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

Haas Automation India Pvt. Ltd. - HAASTEC PUNE 2015, 9th - 12th, December

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Rooftop Mounted System

Solar Lantern & Chargers

Water Pumping System

Address: B / 403 Akruti Trade Centre, MIDC Road No.7, Andheri (E), Mumbai - 400093 T : +91 22 2921 5000, +91 22 3081 6655 F : +91 22 3081 6661, +91 22 2921 5011 | E : solar@ravingroup.com | W : ravingroup.com

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Haas Automation, Inc. • www.HaasCNC.com • Proudly Made in USA

Haas Automation India Pvt. Ltd. - HAASTEC PUNE 2015, 9th - 12th, December

Volume 15 No. 06 | October 2015 | ` 200 | www.engrreview.com RNI No. MAHENG/2004/15135

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45,000 110,000

EDITORIAL INDEX Publisher : Shilpa Kadam CEO : Shekhar Dongre

Editor : Rajeev lyer CMO: Shirish Dongre Advisory Board (Editorial) Mr. T. P. Singh : Director, Flir Systems India Pvt. Ltd. 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. Rajesh Ballamwar : Director, Prolific Systems & Technologies Pvt. Ltd. Mr. P.K. Balasubbramaniian: President, VBS Corporate Support 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

Ador Welding

143

Klüber Lubrication

Aptransco

Kollmorgen

108

Avians Innovations Technology

173

B Bajaj Electricals

Bonfiglioli

Byers Precision Fabricators

Mahindra Stiller

174

Maini Material

Masyc Projects

141

MRK Engineers

171

Cole-Parmer

Custom Sensors & Technologies (CST)

172

NUM Group

D Delta Electronics

Parker Hannifin

Demag Cranes & Components

124

PC|SCHEMATIC

PcVue Solutions

Pepperl+Fuchs

ElMeasure India

170

Extech Instruments

175

F 8

Branch Offices (Zonal): NORTH (Delhi & NCR regions) : Sandesh Jain : 09810837877 / 09871602777

Fluke India

SOUTH (Chennai & Coimbatore) : Y. V. Raghu : 09566141224 Bangalore - Vaman : 09686721340 Kochi - Sanjeev Nair : 09846249568

Gandhi Automations

24, 170

Geissel India

Getzner India

118

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

FARO

EAST (Kolkata & Other regions) : S. Roy - 09433097806

Mahindra Auto Steel

CNC Software

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R Red Lion

Renishaw

70, 74

Rieco Industries

126

Rollon India

112

S Safexpress

Schneider Electric

See Lube

176

Haas Automation

SICK India

110

Hainbuch

Smalley Steel Ring Company

116

https://twitter.com/engrreview

Hangsterfer’s

171

Spraymet Surface Technologies

http://in.linkedin.com/pub/engineering-review/87/b31/97a

Hanna Instruments

6, 102

Supra Industries

169

HARTING

Symphony

137

HMS Industrial Networks

104

HRS Process System

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ENGINEERING REVIEW Overseas Offices USA Nancy TARTAGLIONE, Mepax USA Email: n.tartaglione@mepax.com usa@mepax.com

GERMANY Sebastian OLLIER Mepax Deutschland, Tel: +49 711 222 54 456, Email: deutschland@mepax.com

FRANCE MEPAX SA, Romain CLASS Tel.: +33 1 39 02 77 78, FRANCE

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CHINA/South Korea/Taiwan Mepax - Konaxis Shanghai Julien PENARD Tel : (+86) 21 6252 2731 Email: china@mepax.com

2 | OCTOBER 2015 | ENGINEERING REVIEW

T Testo India

172

The Indian Institute of Welding

140

Tranter India

IEEMA

In ORBIT Tours

122

India Tools & Instruments

174

Ingersoll Rand

V-Guard Industries

J JUNKER Group

Warpp Engineers

169 www.engrreview.com

BUSINESS NEWS

Armes Maini bags the Warehousing Excellence Award 2015

rmes Maini Storage Systems Pvt. Ltd., formed by a strategic alliance of Ferretto Group and Maini Materials Movement Pvt. Ltd., is a leading brand in warehouse storage solutions. Armes Maini was conferred the Warehousing Excellence Awards 2015 at the 9th Edition of ELSC Awards. Armes Maini has won the Award in the category of “Warehouse Material Handling & Storage Solutions of the Year”. The Award ceremony was held on 29th – 30th September at Taj Lands End, Mumbai. Organizedby Kamikaze in association with Safe Express, the event observed over 200 speakers and 700+ attendees. The recognition of Warehousing Excellence Awards 2015 encompasses the excellence amongst warehousing and logistics aspect of user industry. “The award attests not only our innovative warehousing storage solutions, but also the high degree of customer orientation of our services,” said the company in its response. Armes Maini Storage Systems Maini Material Movement 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 Pvt. Ltd. The brand is now a leading manufacturer of industrial racks and storage systems in India. It offers comprehensive storage solutions for a wide spectrum of storage requirements. Armes Maini offers complete storage solutions including pallet racking, multipurpose shelving, mezzanines, automated vertical storage system, automated storage & retrieval systems and more to make warehouses efficient and highly productive.

For more information Web: www.mainimaterials.com 4 | OCTOBER 2015 | ENGINEERING REVIEW

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AUTOMATION » BUSINESS NEWS

Hanna Instruments, Inc. introduces the new Pocket pH Tester HI 98100 Checker plus with replaceable pH electrode facility

anna Instruments is pleased to announce the release of new pocket pH Tester HI 98100 checker plus. The HI98100 Checker Plus is the next generation of the original Hanna Checker pH tester. The Checker is the most popular pH meter in the world with over 1 million meters used since its introduction in 1991. From students to researchers, the Checker has been helping people with their pH measurement as a meter that is simple to use and operate. This meter is very to easy operate, it has lot of good features like single button operation, Replicable pH electrode. The HI98100 Checker Plus pH tester has been designed with many advanced features while maintaining the look and feel of the original Checker. The Checker Plus now offers automatic calibration to one or two points, automatic buffer recognition, calibrated buffer tags, stability indicator, low battery indicator, and selectable automatic shut off. The Checker plus still maintains the iconic pentagon design with a probe that measures 103 mm in length and tapered to a 8 mm diameter making it ideal for test tubes and vials. Features at-a-glance: Economical – The Checker Plus is a full-featured pH tester at a price that anyone that needs to measure pH can afford. Large LCD - Enhanced LCD that

6 | OCTOBER 2015 | ENGINEERING REVIEW

displays reading, stability indicator, low battery indicator and calibration tags. Replaceable pH Electrode - The HI1271 supplied gel filled pH electrode is 103 mm long and tapers to an 8 mm diameter at the sensing end. This narrow electrode easily fits into test tubes, vials, and other containers with small opening. Automatic Calibration - The Checker Plus is calibrated automatically to one or two points. The calibration buffers are automatically recognized and after calibration the buffer values used are shown on the display as a tag. Stability Indicator – An hourglass indicator is displayed on the LCD until a stable reading is obtained. Once a reading stabilized the indicator disappears and a reading can be recorded. Automatic Shut-Off – The meter can be set to automatically turn off after 8 minutes or 60 minutes to conserve battery life in the event that the meter is left on. The auto off feature can be disabled. Long Battery Life - The Checker Plus has an exceptional long battery life of approximately 1000 hours. When the battery power is running low a low battery indicator is displayed. Plastic Carrying Case – The HI98100 Checker Plus is supplied

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

For more information visit the Hanna Instruments website at www.hannainst.com Web: www.hannaindia.in www.engrreview.com

AUTOMATION » BUSINESS NEWS

FARO® Continues to Enhance Customer BIM Workflows with an Updated Release of PointSense Software

FARO also released new versions of its VirtuSurv, TachyCAD, and PhoToPlan software with enhanced functionality. VirtuSurv, the Company’s intuitive and easy-to-use solution for processing point cloud data based on photo-like scan views, offers a new user interface for SEMA GmbH’s timber construction tools software.

ARO Technologies, Inc. (NASDAQ: FARO), the world’s most trusted source for 3D measurement and imaging technology, announces an update to PointSense, the Company’s leading Surveying and As-Built Documentation software suite for the Architecture, Engineering, and Construction (AEC) industry. With the release of Version 16.5, PointSense now includes additional tools and functionality for efficiently processing 3D laser scan data in Autodesk’s AutoCAD® and Revit® packages and accelerates documentation of as-built data. New PointSense functionality for AutoCAD® includes simultaneous fit of multiple polygon cross-sections, single-click plane extraction, and auto-boundary detection. New plant design tools include batch extraction of multiple structural steel elements and enhanced flange tie-in point extraction. Revit® users will also benefit from new, intuitive deformation tools for comparing point clouds to any surface including walls, floors and

8 | OCTOBER 2015 | ENGINEERING REVIEW

ground. Additionally, users of Agisoft’s PhotoScan software can now import their calibrated photos into PointSense’s Heritage tools as an additional reference source for processing their point cloud data. FARO also released new versions of its VirtuSurv, TachyCAD, and PhoToPlan software with enhanced functionality. VirtuSurv, the Company’s intuitive and easy-to-use solution for processing point cloud data based on photo-like scan views, offers a new user interface for SEMA GmbH’s timber construction tools software. FARO’s 3D AEC Software solutions process data from almost any measurement device. Users can find more information on the software applications, including a full list of new features, videos, and options to schedule on-line demonstration appointments at the following site: www.faro-3d-software.com

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

Contents

Vol 15 | Issue 6 | October 2015

PROFILE

TRANTER : Technology leadership in heat transfer specialization

Spraymet Surface Technologies helps in conservation of resources

Tennyson Anthony, General Manager - Sales, Tranter India Pvt.Ltd.

Mr. P.T. Bindagi, Technical Director, Spraymet Surface Technologies Pvt Ltd

REFLECTIONS

124 COVER STORY IN FOCUS DEMAG : Extending growth horizon

143

Smart Grid technology: Revolutionising the economic growth

PC|SCHEMATIC : Time saving electrical CAD software

Ador Welding Academy churns out over 1,00,000 welding professionals

Mr. Ravin Wadhawan, Executive Director, Demag Cranes & Components (I) P. Ltd.

INDUSTRY SPEAK

140

Mr. Vikram Gandotra, Chairman, Smart Grid Division, IEEMA

FACE TO FACE Our National Growth targets will get derailed unless we address the need for 1.2 million Welding Professionals by 2020: IIW

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

TECH TRENDS

141

126

137

Masyc Projects â&#x20AC;&#x201C; A formidable name in bulk handling

Pneumatic Conveying in Chemical Industry

Air Cooling takes away your heat, while being eco-friendly & economical. Symphony shows how.

R. Srinivasan, President, The Indian Institute of Welding

BUSINESS AVENUES .....161 PRODUCT SHOWCASE .....169

Mr. V.B. Bhatia, Jt. Managing Director, Masyc Projects Pvt. Ltd.

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

Mr. Anish Joseph, Business Unit Head Conveying Solutions at Rieco Industries Ltd.

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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 | OCTOBER 2015

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ENGINEERING REVIEW |

13 | October 2015

Contents AUTOMATION

Vol 15 | Issue 6 | October 2015

MACHINE TOOLS

BUSINESS NEWS

Hanna Instruments, Inc. introduces the new Pocket pH Tester HI 98100 Checker plus with replaceable pH electrode facility

CNC Software, Inc. appoints New European Territory Manager

FARO® Continues to Enhance Customer BIM Workflows with an Updated Release of PointSense Software

Customized grinding concepts in Milan

HARTING at the IAA: Proven Plug Socket Power

CNC AXIS sharing innovation paves the way for more versatile machine tools

Total & Parker Set Instrumentation Manifold Standard for projects And Upgrades in Europe

Clean Room High Speed Doors: Air Tight & Hygienic

TECH TRENDS

TECH TRENDS 70

Workpiece inspection and tool setting probes from Renishaw help Vasantha Tool Crafts increase machine utilisation time by 20%

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

ARC Informatique and Ubiquicom join forces to bring location awareness and safety to your SCADA application

HAAS : HE307-CS

Securing the industrial network

Geissel India : German quality produced in India

The new »Minis«: Now compatible with the Hainbuch modular system

Competence and experience – Added value for customers Klüber Efficiency Support helps increase food safety and protect valuable resources

Custom All-Electric Tube Bender Will Accelerate Right-First-Time Production for Precision Metal Fabricator

102 Analyzing the quality of crude oil with an elementary instrument 108 Knowledge is the key to solution 110 Tamper-proof sealing of folded cartons Gloss sensor Glare from SICK 112 Rollon: Managing Misalignment in Linear Motion Systems

CHEMICAL & PROCESS BUSINESS NEWS 28

Advanced food processing technology from HRS PSL showcased at International FoodTec India 2015, New Delhi

ENGINEERING BUSINESS NEWS 30

Cole-Parmer introduces New Oakton® Waterproof pH 450 & CON 450 Meters

Mahindra Auto Steel Pvt. Ltd. (MASL) inaugurates its Auto Steel Service Centre at Chakan, Pune

Trane® introduces GEN YUE – Full DC Inverter VRF System

Department of Heavy Industries, Government of India partners with WIN INDIA 2015 to Promote Indian Capital Goods Manufacturing as a part of ‘Make In India’ initiative

POWER BUSINESS NEWS 50

Prith Banerjee joins Schneider Electric as Chief Technology Officer

Fluke 1736 & 1738 Three-Phase Power Loggers

V-Guard’s Kashipur Factory Felicitated as Bronze Winner in National Awards for Manufacturing Competitiveness (NAMC)

Bajaj Electricals Ltd. IBMS unit bags “Best IBMS Company” Award

REC signs MoUs for Rs.9000 Crores with APGENCO and APTRANSCO

Delta introduced PMH Panel Mount Power Supply Series for Household Applications

GEARS & MOTORS BUSINESS NEWS 42

TECH TRENDS 116 Springs : The key for motion control applications 118 Anti-vibration solutions for India’s power plant building boom 122 CIMES 2016 – The 13th China International Machine Tool & Tools Exhibition 14 | ENGINEERING REVIEW | OCTOBER 2015

Bonfiglioli participates in the implementation of an innovative Powertrain for hybrid Fiat Ducato

LOGISTICS BUSINESS NEWS 44

Safeducate signs MoU with Volvo Eicher www.engrreview.com

AUTOMATION Âť BUSINESS NEWS

HARTING at the IAA: Proven Plug Socket Power Rising demand for E-Mobility solutions

ARTING Automotive will present its newest products and solutions at this yearâ&#x20AC;&#x2122;s International Motor Show (IAA), taking place in Frankfurt between 17 and 27 September. The company develops and manufactures charging equipment for electric and plug-in hybrid vehicles. Customers can use the equipment as it fits their requirements best, since the HARTING vehicle charging cables are available in all three globally used plug system versions (with the corresponding approvals) for the common AC charging interfaces. Therefore, the Type 1 plug is approved for AC in accordance with UL, CE and JET/PSE, and the Type 2 plug is also approved for AC in accordance with UL/VDE. The HARTING GB China plug fulfils the CQC standard. Overall the E-Mobility sector is becoming increasingly important for HARTING Automotive, as the company is experiencing a sharp increase in demand for solutions in this field. HARTING will also be presenting concrete solutions for charging in household plug sockets at its trade fair stand (Hall 3.1, Stand A 15), including a plug with a quick temperature sensor. This sensor provides the customer with extra safety. The electronic Mode 2 charging system offers additional safety features with PE monitoring, DC residual current protection device and temperature shut-off. This corresponds to the state of the art in the relevant international draft standard.

For more information Web: www.HARTING.com 18 | OCTOBER 2015 | ENGINEERING REVIEW

HARTING will be presenting products such as the Type 1 AC plug (left) and Type 2 AC plug (right) at the IAA.

HARTING will also be presenting the GB China plug at the IAA.

www.engrreview.com

AUTOMATION » BUSINESS NEWS

Total & Parker Set Instrumentation Manifold Standard for projects And Upgrades in Europe

Pepperl+Fuchs Acquires One Of The World’s Leading Providers Of Hart Protocol Devices

Pepperl+Fuchs, a world leader in process automation and applications, has acquired MACTek Corporation, a leading provider of HART protocol devices. The move is part of Pepperl+Fuch’s strategy to further extend its integrated solutions offerings and strengthen its position in the WirelessHART market.

otal RC, the refining and chemicals arm of French oil giant Total SA, is standardising on manifolds produced by the Instrumentation Products Division of Parker Hannifin, the global leader in motion and control technologies. The decision follows several years’ extensive temperature, pressure and corrosion testing of products from different manufacturers – Parker is the first company to have secured a 100 percent pass rate. Under the terms of the contract, Parker will supply all the instrumentation manifolds that Total RC needs for new installations and upgrades across its entire European base of refining and petrochemical operations. Most of the company’s requirements will be for manifolds designed to connect process transmitters to ANSI Class 1500 or 600 piping, together with some for use with pressure gauges and lower rated instrumentation tubing. The manifolds cover a diverse range of 2-, 4- and 5-valve configurations. They all either feature flanged inlets and outlets, or utilise Parker’s PTFree connect system. All of the Class 600 and 1500 manifolds that Parker will supply under this contract are NACE MR0175/ISO 15156 compliant and rated for service in sour gas (H2S) environments. All metallic components are manufactured from heat code traceable 316 stainless steel. The valves are high performance globe style bonnet designs, with externally adjustable sealing glands and Graphoil packing. Every manifold includes steam trace ports for heat tracing and all vent valves feature anti-tamper bonnets.

For more information Web: www.parker.com 22 | OCTOBER 2015 | ENGINEERING REVIEW

e are pleased to add the MACTek WirelessHART product line to our existing portfolio,” said Jim Bolin, Pepperl+Fuchs’ executive vice president of the Americas. “This acquisition complements our current product lines well, and allows us to provide an even greater breadth of services to our customers. Founded in 1993, MACTek specializes in HART modems, including VIATOR HART Interface modems. One of the company’s most recent innovations, the BULLET WirelessHART adapter, can be mounted on any device rated for hazardous areas. The HART modem family includes wireless access to HART field devices designed for hazardous areas and Bluetooth-enabled technologies. About Pepperl+Fuchs Pepperl+Fuchs is a world leader in the design, manufacture, application and support of a broad range of robust solutions to process automation markets and applications. A perennial Reader’s Choice Award winner in both Control and Control Design magazines for intrinsic safety equipment and purge & pressurization systems, Pepperl+Fuchs has also been named by Control magazine and the ARC Advisory Group as one of the Top 50 Global Automation Companies. For more information visit

For more information Web: www.pepperl-fuchs.us www.engrreview.com

AUTOMATION » BUSINESS NEWS

Clean Room High Speed Doors: Air Tight & Hygienic Communication by Mr. Samir Gandhi, Director, Gandhi Automations Pvt Ltd to hygiene, sealing, operating reliability, fitting and a trouble free after-sales service. Our Clean Room High Speed Doors satisfy all these requirements and work in strictly regulated operating conditions. Gandhi Automations offers custom-made solutions for these sectors, while investing a lot of time and money in courses and training for the company’s own production staff and technicians.

Mr. Kartik Gandhi – Director, Gandhi Automations Pvt. Ltd.

andhi Automations Pvt Ltd India’s No.1 Entrance Automation & Loading Bay Equipment Company offers Clean Room High Speed Doors - Prime Clean. Clean Room: A Clean Room is an environment typically used in manufacturing and scientific research with a low level of environmental pollutants such as dust, airborne microbes, aerosol particles, and chemical vapors. Simply put a Clean Room has a less or no level of contamination. Usage and Benefits of Clean Room Doors: In the pharmaceutical industry, Clean Room Doors play a crucial role in the manufacturing of pharmaceutical products which require the environment to be free from microbial and

24 | OCTOBER 2015 | ENGINEERING REVIEW

particulate contamination and protected from moisture – controlled environment. Clean Room High Speed Doors designed and manufactured by Gandhi Automations are high in demand in industries such as Pharmaceutical and Chemical, which require quick open and close applications at the entry and exit points as controlled environment needs to be maintained. These industries make high demands with respect

The key features of Clean Room High Speed Doors offered by Gandhi Automations are briefly mentioned below: a. Clean Room High Speed Doors are designed for inside applications and protects your environment against draughts, humidity, dust and dirt b. Operating speed and superior sealing properties improve traffic flows and provide environmental control and savings on energy costs c. Concept of low air permeability in pressurized rooms with positive and negative air pressure d. High door efficiency & low permeability values e. EN 12426 EN 12427 : < 12m3 / m2h ∆ 50 PA f. High leak tightness is due to curtain being tightly integrated in special SS 316 matt finish side guides g. Bottom safety edges and photocells combine to ensure operator safety at all times h. Heavy duty motor: 400V three phase, opening speed upto 1.5 m / s with inverter system i. Size upto: 4000 mm (W) X 4000 mm (H) Website : www.geapl.co.in www.engrreview.com

ROSS CONTROLS Fluid Power Products 5/2 Double Valve 4 2

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Air Entry Packages with Control Reliable Energy Isolation

SERPAR® Double Valves for Clutch/Brake Control

ROSS Pneumatics Products:

Base Mounted Valves Inline Valves Valves for Air Flow Controls Manual & Mechanical Valves

Filters, Regulators, Lubricators Safety-Related Products Double Valves for Clutch/Brake Control

ROSS CONTROLS INDIA Pvt. Ltd. Plot No. 113, Ambattur Industrial Estate, Chennai 600 058, India Phone: 91-44-2624-9040 Email: ross.chennai@rosscontrols.com

www.rosscontrols.com

PROFILE

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.

