Intelligent reuse of existing material Continue on page no.136

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PC|SCHEMATIC - Advanced electrical CAD Easy to use. Reasonable price. Get started now! Have you ever experienced an electrical CAD software that easily handles all practical details, and truly sets you free to focus on your professional challenges? Well, here is your chance! We present PC|SCHEMATIC Automation: Advanced electrical CAD software, at an extremely reasonable price. Download the free PC|SCHEMATIC Automation 40 at pcschematic.com/free, experience the videos at youtube.com/pcschematic, and be surprised how easily you get started!

PC|SCHEMATIC Automation - developed in close dialogue with professionals worldwide over the last 20 years.

PC|SCHEMATIC Market Consultant in India: A.Venkatakrishnan / venkat@pcschematic.in / +91 988 654 0077 - For demo, support & training

FACE TO FACE

Continued from page no.134 - 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. 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”. 136 | MARCH 2015 | ENGINEERING REVIEW

This insight in the IEC/EN electrical standards is an integrated part of PC|SCHEMATIC Automation. However, the program is designed so flexible, that you can also use it for other standards than the IEC/EN standards. - Even for your own set of standards! 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.

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.

• 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!

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

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IN FOCUS

“Selection of the right turbine oil helps equipment perform under the most demanding condition” Q. How important is the focus on energy efficiency for ExxonMobil? Energy Efficiency is visibly a paramount issue for every company in the global industrial sector, no matter how large their operations are or what they specialize in. Obviously, from an operations and cost efficiency perspective, reducing energy consumption can have a positive impact on a company’s bottom line. Also,

minimizing energy consumption can help companies demonstrate to their partners and customers that they are committed to sustainable practices. Deployment of energy efficient technologies reduce the negative impact of energy consumption on the environment and society, at the same time reducing energy costs, thus contributing towards sustainable development The industrial sector is a major consumer of energy, accounting for about half of all the electricity consumed around the world and for about 30 percent of primary energy use. Today, companies in nearly every industrial sector are seeking new ways to reduce their carbon footprint, while striving hard to increase their competitiveness.In response to the latter, industrial equipment manufacturers are designing lighter and more compact equipment so as to achieve maximum system efficiency. Achieving enhanced energy efficiency helps them reduce costs and increase productivity. One opportunity for energy conservation that is often overlooked in industrial facilities is the technology behind the lubricant used. Using energy efficient lubricants will enable manufacturing facilities to operate at maximum efficiency with optimal cost. Typically companies that upgrade their lubricants and reliability practices have been able to document a significant reduction in power requirements. In India, the challenge is to adopt a recognized standard or certification program for lubricants and there is a heightened need for initiating this. 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. For example,Energy Efficiency savings to the tune of 1.5% can be achieved in gas engines operating on Mobil SHC Pegasus 30 in power generation and natural gas compression sectors, while extensive field tests and controlled laboratory assessment have proven up to 3.6% savings with synthetic product such as Mobil SHC 600 series or Mobil SHC Gear series in various industrial and power generation ancillary applications. In hydraulic equipment across many industrial and off-highway applications, one can experience up to 6% pump efficiency with Mobil DTE 10 Excel range of products. Understanding equipment and its application, followed by selection of the right lubricant, help gain the maximum mileage from these technologies. Hence, Mobil Industrial Lubricants not only keep machines at top performance, but also help improve energy output and reduce carbon emissions at the same time Q. How can turbine oils help improve performance? Selection of the right turbine oil helps equipment perform under the most demanding conditions and has a direct impact on the reliability and profitability of a power generation operation. Unplanned outages from lubrication failures result in costly downtime and possible equipment damage.Modern steam and gas turbines subject Continue on page no.140

Mr. Glen Sharkowicz, Industrial Lubricants Marketing Manager – Asia Pacific, ExxonMobil Fuels & Lubricants

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IN FOCUS

Continued from page no.138 the turbine lubricant to even greater demands. Issues such as higher temperatures in bearings, reductionin residence times and varnish deposits have become critical concerns. Since oil is the lifeblood of reliable turbine operation, sound oil condition monitoring is needed to ensure long trouble free operations. Mobil offers a wide range of specially formulated Mobil SHCTM and Mobil DTETM series of turbine lubricants for critical equipment needs. The lubricants are designed to provide uninterrupted operations and long service life, to outstanding synthetic lubricants and greases engineered to perform in extremely demanding environments. The reliable operation of a power generating turbine and its associated equipment is also dependent on the health and well-being of the lubricant in use. Regular oil analysis and condition monitoring is one tool that should be used to maintain the turbine in peak operating condition. The oil analysis program should include the basic tests to assess the physical and chemical properties, contamination issues and performance characteristics of the fluid. Operators should consult with the equipment manufacturer for further guidance on the interpretation of the used oil analysis data. Mobil’s Signum oil analysis program is specifically tailored to monitor critical indicators for in-service lubricating oils. Signum has become a global service based on over 40 years of expertise in lubricating oil analysis. Supported by a team of ExxonMobil formulators, scientists and engineers who not only develop the products, but understand their performance and life cycle in the field, Signum Oil Analysis delivers safety, environmental care and productivity benefits to customers. At Mobil Industrial Lubricants, we are committed to helping 140 | MARCH 2015 | ENGINEERING REVIEW

