Engineering Review - September 2018 by Divya Media Publications Pvt. Ltd.

Volume 18 No. 05 | September 2018 | ` 200 | www.engrreview.com RNI No. MAHENG/2004/15135

FIND THE PROBLEM… BEFORE THE PROBLEM FINDS YOU. • Thermal Cameras • Clamp Meters • Multimeters • Non-Contact Voltage Detector • Moisture Meters

Images for illustrative purposes only.

• Flex Clamps

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CEO CORNER INNOVATION & AUTOMATION : Analysing the trends Some of the technology advancements currently coming from automation vendors are more evolutionary than revolutionary. A little more memory, a little more processor, and Industrial Internet of Things (IIoT) capabilities are all great things, but for many it’s not the same level of “wow factor” as a revolutionary development like the 084 or even a single-loop controller. Consider the current state of various consumer products, such as phones. New phone models mean a bigger screen, better camera or faster processor, which are all great improvements but improvements that are evolving with consumer use as opposed to revolutionizing consumer use. For many, it’s just not the same flare as the moment Steve Jobs demonstrated scrolling on a touch screen for the first time to a captivated audience. The IIoT movement is bringing along a large demand for revolutionary developments. What could possibly be more IIoT than virtualized controllers that orchestrate control strategies through smart distributed control nodes? Or what could be more IIoT than SCADA systems being developed with ARM builds? Manufacturers are asking and vendors are beginning to answer the call. There’s also a huge amount of innovation coming from the engineering and integration side. We believe a lot of the IIoT movement will center on designing intelligent network and security strategies, as well as data contextualization and usage plans. Connecting your plant and collecting all data possible is great, but pairing with a company that understands the data being collected and who can help use it in ways that drive KPIs is critical. Partnering with a company that is constantly scanning the horizon of new technology to evaluate breakthroughs and work on mitigating early adoption risks will pay dividends years from now. Most importantly, partnering with a company that understands they have a social responsibility to keep plants safe and secure both physically and digitally will be a necessity as more smart devices with questionable security protocols inhabit automation networks. Innovation comes in a lot of different packages. Sometimes it’s a revolutionary development like Modicon’s 084 and sometimes it’s controlling a process with a tablet. Regardless of what innovation means to you, make sure it means a lot. Your company, projects and processes will thank you.

CEO

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4 EDITORIAL INDEX INNOVISTA SENSORS

Executive Publisher : Shilpa Kadam CEO : Shekhar Dongre Editor : Rajeev lyer Assistant Editor : Shweta Nanda CMO: Shirish Dongre Marketing Team : Ladoji Pendurkar, Amol Powle, Bhavin Shah, Bharat Shah, A. Purohit, Vinod Surve, Kavita Chaudhari Digital Marketing : Kailash P.

132

ABB

INNOVITES

ACE PRODUCTS & CONSULTING

INORBIT TOURS

ADOR WELDING

48, 132

AMI POLYMER

139

AVIANS INNOVATIONS

133

K K-LITE INDUSTRIES KVTEK

B B&R

BECKHOFF

BETTINELLI

136 64

L LAPP INDIA

24,110

Designer & Layout Arun P. Shinde, Nandan S. Moghe, Dinesh S. Gawade

Online Division Ganesh B. Mahale

CONSUL NEOWATT

Circulation Executive Satish Kadam, Amol Ranshur

16, 80

D DANFOSS INDIA

Head Office : Divya Media Publications Pvt. Ltd., 3rd Floor, Harmony Tower, N.S. Road, Thane-400 602. Maharashtra. Tel: +91 22-25380574/75, Telefax: +91-22-25418254 E-mail: shekhar@divyamediaonline.com Website: www.engrreview.com Branch Offices (Zonal): NORTH (Delhi & NCR regions) : Sandesh Jain : 09810837877 / 09871602777 SOUTH (Chennai & Coimbatore) : Y. V. Raghu : 09566141224 Bangalore - Vaman : 09686721340

E EOS

EUROBLECH 2018

FARO

FKL INDIA

92 104

MARVEL MACHINE TOOLS

138

MASYC PROJECTS

134

MECO INSTRUMENTS

132

MEECH

METSO

R RENISHAW

FLIR SYSTEMS

MANN+HUMMEL

30, 142

ROCKWELL AUTOMATION

ROLLON INDIA

ROVAR PUMPS

120

EAST (Kolkata & Eastern Region) : Sumit Roy - 09830470318 WEST (Maharashtra & Gujarat) : Pune - Shilpa K - 09833373371 Baroda - Dinesh Shah - 09998687659 Rajkot (Saurashtra) - Swapnil Bhatia: 09227909005 https://www.facebook.com/engrreview https://twitter.com/engrreview http://in.linkedin.com/pub/engineering-review/87/b31/97a

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

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

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G GANDHI AUTOMATIONS GEISSEL INDIA

131 84

GEM EQUIPMENTS

134

GOLIYA IMPEX

138

GRUNDFOS

22, 38

SATRONIX SECO TOOLS SHAVO TECHNOLOGIES SKF INDIA

HARTING

100

HEIDENHAIN

116

32 131 32

SMART SENSORS & AUTOMATIONS 139 SOLITAIRE MACHINE TOOLS

163

SUPERSLIDES & BALLSCREWS

44 138

U ULTRACAB

I IAC INDIA IGUS

56 26, 108

INDIA TOOLS & INSTRUMENTS CO. 140

W WINJIT TECHNOLOGIES

6 CONTENTS

Vol 18 Issue 05 | SEPTEMBER 2018

COVER STORY

NEWS

Meech Launches IonWash System for 3D Component Cleaning

Meech launches IonWash System for 3D Component Cleaning

Danfoss India launches its’ first Enclosed Low Harmonic drive

38 GRUNDFOS : Benchmarking the steadfast position through technology innovation

SKF India announces the launch of its new & competitive UC Range

Shift to Smart Factories

LAPP introduces SKINTOP HYGIENIC NPT for food and beverage industry

Seco partners with MachineMetrics to offer Manufacturing Analytics

EuroBLECH 2018: Enormous potential in digitalisation for sheet metal working companies

COMPANY PROFILE

We delight our customers by providing economic solutions to their grinding process

We have implemented 5S across all our manufacturing plants

SEPTEMBER 2018 | www.engrreview.com

B&R joins Huawei’s OPC UA TSN testbed Renishaw opens Additive Manufacturing Demo Center in California

INDUSTRY FOCUS

Soft Solutions for Wire and Cable Industry

Winjit launches Industrial IoT version of its product IoTSense

EOS unveils new series digital industrial AM production

German firm MANN+HUMMEL launches ‘OurAir’ in India

Mr. Saravanan Panneer Selvam Chief Sales Officer, Grundfos Pumps India Pvt. Ltd.

igus introduces the next generation of intelligent cable

A ‘POWERFUL’ EQUATION

56 IAC ENTERS EXPANSION MODE

68 TAKING A GLOBAL LEAD

76 “We give strategic advantages to our customers from diverse industries”

80 Consul Neowatt : A formidable name in power conditioning & power back-up

8 CONTENTS

Vol 18 Issue 05 | SEPTEMBER 2018

TECH TRENDS

FKL MAKE ROLLING EASY

“GEISSEL – CABLE GLANDS AND MORE…”

110

Intelligent machines with no boundaries

LAPP India’s 20-Year Journey to Becoming a Leading Industrial Cable Brand

100 South Africa: Alstom trains travel with HARTING technology

BUSINESS AVENUES

125

PRODUCT SHOWCASE

131

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EDITORIAL BOARD

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

Mr. Ashok Sheth Chairman Solitaire Machine Tools Ltd.

Prof. R. Sreedaran Faculty - Atharva College of Engineering

Mr. P.K. Balasubbramaniian President VBS Corporate Support

Mr. S. A. Mohan Chief Executive Officer Armes-Maini Storage Systems Pvt. Ltd.

Mr. Sriram Ramakrishnan Managing Director & CEO Consul Neowatt Power Solutions Pvt. Ltd.

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

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

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

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12 NEWS

Meech launches IonWash System for 3D Component Cleaning Meech International is announcing the launch of its newest technology, the IonWash, designed for the fast and consistent removal of contamination from 3D components in the automotive, aerospace and electronics sectors, among others. The freestanding 3D component cleaning system incorporates extremely powerful ionisation, as well as blowing and vacuuming airflows, providing a more efficient alternative to manual cleaning. “From the point of inception, the IonWash was developed with ease of use and cleaning efficiency in mind,” explains Adam Battrick, Sales Director at Meech. “Historically, the cleaning of 3D compontents has always been undertaken either by operators handling air guns, or through the use of a compressed air powered unit controlled by a foot switch. However, both of these approaches are heavily reliant on the operator, which leads to inconsistent results – sections of the component may be unevenly cleaned, while contamination blown into the atmosphere may redeposit on the product’s surface. The IonWash single-handedly addresses these issues while also side-stepping others, achieving optimal cleaning performance.” Key to the IonWash’s design are its multi-directional ionising airflow nozzles. The system is capable of provid-

SEPTEMBER 2018 | www.engrreview.com

ing 40 different nozzle placement possibilities, ensuring that the 16 multi directional nozzles can be positioned to cover all surfaces of a 3D component. The flexible design allows the high volume ionising airflow to be directed for a programmed optimal time onto uneven surfaces of the components being cleaned – such as a vehicle lighting clusters or a speedometer casings – neutralising static charges and loosening contaminants in the process. Simultaneously, high volume negative (vacuum) air flow extracts the contamination by pulling it into a vacuum chamber where it is filtered. By providing instant positive and negative high volume airflows, the cycle time is significantly reduced. Adding further to the over-

all flexibility of the IonWash is the presence of an access point on two sides of the system, enabling installation between two lines. The system is available in two standard size cleaning chamber sizes. Another key feature of the IonWash is the inclusion of in-built safety features and intelligent performance monitoring systems. In the event the system experiences any technical issues, an alarm will notify the operator. This helps to ensure that thorough cleaning is maintained at all times, allowing the IonWash to continue working to its full capabilities. Light guard sensors automatically stop the doors from closing when the sensor is interrupted, ensuring operator safety is maintained, and an emergency stop button is also included. Adam goes on to elaborate on the key benefits of utilising this technology: “Meech provides an advanced service and support that begins at the design stage and goes through to delivery, including adaptation of the system to suit particular applications. With a tailored design, the IonWash can be adapted to specification, so that it can be easily incorporated into the end user’s production line. Because it is such a time-efficient and effective technology, the end user is getting a consistently high level of contaminant removal with every cleaning cycle

– the more contamination is removed from the component’s surface, the higher the quality of the finished good will be. By having such a thorough system in place, the reject rate as a result of poor cleaning is exponentially reduced.” Adam concludes: “As production techniques have advanced, so have customers’ quality expectations. Today’s suppliers are looking for more ways to stand out from the competition and product cleanliness plays a key role in that. With IonWash, we have delivered a product that is tailored to multiple industries and incorporates the latest cleaning technology while also taking into account our customers’ needs and expectations. Our current users have already reported a four month return on investment, proving to be a value-added asset to their business. We certainly look forward to seeing how it will perform across all our sectors.”

14 NEWS

ABB CEO meets PM Modi, discusses e-mobility and renewables Spiesshofer’s talks with the Prime Minister focused on how ABB can support the government’s renewable energy targets, and accelerate public transportation’s transition to electric power. “By embracing e-mobility now, India can leapfrog other nations and become a world leader in e-mobility, while at the same time reducing emissions and dependence on fossil fuels. ABB is a technology leader for electric mobility and we are well positioned to partner India‘s electric mobility mission 2030,” said Spiesshofer. Spiesshofer’s meeting with the Prime Minister comes at

a time when India has set an ambitious target of producing 227 GW of renewable energy by 2022, and has launched an initiative to electrically power majority of its public transport vehicles. India is

CHINA INTERDYE 2019 The 19th China International Dye Industry, Pigments and Textile Chemicals Exhibition CHINA INTERDYE 2019 will be held in 10 – 12 April 2019. “China International Digital Textile Printing, Printing and Dyeing Automatics Exhibition - CHINA TEXTILE PRINTING 2019” will be held concurrently. At China Interdye 2018, 630 exhibitors from 17 countries and regions participated, 16,681 visitors from 53 countries visited the exhibition in the area of 40000 sq.m. The highlights of exhibits scope are: Exhibits are scheduled to include a variety of advanced environmentally-friendly dyestuffs, organic pigments, catalysts, intermediates as well as environmental impact

SEPTEMBER 2018 | www.engrreview.com

also investing to make its power grid more resilient in the face of growing demand. “This is not just limited to EV charging infrastructure, but also includes the entire electricity value chain. We

very much look forward to continuing sharing of ideas on driving forward India’s e-mobility revolution,” he added. In India, ABB is the only company with capabilities spanning the entire electricity value chain, from grid infrastructure, to automation and power management, to electrification, including electric vehicle charging. ABB is a digital leader at the forefront of the Energy and Fourth Industrial Revolutions and has been a leader in electrification and e-mobility for well over a century. For more information Web: www.abb.com

by Om Prakash, Director – InORBIT Tours Pvt. Ltd.

assessment equipment, digital textile printers in addition to printing and dyeing automation technologies and materials.

Scope of Exhibits • Dyestuffs Disperse Dyes, Reactive Dyes, Sulphur Dyes, Mordant Dyes, Acid Dyes, Alkaline Dyes, Direct Dyes, Vat Dyes, Cationic Dyes, Oil-Solubility Dyes, Bleaching Agents, Ink, etc. • Intermediates Dye intermediates, Pigment Intermediates, • Auxiliaries & Textile Chemicals Pre-treatment Auxiliaries, Dyeing Auxiliaries, Finishing Agents, Printing Auxiliaries, Pigment Auxiliaries,

Bio-enzymes, etc. • Organic Pigments Azo Pigments, Phthalocyanine Pigments, Lake Pigments, Heterocyclic Pigments, Pigment Printing Paste, Printing Ink etc. • Dyeing Equipments & Instruments Ice Making Machine, Dyeing & Finishing Chemical Equipment, Vacuum Drying Equipment, Control and Protection Equipment, Filtration Equipment, Analysis & Testing Instrument, Pump, Valve, Packaging Equipment, Automatic Control Equipment, Color Card, etc. • Control and Protection Technology

Visitor Profile: Target visi-

tors of the 19th China International Dye Industry, Pigments and Textile Chemicals Exhibition (CHINA INTERDYE 2019) will be Designers, Design Offices, International Sourcing, Agents, Fabric and Textile Accessory Wholesalers, Worldwide Brands Department Purchasing Managers, International Importers and Ready Wear Garment, Companies, International Textile Associations, International Trade Missions are the target visitors.

For more information omprakash@inorbittours.com www.chinainterdye.com/en

16 NEWS

World’s largest Lithium ion battery based UPS project rolled out in India Consul Neowatt recently announced that it is supplying UPS systems with Lithium ion battery to power the IP CCTV cameras that is being installed across Andhra Pradesh as part of the government program for enhanced safety across the state .This is one of the largest deployment of Lithium ion UPS solution in the world covering over 6,000 locations. Speaking on the project Sriram Ramakrishnan, CEO& MD, Consul Neowatt Power Solutions said, “Our customer came to us with the stringent requirement of a long life and maintenance

free UPS solution for outdoor environment to power the CCTV cameras which are spread over length and breadth of Andhra Pradesh. From our experience we know that VRLA (Valve Regulated Lead Acid) batteries are highly susceptible to high temperature and have a very low useful life in outdoor environments. The in-house R&D team at Consul Neowatt evaluated and selected a Lithium ion battery technology which can withstand higher ambient temperatures and has 5 times more cyclic life than VRLA batteries. We then developed

and deployed a smart, safe and reliable UPS solution with the Lithium-ion battery for this critical application. This is yet another example of Smart Power Solutions that we have developed and deployed in India. We have repeatedly shown the ability to be at the forefront of the next technological wave and lead it right here in India”. This project requires a 24 hour operation of the cameras installed on poles in key areas across the state. To ensure uninterrupted operation of the cameras on 24hour basis requires an assured power supply. This assured

uptime is provided through a specially designed Consul Neowatt single phase UPS integrated with the Lithium ion battery that is kept in a special IP55 metal enclosure below the camera. The decision to go with Lithium ion batteries instead of the conventional Lead acid batteries was taken keeping in mind the life of the battery in high heat condition and lower weight of Lithium batteries.

For more information www.consulneowatt.com

Danfoss India launches its’ first Enclosed Low Harmonic drive Danfoss India, an industry leader focused on climate and energy efficient solutions, unveiled its latest product to the Variable Frequency Drives segment – an Enclosed Low Harmonic drive with passive filters, at the Energy Efficiency Summit at Hyderabad, in the presence of His excellence Mr. Sergio Dario Barrientos, Ambasador of Bolivia, Mr. Pankaj Kumar, Secretary, Bureau of Energy Efficiency, Mr. Ravichandran Purushothaman, President, Danfoss India and several other industry experts on Energy Efficiency. The Low Harmonic Drive, which is IEEE 519-

SEPTEMBER 2018 | www.engrreview.com

2014 grid compliant is set to disrupt the power industry with its distinct feature to mitigate harmonic worries and achieve a Total Harmonic Distortion of 5 percent. The product will also help in reducing the energy consumption of external components and reduce the loss of energy in the process. Speaking on the launch of the product, Ravichandran Purushothaman, President Danfoss Drives, said, “With the launch of the new Low Harmonic Drive, we seek to affirm our commitment to our customers and partners by engineering the best possible drive solutions without

compromises and find the optimum outcome for their challenges.” Danfoss’ drives can be utilized across industries such as marine and offshore, waste and wastewater management, HVAC (Heating, Ventilation and Air Conditioning), refrigeration, food and beverages industry, lifts and escalators management, mining and minerals industry, chemical industry and in the management of cranes and hoists which highlights the versatility of the product. During the event, Mr. P L Palanisamy, Director - Danfoss Drives, said, “Danfoss Drives is passionate about

the future where it seeks to capitalize its knowledge and expertise that has been built over the decades. In 2025, we estimate that more than 5 billion people (over 50% of the estimated world population) will benefit directly or indirectly from the benefits provided by Danfoss Drives in their everyday lives with our installed base saving the annual equivalent of 60 hours of global energy consumption.”

18 NEWS

EOS unveils new series digital industrial AM production EOS showcased its latest systems and solutions at the International Manufacturing Technology Show (IMTS) in Chicago, IL from September 10-15, 2018. At the show, EOS launches the new EOS M 300-4 system which is part of the broader, modular metal 3D printing platform EOS M 300 for digital industrial additive manufacturing (AM) production. The EOS M 300-4 expands the portfolio of well-proven Direct Metal Laser Sintering (DMLS) systems, among them the highly popular EOS M 290 system. The EOS M 300 series is an automation-ready, future-proof platform that is configurable, scalable, and secure. It comes with a build volume of 300 x 300 x 400 mm and serves a variety of manufacturing fields, including aerospace, industry, medical, tooling

and automotive. This new modular platform comes with a configurable and scalable equipment architecture, which enables full flexibility and customized system configurations. As such, it is the perfect choice for organizations demanding reliable and robust industrial standard equipment for AM production. For better production flexibility and automation

and depending on system configuration â&#x20AC;&#x201C; customers can choose between different solutions: one, two or four lasers, multi power laser configurations (400 or 1,000 Watt), fixed or variable focus, different types of recoaters, new and expanded exposure strategies, part handling (manual or automated), monitoring options and three different clamping systems (3R, Delphin, Erowa).

Customers can also flexibly choose between two powder dosing options for full build jobs without refilling: bottom-up dosing to become independent of materials particle size distribution; and automated, top dosing to enable a closed loop solution. The EOS M 300-4 with four lasers will be able to offer variable laser power sources in the future â&#x20AC;&#x201C; from 4 x 400, to a mixed set-up of 2 x 400 and 2 x 1,000, up to 4 x 1,000 Watt laser power. The system also offers full field overlap with four scanners, meaning that lasers can reach all spots on the build plate, enabling full flexibility with regards to build orientation. The system enables an increased productivity by factor 4 to 10 compared to the EOS midframe system EOS M 290, dramatically reducing cost per part.

FARO introduces Tracer for projection and inspection FARO announced the release of the next generation of the Tracer platform for laser-guided assembly and verification, the TracerSI Advanced Laser Projection System. TracerSI is a fully integrated, optimized solution that includes both innovative, improved hardware built upon the very successful TracerM product and the best-in-class BuildIT Projec-

SEPTEMBER 2018 | www.engrreview.com

tor software. Like its predecessor, TracerM, TracerSI uses 3D Computer Aided Design (CAD) information to project 3D laser images onto a physical surface and provides a live,

visually rich virtual template which assemblers can use to quickly position components with precision and complete confidence. This solution can deliver significant ROI as organizations no longer have

to invest capital in physical templates i.e., wood or metal mold or tools which also have to be built, maintained, stored or even repaired. Additionally, real time manufacturing errors are mini-

INDUSTRIAL COOLING:

SIMPLIFY YOUR SYSTEM AND TAKE CONTROL OF COSTS

GRUNDFOS iSOLUTIONS

A SMART SOLUTION FOR YOU

INTELLIGENT SOLUTIONS FOR INDUSTRIAL COOLING Industrial cooling systems require an advanced pump setup that can quickly adjust to demand â&#x20AC;&#x201D;but this often leads to increased system complexity and higher operational costs. Grundfos iSOLUTIONS can help you optimise the entire system with intelligent pumps, cloud connectivity and digital services. With our intelligent solutions you can simplify system design, increase energy efficiency and take control of costs. Discover more at grundfos.in

22 NEWS

mized and, as a result, costly scrap and reworks costs are reduced. There are actual, documented cases where rework and scrap savings alone have payback periods as short as 90 days. Pete Edmonds, Vice President Factory Metrology said, â&#x20AC;&#x153;Our initial focus was towards building a better laser projection product but key learnings from the market in-

dicated that there was a need for laser projection system that combined hardware and software in a tightly-aligned, repeatable solution. By integrating the BuildIT Projector software with the Project and Inspect Tracer SI hardware platform, we have taken another major step forward in realizing our vision with the scanning laser camera to be the undisputed solution

leaders across the end-toend build by projection and inspection marketâ&#x20AC;?. TracerSI will transform 2D imagery and its use in every industrial application as it represents the first of its kind laser scanning camera, with projection and high-resolution image scanning capabilities throughout its entire projection volume. Since the laser scanning camera does

not rely on lenses or conventional image capture, the depth of field is equal to the full projection range, there are no lighting limitations since it is laser illuminated, and there are no limitations on frame size and resolution.

point in time, the capability of an industry to balance its environmental and business interests is crucial. A green factory not only entails a sustainable way of production, but it starts at how the facility is built (i.e.) the materials used. Also, it must take into account the energy consumed by the secondary processes of the factory. For

example, temperature control is an important system in a factory, but that does require the temperature control system to function round the clock, as the load varies at different times. Using an intelligent solution like the Grundfos iSolution Temperature Control system ensures full control of temperatures with fewer components and a complete overview of the systemâ&#x20AC;&#x2122;s performance.

For more information Web: www.faro.com/in

Shift to Smart Factories In an industrial setting pumps never work in isolation and are always a part of a larger system. Grundfos has invested heavily in the R&D of its products. It was 7 decades ago when they came up with their first pump, solely built for the purpose of moving liquid from point A to point B. Further developing on the technology, they introduced the E-Solution pumps, whose integrated controls enabled the pumps to adapt to changing demands. This helped further smoothen the pumps and make them more energy efficient. Fast forward to 2007, Grundfos pumps were the first company to couple IOT technology with their pumps, leading to what is now called

SEPTEMBER 2018 | www.engrreview.com

- Grundfos iSolutions. Years of R&D and expertise in the pump industry, the iSolution greatly improved on several aspects. Focusing on intelligent communication between components like the drives, measurement & control systems, the Grundfos iSolution pumps have enabled the end-users to enjoy benefits like user-friendliness, great savings, and extended customization. It is the constant innovation by companies such as these that drive the move towards smarter factories. Another aspect of smart factories is about how clean they are in terms of energy efficiency and anti-pollution measures. At this

Web: www.grundfos.in

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24 NEWS

German firm MANN+HUMMEL launches ‘OurAir’ in India Germany based MANN+HUMMEL Group has announced the launch of its OurAir brand in the Indian market. OurAir offers endto-end indoor air quality solutions that combine MANN+HUMMEL’s 77 years of filtration expertise with cutting-edge digital innovation. These solutions are based on smart devices, where air quality monitors, filters, purification and ventilation systems, integrate seamlessly with the OurAir digital platform. With OurAir solutions, building owners, facility managers and tenants can “KNOW, IMPROVE and MANAGE” the air quality in commercial buildings.

The launch in India also coincided with the official announcement of the accreditation of both the OurAir air quality monitors and digital platform by RESET, the world’s first sensor-based and performance-driven building standard and certification program. The RESET Standard is created with the aim of improving indoor environments and occupant health on a global scale OurAir is the first company to successfully achieve RESET accreditation for both its cloud software (OurAir Digital Platform), and air quality monitors (OurAir SPS208, SPB308, and SPB358), making it the largest complete

end-to-end solution provider in the world. “Access to clean air is vital for human health and well-being. Unfortunately air pollution in India continues to pose a serious challenge. Based on a WHO ranking of particulate pollution in cities in 2018, 14 of the 20 cities with the highest levels are located in our country.” said Pradeep Randhawa, Managing Director, MANN+HUMMEL India. “We are paying a high price for this, where 30% of all premature deaths today are due to air pollution. As a company MANN+HUMMEL wants to contribute. While it is challenging to eliminate outdoor

air pollution, there are effective solutions to ensure good air quality indoors, where we spend up to 90% of our time.” “The launch of OurAir in India is timely. There is an increase in public awareness, growing demand for pollution-free offices and homes, and new government regulations and building standards supporting the adoption of clean air solutions. We expect the market to grow rapidly over the next few years” added Pradeep Randhawa.