26 | OCTOBER 2015 | ENGINEERING REVIEW

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

CHEMICAL & PROCESS » BUSINESS NEWS

Advanced food processing technology from HRS PSL showcased at International FoodTec India 2015, New Delhi The event also saw many visitors from the snack food industry who showed interest in HRS products and solutions; viz, the range of energy efficient Ecoflux* corrugated tube heat exchanger, HRS Funke plate heat exchanger and heat exchanger based systems.

RS Process Systems (HRS PSL) participated in the 10th International FoodTec India 2015 from 14th- 16th Sept, 2015 at Pragati Maidan, New Delhi. The company emphasized the role of innovative technology for food processing while displaying the latest additions to the product range, HRS Monobloc Sterilizer and UHT Sterilizer. To engage with a wider spectrum of the industry at the 10th edition of International FoodTec 2015, HRS exhibited its latest technology in food processing sector along with the main range of heat exchangers, preheater, pasteurisers, evaporators and beverage processing lines. The event also saw many visitors from the snack food industry who showed interest in HRS products and solutions; viz, the range of energy efficient Ecoflux* corrugated tube heat exchanger, HRS Funke plate heat exchanger and heat exchanger based systems. All products have received a very good response and owing to their superior technology have generated interest with more than 200 visitors from well known multinational and Indian food companies including Varun Beverages, Parle Agro, Schreiber, Jadli Foods, Leon foods, and snack food companies like Haldiram’s, Bikaji, Flavorite and many more. 28 | OCTOBER 2015 | ENGINEERING REVIEW

HRS Process Systems Ltd. Overview:

HRS PSL’s Snapshot of key activities:

HRS Process Systems Ltd., (HRS PSL) part of UK based HRS Group, is one of the leading heat transfer specialist that operates at the forefront of thermal processing technology. Established in 2003, with headquarters in Pune, HRS PSL has marketing offices spread across major metro cities of India along with the group companies in UK, Spain, USA, Peru, UAE and Malaysia. HRS PSL offers effective heat transfer solutions for an extensive range of processing applications across a spectrum of industry sectors like Chemical , Petrochemicals/Oil & Gas, Pharmaceutical, Oil & Fats, Fertilizer, Cement, Steel, Power, Agro Chemical, OEM (Original Equipment Manufacturers), Paint, Paper & Pulp, Textile, Automotive, Sugar, Distillery & Breweries, Dairy, Food & Beverage, Nutraceuticals among others. Pioneers in the revolutionary corrugated tube technology for the process industry, HRS PSL offers innovative technology of international standard for thermal processing like corrugated tube heat exchangers, plate heat exchangers, hot water systems, evaporators, systems for food/fruit/ beverage processing, CIP systems, aseptic processing and filling technologies.

Steel Industry witnessed HRS energy efficient heat transfer solutions at RAFTS 2015!!! HRS Process Systems Ltd. been a part of 2nd International Conference on Rolling And Finishing Technology of Steel 2015 (RAFTS 2015) held at Ispat Bhavan, SAIL, Ranchi from 8-10 Sept 2015 as silver sponsor. Witnessing emerging technologies in rolling mill many renowned players in steel industry like SAIL, Jindal Steel, Siemens VAI Ltd, Mecon Ltd, NMDC Ltd, SMS group etc. graced the event by their presence. Knowing the significance of energy efficiency and quality production in steel industry HRS displayed Ecoflux* Corrugated Tube Heat Exchanger, HRS Funke Plate Heat Exchangers and HRS Heat Exchanger based Systems which are proved to be beneficial for many processes in steel industry. HRS Skid Mounted Acid Heating System and Emulsion circuit reheating System were the highlight of the event.

For more Information Web: www.hrsasia.co.in

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ENGINEERING » BUSINESS NEWS

Cole-Parmer introduces New Oakton® Waterproof pH 450 & CON 450 Meters Durable waterproof and dustproof design with IP67 rating

ole-Parmer introduces the latest fully-featured GLP complaint pH meter and conductivity meter from Oakton®, known as a technology leader in water testing instruments. The Oakton pH 450 and CON 450 Meters are waterproof and rugged enough for even the harshest environments. The meters provide automatic and manual temperature compensation to ensure accuracy even with fluctuating temperatures. Get more data at a glance view measurements with temperature and calibration data with % slope or cell constant on a large, backlit display. Select Celsius or Fahrenheit settings to best fit your application. Up to 500 data sets can be stored and easily downloaded with USB or RS-232 cable. A calibration alarm alerts users when it is time to calibrate. The Oakton pH 450 meter also features sixpoint calibration choose USA, NIST, DIN, or custom buffers. Convenient auto buffer recognition automatically identifies the correct pH meter buffer for rapid calibration. The Oakton CON 450 meter offers autorange conductivity from 0 to 199.9 mS in five ranges with automatic calibration up to five calibration points. Selectable temperature coefficient is adjustable from 0 to 10% per °C for accurate compensation of almost any solution. To view the new range of Oakton meters, go to www. ColeParmer.in, or call 022-6139-4444/e-mail response@ coleparmer.in or chat live at www.coleparmer.in About Cole-Parmer: With more than 60 years of experience, Cole-Parmer is a global leader in supplying fluid handling, life science, and general laboratory products, instrumentation, and equipment to the Biotech, Chemical, Academics, Environmental, Food, Industrial Manufacturing, and Print industries. Offering a wide selection of products and instrumentation, Cole-Parmer works with R&D, pilot plant and production, specializing in providing scale-up assistance. With a mix of proprietary products and strategic partnering with leading manufacturers, Cole-Parmer’s business is highly diversified across a spectrum of products, consumables, services and solutions. For more information Cole-Parmer India Pvt. Ltd. Web: www.coleparmer.in

30 | OCTOBER 2015 | ENGINEERING REVIEW

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ENGINEERING » BUSINESS NEWS

Mahindra Auto Steel Pvt. Ltd. (MASL) inaugurates its Auto Steel Service Centre at Chakan, Pune

ahindra Auto Steel, a subsidiary of Mahindra Intertrade, part of the USD 16.9 billion Mahindra Group, today announced the opening of its automotive steel processing facility in the auto belt of Chakan, near Pune, Maharashtra. This state-of-the-art facility is a joint venture with China Steel Global Trading Corporation, Taiwan and Mitsui & Co. (Asia Pacific) Pte. Ltd., Singapore. While Mahindra Intertrade holds 51% in the JV, the other partners hold 24.5% each. The facility has been set up at a cost of Rs 110 crore (USD 17 million) in Phase I, over 10 acres of land, with an annual processing capacity of 100,000 tonnes. This plant is the 7th steel service centre in the Mahindra Intertrade family,

32 | OCTOBER 2015 | ENGINEERING REVIEW

its 3rd in the Pune region, and its 3rd automotive steel processing facility. Equipped with a state-of-the-art Blanking Line from Fagor Arrasate of Spain, India’s first servo line, this facility will offer automotive customers in the Pune region the entire bouquet of services such as sourcing, warehousing, yield optimization, forex risk management and SKU-wise JIT delivery, and products such as blanks, trapezoids and profiles. Speaking at the launch announcement Harsh Kumar, Managing Director, Mahindra Intertrade Ltd., and Member, Group Executive Board, M&M Ltd. said, “It gives us immense pleasure to announce commencement of operations at our new plant in Chakan. This world-class facility located in the automotive hub

of Chakan, and backed by the highest quality steel from our partners, would help redefine the automotive steel supply chain model in the region.” According to Yi-Jen Kuo, Managing Director, China Steel Global Trading India Pvt. Ltd., “China Steel Corporation Group has been at the helm of developing high-end steel products such as automotive steel since 1995. India is one of our key markets for automotive steel owing to the growth potential of the automobile industry. Through our strategic alliance with Mahindra Intertrade and Mitsui & Co., we are confident of providing manufacturers in India with the highest quality products and services, and in turn contribute towards this rapidly developing industry.” This high-strength, high-speed facility has been especially designed for the manufacture of nested blanks, and offers significantly higher levels of material yields to its customers, a distinct plus in the current competitive environment. MASL’s new facility at Chakan is constructed in accordance to IGBC’s Green Building norms, and incorporates features such as enhanced indoor air quality, treatment of non-process waste water, rain water harvesting, et al.

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

ENGINEERING » BUSINESS NEWS

Trane® introduces GEN YUE – Full DC Inverter VRF System Advance Full DC inverter technology gives high IPLV of upto 6.9 & Wide operation range upto 50 °C

rane, a global leader in heating, ventilation and air conditioning (HVAC) systems; and a brand of Ingersoll Rand, has introduced GEN YUE – Full DC Inverter VRF System. Trane’s new product designed for Commercial Real estate, Hospitality & Premium Residential sector will cater to customer needs by driving energy and operational efficiency. Trane® VRF system can make buildings more comfortable to occupy, less costly to own and more profitable to operate. The product tailor made for Indian weather conditions and focused on efficiency and reducing energy costs, will help businesses meet their sustainability goals. GEN YUE equipped with full DC inverter VRF technology offers high reliability, advance controls like 15” Touch Screen controller & inbuilt Modbus Gateway. Sudarshan Ananth, Territory Vice President and Business Head – HVAC & Transport, India Climate Business Unit, Ingersoll Rand said, “As an industry leader, over past last century, Trane has been committed towards delivering highest standard quality and product innovation to our customers. We are delighted to unveil GEN YUE, one of our premium products from Trane brand products range for our customers in India. The new product is not only high on performance but is also environment responsible. GEN YUE offers flexible design and outstanding energy management that addresses energy saving with smooth operation and delights end user.”

34 | OCTOBER 2015 | ENGINEERING REVIEW

Key Features of GEN YUE - Full DC Inverter VRF System Superior Efficiency • Advance FULL DC inverter technology gives high efficiency at partial loads resulting to high IPLV (Integrated Part Load Value) of upto 6.9. • Revolutionary cross flow fins allows better heat exchange, small air resistance & minimizes frost. High Reliability • Designed for harsh Indian conditions, designed to operate at 50 °C. • Hi efficiency DC inverter compressor with improved compression efficiency of 15%. Flexible design • Height difference range of upto 70m, longest pipe length of 200m. • Flexible design applications, maximum 4 modules combination with total capacity of upto 64 HP. Convenient Operation • Wide variety of hi tech controllers to choose from including individual, central, touch screen management system host, Touch Screen GEN NET management system & BMS connectivity.

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ENGINEERING » BUSINESS NEWS

Department of Heavy Industries, Government of India partners with WIN INDIA 2015 to Promote Indian Capital Goods Manufacturing as a part of ‘Make In India’ initiative FICCI to be the Lead Industry Partner for the WIN INDIA 2015 Partnership to enhance and encourage collaborative opportunities between Indian and Global players at World of Industry- WIN India from 09-11 December 2015

annover Milano Fairs India Pvt Ltd, the Indian subsidiary company of the global joint venture of Deutsche Messe (Germany) and Fiera Milano Group (Italy) annouced the partnership between Department of Heavy Industries and WIN India 2015, India’s leading Industrial and engineering trade fair, schedule to be held from December 9-11, 2015 at the Pragati Maidan, New Delhi. 36 | OCTOBER 2015 | ENGINEERING REVIEW

Department of Heavy Industries, Ministry of Heavy Industries and Public Enterprise, Government of India has partnered with FICCI, one of the largest and oldest apex business organization and government advisory, to be the lead agency for executing the partnership for WIN India 2015. This partnership is to work jointly towards promoting India’s high tech engineering and capital goods manufacturing industry as a

part of Government of India’s ‘Make In India’ campaign. WIN India 2015 is the Indain sister event for Deutsche Messe’s largest global industrial engineering trade fair HANNOVER MESSE, where India participated as Partner Country this year, generating interested enquires of close to 1.2 Billion USD at the show.

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Continued from page no.36 This parntership MoU is being seen as a significant step in enhancing India’s ‘Make In India’ focus by extending its progress made at HANNOVER MESSE. WIN India will serve as a platform for the showcase of high tech engineering and capital goods manufacturing innovation on a global platform. The Make in India initiative has generated tremendous positive sentiment and interest from global investors. It is estimated that between April 2014 and February 2015, foreign direct investment in India reached 28.8 billion U.S. dollars – a 40 percent increase compared to the same time period in the previous year. WIN India has been successfully working towards the mission of creating more interest in India as a long-term production location for 8 years now. With more global interest in India, and with our partnership with Department of Heavy Industries and FICCI, we hope to further pave the way for investment and partnerships to enhance India’s economic engagement with Europe and other global economies.“ said Wolfgang Pech, Senior Vice President Deutsche Messe AG and Managing Director Hannover Fairs International, Hannover / Germany In December of this year, Lower Saxony’s undersecretary, Daniela Behrens, will lead a business delegation from Lower Saxony to visit WIN INDIA with the specific goal of meeting Indian companies and intensifying Lower Saxony’s economic relations with India. This is a direct result of India’s Partner Country appearance in Hannover, which is the capitol of Lower Saxony. Learning that there are numerous investment and cooperation opportunities in India, the delegation will visit WIN India 2015. “India is an attractive hub for foreign investments in manufacturing sector. Several companies have set up or are looking to establish their manufacturing bases in India. Department 40 | OCTOBER 2015 | ENGINEERING REVIEW

of Heavy Industries will be the strategic partner of WIN India 2015 with support from FICCI, where both the organizations will together work towards strengthening the Indian manufacturing sector thereby making PM’s vision of Make in India a reality. The partnership also signifies greater government partnership in WIN India, which is an important factor in augmenting the Indian Capital goods manufacturing ecosystem“ said Shri Rajan S Katoch, Secretary, Department of Heavy Industries, Ministry of Heavy Industries & Public Enterprise, Government of India. Speaking at the signing ceremony Mehul Lanvers-ShahTushar Alekar, Managing Commercial Director, Hannover Milano Fairs India Pvt Ltd. said “We are very happy to extend all our support to our partners and are thankful that they have chosen WIN India as the platform of choice for the sector, represented by the Ministry of Heavy Industries and Public Enterprises. At WIN India this year, DHI will showcase the Indian Capital Goods manufacturing sector and its strengths and will focus on Government of India’s successful campaign Make in India, taking forward the progress made as Partner Country at Hannover, Germany. The show is an ideal platform to showcase India’s high tech engineering and Capital Goods companies, Research and Innovation and bring State Governments and other local and global players together to develop the industry. In partnership with Department of Heavy Industries, we along with FICCI, will also organise industry roadshows in XX cities to garner participation and interest from domestic players.” “India is lagging behind in domestic capital goods manufacturing, leading to an increasing dependance on imports in the sector. Capital goods manufacturing is crucial for the development of India’s manufacturing ecosystem as it has a multiplier effect by supplying the equipment and machinery needed

to support and encourage the sector’s growth. Today the capital goods industry contributes a meagre 12% to the total manufacturing activity in the country. We are greatly looking forward to this partnership at WIN India 2015 to promote the Department of Heavy Industries objectives of boosting the Indian Capital goods sector, and promoting India’s focus on Make in India. ” Said Dr. A.Didar Singh, Secretary General, FICCI WIN India is powered by the global industrial trade fairs of Hannover. WIN is the umbrella brand for 5 internationally established trade fairs covering Industrial Automation, Motion Drive Automation, Surface Technology and CeMAT India presenting a comprehensive range of products and technologies for factory, process and industrial building automation; power transmission and fluid power; materials handling and logistics; and surface treatment, respectively. In its 9th edition, WIN India, will be held at the Pragati Maidan Fair Grounds in New Delhi. The show occupies an area of 11000 sq. metres and showcases exhibitors from 27 countries. Leading country participations come from Germany, Italy, China, Taiwan and Korea. True to its global roots, over 50% of products displayed at WIN India are international. Few of the companies that will participate in this year’s WIN India are Festo, Camozzi, Jungheinrich, Hyundai forklifts, Hi-tech robotics, Phoenix Contact, Nord Systems, Gandhi Automation, Balluff India, Beumer Group, Connectwell, Degson, Epson robotics, Faro, Pepperl and Fuchs, Wago and many more.

For more information Web : www.win-india.com www.engrreview.com

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GEARS & MOTORS » BUSINESS NEWS

Bonfiglioli participates in the implementation of an innovative Powertrain for hybrid Fiat Ducato Bonfiglioli Riduttori, represented by Massimo Palomba, Product Manager for Mobile Solutions Electromobility sector, submitted its own electric powertrain implemented for Fiat Ducato within an event organised by the Automotive Innovation Pole in Milan on 16th July 2015.

he conference, entitled “Vehicles for Smart, Green and Integrated Transport: efficiency and eco-sustainability path for the food industry and other sectors”, was organised by the Automotive Innovation Pole (www.poloautomotive.eu), a consortium that includes about 70 companies working in the automotive field including, besides Bonfiglioli Riduttori, Fiat Chrysler Automobiles, Centro Ricerche Fiat, Honda, Tecnomatic and Denso.The

42 | OCTOBER 2015 | ENGINEERING REVIEW

aim of the event was to present the innovative solutions identified in the “eco-smart vehicles” sector that enable drastic reduction of CO2 emissions in urban centres, these solutions were then implemented thanks to the collaboration established between different companies of the Pole. Massimo Palomba presented a powertrain for LCV (light commercial vehicle), applied for this project on the New Ducato, and developed

thanks to the synergy between Bonfiglioli Riduttori, Tecnomatic and the other partners of the Automotive Innovation Pole. In particular, an advanced powertrain system has been developed which will permit a “bimodal” hybrid use of the vehicle thanks to an architecture integrating the normal endothermic propulsion with an electromechanical one. When the vehicle is located in urban centres, you can switch off the combustion engine and activate the limiter with the permanent magnet brushless electric motor. The system is engineered to enable the vehicle to reach 70 km/h in pure electric and provides a battery-pack that guarantees from 40 to 120 km in ECE101R cycle. The geared motor, for the same power delivered compared to those on the market, is made such as to have reduced dimensions and weights (additional weight including batteries less than 200 kg for the base configuration) so as to be easily applied in the standard vehicle. According to the analysis, by using this bimodal hybrid mode it is possible to reduce the emissions by up to 40%.