companies be safer, more productive, and more aware of environmental care practices. By taking a proactive, predictive approach to maintenance through Signum Oil Analysis, the customer can prevent costly production delays and equipment failures, while helping to protect workers as well as the environment. Q. What are the expectations from the Indian market in 2015? The industrial sector is a major consumer of energy, accounting for about half of all the electricity consumed around the world and for about 30 percent of primary energy use. For the period 2010 to 2040, the demand for energy by the industrial sector is expected to grow strongly. For example, global chemicals energy demand is expected to rise by about 55 percent from 2010 to 2040, and will account for 35 percent of the growth in the industrial sector. By 2040, the industrial sector is projected to get only about 15 percent of its direct energy from coal, compared to over 20 percent in 2010. Energy consumption has many business as well as society and environmental impacts and benefits. An increase in energy efficiency works hand in hand with reduced energy consumption. With heightened awareness of this key principle, today, industries around the world are setting up sustainable business practices as they look for energy efficient solutions that minimize energy consumption and maximize productivity. An often overlooked aspect for achieving such efficiencies is the usage of advanced lubrication solutions. Lubricants reduce friction as their primary role in the base case. Today’s lubricants go beyond the basic reduction of friction. Advanced base oils and additives impact traction coefficient in bearings/gears. Advanced High Viscosity Index (VI) fluids offer the potential to use lower viscosity for reduced churning loss and better

heat dissipation. In hydraulics/circulating applications, advanced High VI fluids manage balance of mechanical and volumetric efficiency in pressurized pumps for instance, that lead to reduced energy at start up, and improved lubrication at high temperature of operation. In order to continuously set new benchmarks in lubrication excellence, ExxonMobil works closely with Original Equipment Manufacturers / Equipment Builders to develop the technology that help our common customers achieve improved operational safety, environmental care and increase productivity. For over 100 years, we have deployed a dedicated team of engineers and scientists to work with OEMs and understand the new trends in industrial equipment as well as current and future lubricant requirements, which has enabled us to tailor our lubricants to meet or exceed the performance capabilities needed to help ensure long life performance for our equipment builders (EBs) partners’ equipment. Working side-byside with the world’s leading EBs has often given us unique insights into the development of some of the world’s most advanced industrial equipment and inputs required specifically for investing in R&D to introduce new products with new technologies. With EBs in India facing the challenge of competing on a global stage, ExxonMobil with its close relationship with EBs can deliver a competitive advantage to its partners in identification of potential challenges and barriers that might impact the performance of their equipment, either in the short-term or long-term and drive developments to help customers and their customers to make their operations more efficient and profitable. By doing so, we can offer our customers advanced technology and the highest level of application expertise and be Continue on page no.142

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Continued from page no.140 sure that our Mobil-branded industrial lubricants consistently deliver exceptional performance. Combined, these help enable our customers to maximize their productivity and stay ahead of their competitors. Q. What is the product portfolio in turbine sector? Will the industry see any new additions in 2015? Mobil offers a wide range of specially formulated lubricants for critical equipment needs. From premium turbine lubricants designed to provide uninterrupted operation and long service life, to outstanding synthetic lubricants and greases engineered to perform in extremely demanding environments. Thoroughly tested before they are commercialized, Mobil-branded industrial lubricants and greases are supported by equipment builder approvals. For example, Mobil SHC™800 series, our top-of-the-line synthetic turbine oils are designed for land-based gas turbines, the Mobil DTETM 800 Series, formulated for specific high-efficiency for combined-cycle turbine applications. The new Mobil DTE™ 700 Series meets or exceeds 17 industry and equipment builder specifications for gas and steam turbines. The newest extension of the Mobil DTE™ 700 series, Mobil DTE™ 732 M turbine oil provides optimum protection for heavy-duty, non-geared, single-shaft gas turbines and steam turbines as well as for multi-shaft gas turbines. It has received MSO4MA-CLOO5 approval, which means it meets or exceeds the highest quality-level requirements set by Mitsubishi Heavy Industries (MHI). Mobil DTE™ 932 GT is the latest addition to our turbine oil range. It is specifically formulated for GE frame 3, 5, 6, 7, and 9 turbines and the formulation is based on selected high-quality base oils carefully balanced with a 142 | MARCH 2015 | ENGINEERING REVIEW

proprietary additive system to provide long oil life along with outstanding keep-clean performance. Mobil DTE 932 GT also delivers wear protection and load-carrying performance required for geared turbines. We have introduced above mentioned complete range of turbine oils in India, an important growth market for ExxonMobil. Also, as a company, we place an enormous emphasis on on-going investment in research and development (R&D), working side-by-side with the world’s leading original equipment manufacturers (OEMs) to develop the most effective products and maintenance solutions. This process begins in our Research and Engineering facilities, and is conducted hand-in-hand with leading equipment builders, as well as the users and maintainers of such equipment. Our application-specific expertise and close working relationships with the world’s leading OEMs enable us to provide our customers with products that have global consistency in formulation and performance, help maximize productivity, boost energy efficiency and business sustainability. Q. With offshore wind being discussed in India, what preparation is happening at ExxonMobil for a new business opportunity? The economic growth in India is opening up great potential for development of renewable resources. Technological advancement in this sector is essential for meeting up with ever increasing energy demand of the country. Very recently, the Government of India has announced draft offshore wind power policy which is under active discussion and finalization. New challenges continue to be addressed with our new products and services. 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. Mobil Industrial Lubricants has been at the forefront of lubricant developmentfor the wind energy sector globally for over 30 years, championing best practices from the advent of the industry to its current burgeoning growth. We understand the challenges equipment builder engineers and wind farm operators’ face. Mobil Industrial Lubricants superior lubrication products and services maximize wind turbine productivity while minimizing costs by improving equipment performance and reducing maintenance frequency. We have firmly established our reputation within the global wind energy sector through accomplishments in research and development (R&D), close collaboration with industry decision-makers and the excellent quality of its service. Mobil Industrial Lubricants innovative wind lubrication technology and application expertise have been supporting this growing industry by reducing both maintenance requirements and operational costs. The Mobil-branded fully-synthetic lubricants are specifically formulated to overcome difficult operating conditions associated with offshore For example, Mobilgear SHC XMP 320, our top-of-the-line synthetic wind turbine lubricant, is approved and/or used by several major gear, bearing and wind turbine manufacturers. With extensive builder approvals, it lubricates more than 40,000 wind turbines worldwide. Analysis of over 46,000 used-oil samples of Mobilgear SHC XMP 320 indicates superb wear protection and virtually no alerts due to oil aging.