LAPP introduces SKINTOP HYGIENIC NPT for food and beverage industry When it comes to hygiene, the food and beverage industry sets high demands. This is reflected in the corresponding standards for firms that build plants for food processing. The directives of the European Hygienic Engineering and Design Group (EHEDG) that are accepted in Europe are virtually unknown in India. There is also UL certification for compliant use of components in plants and machinery. LAPP increasingly offers connection systems that meet all standards, to make choosing the right components easier. The latest all-rounder in its

SEPTEMBER 2018 | www.engrreview.com

product range is the SKINTOP® HYGIENIC NPT cable gland, which is now also available with National Pipe Thread (NPT thread) and certified to NSF/ANSI 169 for “food zone non-contact”. The cable gland can be used for filling systems in dairies or breweries, as well as in the chemical and pharmaceutical sectors. SKINTOP® HYGIENIC NPT is a special combination of hygienic design with an NPT connection thread. Most self-sealing pipe threads usually have a gap at the intermediate connection, while part of the outer thread

remains visible. This feature clearly runs counter to the principles of hygienic design, which calls for surfaces to be as smooth as possible, without edges, corners and above all gaps in which food could settle and allow bacteria to develop. LAPP’s engineers came up with a smart design that creates an NPT thread with no gap and no visible thread. The cable gland therefore meets the latest directives of the European Hygienic Engineering and Design Group (EHEDG). It is also resistant to cleaning agents in line with the requirements

of ECOLAB, a provider of products and services for industrial cleaning. The fact that the new SKINTOP® HYGIENIC NPT is UL certified makes it an allround product suitable for both export-focused plant engineering firms in India. As is standard for LAPP, the SKINTOP® HYGIENIC NPT is available in all standard diameters with the corresponding counter nuts. An Electro Magnetic compatibility (EMC) version, the SKINTOP® HYGIENIC SC NPT, is also available.

ENGINEERING REVIEW |

| September 2018

26 NEWS

igus introduces the next generation of intelligent cable At the heart of every intelligent cable from igus is a complex sensor called CF.Q. With the module, the electrical properties can be tested in additional measuring cores and continuously compared with existing empirical values of a given chainflex cable. Damage by bending or extreme loads can be reliably detected. In addition, guide values for the cables can be defined in advance. If the CF.Q module is installed, it informs the customer by actuating a normally closed contact when these predefined values of the electrical parameters change. Only the combination of empirical values and real-time measurement allow users precise maintenance predictions for their cables - especially

in the dynamic production environment. This is made possible by an industry 4.0-capable application called isense-online. It compares the recorded real-time values of the cable and the empirical values existing in a database, and if it detects fluctuations, it prompts the plant operator to initiate maintenance. And this is indeed done before the damage occurs and the production or plant shutdowns become a risk. The new generation of CF.Q modules are now suitable for switch cabinet assembly thanks to tophat rail housings and thus offering additional flexibility for electrical engineers in terms of integration as well as handling. In addition,

the modules are suitable for data logging thanks to the SD card slot. An output of the measured values on a serial interface is also integrated as standard. Customers who want to get a precise insight into the recorded measured values can do so by connecting to the isense-online system via a detailed view. In any case, the user has access to a wide variety of communication channels and reporting options. Maintenance recommendations or impending failures are displayed in the classic browser view of desktop PCs, as well as on all mobile devices such as tablets and smart phones. For maintenance teams and production managers, intelligent igus cables are bringing in

Combined with technology trends such as neuronal networks or artificial intelligence, igus is setting new standards in intelligent cables and predictive maintenance. (Source: igus GmbH) a paradigm shift in maintenance and servicing through accurate prediction.

For more information www.igus.in

Metso wins significant order from JSW Steel Metso has won a significant order to deliver a pellet plant, including grinding, filtration and a pyroprocessing pellet plant to a large-scale steel operation of JSW Steel Ltd. in India. This new order is Metso’s largest global pellet plant delivery, and the single largest installation for Metso 204060 Vertical Plate Pressure Filters VPA, which are used in heavy-duty dewatering applications. “Metso has a proven track record of delivering sustainable performance

SEPTEMBER 2018 | www.engrreview.com

and reliability to the mining industry globally. We are very proud of this order, which further strengthens our position in the Indian mining market,” says Victor Tapia, President, Metso Mining Equipment business area. Metso established its operations in India in 1992, and has been developing a strong footprint in the market ever since. Today, Metso is the leading player in pelletizing in India. “We build long-term relationships with our

customers, which is the key for success. Through them, we can provide our customers with the best solutions to ensure low operating costs while also improving resource efficiency and recovery”, says Kamal Pahuja, SVP, Indian market area at Metso. Metso is a world-leading industrial company offering equipment and services for the sustainable processing and flow of natural resources in the mining, aggregates, recycling and process industries. With our unique

knowledge and innovative solutions, we help our customers improve their operational efficiency, reduce risks and increase profitability. Metso is listed on the Nasdaq Helsinki in Finland and had sales of about EUR 2.7 billion in 2017. Metso employs over 12,000 people in more than 50 countries.

For more information metso.com, twitter.com/ metsogroup

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

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28 NEWS

Winjit launches Industrial IoT version of its product IoTSense Winjit Technologies, a pioneer in providing smart IoT solutions by innovating concepts based on real-time data, was a part of the automation expo at Bombay exhibition centre from 29th August to 1st September 2018 where it launched its Industrial IoT version of its product ‘IoTSense’. The industry 4.0 enabling platform, which is an award-winning full-stack IoT platform built using open standards and is one of the most versatile, scalable IoT platforms. For the manufacturing domain, IoTSense can be deployed for the rapid transition to industry

4.0 standards. It has won the NASSCOM Emerge 50 Award, 2017 for the Most Innovative Product and Business World Leadership & CIO Award, 2017 for the Best IoT Implementation. The full-stack comprises functionality to fetch data from industrial sources like PLC, sensors etc, manage and group industrial assets, monitor and alert exceptions in real-time, perform real-time analytics at the shop floor level, and provide inputs to 3rd party applications like PPC and ERP. The system can start delivering value in less than a week. Winjit also showcased its

automated machine learning product, ‘PredictSense’, which is an automated machine learning platform built on an open API structure using efficient algorithms. It helps you to solve complex real-time business problems with its high-power algorithms in a very less amount of operational time. It builds predictive models which in turn helps you take precise and optimum business decisions. Commenting on the participation & the launch of industry version of IoTSense, Mr. Ashwin Kandoi, Director & Co-Founder of Winjit said, “We are delighted to be

associated with this landmark event as it provides us with an excellent platform to launch our new products, showcase our company, our industry expertise and our solutions to the industrial sector. The industry 4.0 version of our product is aimed at bringing value to customers in the industrial sector.” For more information www.winjit.com

B&R joins Huawei’s OPC UA TSN testbed B&R has joined the OPC UA TSN testbed of Chinese network equipment vendor Huawei. The Austrian auto-mation specialist is now participating in all three of the world’s most significant platforms for practical testing

SEPTEMBER 2018 | www.engrreview.com

of the new communication technology. The two other testbeds are those organized by the Industrial Internet Con-sortium (IIC) in the USA and Labs Network Industrie 4.0 (LNI) in Europe. “Huawei’s testbed gives us

the opportunity to advance the standardization of OPC UA TSN in Asia,” ex-plained B&R Marketing Manager Stefan Schönegger during the presentation of the testbed at the Hannover Messe. “In doing so, we’re making an-

other important contribution toward globally harmonized industrial communication.” From the sensor to the cloud Huawei’s testbed will feature an OPC UA TSN network simulating all aspects of smart factory communica-tion – from individual sensors to the ERP system and on into the cloud. Data will be transmitted exclusively via OPC UA TSN – regardless of whether it is real-time motion control data or aggregated performance met-rics for executive management. There is no need for communication interfaces of any kind. For more information www.br-automation.com

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30 NEWS

Ultracab: A leader which banks on quality Ultracab is promoted and led by Mr. Nitesh Vaghasiya. He is founder and Chairman cum Managing Director of the Ultracab. Under his leadership ULTRACAB has been able to achieve new heights of success in manufacturing and export of Wires & Cables. The company was incorporated in the year 2007 and is engaged in the manufacture and export of wires and cables by using advanced technology and machinery for manufacturing quality products. Ultracab follows strict quality standards during manufacturing process. Once product is ready, it is closely checked for safety and quality assurance by our research

team and on approval, it is marketed for end users, a well-equipped research and development unit that helps us immensely to offer innovative products to our clients. R & D is always a boon for staying ahead of others in this extremely competitive environment and our cables and wires have always assisted in the growth of a substantial segment of Indian industry. A manufacturing unit is situated at Shapar (Rajkot, Gujarat) India, spread over 11500 sq

m area and has 100 per cent in house facility involves modern technology and tools, high-tech machines from wire drawing machine until testing on finished product. Ultracab manufacture wide range of products and all the products are approved and certified by the various Government and Non-government certificate. All products have highest numbers of certificates for quality and standards. Ultracab is ISO 9001-2008, ISO 14001:2004 certified company, and products are certified with ISI: 694, ISI: 1554, ISI: 7098, ISI: 14255, CE, UL (USA), cUL

(Canada), TUV and also qualities are tested and approved by ERDA and CPRI. With the strong quality products standards Ultracab being an approved vendor of government companies as well as public limited companies. In 1996, Nitesh Vaghasiya started his own business of Cable Manufacturing on rental base unit having one small machine of domestic wires and after that he was started his own domestic wire manufacturing unit at Gondal and established Ultracab in year 2007. Due to his focus, the company has won several awards.

Renishaw opens Additive Manufacturing Demo Center in California Renishaw has opened a new Additive Manufacturing Demonstration Center in Newbury Park, California. Working in collaboration with Ibex Engineering, the Demonstration Center is situated within Ibex’s headquarters and allows visitors to explore, interact with and use Renishaw’s latest metal additive manufacturing systems. The center will be equipped to print high-precision titanium (Ti64Al4V) parts on Renishaw’s RenAM 500 series of laser-powder-bed-fusion AM systems. Ideal for industrial production applications, the RenAM 500 series allows for powder

SEPTEMBER 2018 | www.engrreview.com

sieving and recirculation to be carried out automatically within the compact system, reducing the need for manual handling and exposure to materials. To provide a complete picture of the metal additive manufacturing process, the Center will also feature ancillary elements such as wet downdraft, heat treatment, support, machining and inspection technology, and part removal equipment. These components work in concert with the AM system to ensure parts are printed and finished to specifications. Stephen Anderson (AM Business Development Man-

ager, Renishaw USA) stated, “It’s fantastic to be able to place a metal additive manufacturing production cell within Ibex. Not only does it allow us to showcase our latest technologies, but partnering with Ibex provides us access to an expert manufacturer of precision staging equipment who will utilize the technology to develop innovative products, and drive metal AM into new markets and even wider adoption.” Andre Perrin (Ibex Engineering CEO) said, “We have been a user of Renishaw’s high precision encoder systems in our products for many years and have a close

working relationship. They understand manufacturers and manufacturing, the importance of quality, reliability, and most importantly, service. We are very excited about Renishaw’s approach to metal additive manufacturing and their vision to develop high precision, repeatable machines capable of serial production of parts. We look forward to developing new AM parts for our business and to sharing our knowledge with Renishaw’s visitors.”

32 NEWS

SKF India announces the launch of its new and competitive UC Range SKF India recently announced the launch of its new competitive product offering the Ball Bearing UnitsUC Range India in response to the growing/ new market demand and its commitment towards locally produced products at global quality and reliability. These Ball Bearing units combine the Japanese Industrial standard (JIS) compatibility perfectly with SKF reliability. The SKF Ball Bearing Units - UC range, comes with a dependable assurance of world class quality and superior performance. The UC Range has an added advantage of

being cost competitive, as it is manufactured locally in India and brings a higher availability and better service life to the market. The solution is easy to install and directly interchangeable with JIS equipment available in the market today. The enhanced set screw locking system provides 16% better holding power and the rugged integral seal with flinger delivers effective protection in highly contaminated environment . UC range finds applications in material handling, food and beverage, HVAC, metal, agricultural as well as

in textile industry. The product is used in the application like low speed conveyors, screw conveyors, parcel and baggage handling conveyor compressors and fans, poultry equipment conveyors, construction equipment, and stone crushing equipment. Shrikant Savangikar, Director Business Excellence and Sustainability stated, “ The launch of new ball bearing units – UC range is yet another milestone for industrial business in India. We at SKF India constantly endeavor to offer the best in the industry solutions. With the UC range we are proud that we have

enabled enhanced performance for our customers. With UC range SKF aims to provide global quality products locally, thus improving the availability and service levels. The product will to deliver high rotating equipment performance and enhance plant productivity”. The new range of ball bearing units will be made available through SKF India’s existing Industrial distribution network as well as directly for OE requirements.

Seco partners with MachineMetrics to offer Manufacturing Analytics As part of a global initiative to ensure the continued success of its customers, Seco Tools is expanding their customer service capabilities through a partnership with MachineMetrics. MachineMetrics’ manufacturing analytics engine will provide Seco and its customers a technological resource for their advancement into Industry 4.0. “Seco has always been committed to providing our customers with the best products and services available. Partnering with MachineMetrics will allow us to not only continue to help our customers learn about themselves but will transform our ability to help them improve

SEPTEMBER 2018 | www.engrreview.com

their machine tool utilization and production capacity.” said Ben Alexander, Business Manager Online Services at Seco Tools. Seco plans to use the MachineMetrics Industrial IoT platform and its manufacturing analytics applications as a cornerstone in their expansion into new technology services. With data provided by MachineMetrics, Seco can apply their extensive experience and engineering capabilities to the continuous improvement of their customers by helping them make data driven decisions to improve their efficiency and bottom line. Leveraging Seco’s experience in tooling with Machin-

eMetrics’ data collection capabilities will help both Seco and MachineMetrics customers gain a deeper understanding of what’s happening with their tools in real-time. These insights may include predicting tool life, preventing tool breakages, and feed and speed optimization. “This partnership offers an exciting opportunity for both MachineMetrics and Seco Tools to demonstrate the value of data-driven manufacturing and analytics to Seco Tools users around the world,” says Bill Bither, CEO of MachineMetrics, “Together, we can uncover industry-first insights into machine tool and tooling op-

timization that will enhance the availability and reliability of machines for customers.” With the MachineMetrics Production Monitoring application, Seco will enable their global customers to gain visibility into their production using an easy to use, do-it-yourself, completely customizable manufacturing machine monitoring system. The historical and real-time machine data collected by MachineMetrics allows users to gain insight into their machine tool health, identify new service needs with analytics and reporting, predict and deliver early warning of potential machine or tooling failures.

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AC Voltage : 0 ~ 700V. DC Voltage : 0 ~ 1000V. Short circuit current upto 5mA. PI, DAR & Auto Hold Function. 2 Lines X 16 Characters large LCD Backlight display. Auto ranging on all insulation ranges. Internal memory for data storage. 2 optical LEDs are built in for data transfer. TO VIEW THE FULL RANGE OF OUR PRODUCTS VISIT : www.kusamelectrical.com

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34 NEWS

EuroBLECH 2018: Enormous potential in digitalisation for sheet metal working companies New digital solutions increasingly important investment sector for SMEs This year’s 25th International Sheet Metal Working Technology Exhibition will take place from 23rd - 26th October 2018 in Hanover, Germany. A total of 1,500 exhibitors from 39 countries secured their stand at the world’s leading sheet metal working technology exhibition. This year, the show is mainly influenced by the topics Digitalisation and Industry 4.0. The Online Show Preview, which was recently published, provides an overview of new products and technological innovations which will be presented at the show in October. A total of 1,500 exhibitors from 39 countries have booked their stands at the world’s leading exhibition for the sheet metal working industry. EuroBLECH 2018 will feature more than 89,000 square metres net exhibition space, another growth of around 2% compared to the previous event. The most important exhibitor countries are Germany, Italy, China, Turkey, the Netherlands, Spain, Switzerland, Denmark and the USA. For this year’s 25th edition of EuroBLECH, the main topics are Industry 4.0, big data and digitalisation. Especially for small and medium-sized companies these developments offer enormous potential. These new business approaches offer advantages

SEPTEMBER 2018 | www.engrreview.com

working. 1,500 companies will be exhibiting, ranging from large industrial corporations to small innovative start-ups”, continues Evelyn Warwick.

Show Preview now available at www.euroblech. com

in terms of streamlined and less complex processes as well as improvement of productivity and efficiency. “While an app for maintenance control of machines or the interaction of machines and robots across the whole production process were still a vision of the future a couple of years ago, today this is the reality in sheet metal working. Currently, not only large companies are gaining ground in this area, SMEs have also recognised their potential here. Their company size usually allows them to react flexibly and quickly to such transitions, therefore they are in a good position to use digitalisation to their advantage”, says Evelyn Warwick, Exhibition Director of EuroBLECH on behalf of the organisers Mack Brooks Exhibitions. “At EuroBLECH 2018 as the world’s largest sheet metal working exhibition, visitors can expect the most comprehensive technology range in terms of industrial digitalisation of sheet metal

The comprehensive Online Show Preview, with detailed information on many exhibitors and their products, is now available. In preparation of their visit, users will be able to sort entries by product categories or halls, to discover their personal highlights of this year’s exhibition. In this way, visitors can search exhibitor profiles including products and services presented at EuroBLECH 2018 and create their personalised version of the show preview.

New EuroBLECH White Papers available: Digitalisation, Lightweight construction and E-mobility Digitalisation, E-mobility, Lightweight construction – these topics currently play a crucial role in the sheet metal working industry. Networked manufacturing is a key development in Industry 4.0 to increase productivity and reduce downtime of machines. E-mobility bears a lot of challenges for sheet metal working, due to the different manufacturing processes

and materials required for electric cars. This goes hand in hand with lightweight construction, where composites and new technologies become increasingly important and bear certain challenges when joining or separating materials. The new EuroBLECH White Papers covering these three topics will shed some light on the recent developments within these areas and will provide some insight into new trends in the industry. All three White Papers are now available free of charge on the exhibition website www.euroblech.com.

Friday, 26 October: Student Day at EuroBLECH 2018 The young generation is increasingly gaining importance in the sheet metal working industry due to the digital transformation and the related changes to occupational profiles. Therefore, EuroBLECH offers students the opportunity to visit EuroBLECH free of charge. On Friday, 26 October 2018, students will be able to get free entry to the show when presenting a valid student ID at the entrance. During all other show days, students are invited to visit at a reduced student fare of €15 per day ticket. At the show, there will be a job board, where exhibiting companies are ad-

36 NEWS

vertising latest job openings. The job board is also available online: https://www.euroblech. com/2018/english/visitors/ job-vacancies/

EuroBLECH Exhibition Profile EuroBLECH 2018 covers the entire sheet metal working technology chain: sheet metal, semi-finished and finished products, handling, separation, forming, flexible sheet metal working, joining, welding and surface treatment, processing of hybrid structures, tools, additive manufacturing, quality control, CAD/CAM/CIM systems and R&D. The show

attracts sheet metal working specialists at every management level in small and medium-sized companies as well as in large enterprises. Visitors include design engineers, production managers, quality managers, buyers, manufacturers, technical directors and experts from associations and R&D.

countries or halls. The new EuroBLECH App for Android and iPhone can now be downloaded via the App Store. It includes an interactive area map and a function to search for exhibitors and plan your visit to the show, as well as further useful features for visitors of EuroBLECH.

Visitor Information Show Planner and EuroBLECH App

Venue and Opening hours

The new show planner is now available on the EuroBLECH website www.euroblech.com and offers, next to a free text search, the option to select product categories or sort the exhibitor list by

EuroBLECH 2018 takes place at the Hanover Exhibition Grounds in Germany in halls 11, 12, 13, 14, 15, 16, 17 and 27. The show is accessible via entrances West 1, West 2, Nord 1, Ost 3 and Süd 1. The opening hours of the

exhibition are from Tuesday, 23rd October, to Friday, 26th October 2018 from 9.00 to 18.00h.

Advance ticket sale Entrance tickets for EuroBLECH 2018 are now available at a discounted price via the online ticket shop. Tickets can also be purchased on-site throughout the duration of the exhibition. A ticket in pre-sale via the online shop costs €32 instead of €42 on-site and a season ticket online costs €52 instead of €62 on-site. Further extensive visitor information is available on the EuroBLECH website: www.euroblech.com.

Step into the Digital Reality at EuroBLECH 2018 EuroBLECH 2018, the 25th International Sheet Metal Working Technology Exhibition, takes place from 23 – 26 October 2018 at the Hanover Exhibition Grounds

in Germany. Around 1,550 exhibitors from 40 countries will present the complete spectrum (link: https:// www.euroblech.com/2018/ english/event/exhibition-

profile/) of intelligent solutions and innovative machinery for modern production in sheet metal working through numerous live demonstrations at the

exhibition stands. The digital transformation is currently playing a major role in the industry, which enables an increased efficiency and thus a higher level of automation and predictive maintenance. These developments are reflected in this year’s motto for EuroBLECH “Step into the digital reality” since Industry 4.0 and the relating Smart Factory have become major topics in sheet metal working.

Tickets for EuroBLECH 2018 and further detailed information about the exhibition are available on the show website www.euroblech. com

SEPTEMBER 2018 | www.engrreview.com

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38 COVER STORY

GRUNDFOS : Benchmarking the steadfast position through technology innovation Mr. Saravanan Panneer Selvam Chief Sales Officer, Grundfos Pumps India Pvt. Ltd.

SEPTEMBER 2018 | www.engrreview.com

COVER STORY 39

Q. Grundfos Pumps being one of the leading manufacturers of pumps in India & has established its brand in the pumps market, how did in the last few years grundfos achieved remarkable position in Indian market? Grundfos has always remained steadfast in its policy of providing innovative products that add value to the consumers while also being sustainable. This has been our USP, and with customers increasingly becoming value conscious rather than cost conscious, our solutions have found greater relevance in their operations. Additionally, the emergence of next tier of economic hotspots in Tier 2 and Tier 3 towns of India has created new demand pockets that are driving growth of our business. The technical superiority, reliability and efficiency of our products are difficult to match and as such we are able to create our own space in the market.

Q. Can you please brief us about international alliances & Grundfos global infrastructure? Grundfos is present in more than 55 countries with over 80 companies, 40 Manufacturing plants and 13 distribution centers across the world. International Alliances:

Our pump solutions have a significant positive impact on the UN Sustainable Development Goals #6 (water) and #13 (climate) by securing safe and reliable water for people and by reducing energy consumption. • Grundfos is one of the partners in the Water Technology Alliance and Danish Water-Alliance which solves problems in the US Water Missions International and Grundfos have entered into a partnership to implement safe drinking water projects for 24 communities in Southeast Asia, providing access to safe drinking water for an estimated 50,000 to 70,000 people. • The global water crisis is highlighted as one of the world’s biggest issues in the future. Grundfos joins forces with WaterAid in an international collaboration to tackle the global water crisis. • The Danish Refugee Council provides Grundfos knowledge about water shortage in African countries. Based on this knowledge, Grundfos does both donating and doing business with local communities to make sustainable water solutions. Grundfos India along with ten other private sector firms have come together to form the Alliance for Energy Efficient Economy (AEEE) to promote energy efficiency among industries and

households.

Q. What are the latest initiatives Grundfos has undertaken in industrial pumps space? Which are your focus areas? In India, Grundfos has always focused on the ‘No-standard’ pumps for special applications like high temperature, high inlet pressure etc. The focus area today is E-pumps. With digitalization being the mantra of the day, there is a buzz around these products which are pumps with built-in frequency converters, energy saving features, VFD and sensors. The pumps are also compact and hence space saving which makes it an attractive solution for various industrial needs.

Q. What are the market opportunities for Grundfos products in India? How do you plan to position these products? The market is doing well in India as far as industrial applications are concerned. Of course, water treatment is the biggest opportunity, not only in the country but across the globe. Desalination pumps, high pressure pumps used in water treatment are the ones holding the biggest shares in this business. The addition of new technology dosing pumps and systems add value to the customers who are

www.engrreview.com | SEPTEMBER 2018

40 COVER STORY

looking at complete water treatment solutions. Today, Grundfos is offering dosing pumps with 1:3000 as turn down ratio which is unmatched by anyone in the industry. Offering these pumps along with the standard high-pressure pumps and low-pressure transfer pumps as a complete packaged solution, makes it special for Grundfos.

Q. In order to sustain at frontier position, what are the marketing strategies that are applied & will be applied for Indian market? As mentioned earlier, the offering of E-pumps (i-solutions) is a clear differentiator for Grundfos. These motors with built-in frequency converters are of IE5 rating which is a very advanced technology. In India, IE3 is still considered as Premium motors and we are already offering IE5. Positioning these products for various applications in the industry and riding the wave of digitalization is the strategy that Grundfos adopts in India.

Q. Can you please elucidate the contribution of technology innovations in the success of Grundfos products? Technology plays an important role in the way we design and develop our products. Our customers have become extremely tech savvy and they need products suiting their needs. Our solutions provide them exactly that. Grundfos iSOLUTIONS is one such solution. With its state-of-the-art pump intelligence, it ensures that all the pumps, drives, control & protection units, measurement and communication units all work together as one complete, energy efficient and connectivity-based system. Under the iSolutions range, we have Grundfos’ SMART Digital XL DDA and DDE dosing pumps that can dose in accurate measurements, which cuts out unnecessary chemical consumption,

SEPTEMBER 2018 | www.engrreview.com

while consistently reaching processing targets. SMART Digital XL DDA and DDE are all based on tried and tested Digital Dosing™ technology from Grundfos. They offer powerful, variable-speed motors, a universal power supply, and a full-PTFE diaphragm that meets the most demanding requirements for chemical resistance and durability. The pumps open a broad range of dosing applications.

Q. Brief us about the quality policy for Grundfos business? At Grundfos we make sure that, our products are not only energy efficient but are also environmentally safe. Quality management in GRUNDFOS, ensure the reliability of the products & customer satisfaction through continual improvement and development towards the zero defects philosophy at all stages from product development through purchasing, production and distribution to marketing, sales and service. We continuously assess and improve the environmental impact of all our activities by prevention of pollution in compliance with legal & other requirements and by considering the life cycle assessment of the products & services, to promote a culture of sustainability for a greener and cleaner planet. We engage our employees to set a good example of how to show respect and care for the environment.