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

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LOGISTICS » BUSINESS NEWS

~Safeducate signs MoU with Volvo Eicher~ ~Driving Training Schools to be launched across India~

afeducate, the education & training arm of supply chain & logistics industry leader Safexpress, has signed a prestigious Memorandum of Understanding (MoU) with Volvo Eicher Commercial Vehicles Ltd. (VECV). Divya Jain, Founder & CEO, Safeducate, signed the MoU with Vinod Aggarwal, CEO, VECV on 18th of September, 2015 at the Corporate Headquarters of VECV at Gurgaon. Ever since its inception in 2007, Safeducate has been partnering with a number of Government and Private bodies to work in the area of skilling the youth in supply chain & logistics domain. The highly innovative firm has been credited with recently launching India’s first Container School. Now, Safeducate has partnered with Volvo Eicher to skill and train the rural youth by providing Driver Training. Speaking to the media regarding this MoU, Ms. Divya Jain, Founder & CEO, Safeducate said, “Safeducate is proud to partner with VECV for creating Driver Training Schools. We have worked relentlessly over the years towards adding value to the lives of our Drivers. We have been training Drivers regularly over the years, and have even created Driver residential and recreational facilities at our Logistics Parks. We have improved processes significantly to expedite the turnaround of vehicles at our facilities, which is otherwise a big pain area for Drivers. We also keep the average driving time limited to 8 hours at a stretch for a driver, unlike a common scenario in the country where drivers are forced to drive for 12-14 hours in tough Indian conditions.” Ms. Jain further explained, “The main objective of this collaboration with VECV is to familiarize the new and existing drivers with safe and appropriate driving techniques, so as to get the best fuel efficiency from the vehicles

44 | OCTOBER 2015 | ENGINEERING REVIEW

besides driving in a safe manner to avoid accidents. The project aims to promote the profession of Driving among career aspirants.” Notably Divya Jain has authored India’s first Coffee Table Book on Trucking called ‘Horn Please’. This book is an attempt towards glorifying Truck Drivers’ lives and sensitize people towards the cause of Truck Drivers. The book has been featured in the Limca Book of Records 2015 as well. Expressing her views about Truck Drivers and how they are critical to the growth of our nation, Ms. Jain said, “We are very passionate about the cause of Drivers in India, given the sacrifices they make and the vital role they play in the success of our economy. This strategic partnership with VECV, an auto major with international backing & experience, will help us gain access to the best of Driver training material, techniques and tools, which will further enable us to create more and better Drivers. As a part of our rollout plan, we would soon be launching two Driver Training Schools, in association with VECV.” Ms. Jain concluded by saying, “Safeducate is working very hard towards bridging the skills gaps prevalent in the supply chain & logistics industry. Our alliance with VECV would

provide a huge fillip to our efforts in that direction.” About Safeducate Safeducate, a specialist in supply chain & logistics training, was established in 2007, with an aim to meet the continuously evolving needs of the workforce of the supply chain & logistics industry. Led by the alumni of Stanford and Cambridge University, the team blends rich operational experience of the supply chain arena with international knowhow and best practices to create programs which are extremely stimulating, hands-on and practical. Safeducate is backed by a team of highly experienced consultants and trainers. These professionals offer world-class training as part of uniquely designed courses, through which participants gain comprehensive supply chain & logistics understanding. The participants are provided with extensive domain knowledge and practical training, enabling them to face day-to-day challenges while working in supply chain & logistics industry. Safeducate has achieved a landmark of training more than 30,000 people across 52 cities in the country. For more information Web: www.safexpress.com www.engrreview.com

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MACHINE TOOLS » BUSINESS NEWS

CNC Software, Inc. appoints New European Territory Manager

NC Software, Inc. (www.mastercam.com) announced that Sandy Moffat has joined the company to further develop their European distribution channel. Sandy Moffat comes to CNC Software with a wealth of experience within the CAD/CAM industry, having spent the last 14 years at Delcam, Ltd where he was responsible for managing and growing their territories across Asia, Europe, Africa and the Middle East. Sandy was instrumental in helping to increase growth in Japan by 20% and average annual growth across his regions by an average of 14% each year. Sandy joins CNC Software as the European Territory Manager, based in England, to continue the success that the company has had within

that region. “I am excited to start a new challenge at CNC Software and look forward to working with the sales team and the European distributors to further grow their already strong territory,” said Sandy. Doug Nemeth, Director of Sales in North America and Europe said, “Sandy’s wealth of experience and knowledge of the CAD/CAM industry, and particularly the European market made him a natural choice for us. He is a key addition to the CNC Software sales group and we are looking forward to working with him as we continue to grow our channel.” For more information Web: www.mastercam.com

Customized grinding concepts in Milan

t the EMO the JUNKER Group showcased its products for the first time in Europe together with its latest member ZEMA. It was once again obvious that the customized grinding concepts that the Group develops for workpieces regardless of their complexity is the result of an intensive dialogue with its customers. The circular grinding machine Numerika GH 1000 by ZEMA attracted a great deal of attention. The Brazilian grinding machine manufacturer became a member of the JUNKER Group in March. The sophisticated machine concept surprised visitors to the exhibition where it immediately became apparent that ZEMA is competing on an equal footing with European manufacturers. ZEMA can offer its customers sound workmanship, simple operation using the Fanuc or Siemens control and choice of components thanks to its close cooperation with globally renowned suppliers. Visitors were also able to take a closer look at a newly developed workhead at the JUNKER JUMAT 1S when grinding the threads of ball screw nuts. With two opposing clamping devices, downtimes can be minimized considerably: while grinding on the one side, workpieces are unloaded, loaded, clamped and positioned on the other. The only downtime: Swiveling by 180 degrees in less than 3 seconds. Numerous inquiries came in particular from Italian customers with regard to the Lean Selection speed. One or two high-performance grinding spindles mounted at the swivel-action wheelhead (B-axis) work using both the plungecut and QUICKPOINT grinding methods. Thanks to this 46 | OCTOBER 2015 | ENGINEERING REVIEW

Improve workpiece quality, reduce cycle time: The customized grinding concepts of the JUNKER Group met with keen interest at the EMO in Milan

flexibility feature, it is predestined for use in smaller workshops. The LTA Lufttechnik presented its filtration solution at its own booth in Hall 11. The electrostatic oil and emulsion mist filters met with great approval. The modular design renders them suitable for the group or central extraction of several machine tools. All in all, the JUNKER Group is satisfied with the outcome of this year’s EMO. Contracts were concluded, existing customer contacts maintained and promising contacts established – also as regards the search for new sales engineers for the Italian market.

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MACHINE TOOLS » BUSINESS NEWS

CNC AXIS sharing innovation paves the way for more versatile machine tools Multiple CNC kernels can timeshare control of the same axes

UM has launched an innovative new CNC axis sharing facility that will enable designers to create machine tools of unprecedented versatility and productivity. It provides a very flexible and efficient means of controlling a high number of functionally interrelated groups of motion axes, by using advanced dynamic resource allocation techniques to share control across multiple CNC kernels. Typical applications include multi-station production centres and rotary transfer machines with complex multi-role axis control requirements. The new axis sharing facility further extends the flexibility of NUM’s high-end Flexium+ 68 CNC architecture by allowing the control of up to 32 servo drives to be timeshared by any of the CNC kernels in the system. Until now, it was only possible to share control of axes across the eight CNC channels of each individual Flexium+ 68 CNC kernel in a system. While this is more than adequate for most applications, some of the latest generation production machining centres and rotary transfer machines have a high number of stations, each typically comprising a multi-axis head (using the B and C axes) that is shared by several separate machining units in each station. Each machining unit is best served by having its own dedicated CNC channel, with control of the shared multi-axis heads being passed from one channel to another as the machine cycle progresses. For example, a transfer machine with a main rotary table that has 12 stations, each comprising a dual-axis head that is shared with three machining units per station, would require a 36-channel CNC capability – one per machining unit. Each of these channels would need to control two shared axes, three local (or ‘fixed’) axes, and one or more spindles. All five axes of each machining unit must be fully interpolated, and the channel allocation of the two shared axes needs to change every time the rotary table indexes. This can now be achieved by using five Flexium+ 68 CNC kernels and axis sharing. Each individual Flexium+ 68 CNC kernel accommodates any combination of interpolated axes or spindles – up to a combined total of 32 – and supports up to eight CNC channels. At any one time, each channel can control any of these axes or spindles and can either run its own part program asynchronously and operate autonomously 48 | OCTOBER 2015 | ENGINEERING REVIEW

(much as if it had its own dedicated CNC kernel), or it can be synchronised with any of the other seven channels. Control of the axes and spindles can be passed from one channel to another on-the-fly, to maximize use of hardware resources. By using multiple CNC kernels and the new axis sharing facility, machine designers can now implement control schemes for virtually any type of machine tool, regardless of its complexity. The only system requirement is that all shared servo drives must be physically connected to the first CNC kernel in the system. NUM’s Flexium+ 68 CNC architecture is inherently scaleable and suitable for systems with more than 200 interpolated axes and spindles, and more than 50 CNC channels. NUM’s market-leading Flexium+ CNC platform offers a choice of three configurations of CNC kernel, enabling machine designers to create cost- and performance-optimised control systems for a wide range of automation. In addition to the high end Flexium+ 68, the product series includes two configurations for less demanding applications. Flexium+ 6 has a single CNC channel, can control four interpolated axes and a spindle, and is designed for machines of low to medium complexity. Flexium+ 8 is designed for more complex applications; it provides two CNC channels, either of which can control up to five interpolated axes, or four interpolated axes and a spindle. The Flexium+ platform is backed by powerful software. All CNC, servo drive, I/O, automation PLC and safety PLC functions are programmed using a single unified toolset. A fully customisable HMI allows users to add value to their machines, through improved ergonomics and touch-sensitive controls. NUM’s application support software covers a broad range of machining functions, including part grinding, tool grinding, turning, milling, gear hobbing, shaping and finishing, as well as water-jet, laser and plasma cutting. Many of these software packages are nowadays regarded by machine tool manufacturers and users as industry standards.

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

ENGINEERING REVIEW |

49 | October 2015

POWER » BUSINESS NEWS

Prith Banerjee joins Schneider Electric as Chief Technology Officer

chneider Electric, the global leader in energy management and automation, announced the appointment of Prith Banerjee as its new Chief Technology Officer. Prith will be in charge of accelerating Schneider Electric’s R&D throughput and of driving the Innovation and R&D simplification programs under the Company Program “Schneider is On”. He is also a member of the Schneider Electric Executive Committee. Prith brings with him a wealth of experience in Technology R&D. His joining comes at a critical point of transition for the Indian and global industry, in which the business and societal landscape are being transformed by urbanization, digitization and industrialization. Prior to joining Schneider Electric, Prith was associated with Accenture as the Managing Director of Global Technology. He was responsible for overseeing Accenture Technology R&D group, leading the Technology Labs which explores new and emerging technologies, directing Accenture’s annual Technology Vision research, and supervising Accenture’s Open Innovation program with startup companies and universities. In the past, he has also been associated with organizations like ABB as the Chief Technology Officer and Executive Vice President, and HP as Senior Vice President of research and Director HP Labs. Prith has spent a major part of his career as a Professor, Department Chairman, and Dean at the University

Mr. Prith Banerjee Chief Technology Officer

of Illinois, and Northwestern University. He holds a Ph.D. in Electrical and Computer Engineering from the University of Illinois at Urbana-Champaign. Schneider Electric invests heavily in R&D and innovation, thereby connecting its products and systems through the Internet of Things, making energy more distributed and connected. The In India, for India solutions that are expected to evolve under Prith’s able guidance relies on optimized automation and control, advanced remote management, predictive maintenance, enabling managed services, advanced analytics and generation of actionable information to drive informed decision-making in our homes, manufacturing facilities, data centers, buildings and cities. Schneider Electric India R&D facilities and systems serve not only India but the world. With a specialised work force of 1500 people dedicated to R&D and state of the art facility “Innovare” that houses the team and labs, the company has put all its might behind innovation for the future. In sync with the strong government focus on Make in India, Schneider Electric is confident that its superior basket of innovative, cutting edge technological solutions will transform the industry. Schneider Electric India is proud to have an Indian at the helm of Global R&D and is looking forward to reaching new heights of technological excellence. Web: www.schneider-electric.com

Fluke 1736 & 1738 Three-Phase Power Loggers

luke 1736 and 1738 Three-Phase Power Loggers deliver comprehensive data to optimize system reliability and savings. Automatically capture and log more than 500 power quality parameters to thoroughly analyse energy consumption and power quality. Fluke Corp. introduces the 1736 and 1738 Three-Phase Power Loggers, which automatically capture and log more than 500 power quality parameters to give technicians and engineers more visibility into the data needed to make better power quality and energy consumption decisions. The power loggers capture and log voltage, current, power, harmonics, and associated power quality values to deliver comprehensive data for load studies, energy assessments, harmonic measurements, and voltage event. The included Fluke Energy Analyze Plus software provides detailed analysis of energy consumption and power quality and generates reports automatically. They feature an optimized user interface, flexible current probes, and an intelligent measurement verification function designed to reduce measurement errors by digitally verifying and correcting common connection errors. Set up can be further simplified by powering the logger 50 | OCTOBER 2015 | ENGINEERING REVIEW

directly from the measured circuit. The Fluke 1736 and 1738 are the first three-phase power loggers designed to work with the Fluke Connect® system of software and wireless test tools. Fluke Connect tools allow technicians to wirelessly transmit measurement data from their test tools to their smartphones for secure storage on the Fluke Connect® Cloud and team access from the field.* With the Fluke Connect smartphone app, the data from the power loggers can be viewed from a safe distance, reducing the need for protective equipment, site visits, and check-ins. About Fluke : Founded in 1948, Fluke Corporation is the world leader in compact, professional electronic test tools. Fluke customers are technicians, engineers, electricians, and metrologists who install, troubleshoot and manage industrial, electrical and electronic equipment and calibration processes. Fluke is a registered trademark of Fluke Corporation. The names of actual companies and products mentioned herein may be the trademarks of their respective owners. For more information, visit the Fluke website. www.fluke.com/powerquality. www.engrreview.com

POWER » BUSINESS NEWS

V-Guard’s Kashipur Factory Felicitated as Bronze Winner in National Awards for Manufacturing Competitiveness (NAMC)

ndia’s leading consumer electrical and electronics company - V-Guard Industries Ltd.’s Kashipur factory was felicitated as the Bronze Winner in National Awards for Manufacturing Competitiveness (NAMC) instituted by International Research Institute for Manufacturing (IRIM) for the year 2014-15. This award was received by Mr. R. P. Singh – General Manager, Kashipur, V-Guard Industries Ltd. at a glittering ceremony held on 7th August, 2015 at ITC Grand Chola, Chennai. Mr. Anand Louie, Director-IRIM welcomed the gathering and spoke about the optimistic trend prevailing in the Indian manufacturing scenario despite the challenging times at the global arena. The Chief Guest of the function was Dr. S. K. Nanda, IAS, Chairman and Managing Director Gujarat State Fertilizer Corporation Limited. Dr. S. K Nanda distributed the awards, addressed the gathering and encouraged the participants to adopt the global best practices. He also discussed about the development of new technology and innovative products and hinted that improving environmental health & safety standards will be a key to growth in sustaining manufacturing standards in India. Sharing his thoughts regarding this achievement, Mr. Mithun Chittilappilly – Managing Director, V-Guard Industries Ltd. said “It is a moment of great pride and honour for us to have won this prestigious award instituted by International Research Institute for Manufacturing. We at V-Guard strongly believe in adapting to changing trends of this highly competitive and dynamic consumer electricals and electronics industry. V-Guard is committed to 52 | OCTOBER 2015 | ENGINEERING REVIEW

From Left to Right : Mr. Anand Louie, Director, International Research Institute for Manufacturing(IRIM) is standing on the extreme left Dr S. K. Nanda, IAS , Chairman & Managing Director, Gujarat State Fertiliser Corporation Limited is handing over the award to Mr. R. P. Singh General Manager, HWC Factory, V-Guard Industries Limited, Kashipur, Uttarakhand. The others are : Mr. Gnana Reuben, Senior Manager Quality Assurance – Wires & Cables , V-Guard Industries Limited, Mr Ganeswara Rao, Proprietor-Surya Ganesh Electricals, Eluru.

upholding business values and innovation is in our DNA. We as an organization completely understand our responsibility to improve our products to meet our consumers’ preferences and requirements and at the same time abide by the set requisite health and safety standards. This accolade is a testament to our competitiveness in terms of our commitment towards our consumers and the environment at large.” Mr. Gnana Reuben, Sr. Manager- QA, V-Guard along with Mr. Harish, Sr. Manager-Mktg, V-Guard and Mr. Ganeswara Rao, Proprietor-Surya Ganesh Electricals, Eluru (AP) graced the occasion.

Mr. Kochouseph Chittilapilly to manufacture and market Voltage stabilizers. What started in 1977 with two employees and a burning passion is now a force to reckon with in the Indian electric and electronic goods panorama. The company has since then established a strong brand name and aggressively diversified to become a multi-product company catering to the Light Electricals sector manufacturing Voltage stabilizers, Invertors & Digital UPS systems, Pumps, House wiring/LT cables, Electric water heaters, Fans, Solar water heaters and has also recently forayed into Induction cooktops, Mixers and Grinders and Switchgears.

About V-Guard Industries Ltd. V-Guard Industries Limited is a Kochi based company, incepted in 1977 by

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

POWER » BUSINESS NEWS

Bajaj Electricals Ltd. IBMS unit bags “Best IBMS Company” Award Bajaj IBMS today has greatest potential for helping to solve and transform the critical business challenge using technological innovation. The same has been demonstrated in different vertical markets with Projects in Datacentre done on Wireless solutions so that Racks are movable and provide flexible options to datacentre owners and operators.

ajaj Electricals Ltd. is India’s leading consumer durable company with an equally strong presence in the lighting and EPC sectors in the country. Through constant stakeholder engagement and product innovation, we always inspire trust. Bajaj Electricals –IBMS Unit has been awarded “Best IBMS Company” by CIMS Healthcare Excellence Award in July 2015. Speaking at the occasion, Sr. GM and Head IBMS, Mr. Shakti Leekha said. “The Award encourages Bajaj IBMS to keep doing Customer delight, and getting new technologies, product & solution to market by innovating and creating smarter solutions which are Customer-Centric, Open Technology and Simple. Bajaj Electricals has entered into an alliance with Delta Controls to offer dependable, open-platform and user friendly building management system (BMS) and energy management systems (EMS) to commercial, healthcare, education, leisure buildings along with specialised applications for datacentres with energy management and energy reporting tools for energy efficiency. The building management systems provided by Delta Controls consists of controllers that operate on Native BACnet (BACnet/IP, BACnet Ethernet, BACnet MS/TP) along with options of controllers with hot swappable modules for easy maintenance and expansion and Power over

54 | OCTOBER 2015 | ENGINEERING REVIEW

Ethernet (POE) controllers which are IT friendly and future ready with wireless and EnOcean products. The software is designed as a Unified enterprise Platform for Building Automation, Access Control Solution and Lighting Controls with multisite management tools. The software consists of web-based application that combines the power of enterprise dashboards with easy-to-use facility management tools with customizable Energy Management dashboards and powerful energy reports give managers the tools to reduce consumption and drive down costs. Bajaj IBMS today has greatest potential for helping to solve and transform the critical business challenge using technological innovation. The same has been demonstrated in different vertical markets with Projects in Datacentre done on Wireless solutions so that Racks are movable and provide flexible options to datacentre owners and operators. We have been engaged with close to 100 datacentres in last three years only in India and have demonstrated a clear leadership with multiple tier 3 level Datacentre delivered for full range of solutions on IBMS. We today help business by ensuring Buildings work better and help in expanding the bottom line by delivering energy efficiencies and creating a smarter efficient & productive building. Projects done with Radisson Hotel, Goa and Cosmos Bank Headquarters, Pune, are deriving value in

different business environments Hospitality and Banking by using these systems. Bajaj Electricals- IBMS now has the products and solutions for Internet of Things (IoT) and the ecosystem of system integrators to move from smart buildings to smart cities and ensuring conservation of energy. To sustain and gain momentum in bringing this change for smart infrastructure we today have created an eco-system of 30 System Partners who are up-skilled to ensure we develop and maintain the building technologies and solutions. This skilled expert’s pool is growing and by next financial year expect to have 50 system partner organisations working together with Bajaj IBMS to bring this change.

For more information www.bajajelectricals.com www.engrreview.com

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

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POWER » BUSINESS NEWS

REC signs MoUs for Rs.9000 Crores with APGENCO and APTRANSCO

Delta introduced PMH Panel Mount Power Supply Series for Household Applications Highlights & Features Household appliance approvals IEC/EN 60335-1, IEC/ EN 61558-1 and IEC/EN 61558-2-16 • Universal AC input voltage • Full power from -20°C to +50°C operation at operating altitude 5000m • Full corrosion resistant aluminium casing • High MTBF >700,000hrs as per Telcordia SR-332 • Versatile connector options: IP20, Front Face and Harness connectors

EC signed two MoUs for Rs.9000 crores with APGENCO and APTRANSCO. The MoUs were signed in the presence of Hon’ble Chief Minister of Andhra Pradesh Shri N. Chandra Babu Naidu, by Shri Rajeev Sharma, CMD, REC and Shri K.Vijayanand, MD, APGENCO & CMD, APTRANSCO at New Delhi. Secretary, MNRE, Principal Secretary (Energy) to Government of Andhra Pradesh and other dignitaries of APTRANSCO, APGENCO and REC were also present on the occasion. The MoU with APGENCOis for Rs.3,000 crores for setting up a 500 MW Solar power generation project in Anantpur during the 12th Plan Period. The MoU with APTRANSCO is for Rs. 6,000 crores for Transmission & System improvement projects in the Capital region of Andhra Pradesh. The objective of MoUs is enhancing the generation of Green Power and for creation of Transmission network in Andhra Pradesh. REC, a Government of India Navaratna Enterprise, having an asset base of Rs 183175 crores, provides financial assistance for Rural Electrification / System Improvement / Augmentation of transmission and distribution systems and all types of power generation projects including renewables. REC during the financial year 2014-15 sanctioned loans amounting to Rs. 61,421 crores and disbursed Rs.46,446 crores in the same period with net profit of Rs.5,259 crores. REC is also the Nodal agency for implementation of Deendayal Upadhyaya Gram Jyoti Yojana (DDUGJY) and National Electricity Fund (NEF). For more information editor@divyamediaonline.com 58 | OCTOBER 2015 | ENGINEERING REVIEW

elta Electronics, Inc., a global leader in thermal and power management solutions extended its PMH panel mount power supply series with a higher maximum output power at 24V 200W. The product comes with several connector options consisting of Terminal Block, IP20, Front Face and Harness connectors. The PMH-24V200WCBA provides universal input from 85Vac to 264Vac and high efficiency of > 91.5% @ 230Vac in a full corrosion resistant aluminium body. The highly efficient convection cooling construction can operate between -30°C to 70°C. The PMH series is specifically designed for household electrical appliances with safety approvals including IEC/EN 60335-1 and IEC/EN 61558-2-16 as well as IEC/EN/UL 60950-1. In addition, the product meets the EMC approvals to EN 55014-1 / EN 55014-2 for household appliances and EN 61000-6-1 / EN 61000-6-3 for residential environment without extra EMI filter required. New solutions are introduced on a regular basis. For more information or enquiries, please visit www.DeltaPSU. com.