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SUCCESS STORY

Spraymet Surface Technologies helps in conservation of resources Mr. P.T. Bindagi, Technical Director, Spraymet Surface Technologies Pvt Ltd

hat does it take a metallurgist to become an entrepreneur? Besides a good academic background and industry exposure, you also need self-confidence and courage to leave a cushy job and enter business. That’s precisely what Bindagi did. A scholastic career P.T. Bindagi, the Technical Director of Spraymet Surface Technologies P. Ltd., headquartered in Bengaluru. Bindagi took his degree in metallurgical engineering from the Bellary Govt. College. He was state first. After this scholastic career, he took up a job with Precision Fasteners as a metallurgist in their R&D lab. After a short tenure of two years, He joined Ador (erstwhile Advani-Oerlikon) in 1984 and took the onus of product marketing in the newly set up Powder Division. At Ador, he stayed for long 10 years. He had his career progression and soon became the Divisional Manager of Metco Thermal Hard facing Div. In 1987. Bindagi received special training in tribology at Metco, Australia as well as Sulzer Metco, USA. Back home he presented several papers on the nuances of ‘thermal spraying’ in conferences organised by IIW, BARC, VSSC and other organisations.

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The turning point The year 1994 was a turning point for Bindagi. That was the year when he bid adieu to service and decided to be on his own, doing the same thing closer to his heart : propagating the art and science of tribology, harnessing the proven technologies of thermal spray, plasma spray and HVOF. Subsequently, It took hardly a few months for him to give shape to his passion: establishing his own company in the name and style of Spraymet Technologies Pvt. Ltd. Today Spraymet is engaged in thermal spray, ENP plating and weld surfacing. While the main plant is in Bangalore, Bindagi set up the second plant in Pune to stay closer to its customers especially from the automobile sector which is demanding technical excellence, proximity and service all at the same time. Spraymet has the distinction of having pioneered the carbide coatings in the steel mills and galvanizing line roll coating. Proprietary coatings The company owns a few proprietary coatings like moly blend (Spraymet MoB) for metal to metal wear and Ductile matrix carbide (Spraymet DMC) for plastic processing feed screws. Bindagi is keenly interested and is working towards expanding applications in turbine industry, medical implants and other new frontiers. In his quest, to spread knowledge, Bindagi also picks up students from universities for project work related to tribology and wear metallurgy. “Today when I look back, I have the satisfaction of having chosen a

Waste into wealth: Spraymet harnesses the best of surfacing technologies to reclaim machinery components and parts and conserve resources

business line which is not only winning bread for me but also butter for the industry at large,” states Bindagi. There is substance in what he says. He has helped the industry save a lot of money and helped conserve its scarce resources. May his tribe increase!

P.K. Balasubbramaniian www.engrreview.com

MACHINE TOOLS » Tech Trends

HSIL, the faucet people,rely on Haas for high quality and productivity

hen we get up in the morning, the first thing we do is to splash a lot of water on our faces so as to start the day afresh. The humble faucets installed in our sinks and bathrooms do just this and more and have undergone a radical change in both aesthetics and functionality over the last few years. Hindustan Sanitaryware Industries Ltd (HSIL), which already has plants at Bahadurgarh and Hyderabad, set up another plant near New Delhi where it manufactures faucets. Hindustan Sanitaryware Industries Ltd (HSIL) has been manufacturing a wide variety of bathroom products along with faucets for the past 55 years with plants in Bahadurgarh and Hyderabad and a new plant in Rajasthan for faucet manufacturing. “It was just six months ago that the company commissioned a new

plant at Kaharani Industrial Area near Bhiwadi in Rajasthan where HSIL carries out only faucet manufacturing. Though it is a new plant, we have the capacity to manufacture 2.5 million pieces in a year. With around six decades of experience behind us, we are confident of increasing our annual productivity by almost 25 percent YOY depending on the sales and market conditions,” the vice-president of the company, Mr Ajay Jain said. Explaining the manufacturing process in detail, Mr Jain said, “We purchase brass ingots, melt them in large furnaces after which casting and cutting is done followed by machining. Once the component is ready, it is then sent for grinding, polishing, electroplating before being assembled at a different section. The faucet is then ready for despatch into the market.” HSIL is a pioneer in India in the sanitaryware manufacturing domain that has set up fully automated plants and has exploited CNC technology optimally. “From foundry till the plating line, the entire plant is automated. Besides these machines, we have also placed an order for robots from Italy apart from forging and zinc casting machines. This way we have an entire blueprint ready to increase the annual production capacity at this plant at least four times (10 mn) pieces,” Mr Jain said and added that the company Continue on page no.148

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MACHINE TOOLS » Tech Trends

Continued from page no.146

has 22 Haas vertical machining centres (VMCs) on which the machining process is carried out. Apart from the bathroom product division, HSIL also manufactures glass bottles under the brand name of AGI while the sanitaryware products are marketed under the brand name of Hindware and Benelave. “All these manufacturing processes are carried out on Haas VMCs as we find our American made HAAS machines meet our expectations and provide real value for money. . These machines are manufactured at a single location in the US and there quality is good as far as production of our products is concerned. I had personally visited their plant in the US and after lot of deliberations and discussions as regards use of these machines to manufacture