Q. Please highlight more about Grundfos top line product range. Is there any new launch or in pipeline stage? While the CR, Vertical in-line pumps, still leads the important product portfolios in India for Grundfos, there are a few top products that closely follow the leader. Yes, There are a few launches expected this year. The new products will be launched phase wise. Of course there are many digitalized

solutions are in the pipeline which will be a trend setter in the market. Grundfos has a wide range of intelligent pumping solutions. Few that have been key in solving water related issues are: Grundfos’ Demand Driven Distribution (DDD) is a unique pumping solution where the supply of water is programmed as per the demand at the consumer’s end. This system can automatically monitor grid use patterns with remote sensors and adjust the water pressure accordingly using a Grundfos software algorithm. Another smart solution is our Grundfos Remote Management. This is an internet-based, secure and technologically advanced system which helps in the monitoring and managing pump installations in commercial buildings, water supply networks, wastewater plants, etc. with minimal human intervention.

Q. How do your perceive Indian pumps industry against the global market? Indian pumps industry is still experiencing a growth stage, barring a few blips. This is contrast to certain other markets, especially in the west, where the growth has been much slower as demand comes from replacement need rather than first time need. Industries such as power, manufacturing and water management are expected to experience both volume and technology growth. This is contrast to other markets where technology innovation may not be supported with scale that Indian market provides.

Q. What are the key technological trends that are driving pumps industry? While the conventional pump technology still holds fray, the emergence of modern features such

42 COVER STORY

as Remote Monitoring, Distributed Demand Control, IoT are some of the technologies that will become widespread in the future. At Grundfos, we have already been developing such smart products to suit the needs of our customers. We were the first ever pump company to introduce electronics in pumps. Even before the boom of IoT one of our early technologies had made it possible for our pumps to send messages directly to the pump owners regarding all the information about the status of the pumps etc. Over the years we have developed numerous intelligent pumping solutions that are being used world over. As todayâ&#x20AC;&#x2122;s generation has become extremely technology savvy, we are also taking appropriate steps to make our digital interactions simpler, more integrated, and effective. Also recently we launched a mobile application called SmartServ. This app helps reduce the communication gap between the end users and our engineers. Just like any other app you can easily locate a service provider nearest to you, fill in the required details of the complaint/request, attach a picture of the pump/system and raise the service request. You would receive

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COVER STORY 42

an acknowledgement of the request within four hours. A user - friendly mobile app, it is easily available on iOS, Android and Windows.

Q. According to you what is the future of the Indian pumps industry? The future of Indian Pump industry is definitely bright. The potential for pumps is huge. With rise of smart cities, the need for smart and innovative solution will also increase. These cities would need efficient water supply and sewage systems, smart solutions for efficient usage of energy etc. This is where our solutions come in. As aforementioned, we are equipped with smart solutions that can tackle any water related problem with ease.

Q. According you what are the factors affecting to your business? Slowdown in key markets such as real estate has impacted demand to a certain extent. To add to that, import of low cost alternatives tend to divert certain customers away who might be looking for lower upfront costs. However, our long-term outlook remains stable and we see these factors as mere aberrations in our growth path.

Q. What are the issues you need to address that are related to pumps industry? A major issue we face is that people only focus on the cost of the pump. They buy the cheapest option shown to them rather than looking its quality and efficiency. This leads to inefficient utilization of energy, huge operating expenses and constant break-downs. It is also necessary to make sure that these products comply with the set standards â&#x20AC;&#x201C; environmental or others. It is thus imperative we focus at the life cycle cost of a pump, its energy efficiency and the reduction of the carbon footprint left behind.

Q. According to you what are the measures to be taken by Indian manufacturers in order to compete with global players? Understanding of the dynamics of the market, innovation driven by local needs and adhering to strict quality standards are critical to sustain the market leadership in the face of competition. Such strengths are built over time and act as strong competitive advantages over new/recent market entrants, irrespective of their global market position.

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

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44 INDUSTRY FOCUS

We delight our customers by providing economic solutions to their grinding process: Ashok Sheth Vadodara-based Solitaire Machine Tools Limited is a leading manufacturer of Precision Centerless Grinders, with a standing and reputation spanning nearly three decades. Solitaire focuses on designing and manufacturing centerless grinding machines of superior quality, high accuracy and superlative performance. The company is also recognized for timely delivery, installation services, training and after-sales technical support, reveals Ashok Sheth, Chairman, SMT in an interview with P.K. Balasubbramaniian. Excerpts: concrete base. These are slowly being recognized by manufacturers of precision components.

Q. You pioneered the technology some three decades ago. What is the level of sophistication Centerless grinding has attained over the years?

Mr.Ashok Sheth, Chairman Solitaire Machine Tools Limited

Q. You are a prominent name in Centerless Grinding. What precisely is your niche? We have been in Centerless Grinder business of manufacturing and remanufacturing since 1980. The association with Cincinnati Milacron and its grinders made us aware of quality requirements and need to provide solution for the customer rather than supply the grinder. Also we have consistently focused on this small niche part of the grinding sector. The later association with Bocca & Malandrone, Sunebo of Italy for the past 10 years has brought their advanced features like Hydrostatic Slides, Double supported spindles and Vibration free

SEPTEMBER 2018 | www.engrreview.com

We are not Pioneer of this technology, but we brought features, which were not being offered in India. We offered grinders to customers, who were importing new grinders from USA, Europe and Japan. They found that indigenous grinder was of same quality and durability. Over the years, we kept on evolving design and features to improve productivity and quality for customers.

Q. How comprehensive is your range of manufacture today? We can grind components from 1mm diameter to 200 mm diameter. We have supplied grinders to grind small drill bit of 1 mm weighing about 5 grams to rear Axle of Volvo truck weighing 250 kg. We are working on a new grinder to grind parts as small as 0.2 mm diameter. We are launching Centerless Grinder with 5 Axis CNC and with Twin Grip supported wheel width of 300 mm, especially to meet requirement of shock absorber industry and manufacturers of precision shafts and small crank shafts. It will be dispayed at IMTEX 2019.

Q. You say your machines are designed to give â&#x20AC;&#x2DC;superior quality, high accuracy and top performanceâ&#x20AC;&#x2122;. How do you substantiate this statement? We would say that our customers substantiate this statement. We have ground parts with roundness below 1 micron, surface finish below 0.03 Ra, and cylindricity below 2 microns. We have ground small pins at the rate of 30 pins / second, Steel bars at 6 meters / minute feed rate for example while still meeting their stringent standards.

Q. What must be the total headcount of machines you have supplied so far? We have manufactured and remanufactured over 1000 grinders in India in the last 30 years. Our US associate plant in Chicago has supplied close to 1400 grinders since 1980.

Q. Who are your major customers? Our major customers are automotive component manufacturers. Most of our customers in thisfield are MNC plants in India. Many of vehicle manufacturers have recognized Solitaire as reliable source of Centerless Grinders and have been advising their vendors to use our grinders. Other customer base in Engineering industry for Precision components like Hydraulic spools, Crank shafts, Ceramic Parts, Graphite and

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Aluminium components etc.

Q. Could you enlighten us on your manufacturing facilities and wherewithal? We have complete manufacturing facilities comprising Horizontal Machining Centers, Vertical Machining Centers, Horizontal Boring Mills, Slideway Grinders, Cylindrical grinder, Surface grinders, Super finishing machine and all other allied equipment. We also have quality control facilities to inspect ground components with Cylindricity tester, Roundness tester, Surface finish tester, Profile Projector and all other related inspection equipment. We also have 150 vendors to manufacture components as per our drawings.

Q. What’s your export performance? You have also got some Awards we believe. We have exported 25 to 40 % of our sales every year for past six years. We have received EEPC Star Performer award for past 5 years in a row.

Q. Of late, there have been innovations in software for better flexibility and precision in CNC controls. Have you embraced these? Software for efficient working and ease of operation is an evolutionary process. Each grinder is customized with software to meet customer’s requirement. Also all safety interlocks are provided to ensure safety at all times. We are servicing grinders supplied in South America through internet.

Q. Do you also do re-engineering and retrofitting of grinders of any make? What are the benefits the end customer can derive from this activity? We do Remanufacturing and CNC retrofitting in addition to automation for Cincinnati Centerless Grinders of any

SEPTEMBER 2018 | www.engrreview.com

Solitaire offers a comprehensive range of grinding solutions model or any age. We have remanufactured Cincinnati grinder as old as 1939 (close to 78 years old) and brought it back to grinding parts meeting customer’s requirement. The cost compared to new machine could be around 50 % to 60% and customer can still use the asset which is owned by them.

Q. Service is crucial in your line of business. What’s your service setup and response time? We try and train customer’s maintenance personnel in ways to look after the grinder and do the work themselves as far as possible. This saves time as well as cost for them. All required spares are offered with quick delivery. The training to customer’s staff is free at our plant. Also during commissioning, training is given for operation and maintenance. In case required, our factory trained personnel visits and takes care of servicing.

Q. How do you delight your customer? We delight our customers by providing them economic solutions to their grinding process. We provide them various

options and the advantages to make educated decision on their procurement of the grinder. All features and options are discussed in details before placement of order.

Q. What are your future thrusts? We like to work on improving quality and productivity for components being produced on our grinders. For example, we grind a small set of components at 10 metres/ minute and now we are targeting to improve the same and try to reach 15 meters/ minute. In the past, one of our customers was grinding a component in one second and with joint efforts, they were able to bring it to 0.8 seconds per part. That is 20 % increase in productivity. Our focus will be on such accomplishments.

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We have implemented 5S across all our manufacturing plants

Mr. Satish Bhat, Managing Director, Ador Welding Limited

Ador Welding Limited, known by its sobriquet, ‘welders to the nation’ has a standing and reputation spanning over six decades. The company with the widest portfolio of quality products & services, offers complete welding & cutting solutions to virtually all sectors of the economy including automobile, shipbuilding, railways, steel, sugar, mines, oil & gas, chemicals & fertilizers, food processing, pipelines, cement, construction, power plants, atomic reactors and many more. Ador not only manufactures welding products but also PPE and fume extractors to enhance safety and productivity on shop floors as well as at sites. Mr. P.K. Balasubbramaniian speaks to Mr. Satish Bhat, Managing Director, Ador Welding Ltd. to ascertain the safety compliance of the company across its various manufacturing facilities as well as the solutions it offers for personal protection. Excerpts: SEPTEMBER 2018 | www.engrreview.com

Q. What’s your range of manufacture? Which are the products you offer for personal protection and industrial safety? Being a Complete Welding Solutions Provider, we manufacture the entire range of welding equipment, welding automation solutions and we make or supply almost every PPE (Personal Protective Equipment) related to Welding Process. The list includes Welding Helmets (Auto Darkening), Welding Face Shields, Welding Leather Gloves of different types (Ambidextrous General Purpose, General Purpose Rigger, Heavy Duty Heat Resistant MIG Welding Gloves, TIG Welding Gloves with arm

50 INDUSTRY FOCUS

protection), Welding Leather Apron, Leg Guard, Sleeve Guard, Safety shoes, Fume extraction systems, etc.

Q. How do good manufacturing practices contribute to occupational safety? It is a well-known fact that Good Manufacturing practices ensure that the workplace is effectively organized. We have implemented 5S across all the plants and it helps in creating safe working conditions. OSHA has recently updated the Guidelines for Safety and Health Programs it first released 30 years ago, to reflect changes in the economy, workplaces, and evolving safety and health issues. The new Recommended Practices have been well received by a wide variety of stakeholders and are designed to be used in a wide variety of small and medium-sized business settings. The Recommended Practices present a step-by-step approach to implementing a safety and health program, built around seven core elements that make up a successful program. The main goal of safety and health programs is to prevent workplace injuries, illnesses, and deaths, as well as the suffering and financial hardship these events can cause for workers, their families, and employers. The recommended practices use a proactive approach to managing workplace safety and health. Traditional approaches are often reactive – that is, problems are addressed only after a worker is injured or becomes sick. A new standard or regulation is published, or an outside inspection finds a problem that must be fixed. These recommended practices recognize that finding and fixing hazards before they cause injury or illness is a far more effective approach. The idea is to begin with a basic program and simple goals and grow from there. If you focus on achieving goals, monitoring performance, and evaluating outcomes, your workplace can progress

along the path to higher levels of safety and health achievement. Employers will find that implementing these recommended practices also brings other benefits. Safety and health programs help businesses: • Prevent workplace injuries and illnesses • Improve compliance with laws and regulations • Reduce costs, including significant reductions in workers’ compensation premiums • Engage workers • Enhance their social responsibility goals • Increase productivity and enhance overall business operations

turing are even more sophisticated and far-reaching, and addressing those needs by engaging security professionals for expertly planned systems in a modern manufacturing environment is more critical than ever. Manufacturing represents a broad range of companies akin to our Industry and products, but they often share similar security concerns. For example, they may be prone to theft of high-priced or high-demand products. They may also be subject to industrial espionage or sabotage. When you combine those with the threats that come with industrial processes, such as general security, fire or other environmental concerns, the security needs in this sector are significant.

Q. What are the security challenges akin to your industry and how do you address them?

Aspects that have been covered include:

Current security threats in manufac-

• Access control for entrances and high-

Ador safety products SEPTEMBER 2018 | www.engrreview.com

52 INDUSTRY FOCUS

• • • • • • • •

risk areas Intrusion detection Contact and motion sensors Fire systems Video surveillance Environmental monitoring Alarm monitoring Re-evaluate Security Need Regularly Train Users

Any facility needs change with operational changes, expansions, employee turnover and more. ADOR takes time periodically to reassess the security systems to be sure they are still adequate and appropriate. One of the most important and frequently overlooked aspects of physical security in the manufacturing industry is that of training. ADOR has appropriate personnel who are familiar with the security systems to troubleshoot and ensure they are always running properly. ADOR also understands and practices that once trained, the users can be the first line of inspectors in preventing serious issues.

Q. What is the role of plant layout in safety management? It is indeed very critical for all manufacturing plants since a well-designed

layout ensures optimum handling of machineries and utilities which have major impact on safety management system. We have best-in-class equipment and layouts, proper evacuation plan for all the plants and accordingly exit paths and assembly points are well identified in plant layouts. The same has been displayed at all the appropriate places.

Q. What are the procedures you have enforced for access control? The access to our entire premises is controlled by Bio-metric sensors. We have access control in all potential risk areas like LPG gas storage yard, HT yard, HT metering rooms, LT rooms, etc. The access to such areas is restricted to trained and identified employees only; the current access control through lock and key being upgraded to digital access control like biometric security system. ADOR has already installed digital access control for central server room & disaster recovery server rooms located in our Equipment Plant in Chinchwad, Pune. Server rooms are also fire protected through the latest Novac Gas (Clean agent) fire suppression system. We have installed a similar digital access control for TDC-Equipment,

TDC-Consumables and Admin Block located at Chinchwad Plant.

Q. Which are the areas you have brought under digital surveillance? We have installed high resolution & night vision cameras for close circuit surveillance at all critical locations like LPG fired and Electric ovens, FG loading and RM unloading point, Oracle data center i.e. server room and DR area for safety and security reasons. Security persons as well as all HODs have been provided complete access to CCTV.

Q. Coming to personal protection, what are the wares used by your production personnel? All the plants are certified for OHSAS-18001 since last 10 years. PPEs like Safety shoes, Nose-masks, ear plug, safety goggles, Leather gloves, aprons, acid proof suits, helmet, safety belts, welding hand-shields, Welding helmet, sleeve guard, etc. are used by production personnel as per PPE need identified pertaining to manufacturing process/operation. Potential safety risks are reviewed periodically & risks are mitigated through appropriate PPEs & visual displays.

Ador’s Consumables Plant in Silvassa. All Ador plants are certified to ISO 9001:2015, OHSAS 18001:2007 and ISO 14001:2015 SEPTEMBER 2018 | www.engrreview.com

54 INDUSTRY FOCUS

Management Standard ISO 14001:2015.

Q. How do you make the employees aware of the dos and donâ&#x20AC;&#x2122;ts? Do you have periodical training for specific groups? All the Employees are trained on Safety Processes and are very well aware about dos and donâ&#x20AC;&#x2122;ts in routine work and also during an emergency. As per safety training calendar, our firefighting teams across all plants are trained periodically by professional trainers.

Q. Any recognition you have received for safety practices?

Ador Fume Extraction System which enhances safety and productivity on the shop floor

Q. Is gas leakage an issue you should detect and guard against? Fuel GAS leakage can always be high risk and hence, high risk areas like LPG Gas bullets and LPG cylinder banks are protected through Gas leak detection systems. Safety committee is now in the process of incorporating gas leak detection system at internal consumers of LPG gas.

Q. What is your safety policy to pre-empt fire hazards? We have a well-defined Safety Policy announced by Corporate HR. Details of Location Safety Officers, their team members; contact numbers of emergency helplines are displayed. QHSE- policy is displayed at all prominent workplaces in each plant. Members are regularly trained and capable to pre-empt all critical assets in case of fire.

Q. Are your facilities geared for life safety & disaster management? We have well defined emergency response plan for life safety and natural

SEPTEMBER 2018 | www.engrreview.com

disaster. We have a team of well-trained fire fighter disaster control persons across all three plants.

Q. What are the gadgets and equipment you use for environmental protection? We have latest technology Effluent & Sewage Treatment plants in all the manufacturing plants & the treated water is used for gardening purposes only. We are continually expanding green field area in our plants. During 2017-18 we have increased green field area of our plants by 6%. We grow fruits and vegetables in our consumables as well as equipment plant. The Company has also invested in Rain water harvesting across all plants.

OHSA certifications and getting the same renewed year after year is itself an achievement. So far we have not formally participated in any external forum as we consider Safety and Wellbeing as basic thing in our Organization.

Q. As a respected corporate entity, what is the model you have set for Occupational Health & Safety? Our Occupational Health and Safety Model is much wider and include overall Wellbeing of Employees. This ensures best-in-class Workplace Practices, an atmosphere free from any kind of sexual harassments. We are also providing annual health Checkup facilities to our leadership team members and Insurance coverage for all employees even on contract. We also do a lot of work for emotional health of our employees.

Q. Could you enlighten us on your conformity and compliance with safety standards and regulations? All the manufacturing Units of ADOR Welding Limited are certified to the latest standards like QMS Standard ISO 9001:2015, Occupational Health and Safety Management Standards OHSAS 18001:2007, and Environment System

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56 INDUSTRY FOCUS

IAC ENTERS EXPANSION MODE International Automotive Components (IAC), a leading global supplier of automotive components and lightweight vehicle solutions, has enhanced its manufacturing and engineering capabilities in the Indian market with the inauguration of its new state-of-the-art plant in Manesar. Huned Contractor gets further details of the company’s operations in India

Mr. Gajanan GandheSenior Vice President of Asia Operations IAC India

eadquartered in Luxembourg, International Automotive Components (IAC) Group is a leading global supplier of automotive components and systems, including instrument panels, console systems, door panels, headliners and overhead systems to automakers around the world. The company’s 2017 sales were USD 4.4 billion. IAC Group operates more than 50 manufacturing facilities in 16 countries. The company has more than 60 total locations in 19 countries, including 18 design, technical and commercial centres, and employs more than 22,000 people globally.

The Indian Presence IAC India is one of the leading Tier 1 suppliers of automotive interiors systems in India with a dominant presence in western and northern regions and its products include interior parts like cockpits, instrument panels, door trims, floor console and interior trim parts. The company has four manufacturing facilities with plans to expand its operations to include Nashik and consolidation of its manufacturing facilities at Manesar to make room for a bigger and more sophisticated

SEPTEMBER 2018 | www.engrreview.com

operation. In order to support manufacturing, and to meet the constant evolution of regulations and changing trends, IAC has now relocated its HQ and engineering centre to Pune where it can accommodate a larger workforce to meet the increasing demand from local and offshore business.

The New Plant The new 60,000 sq. feet Manesar plant consolidates two older operations in near proximity into one manufacturing location. The company invested more than USD 2.0 million in the modernisation of the equipment and facility, which will employ approximately 220 people. It will produce vehicle headliners, centre console systems and instrument panel components, and provide expanded manufacturing and engineering support to domestic and global original equipment manufacturer (OEM)

customers in the New Delhi automotive region. “IAC is committed to investing in India and creating a meaningful presence near its major automotive centres,” said IAC Senior Vice President of Asia Operations Gajanan Gandhe. “Our new facility in Manesar will help us better serve current customers’ needs and offer regional advanced manufacturing and engineering capabilities for next-generation vehicle interiors,” he added. This is the second location opened by IAC in India in the past 13 months.

Global Engineering Centre In June 2017, a regional and global engineering centre was established in Pune to focus on application development engineering to support the vehicle interior needs of domestic and global OEM customer programs. The new engineering centre also has a dedicated team to work on upcoming

58 INDUSTRY FOCUS

trends and regulations with key focus on cost optimization. The engineering centre is expected to attract a lot of fresh and key market talent and will also cater to increasing workload from IAC’s European and American operations that have resulted from providing flawless and high quality work over the past seven years. As Sitangshu Nandy, General Manager, Program Management, put it in an interview last year, “IAC believes in introducing upcoming trends aligning to the regulatory requirements. The company is working with OEMs on various initiatives, including lightweighting technologies and providing better noise and vibration insulations inside the cabin. Considerable amount of focus is being given by OEMs to improve interior haptics and to bring a richer feel inside the cabin through refining ambient lighting, soft surface materials, etc. The centre will also focus on developing functional prototypes for consumer/customer clinics and feedback, reverse engineering, benchmarking and simulations through computer-aided engineering.” IAC is in the process of setting up new lines for headliners that will cut down the weight of the current headliner by 40% with improved sound absorptions. Other technologies to increase natural and recyclable composites will not only provide the advantage of lightweighting but will also improve the recycleable content of the vehicle.

Enhancing Vehicle Safety IAC successfully introduced a patented air bag chute (canister) about six years ago with an Indian OEM that passed all environmental and regulatory testing. Based on its success, other OEMs are now working with IAC to introduce the same design for their upcoming vehicles. The company has also implemented a patented design for

SEPTEMBER 2018 | www.engrreview.com

side impact crash pad that is capable of meeting side impacts for 5, 50 and 95 percentile occupants, thus providing a versatile and economic solution to the challenging regulatory requirement. Soon IAC will have the capability of introducing curtain air bag (CAB)ready headliners from its new line. IAC India has capability of simulating crash conditions in-house through CAE, thus providing a risk-free design to customers.

Indian Automotive Industry “The Indian automotive industry is one of the most frugal markets in the world and continuously expects more with least cost impact. This will drive lot of innovations that will flow back to developed markets, especially when we have limited natural resources and quickly evolving markets. Techies will play a major role in bringing to the table many innovations in connected cars that can be customised by the owners. However, we believe India will be absorbing lot of regulations and will implement them in the near future to make roads safer for both vehicle owners and pedestrians. Regulatory bodies have already shown the intent of

implementing safety and environmental norms by making air bags compulsory and enforcing BS4 from April this year and BS6 from 2020. It is also expected that India will introduce fuel economy standards similar to the CAFE standards in the US market,” opined Nandy.

Growth Vision “Whatever IAC has achieved is with a philosophy of win-win, whether it’s with our customers or supplier partners and our solutions are based on proposals where both parties benefit. This creates a long-term strategic relationship and enhances trust. IAC has been successful in bringing the latest trends and technologies to most of our customers. As a matter of fact, many of the automotive OEMs are currently engaged in discussions with IAC to upgrade or be ready for the upcoming market trends. The company intends to keep expanding its operations and add value. The objective is to be present in all the automotive regions of India in the near future either through organic growth or through joint ventures and acquisitions,” Nandy said.

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60 INDUSTRY FOCUS

Soft Solutions for Wire and Cable Industry In this interview with Huned Contractor, Albert Groothedde, CEO, InnoVites, elaborates about how their product CableBuilder gives cable manufacturers the extra edge and also touches on the extended product offering called CableSuite Mr.Albert Groothedde, CEO, InnoVites

Q. Could you explain the benefits of CableBuilder, Cimteq’s software for the cable industry? The success of the sales department in this industry can be defined by simply multiplying two factors: the number of quotes that the company issues to customers and the quote to order conversion ratio. CableBuilder helps cable manufacturers to excel at both factors. By implementing CableBuilder, the calculations of all technical and commercial properties of the cable can be automated. A new design and a quote can be produced in just minutes, rather than hours. This dramatically improves the productivity of the sales and engineering team. Also, the workflow capabilities further streamline the processes, to avoid all delays. So CableBuilder allows our customers to produce more quotes with the same resources. CableBuilder can also automatically generate the necessary technical documents, such as TDS with a consistent high quality. Human errors are avoided. The software is also capable of creating 2D and 3D drawings with photo-like quality.

Q. Does InnoVites have exclusive partnership with Cimteq for CableBuilder? Yes, InnoVites is the exclusive partner

SEPTEMBER 2018 | www.engrreview.com

for Cimteq in India. We implement CableBuilder at our customers’ sites in India and around the world. The longterm partnership of InnoVites with Cimteq is based on our common business strategy to have an exclusive focus on the wire and cable industry.

Q. CableBuilder has been in India for a decade now. How has the journey been and who are your major clients in India? It has been an interesting time actually. The first years were challenging while we were building our team in India and doing our first implementations for customers at the same time. I am very grateful to our employees in India who worked hard to make it a success. After more than 10 years our team in Hyderabad is well-established and serves the wire and cable industry in India and

abroad. Our customers in India include Polycab, Sterlite, CCI, RRK, LAPP India, Siechem Cables, and many more. As you can see, CableBuilder is scalable and can be used not only by the largest but also the smaller cable manufacturers. I am now looking forward to meeting many friends again at the Wire India show in Mumbai in November. Since 2008 InnoVites has been a regular exhibitor and we have established many business relationships at these events.

Q. Is CableBuilder sold as a standard package or it is customised as per the client’s requirements? CableBuilder is standard software and used to design all types of cables from LV and MV to instrumentation and optical fiber cables. All cable manufacturers have their unique capabilities in terms of production resources and engineering philosophy. Cimteq understands this and has therefore made CableBuilder completely flexible. In the implementation we configure CableBuilder to the unique requirements of our customers. The flexibility of CableBuilder allows the engineering team to continuously experiment, improve the designs and implement innovations while securing the lessons learnt in the CableBuilder library.

62 INDUSTRY FOCUS

Q. India has a huge class of marginal players in the home cables sector. Do you feel that CableBuilder can help the better ones of the lot to turn into ‘formal’ players? Sure, with CableBuilder they can formalize their engineering operations to achieve the quality level needed to enter new markets. As explained earlier, CableBuilder can also assist the sales team in producing high quality quotes faster.