For more information Delta Group, Web: www.deltaww.com

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POWER » BUSINESS NEWS

“ELECTROMATION INDIA 2016” : The biggest trade fair in Vadodara Gujarat- Power hub of the Gujarat “. “ELECTROMATION INDIA 2016” will be held from 7th to 9th January, 2016 at Akota Stadium, Vadodara, Gujarat.

LECTROMATION INDIA 2016 is the Gujarat’s first ever focused Exhibition on Automation, Instrumentation, Electronics and Electricals. “ELECTROMATION INDIA 2016” will be held from 7th to 9th January, 2016 at Akota Stadium, Vadodara, Gujarat. ELECTROMATION INDIA 2016 will be a very healthy platform for bringing togetherness by increasing SPEED, SCALE & SKILL development through the focused exhibition on ELECTRICAL, ELECTRONIC, INSTRUMENTATION & AUTOMATION. With the advancement in technology and new products & services, the Indian industries now are waking to the global demands. ELECTROMATION INDIA 2016 is instituted to showcase to the Indian industries, the new technologies, advancement, systems and services being available. Mr. SURINDER KUMAR NEGI Managing Director of Gujarat Energy Transmission Corporation Ltd (GETCO), said The SPARK MEDIA has aptly selected the theme “ELECTROMATION”, which signifies integration of Electrical, Electronics and Automation. There have been several inorganic and organic changes in the manufacturing sector in last two decades and in the journey, we have shifted from conventional manufacturing to lean manufacturing processes. Automation in the Electrical and Electronics machines brought a paradigm shift to make manufacturing sector cost effective, quick & fast, scalable and more accurate and reliable. The role of Information Technology and human 60 | OCTOBER 2015 | ENGINEERING REVIEW

skills made processes efficient and sustainable with minimum human interface. Mr. S.R. Bhatt, Director General of CPRI (Central Power Research Institute) said that ELECTROMATION INDIA 2016 will help Industry to boost Indian exports of equipments of Automation to the entire World thereby strengthening the “MAKE IN INDIA” campaign. CPRI is sure that ELECTROMATION INDIA 2016 will address many of the challenges faced by the Power Sector also, wherein the Power Utilities can be benefited from the take-away in the areas of Power System Automation and Smart Grid. ELECTROMATION INDIA 2016 exhibition will definitely elevate the business of Gujarat state to the global, said Gokul Sagpariya President of RAJKOT ENGINEERING ASSOCIATION. Dr. Akshai Aggarwal, Vice-Chancellor of GTU (Gujarat Technical University) said that GTU has been working jointly with industries through GTU Innovation Sankuls (Industrial clusters of the area). It has been working with the students through the GTU Innovation Clubs, Open Source Technology Clubs, Mobile & Wireless Technology Clubs, S-4 Extension Centers etc. GTU’s Faculty Development Program is the largest such program in the country. India needs good technologists in all the different fields of technology. ELECTROMATION INDIA 2016 Expo in Vadodara will provide good amount of opportunities for innovative new technologies and open new source of technology. Let us, therefore, work together during ELECTROMATION

INDIA 2016. ELECTROMATION INDIA 2016 is well supported by many Organizations such as International Association of Automation ( ISA), Gujarat Energy Transmission Corporation Ltd (GETCO), Central Power Research Institutes ( CPRI), Gujarat Technical University ( GTU) and various industries associations like All India Electronic Association ( AIREA), Jamnagar Factory Owners Association, Dahej Industrial Association, Gujarat Safety Council, Vadodara, Rajkot Engineering Association and Federation of Small Scale Industries, Vadodara. ELECTROMATION INDIA 2016 is the Gujarat’s First Ever Focused Exhibition on Electricals, Electronics, and Instrumentation & Automation and also Gujarat is a land of limitless opportunities. The main objective and purpose to hold this ELECTROMATION INDIA 2016 in because it is an important industrial, cultural and educational hub of western India... and its right on the corridor of DMIC (Delhi-Mumbai Industrial Corridor) Major industries include Power, Petrochemicals, Engineering, Chemicals, Pharmaceuticals, Plastics, IT etc. ELECTROMATION INDIA 2016 will help all AUTOMATION EQUIPMENT MANUFACTURERS to reach out to their respective customers in customised Sector. Welcome to ELECTROMATION INDIA 2016 at Akota Stadium, Vadodara, Gujarat! For more information www.electromationindia.com www.engrreview.com

COVER STORY

Tennyson Anthony General Manager - Sales Tranter India Pvt. Ltd.

Technology leadership in heat transfer specialization Q. Being the key player in heat exchangers business, Please brief us about recent initiatives undertaken in Chemical and Process equipment industry? The chemical and Process equipment

62 | OCTOBER 2015 | ENGINEERING REVIEW

industry in the past one year has taken cautious steps to prepare the ground for taking advantage of the expected uptick in the Indian economy. We will see enhanced investment coming into the sector once the

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COVER STORY

uptrend looks sustainable.

Q. What are the market opportunities for Chemical & Process equipment industry in India? The major market opportunities going forward would be coming from the power sector – Thermal, Nuclear & Renewables with nuclear leading the way though this sector will continue to be a price sensitive market. The refining and downstream oil & gas sector will also see renewed investment flowing in with the crude prices dropping and sustaining at lower levels. Our storage tank heating (plate coil) solutions comes into play for this segment apart from welded product range (SPW & DPW) for high temperature and pressure applications. The government decision to boost ethanol production by making 10 per cent blending with petrol mandatory starting October 2015 will see good opportunities from this sector & we are well positioned to tap this opportunity

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with our “Tall Boy”range of wide gap gasketed plate heat exchangers for high fouling duties.

Q. The incisive competition leads to work on lower profit margins, how do you tackle this position by implementing what kind of marketing strategy? The market downturn has led to reduction in project enquiries with the profit margins shrinking. As an organization we have focused on improving our channel partner network to improve our reach & provide faster service to our end users. Our endeavor is to support our customers during the life cycle of the heat exchangers both onsite & also at our well-equipped service center in Pune. The focus is also on looking for opportunities for conversion of existing heat transfer equipment to plate type heat exchangers by stressing on the total cost of ownership & the return on investments. We continue looking for new opportunities in the heat recovery segment utilizing our efficient range of plate heat exchangers. At the same time we are in the

ENGINEERING REVIEW | OCTOBER 2015 | 63

COVER STORY

process of making our post order execution system robust to ensure customer delight at every touchpoint. Satisfied customers lead to profitable business.

Q. According to your opinion how does the synergy of R&D & technology developments is maintain to maintain the position in the market? To stay ahead of the curve an organization has to anticipate the changing requirements of the marketplace. Even in a mature product line there is always a possibility to innovate and bring technology development to the existing product which can turn out to a game changer in the long run. R&D plays an important role in ensuring an organization retains its leadership position. Tranter is committed to product innovation and the well-equipped test lab in our Pune plant plays a major role in testing new product innovations & improvements which are designed by the global R&D team.

Q. What are the recent development in Chemical & Process equipment sector? The growing global focus on energy efficiency against a backdrop of depleting fossil fuel resources, rising focus on green energy and emphasis on curbing environmental pollution and climate, is poised to benefit the market for energy efficient compact plate heat exchangers. Stringent wastewater treatment laws, against a backdrop of rising levels of water pollution and contamination, are providing fertile opportunities for the growth of heat exchangers in wastewater treatment plants

Q. Could you brief us on Indian & Global perspective of Chemical & Process equipment industry? With the current downturn in the global economy we will see consolidation in the sector which will lead to efficient usage of resources. In India

64 | OCTOBER 2015 | ENGINEERING REVIEW

we should see opportunities coming from heat recovery applications wherein customers would previously have not used a heat exchanger or would have been using an inefficient method of recovery.

Q. According you what are the factors affecting to Chemical & Process equipment business? Project delays due to noncompliance of various regulatory norms would still be the major stumbling block for business to pick up in India apart from the global economy slowdown. Also a lack of focus on the long term costs of owning a heat exchanger is another stumbling block for the growth of this business in India.

Q. What are the key technological trends that are driving Chemical & Process equipment industry? The highly mature global heat exchangers market is set to thrive on replacement demand coming from frequent upgrades and incremental technology improvements with energy efficiency benefits driving migration from shell and tube to compact plate heat exchanger solutions. Also poised to drive future gains are innovations that help lower total ownership costs and increase durability and efficiency of heat exchangers.

Q. What is your vision for your company? We would like to identified as an organization which would be the customerâ&#x20AC;&#x2122;s first choice when it comes to their requirement for energy efficient & compact solutions for heat transfer.

Q. Please let us know the issues you need to address that are related to Chemical and Process equipment industry. We need to improve the knowledge of customers related to how an inefficient method of heat transfer is leading to higher operating costs & lower yields and productivity. With our focus on the total cost of ownership of a Tranter plate heat exchanger we help the customer save on their operating costs in terms of not just using a more efficient heat transfer solution but also in saving on operating costs of allied equipment like pumps .

Q. What is your advise to the Indian Chemical & Process equipment manufacturers to achieve global competitiveness? The heat transfer fraternity needs to bring the spotlight on issues related to inefficient heat transfer methods & focus on reducing downtime on their equipment by bringing in innovative solutions for life cycle management of their products.

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ENGINEERING REVIEW |

65 | October 2015

IN FOCUS

Smart Grid technology : Revolutionising the economic growth Indian companies can cater to the needs of reliable power for the Smart Cities in India if they build their solutions with the latest available technologies ensuring the required quality and features. Mr. Vikram Gandotra, Chairman Smart Grid Division, IEEMA

Q. Can you comment on the journey status of SMART GRID over the last five years? How do you foresee the next five years? Do you feel AUTOMATION plays important role in metering Power, Electricity in coming future? Smart Grid is a journey of the utilities which manage the value chain of power generation , transmission and distribution, towards improving the experience of the end consumer. This journey involves leveraging the benefits of ICT to improve the various processes such as Metering and Peak Load Management, improving the reliability of power supply. There have been some initiatives taken by certain utilities and these have shown positive results. The utilities in cities like Delhi, Mumbai, Kolkata amongst others have been on the forefront in working on newer ways to bring the positive changes in their operations. The Government of India and state owned utilities on their part has been working on providing the basic framework through the very 66 | OCTOBER 2015 | ENGINEERING REVIEW

ambitious R-APDRP program and now the IPDS scheme. These programs have played a very important role and the results will be seen in the coming years. There is still a very long way to go and with proper commitment and planning the utilities are on their way to transform the experience of their consumers. Q.SUB QUESTION: Tell us in brief about the importance of SMART GRID for SMART CITIES! Do you feel Indian Companies can cater the needs for power, Electricity for SMART CITIES? As you know the concept of Smart Cities consist of several sub-systems covering areas such as Transit, Security, Water, Power and waste management. What is important to keep in mind is that all the other sub-systems need a very reliable power supply which is what the Smart Grids will ensure. In other words Smart Cities will be built on a strong foundations of Smart Grids. Indian companies can cater to the needs of reliable power for the Smart Cities in India if they build

their solutions with the latest available technologies ensuring the required quality and features. With the globalization the companies have access to the latest technologies but need to have strong local R&D and product development in place. Q.What are the major challenges faced by the SMART GRID MANUFACTURING Industry and your suggestions to combat them? What are the plans by SMART GRID division of IEEMA to resolve these issues? Some of the most important challenges that are being faced by the Industry is the inconsistency of budgeted cost of pilot projects in comparison to the actual costs and the unpractical financing conditions which have led to the inherent delays and uncertainty in the launch of Smart Grids. Also the preparedness of the utilities with respect to the basic requirements and the willingness to change the existing processes need to be improved. Continue on page no.68 www.engrreview.com

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Continued from page no.66 The motivation of the utilities staff especially at the lowest levels to bring in technology to improve the transparency is another area that needs attention. Delays and unclear terms and conditions lead to uncertainty of investment decisions for the manufacturing industry. On both the industry & utilities side, there needs to be an awareness that the newer products and technologies will have lower lifecycle than the conventional products but the benefits from these technologies will come with a higher rate of return. Both these types of products have to work together and hence there have to be solutions of technology and processes accompanied with the new mindset. IEEMA SG Division is working with various stakeholders to address these issues in a pro-active manner. Q. Do you think the Government ( Central & State) is doing enough for promoting Smart Grids ? The governments both at Central and State level have started taking some steps such as notification of National Smart Grid Mission which will be the apex body. However the process needs to be expedited to bring in more clarity at all levels. Also the state utilities need to appreciate the benefits of the Smart Grid technology and solutions and encourage these projects to be completed at the earliest. Smart Grids require a very strong communication network and one of the popular and cost effective communication is through the network of mobile telcos. This has proved to be a weak link as the business interests of utilities and telcos do not converge for telcos to give adequate importance to the needs of the utilities. A mechanism needs to be built by the Government ministries/ bodies to give priority to the needs of the utilities 68 | OCTOBER 2015 | ENGINEERING REVIEW

otherwise the utilities will have to seriously think of having their own dedicated communication network. Q. What do you feel the industry should be doing to promote the technologies and help the customer? What are your expectation from ELECRAMA 2016 for the Industry? How ELECRAMA 2016 will benefit to Industry? The industry on the one hand needs to educate the government bodies, utilities and consumers on the benefits of the Smart Grid Technology and on the other hand work on strengthening their capabilities of manpower and technology in order to deliver consistent quality products and solutions which live up to the promised benefits. The Industry and Utilities will need human resources with the new skill sets and both together must find ways to work with the academic institutions so that our future engineers come well prepared. Industry players need to look beyond short term business goals and look at the larger perspective and thus due care needs to be paid to conformance of standards and inherent good quality in the products. Indian industry needs to play a more active role in standardisation. Elecrama 2016 provides a unique platform to the Indian manufacturing community to not only display their latest products but also engage with the various stakeholders to prepare for the future growth in Smart Grids. Q. What were some of the achievements and challenges during your tenure as the chairman of IEEMA , SMART GRID division so far? What is the way ahead for the division? IEEMA Smart Grid Division is one of the youngest Divisions of IEEMA and in the short time I am happy to share the Division has engaged

with all the stakeholders actively. I along with my divisional members have organized special sessions with free exchange of views between the IEEMA members, representatives from ISGTF, CEA and independent consultants. Smart Grids cover not only the Power and Automation Industry players but also touch the IT and Communication players who may not be IEEMA members. In order to close this gap we have also invited some important partners of the power industry such as IT and Communication solution providers for discussions to develop better understanding of issues and concerns of each other and find acceptable solutions. The IEEMA Smart Grid Division will continue to engage with all the stakeholders of the Smart Grid space and bridge the gaps between them for developing sustainable business models. One very important aspect of the Division is to support the members who wish to develop into technology, product or solution providers for Smart Grids by providing them the required platform. IEEMA has members who are experts in all the areas of power sector and also the members may be very small enterprises or very large global corporations. I see this as a unique and very powerful constellation of resources which are available in the IEEMA SG division which will truly play a very significant part in success of Smart Grids in India.

Mr. Vikram Gandotra works as General Manager at Siemens Gurgaon and heads the Strategy & Marketing function for Digital Grid business.

He may be contacted at vikram.gandotra@siemens.com

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MACHINE TOOLS » Tech Trends

Workpiece inspection & tool setting probes from Renishaw help Vasantha Tool Crafts increase machine utilisation time by 20%

asantha Tool Crafts Pvt. Ltd. established a plant at Coimbatore in 1989 to manufacture injection moulded parts. From its inception, the company has provided complete solutions to its customers, from product design to manufacturing. With the help of Renishaw’s RMP600 touch trigger probe and TS27R tool setting technology, Vasantha Tool Crafts has successfully increased the utilisation of every one of its machine tools by 20%, and reduced part setting process time from one hour to just three minutes.

Mr R. V. Rao, General Manager of Vasantha Tool Crafts Pvt. Ltd. uses Renishaw products for reducing breakdowns and increasing value

Productivity solutions According to Mr. R. V. Rao (General Manager): “In order to manufacture precision components it is vital to follow the right process, from initial design to the final quality check. Precision and quality are the company’s hallmarks, and in this respect the decision to utilise Renishaw systems has been very beneficial, as they not only encompass the best productivity solutions but are also

highly reliable. These solutions are used with various product mixes, reducing breakdowns and increasing value.” The company initially employed manual part and tool setting methods using dial gauges and a ‘tools via block’ method. Setting using these methods took hours to complete as everything was dependent on individual operator skill and experience. After replacing these time consuming manual processes with automated Renishaw probing systems, Vasantha Tool Crafts Continue on page no.72

RMP600 - Compact high-accuracy 3D measurement touch probe

70 | OCTOBER 2015 | ENGINEERING REVIEW

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20 - 21 November 2015 2015

Hotel Crowne Plaza, Gurgaon

To champion the cause of productivity in the metal working industry, Indian Machine Tool Manufacturers' Association (IMTMA) is organizing the National Productivity Summit (9th in the series) on 20 – 21 November 2015 at Gurgaon. The event showcases best productivity practices in metalworking through live case study presentations, Plant visits and Keynote sessions.

Leaders Speak Renowned industry experts will deliver Keynote addresses on various facets of productivity. Ø ‘Ascent : A Practising Manager's Growth Mantra’

Live Case Study Presentations ! Contesting Companies

Mr. Amit Chatterjee, Managing Director, Sartorius India Group

Ø ‘Hitech’s Journey in achieving productivity excellence’

Mr. Rajesh Magoo, Chief Operating Officer, Transmission & Engine Component Business, Hitech Gears

Ø ‘Quality Route to Productivity’

Mr. Rajeev Wasan, Sr. Vice President - Manufacturing, Honda Cars India Ltd.

Ø ‘Challenges in improving metal working productivity’

Mr. M M Singh, Executive Adviser, Maruti Centre for Excellence*

Plant Visits (19 November 2015) The plant visits scheduled a day prior to this summit, on 19 November 2015, provides an excellent opportunity to witness productivity improvements on the shop floor.

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TOUR A : Hero Motocorp and Sona BLW Precision Forgings or TOUR B : Hitech Gears and Honda Motorcycle & Scooters India

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MACHINE TOOLS » Tech Trends

Continued from page no.70 has been able to optimise cycle times, thereby reducing costs and achieving significant improvements in quality and reliability. Solutions implemented Vasantha Tool Crafts installed the Ren‑ ishaw RMP600 – a compact, high‑accu‑ racy‑touch trigger spindle probe with radio signal transmission – to enable automated job set up. The company also installed the TS27R contact tool set‑ ting probe to enable broken tool detec‑ tion and rapid tool length/diameter measurement. As well as the significant reduction in part set‑up time enabled by the RMP600, the implementation of the TS27R has also benefitted the com‑ pany. It has reduced the time taken to set tool offsets by 80% and significantly decreased human error, leading to a reduction in scrap. Setting parts and tooling using Renishaw probes has increased productivity, throughput and machine up time, giving Vasantha Tool

RMP600 probing the mold plate

Crafts a competitive edge. The company has now decided to install Renishaw probing systems on all of its machines as part of its quality control policy. Mr. A. Dayanand Reddy (Manag‑ ing Director) says: “Renishaw probing systems have been beneficial as they encompass the best productivity solu‑ tions, which are impeccable and highly

dependable. These solutions are also extremely versatile, ensuring that the company is on the right track. Renishaw has been a trustworthy partner in pro‑ viding a complete solution and trans‑ forming our manufacturing process.” For more information Web: www.renishaw.com

Machining set up at Vasantha Tool Crafts Pvt Ltd

72 | OCTOBER 2015 | ENGINEERING REVIEW

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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.

74 | OCTOBER 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 generation plants, cement manufacturing plants and other heavy engineering Continue on page no.76 www.engrreview.com

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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

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.”