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faucets, we were rest assured with Haas’ technology and placed a single order of 22 machines,” Mr Jain quipped. On a query about the technical benchmarks that HSIL considered before finalising Haas, Mr Jain mentioned that high rapids and feeds combined with quick tool changes and excellent spindle rpm/torque ratios resulting in increased productivity were among key reasons for this decision. The Haas team also helped us in design, development and supply of fixturing after studying our many components. This helped us in

machining most of our components in a single set up. Our process involving machining in a single clamping ensures accuracy, reduces cycle time and makes redundant the need to change references. The resultant flexibility and excellent component cycle times of 3 mins or less ensured that we did not look beyond HAAS for our machining requirements. Besides meeting all the technical product parameters, the HSIL management is also happy with the way the Haas engineers have been responsive towards company’s grouses, if any. “Right from prompt delivery to timely service, the Haas engineers have been supportive towards our needs and have cooperated with us in resolving all our problems right from installation of the machine to improving its productivity,” Mr Jain added.

For more information Web: www.HaasCNC.com

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EVENT PROFILE

ACHEMA GERMANY 2015

31st World Exhibition Congress • Frankfurt - Germany 15 - 19 June 2015 by Mr.Om Prakash – Director, In ORBIT Tours, official tour operators appointed by DECHEMA, the organizers of ACHEMA 2015

ECHEMA of Germany, the organisors of ACHEMA 014 has announced the next event ACHEMA to be held in Frankfurt, Germany from 15 – 19 June 2015. World Forum of the Process industry The process industry is the key driver of innovation and growth fuelling the global economy – but, paradoxically, it is at the same time undergoing massive changes. Energy turnaround, globalization, eco-efficiency, process optimisation, and bioecnomy – these are the buzzwords currently putting pressure on our sector. As if this were not enough, the need to have the edge over the competition and be even better positioned tomorrow than today is a constant challenge. & not even the process industry can escape the fact: the secret of success lies in coming up with innovations at the right time and in the right place – & having an instinct for the heartbeat of the sector. Networking and Investment Decisions Around 3,800 exhibitors from over 50 countries, 170,000 participants from more than 100 different countries including 30,000 executives from top and middle management, make ACHEMA the communication hub of the process industry. This is where the technology trends of our sector are launched, investment decisions are taken and new ventures initiated.

Innovative - Interdisciplinary - Interactive As the summit meeting of the leading companies of a globally networked industry, ACHEMA is the platform that pinpoints new perspectives, facilitates

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a dialogue between producers and users and mobilises synergies. For the process industry ACHEMA is both an innovation driver and an economic powerhouse. Nowhere else can complete solutions for all areas of the process industry be found in such depth, breadth and modernity. Technological diversity creates synergies Environmental Protection and Biotechnology are integral general topics at ACHEMA, both exploit the technological solutions enabled by proves engineering. As a result, the synergistic concept of production-integrated environmental protection has become one of the hall marks of ACHEMA. Nowhere is the integrations of molecular and industrial biotechnology so tangible than at ACHEMA. The great challenges facing us today, such as the energy turnaround, demand innovative solutions – while at the same time creating synergies.

Focal Themes Topics that touch the pulse of the process industry…to which ACHEMA 2015 gives vital impulses • ‘Bio based World’ : Key venue for industrial (“white”) biotechnology • Innovative Process Analytical Technology (PAT) : bridging the gap Between automation and analytics • Industrial Water Management: concepts for ecologically & economically efficient hydrological cycles. Biobased World – Integrated concepts For Biomass & Bioprocess Engineering Biobased World sumps up the expertise of the process industry, presenting ways

and means of transforming visions into reality. ACHEMA 2012 – Facts & Figures 3,773 exhibitors from 56 countries 166, 447 participants from 111 countries No other event for our industry attracts anything approaching our high exhibitor figures or can complete with our ever-rising top ratings for exhibitor satisfaction. ACHEMA records broadbased acceptance in its target groups & upholds its undisputed position as the world forum of the process industry. Exhibition Groups/Area • Research and innovation • Literature, Information, Learning & Teaching Aids • Laboratory & Analytical Techniques • Engineering • Mechanical Processes • Thermal Processes • Pumps, Compressors, Valves and Fittings • Pharmaceutical, Packaging and Storing Techniques • Industrial and Labour Safety • Instrumentation, Control and Automation Techniques • Materials Technology and Materials Testing • General Topic Environmental Protection • General Topic Biotechnology

For more information, Tel: 022 2422 9281/40436868, Email: omprakash@inorbittours.com www.engrreview.com

GROUP

Innovation is life

years of excellence

Moisture ruins electrodes during storage Electrodes

Keeps electrodes dry during storage for a perfect weld • Avoid underbead cracking • Avoid porosity in weld deposit • Avoid excessive splatter • Eliminate wastage

Backed by

Service

ECODRY Desiccant Wheel

Call us today for cost effective solutions ISO 9001:2008 & 14001:2004 CERTIFIED

Phone: +91 11 23906777 • E-Mail: bryairmarketing@pahwa.com CIN: U74210DL1981PTC012456

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At the heart of it all

Leaders in Dehumidiﬁcation ... Worldwide 26.06.2014

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PRODUCT SHOWCASE

Information on latest products in industry

Tripple level spring clamp terminal blocks ATL2.5, ATL2.5H & ATLG2.5

The ATL2.5 series Terminal Blocks are an ideal choice for control systems where sensor & actuator applications are involved. The simplified three level connections tremendously increase wiring density in the circuit. The top level

of the ATL2.5H Terminal Block provide connection points for signal wires while the middle and bottom level are used for positive and negative potentials. The ATLG2.5 is a triple level Terminal Block with an additional connection for earthing cables. This separate connection point is appropriately identified by the Green–Yellow imprint on its top.