Q. Large domestic cable manufacturers are moving towards extra-high-voltage cables. Does CableBuilder cater to such products as well? Sure, CableBuilder is not only capable of dealing with the construction of these cables, but it also comes with a module to calculate the electrical properties of

SEPTEMBER 2018 | www.engrreview.com

cables.

concepts?

Q. Given that power transmission and distribution is going to be a growth area in India for several years to come, how do you see prospects for CableBuilder in the subcontinent?

Manufacturers embrace the concepts of Industry 4.0 as it makes them more responsive to change. Changes happen always, everywhere: customers cancel their orders or request modifications in constructions that have been released to the factory already. Suppliers deliver materials late or materials don’t pass quality tests. To take care of such problems, InnoVites delivers the CableSuite, a set of integrated business applications for the wire and cable industry. CableSuite comes with CableBuilder, CableERP and CableMES and is designed to automate all processes: from controlling machine settings to alerting customers about deliveries. CableSuite is the innovative platform that brings agility to wire and cable companies, making them thrive, now and in the future.

The current Indian government is stimulating infrastructure development, which is very encouraging. It will result in double-digit growth for the wire and cable industry now and in the coming years. We expect to extend our already strong base in India and serve many more customers in the years ahead.

Q. Manufacturers around the world are adopting the Industry 4.0 concepts to enhance their performance. How does this affect the wire and cable industry and does InnoVites’ software support these

www.engrreview.com | SEPTEMBER 2018

64 INDUSTRY FOCUS

A ‘POWERFUL’ EQUATION KVTEK designs and manufactures the most technically advanced and easy-to-use products for high voltage, high current and high power test systems and measurement instruments. In this interview with Huned Contractor, Managing Director and CEO Anil Uppal, elaborates about the company’s products and growth strategy transformers are currently tested and will significantly improve the testing throughput of transformers as this eliminates the need of changing connections between the two MG sets required for complete transformer testing. Besides, we also undertake the responsibility of setting up the test labs on turnkey basis or provide consultancy for setting up HV test labs.

Q. How is the focus changing in India as far as electrical testing and measurements concerned?

Mr. Anil Uppal Managing Director & CEO KVTEK

Q. What are the products offered by the company? KVTEK’s area of operation is mainly focused on high voltage testing and the range of products manufactured by us includes impulse voltage test systems, impulse current test systems, HV AC series resonant test sets, HV AC dielectric test sets, HV PD test equipment, RF shielded rooms and enclosures, capacitance and TAN delta test sets, transformer loss measuring systems, ratio and phase angle error measuring equipment required for CT/PT and CVT testing, AC/DC kilovoltmeters, on-line transformer moisture absorption systems and their associated accessories. We have in the last couple of years started manufacturing static frequency converters as well which are slowly replacing motor generators test sets required for transformer testing. This in due course of time will change the way

SEPTEMBER 2018 | www.engrreview.com

There is a definite shift in the awareness about the need of quality electrical test and measuring equipment, thanks to the insistence by major utilities in the country and also the awareness drive created by NABL. However, the major challenge that one faces in this arena is the complete lack of infrastructure to support electrical test and measuring instruments industry. Basic things like majority of components, raw material, etc. required by the test equipment industry still need to be imported and not enough support structure in terms of calibration facilities is available in India. World over this industry is supported by the research work that goes on in technical universities but for some reason there is a complete disconnect between universities and the industry in India. The other major reason why this industry is not growing rapidly in India is due to our infatuation for all imported products in general. The basic assumption that anything that is coming from Europe or the US is superior and everything that is manufactured in India is not up to the mark is hurting this industry. There have been cas-

es wherein we have been invited by companies for demonstration of certain test instruments and even after successful demonstration these have not been bought by them just because they do not come with a foreign label. This mindset is slowly changing but it still has a long way to go.

Q. What is your observation about the demand for the latest technologies in India? The demand for latest technologies in India is definitely improving; slowly but surely it is increasing. Most companies do evaluate both options i.e. latest technologies and old style testing equipment and some actually opt for the latest technologies. However, the percentage of such companies is small right now. The primary reason for not opting for the latest technologies is the cost difference between the two and in some cases it is actually the lack of awareness. However, what companies do need to realise is that new technologies may be little expensive initially but in the long run will actually work out to be more cost-effective due to reduced testing time with increased automation and low downtime as most issues can be resolved online.

Q. How big is your market share or presence in the Indian power sector? We are a very young company and the only one in the field of manufacturing HV test equipment in India. Traditionally, this market was the stronghold of manufacturers from Europe and the US. But their share became very small with the emergence of Chinese companies in and around 2005. However,

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66 INDUSTRY FOCUS

with increasing quality issues and lack of service support from the Chinese companies, our share in this industry is steadily increasing and right now we are doing pretty good in terms of volume of business.

Q. What are the new types of equipment that you are planning to bring to India? Static frequency converter is the latest equipment that we have introduced in this market and once this gets established properly only then we will be launching the next product. There are two new equipments we are working on right now.

Q. What kind of competition do you face in the Indian market? Our main competition is from Chinese companies only as we do not have any other manufacturer in India. But of late, we are experiencing that from Europe as well since some have started offering

very low quality products with pricing matching their Chinese counterparts. We firmly believe that these are not the companies that will last long as their intent is not to supply quality products but to make a quick buck and move on. However, the worry is that in India, industry in general has blind trust on all companies with the European tag on

it and so the risk of them making the wrong choice is quite high.

Q. What are the impacts on your business of the new governmentâ&#x20AC;&#x2122;s plan to speed up electrification in the country? Our business is a capital equipment business and is likely to improve only with increased electrification in the country. Higher electrification means more investment in manufacturing power equipment industry and that means more investment in test labs. Of late, there is significant increase in third party test labs as well, which is helping our business in a big way.

Q. What technological innovations would you incorporate in your products for making them more superior and efficient? We have a dedicated research and development team who are regularly working on improving the quality of products manufactured by us. Besides quality, the focus is always on improving automation levels based on customer feedback so that testing throughputs can be improved significantly. The static frequency converter is exactly such a product that will immensely help the transformer industry in reducing the time required for testing transformers.

SEPTEMBER 2018 | www.engrreview.com

ENGINEERING REVIEW |

| September 2018

68 INDUSTRY FOCUS

TAKING A GLOBAL LEAD

Erick Sharp President & CEO ACE Products & Consulting

Known for bringing innovation in laboratory testing for various manufacturing segments, the USbased ACE Products and Consulting is now looking for an opportunity to set up its services and technology base in India. In this interaction with Huned Contractor, the company’s founder elaborates about what they do and how it benefits the industry

SEPTEMBER 2018 | www.engrreview.com

CE Products and Consulting may have seemed like a new kid on the block a few years ago – but make no mistake – this young, dynamic company of highly trained professionals, led by president and CEO Erick Sharp, is no newcomer to the testing and research and development services industry. With over 100 years of combined experience, the ACE management team is pushing ahead with key growth initiatives to help their current and future customers and the industry. The company, an ISO 17025:2017 accredited, independent laboratory facility, offers a full-range of high-quality testing, research and development and consulting services to various industrial sectors, especially rubber and silicone. Housed in a modern 172,000 square feet industrial park facility, ACE is located in the heart of rubber country on 72 acres of land and has ample room for expansion beyond the immediate

planned expansion. The company’s immediate access to rail transport and major shipping road routes make it an ideal site for attracting additional polymer-type businesses to the park. ACE has embarked on a six-phase growth plan that will continue over the next 18 months. Phase I (testing lab) and Phase II (process lab) are complete. Phase III (conditioning lab) is near completion and Phases IV-VI are under construction in ACE’s additional 8,000 square feet of space. That is in addition to the original 10,500 square feet for a total of 18,500 square feet.

Before ACE Prior to launching ACE, Sharp worked with Portage Precision Polymers, Inc. (P3) for several years. Then, in December 2014, P3 was acquired by Hexpol AB and it was then that Sharp decided to exit the corporate environment and start something new. “I have been

70 INDUSTRY FOCUS

through this before, going big to the corporate side. I would rather go completely to the other side and start grassroots,” he says. So, at the start of the year 2015, Sharp decided to launch out on his own and he started ACE Products and Consulting. The company began operations with some basic testing and research and development equipment in a 2,000 square feet facility in Akron, Ohio. “That was going well for us and there was a lot of feedback from customers pushing us to go into independent testing and expand the scope of what we were doing,” Sharp says. He had been looking at “industry anxieties” in the rubber and silicone industry for several years prior and began establishing a plan to build the next generation of an independent testing laboratory with a broader scope for research and development. Sharp noted that he could maintain the business as a small company or look for investment partners to grow and become a worldclass laboratory. He decided to invest in growth. Erick Sharp is a man who is never content with the status quo. It was then that he teamed up with three other investors as part of his core team. He began acquiring additional equip-

SEPTEMBER 2018 | www.engrreview.com

ment, adding capabilities and planning for ACE’s laboratory accreditation. Moving to Ravenna gave ACE the space to expand while being in a strategic location to key customers.

Pursuit of ISO 17025:2017 Accreditation Throughout the year during 2017, the ACE team worked tirelessly to earn its ISO 17025:2017 accreditation as an independent testing laboratory – a requirement by many customers. Accreditation was awarded in 2017 and was facilitated by the company’s technical team which consisted of several key employees with many years of experience working in an accredited lab at DuPont.

Investors with the Right Stuff Erick Sharp also values input from his highly experienced group of three primary investors. They all have backgrounds in business and help him avoid pitfalls as he continues building ACE from the ground up. Two of those investors are silent partners and the third is Doug Hartley, who currently serves ACE as vice president of sales and marketing. Hartley and Sharp share a past history through their work at P3.

The two men collaborated on many ideas after ACE was launched and Hartley looks forward to spending time advising and mentoring at ACE. An example of the insight and advice the investors and Hartley offer is the installation of a Laboratory Information System (LIMS). The LIMS system is designed to help track samples and tests for customers in a much more robust and valuable manner than current industry methods. Hartley recognised that some sources have advised on waiting to implement the system. However, Hartley encouraged Sharp to move forward with the implementation of the LIMS system knowing that it would help set ACE apart from other laboratories. “I knew how costly implementing LIMS would be, particularly not having it available from the start but then having to convert to it later,” said Hartley. “If we came out of the gate with LIMS in-place, that would provide a cost-savings for ACE but also provide a better quality of product right away for customers. That’s vitally important,” he adds.

Expanding Capabilities ACE continues to focus on physical and mechanical testing,” Sharp says, in addition to providing evaluations on raw materials. Another service is the capability to do silicone testing. “We are moving forward with silicone testing carefully. We don’t want to be labeled as solely a silicone lab because we are both a rubber and silicone lab. However, a rubber lab that does silicone and has that capability helps set us apart from other rubber labs,” he says. As silicone becomes more widely used in various applications, ACE’s ability to provide silicone testing opens the door into new markets. Some of those areas where Sharp sees silicone taking over are in the automotive market for heat applications and in the construction market for weather-ability applications.

74 INDUSTRY FOCUS

Sharp notes that being able to compare samples side-to-side within the same lab is of value to customers.

Educational Opportunities Erick Sharp is also a man with heart

SEPTEMBER 2018 | www.engrreview.com

and a big vision. He has a passion for people, the industry and continuous learning. To that end, he is planning to enlist ACE as a means to provide educational opportunities to the industry by establishing approved, free training

courses on a quarterly basis. “We want to put some practical knowledge out there. With the lab’s testing capabilities and process equipment, we are in a position to be able to talk about and demonstrate the details of rubber processing and testing in real-time situations. The goal is to make the manufacturing sector seem less complicated and more practical,” he says. Training won’t be focused solely on lab testing – it will also include elements of extrusion, molding and fabrication. “We want to modernize and simplify the concept of rubber to the industry,” he states, adding, “We want to help be that interpreter and find a way that resonates with the learning style of those graduating or just starting out in a career so that we can get people into the industry and maybe make it look cool in the process.” Erick Sharp is always looking forward to the potential for new growth. If volume continues current trends, he expects to hire additional employees and be close to 20 employees within the next three years. And India is definitely on his list for geographical expansion. “I see great potential in sectors like rubber and automotive. And that is where we can chip in with our expertise,” he says.

76 COMPANY PROFILE

“We give strategic advantages to our customers from diverse industries” Rupesh Paparaju, Director, Bettinelli Automation Components, India

ettinelli S.p.A, established in 1953, specializes in the development and manufacturing of precision motion control components and systems. In 1996 a separate division named CDS Cam Driven Systems was created for engineering solutions in automation and motion technology. CDS produces the widest range of mechanical Cam Driven Units, commonly known as rotary / indexing tables for precision motion control applications, requiring rotary or linear transfer, positioning and handling. The products range includes, cam indexing and servo-driven tables, ring positioning drives, intermittent and oscillating drives with parallel or right angle configuration, rotary & linear part handlers, precision link transfer systems, and epicycloidal servo reducers.

in Italy. The regimen starts with design & engineering, CNC induction hardening, CNC milling, grinding, quality check and then assembly, painting and shipment. In order to ensure quality, all components are machined internally, including the cam hardening by a proprietary CNC controlled induction hardening equipment. For better finish, the products are also subjected to chemical nickel plating, blasting and painting. The manufacturing process is constantly controlled to conform to international standards. The company’s quality systems are ISO-9001-2008 certified.

Strategic advantages

Over the years, Bettinelli Group and CDS Indexers have become synonymous with high quality automation products and technologies. “Our design and manufacturing systems have furnished competitive and strategic advantages to numerous industries in pharmaceutical, automobile, manufacturing, packaging and a plethora of other sectors. And for automation functions, our solutions are invariably preferred by companies,” says Rupesh Paparaju, Director, Bettinelli Automation Components, India. The Indian subsidiary, headquartered in Pune, serves its customers in India by providing installation, commissioning, and after-sales support. It also offers technical consultation.

Wide ranging products The broad product spectrum covers IP parallel shaft indexers, IT roller dial indexing tables, TR roller dial indexing tables, HP roller dial indexing tables, IG/IGA roller gear indexer, TL precision link conveyors, MHP/LHP part handlers, FT-HT open center ring tables and packages of rotary indexing tables. Bettinelli has a wide range of standard products. These are delivered in 3 weeks. When it comes to customized products, these are designed, manufactured and shipped in 6-8 weeks. The manufacturing takes place centrally

SEPTEMBER 2018 | www.engrreview.com

Rotary Indexing Tables, TR Series

78 COMPANY PROFILE

Parallel Shaft Indexer In the pharmaceutical industry cam driven systems are used in filling, blister pack, tablet making and packaging machines. In automobile industry, they are used in pallet transfer tables, assembly machines, painting applications and test rigs, just to mention a few. In machining industry, they are used with advantage in deburring, lapping and pressing machines and in transfer lines. In SPM & robotics, they find applications in transfer lines, station loading, sequential operations and so on. Inwelding, these indexers are inevitable in positioners,

SEPTEMBER 2018 | www.engrreview.com

synchronous welding, robotic welding and component transfer. Packaging too is a major application area. Cam systems are used in box filling machines, wrapping machines, cartoning and capping machines. Indexers are also used in casting, printing and cosmetics industries.

Closer to the customer The Indian arm of Bettinelli, based in Pune, Bettinelli Automation Components Pvt. Ltd., is highly customer-centric. “Our presence in India means quite something in fostering a symbiotic rela-

tionship with our customers. It helps us to match our world-class products with our eminent customer support,” underlines Paparaju, Director, who has built up a team to improve Bettinelli’s response time. “CDS are high-tech products which lend themselves to enhance the operational efficiency and productivity at the customer’s end. We stay close to the customer to understand his needs and offer customized solutions within the shortest possible time to ensure peak uptime of his equipment and operations”, he adds. - P.K. Balasubbramaniian

80 COMPANY PROFILE

Consul Neowatt : A formidable name in power conditioning & power back-up Consul Neowatt Power Solutions is a formidable name in power conditioning and power back-up products, services and solutions. Maintaining its leadership position for over three decades, this premier power electronics company, adjudged as the fastest growing UPS entity in India, is spreading its wings with an aspiration to become the Indian multinational in its chosen field. Power quality problems including blackout & brownout and voltage sag & swell and harmonics are indeed a menace causing incalculable damage to quality and productivity in the industry. We have no control over the grid power coming into the utility meter. However, Consul Neowatt has a panacea to offer - a proven technology solution to keep the plant and machinery humming uninterruptedly, providing clean power at the customer’s end. Solutions Galore

Mr. Avneet Singh Marwah CEO/Director SUPER PLASTRONICS PVT LTD

Mr. Sriram Ramakrishnan, Managing Director & CEO, Consul Neowatt Power Solutions Pvt. Ltd.

SEPTEMBER 2018 | www.engrreview.com

For addressing voltage sag & swell, Consul Neowatt offers Servo Controlled Voltage Stabilizer, 1 KVA to 3500 KVA. For blackout or brownout, the solution is UPS 1 KVA to 800KVA. One can also connect up to eight UPS units in parallel to obtain a power backup of 6,400 KVA. For harmonics, the panacea is Active Harmonic Filters. The harmonic current required for your non-linear loads like VFDs will be supplied by Harmonic Filters so that only clean power will be drawn from the grid. Says Sriram Ramakrishnan, MD & CEO, Consul Neowatt: “We are India’s premier power electronics company. In fact, we are the only power electronics company in India with integrated capabilities including R&D, Manufacturing, Sales & Service. While the history of the company goes back over three decades, over the last five years we have introduced many new state-of-the-art products and solutions which have helped us take market share away from the MNCs. Today Consul Neowatt is a viable alternative to MNCs for customers looking for cost-effective, reliable, energy efficient and innovative power electronic solutions.“ “UPS is our largest product line,” adds Sriram. “In fact and we are No.4

in the country behind 3 MNCs. But we are the fastest growing UPS company in India and the No.1 Indian UPS company. In power conditioning products like voltage stabilizers and Active Harmonic Filters, we are the market leader and have the No.1 market share in India. SoftDisk (SD) has adjudged us as the No.1 power electronics company for the last three years, the latest being the ‘SD Awards 2017’. We also manufacture low voltage isolation transformers used in conjunction with our servo stabilizers for power protection of equipment used in metal cutting and metal forming industries. Other innovative products we offer include Solar Inverters with energy storage capabilities and static transfer switches which ensure uninterrupted power for critical loads when supplied from two power sources. “

Comprehensive Range The company’s range of manufacture comprises power conditioning products such as Servo Controlled Voltage Stabilizers - both air cooled and oil cooled, Active Harmonic Filters, Isolation Transformers; Power Backup Systems like Single Phase & Three-Phase UPS - IGBT based Rectifier and Inverter both transformerless and with built-in isolation transformer, high efficiency Offline UPS; Static Transfer Switches; Solar Off Grid

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82 COMPANY PROFILE

and Hybrid Inverters and customized power electronic solutions. The UPS market in India is said to be of the order of Rs.3600 crores. Consul’s market share is about 7%. “Last year the company achieved a turnover of Rs.355 crores and this year it is aiming to achieve Rs.500 crores. Consul’s Sunbird Solar Inverters are unique and incorporate ‘USE’ technology - USE stands for ability to Use, Store and Export Solar energy. The company can use solar energy to provide power to connected equipment, store energy in the battery and also export excess solar power to the grid. It is one of the very few companies in the world who make Solar Inverters with USE technology. “We have supplied Sunbird Solar Inverters ranging from 1 KW to 400 KW and are the market leaders for three phase off-grid and hybrid solar inverters with energy storage. Over the last few years we have supplied close to 50MW of our Sunbird Solar inverters for a variety of applications deployed in large projects that include homes under Remote Village Electrification as part of the Deen Dayal Upadhyaya Gram Jyoti Yojana (DDUGJY) Project, Petrol Retail outlets of major retailers like IOCL, BPCL, HPCL, and Reliance, major Educational Institutions like the IITs, Sports complexes, and Government Establishments – Defence, Police and Railways,” elucidates Sriram. One of the unique projects it did was

Innovative Power Conditioning & Power Backup Solutions for clean and uninterrupted power supply for the Sabzi Mandi project initiated by the Government of Uttar Pradesh. This is a full-fledged market facility for farmers well equipped with cold storage facilities, shops, drainage systems, and warehouses. The project covers 16 locations in the state and is fitted with multiple units of 150kw to 400kW Sunbird solar inverters with solar panels and batteries to be self-sufficient for uninterrupted power supply. The solar power in these sites support a mixed load of pump motors, lighting, cool storage fans and other infrastructural needs of the Mandi’s totally eliminating the need for DG power and using the Mains power only as a backup if generated solar power is not sufficient.

Pan-India Service Network Service is a big differentiator for the company in how it supports its customers. It has invested extensively in leveraging technology for its service operations. “Our complete installed base of over 1,00,000 units are maintained

in SAP. This allows us to quickly and efficiently respond to customer support calls. In our segment, we are the only company with a pan-India service network. We have 350 plus company trained service engineers in 85 locations across the length and breadth of the country. We operate our customer call center 365 days a year with four language support. We can receive service request 24 x 7. Service request is also received through mobile app,” explains Sriram. Consul has two manufacturing plants - one in Chennai and the other in Pune. The factories are ISO 9001, ISO 14001 and OHAS 18001 certified. It also has 26 branch offices throughout the country. The company has a workforce of 800 employees on pay roll. “We are a 35-year old company. We started off with servo stabilizers, but today Consul Neowatt is known as Global Indian UPS company - the fastest growing UPS company rather. “The company’s vision is to become India’s premier provider of power backup & power conditioning products, services and solutions and to be the preferred power partner for its customers. “Towards this end, our mission is to add value to our customers with cost-effective, innovative, energy efficient and reliable power backup and power conditioning products and solutions,” underlines Sriram.

Consul Neowatt’s manufacturing facilities in Chennai and Pune SEPTEMBER 2018 | www.engrreview.com

Electronic Components, Modules and Systems.

Superior Solutions for a Smart World. Product portfolio • Ceramic capacitors • Aluminum electrolytic capacitors • Film capacitors • Ferrites and inductors • EMC and power filters • High-frequency products • Piezo components • Protection devices • Sensors and sensor solutions

Power Quality Solutions (PQS) • LV and MV PFC capacitors (resin, oil, gas, impregnated) • Power factor controllers • Capacitor duty contactors • Thyristor switching modules • Detuned filter reactors • MV capacitor switches • LV and MV reactive power compensation systems • Power quality audits

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84 TECH TRENDS

“GEISSEL – CABLE GLANDS AND MORE…..”

eissel India, started in 1994, as a turned parts manufacturer, branched out into cable glands and electrical wiring accessories from 2009, to serve the vast and yet fully untapped Indian market. In just 8 years and over 100+ satisfied customers, it has earned a name for itself among the users of its products, some of them being large International Companies. The sections of industry served by Geissel India are aerospace, automation & robotics, power, hydraulics, material handling, and pneumatics, to name just a few. Ably assisted by its R & D centre at its mother plant in Germany, Geissel is first in manufacturing the IP 68 Double Compression gland for armoured cables in India. Besides this, it has diverse products like standard IP 68 & 69, multisealing cable glands, plugs, reducers, enlargements, lock nuts, conduits, etc., made in brass, polyamide & stainless steel S.S 303 (1.4305), S.S

316 Ti (1.4571), and all according to ROHS standards. Geissel India is now compliant with the latest standards of ISO 9001:2015, ISO 14001:2015 & OHSAS 18001:2007, thus totally committing itself to Quality Management Systems, Environment and Health & Safety. From using recycled water, to harnessing its self-produced solar energy for 100% of its own consumption at its German plant, the Group is committed to protect natural resources and implementing sustainability for this generation and the ones to come.

For more information: Email: info@geissel-india.com

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

88 TECH TRENDS

Intelligent machines with no boundaries ZTI Smart Machines produces machines for automating and mechanizing the processing of extremely sensitive products, such as vegetables, fruit and flowers. They also offer solutions for the automotive and health care sectors. Their components have to be sensitive too - like the Compact Rail from the Rollon Group: compact size, fast (up to 9 m/s) and quiet, they are easy and inexpensive to mount on all surfaces, even unfinished surfaces, thanks to their capacity to deal with misalignment up to 4 mm. Following Rollon’s suggestions, the Corenso machine is made with Compact Rail linear rails.

apply knowledge from the automation industry to create and intelligent solution for the medical assistance sector. This is an authentic case of technology transfer,” affirmed Hans Keijzer with satisfaction. There are also other examples: ZTI tests machines that must function in harsh environmental conditions, with solutions that are currently used in the aeronautical industry, and it experiments with machines in humid environments using technologies that were created for the naval sector.

Software as a support

he development of intelligent machines is a complex process that requires broad knowledge about mechanical engineering and software development, but also the intelligence to use the existing technologies in other sectors. The machines from the Dutch company ZTI process mainly fruit. They peel and cut mangoes in Mexico and kiwi in Qatar. But the company is receiving an increasing number of requests to solve complex problems in other sectors.

The importance of automation Hans Keijzer, Director of ZTI said: “Boundaries between the various sectors no longer exist. Robotic technologies and diagnostic imaging are an example of a logical integration of our intelligent machines for processing or of handling packaging. Still today, it is easy to find

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products being inserted into a machine manually or packaged by hand. This requires more personnel and continuous action, while using diagnostic imaging can enable a robot to do these things.” An example of the absence of boundaries is a test instrument developed by ZTI for lifting systems made by Arjo Huntleigh, which makes caring for patients in hospitals or at home easier. “The client has developed a complete test procedure for its lifters, but the load was only tested as a static load, from a stopped position, and a maximum weight of 350 kg was used,” said Keijzer. Later, ZTI developed a mobile testing device in the form of an actuator that can simulate a load as the lifter is moving. The Ambulante Tilhulp Tester (ATT) can be connected to a notebook and after having run the test, it produces a report. In this way, it is easy to calibrate equipment. “For the ATT, we

To make sure that all these technologies from different sectors and all components from suppliers harmonize perfectly, ZTI uses CAD to do broad-scale 3D simulations. “In this way, we can know precisely if the machine fulfills client requirements perfectly and if other problems could emerge. We also want to decide which components are necessary to build the machine and which suppliers we need to contact,” explained Keijzer. With these parameters in mind, ZTI develops one or more test plans. Do the components adapt perfectly? Is there a risk that something will jam or be damaged? ZTI wants to know the answers to these questions before starting production. “The challenge for companies, with the elimination of boundaries, is the fact it is necessary to acquire more knowledge than in the past to develop a machine. At ZTI, we are used to doing that, but we have also learned that it is extremely important to be able to count on your own suppliers. All of the technology and components must match perfectly, like in a puzzle,

Linear solutions global provider.