Continued from page no.74 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 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. 76 | OCTOBER 2015 | ENGINEERING REVIEW

Primo – twin probe system

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

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 Web : www.renishaw.com www.engrreview.com

ENGINEERING REVIEW |

77 | October 2015

MACHINE TOOLS » Tech Trends

HAAS : HE307-CS The owner of CNC-Bearbeitung Jürgen Buss GmbH, a thriving subcontractor in southern Germany, is a lover of all things American, including classic cars, motorsport (especially NASCAR), and Haas machines. Since he began his company in 1992, he has made impressive progress, thanks in large part, he says, to his investment in several Haas CNC machines, including a UMC-750 five-axis universal machining centre. Haas and the need for speed Located around 40 km north of Stuttgart, CNC-Bearbeitung Jürgen Buss GmbH (known locally as Buss Toolmaking) has earned its reputation as a competent and reliable partner in CNC machining and toolmaking to industries such as automotive, medical, environmental, and agriculture; the wisdom of not allowing more than 10 to 15 percent of turnover to be spoken for by any single customer demonstrates astute management. Indeed, this ethos is applied similarly to its machine tool investments, exploiting the industry-leading, price-specification ratio of Haas machines to ensure the company can compete in a highly competitive subcontract arena. Overseeing the company is owner and founder Jürgen Buss. Mr. Buss ended his employment with a local engineering firm at the age of 26, 23

78 | OCTOBER 2015 | ENGINEERING REVIEW

years ago, opting instead to use his CNC machining background to begin his own company milling plastic components that formed part of systems for chimney gas measurement. The systems were successful, and as well as several contracts for steel components, he had the beginnings of his business. So far, he hasn’t looked back. Mr. Buss acquired his first Haas machine in the mid-1990s as a cost-effective, high-quality alternative to the established German, Swiss, and Japanese makes prevalent in the local market at the time. Several Haas CNC lathes were acquired to run alongside four Haas CNC Super Mini Mills. And, although the global downturn of 2009 meant the company had to restructure and sell some of its capacity, the Continue on page no.80

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MACHINE TOOLS » Tech Trends

Continued from page no.78 revival of the economy at the turn of the decade soon saw Mr. Buss back on the Haas investment trail. The latest arrival is a Haas VM-6 vertical mouldmaking machine,” he says, “which joins a VF-2 vertical machining centre, a VF-2SS super-speed vertical machining centre, a DT-1 drill/tap centre, and a UMC-750 five-axis universal machining centre that was installed in January 2014. The Haas machines, which run for 10 to 12 hours a day, process all kinds of materials, ranging from plastics and aluminium castings, through

80 | OCTOBER 2015 | ENGINEERING REVIEW

brass and steel, to stainless steel and hard alloys. Batch sizes are anything up to 1000-off.” Mr. Buss admits he has a soft spot for American engineering. He owns a Ford Mustang and a Jeep, as well as the obligatory Harley Davidson. Of course, he has already visited the Haas factory in Southern California to see where his machines are designed and built. “The story of Haas is very interesting,“ he says. “The company’s history was explained to me, and I have total admiration for what Gene Haas and his colleagues have achieved. The idea of creating a virtually modular machine tool system based on low cost but high quality was a masterstroke. The success of the machines is mirrored by the success of the company’s NASCAR team, Stewart-Haas Racing. In fact, NASCAR racing was definitely a highlight of the trip; a unique experience. Utter madness! The whole world is now curious to see if this success can be replicated in Formula One.” Mr. Buss’s love of racing is repeated in his machine shop. As well as mounting several vises on each machine to give high throughput – the UMC-750 houses a pair of vises, the VM-6 has three vises, while the DT-1 has four – the high-speed machining option in the Haas control also features on every

machine. The high-speed machining option works by analysing the change in vector direction, or change in angle, from one block to the next. When the change in vector direction is very small, as with code produced by using a small cut tolerance value, the control can interpolate the motion at a higher feedrate than when the change in vector direction is greater. Impressively, the Haas high-speed machining option can process at a speed of up to 1000 blocks per second – that’s one block every one-thousandth of a second! Today, the ISO9001 accredited company run by Mr. Buss has customers as far away as 100 km, securing new contracts largely through recommendation. Mr. Buss concludes: “Put simply, the speed and precision of Haas CNC machine tools – tolerances are often in the realm of 0.005 to 0.01 mm – have made our company the envy of the German subcontract machining industry.”

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

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

Rollon Group opens in India

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ROLLON India Pvt. Ltd. - INDIA 1st ďŹ&#x201A;oor Regus Gem Business Centre 26/1 Hosur road, Bommanahalli Bangalore 560068, INDIA www.rollonindia.in - info@rollonindia.in

ENGINEERING REVIEW |

81 | October 2015

MACHINE TOOLS » Tech Trends

The new »Minis«: Now compatible with the Hainbuch modular system

ometimes small things turn out to be a big success. And that’s true for the mini chucks. But one thing they haven’t had until now was compatibility with the Hainbuch modular system. That’s no longer the case, and of course this includes both series of chucks: the round Spanntop and the hexagonal profile Toplus. Because of its reduced interference contour, to be able to use the modular system the Spanntop mini chuck comes with an adapter ring. The existing Mando Adapt mandrel and jaw module work perfectly with the new Spanntop mini. The Toplus version does not use an adapter ring, instead it has ring of attachment holes for fixing the jaw module, and next year it will get its own Mando Adapt series of adapters. And finally, as another piece of good news, Spanntop and Toplus minis both have full through-bore and are available in three standard lengths to suit all machines and drawtubes.

Pictures 1: Set-up for any draw tube position with three versions of the Spanntop mini chuck.

Reduced clamping device interference contour and less mass These two factors play an ever more important role in any machining process. Tool accessibility and low energy consumption are key criteria for modern workholding making them ready for the challenges of the future. Increasingly parts have smaller dimensions and higher tolerances than in the past, So the emphasis is no longer on the chuck size but rather on the complete process. Thanks to greater tool accessibility, the mini

chucks can use shorter and therefore more stable tools on the main and counter spindles. This again has a direct influence on the surface finish. Not only is the mass reduced by over 38%, the chuck diameter and the total lengths have also been considerably reduced [by a third or a quarter]. So the “little” chucks make a “big” difference. The reduced interference contour makes it easier to choose the right tool and this helps with the issue of reduced space especially in counter spindle machines. The reduced mass is also results in lower energy consumption especially in mass production. Because spindle acceleration and deceleration are more dynamic this shortens the cycle times, and all this contributes to lowering the cost per workpiece.

Hainbuch at the EMO 2015 in Milan: Hall 4. Stand B06

Pictures 2: The mini product series with Hainbuch’s tried and trusted modular system.

82 | OCTOBER 2015 | ENGINEERING REVIEW

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Competence and experience – Added value for customers Klüber Efficiency Support helps increase food safety and protect valuable resources

ext to a lubricant that is optimally suited for the respective application, its proper handling is also essential for food safety. In particular within a sensitive area such as the food-processing industry, stringent requirements have to be met. Therefore, Klüber Lubrication offers a wide range of speciality lubricants and services for the food sector. In addition, KlüberEfficiencySupport can help protect valuable resources such as energy and water, thus helping to reduce operating costs. “Klüber Lubrication is more than just a manufacturer of speciality lubricants”, explains Aldemir Oliveira, Global Market Manager Food Industry at Klüber Lubrication. “We as the specialist offer our customers a comprehensive lubrication package. Lubricant users benefit from our experience and tribological know-how and do not have to worry about finding the optimum solution for their particular application themselves.” The services and consulting services combined under the keyword KlüberEfficiencySupport are precisely tailored to the requirements and challenges of the respective customers – far exceeding the actual lubrication issue. In close cooperation with lubricant users, the tribology experts of Klüber work on the systematic optimisation of lubrication processes in the plant. This

84 | OCTOBER 2015 | ENGINEERING REVIEW

includes services such as the development of lubrication schedules, cleaning and relubrication, general inspections as well as lubricant and component analyses. All this is aimed at the optimal utilisation of the machines and know-how of the staff. Another important offering from Klüber Lubrication is training tailored to the food-processing sector. Besides tribology basics and the properties of oils and greases, the lubrication of machine elements operating in the sensitive environment of the food-processing sector is at the focus of these Klüber College trainings. Participants learn about the optimisation of lubrication processes, inspections and maintenance, correct lubricant application and the prevention of typical errors such as excessive lubrication or lubricant starvation.

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

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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,

86 | OCTOBER 2015 | ENGINEERING REVIEW

PC|SCHEMATIC - and its distributors - offers a consulting service, consisting of an analysis of the already existing electrical documentation. Based on this analysis, the optimal set of subdrawings, models and project templates can be effectively created. This also has the consequence that new users can get started creating complete electrical documentation projects really quickly. In larger companies, this way of working might result in that just one single person needs to be pointed out as the main responsible for creating the company subdrawings, while the others in future almost only will need to create documentation by dragging templates and subdrawings into projects. Experiences from the industry suggest that the documentation time can be reduced by up to 80 percent. Why should I buy PC|SCHEMATIC Automation? People buying PC|SCHEMATIC Automation usually tell us they did it because: • It is easy to work with, and is very flexible in the everyday work routines. • The Module and Model Based drag’n draw functions, makes it possible to create electrical schematic pages extremely fast. • We have an excellent support team, and you can get support via NetViewer. Our support team can then see your screen, and guide you directly on your own PC. • Intelligent reuse of existing material - with intelligent renaming saves lots of time. Continue on page no.88

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Continued from page no.86 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.

• 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. 88 | OCTOBER 2015 | ENGINEERING REVIEW

Electrical standards: How well are they integrated in PC|SCHEMATIC? At PC|SCHEMATIC we have detailed insight in electrical documentation standards, and we are active members of standardisation committees. We also publish the book “Electrical documentation according to standards”. This insight in the IEC/EN electrical standards is an integrated part of PC|SCHEMATIC Automation. However, the program is designed so flexible, that you can also use it for other standards than the IEC/EN standards. - Even for your own set of standards! Support: How can I get it? When you buy PC|SCHEMATIC Automation, you get “Tier 2support” from the PC|SCHEMATIC in India as well from our Head Office Denmark. This can take place using e-mail, telephone or NetViewer (where we can guide you directly on your own PC). • Free access to the complete set of electrical design manuals for PC|SCHEMATIC Automation. • Free access to our electrical design videos - where you can see PC|SCHEMATIC Automation in action. • Free access to articles about

Contact us at any time At PC|SCHEMATIC we are very interested in hearing about your experiences using the PC|SCHEMATIC Automation program. It is because of the feedback from our many users, that we are able to make a better product year by year! So Feel free to contact us at any time. Conclusion Your success is our success We want YOU to experience success and achieve your goals – regarding your customers, your workers, and your possible superiors. This is important to us. Because when you achieve success, we succeed as well.

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

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MACHINE TOOLS » Tech Trends

Custom All-Electric Tube Bender Will Accelerate Right-First-Time Production for Precision Metal Fabricator Unison’s US support office receives first order – just weeks after opening!

nison’s new North American support office in Asheville, NC, has received its first order for an all-electric CNC tube bending machine, just five weeks after opening. The order was placed by Byers Precision Fabricators, Inc., of Hendersonville, NC, for a versatile dual-head machine that is capable of meeting a diverse range of tube and pipe bending needs. Byers Precision Fabricators produces components and assemblies mainly from sheet and tubular aluminium and stainless steel. Most tubular parts are fabricated from 3/8 to 1-inch ANSI Schedule 40 or 80 stainless steel pipe stock. Until now, Byers has outsourced the bulk of its tube and pipe bending needs to third-party suppliers, except for a small amount of work which it produces using manual bending techniques. However, this approach was becoming increasingly expensive and created production bottlenecks. As Roger Byers, President of Byers Precision Fabricators, explains, “Bringing our tube bending operations in-house greatly enhances our flexibility to meet complex shape requirements, tight delivery schedules and last-minute design changes – which is important for several of our customers in processing sectors such as nuclear power. It also allows us to broaden our range of fabrication services, which is critical for a subcontracting workshop like ours. We chose a Unison machine primarily on the strength of its performance and the 90 | OCTOBER 2015 | ENGINEERING REVIEW

company’s reputation. Unison’s support is also proving exemplary – the company has even handled some specialist pipe part production to help us, until we take delivery of the machine in a couple of months. This level of support is way beyond that of many machine tool manufacturers, and we look forward to a successful partnership.” Byers operates a modern machine shop, and is renowned for maintaining a pristine work environment. From the outset, the company was keen to avoid the type of hydraulic tube benders that are used by many fabricators, which are notoriously noisy and difficult to keep clean. It was also deterred by the difficulty of obtaining accurate and repeatable results from hydraulic machines. Avoiding material wastage was another factor – hydraulic tube bending often necessitates multiple trial runs before a good part that meets specification can be produced. Having chosen to adopt all-electric CNC tube bending technology, Byers looked at various manufacturers and singled out Unison’s machines as the best on the market. It also found that Unison was prepared to develop a bending solution to meet specific application needs. The fact that the company has just opened a support office in Asheville, a short drive from Byers’ facility in Hendersonville, was the final clincher. The machine for Byers is a version of the 2-inch (50 mm) capacity CNC all-electric tube bender from Unison’s Breeze range, customised to maximise versatility of

use. The machine features two independent bend heads that provide both left-hand (CCW) and right-hand (CW) bending to accommodate the most complex shape requirements, and is capable of handling many popular tube and pipe sizes – including 1.5 inch Schedule 40 stainless steel stock with an outside diameter of 1.9 inches. The machine bed is designed to accommodate tube lengths up to 20 feet. Some of the more specialist parts that Byers currently produces feature a variety of complex closely-spaced bends, with radii as small as 60 mm. The Unison tube bender will enable the company to produce these parts very efficiently in a single uninterrupted machine cycle. Single-piece part fabrication will also help Byers to further increase the speed and efficiency of production by eliminating multiple cut-to-length and welding operations. A further advantage of the Unison machine is its fully automated, software-controlled setup. Byers produces parts in a wide range of batch sizes, even in single or very small quantities, so machine setup time has a major bearing on productivity. The machine that is being supplied to Byers can typically be reconfigured by a single operator in less than 15 minutes. To help maximise throughput and accelerate right-first-time production of parts, both bend heads on the machine will be equipped with Continue on page no.92

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MACHINE TOOLS » Tech Trends

Continued from page no.90 Unison’s unique laser-based springback measurement and correction system. This helps to ensure bending precision by automatically compensating for the natural tendency of metal tubes to spring back slightly after being bent – eliminating costly scrap. Unison will also be supplying a comprehensive control and support software package. In addition to Unison’s Windows-based Unibend machine control software, this will include internet-based remote diagnostics and video monitoring facilities, as well as a powerful Op2Sim 3D tube bending simulator. The simulation software uses a CAD (computer aided design) model of the bending machine to generate detailed video imagery. It offers collision detection facilities, with user-adjustable parameters for real-world environmental factors such as the distances between the tube centreline and the ceiling, floor and walls of the workshop, and has in-built artificial intelligence to reiterate bend cycles until a successful solution is found. The simulator will enable Byers to develop production-ready tube bending programs offline, without needing to test and optimise them on the bending machine, saving valuable production time. The data for bending programs and simulation can be input manually from customers’ drawings, derived from CAD models of parts, or obtained by reverse-engineering existing components using Byers’ tactile or laserbased CMMs (coordinate measuring machines). According to Jeff Cox, a member of Byers’ CAD/CAM Department, “The bending machine will be networked to our CAD/CAM facilities – Unison is handling the system integration aspect. About 90 percent of our customers submit drawings, and most 92 | OCTOBER 2015 | ENGINEERING REVIEW

of these are backed by CAD models. We use SolidWorks CAD software extensively for design and development work, so we have also ordered the TubeWorks add-in software from Unison. This will enable us to extract manufacturing information such as tube specifications and CNC bending data direct from the CAD models in a matter of minutes, accelerating our RFQ (request for quotation) procedures.” Dale Coates, responsible for market development at Unison’s Asheville office, points out that the Byers order is a significant milestone in Unison’s history. “This is the first order that Unison has received following its decision to open a direct sales channel in the US and comes from a renowned manufacturer. We are also delighted to announce that Byers has agreed to act as a reference site for Unison. Its Hendersonville facility is only 15 miles from our office and we look forward to showing our bending machinery operating in such a modern fabrication environment.” About Byers Precision Fabricators Byers Precision Fabricators, founded in 1942, is a high tech company that uses state of the art fabrication equipment and trained personnel to provide a broad spectrum of fabrication services. Byers Precision operates from a modern 60,000 sq. ft. facility housing 5-axis laser, sheet laser and water-jet cutters. Byers’ equipment list also includes CNC lathes and mills, press brakes and welders, allowing the company to perform all types of machining, forming, and welding. The company also has the capability of finishing tubular and sheet metal parts. A flexible manufacturing strategy accommodates in-house production of components and assemblies in quantities from singles to mass production. The quality of Byers’ work is assured through its NQA-1 and ISO 9001:2008 compliant quality

management systems. Byers Precision Fabricators provides services to the nuclear, automotive, pharmaceutical and other industries requiring precision parts and assemblies. For more information www.byersprecision.com About Unison Unison started in business by developing control systems for metalworking machinery – supplying a number of prominent UK machine manufacturers in the 1970s and 1980s. In 1991 the company moved into machinery design, focusing on machines for tube bending. At that time, tube bending machines were powered hydraulically. In the early 1990s Unison invented a range of machines employing electrical servo-motors for controlling bending motion. These were the world’s first ‘all-electric’ machines for tube bending. The performance of Unison’s new machine design – with its fast and repeatable software-controlled set-up, right-first-time action, low power consumption, and quiet and clean operation – was an instant success. The company has progressively led the tube bending machinery industry by increasing the tubing diameters that can be formed using all-electric motion and is now one of the world’s leading manufacturers of tube bending machines and associated software. In 2014, Unison took another quantum leap in tube bending machine performance by developing a servomotor-powered machine architecture that is capable of bending thick-walled piping with diameters of 10 inches/273 mm and more. The company opened its own direct support centre in North America in 2015. www.unisonltd.com

For more information www.byersprecision.com www.engrreview.com

Reliable & High-Quality Pumps & Pumping Solutions The DESMI ROTAN® gear pumps are commonly used for paints, resins and coatings. A leading paint factory manager states: “ROTAN® pumps have for decades been used in many of our plants. The ED model was chosen due to its magnetic coupling. A magnetically coupled design, which has no rotating seals, ensures less downtime and lower operating costs. Every pump in our new facility is magnetically coupled, and thus we have eliminated the problems associated with packed glands and mechanical seals.” Please do not hesitate to contact us in case you need more information about our pumps and pumping solutions.

PROVEN TECHNOLOGY www.desmi.com

DESMI Pumping Technology A/S (India Liaison Office) 413, Aditya Trade Centre, Ameerpet Hyderabad – 500016  91- 8790122223 Email: srai@desmi.com

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AUTOMATION » Tech Trends

ARC Informatique and Ubiquicom join forces to bring location awareness and safety to your SCADA application

RC Informatique is an independent provider in HMI/ SCADA software. With its core product, PcVue®, the company has been contributing to the evolution of the automation industry for 30 years. The PcVue Solutions range provides a flexible solution for supervising industrial processes, utilities and infrastructure. Based in Milan, Italy, Ubiquicom is an award-winning technology company specialized in the design and development of products and solutions for the positioning and tracking of people and assets in unconventional contexts and using unconventional technologies. The two companies at the forefront of technological innovations, chose to collaborate and combine their skills to offer a unique mobility solution. This partnership manifests a joint effort to instill mobility at the heart of supervisory systems. A deliberate move from

ARC Informatique in order to step into the field of Internet of Things (IoT) by interfacing with established networks such as LoRa, Sigfox, etc.

Based on the real-time monitoring of biometric and environmental parameters, Ubiquicom adds an upper layer application to the PcVue Geo Map Control with its Locator Suite. Easy to configure and performed via Web services, these new features allow the detection and tracking of people and assets directly displayed as PcVue markers (which can be symbols) in a geographical map. This detection and tracking is efficient whether indoors and outdoors regardless of the network’s type and available communications (GSM, WiFi, Bluetooth, BLE). Through this collaboration, ARC Informatique reaffirms its ambition to provide an innovative mobile offering for SCADA.

For more information www.pcvuesolutions.com 94 | OCTOBER 2015 | ENGINEERING REVIEW

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AUTOMATION Âť Tech Trends

Securing the industrial network By Diane Davis

A Diane Davis is director of product management, networking, at Red Lion Controls, a US manufacturer of industrial automation and networking solutions that help organizations connect, monitor and control assets worldwide.