Specification Number of Levels : ATL2.5 – 3 Feed through levels : ATL2.5H – Top feed through and middle & Bottom half connection : ATLG2.5 – 3 Feed through Levels + 1 Ground connection Terminal Pitch

: 6mm

Connection Possibility : Stranded Wire – 0.2 – 2.5 Sq.mm Solid Wire – 0.2 – 4 Sq.mm Approvals : UL, CE Rated Voltage : 500V Rated Current : 24 A Applications: These Terminal Blocks are an ideal choice for motor, sensor, actuator and initiator connections. For more information Connectwell Industries Pvt. Ltd. D-7, Phase 2, M.I.D.C., Dombivli - 421 204, India Tel.: +91 251 3980 600, 3980 800, Fax: +91 251 3980 700 Email: connect@connectwell.com Website : www.connectwell.com www.engrreview.com

Conduits

The Flexible Corrugated Conduits are made up of high quality materials, they have extremely small bending radius. These Conduits offer good impact resistance and come with added benefits like being UV Resistant, Halogen Free, Acid Proof and Flame Retardant in Nature. Specifications: Available Materials : Polyamide 6, Polyethylene, Polypropylene, Galvanized Steel & PVC Coated Galvanized Steel.

Temperature Range : For Polyamide 6 -40 oC to +105oC Continuous, +150oC Short Term For Polypropylene -40oC to +135oC Continuous, +150oC Short Term For Polyethylene 15oC to +60oC Continuous Resistant : Polyamide 6 – Alcohol, Benzol, Greases, Mineral Oil, Diesel Fuel, Sea Water, Petrol etc. Polyethylene – Acid, Sea Water, Ammonia, etc. Protection Class : IP 67 & IP 68 Application: These Conduits find their applications in Machine Tool, Industrial Machinery, Chemical Machinery, Ship and Train Building, Switch Cabinet, Movable Machine Parts etc.

For more information Controlwell India Pvt. Ltd. C-203, Prithvi Park, Plot No. 4,5 & 6, Sector 30, Sanpada, Navi Mumbai 400 705. (INDIA) Tel.: +91 22 2775 6293 ,Fax: +91 22 2775 8767 Email: sales@controlwell.com Website: www.controlwell.com

KING CUT PRO – The Large Gantry Type CNC Cutting Machine Ador’s KING CUT PRO is a CNC portal cutting machine which is very precise and reliable. The machine has one head for plasma sheet metal cutting ENGINEERING REVIEW | MARCH 2015 | 165

PRODUCT SHOWCASE

and one head for flame cutting of sheet metal with a dual side longitudinal drive with AC motors. The standard equipment comes with a basic machine package with CNC controller, one torch, central gas diffusion with manometers and a remote flame ignition. The following equipment are supplied as required by the customer: Additional Equipment: • Plasma power source KJELBERG with machine torch • Programming software MOST 2D • Support table for sheet metal with segment extraction system • Extraction-filter system • Laser position indicator for determining the cutting point Optional : • Extension of the longitudinal rail • Additional cutting head The CNC Controller – Phantom: The Phantom brings you the performance of a cutting edge CNC that is built on more than 40 years of experience in the motion control and cutting industries.

This controller is designed for multiple axis cutting machines and features the latest advances in CNC technology on a proven platform engineered to increase productivity, reduce costs and enhance profitability. The software provides flexibility, ease of operation and technologies that put Ador’s experience and expertise in your operator’s hands, resulting in extremely good cut quality and high productivity. The Phantom can operate any cutting machine and interface with virtually all plasma systems. Following are its standard features: Bright touch screen interface, Touch screen interactive display, Expandable shape library, True multi-tasking environment, Fast Dxt file conversion, Go to(Job interrupt), Quick plate alignment, and Monitor & track consumables. Advanced Plasma Process Control (Plasma Process Wizard) is available as optional extra. Ador offers cost-saving height control unit for simple plasma cutting applications. The KHC1 system provides all the essential functions that are needed for good cuts and optimum utilization of work-piece.

For more information Corporate Marketing Office Ador Welding Limited Akurdi Chowk , Chinchwad, Pune 411 019 Phone: 020- 4070 6000 Email: cmo@adorians.com

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JV Kraft-Vertical machining centre

LMW Machine Tool Division Introduces an All New Vertical Machining Centre “JV Kraft” in the X 800mm range which caters the needs of diverse industrial segments from Aerospace to Job shops. The machine is equipped with robust spindle, constructed to minimize axial and thermal expansions and is dynamically balanced to

ensure extremely low runouts. The high precision feed mechanism provides high accuracy, rigidity and repeatability. The highly reliable swift Automatic Tool Changer (ATC) adds a new dimension to vertical machining. This stateof-the-art machine has been designed to meet the ever-growing demand for speed and accuracy of the user industry for high quality and high volume production. The machine is designed with the motto of best price-to-performance ratio and true to the goal of providing value creation through innovation.

For more information Lakshmi Machine Works Limited Machine Tool Division, Arasur Coimbtore 641 407 Tel : +91 422 3021300E-mail: mtd_marketing@lmw.co.in

GEM’s Bottle Type FRP Cooling Tower high efficiency, noiseless operation, minimum water loss and long service life.

GEM’s Nexgen Bottle type FRP Cooling Tower is known for the benefits it offers like low maintenance,

Following are some of the constructional features of this trendsetting product: • Superior extended shaft flange mounted frame, waterproof with aluminium body, epoxy painting, SS shaft and EPDM sealing; saves power; highly reliable and built to last. • RTM Mould body, UV protected and with glossy finish www.engrreview.com

PRODUCT SHOWCASE

• FRP Louver profile reduces water spillage loss, prevents entry of foreign particles and extends cycle for blow down. Also proper L/G reduces evaporation loss. • High Efficiency Aero Dynamic Fan: Axial flow, direct driven, low noise, long life, corrosion -free

aluminium, computerized balanced and wind tunnel tested. • Revolutionary Spiral Fills: Rigid PVC – with long life, clogg-free and ease of assembly. UV stabilized • The product is offered to the customer with a 5-year warranty – for the first time in India.