CMY

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

Linear Line

Actuator Line

Telescopic Line

Actuator System Line

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

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and the success of our work depends on the advice given by our suppliers about the quality and feasibility of our projects,” said Keijzer. ZTI handles mainly design and development of machines, and works in close contact with external suppliers that make the components that it needs.

Trust between partners An example of this trusting relationship between ZTI and its suppliers is the collaboration with Rollon, the global provider of linear solutions and systems for industrial automation. Keijzer sustains that: “When we developed a dryer with rollers for our client, Corenso, we found ourselves facing a few challenges. Being able to consult with Rollon was a precious resource. The supplier had thought about how to build this system

and which rails were best for those environmental conditions.” Corenso had asked ZTI if they were able to design a machine that counted tubes, stacked them, dried them and put them in boxes. Data relating to tube diameter, stacking and length was inserted separately into the system so that the machine could adopt precisely the right work mode for the tubes being treated. ZTI designed the machine with a fan that blows low humidity conditioned air onto the stack of tubes. The tubes can then be packaged

Compact Rail linear rails by Rollon are mounted both in vertical and horizontal positions.

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immediately for shipment. Therefore, Corenso does not have to transport large quantities of tubes in a dryer any more. Moreover, the machine allows the company to save 36 hours, because the tubes no longer have to remain in the dryer. One of the design challenges was the way in which the tubes would fall from the moving conveyor belt and land in slightly different ways each time. One solution was to stop the machine and stack the tubes manually in the correct position, but that took too much time. Now, ZTI has a module that positions the tubes precisely one next to the other before stacking them. Another problem is the fact that a large quantity of dust is produced in environments where paper is handled. “Machine components, such as rails, must also be able to handle dust. We can’t have the system locking up because the rails are dirty and clogged. Rollon advised us to use the Compact Rail products, which do not require maintenance,” said Keijzer. This open rail can be cleaned easily and the rollers on the track are built to withstand dust and lubricants for their lifetime. “This is why this rail is ideal for dusty environments.”

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

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FKL MAKE ROLLING EASY

t’s a world without limits. A world which is dreaming, challenging, doing and growing everyday. A world that requires versatile skills, continuous innovation and determination to find solutions to its challenges.This world needs one stop solution for all its problems. FKL India Pvt. Ltd. is an authorised distributor of FKL, s.r.o., Slovakia and started its operation in the year 2007 in pursuit of providing world class Shaft Solution in India. With a state-of-the-art manufacturing plant &centralized warehouse in Ahmedabad, FKL India has surely got the momentum right. Efficient team, customer focus, exceptional quality, unrivaled services and competitive prices have made FKL the preferred brand in Indian industrial markets.

FKL VISION Vision without Action is merely a dream. Vision with Action can change the world. The FKL Vision - To be reckoned as one of the leading players of Industrial

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Bearings segment in India. We aim to be amongst the top 6 leading brands (in terms of market share) in Industrial Bearings industries. To be the Brand asked for by its name, preferred for its unsurpassed quality and associated with organizations whose zeal and values are similar and associated with organizations whose zeal and values are similar. Our vision serves as the beacon and guides every aspect of our business by describing what we need to accomplish in order to continue achieving sustainable and quality growth.

FKL MISSION To be the preferred choice of our customers by serving them with. World - Class products & services at competitive prices • Just in time (JIT) delivery assurance • Application Optimized Solutions • Solutions to improve their rotational efficiency & effectiveness, in turn making them more successful and profitable. Our roadmap starts with our mission

which is enduring. It declares our purpose as a company and serves as the standard against which we weigh our actions and decisions.

TECHNOLOGY Manufacturing is more than just putting parts together. It’s coming up with ideas, testing principles and perfecting the engineering, as well as final assembly. FKL India having a manufacturing plant in Ahmedabad in technical collaboration with FKL s.r.o. It is equipped with state-of-the-art machineries and Quality testing equipment. Our skilled professional are working relentlessly for achieving the best quality which FKL offers to customers.

For more information E-mail: marketing@fklindia.com

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Easy and secure transfer of process data to mobile end devices The TwinCAT IoT Communicator makes it easy for PLCs to communicate with mobile devices by connecting the TwinCAT controller directly and securely to a messaging service through TLS encryption. For smartphone and tablet users, the associated IoT Communicator App ensures that process data can be represented on all mobile devices in a clear overview. Alarms are sent to the device as push messages.

The TwinCAT IoT Communicator software and the IoT Communicator App provide convenient and secure access to process data via mobile end devices.

he TwinCAT 3 IoT Communicator exchanges data using a publish/subscribe mechanism. Since no special firewall settings are needed, integration into an existing IT network is easy. Information is exchanged via a message broker that uses the standardised MQTT protocol and acts as a central messaging service in a cloud or local network. A high level of communication security is guaranteed by proven TLS encryption (up to version 1.2). Transmitted process data can be dis-

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played on mobile devices using the IoT Communicator App, which is available for both Android and iOS operating systems. The IoT Communicator App also incorporates an integrated QR code scanner to facilitate entry of access data for communication between the broker and individual users. The TwinCAT IoT Communicator simplifies the transmission of push messages. It offers a number of advantages over conventional e-mail and SMS messages by visualizing live data, vari-

ables and status values. This makes the IoT Communicator an ideal addition to the related TwinCAT IoT and TwinCAT Analytics software products.

For more information E-mail: info@beckhoff.co.in Web: www.beckhoff.co.in

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How to Navigate the Road to Smart Manufacturing When planning a smart manufacturing strategy, focusing on four key areas can help drive a more successful IoT implementation. Numerous initiatives have been put into motion around the world to fundamentally transform manufacturing as we know it. The initiatives have different names from the Smart Manufacturing Leadership Coalition and Industrie 4.0 in the West, to Made in China 2025 and Manufacturing Innovation 3.0 in the East but they share a common pursuit: smart manufacturing. This global push for smart manufacturing is underway for good reason. By providing greater connectivity across a manufacturing enterprise and the ability to act on production intelligence, smart manufacturing offers many opportunities for industrial firms to improve operations, create new value and respond to challenges such as the skilled-labor shortage. For example, manufacturers are using embedded machinery intelligence to predict equipment failures and improve productivity. They’re using remote-access capabilities to monitor multiple machines simultaneously from a centralized location, allowing them to use labor more efficiently. They’re extending this greater connectivity and information-sharing outside their production walls to track and coordinate supply chain activities better. They’re also using contemporary cloud technologies to change business models and build new revenue streams. However, while some forward-thinking manufacturers have embraced smart manufacturing fully and already are reaping the benefits, most still have much work ahead of them. Case in point: Only 11% of manufacturers have implemented a strategy to

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apply Internet of Things (IoT) technologies to production processes, according to a recent survey by The MPI Group. Even worse, about half of manufacturers said they’re still struggling with the basics of defining and implementing an IoT strategy.

Building the Infrastructure Adoption of key technologies is an essential part of a smart manufacturing approach. This includes using the IoT, an ever-growing proliferation of connected “smart” devices, to improve understanding of quality, efficiency, security and safety. It also includes the strategic use of cloud computing, mobility and data analytics. While most industrial firms are not yet prepared to deploy smart manufacturing technologies, they clearly see opportunities for using them. According to the MPI study, the top five objectives manufacturers identified for incorporating the IoT into their operations are: • Improved product quality. • Increased speed of operations. • Decreased manufacturing costs. • Improved maintenance. • Uptime and improved information for business analytics. Achieving these objectives requires an integrated architecture and a strategy for using smart manufacturing technologies. Specifically, manufacturers must converge their IT and operations technology (OT) systems into a single, unified network infrastructure and identify opportunities for using IoT technologies that allow seamless connectivity and information-sharing across people, processes and things. At the same time, manufacturers also need to manage their greater abundance of data efficiently and in ways that

help them make better, faster business decisions. This includes using IoT device intelligence, cloud connectivity and data analytics all together to help manage the large data sets required for balancing production activities based on upstream inventories and downstream demand. Rockwell Automation calls this The Connected Enterprise. Manufacturers seeking to build a Connected Enterprise in support of deploying smart manufacturing should focus on four core tactics:

1. Increasing Quality and Productivity. Quality-management and continuous-improvement programs can do only so much when the information they rely on is limited or not available in real time. Manufacturers are using embedded machine or equipment intelligence to monitor most product specifications in real time, either from a customer or regulatory perspective. More than that, they’re using this intelligence to address product defects and variations rapidly as they happen, verify quality goals are met and improve customer satisfaction. Using embedded intelligence to improve control and transparency of manufacturing processes also creates new opportunities to improve productivity. For example, operators on the plant floor now are analyzing real-time production data to uncover hidden inefficiencies and implement changes faster. At the supply-chain level, managers and logistics professionals are using smart manufacturing technologies to deliver critical information, such as forecasts and schedules to suppliers, while also monitoring delivery perfor-

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mances.

2. Improving Decision-Making. Better decision-making in a Connected Enterprise begins with working data capital. However, most manufacturers have older systems in place that will need to be updated for the next generation of productivity. This involves reconciling their disparate OT data sources with their current IT systems, extracting the right data from smart manufacturing technologies and transforming that data into actionable information. Manufacturers that have taken these steps and armed themselves with better information are using it to optimize their assets, improve their responsiveness to changing customer needs, refine work flows and reduce inventory. More than that, they’re gaining new, strategic insights that help them understand their businesses in deeper ways, including: • Identifying operational strengths and weaknesses • Analyzing processes and planning improvement initiatives • Designing and implementing better production systems • Developing targeted training programs • Establishing performance management systems

3. Establishing Safe and Reliable Operations. Achieving safe, compliant and reliable operations is an ongoing concern for any manufacturer, and smart manufacturing provides new opportunities for dealing with some of these age-old challenges. The most obvious opportunities will include replacing obsolete and isolated automation systems that have exceeded their life spans, are difficult to connect and are no longer supported by their manufacturers. However, manufacturers also should define new requirements based on past performance in areas such as employee injuries, machinery down-

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time and work stoppages. From there, they can prioritize processes and equipment for redesign. They should consider using embedded intelligence to gather real-time data, including equipment status and exception-based reporting, that can be contextualized and delivered as role-based analytics in areas such as quality, safety, compliance, energy usage and downtime issues. Different stakeholders, from quality and safety managers to operators and maintenance technicians, then can use that information to optimize machine performance, manufacturing processes and compliance. Manufacturers also should make these processes collaborative, such as asking line workers where smarter machine assets can provide more visibility and control of complex production processes.

4. Securing the Infrastructure. Greater information availability and more connection points can introduce greater risk to manufacturing environments in the forms of internal and external threats. Cyber attackers are looking beyond corporate servers to target operations technologies, while decades-old devices and controls on the plant floor can be more susceptible to breaches through both malicious attacks and unintentional employee actions. No single security technology or methodology will suffice in this complex threat landscape. Instead, manufacturers must use a comprehensive, defense-in-depth approach that establishes security safeguards at different layers to stop threats on multiple fronts. A robust and secure network infrastructure should be built on standard and unmodified Ethernet, which has become the industry preference for security purposes. It also should allow technicians to manage software installations, patches and upgrades securely for years to come and incorporate strong security policies and procedures for

everything from machine operations to bring your own device (BYOD).

Beginning the Journey Smart manufacturing offers great potential, and it all begins with establishing a Connected Enterprise as the foundation for achieving greater connectivity and information sharing. Let’s answer some of the most common questions manufacturers ask as they prepare to build a Connected Enterprise:

What continuous improvement processes can smart manufacturing help me with? This will depend on a manufacturer’s specific operations and business goals. But some good areas to start with include overall equipment effectiveness (OEE), product quality, downtime, scrap, worker safety and energy consumption.

Which business process transformation is going to provide me with a competitive advantage? And is smart manufacturing going to get me there? Enterprise-wide connectivity can help manufacturers coordinate operations better across all levels to create more demand-driven operations. Asset intelligence also can transform maintenance approaches from reactive to predictive to help improve uptime. And automated data collection and reporting can save significant time compared to manual processes, especially in highly regulated industries.

What organizational changes are needed to facilitate smart manufacturing? IT/OT convergence is absolutely essential, and a similar convergence also must occur within the workforce. IT and operations personnel historically have worked separate from each other, but tighter collaboration is needed in The Connected Enterprise. Manufacturers

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must bridge the gap between these two groups while equipping them with new skills for managing industrial networked technologies.

How do I measure the benefits? The same working data capital used to monitor operations will help quantify benefits. Data can be viewed historically over set periods of time in KPI dashboards to measure OEE increases, quality improvements, scrap reduction and labor use. Standardizing data col-

lection and reporting in The Connected Enterprise also can help compare performance across sites.

Am I ready for an ongoing journey to The Connected Enterprise versus a one-time event? Any path to The Connected Enterprise should begin with a comprehensive assessment. With an eye on the manufacturer’s current and future states, the assessment should cover the organization’s network infrastructure, manufac-

turing environment, data and reporting capabilities, and security policies. In the end, this will help identify what can be upgraded and what needs replacing. Manufacturers that address these questions up front and keep the four core tactics for building a Connected Enterprise in mind as they plan a smart manufacturing strategy will be better prepared to capitalize on its true potential.

South Africa: Alstom trains travel with HARTING technology Partnership with Hiconnex Industrial / Local Han-Modular® connector production / Win-win-win-situation for all companies involved

T Chris Brand (left), General Manager of Hiconnex Industrial, and Bernd Fischer, General Manager Corporate Regional Management of HARTING Technology Group, are pleased about the partnership.

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he HARTING Technology Group is expanding its business activity in South Africa. Han-Modular® connectors are now produced for the train division of the French industrial group Alstom. HARTING has a sales office in Johannesburg. The Technology Group is able to provide services and solutions for its partner Hiconnex Industrial to comprehensive national standards and with the well-known HARTING quality. The cable and connector distributor Hiconnex Industrial handles the complete assembly of Han-Modular® connectors. These Han-Modular® connectors are fitted into Alstom trains, which are then delivered to the South African national transport company PRASA. “This partnership is a win-win-win situation for all companies involved: for Alstom, for Hiconnex Industrial and for HARTING,” says Bernd Fischer, General Manager Corporate Regional Management at HARTING. And, what is also very important, with this project all companies support local market in

South Africa. “We are delighted that Alstom is impressed with our expertise and quality products in the rail sector,” says Chris Brand, General Manager of Hiconnex Industrial. HARTING and Hiconnex Industrial are looking to develop a longterm partnership.

About HARTING: The HARTING Technology Group is one of the world’s leading providers of industrial connection technology for the three lifelines of Data, Signal and Power and has 13 production plants and branches in 44 countries. Moreover, the company also produces retail checkout systems, electromagnetic actuators for automotive and industrial series use, as well as hardware and software for customers and applications in automation technology, robotics and transportation engineering. In the 2016/17 business year, some 4,650 employees generated sales of EUR 672 million. For more information Web: www.HARTING.in

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OPTICAL GAS IMAGING FOR THE CHEMICAL INDUSTRY Optical gas imaging cameras are a proven method to detect dangerous and costly gas leaks in time. Optical gas imaging technology has been successfully applied in the oil refining, chemical, petrochemical and many other industries to help improve worker safety and prevent costly production shutdowns.

The FLIR optical gas imaging camera lets you see gas leaks quickly, easily, and from a safe distance

hemical compounds and gases are invisible to the naked eye. Yet many companies work intensively with these substances before, during and after their production processes. The FLIR Gas Detection cameras are infrared cameras which are able to visualize gas by utilizing the physics of fugitive gas leaks. The camera produces a full picture of the scanned area and leaks appear as smoke on the camera’s viewfinder or LCD, allowing the user to see fugitive gas emissions. The petrochemical industry produces hydrocarbon and other substances using base feed stocks from the oil refining companies either by conversion processes or further separation that is not normally carried out at an oil refinery. Most of the chemicals used or made in these industries have good visibility using the mid wave gas detection camera. The chemical industry produces non-hydrocarbon or inorganic chemicals from base feed stocks. These are often a mixture of batch and continuous processes that yield very high purity products. The mid wave gas detection camera has a good response to a lot of chemicals found in this sector.

Safety : The key success factors of

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optical gas imaging cameras for businesses are safety, efficiency and profitability. A gas detection camera is a quick, non-contact measuring instrument that can be used in hard-to-access locations. It can detect small leaks from several meters away and big leaks from hundreds of meters away. This way, operators do not need to approach the leak from close by, which improves the safety significantly.

Efficiency : Working with sniffers or probes can be very time-consuming and a lot of the time spent inspecting installations that are safe and leak-free is wasted. Using a Gas Detection camera you get a complete picture and can immediately exclude areas that do not need any action. This saves a lot of time and personnel. With a gas detection camera, measurements can be carried out remotely and rapidly and – most important of all – problems can be identified at an early stage.

Environmental Regulations Optical gas imaging allows the industry to comply with new industrial emissions regulations & procedures as set by the new IED (Industrial Emissions Directive) within the EU as part of the BREF (Best

Available Technique Reference) for Refining or Mineral Oil & Gas. Chapter 5.1.4 is the draft BREF conclusion, for the Refining or Mineral Oil and Gas industry sector, stating optical gas imaging is one of three BAT (Best Available Techniques) which must be used for monitoring diffuse VOC emissions.

Optical Gas Imaging Cameras: Buy Or Loan? Although the cost of optical gas imaging cameras has decreased in recent years, purchasing a gas detection camera is still a significant investment for a lot of companies. According to Frank Zahorszki, CEO of Itema GmbH, a German service company specialized in thermographic inspections, the purchase price of an optical gas imaging camera should not deter smaller chemical companies from making use of this technology. “Today, more and more companies are contracting outside service providers for leak detection and repair to specialized service companies”, says Zahorszki. “This begs the question whether your company should buy or loan an optical gas imaging camera.” The two main reasons for a plant buying an OGI camera are the amount of targets to inspect and the just-in-time availability of the camera in case of a leak. Companies that only require one to

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five inspection days per year, or companies that have the convenience to wait for a service company to come over, will opt for an external contractor. Very often, companies need to monitor different types of gases with different types of cameras, which justifies an external service provider even more. The gas detection camera technique has a wide range of potential uses in the chemical and petro-chemical industries.

GF320: Hydrocarbons Optical gas imaging cameras like the FLIR GF320 help to spot leaks in piping, flanges and connections in petrochemical operations. The GF320 can rapidly scan large areas and pinpoint leaks and is ideal for monitoring plants that are difficult to reach with contact measurement tools. Literally thousands of components can be scanned per shift without the need to interrupt the process. It reduces repair downtime and provides verification of the process. Above all it is exceptionally safe, allowing potentially dangerous leaks (e.g. methane) to be monitored from several meters away.

GF346: Improving Workplace Safety Optical gas imaging cameras are an efficient way to inspect the workplace for dangerous gas leaks. This can especially be useful in foundries or in other processes where significant amounts of carbon monoxide (CO) are generated. CO is a colorless, odorless gas usually formed during the combustion process. Anywhere there is a heated process leading to the formation of smoke such as

Captured gas leak from production site. SEPTEMBER 2018 | www.engrreview.com

moulds and cupola furnaces CO will be present. Workers on charging platforms or catwalks can unknowingly breathe high concentrations of this gas. This can block oxygen being transported, from the lungs, causing the worker to suddenly lose consciousness. High concentrations may prove rapidly fatal without any warning symptoms.

GF309: Furnace Inspections The FLIR GF309 is designed for high temperature industrial furnace applications. These cameras are ideal for monitoring all types of furnaces, heaters and boilers, particularly in the chemical and petrochemical industries. Custom-built to see through flames, the FLIR GF309 also features a detachable heat shield designed to reflect heat away from the camera and camera operator, providing increased protection.

GF343: Leak Tightness Testing Carbon dioxide (CO2) is considered to be a relatively inexpensive tracer gas for tightness testing. The method is also reliable, can be used to test complex equipment, and CO2 is easy to obtain. With optical gas imaging cameras, like the FLIR GF343, you can see CO2 leaks quickly, easily, and from a safe distance. This is very helpful at turnarounds and shut-downs to test the inertization and filling of the equipment.

GF306: Crackers , Ammonia, SF6 Cracking is a conversion process used in petroleum refineries which converts the high-boiling, high-molecular weight hydrocarbon fractions of petroleum crude

Gas leak is clearly visible on the thermal image.

HSM is in part an image subtraction video processing technique that effectively enhances the thermal sensitivity of the camera. oils to more valuable gasoline olefinic gases and other products. Gases escaping from the cracking process can be highly flammable and dangerous. Being a non-contact measurement device, OGI cameras like the FLIR GF306 are ideal for monitoring chemical plant process areas/operations, such as steam crackers and reformers, especially for components that are difficult to reach with contact measurement tools.

High Sensitivity Mode FLIR gas imaging cameras are surprisingly sensitive, so they can be used to detect even smaller gas leaks from about several meters away. This is especially the case when operation in the High Sensitivity Mode (HSM). This is a special feature included in all GF-Series optical gas imaging cameras. It is an image subtraction video processing technique that effectively enhances the thermal sensitivity of the camera. The HSM feature subtracts a percentage of individual pixel signals from frames in the video stream from the subsequent frames, thus enhancing the differences between frames, which make leaks stand out more clearly in the resulting images.

For more information FLIR Systems India Pvt. Ltd 1111, D Mall, Netaji Subhash Place, Pitampura, New Delhi â&#x20AC;&#x201C; 110034, INDIA Tel: +91-11-4560 3555 | Fax: +91-11-4721 2006 Email: flirindia@flir.com.hk Webiste: www.flir.in

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Clean guidance: New igus liner with FDA and EU conformity for linear systems The company igus is expanding its range of liners with the FDA and EU-compliant high-performance plastic iglidur A160

inear guide systems from igus ensure the precise and quick adjustment of machines in the food and beverage industry. Integrated, maintenance-free and wear-resistant liners used in the carriages enable the linear guides to glide without lubrication. The company igus has now developed an FDA and EU-compliant liner made from the high-performance plastic iglidur A160, which is particularly suitable for the special hygienic requirements of the food industry. It is particularly characterised by its long service life on FDA and EU-compliant stainless steel shafts and in wet areas. Clean, lubrication-free and corrosion-resistant: these are requirements in the food industry for the installed machine elements. This increasingly makes maintenance-free plastic solutions the right choice. Lubrication-free linear guide systems from igus are already used in numerous applications in the food and packaging industry due to their wide range of performance, be it in beverage filling systems or in the bottle processing industry. Liners made of

high-performance plastics ensure a smooth and clean adjustment. Especially for applications in the food industry, users can now rely on hygienic linear guides thanks to the new lubrication-free linear plain bearings made of iglidur A160. The blue material complies with the FDA and EU Regulation 10/2011 EC and is therefore suited for the special requirements of the food industry. The iglidur A160 has a high and online-calculable service life on stainless steel shafts, even in wet areas. The high-performance plastic is also characterised by its high media resistance. Another advantage: the liner is impervious to contamination thanks to the integrated dirt channels, and is easy to clean and replace. The new linear bearing component is currently available in eight dimensions for all drylin W housing bearings and carriages as well as for all drylin R round guides.

Tested wear resistance on stainless steel shafts In the companyâ&#x20AC;&#x2122;s own 2,750 square-me-

The wear test in the in-house igus test laboratory demonstrates that the liner made of iglidur A160 is the optimum sliding partner for stainless steel shafts. (Source: igus GmbH) SEPTEMBER 2018 | www.engrreview.com

Approved for food contact: The new liner made of iglidur A160 from igus. (Source: igus GmbH) tre test laboratory, igus has tested the new liner on various stainless steel shafts vis-a-vis plastic liners that are already in the igus range made of iglidur J200, iglidur J, iglidur A180, iglidur E7 and iglidur X. The iglidur J200 is an established standard material on aluminium shafts, while iglidur J is suitable for all shaft surfaces. For users who rely on drylin linear systems with steel shafts, igus has, with the iglidur E7, an endurance runner in its product range, while the use of iglidur X liners is particularly suitable for applications requiring high temperature resistance and high chemical resistance. The wear test clearly showed that the new iglidur A160 liner has the best wear values on various stainless steel shafts. Therefore, the new liner is an ideal sliding partner for stainless steel linear guides used in the food industry.

For more information Web: www.igus.in

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LAPP India’s 20-Year Journey to Becoming a Leading Industrial Cable Brand This year marks the 20th anniversary of the LAPP’s presence in India. From its maiden manufacturing unit in Jigani, Bengaluru in 1998 to LAPP Group’s biggest operation outside of Germany, LAPP in India has indeed traversed a long way. Shweta Nanda of Engineering Review spoke to Marc Jarrault, Managing Director, LAPP India Pvt. Ltd., to know more about the journey so far, significant milestones and the company’s formula for success

Marc Jarrault, Managing Director, LAPP India Pvt. Ltd

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espite stiff competition, LAPP in India has clocked steady growth and positive turnover year-on-year over its 20-year history in India. Keeping up with the technological advancements and evolving customer requirements, the company has grown from strength to strength. Starting out by largely catering to original equipment manufacturers (OEM), the company has significantly expanded its offerings. In the last two decades, LAPP in India has established itself as a top player in the Indian cable and wire market, with remarkable achievements to its credit. “Foraying into the Indian market has proved to be a rewarding decision for us at LAPP. The journey has been really exciting and we have seen several positive milestones,” shares Marc Jarrault, Managing Director, LAPP India. Today, LAPP India holds a significant market share in the Indian industrial cable manufacturing segment. It has emerged as a dominant player providing Control, Power and Data products to high-growth industries right from metals and mining to power plants (nuclear &thermal), infrastructure – buildings & metros and automation. The company has been witnessing a steady growth spurt in the past years. “We have been growing at more than 15% in the last four years with an estimated growth of 20% for the current year. We have specialized products manufactured to meet the specific needs of industries including automation, F&B, building infrastructure, railways and metros and

many more which have been witnessing considerable growth over the last few years. We have been part of all the major metro projects, key solar energy projects and several plant engineering projects,” informs Jarrault. The company boasts a strong product portfolio and offers standard products to custom-built solutions to meet customer requirements. Shedding more light on the company’s key products Jarrault says, “In an industry where brands do not hold much value, we are the first cable and connectivity solution provider to have developed strong product brands worldwide. Our brands are ÖLFLEX® universal cable used in control applications, UNITRONIC® data transmission, ETHERLINE® Ethernet technology-based networks, HITRONIC® fibre optic cables, EPIC® connectors, SKINTOP® cable glands, SILVYN® protective cable conduit systems and cable carrier system, and FLEXIMARK® permanent marking system for a clear overview inside a control cabinet. Additionally, we also offer ÖLFLEX® CONNECT customized cable assembly solution to provide complete end-to-end solution to our customers.”