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s connectivity expands between machines on the factory floor to devices and corporate offices managing the supply chain, industrial networks require enhanced security to help ensure data is protected and flowing efficiently between network assets. Network expansion into the field is most easily accomplished by using industrial routers to provide secure, reliable, high-speed communication. But before making investments in these industrial routers, there are some key factors to keep in mind. One of the downsides to increasing connectivity is the potential for industrial networks to be more vulnerable to cyber threats, such as remote attacks and viruses. This is one of the reasons why it is important for decision-makers to evaluate security features before investing in networking equipment. When deploying wired routers to monitor and control industrial assets, data security should be a top consideration. Best practices should be put in place to address communication across the network, the type of data being processed and the users who have access to both the data and hardware. Some wired routers utilize Virtual Private Networks (VPNs) to securely extend the private (corporate) network to remote locations, like factory floors. Companies should look for products that allow the use of IPSEC and OpenVPN each of which offers unique VPN features for different network applications. IPSEC uses robust encryption and shared parameters to secure data traffic from the head end to remote assets. OpenVPN utilizes shared certificates to ensure data security while providing secure data transmissions between routers. The next layer of security is a firewall that uses Stateful Packet Inspection

(SPI). The SPI process scans individual packets of data and approves or denies each packet based on known services that are currently running. For instance, a remote site may only be allowed to transmit Modbus data packets to limit the usage of data required. In this case, any non-Modbus data would be rejected by a firewall in the router. Similar to a firewall, which approves or denies data packets, routers and RTUs should also offer an Access Control List (ACL) a list of approved or denied user credentials that allow or deny users access to the cellular device. Coupling an ACL with user-level authentication adds security by only allowing certain services to be accessed by specified users. Devices should also offer the ability to meet varying environmental requirements, such as wide operating temperature ranges, fluctuating input power voltages and air with particulate matter that may cause failure in devices with moving parts. As a primary WAN connection or a backup to existing network links, the right wired routers should also be well-suited for harsh industrial environments, such as oil and gas, energy and water/wastewater applications where security and reliability is paramount. Increasing industrial network connectivity on the factory floor is a sound investment to enhance communication among offices, plant locations and devices. Decision-makers should take the steps necessary to protect their infrastructure by evaluating security options alongside network performance.

For more information Web: www.redlion.net www.engrreview.com

AUTOMATION » Tech Trends

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 & family run Company since 1920, manufactures goods as per exacting German standards and has created a niche for itself in the Indian electrical market with its International Class Products. The “Geissel” brand of cable glands is well known and accepted worldwide. Products include cable glands in brass, polyamide and stainless steel S.S 303(1.4305) & S.S. 316 TI (1.4571) – according to RoHS standards, in IP 54, IP 68 and EMC - upto cable dia of 116 mm with all kinds of threads, i.e. Pg, metric and inch. Other products are plugs, reducers, enlargements, lock nuts, etc. Three recently introduced products from the Geissel stable have created an impact in the Indian electrical market: Double compression cable glands, Conduits and Conduit glands. Double Compression cable glands: The first of its kind in the Indian market with IP 68 and only three sizes to suit cable dia from 12 – 34 mm. Introduced just over a year ago, discerning customers have praised the product for its design, easy application and convenience of only three sizes. Designed and engineered in Germany, but manufactured in India, customers of International repute are finding many advantages in using these glands over others. Conduits & Conduit glands: The conduits are available in galvanized steel as well as PVC coating

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on galvanized steel in grey and black colours. Complementing them are the conduit glands which fit the conduits perfectly. The design and application is simple and customers get a one-stop solution to their needs for conduits and the ease in fitting them. Geissel has also achieved success in their EMC glands. Available in brass with nickel plating in metric as well as Pg threads, these glands are very userfriendly. Customers of international repute have appreciated this simple but effective design. To promote and exhibit its products, Geissel has taken part in numerous exhibitions since the past six years, in India and abroad. Geissel India’s USP is the availability of all products ex-stock from their factory in Pune.

For more information: Website: www.geissel.com www.engrreview.com

Interface

Highest degree of variability. For each application purpose.

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AUTOMATION » Tech Trends

Analyzing the quality of crude oil with an elementary instrument

rude oil is a term that has been given to the raw, unprocessed oil obtained from the earth. It is a fossil fuel that is formed due to compression of a wide range of organic matter under heated conditions. They vary in colour from clear to dark black and in viscosity from water to hard solids. The most important points that make crude oil one of the most valuable assets is that it contains a lot of energy in them. The fractions that are obtained from crude oil like gasoline, diesel fuel, naphtha, petrol and so on are used as fuel for utilizing this stored energy. The second most interesting characteristic of crude oil is that it can take up many different forms, from gases that are lighter than air to liquids to solids like tar or wax.While crude oil contains high amounts of hydrocarbons, it also contains water, chloride salts and other impurities. A desalting process can remove many of the impurities. This process involves the addition of water to dissolve the salts and other impurities from the crude oil feedstock. The mixture is then separated; the water goes to an industrial wastewater treatment facility and the refined petroleum is developed into different petroleum products. The desalting process removes the majority of chloride salts, which if present in the oil at high temperatures can form hydrochloric acid. The hydrochloric acid formed can readily corrode equipment throughout the refining process. As a result, the desalting process is crucial to crude oil refining. Organic chlorides are also present in crude oil as chloroform and chlorobenzene. While these compounds are generally not present naturally, the oil can be adulterated when additives, cleaning solutions or chemicals for oil recovery are used. As a result, refineries typically do not accept crude oil that contains more than 5 parts per million (μg/g) of organic chloride. Naphtha is a derivative of crude oil which is collectively described as a family of volatile liquid hydrocarbon

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mixtures. Naphtha is a major component of gasoline and other fuel types Chlorides are frequently occurring contaminants in naphtha and crude oil, often exceeding concentrations of 3 ppm (mg/L). To minimize corrosion and scaling, chloride levels should be kept below 1 ppm. Chlorides can be detected and monitored in naphtha and crude oil through a reduction with sodium biphenyl and subsequent potentiometric titration. Organic chlorides are determined through potentiometric titration per Standard Method ASTM D4929. This method utilizes a sodium biphenyl reduction of the organic chlorides to yield inorganic chlorides. The chlorides are then extracted from the petroleum sample into an aqueous phase and titrated with silver nitrate. An oil and natural gas supplier was looking to determine the concentration of chloride in naphtha and crude oil. The supplier wanted to follow the Standard Test Method ASTM D4929-99 for the determination of chloride in crude oil; this method approves the use of a silver-silver chloride billet-type electrode. For this application, Hanna Instruments recommended the HI902C Automatic Titration System with the HI5110 glass body ORP Half-Cell Electrode for Argentometric Titration. The HI5110 has a silver ring as part of the indicating electrode. This silver ring is also known as a “silver-billet”. Since the method uses organic solvents as part of the sample preparation, it is necessary to have chemically compatible materials including glass body electrodes. For the reference the double junction glass body HI5311 Reference Half-cell is recommended. The titration is then performed with a known volume of a prepared naphtha or crude oil sample that is titrated potentiometrically with a standard solution of silver nitrate. This titration results in a precipitation reaction of silver chloride from the silver nitrate titrant and the chloride present in the sample. The

method also requires a blank titration to be performed, which is used to determine the exact volume of titrant that is consumed by the reagents, excepting the naphtha sample. Electrode preparation is a critical step in this method. It is necessary to coat the silver billet before performing both the blank and sample titrations, as it is the sensing element for the reaction. Coating the silver billet prevents any imperfections in the silver-halide coating, which can lead to erratic ORP recommended. Prior to analysis, the electrode is filled with 3.5M KCl HI7082 Electrolyte Solution. The silver billet electrode is first soaked in sodium hypochlorite, rinsed with deionized water, and polished with fine grit sandpaper. The electrode is then placed in a saturated potassium chloride solution and an alternating voltage is applied for intervals of several seconds. The reference electrode is then emptied of the aqueous KCl electrolyte and filled instead with aqueous 1M KNO₃ HI7072 Electrolyte Solution. Following this procedure crude oil can be analyzed in a very affordable way and also the titrator produces quick, precise, and consistent results with a very minimal amount of manpower. Pavithra Manayil Applications Specialist Web: www.hannaindia.in www.engrreview.com

AUTOMATION » Tech Trends

Realizing the Internet of Things Oxford school has online control of heating, ventilation, water, lighting etc.

A A Netbiter gateway is connected to the controlling Rockwell PLCs. Users access the premises at www.netbiter.net.

t the EF International Language Centre in Oxford, system integrator Global Electrical Solutions Ltd. has installed a building management system to keep track of heating, ventilation, water, lighting etc. By connecting Netbiter Remote Management gateways to Rockwell control panels in the building, users can see current temperatures, levels, and consumption online. They can even turn on lights or open windows remotely – truly realizing the Internet of Things. Global Electrical Solutions (GES) is a UK-based system integrator specializing in assembling highly efficient control panels used in buildings, power & energy, manufacturing etc. At one of their recent installations at the EF International Language Centre in Oxford, they have used the Netbiter Remote Management solution to remotely monitor and control the building premises. The Netbiter Argos web interface works as a front end towards the user displaying current values from the building and also allows users to generate reports and get alarms whenever certain thresholds are reached.

How it works

Real values, real pictures. GES have used pictures from the actual premises in the school when creating Netbiter dashboards. In these dashboards, users can see exact values in realtime and control heating and ventilation remotely.

A Netbiter EC310 gateway is connected to the Rockwell Micro800-series PLCs which control the different systems in the building. The Netbiter gateway sends data to the cloud-based Netbiter Argos service where it is stored and accessed. GES and the building owners can log in to www. netbiter.net to see current values and even start or stop equipment, open windows and turn lights on or off from their Netbiter Argos dashboard. Furthermore, they can get alarms via email if certain values are reached (for example if CO2 levels are too high). It is also possible to generate reports on consumption and performance over time. “It works really, really well,” says Mark Jenkyns, Managing Director at Global Electrical Solutions. “It is easy for us

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AUTOMATION » Tech Trends Continued from page no.104 to create graphical dashboards in Netbiter Argos, so we basically use it as the front end for our Building Management System.”

Fewer service visits means quick ROI The remote management solution has been well received by Global Electrical Solution’s customers as it gives both better

control and lowers costs for maintenance as costly service trips can be reduced to an absolute minimum. Since the price of a remote management gateway usually equals the cost of a service visit, the return on investment is usually just a couple of months.

Mark Jenkyns explains: “When the customer reports a heating problem, there is a good chance it’s a sensor failure which would normally require an engineer visiting site with test equipment. With the Netbiter onsite we can now log in to any one of the buildings controllers and inspect the real time values to determine if the sensor is faulty or not without leaving the office. A new part can be ordered and installed within a fraction of the time. Mark Jenkyns experienced one of the benefits himself when installing the remote monitoring solution in one of the rooms of the school: “When I got back to the office, I realized that I had forgotten to turn the hot water back on. But since the room now had Netbiter installed, I could easily go in and turn it on with a click of the mouse. Many service trips and maintenance issues are usually simple fixes like this, so with Netbiter we can save a lot of time and money for both us and our customers.” GES has now installed Netbiter at two schools and a hotel in the Oxford area and can see many other applications for Netbiter connected to their control panels. “It really gives our offering an edge as it provides customers with an easy-to-grasp overview of their systems and keeps costs for maintenance down” finishes Mark Jenkyns. HMS Industrial Networks HMS Industrial Networks is the leading independent supplier of products for industrial communication including remote management. HMS develops and manufactures solutions for connecting automation devices and systems to industrialnetworks under the Netbiter, Anybus and IXXAT brands.Development and manufacturing take place at the headquarters in Halmstad, Sweden and in Weingarten, Germany. Local sales and support are handled by branch offices in China, Denmark, France, Germany, India, Italy, Japan, UK, and USA. HMS employs over 350 people and reported sales of 57 million EUR in 2013. HMS is listed on the NASDAQ OMX in Stockholm.

For more information www.anybus.com

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AUTOMATION » Tech Trends

Knowledge is the key to solution The new KOLLMORGEN catalog offers huge flexibility

ntegrated solutions are now the benchmark for drive and control technology in machine and plant engineering. As a result, product documentation and sales literature are increasingly focused on solution packages. The latest catalog goes far beyond a simple guide for selecting individual products. The latest edition “KOLLMORGEN - Motion Control and Drive Solutions” complete catalog, covering over 100 product and solution ideas, is available to download from the website. Machine automations only deliver their full performance if control intelligence and drives work together to deliver maximum power. If the overall context is optimized, it helps the individual motor or controller. Intertwined automation and motion control systems determine the scope of productivity and efficiency. The new KOLLMORGEN complete catalog is

therefore far more than a portrayal of defined product worlds. Direct drives, servo motors, Safe Motion, distributed and central servo amplifiers, and the complete Kollmorgen Automation Suite: The new catalog combines key figures, selection guides, or sizes with concentrated solution ideas in order to develop the next generation of machine design today.

About Kollmorgen Kollmorgen is a leading provider of integrated automation and drive systems along with corresponding components for machine builders all over the world. With more than 70 years of Motion Control Design and application experience and profound knowledge of constructing standard and special solutions, Kollmorgen supplies solutions time and again that stand out in terms of performance, quality, reliability, and ease of use. As a result customers can achieve a market advantage which is beyond question.

For more information Web: www.kollmorgen.in

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AUTOMATION » Tech Trends

Tamper-proof sealing of folded cartons Gloss sensor Glare from SICK

he Glare gloss sensor from SICK is specially designed to recognize and differentiate objects on the basis of their gloss in order to control production processes. The Glare sensor analyzes the spatial distribution of reflected light using Delta-S technology. This allows the sensor to determine the gloss level of flat object surfaces and to differentiate between objects of differing gloss levels. The measurement result is transmitted to the process controls either via two digital switching outputs or IO-Link. Several operating modes are available, making the Glare sensor perfectly suited to a range of different applications. The combination of intelligent signal evaluation algorithms, the multi-sensor arrangement and sensitivity adjustments ensure increased operational safety in industrial applications. The Glare’s IO-Link

interface enables the sensor to be integrated into the machine controller, featuring automatic, process-oriented configuration and online diagnostics. Maximum protection against tampering – the aim of EN 16679:2014 This makes the Glare gloss sensor outstanding for the implementation of DIN EN 16679 “Packaging – Tamper verification features for medicinal product packaging.” It will expand guideline 2011/62/EU (Falsified Medicines Directive) to ensure the genuineness and verifiability of individual packs, and thus to prevent forged or adulterated medication and lifestyle preparations from entering legitimate distribution channels. As a form of protection against prior opening, transparent seals neither affect the pack design nor cover up the required wording or markings

on the packaging. The damage to the perforation when first opened, however – i.e., the broken edge that results from opening – is instantly visible. In the scope of already realized applications two label dispersers are used, for example, that attach the safety labels to the two opening flaps. In order to identify errors in dispensing or attaching the labels immediately, 100 percent reliable detection of the applied labels is essential. Glare’s innovative detection concept has made it possible to design the tamper-evident function of a system with maximum process reliability. Even when there is still a transitional period of approx. three years to implement the directive, manufacturers and packagers of human medication must now deal with the requirements on their packaging lines. In addition to the thorough checking of pharma packaging, Glare opens up a range of further interesting applications such as the monitoring of damp oil, adhesive or paint coatings in auto-mobile production, the monitoring of smoothing, cleaning and polishing processes, the detection of glossy or transparent pack-aging in food and drink technology, the monitoring of glue applications in wood and furniture production, and the checking of coatings on assemblies and layers in the construction of solar panels and flat-screen monitors. Glare, in addition to the known features of reflectance, color and luminescence, expands with the gloss the spectrum of the optical properties of objects for reliable detection of objects for the automation of machines.

For more inforamtion Web: www.sick.com

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AUTOMATION » Tech Trends

Rollon: Managing Misalignment in Linear Motion Systems Of all the factors that contribute to the premature failure of linear bearings, misalignment ranks near the top of the list. Here’s how to cope without breaking the bank.

Rollon’s Compact Rail system is inherently tolerant of misalignment, thanks to a rail geometry that can absorb alignment errors in one or two axes.

hen design engineers evaluate linear bearings, they always ask about performance attributes such as speed, load capacity and lifecycle. Then they want to know the price. It’s rare, however, that they ask about the bearing’s sensitivity to misalignment. And that’s a big mistake, because misalignment represents one of the leading causes of premature linear bearing wear and failure. Linear bearings that should last for years based on expected life calculations can quit after a just few months if they are not aligned to the geometric tolerances they require to run smoothly. Usually, alignment problems begin with the design and preparation of the machine frame itself. It may not be flat, straight or parallel enough for a bearing to mounted properly. For example, mounting surfaces may have one or more high spots that will read through to the installed bearing rails. Or the frame design may make it difficult to mount bearing rails parallel to one another in the horizontal axis, vertical axis or both. Whatever the type of misalignment, the

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result is uneven loading of the bearing’s rolling elements and raceway surfaces, including excessive point loads. These uneven loads typically cause wear in the form of pitting. Just as a pothole in the road starts small and then grows as more cars drive over it, pits on the rolling element and raceway surfaces grow with each pass of the carriage. At some point, even before it fails catastrophically, the pitting can cause the bearing to become noisy and sluggish. By shortening the working life of linear bearings, misalignment can be a significant cost driver for both the machine builder and owner. Machine builders suffer from higher warranty costs when bearings fail prematurely—not to mention the less tangible cost of a damaged reputation for quality. Machine owners, meanwhile, have to contend not just with the cost of buying and installing new bearings but also any downtime costs. Rather than incur these costs once the machine has gone into service, it’s far better to deal with misalignment upfront. In general, there are two ways to do so. The hard way involves design and manufacturing procedures

Axial Parallelism Error that attempt to eliminate misalignment altogether. The easy way accepts misalignment as a fact of life and employs linear bearings that inherently have a wide alignment tolerance. Both of these strategies have their place, but they also have drastically different cost implications.

The Hard Way : Linear guides that use recirculating balls are well-established in high precision motion applications for good reason. When properly installed and maintained, these linear guides are designed to meet the stringent positioning accuracy requirements of machine tools and other precision industrial machines. In fact, the best of these guides can be found

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on motion axes that offer repeatability at the micron scale. But this kind of precision doesn’t come cheap. It requires machine builders take expensive steps to create nearly perfect mounting surfaces for linear guides. Some ultrahigh precision guides, for example, call for mounting surfaces that are straight, flat and parallel within a few tenthousandths of an inch. This process of eliminating misalignment starts when the machine is still on the drawing board. To accommodate ultrahigh precision guides, design engineers will often have to specify pricey frame materials and fabrication methods that will facilitate the creation of flat, straight, parallel mounting surfaces. Typically, the required geometric tolerances will call for precision grinding and lapping operations whose cost rises exponentially with the length of the linear axis. What’s more, misalignment can also result from deflections of the mounting surface when loaded. So ultra-high precision guides may also need engineers to beef up parts of the machine frame in order to provide linear guides with a mounting surface that is rigid enough to prevent deflection. Steps to combat misalignment also take place on the assembly floor. Assemblers often have to pull linear guides into alignment inch by inch, using custom fixtures, finicky bolt adjustments and shims. This process is nothing new for many machine builders, but it is time-consuming and expensive. And like machining, costs rise with the length of the axis.

The Easy Way : The other broad strategy for dealing with misalignment is to live with it by choosing linear bearings that can self-align. In contrast to recirculating ball systems, another type of linear bearing feature large rolling elements, rail profiles that give the rolling elements some wiggle room and a simple preload adjustment that enable equal loading of all rolling elements. The Compact Rail System from Rollon is a prime example of this misalignment-tolerant design. Its rollers have enough rotational and lateral freedom within the raceways to offset even large misalignments in all axes. Whereas ultrahigh precision guides measure

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Alignment Errors In Two Planes Rollon’s K and U Rails work together to absorb alignment errors in two planes. The K Rail geometry gives the roller a rotational freedom that offsets differences in rail height, while the U Rail’s flat raceways allow lateral freedom to offset parallelism errors in the horizontal plane. The system will tolerate significant misalignment (see graph) without an effect on wear or longevity.

acceptable misalignment in arc minutes and microns, the Compact Rail system measures it in degrees and mm. For example, Compact Rail rollers can rotate up to 2 degrees relative to the rail without affecting functionality or increasing wear. This rotational freedom allows the system to accommodate a 20 mm difference in rail height when the distance between rails is 500 mm. Likewise, the roller’s ability to translate laterally allows it to adjust to parallelism problems in the horizontal axis that is, when rails toe in or toe out. The largest Compact Rail size, for example, can adjust to displacements up to 3.9 mm over a 4080 mm rail length Finally, because the elements are so large and can move within the raceway, they can also adjust to localized variations caused by high spots in mounting surfaces or by a less than exacting assembly process. For machine builders, the benefits of a self-aligning system come down to design freedom and cost reduction. When the condition of the bearing mounting surface becomes less critical, it is easier to design all or part of a machine frame using lower cost materials and fabrication methods. Compact Rail, for instance, has been directly mounted to sheet metal, a surface that would be too compliant for conventional linear guides. Gone too are the expensive grinding of mounting surfaces

The Compact Rail system offers three different rail profiles, which can be combined to compensate for different types of misalignment.

and the fussy assembly methods.