For more information GEM Equipments (P) Ltd. SF No.103, Avinashi Road, Arasur, Coimbatore 641 407 Phone: 0422-2363800 / Email: sales@gemindia.com

Z 5/42

ZIP have developed Hex Socket type, Square hd & Hex hd type, BSP straight, Tapper plug, BSPT, NPT, NPTF, MM size, Hex hd washers faced collar plug, Hex socket type Allen plug, BSP copper washers, BSP Hex nut, BSP/ BSPT 1/8 to 1.1/2”, NPT/ NPTF 1/16 to 1.1/2” MM size 5 to 48 mm dia. www.engrreview.com

STANDARD REFERENCE:It can be supplied as per IS, DIN, ASTM, JIS & GOST standards or as per party’s samples or drawings. THREADS:BSP, BSPT, NPT, NPTF, MM size, Standard coarse & Fine pitch.

MATERIAL’S GRADES:M.S., En - 8, 8.8gr, En - 19, 10.9gr, Brass, Aluminum SS 304 - 316 & 410. HTS, RSTV Grade. APPLICATIONS:-

These items are used at Engineering Industries, Machine Tools, Automobiles, Hydraulic, Pneumatic, Pump & Valve, etc. and such other various Industries.

For more information ABC INDUSTRIAL FASTENERS E-122, Ansa Industrial Estate, 1st Floor, Sakivihar Road, Sakinaka, Andheri East, Mumbai - 400 072. Tel.: 022-2847 0806 / 6692 3987, Fax.: 022-2847 0705, E-mail : abc@precibolts.com | zenith@zip-india.com Website:- www.zip-india.com

Outperform with the New Yale Maini Diesel forklift truck Maini Materials Movement Private Limited (“MMM”) is a leading industry player in the MATERIAL HANDLING, STORAGE SOLUTIONS and PEOPLE MOVEMENT space. MMM has strategic alliance with NACCO Materials Handling Group (NMHG), USA for manufacturing and marketing Yale brand Forklifts, High reach trucks, Order pickers, VNA etc. in India. MMM’s manufacturing expertise combined with Yale’s global reputation for excellence and innovation delivers comprehensive material handling solutions to customers across sectors. The manufacture of selected Yale products in our state-of-the-art manufacturing facility in Bangalore enables us to respond quickly to the demands in a dynamic and rapidly expanding market place. The introduction of new diesel counterbalance forklift truck will strengthen the

position of Yale and MMM in the growing Indian forklift truck market. Designed to meet the specific requirements of the Indian market, the New Yale - Maini diesel trucks are available with efficient, quiet, clean running engine. The range consists of GDP20UX (2000 kg) and GDP30UX (3000 kg) with 3.1 L engine which is ideally suitable for all standard applications. Key Features of the truck: • The ergonomically designed Diesel forklift’s operator compartment and familiar automotive layout enable the operator to work comfortably, reducing tiredness during handling operations. • The simplicity of the components and specification makes servicing quick and easy. • The use of proven, high quality, robust components, efficient filtration and excellent cooling

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result in reliable operation and lower wear and tear with this equipment, thus low service and maintenance cost. About Maini Materials Movement Private Limited Maini Materials Movement Private Limited (“MMM”) is a [premium brand in material-movement and in-campus electric mobility solutions]. A culture of innovation, thought-leadership and quality-focus defines us. MMM solutions

range from Hand Pallet Trucks, Battery Operated Pallet Trucks, Platform Trucks, Manual & Electric Stackers, Goods & Scissor lifts, Tow Trucks, Dock Levelers, Forklift Trucks, Reach trucks ,Order Pickers, Flame proof Trucks, Industrial racking, Bolt less shelving systems ,Mezzanines and in-campus electric buggies to help you achieve high level of space efficiency and Manufacturing Productivity.

For more information Maini Materials Movement Private Limited E-mail: mtrlsmov@maini.com / www.mainimaterials.com

Retrieval systemVERTIMAG from Armes Maini With ever increasing land prices and high investments that go into building warehouses, the need for infrastructure offering greater productivity while saving space is paramount. Managing your inventory in limited warehouse space can be a daunting task, especially when the challenges of systematic organization have not been met. Armes Maini offers Vertimag®, a fully automated modular vertical storage solution. Vertimag® gives total control on inventory storage and access, optimizes resource function, reduces loss and enhances your work-flow. Vertimag works on goods to man principle. It is an ideal solution for handling materials of every

size, weight and dimensions. It has considerable vertical extension and as an option is designed to have more than one work station on the same machine. Vertimag comes with host of features: • Choice of various tray sizes and loads per tray suiting your needs • Scalable, upgradable • Can be integrated with any ERP system for realtime inventory • In-built intelligence to maximize storage • Provision for multi-user applications ®

Vertimag® offers benefits towards: • Optimization of space utility, timing, work cycles, human

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resources, production & storage needs & department synergies • Automated operations • Check on stock pilferage • Higher throughput With Vertimag® you can: • Eliminate stock pilferage • Eliminate human errors • Minimize time spent on picking & refilling • Archive easily & systematically • Store expensive goods safely • Store components allowing specific extraction on need using a computerized system • Reduce handling costs and unused volumes • Easily upgrade storage space • Save space, time, resources and boost productivity Though having high cost of acquisition than the conventional racking systems,

it has colossal applicability from electronic to pharmaceutical industries and from slow to medium moving goods and it equips the warehouses with a greater ability to meet the fluctuating demands of the market. About Armes Maini Storage Systems Private Limited: Maini Materials Movement Private Limited has teamed with Ferretto Group, Italy – an industrial holding group focused on ‘Logistics & Storage systems’ to form a Joint Venture (JV) named Armes Maini Storage Systems Private Limited. Armes Maini Storage Systems Private Limited is now one of the leading manufacturers of industrial racks and storage systems in India. It offers comprehensive storage solutions for a wide spectrum of storage requirements.