Innovation at the Core A firm eye on innovation coupled with a strong focus on quality is at the core of LAPP India’s success story. The company continually undertakes innovations and performs various standard tests on the cables manufactured. It has brought some leading cutting-edge technology to India in the field of cable and

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connection technology. “LAPP has always backed research and development when it comes to innovating products to meet the new age requirements. As part of our R&D initiative we have a full-fledged Innovation and Engineering Centre and state-of the art laboratory in India where we develop new compounds, deploy new raw materials and look at generating more efficient and advanced ways of transmitting energy and power & data. Both our manufacturing facilities in Bengaluru and Bhopal have advanced testing facilities that put every raw material batch received through a rigorous testing process to ensure zero field failure and lower process rejections,” asserts Jarrault. Apart from manufacturing innovative products, the company also encourages its customers to innovate. As a part of this initiative, it recognizes industries that use LAPP cables and associated products and solutions for developing innovative products, which have a strong impact on sales, productivity improvement, energy savings and sustainable development with LAPP’s Innovation Award. Additionally, LAPP believes in fostering innovation with young minds and hence has established Centre of Excellences (CoEs) at engineering institutions across India to support the spirit of knowledge creation, insights, implementation, and imparting thought

First manufacturing plant at Jigani in Bengaluru

leadership. “Our first CoE was established in PSG College of Technology, Coimbatore, where PSG academicians, LAPP experts, and students focus on understanding cables and researching on new trends. Our next CoE in RV College of Engineering, Bengaluru, consists of a laboratory facility with end-to-end cable research and testing equipment. This center provides scope for students to understand and test cabling technology solutions. Moreover, LAPP has also sponsored their Hybrid car under the Ashwa Racing Foundation by providing them cables for designing the car to compete at national and global events. This year, RV College won 2nd position at Formula Hybrid car race at the U.S.,” updates Jarrault.

Adapting to New Technology Trends One key reason that helps LAPP stand

Bhopal manufacturing facility

SEPTEMBER 2018 | www.engrreview.com

uniquely among its Indian peers is the fact that it keeps pace with the ever-changing world of technologies. To meet the growing demand of the manufacturers, the company is focusing on developing solutions for the era of Industry 4.0 and IoT. For Industry 4.0, the company’s focus lies in developing solutions that are designed with data cables that ensure minimal loss of data/signal and uses networking which assures high speed data communication. “We are actively re-thinking and re-defining the cable and connection technology to meet the challenges of the smart factory of the future. As a step towards this initiative, we have developed highly flexible ETHERLINE® FD Cat. 6A that can transmit highest data rates with consistent reliability in drag chains that are under constant movement with a data rate of 10 Gbit/s. Our next remarkable product for the new age factories is ETHERLINE® EC. These cables are 30% thinner than usual yet robust solutions, suitable for use at sensor level which allows the best bending radii. To further strengthen our offering for smart factories, we launched ETHERLINE® ACCESS, the managed and unmanaged switches. The switches along with data cables and connectors from LAPP’s range of products offering for the industrial network solutions ensures reliable connectivity,” reveals Jarrault.

114 TECH TRENDS

Commitment towards India market The company has always sensed huge opportunities in the Indian market and has shown inclination towards manufacturing in India. In fact, LAPP was the first international cable manufacturer to set up operations in India. “For us it was always important to manufacture products within the country as it gives us the edge to produce products designed for Indian needs with international standards at affordable price,” asserts Jarrault. To serve its customers better and address their timely needs, the company today has two manufacturing plants in Jigani, Bengaluru and Pilukedi, Bhopal, 23 sales offices, 5 warehouses and 5 service points spread across the nation. With this network, it is now successfully offering its huge range of 40,000 products, meeting all the international standards to its customers. “Both our manufacturing plants have state-of-the-art machineries and follow strict safety norms that facilitate us to have a production capacity of more than 200,000 kms of multi-core cables and 216,000 kms of single core wires per annum to service our 7,000 customers pan India,” informs Jarrault. As part of its commitment of caring for and protecting the environment both the company’s plants are RoHS certified. The company has an observant quality control system to ensure that at every stage, the manufacturing process

is monitored and measured. The focus on quality can be gauged from the fact that the company’s manufacturing plants and sales offices are certified under ISO 9001:2008. In order to take its customer service to another level, the company has undertaken another commendable initiative by establishing an online store - LAPP eshop - https://shopasia.LAPPgroup. com/in/. This initiative will allow small and medium businesses the ability to buy directly from the manufacturers on a click of a button. “The store has a user experience that allows our customer to do a hassle-free purchase of more than 20,000 LAPP products with an easy and secure payment option and free pan-India shipment. The store was initiated to strengthen our motto, ‘We are where you are’,” elaborates Jarrault. Besides the customer service and product quality, the company has invested heavily in its supply-chain management to move its heavy-duty goods from the factory to its customer’s base which is spread across the country. “LAPP’s investment is considerable in creating a network of strategically located warehouses for fast moving articles from source to destination,” states Jarrault.

The Way Ahead The company is eyeing further growth in India, which is slated to emerge as a manufacturing hub for machines and

An inside view of LAPP’s Bengaluru facility SEPTEMBER 2018 | www.engrreview.com

equipment as a part of Make in India campaign. LAPP in India has extensive growth plans and is aiming to reach Rs 1,000 crore in the next four years. It is also planning to increase its active customer base and strengthen its presence in key segments like infrastructure, automation, to name a few. Further, the company is also planning to increase its base from current 5 cities to 20 cities in the retail segment in the next four years. “This would ensure that we are not only seen as a leading industrial cable manufacturer but also a prominent player in the retail market targeting electricians and end consumers. We are focused on delivering not only products but customized products and solutions to meet customer requirements,” says Jarrault. The company plans to further continue to strengthen its customer service by setting up more warehouses and service points. “We are expanding our production capacity in Bengaluru and Bhopal plants to meet the growing requirements of our customers, which will help us in broadening our market offerings. We also plan to enlarge our product portfolio that allows our customers to conveniently buy complete connectivity solution from a single source,” adds Jarrault. The company is also focused on developing solutions for infrastructure segment by offering products that support the Government’s 100 smart cities initiative and for all future metro projects. Clearly, with LAPP’s eyes firmly set on the demands of the Indian market and the company continually focusing on embracing futuristic technologies, it is geared up to take the next big leap in the coming years. As India experiences rapid infrastructure and manufacturing development, LAPP with its comprehensive product portfolio and worldclass customer service is all set to be a part of India’s growth story. For more information https://lappindia.lappgroup.com/

116 TECH TRENDS

HEIDENHAIN Encoders for industrial robots Significant accuracy improvement at the tool center point Speed, power and durability are key characteristics of industrial robots. These robots are typically used in applications such as welding or in lifting heavy components for vehicle assembly. Yet despite advanced calibration methods, the position accuracy of industrial robots has been inadequate for certain tasks. This is now changing thanks in part to highly accurate, output-side encoders from HEIDENHAIN and AMO.

he main driver behind this development has been the aerospace industry because it must perform highly accurate machining operations on very large components. Machine tools would achieve the required level of accuracy with ease but are either too inflexible or too expensive as special-purpose machines for the job sites and working spaces involved. A robot, however, can easily reach any position on a very large component, such as the fuselage of an aircraft, and can perform tasks on it such as drilling and milling. Accuracy is impaired by many factors For these kinds of applications, however, the tool center point (i.e., the tool at the end of the robot’s arm) must be positioned and guided with sufficient accuracy. This is where the classic industrial robot runs up against its limits.

Deviations result from a variety of factors: • In order to achieve the desired level of maneuverability, robots with serial kinematics are required, such as articulated robots with six axes. • Each one of these axes is driven by a servo motor with a gear train. Zero position error, backlash, and joint elasticities are the main sources of inaccuracy. • Applied forces and dynamic effects during the machining process affect the rigidity of the robot’s mechanics and negatively influence the absolute position accuracy. Thanks to advanced calibration methods, it is already possible to move a tool center point to a certain position

SEPTEMBER 2018 | www.engrreview.com

repeatedly to within several hundredths of a millimeter. Depending on the manufacturer, the repeatability of articulated robots as per ISO 9283 is ±0.1 mm or better. However, when compared with repeatability, the absolute position accuracy that can be achieved within the robot’s coordinate system is worse by a factor of ten. Depending on their design, maximum range, and maximum load capacity, articulated robots currently achieve an absolute position accuracy of ±1 mm. This is insufficient for meeting the accuracy requirements of industries such as the aerospace sector. Yet robot manufacturers have been responding to this problem.

accuracy, and they are resistant to strong vibrations. Since these encoders feature a purely serial EnDat interface, even applications exposed to strong electromagnetic interference do not impair data transfer quality or safety. These inductive rotary encoders support safety integrity level SIL 2, category 3 PL d. They can even attain SIL 3, or category 4 PL e, if additional measures are taken on the control. These encoders also provided the added safety advantage of mechanical fault exclusion against the loosening of the shaft and stator connection. With this safety package, these inductive rotary encoders can also be used in systems designed for human-robot collaboration.

Step 1: highly dynamic motor control

Step 2: secondary encoders for highly accurate position measurement

Classic rotary encoders continue to provide the servo motor feedback at the robot’s axes. Because servo motors require high control dynamics, the robust inductive rotary encoders from HEIDENHAIN, such as those of the ECI 1100 and 1300 series, or multiturn models of the EQI 110 and 1300 series, are ideal for this type of application. These encoders deliver high control quality and system

Robotics manufacturers can significantly improve the absolute position accuracy of their robots by using additional, high-accuracy angle encoders or rotary encoders at every robot axis. These socalled secondary encoders, which are mounted after each gear train, capture the actual position of every robot joint. This allows the encoders to account for

Figure 1: Classic HEIDENHAIN rotary encoder for motor feedback

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| September 2018

118 TECH TRENDS

Table 1: Comparison of the most important specifications for typical secondary encoders

ECA 4000

Figure 2: Improvement of the absolute position accuracy through the use of so-called secondary encoders on every axis zero position error and backlash. The retroactive forces on each axis resulting from the machining task are measured as well. All of this results in a 70 to 80 percent improvement of the absolute position accuracy at the tool center point. Modular angle encoders, such as the HEIDENHAIN ECA 4000 with optical scanning, the HEIDENHAIN ECI 4000 rotary encoder with inductive scanning, and the AMO WMR angle encoder, are well-suited for these applications. Thanks to their modular design with a scale drum or scale tape and a separate scanning unit, these encoders are well suited for large hollow-shaft diameters and for the challenging installation requirements often encountered in robots due to space constraints. The signal quality of these secondary encoders is considerably better than that of the rotary encoders on the servo motor, meaning that the returned position values

Figure 3: High-accuracy HEIDENHAIN and AMO encoders for absolute position measurement on robots SEPTEMBER 2018 | www.engrreview.com

ECI 4000

WMR

Scanning principle Absolute, Optical

Absolute, Inductive

Incremental, inductive

Inside diameter

70 mm to 512 mm

90 mm / 180 mm

60 mm to 10 000 mm

Resolution

29 bits

20 bits

Depends on the subsequent electronics

System accuracy

±2“

±25“ / ±40“

±3“ per meter of arc length

Resistance to contamination

Mounting tolerances

are significantly more accurate even for highly dynamic movements.

Step 3: accurate position measurement for movable robots In order to reach all of the machining positions on very large or long components, such as an aircraft fuselage or for manufacturing large composite fiber components, robots can be moved along the length of the component on linear axes. For the highly accurate positioning of robots with a linear drive, enclosed linear encoders from HEIDENHAIN are available in lengths of up to 30 m. Position measurement from a linear encoder compensates for thermal errors and other factors that influence the feed mechanisms. These factors cannot

Figure 4 : HEIDENHAIN linear encoders

be captured by means of conventional position detection methods based on the pitch of the recirculating ball screw and the angular position of the rotary encoder on the motor.

Conclusion: highly-accurate position measurement improves accuracy at the tool center point The use of secondary encoders on all of a robot’s axes, as well as the use of linear encoders for positioning the robot relative to the workpiece, enables a level of accuracy at the tool center point that allows appropriately equipped industrial robots to perform positionally accurate machining and handling tasks on components. Angle and linear encoders from HEIDENHAIN and AMO offer not only the required system accuracy but also the necessary flexibility for installation in complex and compact robot mechanisms. The suitability of these encoders for safety-related applications also makes it possible to implement human-robot collaboration systems.

Web: www.heidenhain.com

120 TECH TRENDS

Effects of Pipe-line Strain / Stress on Positive Displacement Pumps By M. Ganesan, Managing Director Rovar Pumps Private Ltd. How does a faulty pipeline strain adversely affect the positive displacement pumps (Gear, Screw, shuttle block, lobe pumps)? Why most of the time the pump bears the damage for faulty pipeline stresses imposed? It is not the other way? Are the problems encountered while commissioning a PD pump in a new installation - an indicator of faulty pipe strain? How pipeline strain kills a pump? Why pipe stress elimination should be validated during commissioning of a new pump?

or a pumping system, more care should be taken while designing the pump and pipelines (strainer, valves, etc). A premature pump failure leads to maintenance and operational losses, unless resolved. Eighty five percent (85%) of all pump problems/failures are due to some form of misalignment, either between the pump and prime mover or within the pump itself. Pump failure analysis conducted in most of the process plants have revealed that 70% of chronic pump problems involved pipeline strain. Always the pump should be independent and no pipeline forces imposed. Pipe flanges and pump flanges must be squarely together before bolting and tightening.

What is pipe-line strain /stress? Letâ&#x20AC;&#x2122;s discuss. Introduction Pump being the heart of every industry

SEPTEMBER 2018 | www.engrreview.com

Unsupported, inappropriate pipelines create misalignment between pump suction/discharge flanges to the corresponding pipe flange connections. Parallel and

122 TECH TRENDS

angular misalignment of piping flanges at the pump nozzle develop unwanted pressure and movement in the piping system, which causes: 1. Misalignment of pump and motor coupling 2. Dragging of casing, makes the rotor elements to rub with casing 3. Casing distortion 4. Excessive radial and axial loads on pump Casing, Gears, Bearing, Bush & Shaft seals 5. Excess vibration on piping, pump and motor. Excess wear caused by static vibration 6. High motor current consumption or motor current shoots up erratically very high. For example 100% or more than the full load current. Even when discharge pressure is less. 7. In some cases, these faulty pipe work may distort and crack the pump casing. 8. The faulty /unsupported pipe weight along with weight of the liquid inside the pipe and the hydraulic pressure, drag the pump/pump flange violently towards one direction. 9. Pre-mature pump failures 10. Incorrect alignment between pump and driver can cause extreme heat in couplings which leads to coupling failure, and key way damage. 11. Proper care must be taken by providing sufficient permanent supports to the suction and discharge pipelines, preferably near to the pump flanges.

SEPTEMBER 2018 | www.engrreview.com

Proper Installation

Conclusion

• Pump and motor common base frame should be grouted properly and allowed to cure, before installation pump and connecting pipelines. • Expansion joints/bellows are used to minimize the forces • Always piping should be started from the pump flange instead of pipe is terminated at the pump • Consider thermal expansion • Check by rotating the pump and motor manually before and after connecting the pipelines. In case of improper pipe strain, the pump rotary elements rub the casing, making it difficult to rotate. • The gap between pipe flange and pump flange does not exceed the thickness of three gaskets • Pipe flange bolts must drop in without dragging • Long bars, pullers, jacks should not be used when aligning a pipe flange connecting to pump flange. • After connecting the pipeline flanges to pump, validate the coupling alignment between motor and pump. Now disconnect the inlet flange of the pump. Then recheck the coupling alignment. If the alignment has moved, there is pipeline stress. Do the same for outlet flange, check and correct. • One of the most effective ways to promote awareness of these potential issues is training.

In all PD pumps the main casing is bolted with base frame and rotor rotates concentric to the casing. Due to the pipeline stress/strain the pump casing is pulled/pushed to one direction. This action disturbs the concentric rotor, making the rotary elements and stationary casing to rub each other, resulting in ceasing/jamming the pump. Please note that in PD Pumps the rotary elements (gear, screws) are designed to run with close clearance, and a very close tolerance is maintained between rotary elements and casing. A faulty / unsupported pipe stress can easily jam and restrict rotor rotation. Any stress on pump casing by pipe system greatly reduces pump life and performance. Centrifugal pump and Positive displacement pump on faulty pipe-line Though pipe strain affects all types of pumps, Centrifugal pump runs with only one impeller, having sufficient clearance between impeller and casing. At the same time, PD pumps have two or three pumping elements which run in close tolerance to each other and to the casing. Hence PD pumps are more prone to pipeline stress damage than centrifugal pumps.

For more information Email: sales@rovarpumps.com Website: www.rovarpumps.com

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INSIDE BUSINESS AVENUES Information on latest manufacturing projects in India SR. NO.

CATEGORY

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02.

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he group plans to develop its third housing project named ‘SHRI Sky Park’ in Greater Noida. Around 2,000 units would be build under this project. The project would be constructed as per the area norms laid down under the Pradhan Mantri Awaas Yojana (PMAY). Place : Greater Noida Uttar Pradesh Industry: Real Estate “SHRI group”

“Sapna Garg, Sr Marketing Manager, 133 A Block . Sector 63, Noida-201301, Uttar Pradesh. Tel: 0120-4919999, E-mail:sapna.garg@shrigroup.net, (Pradeep Kumar Agrawal, MD)

onstruction of Dwarka Expressway from Shiv Murti Intersection at km 20 of NH 8 till rail under www.engrreview.com | SEPTEMBER 2018

126 BUSINESS AVENUES

bidge rub near Swarka, Sector 21 from km 0.800 to 5.300 PKG I in Delhi on EPC mode.” Place : Dwarka Delhi Industry: Roads/ Highways/ Bridges National Highways Authority of India “Dinesh Yadav, General Manager (Tech), NHAI HQ, Dwarka Sec-10 New Delhi-110075, Delhi. Tel: 011-25074100, 4200, Ext 1232, Fax: 25093507, E-mail:dineshyadav@nhai.org, Web: www.nhai.gov.in

lans to undertake the rehabilitation and upgradation to two lane with paved shoulders of Punjab Haryana border to Moonak Jakhal Budhlada Bhikhi from km 236.600 to 239.400 and km 244.750 to km 287.710 section of NH 148b falling in the state of Punjab on EPC. Place : Patiala Punjab Industry: Roads/ Highways/ Bridges “Ministry of Road Transport and Highways” Executive Engineer, Central Works Division, PWD B R Branch, Sangrur, Nabha Road, Patiala-147001, Punjab. Tel: 0175-2357556, E-mail:cenhpun- jab@gmail.com

lans to assign the construction of water works for Anaj Mandi Bathinda. The works comprises construction of pump chamber, staff quarter, UGSR 200000 Ltr, Toe wall, brick wall around water works, corner pillar, gate pillar, DI water supply line, fire hydrant, sluice valve, fire hydrant haundi, sluice wall haudi, etc. The completion is targeted in six months. Place :Bathinda Punjab Industry: Water Sector Punjab Mandi Board “Darshan Singh Sangha, Executive Engineer (PH), Punjab Mandi Bhawan, Sector 65-A, SAS Nagar (Mohali), Punjab. T: 0172-2791326, 2791226

lans to assign the construction of Circular Shape RCC OHSR of 200000 Ltr (44100 Gln) complete and supplying, fixing CI/DI double fanged pipes, etc at NGM Bathinda, Distt. Bathinda. The completion is targeted in 4 months. Place : Bathinda Punjab Industry: Water Sector Punjab Mandi Board Darshan Singh Sangha, Executive Engineer (PH), Punjab Mandi Bhawan, Sector 65-A, SAS Nagar (Mohali), Punjab. T: 0172-2791326, 2791226

he company has awarded two contracts to a consortium of Maire Tecnimont SPA subsidiaries. The scope of the

SEPTEMBER 2018 | www.engrreview.com

contract is to provide engineering, procurement, construction, and commissioning services for implementation of two petrochemical units to be located adjacent to Guru Gobind Singh refinery at Village Phullokhari, about 35 km from Bathinda.” Place : Bathinda Punjab Industry: Petro- Chemicals HPCL- Mittal Energy Ltd. (HMEL)” Rajesh Gupta, AGM, INOX Towers, Sector 16 A, Plot No. 17, Noida - 201301, Uttar Pradesh. T: 0120-4634500, info@hmel.in, rajesh. gupta@hmel.in, (Prabh Das, MD & CEO)

ruit juice maker has recently set up a new manufacturing facility in Uttar Pradesh. Place :Varanasi Uttar Pradesh Industry: Food and Beverages Man- pasand Beverages “Najuk Trivedi, Manager (Corporate Communication), E-62, Manjusar G.I.D.C., Savli Road, Vadodara-391775, Gujarat. T: 02667- 290290, 290291, najuk.trivedi@ manpasand.co.in, info@manpasand. co.in, (Abhishek Singh, Director)”

alipara-Charduar-Tawang road covering 320-km is in delay mode for the last ten years due to paucity of funds and forest clearance issue. The road construction will be completed within December 2021. Place :Tawang Arunachal Pradesh Industry: Roads/ Highways/ Bridges Border Roads Organisation (BRO) “Brig. A K Das, DDGTP, Head Quarters DGBR, Seema Sadak Bhawan, Ring Road, Naraina, New Delhi -110010. T: 011-25696086,23011862, 23015444, M: 8800394003, akd65pms@yahoo. co.in, jscw-mod@nic.in, (Bharat Khera IAS, Joint Secretary (Air, Ceremonial, Border Roads)

lans to start installation of smart meters soon in the city of Lucknow. Energy Efficiency Services Ltd (EESL) will supply the smart meter to MVVNL. The meters will be installed free of cost for the customer. Place : Lucknow Uttar Pradesh Industry: Smart Meters Mr. Sanjay Goyal, MD Madhyanchal Vidyut Vitaran Nigam Ltd (MVVNL) Noman Ahmed, Chief Engineer (Technical) MVVNL office 4-A, Gokhale Marg, Lucknow- 226001, Uttar Pradesh. Tel: 0522-2208769, 9415999452,

BUSINESS AVENUES 127

WEST INDIA

lans to assign the appointment of architectural consultant for construction of Passenger Terminal Building and allied works for New Greenfield Airport at Hirasar, Rajkot. EIL has invited bids on behalf of Airports Authority of India. Place :Rajkot Gujarat Industry: Airport/ Aviation Engineers India Ltd “K N Mahapatra, GM (SCM), Gurugram, Haryana. T: 0124-3802086 / 2147, kn. mahapatra@eil.co.in arvind.kumar@eil.co.in”

VK has invited expression of interest from EPC (engineering, procurement and construction) contractors for works related to the greenfield Navi Mumbai International Airport project. Place :Navi Mumbai Maharashtra Industry: Airport/ Aviation GVK Power and Infrastructure Ltd “Ram Mankekar, Group Head & VP Corporate Communications, Terminal 1 B, Domestic Airport, GVK, 1st Floor, Vile Parle, Mumbai-400099, Maharashtra. Tel : 022-66850900, 66852041, E-mail: ram.mankekar@gvk.com

utomotive component manufacturer plans to set up a new plant. The work includes building construction, infrastructure and procurement and installation of plant and machinery. Place : Maharashtra Industry: Automotive Components Pricol Ltd “Siddharth Manoharan, Manager (Corp Comm.), 109 Race Course, Coimbatore - 641018, Tamil Nadu. T: 0422-4331100/ 4336000, F: 4336299, factory@pricol.co.in, www.pricol.com, (Vikram Mohan, Managing Director)

etting up 1.2 MT of bulk cement terminal at Kalamboli in Mumbai Place : Mumbai Maharashtra Industry: Cement Vicat Group Anoop Kumar Saxena, CEO, Reliance Majestic Building, 8-2-626, Road No.10, Banjara Hills, Hyderabad-500034, Telangana. T: 040-30006999, F: 30006977, E-mail: media.bharathi@vicat.com

lans to undertake the construction of Police Station Building (Type -II) at Shirajgaon Kasaba Tq.Chandur Bazar Dist. Amravati. The completion is targeted in 9 months. Place :Amravati District Maharashtra Industry: Construction Maharashtra Public Works Department “S S Chenge, Executive Engineer, Public Works Division, Amravati, Maharashtra. T: 0721-2662542, 2667229, 2565449, M: 7387149848, E-mail:amravati.ee@mahapwd.com, www. mahapwd.org

he company plans to develop IT park with the name ‘Commerzone’ on a 30 acre land parcel in Ghansoli in Navi Mumbai. Place :Navi Mumbai Maharashtra Industry: IT Park K Raheja Corp “Cheryl Waldiya, DGM (Corp. Comm), Raheja Tower, Block G, Plot No. C-30, Bandra Kurla Complex, Bandra (E), Mumbai- 400 051, Maharashtra. T: 022 26564000, M: 9322198940, E-mail: cwaldiya@kraheja.com, sales@kraheja.com

lans to assign the design, engineering, supply, fabrication, erection, testing, commissioning of Integrated Facilities Complex comprising Group Gathering Station (GGS), Effuent Treatment Plant (ETP), Water Injection Plant (WIP), Gas Compression Plant (GCP) at Nandasan Field of ONGC Mehsana Asset, Gujarat. The work is likely to start soon. www.engrreview.com | SEPTEMBER 2018

128 BUSINESS AVENUES

Place : Mehsana Gujarat Industry: Oil and Gas ONGC Ltd “Vivek Chavhan Sr. Manager (MM), Onshore Engineering Services (OES), 2nd Floor, Tower B, Deen- dayal Urja Bhavan, 5, Nelson Mandela Marg, Vasant Kunj, New Delhi-110070. Tel: 011-26752341,2350, 2378, Fax : 011-26129091

lans to install intelligent parking management system at nine multilevel parkings and two off-street parkings in the city of Surat.