Which Way? When comparing the two approaches to misalignment, eliminating it or adjusting to it, keep in mind that both have their place. Some linear axes truly do need a rigid bearing with the best possible precision. In these cases, there is little choice but to spend the money on machine frame upgrades, precision grinding and careful assembly. Others axes, ones with slightly lower precision and accuracy requirements, will be better served by a more compliant guide that can align itself to imperfect mounting surfaces. Costs in these cases will be lower. What machine builders sometimes fail to realize is that these two approaches are complementary. Many machines will have linear axes with different accuracy and precision requirements. Consider machine tools, for example. The spindle may need the most accurate linear motion system money can buy, while the tool changer and door do not. All too often, however, the same type of precision bearing that is required for one part of the machine will, by default, be used throughout all or most of the machine, driving up costs unnecessarily. A better way to go is to pick the best linear bearing for each axis individually. And whenever a self-aligning style will meet the accuracy requirements for a given axis, it will save money. Rollon India Pvt. Ltd. 1st floor, Regus Gem Business Centre 26/1 Hosur road, Bommanahalli Bangalore 560068, INDIA Tel: +91 80 67027066 Fax: +91 80 67027004 E-mail: info@rollonindia.in Web: www.rollonindia.in www.engrreview.com

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ENGINEERING Âť Tech Trends

Springs : The key for motion control applications

t its most basic level, a spring is a device used to store mechanical energy. Although often out of sight, springs play an important role in many motion control applications. They are used in gear assemblies, actuators, rotary unions, and different kinds of clutches, among other applications. There are many different varieties of springs making it virtually impossible to cover them all in great length. Compression springs are some of the most common types of springs in use. The compression style wave spring is made of coiled flat wire with waves added along the coils to give it a spring effect. They can be used in place of conventional round wire compression springs in applications that require minimal space yet similar deflection. Generally, they occupy one-third to one-half of the space of comparable round wire springs offering more deflection with the same load specifications. Wave springs are one alternative to coil springs. Wave springs are typically manufactured from a single filament of flat wire formed in continuous precise coils with uniform diameters and waves. They are manufactured with either plain ends (wavy) or squaredflat ends (shim ends). Generally, 17-7 PH is used as the standard material for wave springs. One advantage of wave springs is that they save space in many applications. By reducing spring operating height, these springs also decrease the spring cavity. A smaller assembly size and less material used in the manufacturing process can lower cost. Wave springs operate as load bearing devices. They take up play and compensate for dimensional variations within assemblies. A range of forces

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can be produced whereby loads build either gradually or abruptly to reach a predetermined working height. This establishes a precise spring rate in which load is proportional to deflection. Some manufacturers offer single, nested, and multi-turn wave style springs. A single-turn wave spring with overlapping ends saves axial space so that more space is given for travel. The spring clings to the bore, which saves more radial space. The overlapping ends prevent radial jamming because a circumferential movement is allowed. The spring ends could move against each other so that the specification load at work height is always given. Nested wave springs suit applications requiring higher forces to meet safety regulations, such as those in government or military applications. A nested wave spring provides a higher load than a single-turn wave spring (or alternatively, a stamped wavy washer) and uses the same radial space as a single-turn design. Multiple-turn wave springs do not cling to the bore, because radial jamming affects the specified load at work height. If the design of the multi-turn wave spring results in peripheral movement of the turns against each other, this could render the spring unstable. Compared to a single-turn design, bigger travel/deflection is possible because the deflection in total is split. Every turn has to tolerate less deflection compared to a single-turn design. Use of a multi-turn wave spring could also save 50% in axial space compared to a traditional coil spring. There is also no concern about torsional movements during the compression to work height as there is with a coil

spring; a wave spring always provides its load in an axial direction. Very similar loads without big tolerances are provided at different work heights; in that way, the application could be easily adjusted to meet given requirements. Lastly, although wave spring applications can be diverse, there is a basic set of rules for defining spring requirements. Those requirements are used to select a stock/standard spring or design a special spring to meet the specifications. When selecting a wave spring, the load requirement is probably the main factor to consider. The load requirement is defined as the amount of axial force the spring must produce when installed at its work height. Some applications require multiple working heights, where loads at two or more operating heights are critical. Often minimum and maximum loads are satisfactory solutions, particularly where tolerance stack-ups are inherent in the application. High temperature, dynamic loading (fatigue), a corrosive media or other unusual operating conditions are also important considerations in spring applications. Solutions to various environmental conditions typically call for the selection of the optimal raw material and operating stress. If the work height per turn is less than twice the wire thickness, the spring will operate in a â&#x20AC;&#x153;non-linearâ&#x20AC;? range and actual loads may be higher than calculated. It is not recommended to compress a wave spring to solid. Radial expansion and diameter tolerance must be taken into account while designing a spring to fit in a bore and/or over a shaft. For more information Web: www.smalley.com www.engrreview.com

ENGINEERING » Tech Trends

Anti-vibration solutions for India’s power plant building boom The Austrian company Getzner minimises vibrations and increases safety in power plants. Recently the innovative solutions have been installed in a GMR Chhattisgarh Energy Limited, 1370 MW power plant in Raipur, Chhattisgarh.

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

India has big power generation plans: Recent headlines include the plan to build the world’s largest solar power station, the world’s biggest thermal power plant and more than 20 nuclear power plants. With this construction boom come higher requirements for quality, efficiency and safety. The experts from the Austrian company Getzner developed high-tech materials to effectively minimize vibrations and structure-borne noise of machines, turbines and generators – a solution highly demanded in the Indian market. As the Indian economy keeps growing and developing, the country’s hunger for energy remains gigantic: Currently, six nuclear power plants are under construction in India, plans for approximately 20 more are in the drawer. India has around 41 118 | OCTOBER 2015 | ENGINEERING REVIEW

GW of installed hydropower capacity while an additional 13 GW is under construction. In January 2015, the Indian government significantly expanded its solar plans, targeting US$ 100 billion of investment and 100 GW of solar capacity by 2022. “These impressive figures demonstrate the huge potential of the Indian energy market”, states Sanjay Risbood, CEO of Getzner India Pvt. Ltd. The Austrian company Getzner Werkstoffe provides innovative, proven solutions to reduce vibrations transfer of machines, pumps, turbines and generators. “Vibrations cause noise and damage. This is not only harmful to the immediate surrounding area, but also negatively affects manufacturing and quality processes in the vicinity and disrupt the neighbourhood and

environment”, explains Mr. Risbood. The high-tech materials Sylomer® and Sylodyn®, developed in-house by the Getzner engineers, are used for vibration isolation in railway, construction and industry applications. Mr. Risbood: “There are many benefits: Elastically mounted devices are more cost-effective and efficient in the long term. Vibration protection increases the value of office space, production processes and adjoining residential buildings. Last but not least, optimum vibration solutions usually account for less than 1% of the initial cost, whereas solutions that are added later are expensive and less effective.” The Getzner bearings are easy to install, maintenance-free and consistently effective throughout the service life of the machine. “As the bedding is individually calculated and adapted, it is possible to achieve a low natural frequency and greater effectiveness”, adds Sanjay Risbood. Successfully installed all over India From Bihar and Rajasthan to Gujarat, Tamil Nadu, Karnataka and Madhya Pradesh: Getzner has provided its innovative solutions in numerous power plant projects throughout India. Among others, the Austrian vibration isolation experts installed their innovative solutions at two thermal power plants by Essar Power in Salaya/Gujarat and Mahan/Madhya Pradesh. Three years ago, Getzner started its work for a thermal power plant with the capacity of 2x685 MW, built by India’s GMR Group. In the facility in Raipur, Getzner isolated 14 machine

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ENGINEERING » Tech Trends

Getzner vibration isolation solutions in Austrias Rettenbach hydroelectric power station. Image source: Getzner Werkstoffe, may be used free of charge

Getzner’s solutions protect machines, devices and the surroundings from vibrations. Image source: Getzner Werkstoffe, may be used free of charge

Continued from page no.118 foundations having machines like pumps (Motor Driven Boiler Feed Pumps) and fans (Forced Draft fan, Primary Air fan etc.). Sanjay Risbood: “The basic need for our vibration isolation systems was to restrict the flow of vibrations to nearby structures and to bring down the size of the foundation as the subsoil shear modulus was very high.” Convincing results worldwide The Getzner solutions Sylomer® and Sylodyn® have proven themselves in numerous power plant projects around the world. A very interesting project was carried out in the Austrian Alps: Getzner was responsible to minimize vibrations at the hydroelectric power station in Rettenbach, Sölden, which is in the vicinity of a primary and secondary school as well as a kindergarten and a luxury hotel. “The complex surrounding conditions placed particular demands. The geographical situation made the project even more challenging, because the power station uses water from two rivers and two turbines had to be installed. That means that two sets of vibrations needed to be isolated”, reports Sanjay Risbood. The Getzner engineers calculated the optimum natural frequency for the elastic mounting of the power 120 | OCTOBER 2015 | ENGINEERING REVIEW

station building on the basis of the disruptive frequency data from the turbine manufacturer. The tailor-made concept included the decoupling of the whole building from its surroundings with Sylomer® mats and largescale side installations in the direction of the school building. Extensive vibration and acoustic measurements demonstrated the effectiveness of the Getzner solution: “Both in the school rooms and outdoors, the vibration values lie far below the human perception threshold.” Getzner - “engineering a quiet future” Founded in 1969 as a subsidiary of Getzner, Mutter & Cie, Getzner Werkstoffe is one of the leading specialists in vibration protection. Solutions from Getzner are used in the rail, construction and industry sectors to reduce vibrations and noise, improve the service life of bedded components and minimise the need for maintenance and repairs on tracks, vehicles, structures and machines. The elastic bearings are based on the materials Sylomer® and Sylodyn®, both of which are developed and manufactured in Buers, Austria. Alongside its locations in Buers and in Germany, Getzner also has sites in China, France, India, Japan, Jordan and the USA. Its tightly-knit distribution network in Europe is complemented by

its distribution partners in the USA, South America and the Far East. The company’s partners in a total of 35 countries around the world distribute Getzner products to every location. By reducing noise and vibrations, Getzner is making a valuable contribution towards enhancing the quality of people’s living and working conditions. Data & facts – Getzner Werkstoffe GmbH Founded: 1969 (as a subsidiary of Getzner, Mutter & Cie) Chief Executive Officer: Jürgen Rainalter Employees: 220 in Buers, 100 abroad 2014 turnover: 70.3 million euros Business areas: Rail, construction, industry 2014 output: 7,367 metric tons of technical PU materials 2014 recycling: 17 metric tons of residual PU materials Headquarters: Buers (AT) Locations: Amman (JO), Berlin (DE), Charlotte (US), Kunshan (CN), Lyon (FR), Munich (DE), Beijing (CN), Pune (IN), Tokyo (JP) Ratio of exports: 86 percent Getzner India: In 2009, Getzner started its 100% subsidiary in India to provide prompt marketing & technical services for the customers in India. The contact details of the Indian subsidiary:

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CIMES 2016 – The 13th China International Machine Tool & Tools Exhibition 22 – 26 June 2016, Beijing, By Om Prakash, Director – Inorbit Tours Pvt. Ltd.,

IMES 2016 is a truly global machine tool trading and sourcing platform hosted in the world’s biggest machine tool market: China. As Asia’s leading machine tool exhibition for metal cutting tools and CNC machine trade, it also showcases the very latest high-end metalworking and industrial automation technology. In 2016, CIMES will showcase the world’s top industry giants and international pavilions from key manufacturing countries. In order to maximize the ROI for exhibitors and buyers at this Industrial automation exhibition, the organizers will invite an unprecedented array of VIP buyers from key Asian application industries including aerospace and aviation, medical equipment, shipbuilding and new energy. Accurate product segmentation and highly efficient marketing solutions will allow facilitate the establishment of powerful, direct connections with matching business partners. • Exhibition Area(sqm):120,000 • Number of Exhibitors:1300 • Supporting Associations &National Pavilions:30 • Number of Visitors:150,000 • Total Turnover(RMS/million):2840 Exhibit Profile a. Machine Tool, Tools and Accessories b. Metal cutting machinery c. Metal forming machinery d. Sheet metal and plate processing machinery e. Metal tube and pipe processing machinery f. Special purpose machinery g. Special purpose machine tool h. Cutting tool, fixture, accessories, parts and components, i. electrical tools, hydraulic tools, pneumatic devices, ◆ abrasives, precision measuring technology and devices j. Automation and Motion k. Flexible manufacturing technology and equipment l. Numerical control systems, embedded systems and servo systems m. Industrial robots n. Frequency conversion and timing, sensors and motors electrical tools, hydraulic tools, pneumatic devices, o. abrasives, precision measuring technology and devices p. Automation and Motion q. Flexible manufacturing technology and equipment r. Numerical control systems, embedded systems and servo systems s. Industrial robots t. Frequency conversion and timing, sensors and motors u. Programmable logic controller and related technology v. Electronic drives and control systems w. ◆Mechanical, hydraulic and pneumonic driven devices x. Heat Treatment and Other Technology

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y. Foundry technology and equipment z. Forging technology and equipment a. Heat treatment technology and equipment b. Welding and cutting-off technology and equipment c. Other Manufacturing Technology and Equipment d. Bearing manufacturing technology and equipment e. Gear generating technology and equipment f. Mould processing technology and equipment g. Other manufacturing technology for the making of auto parts Highlights for Int’l Visitors: • Source from 3200 pieces of Equipment and Tools, displayed onsite • Factory Visits • New Robot Pavilion and more than 60 technical seminars and workshops

CANTON FAIR 2016 CHINA 119th Chinese Import & Export Commodities Fair Phase I: Apr.15th -19th, Phase II: Apr. 23rd -27th, Phase III: May 1st - May 5th. Guangzhou

19th China Import and Export Fair, commonly known as CANTON FAIR, is China’s oldest and largest comprehensive trade fair. Held twice each year. The fair includes a large variety of exhibits and draws business people from more than 211 countries. The Canton Fair boasts a history of development for over 58 years, which has witnessed the development of China foreign trade and China’s exchange with the rest of the world in terms of politics, economy and culture. Renowned as “China’s No.1 Fair”, the Canton Fair is the key trade bridge and platform that promotes world trade development, 119th China Import and Export Fair for more than 150,000 Consumer & Industrial products in Three Phases. This is the platform to diversify into new products. Indian Visitors may select their preferred phase out of 3 phases as per the products list here below. China boasts boundless opportunities as usual. The 119th session of China Import and Export Fair from April 15 to May 5, 2016, will be the best platform for growth of business. 118th China Import and Export Commodities Fair: The 118th Canton had 60228 stands/booths attracting 24700 exhibitors from the Consumer & Industrial products industry displayed their products which included Electronics & Household Electrical Appliances; Hardware & Tools; Machinery; Vehicles & Spare Parts; Building Materials; Lighting Equipment; and Chemical Products; International Pavilion Consumer Goods; Gifts; and Home Decorations Textiles & Garments; Shoes; Office Supplies, Cases & Bags, Recreation Products; Medicines, Medical Devices, Health Products; and Food; International Pavilion. The show attracted more than 186,104 buyers from over 211 countries and regions around the world. Special travel package: A special visit is arranged to visit the above trade fair in China. Details can be obtained from Om Prakash – Director, In ORBIT Tours Pvt. Ltd. Tel: 022 – 24229281, omprakash@inorbittours.com www.engrreview.com

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REFECTIONS

DEMAG : Extending growth horizon Q. What are the exciting developments in your domain? What are the proactive initiatives you take to meet the changing needs of your discerning customers? At Demag â&#x20AC;&#x201C; Terex Material Handling, our motto is to deliver Safety, Efficiency and Reliability to our valued customers. We continue to innovate & Mr. Ravin Wadhawan, Executive Director, upgrade our Prod- Demag Cranes & ucts & Services for Components (I) P. Ltd. these vital attributes. Today with increased awareness and stringent government norms, industries demand enhanced safety when looking for material handling equipment, particularly demand for enhanced safety, reduced human intervention, optimal operating cost over a lifetime of the equipment & space efficiency (compact). Across various geographies, for applications mainly in Automobile (Die transfer), Bulk material handling (Solid Municipal Waste, Cement, Coal), Steel & Paper handling, we provide with semi or fully-automatic process cranes, optimized to meet specific requirements of our customers besides the vital attributes discussed above. These cranes can communicate with integrated high-level control systems, for instance warehouse management. All functions, including the load pick-up, transfer and deposit are controlled by a Computer ensuring that a specified load handling per time requiring minimal supervision or intervention, and could be limited to an emergency stops. At the moment, we are gearing to roll out many innovations in the market, one of them being Cranes with V-type girder. The construction of the V-type crane offers considerable technical benefits compared to conventional cranes that have closed box girders or I-beam girders. Its innovative design reduces 124 | OCTOBER 2015 | ENGINEERING REVIEW

oscillation frequency by 30 percent, cuts its weight by an average of 17% easing transport and installation cost and doubles its service life to more than 500,000 changes of load. The new girder concept offers significantly improved efficiency for handling loads and higher handling rates. Many of our customers in India have welcomed this solution. We are also coming up with many service products complementing preventive maintenance so that our customers can have a better control of maintenance and avoid possible breakdowns. One such product is StatusControl system, which allows remote access to the system in real time and gives a complete picture of operating data and analysis at a glance. The biggest advantage this system brings over operational efficiency and reliability is the enhanced safety. We have also partnered with ABB to provide our customers with Complete Care of VFDs, so that our customers will be able to avoid possible breakdowns or deal with them in shortest possible time at lesser cost. Q. Could you give a brief idea of your product portfolio and services spectrum? We cater to complete in-plant material handling requirements for steel plants, automotive sector including ancillaries, general engineering, power equipment manufacturing, power generation in traditional (hydro & thermal) & renewable energy sectors (wind), paper manufacturing and warehousing etc. with a range of products and solutions encompassing chain hoists of 80 kgs to EOT of 400T capacity in varying configurations. On services part, we have deployed a team of specialists & skilled technicians offering value-added services like spare parts management, aftermarket services like Annual Maintenance Contracts, life enhancement & modernization/refurbishment, etc. Given our versatile expertise, we cater to service needs of Demag

as well as non-Demag brand products, which our customers see a major relief. Q. Whatâ&#x20AC;&#x2122;s the difference you have made to enhance the operational efficiency of your customers? At Demag, we collaborate with our clients to understand their needs and wants, and helping them select the right product with right attributes is only the first step in this direction. We advise on the right speed combinations to meet load cycle requirement, right mechanisms and controls for high-precision and safe movement, energy-efficient & reliable components for minimizing power consumption and maintenance cost in general and recommend configurations for reduced human intervention. We also educate clients on right maintenance practices; training customer officials for appropriate product usage & maintenance knowledge are some of the distinct efforts. Q. Whatâ&#x20AC;&#x2122;s the future of materials handling in India and where will you figure in this big picture? The future is definitely where Safety, Efficiency & Reliability will prevail. As an organization with close to 200 years of experience in understanding material handling for the industry, learning over this period in serving & satisfying customers from far-spread geographies across the world and as an organization that strongly believes in advancing through innovation in technology & services, we will continue to be preferred choice in the market and grow to take the top slot. www.engrreview.com

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Pneumatic Conveying in Chemical Industry By Anish Joseph

Pneumatic conveying system for solid chemical powder is seen as the next thing in the chemical industry. This provides the required automation to transfer powders through closed pipeline ensuring zero spillage, less manpower in process to handle and in turn giving clean environment to work for our colleagues. Mr. Anish Joseph Business Unit Head - Conveying Solutions at Rieco Industries Ltd. He has over 17 yearsâ&#x20AC;&#x2122; experience in the field of conveying. A pioneer in the field of conveying, he has implemented various new ideas and technologies which have benefited many industries. He has traveled widely and executed more than 80 projects involving pneumatic conveying solutions.

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ll Industries and sectors are experiencing the immense pressure of automated systems for quick production, less manpower and clean environment. Pneumatic conveying system for solid chemical powder is seen as the next thing in the chemical industry. This provides the required automation to transfer powders through closed pipeline ensuring zero spillage, less manpower in process to handle and in turn giving clean environment to work for our colleagues. Conveying system transfers material from one place to another through medium (Atmospheric Air/ Nitrogen gas or other inert gases) Some of the typically handled materials are Alumina, Aluminum oxides, Ball clay, Barite, Bauxite, Bentonite, Borax, Brown Friction powder, Calcium Carbonate, Calcium Chloride, Carbon Black, Roasted Coffee beans, Green Coffee Beans, Cullet, Detergent powder, Fine coal, Fly ash, Foundry molding sand, Glass batch, Glass beds, Gypsum, Iron Oxide, Kaolin clay, Kyanite, Lime, Magnesium, Milk powder,

Peanuts, Para-formaldehyde, Quartz, Roofing granulates, Salt, Silica Sand, Soda Ash, Sodium Sulfate, Steel Chips, Sulfur, Sugar, Talc, Titanium oxide, and much more! We at RIECO have been in this field for the last 35 years and has successfully handled and given effective solutions to the industry. Our expertise is well appreciated by our esteemed customers in the Chemical industry and has served them as boost to improve their productivity. CASE STUDY SYSTEM: Vacuum based lean phase pneumatic conveying system for Para-formaldehyde & Brown Friction powder SYSTEM DESCRIPTION: RIECO has successfully executed an order of vacuum based lean phase conveying system for specialty chemicals powder application at Mangalore. The powder being conveyed is Para-formaldehyde and brown friction powder having the Continue on page no.128 www.engrreview.com

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Tech Trends

A typical flow scheme for the material conveying system:

Continued from page no.126 bulk densities of 720 kg/m3 and 400 kg/m3 respectively and particle sizes in the range of 0.85mm-0.046mm. Powders are charged in the system through a 1 ton big bag unloading station and conveyed to the four numbers of weighing silos. The Material is conveyed at the rate of 2 tons/hr and 4 T/hr through a distance of 110 metres and 40 metres. The entire powder conveying system is supplied in SS-304 material of construction. Big bag unloading station is equipped with 1 ton capacity big Bag handling hoist arrangement, feed hopper and bin mounted dust collector with centrifugal fan to ensure the dust proof bag charging operation. Manual knife gate valve is provided at the discharge of dumping station for the ease of maintenance. Then these powders are charged in to the conveying line through special types of rotary air lock valves and loading tee arrangement. Rotary air lock valves are specifically designed for pneumatic conveying application. 128 | OCTOBER 2015 | ENGINEERING REVIEW

Sufficient amount of vacuum is generated in the system with the help of twin lobe positive displacement type roots blower. Selection of roots blower volume, suction pressure and pipe sizes plays an important role in designing the conveying system. Destination weighing silos are equipped with the dust collectors which separate the air from the powders and keep the environment clean. Electro-pneumatically operated diverter valves are provided for the selection of the specific destination silo. Further automation is attained with the help of PLC panel and feedback from different electrical accessories like level switches, limit switches, load cells, Electro-pneumatically operated butterfly valves, knife/slide gate valves, etc.