Armes Maini Storage Systems Private Limited Web: www.armesmaini.com or write to us at mtrlsmov@maini.com

Snap-off blades

KDS, Japan is a prestigious brand in the market of cutting tools. We are pleased to introduce it on a large for the very first time in

India. Our product range includes: • L-27 cutter with safety knob • LB-10- snap-off blades www.engrreview.com

PRODUCT SHOWCASE

with dimesions 100mm X 18mm & 0.5 mm thick (10 pcs per box) • LB-10 snap-off blades with dimesions 100mm X 18mm & 0.5 mm thick (50 pcs per box) • HB-10 snap-off blades with dimensions 125mm X 25mm & 0.7mm thick (10 pcs per box) • SB-10 snap-off blade with dimensions 9mm x 80mm & 0.38mm thick (10 pcs per box) These blades are very high quality and are correctly

angled to perform razor smooth cutting. The above mentioned product range can be used in varied industries from heavy duty cutting like that of rubber and conveyor belt as well as light-duty cutting like paper or cardboard. These products are made from the best Japanese technology due to which you will never have to compromise on the quality of the product and thereby the end product will be perfect.

For more information Platinum Edge 67 Free Press House, Free Press Journal Marg 215 Nariman Point, Mumbai-400021 Email: sales@platinumblades.com

Industrial Gas Leak Indicator : Plus Series

SUBTRONICS (INDIA) PVT. LTD. an ISO 9001:2008 certified company, introduces Industrial Gas Monitors in it’s most advanced form ever - The ‘Plus Series’ a re-defined and www.engrreview.com

re-engineered unit with latest elegant design, new features and robust state of the art detection technology available today. This, Indian Patent Office registered design, has faster signal processing, higher accuracy and wider coverage area and can detect a range of more than 300 gases. Export ready dual operating voltage (230/110VAC), imbibes

latest surface mounting technology that enables reduction in current consumption thus saving power and energy. Read atmospheric variations using its “Three Status” – registered technology, sounding alerts only at high levels of potentially toxic or hazardous gas, fumes, vapor in L.E.L or T.L.V ranges and implements special dedicated false alarm proof system ensuring highest reliability. Prominent features include Three Status

technology, 100% compatible to your existing system, PLC, DCS, SCADA or any annunciator panel, flexible mounting options and is shipped in specially designed ‘Kit–Form’ with simple ready to use templates and illustrated manual for an easy and quick operation. Subtronics has been manufacturing safety devices for over 40 years with over 4500 clients and is a recipient of 33 awards for its excellence and contribution to the field of safety.

For more information SUBTRONICS (INDIA) PVT. LTD. 147, Kaliandas Udyog Bhavan, Near Century Bazar, Prabhadevi, Mumbai – 400 025. India. Tel: +91 (022) 2422 4461 / 2430 3047 (Telefax) Email: service@subtronicsindia.com Web: www.subtronicsindia.com

Tube Notching Machine M 700 Pipe joints are generally at right angles, where in one pipe end is notched, before the pipe is welded with the 2nd pipe. Auto and two wheeler components, display systems, scaffoldings piping, tubular steel furnitures are examples where such requirement arises. A fast and acceptable notched end for a pipe or tube (circular or rectangular) can be achieved in quantity by use of specially

designed machine offered by our company. Two sides of a pipe are notched in one loading of a pipe. The notching takes places from the inside to the outside of the pipe. No distraction takes place. The edge of the pipe is a die cut edges. Joints can b created for pipes of different diameters. Punches and dies in this machines are inter changeable.

For more information UNIPUNCH TOOLINGS PVT. LTD. Contact Person : Mr. Vikram Sarathy Mobile : 099419 05061 Email : unipunch@gmail.com Website:http//www.fabmachinesindia.com

ENGINEERING REVIEW | MARCH 2015 | 169

PRODUCT SHOWCASE

Porto & Max Vista Automatic sectional overhead doors use which, in turn ensures a quick, hassle free and accurate replacement of old doors. Their compact size ensures more available space both inside and outside the premises. Depending on the structure of the building and the requirement a choice can be made from a standard lift, vertical lift, horizontal lift, low headroom or inclined lift. Porto range comprises of a wide series of track systems, panel options and safety features. Special glazed doors provide excellent lighting and vision into the building where required. India’s No.1 Entrance Automation & Loading Bay Equipment Company, Gandhi Automations Pvt Ltd offers Porto and Max Vista - Automatic Sectional Overhead Doors - the ideal solution for all industrial and commercial needs. Porto: Porto Sectional Overhead Doors are ideal for all industrial and logistics needs. The design and different solutions offered ensure the door to be aesthetically pleasing and perfectly suited to any architectural environment - from modern and traditional industrial buildings to fine commercial buildings. As these doors slide vertically, stopping in the proximity of the ceiling, they blend in with the architectural features of the building. Porto doors are built to ensure the highest ease and flexibility of

Max Vista: Max Vista Sectional Overhead Doors are ideal for industrial and commercial buildings. The doors are made with a combination of aluminium panels and transparent acrylic, grilled or meshed windows giving it a distinctive look and enhancing the look of a building. Max Vista Doors make the environment bright and pleasant to work in as it allows natural light to pass through the large clear areas. Gandhi Sectional Overhead Doors provide heat insulation and sound proofing thus improving the working conditions on the premises and saving energy. The products are affixed with a CE mark making them reliable and safe. Key Features: • Reliable and low- noise