Place : Surat Gujarat Industry: Parking Management Surat Smart City Development Ltd (SSCDL) “Devang Patel, Executive Assistant (Information System Department), 115, Smart City Cell, Surat Municipal Corporation, Muglisara, Main Road, Surat-395003, Gujarat. T: 0261-2278429,2423751, M: 9724345495, suratsmartci-tycell@gmail.comon, itman@suratmunicipal.org, (C Y Bhatt, CEO)

SOUTH INDIA

lans to establish a grinding unit of 1.7 mtpa capacity at Vizag in Andhra Pradesh. Place :Visakhapatnam Andhra Pradesh Industry: Cement Vicat Group “Anoop Kumar Saxena, CEO, Reliance Majestic Building, 8-2-626, Road No.10, Banjara Hills, Hyderabad-500034, Telangana. T: 040-30006999, F: 30006977, E-mail:media.bharathi@vicat.com

lans to add a second line of 2.75 mtpa capacity in existing Kalburgi cement plant. Place :Kalburgi Karnataka Industry: Cement Vicat Group “Anoop Kumar Saxena, CEO, Reliance Majestic Building, 8-2-626, Road No.10, Banjara Hills, Hyderabad-500034, Telangana. T: 040-30006999, F: 30006977, E-mail:media.bharathi@vicat.com

he company has received green clearance for expansion cum modernisation of its fertiliser plants in Karnataka. The environment clearance has been given by the nodal ministry of environment to MCFL’s proposed project SEPTEMBER 2018 | www.engrreview.com

Place :Karnataka Industry: Chemicals / Fertilisers” Mangalore Chemicals and Fertilizers (MCFL) “T M Muralidharan, Vice President (Finance), Level-11, UB Towers, UB City No.24, Vittal Mallya Road, Bangalore - 560001, Karnataka. T: 080-39855599, (N. Suresh Krishnan, Managing Director)

lans to undertake the establishment of a New Market at Sardapur (V) under AMC Siricilla of Rajanna Siricilla District. The completion is targeted in 6 months. Place : Siricilla District Telangana Industry: Construction Department of Agricultural Marketing, Govt. of Telangana A. Sridhar, Superintending Engineer, BRKR Bhavan, 1st foor, ‘D’ Block, Tank Bund Road, Hyderabad- 500063, Telangana. T: 040- 23269990, F: 23266091, M: 7330733123, (G. Lakshmi Bai, Director, T: 040-23269990)

etting up a water desalination plant near New Mangalore Port. The completion is targeted by 2020. Place : Mangalore Karnataka Industry: Desalination “Mangalore Refinery and Petro- chemicals Ltd (MRPL)”

BUSINESS AVENUES 129

“Sushil Chandra, GGM (CS & Projects), Kuthethoor P.O., Via Katipalla, Mangalore-575030, Karnataka. T: 0824-2270400, F: 2271404, mrplmlr@mrpl.co.in, sushilchandra@mrpl.co.in, venky_m@mrpl.co.in, (M Venkatesh, Managing Director)”

lans to open a convention hotel near Bengaluru International Airport. Place :Bengaluru Karnataka Industry: Hospitality Clarks Exotica Convention Resort & Spa “Prakhyath Shetty, General Manager, Swiss Town, Hollywood Junction, Sadahalli Post, Devanahalli Road, Bangalore - 562110, Karnataka. Tel: 080-71777000, 40977828, M: 9686682337, E-mail: salesco.blr@clarksexotica.com

he central public sector enterprise plans to undertake expansion of the storage capacity of its Cherlapalli LPG bottling plant from 1,200 tonnes to the current 1,900 tonnes. Place : Cherlapalli Telangana Industry: Oil & Gas Bharat Petroleum Corporation Ltd (BPCL) “Sundarajan, DGM (Brand and PR), Bharat Bhavan, 4 and 6 Currimbhoy Road, Ballard Estate, Mumbai - 400001, MH.

T: 022-22713000, Extn-3342, sundarajanss@bharatpetrolium.in, (D Rajkumar, CMD)”

lans investment in Tamil Nadu over the next three years comprising pipeline expansion, construction of captive jetty, additional facilities for petrol and diesel handling, POL (petroleum, oils and lubricants) terminals, etc. Place :Tamil Nadu Industry: Oil and Gas Indian Oil Corporation Ltd (IOCL) “Kalikrishna M, Executive Director (CC), IndianOil, SCOPE Complex, Core-2, 7, Institutional Area, Lodhi Road, New Delhi-110003, Delhi. T: 011-26260142, 24364604, kalikrish-na@iocl.com (R. Sitharthan, Executive Director - Tamil Nadu and Puducherry)”

lans to undertake the six laning of road connecting to NH 16 at Gaju- waka to Gangavaram Port and four laning of road connecting Gangavar- am Port to Beach road in Visakhapat- nam district in the state of Andhra Pradesh on EPC mode (Package II) under Bharatmala. Place :Visakhapatnam Andhra Pradesh Industry: Roads/ Highways/ Bridges National Highways Authority of India “Anil Kumar Sharma, GM (Tech), NHAI, HQ, G-5&6, Sector-10, Dwarka, New Delhi-110075, Delhi. T: 011-25074100

EAST INDIA

he company plans to set up a clinker unit in Madhya Pradesh and another unit whose location is not yet finalised. Funding is planned through internal accruals and debt. Place : Dhar Madhya Pradesh Industry: Cement Wonder Cement “Zahid Afroz Khan, Assistant General Manager, 17 Old Fatehpura, Udaipur-313004, Rajasthan. Tel: 0294-33991133, zahid.khan@ wondercement.com, (Sailesh Mohta, President Marketing),

(Jagdish Chandra Toshniwal, MD)”

lans to undertake the construction of 500 bedded hospital building in the campus of MGM medical college, Jamshedpur. The work is yet to start. Place : Jamshedpur Jharkhand Industry: Construction Jharkhand State Building Construction Corporation Ltd Director, Jharkhand Project, Building, PO Dhurwa, Ranchi-834004, Jharkhand, T: 0651-2446259, www.engrreview.com | SEPTEMBER 2018

130 BUSINESS AVENUES

E-mail: jsbccIjharkhand@gmail.com

E-mail:choubeypc@indianoil.in lans to undertake the construction 10,632 more affordable houses in Chhattisgarh. The Centre has approved this project recently under PMAY(U). The work is likely to start soon. Place : Chhattisgarh Industry: Housing State Urban Develop- ment Agency, Chhattisgarh “A K Saxena, Project, OSD PMAY, Indrawati Bhawan, 4th Floor, D Block, SUDA Secretariat, Naya, Raipur-492002, Chhattisgarh.M: 9424209003, E-mail:aksaxena254@gmail.com

lans to undertake the construction of 500 bedded hospital building under medical college, Hazaribagh. Place : Hazaribagh Jharkhand Industry: Construction Jharkhand State Building Construction Corporation Ltd Director, Jharkhand Project, Building, PO Dhurwa, Ranchi-834004, Jharkhand, T: 0651-2446259, jsbccIjharkhand@gmail.com lans to undertake the widening and reconstruction of drains in stockyards in CHP Stage-I and II, repairing black topping of WBM roads and related works in CHP area of NTPC Vindhyachal. Place : Singrauli District Madhya Pradesh Industry: Construction NTPC Ltd A. K. Saha, Sr Manager (CS), Vindhyachal Super Thermal Power Projects, P.O. Vindhyanagar, District: Singrauli - 486885, Madhya Pradesh. M: 9434751544, E-mail:aksaha03@ntpc. co.in

lans to augment the Paradip-Haldia- Durgapur LPG Pipeline and extend upto Muzaffarpur and Patna. As

part of the augmentation plan, new facilities will be added at Paradip and Balasore. The commissioning is targeted by December, 2020. Place: Paradip Odisha Industry: Gas Infrastructure Indian Oil Corporation Ltd (IOCL) “P C Choubey, Executive Director (Pipelines Division), IOCL, South Eastern Rigion Pipeline, 3rd Floor, Alok Bharti Tower, Saheed Nagar, , Bhubaneswar - 751007, Odihsa. Tel: 0674-2548915, 2374505, E-mail: choubeypc@indianoil.in

lans to enhance its LPG bottling capacity, including setting up of two greenfield plants at Agartala in Tripura and Barapani in Meghalaya, in North East by 2020. Place: Paradip Odisha Industry: Gas Infrastructure Indian Oil Corpora- tion Ltd (IOCL) “P C Choubey, Executive Director (Pipelines Division), IOCL, South Eastern Rigion Pipeline, 3rd Floor, Alok Bharti Tower, Saheed Nagar, , Bhubaneswar - 751007, Odihsa. Tel: 0674-2548915, 2374505, SEPTEMBER 2018 | www.engrreview.com

MRC has suggested in its techno- economic feasibility study the requirement of 31 acre of land for the proposed project of an alternate road link from Chandigarh to Chandigarh International Airport.The Government of Chandigarh (U.T.), Punjab and Haryana are the stakeholders in this project. DMRC has suggested to constitute a new entity Greater Chandigarh Transport Corporation for executing the project. Place : Chandigarh (U.T.) Industry: Metro Rail Delhi Metro Rail Corporation R K Gupta, GM (Contracts), DMRCL, 5th Floor, C-Wing, Metro Bhawan, Fire Brigade Lane, Barakhamba Road, New Delhi–110001, Delhi. T: 011-23415838, 23417910/12, (Anuj Dayal, Executive Director - CC, T: 011-23418415)

lans to set up a 1,500-MW pumped storage facility at Lugu Pahar near Bokaro in Jharkhand. So far, a pre-feasibility study has been done. Detailed project report will be ready in two years. Place :Bokaro Jharkhand Industry: Power Damodar Valley Corporation (DVC) B Nandi, Chief Engineer (Project), DVC Headquarter, DVC Tower, VIP Road, Kolkata-700054, West Bengal. T: 033-23553072, basudev.nandi@dvc.gov.in, (P.K.Mukhopadhyay, Chairman)

ndore-Manmad Railway Line Project covering 362 km is planned through a joint collaboration between JNPT, Railways and state governments of Madhya Pradesh and Maharashtra. Place : Indore Madhya Pradesh Industry: Railways Indian Railways Ved Prakash, Director (Information & Publicity), Rail Bhavan, Raisina Road, New Delhi-110001, Delhi. Tel: 011-23381224, M: 9810039038, E-mail:dip@rb.railnet.gov.in

PRODUCT SHOWCASE 131

PRODUCT SHOWCASE High Speed Self Repairing Door by Gandhi Automations

Prime Reset is a unique High Speed Self-Repairing Door with the latest technology that prevents downtime of the door system. In case the curtain is impacted accidentally it will cause the curtain to move out of the guides without damage. The movement of the door is designed in such a way it can be recovered with a simple opening and closing operation. Gandhi Automations manufactures doors of the highest quality that meet the issue for greater flexibility desired by clients. High Speed Self-Repairing Door in PVC is the most suitable solution in the field industries, it lowers the time of transition from one facility to another, avoiding any human error which can cause damage to the High Speed Door and all this thanks to the innovative ANTI CRASH SYSTEM. Gandhi Automations provides a world class product with great security.

Below are the features of self-repairing high speed doors offered by Gandhi Automations:• Flexible and Self-Repairing Door • Functional, safe, quick and resistant • Innovative anti-crash system • Can be equipped with PVC vision windows • Self-Lubricating maintenance free guide • Smooth and silent opening and closing • Protects traction unit, enables rapid wiring and safety photocell • Flexible curtain in self-extinguishing material • Self-resetting without intervention • Quickly back to operation • Control panel designed for an intensive continuous service

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

The new Gast 86/87R Series of oil-less rocking piston compressors and vacuum pumps While other manufacturers have been busy selling rocking piston compressors that produce a lot of noise and less-than-ideal pressure, Gast has been quietly setting the new standard by re-engineering our oil-less rocking piston from the ground up. The result is a unit that delivers quieter performance, higher pressure, a longer life and greater application flexibility. The sleek, new 86/87R Series is not just another pretty product. It’s beauty runs deep as it performs in ways not yet seen in the industry. The patented crossover chamber design regulates and controls airflow to dampen sound and optimize performance, while delivering a wide range of pressure level options. Because the 86/87R Series can easily retrofit into an existing footprint, it’s also a smart, flexible solution for a wide range of markets and applications, viz. Environmental, General industrial, medical, printing & packaging, food and beverage, transportation, laboratory, and material handling.

Designed to performs “When we set out to re-engineer our rocking piston compressor, we aimed to do more

than just increase pressure. We set out to dramatically reduce sound, enhance flow, create a standard footprint for easy retrofit anywhere in the world and improve the compressor’s aesthetics,” says Gast. The inherent design of rocking piston technology makes it the optimal choice for applications requiring high pressure or vacuum and air flow in a small package. The flexible cup is made with superior materials and mounted on top of the connecting rod, creating vacuum or pressure while maintaining a tight seal against the cylinder walls in a rocking motion. The forgiving design has fewer components, causes less friction and has a low exhaust temperature, for greater reliability and durability for the life of the product. Despite it’s small size, the versatility of 86/87R means this is the right product to deliver quality air solutions.

Shavo Technologies Pvt. Ltd. Shavo House, S.No.21A/10B, Plot No,394 South Main Road, Hotel Cozy Inn Chowk Koregaon Park, Pune - 4112 001 Phone: 020-2615 9641 Email: shavogroup@vsnl.com

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132 PRODUCT SHOWCASE

Pioneer in intuitive programming • Offer the easiest-to-use & most adaptable alternative Automation Solution for specialized & demanding needs • An experienced technical team • A pioneer in the simplification of programming

em4 - MORE THAN JUST A PLC • All-in-one fully connected nano-PLC • Remote management & maintenance on a PC & mobile devices • Accurate & performant sensor measurement

Millenium 3 - Logic Controller • Compact & expandable • Easy to program • Multiple configuration options.

Specialist in electromagnetic & electronic technology • Specialist in time management with an extensive automation components offer that includes timers, monitoring relays • In addition to highperformance products, advice and support, offers tailor-made solutions for any application

TIMERS: • Simple to use • Multi voltage • Multi or mono function

MONITORING RELAYS: • Close-up protection for total availability of equipment • All anomalies are detected • Optimise continuity of service.

For more information InnoVista Sensors India Pvt Ltd Div 1, BNR Complex, Plot No.92/1A, 1st Floor, H P Avenue Road, Konappana Agrahara, Electronic City –Phase 1, Bangalore – 560100, India E-mail: india@innovistasensors.com Web: www.innovistasensors.com

SEPTEMBER 2018 | www.engrreview.com

Welding Fume Extractor, King Extractor-II-MU 3 Welding Fume Extractor, King Extractor-II-MU 3 is a mobile mechanical high efficiency self-cleaning filter designed for workplaces. The filter cleans air from different kinds of dry dust, welding aerosols & other dry contaminants from most industrial processes. The filter cartridge is cleaned automatically without interrupting the filtration process. The cleaning extends the cartridge service periods and minimizes maintenance.

The Filter is designed for continuous indoor operation under the following climatic conditions: • Air temperature from +10 deg. C to +45 deg. C. • Relative humidity : 80% at 25 deg. C • The compact construction integrates the filter,

extraction arm and fan • The filter can be used at workplaces unreachable to other ventilating equipment, & • The filter requires connection to a general compressed air supply. The standard delivery set includes Built-in fan, Control console, Filtering cartridge of respective type, Spark arrester, Oil separator with reduction box for compressed air system, and Electrical grounded cable L= 5 m with plug.

For more information : Ador Welding Ltd. Akurdi, Chinchwad, Pune 411 019 Phone: 020-4070 6000 , Email: cmo@adorians.com Web: www.adorwelding.com

MECO INSTRUMENTS : SMP48 MECO is an ISO 9001: 2015 certified company offering various reliable, long – lasting and affordable instruments since 1962. Our team of skilled and trained personnel is equipped with complete in-house facility for design, development and manufacturing world class

products. Many products have been designed by our R & D Department (Recognized by Department of Scientific &

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Industrial Research, Ministry of Science & Technology, Govt. of India, New Delhi) for which MECO HAS 30 DESIGN PATENTS.

•

Keeping pace with India’s growing requirements, MECO has newly introduced products are: • 3 Phase TRMS Multifunction Power and Energy Meter with M. D. & T. H. D. • Power and Harmonics Analyzer used for Testing, Monitoring, Measuring, Analyzing Quality power in Electrical System. • Digital Panel Meters – SMP48 and SMP96 with programmable Digital Ammeter and Voltmeter And A, V, W, VAR, VA and PF Meters in 72x144, 144x144 mm for LT and HT Panels. • POWERGUARD – TRMS for monitoring the power consumption of domestic and industrial loads. Its ideal for production & quality control of various types of electrical appliances like air conditioner, refrigeration, washing machine etc. • Data logging PC Interface Digital Multimeter with USB Port, TRMS Auto ranging Professional Digital Multimeter 6000 / 6600

•

Count, are some of the new launches. Digital Insulation Testers – 500V, 1000V, 2500V, 5000V. Digital Clamp meters with 1200A DC / AC TRMS and 1000A AC TRMS and various sizes, and functions. Phase Sequence Indicator, Digital Earth Tester and Transformer Turns Ratio Meter are products that complement the basket of an electrical engineer and technician. Vehicle Battery System Meter, Multifunction Automotive Meter and Digital Automotive Multimeter cater to the needs of the automotive sector. Handheld Thermal Imaging Camera and Laser Distance Meter finds application in maintenance of buildings, electrical equipment, transport industry , electronic / electrical manufacturing, archaeological study, smelting fields to name a few. Clamp-On TRMS Power & Energy Meter with Automatic Computation of 1 Phase & 3 Phase Parameters is useful to check motors, compressors, HVAC systems etc. Solar Power Analyzers are useful for Measuring Power in Solar Systems.

For more information MECO Instruments Pvt. Ltd. Plot No. EL-1, MIDC Electronic Zone, TTC Industrial Area, Mahape, Navi Mumbai 400710. (INDIA) Tel: 0091-22-27673311-16 (Sales),27673300 (Board) Fax: 0091-22-27673310, 27673330 E-mail: sales@mecoinst.com Web : www.mecoinst.com

The Best Operating Door for Busy Workflow: Avians CE Certified High Speed Doors Avians is one of the pioneer manufacturers and an endto-end solutions’ provider for high-end automatic doors and loading bay solutions .The Parent Company A Mathurbhai & Co was started in 1982 with manufacturing and development Center, Which gradually grew with strong expertise, Hard Work & Loyal clientele to become Avians Innovations Technology Pvt. Ltd. in 2007. Headquartered at the core of Pune’s industrial and automotive area (PCMC), Avians has a 2,80,000 sq ft. plant and warehouse facility. The team that started with few engineers and technicians has now grown into a massive team of experts. Their vision to deliver the best and innovative solutions in accordance to the client’s requirement sets them apart in the industry. Avians is a reputed name that’s been setting up time to time an example of par excellence services. The design and execution team of Avians creates a complete environmental protection against wind, heat, cold, dust, pests and intruders. Avians Research & Development team is working with all their experience and expertise for the betterment of products. The Avians range of High Speed Doors is designed for safe, quick, efficient and trouble-free operation for any internal busy doorways. Avians CE certified High Speed Doors and other entrance products

are known to several leading players in current market. The door curtain rolls up at a very high speed on the shaft which in turn is directly connected to the high performance drives. These doors are characterized by their high-quality components and well-conceived design. These High Speed Doors can be used both inside and outside in sheltered areas that have low wind loads and moderate temperature. Avians High Speed Roll up Doors curtain is made of high tear tensile strength best quality PVC material, controlling environment conditions inside the factory. These High speed roll up doors improves the flow of traffic through busy doorways. Doors have self-supporting structure for simple and reliable operations. Speed adjustment possible in all types of high speed roll up doors. Due to their modern and variable look, our high-speed doors perfectly match architecture of any building. These High Speed Doors are designed to ensure smooth and noiseless operation. Opening /Closing

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134 PRODUCT SHOWCASE

speed 0.8 to 2 m/sec helps in faster movement of traffic. Available in standard curtain, anti-crash mechanism, clean room and cold room applications. European makes motor & controller are suitable for high speed operations comes with compact control panel with advance control feature

which accommodates various accessories. PVC Fold up doors is perfectly suited for the exterior installation and is ideal for extra wide opening. Our Drives are inbuilt with Special Anti Drop Electromagnetic brake device to ensure that the door does not free-fall in any worst conditions.

For more information Avians Innovations Technology Pvt. Ltd. Regd.off. 615/25, Pradhikaran, Nigdi, Pune-411044 Corp.Off. & Plant: 60-61 Dehu Alandi Road, Jadhav Wadi, Chikhali, Pune, Maharashtra- 411062 Boardline:. 91 20 71 400 555(100 lines) Mo.: +91-8390 3004 00 Email: sales@avians.co.in, website www.avians.co.in

Nexgen Refrigerated Air Dryers The Nexgen Refrigerated Air Dryers from Gem Equipment are known for engineering excellence, innovation and reliability. The heat exchangers are designed to provide worry-free, highly efficient heat transfer whether you are processing simple fluids, viscous solu8tions, or particulates. They feature honey comb construction of aluminium fins, true cross-flow for greater effective temperature differences, non-clogging larger cross-sectional area for air flow, integral air-air and air-refrigerant exchanges, with stainless steel demister moisture separator, robust non-corrosive grade aluminium, & larger heat transfer area for higher efficiency. The rugged electronic panels display both inlet and dew point temperatures. They incorporate a Tripper modSEPTEMBER 2018 | www.engrreview.com

ule with alarm for compressed high discharge pressure, compressed low suction pressure, expansion valve malfunction, auto drain valve function and fan motor cycling. Introduction of speed control is one of the major developments towards the optimization of refrigeration systems based on average load. For periods of high cooling demand, the compressor speed can be increased which results in a higher refrigerant flow and thus higher cooling capacity and vice versa during periods of low cooling demand. Compressed air purification equipment must deliver uncompromising performance and reliability while providing the right balance of air quality with the lowest cost of operation. As a quality-centric group, Gem ensures that its dryers are test at each

stage of assembly as per ISO 7183 or relevant standards. It maintains stringent engineering practices throughout the production process to achieve higher reliability. Gem’s state-

of-the-art ISO 9001-23008 certified facility is equipped with dedicated men and machines to chisel out products of impeccable quality and reliability.

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

Masyc’s Reversible Hammer Crusher MASYC, an ISO 9001-2008 certified company, specializes in the field of Bulk Material Handling System, Conveyor Equipment, Crushers and Screens, etc. The Reversible Hammer Crushers are manufactured based on proven technology and under in-house strict quality control. It has the unique design feature such as Welded Casing, Screwed Liner with High Carbon Steel Plates, Hammer heads made of chrome alloy cast steel or manganese steel depending upon the application. Rotor shaft is made out of forged steel, Hammer grinding path with Wear Resistant Plates which are Mechanically/ Hydraulically adjustable and Dust Proof Spherical Roller Bearing. It crushes material in two stages i.e. initially the material is reduced by impact between hammer

and material followed by scrubbing action (attrition) against breaker plate. Masyc’s Reversible Hammer Mill is used for Hard Coal, Lignite, Cooking Coal, Lime Stone, Gypsum and other soft and medium hard materials. These Mills are rugged in structural, design and easy to maintain, having high throughput and low wear. The maximum reduction ratio can be as high as 12:1 depending upon the WBI of the material. Masyc can offer Reversible Hammer Crusher up to a capacity of around 700 TPH and having Rotor dia 2000 mm. Its major customers include Ultratech, Bhushan Steel and Power, Binani Cement, Nirma, Amrit Cement, Jindal Saw, Orient Cement, etc.

For more information Masyc Projects Pvt. Ltd. 20, Community Centre Mayapuri, Phase -1 New Delhi 110 064 Tel +91-11-28115453, 28115745, 28113383 Fax: +91-11-28116850 Email: masyc@masycproject.com Web www.masycproject.com

136 PRODUCT SHOWCASE

Architectural Lighting

For more information K-LITE INDUSTRIES D-10, Ambattur Industrial Estate,Chennai-58 Tel: 26257710,48581950, Fax : 26257866 Cell: 95000 79797, 95000 85511 E-mail: info@klite.in / Web: www.klite.in

Digital Analog Control Solid State Relays Features :

K-LITE INDUSTRIES an ISO company, manufacturing indoor and outdoor luminaires have launched a new series of LED Architectural Lighting. Being the trend setters in outdoor lighting and inspired by the “Make in India” vision, K-LITE, through their innovative outlook, have showcased an all new product portfolio under Architectural Lighting. The application includes Facade Lighting, Pathway Lighting, In-ground Luminaire, Uplighter, Up-down Lighting, Billboard Lighting, Vertical Light Bars, Wall Washers, Area Lighting poles and above all popular sleek polar lighting solutions. The solutions offered are backed by extensive understanding of illumination in urban spaces and the expertise gained over a period of three decades. The fixture are designed to provide value technology, ideally suited to Indian Conditions. The

SEPTEMBER 2018 | www.engrreview.com

LEDs used comply to LM 80 testing requirements and from Internationally reputed makes such as Nichia / CREE. The luminaires are RoHS, LM 79 and CE certification compliant. The luminaire efficacy (lumens/ per watt) is much above 100 for all luminaires. Varied optical options for lighting distribution and correlated colour temperature (CCT) for cool white, neutral white or warm white are available to suit specific requirements. The outstanding item of the series viz., the Sleek Polar Lighting Solutions is a contemporary design that is both timeless and unique in its impression. Compact without visible mounting equipment and optimised integration, Polar Lighting is in perfect continuity with the geometric lines of the square column. These assemblies are ideal for surroundings of contemporary architectural constructions.