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Tech Trends

Air Cooling takes away your heat, while being eco-friendly and economical. Symphony shows how. Tomorrow’s world needs environment-friendly, energy conserving solutions and products. With increased global warming and environmental impact, people around the world recognize that businesses must act responsibly and offer green products to customers.

n the today’s era of global warming, the average temperature are on rise and summers are getting hotter every year, leaving the people with no choice but to resort to some or the other cooling solutions including fans, air coolers or air conditioners for some comfort depending upon their requirement and budget. For a country like India which is struggling with huge power deficits and where power cuts are in vogue in different parts, air conditioning is certainly not the only solution for cooling needs across the board from home to offices and commercial spaces to malls and airports, nor is it economically feasible. Tomorrow’s world needs environment-friendly, energy conserving solutions and products. With increased global warming and environmental impact, people around the world recognize that businesses must act responsibly and offer green products to customers. Air cooler is the best solution that comes to mind in the current situation, which is a green and environment-friendly product as it consumes merely one tenth of the electricity as

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compared to air conditioners. Also unlike air conditioners, which release CFC gas, air coolers do not emit hazardous greenhouse gases responsible for global warming and other environment-related problems. Further with our environment continuously undergoing changes, we need to constantly upgrade our structural designs and technology, incorporating good practices that result in environment protection, water conservation, energy efficiency with thoughtful use of natural resources while maintaining healthy indoor environment. Symphony pioneered branded Air Coolers Symphony Ltd is one company that enables people across the World to capitalize on eco–friendly, energy-saving air cooling technologies as serious alternative to high energy consuming and not so eco-friendly air-conditioners. Symphony Ltd provides air cooling solutions for residential and industrial segments offering advanced, energy efficient cooling and humidification solutions. Having established a leadership position in the home air cooler segment, the company is all set to provide air cooling and humidification solution for industrial and commercial units. ENGINEERING REVIEW | OCTOBER 2015 | 137

Tech Trends

Central Air Coolers from Symphony

Symphony pioneered branded air coolers in India by launching India’s first branded air cooler in the year 1989 and since than it has never looked back. Now Symphony commands 50% market share among organised players. The uniqueness of Symphony Ltd is that it is the only company which is focused on ‘Air coolers’. The strategy here has been ‘One Product Many Markets’ and over the years this strategy has paid off well and company today is world’s largest air cooler company and truly an international brand selling its air coolers under its own brand name in over 60 countries. Symphony possesses the largest number of trademarks and registered designs in the international air cooler industry with 108 trademarks, 49 registered designs, 7 copyrights and 8 patents. The company has been awarded Guinness World Record for creating the world’s largest functioning air coolers. Advantages of Air Cooling Air coolers use fresh, clean air from the environment. They also allow you to keep windows open for better air circulation whereas AC’s circulate stale air inside a sealed room. 1. Green Product: Air coolers are green product and unlike air conditioners, air coolers do not emit hazardous greenhouse gases responsible for global warming and other environment-related problems. 2. Energy-efficient : Further air coolers consume up to 10 times less energy than ACs. They can also 138 | OCTOBER 2015 | ENGINEERING REVIEW

work in low voltage areas. 3. Low on Maintenance : Air coolers require low maintenance; you rarely need to summon a mechanic for maintenance as in the case of ACs. 4. Environmental Friendly : Air coolers present significant environmental benefits with no harmful Chlorofluorocarbons (CFC) emissions and offer energy saving green cooling solutions. Symphony: Leading organised player in central air cooling As the name suggests, these coolers are comprehensive cooling solutions, addressing the cooling needs for large enclosed areas, factories, warehouses, retail chains, banquet halls, auditoriums, etc. Central air cooling is gaining increasing importance as corporate houses are looking to create a congenial working environment for their shop floor teams. Large and small factories are the most pertinent examples as corporate houses can ill-afford centralized air conditioning due to open-air areas as well as prohibitive capital and operating costs. “In earlier years due to lack of awareness and non-availability of the air cooling solutions for industrial undertaking, the penetration was low but it is improving rapidly. Further looking at the size of the Indian market and growth potential we can say the segment has immense opportunities in years to come. The market for industrial coolers in India is huge and

growing rapidly,” says Sanjay Sheth, General Manager, Symphony Ltd. Recent trend indicates that big businesses across various sectors are opting for central air cooling for spaces which are difficult to centrally air-condition. The installation of air-conditioning system in these areas may not be feasible or is a huge capital and operational expense. By providing better working condition to employees one can create a safer and more productive working environment. Cooler staff is more alert, efficient and productive. Cooler machines last longer and can produce more. Symphony is at a nascent stage in central air cooling segment but going forward, increased focus on strengthening product awareness and the corporate brand in domestic and international markets for this product are expected to generate sizeable volumes over the medium-term. The Company has a decent project pipeline, which provides assurance of a healthy business growth. “Our expertise in large metal Air Coolers and central air cooling provides us with the capability to implement large-scale industrial cooling solutions for a large number of industrial customers in India. We believe that the market for centralized Air Coolers is larger than for centralized air conditioning systems,” remarks Sanjay Sheth.Symphony strengthened its leadership team, widened its distribution network, and collaborated with many large opinion-driving HVAC consultants and large nationally renowned HVAC contractors for industrial cooling solutions. www.engrreview.com

Tech Trends

Symphony’s Central Air Cooling Installations Dominant presence in industrial cooling Expanding its presence in Indian industrial and commercial cooling market, the company has completed many prestigious installations of central air cooling systems till date. Symphony has completed installation of central air cooling systems for renowned clients, namely Asian Paints, DHL, Dixon Technologies, Swaminarayan Temple, ISKCON Temple, Marico in India and Walmart, GE, Prestolite, Lear Corporation, among others. The company’s clientele includes leading Textile, Auto, FMCG, Healthcare, Retail & Hospitality, Engineering, Logistics & Warehousing, Chemical, Consumer Durable companies among many others. Affordability and low maintenance cost of central air cooling are also likely to play a big role in growth momentum for the segment in coming years. Industrial air coolers are attractively priced, for a large residential house (approximately 2,000 to 3,000 sq ft) investment for cooler ranges between Rs. 1 to Rs. 2.5 lakh -- about one-third, or 40% of investment required for centralized air

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conditioning. Electric consumption of central air cooling system is only about 10% of the consumption of centralized air-conditioning. In other words, payback period from central air cooling is less than one year, just from saving of electricity of air cooler vis-a-vis air conditioner. Growth drivers • Firstly, it is proven that better work condition has helped increase productivity considerably. Same is supported by a NASA report which stated that at 38 degrees temperature, there is a 62% loss of work output and at 41 degrees, it goes up to 79%. Hence, there is an immense potential for industrial air cooling in India, wherever air conditioning is just not feasible. • Further shifting to air cooling for commercial and offices, retail and hospitality industry over air conditioning has helped big time in saving costs to the companies as air coolers use 90% less energy than an air conditioner does. • Industrial cooling also provides solutions to air cool segments such as airports, malls, retail chains,

factories, banquet halls, which are difficult and very expensive to air condition. • For certain factories, centralized cooling becomes mandatory due to operational process or product characteristics like textile applications, certain dyes and intermediates and certain chemicals, industrial coolers emerge as the most cost-effective solution. • In factories that house large boilers, large furnaces and other equipment, which generate a lot of heat, air cooling is the only cooling solution. Air coolers also find applications in warehouses that need to store material at controlled temperatures. In large commercial space and retail malls which have expansive open areas, industrial air coolers are the only workable cooling solution. Interestingly, wherever central air conditioning is used, there is potential even of using central air cooling or ducted air coolers.

– P.K. Balasubbramaniian

ENGINEERING REVIEW | OCTOBER 2015 | 139

INDUSTRY SPEAK

Our National Growth targets will get derailed unless we address the need for 1.2 million Welding Professionals by 2020 : IIW

‘Make-in-India’ Campaign has surged the growth prospects of the Manufacturing sector, but hue and cry of perennial skilled labour shortage has become vociferous in the automobile, construction, power & defence sectors.” – R. Srinivasan, President, The Indian Institute of Welding

here’s an alarming gap between demand and supply of skilled manpower in the country. If the infrastructure developments are in low ebb, the main reason is shortage of welding professionals. The country needs something like 1.2 million welding professionals including welders, cutters, fitters, equipment operators, inspectors and engineers by 2020. “In fact today a number of project contractors are importing welding and cutting operators from China., Russia & East European Countries,” revealed Mr. R. Srinivasan, President,The Indian Institute of Welding in a press meet in Mumbai on 15th Oct. “Our country is in dire need of overhaul of the current practices and must embrace and adopt new technologies to ensure we achieve the 12th plan targets,” he added. “We have already made representations to the PM’s Office as well as to the Union Ministry for Skill Development to bring home the fact that our 12th plan targets of adding 90,000 MW power generation capacities and creating new construction assets of 52 lakh crores may all get derailed for lack of sufficient

140 | OCTOBER 2015 | ENGINEERING REVIEW

skilled workers. The National mission of building 20 kilometres of new highways each day is already falling behind. The ‘Make-in-India’ campaign has surged the growth prospects of the Manufacturing sector, but hue and cry of perennial skilled labour shortage has become vociferous in the Automobile, Construction, Power & Defence sectors,”he added. Skilled welding professionals at all levels viz. pipe and plate welders, supervisors and welding engineers continue to be in short supply. The Union Government’s skill development machinery which targets to skill over 500 million Indians by 2022 must work to address the severe shortage in employable skills of the Indian workforce. It is unfortunate that such a vital subject like Welding is not included in the curriculum of our engineering colleges. The Indian Institute of Welding (IIW) has offered to partner with the Union and State Government machinery to up-skill Indian youth and overcome the shortage of competency-certified welding workforce. New trained welders need to be recruited, and uncertified welders may need to be retrained for manufacturing jobs of the 21st century. Students including those with SSC certification may contact the IIW Kolkatta based HQ or closest regional branches to examine the possibility of a career in welding. The compensation for welders is said to be very healthy. Many industries want to optimize their capital investments and rely on welders who have the ability to rebuild fairly old and worn out equipment. Such skills have become rare and are in great demand. “If you pursue welding, you will never be out of a job,” declares Srinivasan. IIW established in 1966 at Kolkata, is today an active member of the International Institute of Welding. IIW has a membership base of 4000

plus professionals and 350 corporates. It is a nationwide non-profit making organization dedicated to foster the development of welding science, technology and engineering in India. The Institute is rendering yeoman service in the areas of education, certification, training and dissemination of knowledge and information - all related to welding. The Institute has branches in 14 strategic locations across the country. With over 700 professional members, 120 student members and 70 corporate members, IIW Mumbai Branch is the largest branch of the Institute. IIW is holding a National Welding Seminar and WELD INDIA EXPO from 9th to 11th Dec. 15 at CIDCO Exhibition Centre, Vashi, Mumbai. Eminent speakers from CII, FICCI, and NABET (National Accreditation Board for Education and Training) are expected to participate in the seminar and deliberate on the relevant issues. The event aims to showcase the latest in welding technology, products & systems used globally. IIW will sit with the Government officials and administrators of the State- run IIT’s to update their curriculum, match their syllabus and facilitate training with industry participation on welding technology. The growth of welding industry is linked to the production and consumption of steel in the country. By 2019-20, the country’s steel consumption is expected to almost treble, touching some 220 million tons. This naturally means more industrial activities and dependence on welding and the need for more and more welding professionals. “Unless there’s a concerted effort now on, involving all professional bodies, industry, academia and the government, our ambitious growth targets will only be on paper,” cautions the IIW President. – P.K. Balasubbramaniian www.engrreview.com

FACE TO FACE

Masyc Projects – A formidable name in bulk handling New Delhi-based Masyc Projects is a well-known name in bulk materials handling. The company’s niche lies in handling corrosive and abrasive materials in harsh environments. It has a wealth of experience in offering customized materials handling solutions for a wide spectrum of industries. Mr. P.K. Balasubbramaniian converses with Mr. V.B. Bhatia, Jt. Managing Director, Masyc Projects to know more about the company’s capabilities and commitments in bulk handling. Excerpts: Mr. V.B. Bhatia, Jt. Managing Director, Masyc Projects Pvt. Ltd.

Q. You have been into bulk handling for decades. What precisely is your niche?

Q. What are the various materials handling applications in glass industry? Could you describe?

We are proud to be among the chosen few manufacturers who can fulfill all the requirements of Bulk materials handling systems and equipment requirements in different process industries like Cement, Pulp & paper, Steel, Coal, Glass, Fertilizer, Mining, Power, Agriculture, etc.

In glass industry, we handle various materials like sand, soda ash, fluorspar, cullet, etc. We also do batch houses, cullet handling & washing, weighing hoppers, etc.

Q. What are the solutions you offer for handling abrasive materials in cement plants?

Q. For powder handling, what are the different equipment you offer? For Powder handling, we offer Pipe Conveyors depending upon the

applications.

Q. Which is the largest / longest Belt Conveyor you have supplied? The longest Belt Conveyor we have supplied is the Cross-country Conveyor of 2.1 Km long.

Q. Your Side Wall High Angle Conveyor is said to be an engineering marvel. What are its design features and applications? It can take various shapes and can

Handling abrasive materials especially in cement plants, is our area of specialization. We recommend the use of liners for such applications.

Q. Steel industry is a major user segment for your materials handling solutions. What are the systems going there and for what applications? To steel plants we supply Belt Conveyors, Belt Changing Devices, Bucket Elevators, Trippers, Shuttle Conveyors, Steep Angle Conveyors for Raw Material Handling, Beneficiation, Palletization Plants, Coal & Coal Washeries, etc.

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A Typical Apron Feeder / Conveyor from Masyc

ENGINEERING REVIEW | OCTOBER 2015 | 141

FACE TO FACE

be used where we have space constraints.

Q. Could you give some idea of your manufacturing facilities and quality obsession?

Q. What’s the success rate of your Apron Feeders & Conveyors, and which are the industries that benefit from these systems?

We have well equipped six manufacturing units, having individual production and quality control heads. One unit is dedicated to manufacturing Rollers, where all testing facilities are available. One of the units is dedicated only to manufacture of Pulleys, where all testing facilities are also available. In another unit only Idlers & Frames are manufactured and in rest of the factories all types of heavy fabrication is done.

The success rate of our Feeders and Conveyors is 100% and the different process industries which are benefited are Cement, Pulp & Paper, Steel, Coal, Glass, Fertilizer, Mining, Power, Agriculture, etc.

Q. Let’s take Lafarge India. Which are the various customized products of Masyc in use at their end? For Lafarge India, we have designed, engineered & supplied Belt Conveyors, Trippers, Shuttle Conveyors, Screw Conveyors, etc. including Design Engineering of Heavy Structure.

Q. You are offering such a wide variety of products & solutions to the core sector. What are your design and project engineering capabilities? We have a full-fledged Design and Project Department to cater to the industry’s varied problems in material handling.

Q. What are your major strengths? Engineering, Delivery.

Quality

and

Timely

Q. What are the challenges ahead for a company like you? To survive and stay ahead, we have to keep ourselves abreast of the latest technology and provide technically viable solution to the client.

Q. What are your views on the prospects of bulk materials handling in India? The future of bulk materials handling looks to be good.

Masyc designs and commissions Belt Conveyors running to miles. The largest Belt Conveyor supplied by Masyc is of 2.1 km long.

142 | OCTOBER 2015 | ENGINEERING REVIEW

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IN FOCUS

Ador Welding Academy churns out over 1,00,000 welding professionals

dor Welding Ltd. (formerly Advani-Oerlikon Ltd) , a pioneer in the welding industry in India with a history spanning over six decades, is popularly known as ‘Welders to the Nation’. Ador Welding’s contribution towards welding education in the country is commendable. It has hitherto trained over 100,000 personnel in the art and science of welding and made them professionals. These professionals have all been absorbed in various sectors of the industry. There is a dearth of welding professionals in the country. Welding is still not in the curriculum or being taught in the engineering colleges! Ador Welding Academy – an institution AdorWelding Academy Pvt. Ltd, a

100% subsidiary of Ador Welding Ltd., is an institution in itself with a standing of over four decades engaged in skill training. It develops innovative tools to support the welding skill development and technical education. Under Pre-Service Training, the Academy provides employment-linked finishing courses for various levels in the welding domains: Welders, Supervisors, Engineers & Inspectors. It collaborates with regional & national agencies with proposals for competency and assessment standards, complementary training modules and any other initiative that will strengthen the national skill mission. It also co-develops concurrent certificate modules in welding production with diploma and degree colleges to improve the employability of pass-outs. A training session in progress at AWA

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ENGINEERING REVIEW | OCTOBER 2015 | 143

IN FOCUS

Under ‘In-Service Training’, the Academy enhances skill sets and on-thejob performance to meet industry requirements for best manufacturing practices. It collaborates with corporates to design and deliver career-oriented training modules to welding personnel. These modules will be on-site or off-site and would include content on related technical theory as well as employability skills that would enable employees achieve higher competence levels. Under ‘Technical Training’, the Academy covers a wide range of topics starting from arc physics & controls, to weld defects & remedies, types of welds, materials& microstructures, chemical & mechanical attributes of weld joints, codes & specifications, welder performance qualification, structuring quality plans & policies including occupational health and safety. The faculty comprises academically qualified personnel who have hands-on experience in assisting fabrication shop managers in good manufacturing practices. This helps them relate theoretical concepts to real shop applications and provide the impetus for engineers to develop confidence to explore opportunities for improvement at their workplace. Under ‘Graduate Programs’, the Academy works with BE and Engineering Diploma Colleges to provide students with opportunities to improve their employability in welding and manufacturing careers. The short period modules(25-350 hours), which include theoretical and practical components, will prepare students for gainful job roles in production, design, and project engineering related to welding fabrication in engineering companies. The Academy is also into Consultancy & Research to help to help the industry follow worldclass welding practices in India. Spreading the wings In addition to its training centers in 144 | OCTOBER 2015 | ENGINEERING REVIEW

Practical training through demonstration

Pune and Raipur, the Academy has added fournew locations of training at : Killari, Dist. Latur, Maharashtra ; Chandrapur, Maharashtra; Hosur, Near Bangalore, Karnataka ,and Chennai, in Tamil Nadu. The Academy has the distinction of having contributed to building National Occupation Standards (NOS) and Qualification Pack (QP) for various Sector Skill Councils, and has conducted training for trainers under Automotive Skills Development Council (ASDC)’s sector skill council. The Academy’s association with Dr. Babasaheb Ambedkar Research & Training Institute (BARTI) is on a growth path. Hereafter the programs under BARTI will also be implemented in Chandrapur and Killari, along with Pune center. Repeat orders from the customers like General Electric (GE), Mahindra & Mahindra (M&M), John Deere, TATA Power and others are testimonials to the quality of service the Academy provides to its clients. Welders from Bhutan, working on Chuka Hydel Project have been recently trained in advanced courses. They were earlier trained by the Academy on mid-range welding course. The Academy has successfully conducted IBR qualification project for GE welders. These welders were to

be certified for different materials and positions and in the first attempt all the welders have passed the test and have been qualified by IBR. In the coming years, the Academy has plans to launch training programs on Non-Destructive Testing (NDT) as well. Indeed, Ador Welding Academy is an eminent knowledge partner making a significant contribution towards skill development and education in welding in the country, thereby helping to bridge the gap between demand and supply of qualified welding personnel to meet the existing and emerging needs of a burgeoning economy. - P.K. Balasubbramaniian

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

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