170 | MARCH 2015 | ENGINEERING REVIEW

operation. • Extreme robustness. • Safe operation in compliance with safety requirements. • Design-oriented surfaces and optimum light solutions. • Minimal bulk for more

space indoors and outdoors • Easy and practical to open and operate • Energy savings and more comfort • Bright indoor environment and attractive design

For more information Gandhi Automations Pvt. Ltd. 2nd Floor, Chawda Commercial Centre, Link Road, Malad (W), Mumbai – 400064, India. Tel : +91 22 66720200 / 66720300 (200 lines) Fax : +91 22 66720201 Email : sales@geapl.co.in Website : www.geapl.co.in

Reparing / Calibration Of Precision Measuring Instruments We can Repair all types Precision Measuring Instruments i.e. Calipers, Micrometer, Dial gauge , Bore gauge , Height gauge , Hardness Tester, Vibration meters, DB meter, Torque wrenches & Many Many Other Items of IMPORTED / INDIAN make & Also Provide u all New Instruments. For more information India Tools & Instruments co. MUMBAI – INDIA Tel: 09819345050/022-23428862 E-mail: ojus_itico@hotmail.com Web: www.indiatool.net

ITI-160(P) Portable Digital METAL Hardness Tester Advantages • Largest screen 3 inch , showing all functions and parameters.it is the largest screen of leeb

hardness tester , easy read and operate. Main Application • Die cavity of molds www.engrreview.com

PRODUCT SHOWCASE

BEI SENSORS Heavy Duty Encoder Specially for Steel, Paper, Cement & Crane Industries

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• Bearings and other parts • Failure analysis of pressure vessel, steam generator and other equipment • Heavy work piece • The installed machinery and permanently assembled parts • Testing surface of a small hollow space • Material identification in the warehouse of metallic materials • Rapid testing in large range and multimeasuring areas for large-scale work piece Technical Specifications • Measuring range: HLD(170~960)HLD • Measuring direction: 360° • Hardness Scale:

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For more information India Tools & Instruments co. MUMBAI – INDIA Tel: 09819345050/022-23428862 E-mail: ojus_itico@hotmail.com Web: www.indiatool.net

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HL、HB、HRB、HRC、HRA、HV、HS Display : 3 inch screen , Data memory : 600 groups max.(relative to impact times 32~1) Printing paper : width is (57.5±0.5)mm, diameter is 30mm Battery pack : 6V NI-MH Battery charger: 9V/500mA Continuous working period: about 150 hours(With backlight off, no printing) Communication interface: USB1.1 Outline dimensions: 210mm×85mm×35mm ( Instruments weight : 350 Gram)

Model: GHM9 Series. • Especially designed for heavy duty applications: steel and paper mills, lumber, cranes, etc… • Solid shaft of 12 mm or 11 mm with RE0 115 mm flange (Euro flange B10) for tacho generator type mounting. • Excellent resistance to shocks/vibrations and to extreme axial/radial loads. • High protection level: IP67. • Connection with terminal box (cable or

• • • •

connectors output also available). Electronic compatible with industrial standards. Electronic permits to drive different inputs (PLC + display for example) Digital incremental output, optional analogue output (tachoencoders, optotacho) or sine output. Resolution up to 10000ppr. Mechanical over-speed switch option. Protection against short circuits for electronics. Option ‘’Max control’’: the encoder gives on real time its physical environment parameters: shocks and Vibrations, too high or too low temperature, too low or too high supply, quality of the output signals .

For more information CST Sensors India Pvt Ltd. 23, Trident Towers, 4th Floor, 100 Feet Road, Ashoka Pillar Road, 2nd Block, Jayanagar,, Bangalore 560 011 Tel: 080-41132204/05. Fax: 91-80-41132206. Email: india@cstsensors.com / Web: www.cstsensors.com

ENGINEERING REVIEW | MARCH 2015 | 171

PRODUCT INDEX Product Name

Company Name

Page no.

BEI SENSORS Heavy Duty Encoder

CST Sensors India Pvt Ltd.

171

Conduits

Controlwell India Pvt. Ltd.

165

GEM’s Bottle Type FRP Cooling Tower

GEM Equipments (P) Ltd.

166

Industrial Gas Leak Indicator : Plus Series

SUBTRONICS (INDIA) PVT. LTD.

169

ITI-160(P) Portable Digital METAL Hardness Tester

India Tools & Instruments co.

170

JV Kraft-Vertical machining centre

Lakshmi Machine Works Limited

166

KING CUT PRO – The Large Gantry Type CNC Cutting Machine

Ador Welding Limited

165

Outperform with the New Yale Maini Diesel forklift truck

Maini Materials Movement Private Limited

167

Porto & Max Vista Automatic sectional overhead doors

Gandhi Automations Pvt. Ltd.

170

Reparing / Calibration Of Precision Measuring Instruments

India Tools & Instruments co.

170

Retrieval system- VERTIMAG from Armes Maini

Armes Maini Storage Systems Private Limited

168

Snap-off blades

Platinum Edge

168

Tripple level spring clamp terminal blocks ATL2.5, ATL2.5H & ATLG2.5

Connectwell Industries Pvt. Ltd.

165

Tube Notching Machine M 700

UNIPUNCH TOOLINGS PVT. LTD.

169

Z 5/42

ABC INDUSTRIAL FASTENERS

167

172 | MARCH 2015 | ENGINEERING REVIEW

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BUSINESS AVENUES

INSIDE

BUSINESS AVENUES Information on latest manufacturing projects in India

INDEX Sr. No.