• Microcontroller based Phase Angle Control (Proportional Controller) 0-100% Linear • Burst Fire Control • Soft Start/Soft Stop • Status Monitoring • Control input of either 4-20mA built-in Vcc or 0-10VDC external Vcc of 5 - 32 VDC required or external potentiometer, varying the control input linearly varies the AC output power from 25-530 VAC. Models of 25A, 50A, 90A thyristor based. • A control input of 4mA or 0VDC corresponds to zero output power whereas a control input of 20 mA or 10VDC corresponds to full output power (0100% LINEAR). The Phase angle controller varies the firing angle on the output SCRs proportionally to an analog control signal, effectively varying the power delivered to the output load. Frequency 50 Hz to 60 Hz. These Control

relays can provide added flexibility and reliability to your application with all the known benefits provided by the use of solid state switching technology. Offering precise power control suitable for numerous Factory Automation applications our relay can reliably control resistive loads like heaters, lighting and slightly inductive loads. The relay can also be used for soft turn-on of high-power incandescent lamps The analog series is ideal for temperature control, tungsten lamp dimming and universal motor control too.

For more information Satronix (I) Private Limited. 421 Laxmi Plaza, Laxmi Industrial Estate, Off Link Road, Andheri West, Mumbai- 400053 Tel : 91 22 26325242, Cell : 9820143488 Email : sales@satronixindia.com, satronix@gmail.com

138 PRODUCT SHOWCASE

Ballscrews with Rotary Nut (Compact) - FSKT

The Rotary Ball Screw is a rotary-nut ball screw unit in which a ballscrew nut is integrated with a support bearing. The support bearing is an angular bearing that has a contact angle of 60°.It is best suited for an application that requires rotation of the ball nut while the screw shaft is fixed.

bolts, a ball nut rotation mechanism is gained. And the timing pulley (prepared by the user) is directly secured to the end face of nut.

Simple Shaft End Configuration Shaft end configuration is simple because this unit does not need support bearings.

Features Rapid Feed Compact and High Positioning It is a compact design using nut and support bearing as an integral unit. Angular contact ball bearing makes a better axial load. Zero backlash and higher sti ness construction give a high positioning.

Simple Installation By simply mounting this model to the housing with

No inertial effect produced by the integral unit rotating and the shaft ¬fixed. Thus in high slenderness ratio also rapid feed requirement and select smaller motor to drive.

Application Semi-Conductor Industries/ Robots/Wood Machines/Laser Cutting Machines/Transporting Equipment…etc.

For more information SUPERSLIDES & BALLSCREWS co.INDIA PVT. LTD. SUPERSLIDES HOUSE, A-774 T.T.CIndustrial Area,Off Thane-Belapr Road, Next to SGS, Koparkhairne, Navi Mumbai-400 701 INDIA Tel: 022-4935 555 (40 Lines) Fax :022-49355556 E-mail: sales@superslides.in / info@superslides.in Website: www.superslides.in

SEPTEMBER 2018 | www.engrreview.com

SHEET STAMPING PRESSES Marvel Machine Tools Pvt. Ltd.- Mumbai offers good quality sophisticated preowned CNC & Conventional Metalworking & Sheetmetal Machine Tools such as Press Lines, C & H Frame Presses, High Speed Presses, Hot Forging Presses, Trimming Presses, Knuckle Joint Presses, Vertical & Horizontal Machining centres, Turning Centres, Drill-Tap Centres, Vertical & Horizontal Borers, Vertical & Horiztonal Lathes, Milling, Grinding machines etc of reputed international makes from around the world from ready stock. Featured is a 300 Tons Capacity Straight Side Double Crank Press of SATO JAPAN make. Machine

is in excellent condition. Technical Specifications: SSDC Press Model-DCP-300, Cap - 300T, Stroke – 350mm, Bolster Area -2150 x 1180mm, Slide Area-2000 x 1070mm, Die Ht – 600mm, Adjustment -200mm, SPM -22, With Die Cushion.

For more information Marvel Machine Tools Pvt. Ltd. 304~306, Himalaya House, 79, Palton Road, Opp. J.J. School Of Arts, Mumbai – 400 001 (Maharashtra) India. Tel.: 022-22657481 – 82 Email : info@marvelmachinery.com Website: www.marvelmachinery.com

DIGITAL CLAMPMETERS (MODEL: R-2070C) “MECO-G” introduces new improvised Digital Clampmeter Model R-2070C in attractive colour casing. This instrument is 6000 Counts, True RMS AC Current Measurement with Backlight LCD Display. This instrument is small in

size and can be easily carried. It can measure AC/ DC Voltage, Resistance, Capacitance, Temperature & Frequency. Special functions like hFE Test, Diode Test, Duty cycle, Audible continuity Test are available in

PRODUCT SHOWCASE 139

this instrument. NCV, Data Hold & Automatic Power OFF is additional feature. This instrument is supplied with Test Leads, Carrying Case, K-Type Thermocouple Leads &

operating manual. These instruments are useful in various industries, research institutes, maintainence engineers etc. It works with 2 AAA size batteries.

For more information M/S. GOLIYA IMPEX 316, BHARAT INDUSTRIAL ESTATE, T.J.ROAD, SEWREE, MUMBAI- 400 015, INDIA TEL.: 91-22-24149657, 24179467 FAX: 91-22-24130747 E-mail: sales@goliyainstruments.com; info@goliyainstruments.com Web: www.goliyainstruments.com

Accessories for Safety Pull Cord Switch

SMARTsaa, an associate company of Protocontrol Instruments I Pvt. Ltd. Pune offers variety of accessories for Safety Pull Cord Switches for use on machines like cutting machines, printing machines and wood working machines for emergency stoppage.

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Accessories: • Wire Rope Holder : CPA-

•

01 : For easy removal of rope while maintenance work Wire Rope thimble: CPA02. Protects rope against breakage due to small loop Cable rope clamp : CPA -03 , for holding the rope tightly Pulley : CPA-04 to be used when rope is turned around the corners Stay Bolt : CPA-05 for

holding the rope • Turnbuckle for adjusting the cable tension: CPA-06 • Spring for rope tension : CPA-07 • Steel rope , PVC coated, 5 mm diameter : CPA-08 • LED Lamp for indication of operated switch • Additional Junction Box for termination of wires : JB SPC

• Cable glands : M 20 , ½ inch NPT , ¾ inch BSC The rope is to be hooked around the work area and at convenient height such that the operator will find is convenient to pull when in an emergency by using turn buckle, spring and thimbles.

For more information Smart Sensors And Automations E-12, Mangalmurti Industrial Estate, T-80, MIDC, Bhosari Pune : 411026 India M : 7028376392 E mail : sales@smartsaa.com, smartsaasales@gmail.com

Silicone Sleeves for Corona Treater APPL’s di-electric silicone sleeve manufactured from a very specific silicone rubber compound, providing excellent electrical, thermal and chemical resistance, making it ideally suited to the harsh environment that is the corona treatment process. APPL’s silicone sleeves are produced specifically as an electrical dielectric sleeve and is manufactured to extremely close tolerance, ensuring

reliable and consistent corona treatment performance. APPL’s sleeves are available in the sizes 50 mm (2”), 75 mm (3”) & 98 mm (4”) nominal diameters. It is also available in custom color & sizes as per the requirement.

For more information Ami Polymer Pvt. Ltd. 319, Mahesh Industrial Estate, Opp. Silver Park, MiraBhayander Road, Mira Road (E), Thane - 401104, Maharashtra. INDIA Tel.: +91 22 28555 107 / 631 / 914 | Cell: +91 86910 13935 Email: mktg@amipolymer.com | Web: www.amipolymer.com

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140 PRODUCT SHOWCASE

NEW Digital Barcol Impressor DBI-1000

Low Cost Digital Ultrasonic Thickness Gauge

A digital indentation hardness tester, is the latest design and development of our company. It is characterized in that provided with a balance positioning, a digital display of hardness value, and a non disassembly calibration and adjusting. It is with good stability, convenient calibration, and high accuracy of detection. It is mainly used in aluminum processing industry, testing pure aluminum, soft aluminum, thick aluminum alloy, aluminum strip, aluminum rod, aluminum castings, aluminum forgings and aluminum alloy products. Also, it can be used for glass steel industry. The relevant standard is ASTM B648-00, ASTM HD2583-07, and GB / T 3854-2005.

This state-ofthe-art Digital Ultrasonic Thickness Gauge is the most accurate way to measure the wall thickness of materials such as steel, cast iron, plastic and more. Once meant only for professionals and electrical technicians, our wholesale price makes this device available for easy around-thehouse use! The simple to use and durable Digital Ultrasonic Thickness Gauge uses ultrasonic technology to safely measure the thickness of materials such as steel, aluminum, titanium, plastics, ceramics, glass, and most other materials (as long as it has parallel top and bottom surfaces). The gauge provides basic measurement, scanning, adjustable sound velocity, and extended storage capabilities for additional flexibility. The innovate gauge design features an intuitive interface that makes set up and operation easy. Simply calibrate the gauge to a known thickness or sound velocity and begin taking measurements.

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Features: • Small in size, portable. Single hand operation, easy to use. Can be used in any occasion as long as the hand can reach. • Wide test range, can test from very soft pure aluminum to a particularly hard aluminum alloy. effective test range equivalent to

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the Brinell Hardness of 25~150HB. No need to be supported. Just test on one side of the sample with the hardness tester, no need to be supported. It is suitable for the test of large and extra thick workpiece. With the maximum hold function, recording the maximum hardness value during measurements. Can be used for measuring not only Barcol Hardness, but also Brinell Hardness (HB), Vickers Hardness (HV), Webster Hardness (HW), Rockwell Hardness (HRB/HRE/HRF/HRH). With the function of calculating the average value, can calculate the average value of the 29 sets of data at most.

Applications fields: Aluminum, Aluminum Alloys,Soft Metals ,Composite Materials, Glass Steel.

Parameters

Barcol Hardness (Hba), Brinell Hardness (HB), Vickers Hardness (HV), Webster Hardness (HW), Rockwell Hardness (HRB/ HRE/HRF/HRH)

Measurement Range

0~100 HBa, equivalent to the Brinell hardness of 25~150HB

Resolution

0.1 HBa For more information Toolpost (india) Tel: 09819345050 / 022-23428862 E-mail: ojus_itico@hotmail.com

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Manufacturer Specifications • Measuring range: 1.2~220mm (Steel) • Accuracy: ±(1%H+0.1)mm • Resolution: 0.1mm • Sound velocity range: 1000~9999m/s • Working frequency: 5MHz • Minimum limit for tube measuring: F20*3mm (Steel) • Auto calibration • Auto linear compensation: this advanced software program enhances the precision by correcting the non-linear accuracy of the transducer • Data store/ Data recall/ Data delete function • Sound velocity measurement • Low battery indication • Auto power off • LCD backlight display • Power: 2x AA Batteries (not included) • Dimensions: 154 x 73 x 27mm.

For more information India Tools & Instruments Co. – BOMBAY - INDIA Tel: 022-23428862 / 9819345050 E-mail: ojus_itico@hotmail.com web:www.indiatool.net

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142 CASE STUDY

Intelligent manufacturing solutions halve production time of gas turbine components

RMP600 machine tool probe locating the position of an airfoil

oncasters Precision Castings â&#x20AC;&#x201C; Deritend, is a leading manufacturer of investment cast and machined industrial gas turbine airfoils. These airfoils are manufactured in nickel and cobalt based superalloys. The company is committed to growth and it backs this commitment with a willingness to invest in continuous improvement through lean manufacturing and rapid prototyping. As a result, it has seen considerable growth in demand for its machining services, which support its investment casting business. This demand has led to a significant investment of over ÂŁ2 million in Mazak machine tools, infrastructure and manufacturing software to efficiently machine over 14 new products.

Background Prior to making the investment in Mazak five-axis machining centres, similar

SEPTEMBER 2018 | www.engrreview.com

work had been undertaken using conventional three-axis machining centres with hard location fixturing. The processes were not only time consuming but also demanded a high level of skill from the machine operators. For a typical nozzle component the cycle time, including setting and machining would be four hours, which exceeded the capacity available to meet the increased demand. In addition, the use of hard fixturing was viewed as obsolete technology and an expensive solution by the engineering team. Therefore, the decision was taken to make a major investment in machining technology and three Mazak VORTEX i-630V/6 vertical machining centres were ordered. These machines would allow Doncasters to keep the machining work in house and provide a single-source solution for its customers. As part of the investment the ma-

CASE STUDY 143

chines were equipped with Renishaw RMP600 high-accuracy probes, featuring patented RENGAGE™ strain gauge technology. Their ability to deliver unrivalled submicron performance when applied to complex 3D shapes and contours, made them ideal for the work being undertaken. However, during initial application discussions, it was recognised that additional support would be required and Renishaw called in its associate company, metrology software products ltd (MSP).

Challenge The challenge was to improve rightfirst-time machining rates and in doing so eliminate any potential for errors to arise, as well as increasing overall productivity. Doncasters’ Engineering Manager Ollie Macrow explains: “When you are dealing with £10,000 Inconel castings it’s nice to have the assurance before you cut metal that the machined part will be correct. Costs are also a concern: in addition to the cost of the casting there is the time that is lost and

– given the material – the relatively high cost of tooling. Additionally, there are certain components that are not reworkable, so if it’s wrong after machining, it’s scrap. We knew we had to probe the part, but our challenge was to figure out a way of doing it successfully without hard fixturing.” Compounding the issue was the company’s relatively limited experience with probing, which it had previously used only for basic adjustments and simple flat plane alignment, so Renishaw’s input would be vital. Doncasters also wanted to eliminate the need for costly and time consuming hard fixturing. “Hard fixturing posed numerous issues: it’s expensive; requires high skill levels to present the parts correctly; and if a fixture becomes damaged you can’t machine as the part can’t be aligned, so fixtures have to be maintained to a high level, which adds time and cost. Our challenge was to replace these fixtures with simplified, modular-type systems and reduce human interaction in the setting process,” continues Ollie. Production targets also had to be met, so reducing set-up times was a key consideration in the introduction of the Mazak machines. While carrying out the bulk of the machining in-house using these new machines, there was still a requirement to sub-contract out some secondary operations. However, by improving productivity, the aim is to bring these operations inhouse later. “This will have a positive impact on our productivity. If we can machine on-site, we won’t have to ship parts out and wait two days for them to go back and forth,” explains Ollie.

Solution

Ollie Macrow, Engineering Manager at Doncasters Precision Castings – Deritend inspecting benchmark results

Having reviewed the project, the Applications Engineer from Renishaw, recognised that MSP’s NC-PerfectPart and NC-Checker software in combination with the RMP600 probe would provide the best overall solution for Doncasters’

NC-Checker monthly benchmark screen requirements. This combination of hardware and innovative software allows users to identify errors in part positioning and a machine’s geometric performance prior to a part being cut. The initial step is to ‘map’ the machine tool to create a benchmark. NC-Checker checks the performance of the probe prior to carrying out five-axis checks of the machine tool. This ensures that every aspect of probing and machining performance is within set tolerances prior to part setup and metal cutting. The machine check can run on a regular basis, as it takes just a few minutes to complete. Over time it will ensure the machine continues to operate within set parameters and produce accurate parts. NC-PerfectPart solves the problems created by poor part alignment on the machine tool. This is of particular importance on components with free-form, complex shapes and those subject to five-axis machining. Setting up these parts can be time consuming, and very difficult to achieve accurately and consistently. These challenges are overcome by probing the part with the RMP600 using a program created from the component’s CAD file. From this initial measurement an alignment is

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144 CASE STUDY

Doncasters Precision Castings – Deritend manufacturing facility created to eliminate any errors in the positioning of the part in the machine. The alignment is then uploaded to the machine control and compensations are automatically calculated to produce a part program perfectly aligned to the part. Set-up is automated, meaning that fixturing is no longer as critical in the process, any manual set-up error is eliminated and the time required to set even the most complex of components is reduced to minutes. Furthermore, elements such as material condition, pallet loading systems and temperature, can all be accounted for at the initial stage of the machining process reducing further the risk of producing bad parts. After metal cutting, NC-PerfectPart can confirm the accuracy of the finished component prior to it being removed from the machine tool and inspected on a CMM.

Results Before the addition of the RMP600 and

SEPTEMBER 2018 | www.engrreview.com

MSP software it would take four hours to set and machine a typical industrial gas turbine nozzle. Now that same part can be probed, machined and checked in under two hours, so Doncasters has increased productivity by 50%. On more complex components, the machining time could be up to eight hours and require the presence of a highly skilled operator to oversee the machining process. These parts are now produced in the same two-hour cycle as simple parts, generating even greater savings. In working with Renishaw and MSP, Doncasters has improved alignment systems to achieve overall better results; the correlation between on-machine measurements, CMM results and Bluelight scanning system data is also improved. Commenting on the success, Ollie Macrow explains: “What has happened here is a really positive story, and we would be nowhere near where we are now without the support of Renishaw and MSP”.

He continued, “When we first decided to buy the machines, we sat with Mazak and said “How are we going to do this?” They didn’t think it was possible with our current set-up and then Renishaw came along and in conjunction with MSP provided the solution we needed. Our customers are giving us positive feedback as we have greatly improved our right-first-time pass rate. I genuinely feel that we would not be successfully machining castings without the help of Renishaw and MSP The support we get from them is great; they are at the end of the phone if we call, and on-site when we need them.”

For more information www.renishaw.com/doncasters

146 EVENT PROFILE

ENGINEERING REVIEW magazine marks it successful presence in

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EVENT PROFILE 147

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ENGINEERING REVIEW |

148

| September 2018

A GLOBAL DISPLAY OF IN

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PRODUCT INDEX 153 A

CNC Vertical Machining Center

IBC 117

FRONT COVER - HALF FOLD Fire Fighting Hoses

109

AC Lenear Servo Motor

115

Compressed Air Dryers

AC Servo Systems

115

Compressed Air Pipeline Network System

Actuator

Fittings

121

Actuator Line

Conductivity Meter

Flanges

121, 123

Agro Files

Conduits

Flex Clamps

Connectors

Flexible Couplings

Air Compressors

Fire Rated Rolling Shutters

INNER IFC 115

Air Entry Package

Consumables

Fluid Dispensers

Air Plazma Cutting Machine

Contouring Control

Fluid Distribution Systems

Folding Doors

Forged Rounds

117

Fourslide Parts

Aluminium Profiles

115

Auto Cables

Automation Products

Curvic Coupling Cycloidal Gear Boxes

115 102, 103

D B Ball Transfer Units

115

DC/AC Geared Motor

115

Deceleration Products

119

G Gas Management

Ballscrews

Digital Clampmeters

Gas Springs

Barrel Pumps

Digital Earth Testers

Gauge

45 27

Bars

121

Digital Multimeter

Gear Boxes

Bars & Flats

123

Digital Refractometer

Gearbox

Dimond Files

Gears

102, 103

Dock Levelers

Braided Hoses

Dock Leveller

Brake Motors

Dock Shelters

Double Valves

Driven Soluiton

Bearings

59, 93

Bevel Gear Boxes

C Cable Glands

53, 99, BACK PAGE

Cable Protection

BACK PAGE

119

72, 73 115

Glass Balls

Grinding Media

H Harmonic Filters

Heat Exchangers

High Pressure Compression Springs

Cables

Earthing Electrodes

High Speed Doors

Cam Driven Systems

Electronic Components

High Voltage Insulating Matt

111

Carbon Steel Flanges

117

Electronic Modules

Hydraulic Pipes

117

Casting

101

Encoders

Hydraulic Press

Centerless Grinders

Energy Absorption

Ceramic Balls

& Vibration Isolation Products

5, 11

Hypid Gear Boxes

102, 103

Ceramic Cappilaries

Energy Isolation

Ceramic Insulators

Engineering Files

Industrial Connectors

Ceramic Pyrometry Tubes

Extension Springs

Industrial Enclosures

BACK PAGE

Ceramic Solid Rods

Circular Connectors Clamp Meters Clamp Sensors Clamps for Linear Guids CNC Cutting Machine CNC Turning Center

BACK PAGE INNER IFC 17 115 77 IBC

Industrial Forgings F

Industrial Plugs

Fasteners

123

Ferrous Metals Balls

Fiber Laser Marking Machine FRONT COVER - HALF FOLD Fiber Laser Metal Cutting Machine

117 86, 87

Industrial Sensors Industrial Shock Absorbers

91 119

Inflatable Gaskets

Inflatable Seals

Instrumentation Fittings & Valves

www.engrreview.com | SEPTEMBER 2018

154 PRODUCT

INDEX P

Insulation Resistance Tester

Insulation Tester

pH Electrode

Silicone Tubes

Insulation Testers

ph Testers

Sliding Doors

pH/mV/Temp Bench Meter

Solar Inverters

pH/mV/Temp Portable Meter

Solar Module Analyzer

Phase Rotation Testers

Solar System Analyzer

L Large Dia Slewing Ring

115

Laser Welding Machine

Pinions

FRONT COVER - HALF FOLD

Pipe Fittings

Shop Aids

115 117, 123

135, 137

Speed Regulators

119

SPM Machine

Lighting Systems

IFC

Pipes

121

Stainless Steel Flanges

Lighting Transformers

105

Pipes & Tubes

123

Static Elimination Solutions

Linear Actuators

115

Planetary Gear Heads

Steel Balls & Rollers

Linear Guideway

Plasma CNC Cutting Machines

Linear Line

Plastic Balls

102, 103

Linear Motion Guides

115

Portable Appliance Testers

Lockable Gas Springs

119

Power & Harmonics Analyzers

Power Meter

Precision Air Moving Products

Loggers

Logistics Services

Logout Tagout Products

151

Loop/PSC/RCD Testers

Precision Ball Screws Precision Centerless Grinder

115 43

Precision Measuring Instruments 135, 137 M

Precision Turned Parts

Measuring & Gaging Equipment Mild Steel Flanges

135, 137 117

Mini Compression Springs Moisture Meters

47 INNER IFC

Motorised Rolling Shutters

Motorized Rolling Shutters

Motors

FRONT GATEFOLD

Presses

99 119

Pressure Control Solutions

Project Engineering Solutions

Pump Solutions

Pumps

Multi-Axis Motion Controller

115

Racks

115

Multifunction Meters

105

Rails

Multifunction Testers

Multimeters

INNER IFC

N Needle Files

Non Ferrous Metals Balls

Non-Destructive Testers

135, 137

107

Rodless Cylinders

119

Oil & Coolant Mist Cleaner Optical Measuring Instrument Oxy-Fuel CNC Cutting Machines

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115 135, 137 61

Switches

115 FRONT GATEFOLD

Switchgears

T Telescopic Line

Temperature Meter

Tension Springs

119

Testing Apparatus Thermal Cameras

135, 137 INNER IFC

Torsion Springs

Transfer Switches

Tubes

121

U 25

V Valves Voltage Detector

95 INNER IFC

Voltage Testers

65 W Wave Springs

Welding Carriage Machine

Welding Equipments

Scientific & Laboratory Apparatus 135, 137

Welding Machine

Sectional Overhead Doors

Workholding

S Safety Gloves Saw Files

Robotic Welding

Rotary Encoders

Stepper & BLDC Motor

UPS

Refining Furnace

117

Servo Stabilizers

113 57

5, 11

135, 137

Sheets

121

3 & 4 Digit Programmable Voltmeter

Sheets & Plates

123

4 Digit Programmable Ammeter

AD INDEX 155 COMPANY NAME

PG. NO.

COMPANY NAME

PG. NO.

A.C. AUTOMATION

119

DELAIR INDIA PVT. LTD.

ADOR WELDING LIMITED

DOWEL ENGINEERING WORKS

AMI POLYMER PVT. LTD.

COMPANY NAME

PG. NO.

GRUNDFOS PUMPS INDIA PRIVATE LTD.

117 H 97

HACOP PUMPS PVT. LTD.

HANNA EQUIPMENTS (INDIA) PVT. LTD.

APEX PRECISION MECHATRONIX PVT. LTD.

115

ELECTROTHERM (INDIA) LTD.

HARTING (INDIA) PVT. LTD.

AURUM ALLOYS & ENGINEERING LLP

121

ELGI EQUIPMENTS LTD.

HEIDENHAIN OPTICS & ELECTRONICS INDIA PVT. LTD.

AUTOMATIC ELECTRIC LTD.

105

EPCOS INDIA PVT. LTD.

83 HRS PROCESS SYSTEMS LTD.

HUMMEL CONNECTOR SYSTEMS PVT. LTD.

BACK PAGE

AUTOMATION INDIA WELDING TECHNOLOGY (P) LTD.

AVIANS INNOVATIONS TECHNOLOGY PVT. LTD.

107

EPPINGER TOOLING ASIA PVT. LTD.

E-SQUARE ALLIANCE PVT. LTD.

102 - 103

151 I

F B

BETTINELLI AUTOMATION COMPONENTS PVT. LTD.

BIRLA PRECISION TECHNOLOGIES LIMITED

FKL INDIA PRIVATE LIMITED

FLIR SYSTEMS INDIA PVT. LTD.

INNER INSIDE FRONT COVER

IGUS (INDIA) PVT. LTD.

INDIA MACHINE TOOLS SHOW - 2019

149

INDIA STEEL - 2019

124

INDIA TOOLS & INSTRUMENTS CO.

135, 137

57 G

CHHATARIYA RUBBER & CHEMICAL INDUSTRIES

CONSUL NEOWATT POWER SOLUTIONS PVT LTD

GALAXY EARTHING ELECTRODES (P) LTD.

INNOVISTA SENSORS INDIA PVT. LTD.

FRONT GATEFOLD

GANDHI AUTOMATIONS PVT. LTD.

INORBIT TOURS PVT. LTD.

141

GEISSEL INDIA PVT. LTD.

INSTAMOD AIRPIPE PVT. LTD.

109

www.engrreview.com | SEPTEMBER 2018

156 AD

INDEX

COMPANY NAME

PG. NO.

COMPANY NAME

PG. NO.

COMPANY NAME

PG. NO.

INTEC - 2019

MARVEL MACHINE TOOLS PVT. LTD.

119

ROSS CONTROLS INDIA PVT. LTD.

MECO INSTRUMENTS PRIVATE LTD.

ROVAR PUMPS PRIVATE LIMITED

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MEHTA CAD CAM SYSTEMS PVT. LTD.

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JINDAL STEEL & POWER LTD.

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148

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